Service Manual: General

10 General
20 Engine
30 Electrical
system
205, 255, 305

355, 365, 405 40 Power
transmission
455, 465, 555

565, 665, 865 50 Brakes
600, 700, 800

900, 415M, 60
Front axle and
steering sys-
A75, A85, A95

tem
70 Frame and
wheels
Service Manual
Tractors
80 Cab and
shields
90 Hydraulics
Valtra Inc.
FIN---44200 Suolahti, FINLAND
100
Phone +358 2045501
Telefax +358 204550387 Tools
www.valtra.com
Order no 39 200 212
ENGLISH
Copyright E 2006 by Valtra Inc.
10. General 11. Layout
12. Maintenance
1
2
To the reader
The Service Manual for the Valtra ---Valmet 205---900 tractors is intended to be a practical reference source to be used in workshop.
The repair instructions in the manual are based on methods which have been worked out in practice during normal workshop
conditions and which are based on the use of special tools from the manufacturer when stated in the instructions. The manual
also contains descriptions of the design and function of the components.
Detailed maintenance instructions can be found in Operator’s Manual.
The Service Manual will be continually updated with new revised pages which should be inserted in the manual. Alterations and
additions will first appear as service bulletins.
Only genuine Valmet spare parts should be used to ensure the best possible function of the machine. Certain operations should
be carried out with the aid of special tools designed by Valmet.
Valtra Inc.
Tractor Service
Note! This Manual also includes tractors 600, 700, 800 and 900 as follows:
--- The build ---up of brakes, cab (not roof), front axles and hydraulic power lifts on 600 ---900 tractors is the
same as on 865 ---tractor. If no separate instructions are given, the instructions for 865 tractor are good for
600 ---900 tractors. Transmission on 600 ---900 tractors is the same as on 865, except that 600 ---900 tractors
have a modified low gear and also an alternative Overdrive is available. These new components require
some minor changes in the main gearbox and for these reasons 600 ---900 tractors have transmission 270
(865 has transmission 250).
--- Electric system on 600 ---900 has been shown in section 31.
--- Engine differences are described in sections 21, 22 and 23. 600 and 700 tractors have a Bosch in ---line
fuel injection pump and 800 ---900 a Stanadyne rotary distribution pump.
3
4
1. 9. 2001 Model Code Page
10. General 205-- 900 110 0
1.4.2006
The following supplements have been published for the Valmet 205---900 Service Manual:
Ordering number Date Content

Service Manual 39 200 211 04/1986 First edition
39 251 211 1.7.1989 --- technical modifications
--- model 455
--- new hydraulic power lift (610312---)
--- fitting instructions for optional equipment
--- models 205, 355, 555 and 415M
--- Autocontrol power lift
--- Agrodata performance monitor
--- models 565 and 665
--- 20---series engines
--- Sige front axle
--- Danfoss steering valve
--- models 255 and 465
--- 2---speed PTO unit
--- hydraulic system with priority valve
--- PTO shaft brake
--- front PTO unit
--- front lift
39 251 216 31.1.1996 --- only for 665---4MOD models
39 251 217 1.5.1996 --- model 865
--- Kontak valves for auxiliary hydraulics
--- technical modifications
39 251 218 1.3.1997 --- AD ---instrument
Supplements --- Control Stop
--- AC power lift on 865
39 251 219 1.1.1998 --- tractors 600, 700, 800, 900
--- modified low gear
--- overdrive
39 259 211 1.6.1998 --- air conditioning
--- HiShift
--- latest fitting instructions for optional equipment
39 259 212 15.4.1999 --- ACB power lift
--- new front PTO
--- new E ---engines for 700 and 800
--- new control valve of ACB power lift
--- pressure ait brakes for trailer
39 259 213 1.9.2001 --- E ---engine on 600 and 900 tractor
--- new coolant pump on 600---900
--- expansion tank for engine coolant
--- Infoline and Agroline instruments
--- PTO HiShift
--- updated fitting instructions for optionl equipment
39 259 214 10.10.2003 --- 12+12R gearbox
--- shuttle
39 259 215 1.4.2004 --- Bosch VE rotary pump
--- wiring diagrams (M21101---)
5
Model Code Page
10. General 205-- 900 110 0
1.4.2006
Ordering number Date Content

Service Manual 39 200 212 04/2006 Second edition
6
Model Code Page
10. General 205-- 865 110 1
1. 12. 1986
Layout of Service Manual

1. Division into groups
The manual is divided into groups (10---100) which are based on the make ---up of the tractor. The groups are listed on the first index
leaf.
Example. 10. General

20. Engine, fuel and cooling systems
30. Electrical system
40. Power transmission
a.s.o.
The number designation for each group is given in the top left box of the respective pages (and the first figure in the code designa-
tion).
Code Page
410 1
50
60
70
80
90
100
2. Division into components or sub ---groups
Each group is further divided into components or sub ---groups. The number and the name of each component is given in the top
left box on each page (and comprise the two first figures in the code designation).
Example. 41. Clutch

42. Gearbox
44. Low gear
45.Final drives etc.
7
Model Code Page
10. General 205-- 865 110 2
1. 12. 1986
3. Tractor model
At the top of each page it is indicated for which tractor the page is valid.
4. Code designation
Three ---digit code designations are used to separate the different document groups for the respective components. The same
code is also used in the Time list as a reference to the text in this manual. The code designation numbers appear in the box at
the top of the page and also in the headings.
Example: Code 410

--- Group: power transmission (4)
--- Component: clutch (41)
--- Document group: general (410)
5. Page numbers
The instructions for all components are numbered in consecutive order in the right---hand box at the top of the page. The page
numbers begin with page 1 for each component.

41. Clutch 205---665 410 1
15. 5. 1993
6. Date
At the top of each page there are two boxes for dates. In a case of revised issue, the date of the earlier issue is printed in the
crossed ---over box and and the date of the current issue is printed in the proper date box.
7. Additions and amendments of the service manual
New and up ---dated pages will be continuously added to the service manual. The new pages should be inserted as indicated by
the code: the first digit (also the first digit on the index leaf) indicates the group:
--- the two first digits indicate the component or sub ---group.
--- the third digit indicates the document group for the respective components
--- the page number indicates the definite position of the page within the service manual.
If there are two pages with the same code and page number, it is the page with the later date in the date box and the old date
in the crossed ---over box which is valid or which is the current page.
When an entirely new set of repair instructions is issued, it will be accompanied by instructions on where the pages should be
inserted in the file.
8
Model Code Page
1. 12. 1986
10. General 205-- 865 110 3
1. 3. 1997
Code designations in the Service Manual

60. Front axle and steering system
10. General 61. Steering system

110 General, lay out 610 Technical data, description, tools
120 Maintenance 611 Steering valve
612 Priority valve
20 Engine 613 Steering cylinder
21. Engine 62. Non ---powered front axle

210 Technical data, description, tools 620 Technical data, description, tools
211 Cylinder block and flywheel housing 621 Front axle
212 Cylinder head and valve mechanism
213 Crank mechanism 64. Powered front axle
214 Auxiliary drive gears (timing gears) 640 Technical data, description, tools
215 Lubrication system and oil sump 641 Housing and central pivot bearings
216 Induction and exhaust system, turbocharger 642 Drive shafts
219 Removing and fitting engine 643 Hubs
644 Differential
22. Fuel system 645 Adjustments
220 Technical data, description, tools
222 Fuel feed pump and fuel filters 70 Frame and wheels
223 Injection pump and injectors 710 Frame
720 Wheels
23. Cooling system
230 Technical data, description, tools 80 Cab and shields
231 Cooling system 810 Cab
820 Shields
30 Electrical system 830 Air conditioner
310 Tractor electrical system, wiring diagrams
320 Autocontrol hydraulic power lift 90 Working hydraulics, power lift
330 Agrodata performance monitor
331 AD ---instrument 91 Working hydraulics and mechanical power lift
40 Power transmission 911 Pump and pipe system
912 Hydraulic power lift
41. Clutch 913 Adjustments
410 Technical data, description, tools 914 Power lift, 610312---
411 Clutch assembly and pedal rods
92. Electro---hydraulic power lift
42. Gearbox
420 Technical data, description, tools 100 Special tools
421 Selector forks 101 Special tools ETV
422 Gear levers 102 Locally prepared tools ET
423 Shafts and gear wheels in gearbox
424 Differential
43. Torque converter and shuttle on 415 M
44. Low gear

441 Low gear
45 Final drives
451 Final drives
46. Power take off

462 Power take off
50 Brake system
511 Service brakes
512 Parking brake
9
Model Code Page
1. 12. 1986
10. General 205-- 865 110 4
1. 3. 1997
General instructions for repairs
Outer oil seals

The Service Manual contains instructions for changing all outer oil seals, (e.g. oil seals on the PTO shaft end, on the output shaft
to the front wheel drive and on the pinion shaft on the powered front axle, and so on).
Sealing compound and glue

If sealing compounds or glue are required for the repair work, the instructions will specify a sealing compound or glue which is
readily available through specialist dealers. Some seals should be greased before fitting and the space between the lips of the
seal should be filled with universal grease. If the seal is to be pushed over splines or sharp edges the seal should be protected
with for example a thin plastic foil.
Tightening torques and setting values

All necessary tightening torques and setting values for each repair operation are given at the beginning of each repair section
under the heading Technical Data. The most important values can also be found in the repair instructions.
Table 1 later gives the tightening torques in order of dimension, quality and surface treatment. The values given in the table should
be used if the tightening torque is not given in the repair instructions.
Safety
Always bear safety in mind when repairing or servicing the tractor. Use tools and lifting devices in the correct way . When you
are removing tractor components or splitting the tractor, every tractor part must be supported in such a way, that no risk of accident
exists. Avoid working under the supported tractor part if it is not absolutely necessary. When supporting the tractor the centre of
gravity of the frame part must always be checked. For instance the wedges must always be fitted between front axle and engine
to prevent axle oscillation when splitting the front frame of the tractor.
Trouble ---shooting
The following procedure, combined with the information contained in the workshop manual will be helpful in tracing faults accu-
rately. It consists of following a number of logical steps to locate and correct the problem:
a) Determine the problem
b) List possible causes
c) Differentiate the causes
d) Conduct checks in logical order to determine the exact cause
e) Consider approximate remaining service life against cost of parts and labour..
f) Make any necessary repairs.
g) Recheck the parts and functions for correct operation
10
Model Code Page
10. General 205-- 865 110 5
1. 12. 1986
Table
Table 1. Tightening torques, metric standard thread (ISO)
Tightening torques Nm1)

Dim. Quality, surface treatment, material and so on
8.8 8.8 8.8 10.9 12.9
lubr. tol.± Zne2) tol± Znk3) tol. ± lubr. tol. ± lubr tol. ±
M4 --- --- --- --- ---
M5 6,4 0,6 5,7 0,5 --- 9 1 11 1
M6 11 1 10 1 12 1,2 15 1,5 18 2
M8 25 2 23 2 30 3 35 4 45 5
M10 50 5 45 5 60 5 70 7 90 10
M12 90 10 80 8 100 10 125 10 151 15
M14 140 15 125 10 160 15 200 20 240 20
M16 220 20 195 20 250 25 300 30 370 40
M18 300 30 270 30 350 35 430 40 510 50
M20 430 40 380 40 480 50 600 60 720 70
M22 570 60 500 50 650 65 800 80 970 100
M24 740 70 660 70 830 80 1030 100 1250 120
M27 1100 100 950 100 1200 120 1500 150 1800 180
M30 1500 150 1300 130 1600 160 2040 200 2500 250
1) 1 Nm=0,102 kpm
2) Zne=zinc electroplating
3) Znk=hot galvanized
If the bolts differs from the standard range the values in the
table must not be used.
11
Model Code Page
10. General 205-- 865 110 6
1. 7. 1989
Conversion table for common units

Quantities and units Conversion factors
Overall and detail dimensions millimetres (mm) 100 mm=3,94 inches
1 inch=25,4 mm
Short distances e.g. turning circles metres (m) 1 m=3,28 ft

1 ft=0,305 m
Travel distances kilometres 1 km=0,62 mile

1 mile=1,61 km
Tractor weights, axle loadings kilograms (kg) 1 kg=2,2 lbs

1 lb=0,454 kg
Travel speed kilometres per h (km/h) 1 km/h=0,62 mph

1 mph=1,61 km/h
Drawbar pull kilonewtons (kN) 1 kN=224,8 lbs

1 lb=4,448 N
Power (identified by such terms as crankshaft power, 1 kW=1,34 hp

pto power, belt power, drawbar power, indicating 1 hp=0,746 kW
the point at which the measurement was taken)
kilowatts (kW)
Engine torque newton metres (Nm) 1 Nm=0,74 ft lb

1 ft lb=1,356 Nm
Fuel consumption by weight (kilograms per hr, kg/h) 1 kg/h=2,2 lb/hr

(by volume) litres per hr (l/h) 1 lb=0,454 kg
1 l/h=0,22 gal/hr
1 gal=4,54 l
Fuel economy (specific fuel consumption) 304 g/kWh=0,5 lb/hp hr

grams per kilowatt hr (g/kWh)
Engine displacement litres (l) 1 l=61,02 m cu in

100 cu in=1,639 l
Hydraulic pump 1 MPa=145 psi

pressure ---mecapascal (MPa) 1000 psi=6,9 MPa
delivery ---millimetres per sec (ml/s) 100 ml/s=1,32 gpm
1 gpm=75,77 ml/s
Tyre
pressure ---kilopascal (kPa) 100 kPa=14,5 psi
1 psi=6,9 kPa
Area acres---hectare To convert multiply by

0,404686
Volume bushel---litre To convert multiply by

39,3687
Quantity pound per acre ---kilogram per hectare Multiply by 1,12085
Volume Multiply by
superficial foot---cubic metre 0,002360
12
Model Code Page
1. 5. 1996
12. Maintenance 205 -- 900 120 1
1. 1. 1998
Maintenance 205---900
Note! Detailed maintenance procedures are given in the
--- When changing the oil, bear in mind that the oil can be very
Operator”s Manual. hot when it drains from the tractor. Waste oil and oil filters
should be handled carefully and disposed of properly.
--- After completion of the service work always replace all
safety covers etc.
When servicing:
--- Always stop the engine before doing any servicing work.
--- Apply the parking brake to ensure the tractor cannot move.
Lubrication of points provided with grease
If the ground is uneven the wheels should be scotched nipples
--- Always observe the utmost cleanliness in all maintenance
--- Always clean the grease nipples before applying the
work.
grease gun.
---Thoroughly wipe off filler caps and plugs as well as sur- --- Pump in grease to the nipples until clean grease is
rounding parts of the tractor before filling up with fuel or oil. squeezed out (unless otherwise instructed).
--- Inspect the oil and filters when changing. Large amounts of --- Wipe off all surplus grease which has been squeezed out
dirt (e.g. heavily clogged filters) can point to a fault which at the lubricating points.
could cause extensive and costly repairs if not corrected in --- Preferably carry out lubrication with bearing points and
time. joints unloaded and with the bearings in different position (
e.g. lubricate the steering knuckle bearing on the steering axle
--- When carrying out checks the tractor should stand on level
with the wheels at both full left and right lock and with the front
ground. axle lifted up).
--- Levels should be checked in the morning when the oil is
cold and has had time to run down to the bottom of the unit
concerned. Lubrication and maintenance schedule
All intervals are counted from zero on the hour recorder. For
example, 1000---hour service is carried out every 1000 and
2000 hours according to the hour recorder (yearly or every
other year) even if the operates have been carried out at the
guarantee service.
Example:
The 1000---hour service includes all operates listed under
daily/every 10 hours,weekly/every 50 hours,250, 500 and
1000 hours.
13
Model Code Page
1. 5. 1996
12. Maintenance 205 -- 900 120 2
1. 1. 1998
7 6 12 1 9 10 4
7 6 11 4 2 3 5 4 4
Maintenance daily/weekly Weekly/every 50 hours

4. Lubricate front axle and steering nipples
Daily/every 10 hours 2 ---wheel drive
1. Check engine oil level --- axle mountings (2 nipples)
2. Check coolant level --- steering knuckles (2 nipples)
3. Clean the cyclone cleaner (check oil elevel in filter on --- tie ---rod ends (4 nipples: not on later models)
205). 865, 800 and 900 tractors have not a cyclone but 4 ---wheel drive
an ejector pipe. --- universal joints (ZF: 4 nipples, Sige: 2 nipples)
--- front axle mountings (ZF: 6 nipples, Sige: 4 nipples)
--- steering knuckles (on later models 4 nipples)
5. Lubricate propeller shaft, 4WD (3 nipples). On later models
there are no grease nipples for propeller shaft.
6. Lubricate brake and clutch pedals (2 nipples)
7. Lubricate top link and lifting links (5 nipples)
8. Lubricate extra lifting cylinder nipples (if fitted)
9. Check fluid level in windscreen washer
10. Check fan and alternator belt
11. Check electrolyte level in battery
12. Drain water from fuel filter (20---series engines). 865, 800
and 900 tractors also have a separate water trap.
14
Model Code Page
1. 1. 1998
12. Maintenance 205 -- 900 120 3
1. 6. 1998
35 36 32
39 28 33 21 19 15 41 40 15 37 41 14 25 31
29 26
30 23
39 19 17 16 20 13 43 33 42 37 25 24
27 32
3055--- 69
Every 250 hours Every 1000 hours/yearly

13. Clean heating system air filter. 600---900: Clean air filter of 29. Change oil in hydraulic system
roof fan. 30. Change oil in power transmission
14. Clean air filter (change if necessary) (on 255 change oil in 31. Change oil in differential, 4---wheel drive
filter) 32. Change oil in hub reduction gears, 4---wheel drive
15. Change engine oil and oil filter 33. Clean hydraulic pump suction strainer
16. Change hydraulic system pressure filter. First change at 34. Drain fuel tank
100 hours Service inspection. The second change at 250 35. Change fuel filter. 865, 800 and 900 with Stanadyne water
running hours and the third at 500 hours. After that at inter- trap: also change the water trap filter.
vals of 500 running hours. 36. Change safety filter in air cleaner (om 255, clean the filter)
17.Lubricate gear lever joints 37. Check, adjust and lubricate front wheel bearings,
18.Check tyre pressures and wheel nuts 2---wheel drive
38. Check and adjust front wheel toe ---in
Every 500 hours 39. Lubricate drive axle bearings (2 nipples)
19. Clean separate water trap on 865 (not 865, 800 and 900, if 40. Adjust valves
a Stanadyne water trap has been fitted). 40a. 600---900: Change air filter of roof fan.
20. Check brake pedal free travel 40b. 600---900: Change breather filter (in filling cap)
21.Check propulsion clutch pedal free travel
22. Check PTO lever free travel Every 2000 hours/every other year
23. Check oil level in power transmission 41. Clean cooling system
24. Check oil level in differential, 4---wheel drive 42. Check alternator
25.Check oil level in hub reduction gears, 4---wheel drive 43. Check starter motor
26. Check oil level in hydraulic system 44. Check and clean injectors
27.Change pressure filter in hydraulic system
28. Change oil filter in transmission Every 4000 hours (not 205, 355, 365 and 665)
45. Turbo unit checked at authorized workshop
15
Model Code Page
15. 4. 1999
12. Maintenance 205 -- 900 120 4
1. 9. 2001
Recommended fuel and lubricants

(All volumes are incl. of filters)
Part of machine SAE class API grade Volume (litres)

Engine
--- 205, 255, 355, 365, 600 15W/40 (+40... ---10˚C) CE 7
--- 305, 405, 455, 465, 700, 555, 565 10W/30 (+30... ---20˚C) CF/CF ---4 7
--- 665, 800, 865, 900 9
Working hydraulics HT60: ---30˚C...+30˚

HT100: ---10C...+40C ISO VG 32 35 (upper mark)
32: ---30 ˚C...+30˚C ISO VG 46 25 (lower mark)
46: ---10˚C...+40˚C
Power transmission HT60: ---30˚C...+30˚ GL ---4 23 (865, 600---900: 27)
HT100: ---10C...+40C (G2---98)
Powered front axle ZF:
--- differential 4,5
--- hubs 2x0,5
Powered front axle Sige (Dana): 80W/90 GL ---5 (LS)
--- differential 6,5
--- hubs 2x0,8
Fuel tank
--- 205---865 Diesel fuel 73
--- 600---900 79 (extra tank 103)
Cooling system without expansion tank: Anti ---feeze agent+water (stan-
--- 205---565, 600, 700 dard ASTM D3306---86a or BS 10 (600, 700: 11,5)
--- 665, 865, 800, 900 6580:1985) 11,5 (800, 900: 13,5)
Cooling system with expansion tank:

600---700 13,5
800---900 15.5
Windscreen washer Washer fluid 1,5
Front PTO See code 460.
Note! The following Valtra oils are recommended:

Valtra Engine in engine
Valtra transmission in Power Transmission
Valtra Hydraulic in hydraulic system
Valtra Axle in Powered front axles.
Note! Recommended oil in front PTO, see code 460.
415M -- tractor
Oil specification in torque converter/reverse shuttle:

--- automatic transmission fluid (ATF), which meets requirements: Dexron, type A Suffix A
Oil volume:
--- total volume 8,3 litres
--- change volume 6 litres
Other maintenance instructions and filling quantities are the same as on 405 tractor.
16
20. Engine 21. Engine
(309--- and 311---engines)
22. Fuel system

(309--- and 311---engines)
23. Cooling system

(309--- and 311---engines)
21A. Engine
(320,420---engines)
22A. Fuel system

(320,420---engines)
23A. Cooling system

(320,420---engines)
17
18
Model Code Page
21. Engine 205-- 555 210 1
1. 12. 1986
Contents
General (Op. no. 210):
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repair instructions
Cylinder block and flywheel housing (Op. no. 211):
1. Cylinder block and cylinder liners:

A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Fitting plug at rear end of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. Fitting cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Flywheel housing:
A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder head and valve mechanism (Op. no. 212):
1. Cylinder head:
A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Changing copper sleeve for injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.Valve mechanism:
A. Reconditioning rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Changing camshaft/camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crank mechanism (Op. no. 213):
1. Crankshaft:
A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Connecting rods and pistons:

A. Removing piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19
Modell Code Page
1. 7. 1989
21. Engine 205 -- 555 210 2
10. 1. 1992
Engine timing gears (Op. no. 214)

1. Timing gear casing:
A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing crankshaft front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication system and oil sump (Op. no. 215)

1. Lubrication system:
A. Reconditioning lubricating oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing lubricating oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inlet and exhaust systems, turbocharger (Op. no. 216)

1. Inlet and exhaust systems:
A. Checking air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Checking inlet and exhaust systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Turbocharger:
A. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Reconditioning turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing and fitting engine (Op. no. 219)

1. Removing and fitting engine by parting tractor:
A. Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Removing and fitting engine without parting tractor:

A. Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Fitting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical data
Tractor 205 305 355 405 455 555
Designation D27D2 TD27DS3 TD33D TD27DS4 TD33DS4 TD33DS 555
Turbocharger no yes no yes yes yes
No of cylinders 3 3 3 3 3 3
Displ. dm3 2,7 2,7 3,3 2,7 3,3 3,3
Stroke mm 114 114 120 114 120 120
Cyl. bore mm 100 100 108 100 108 108
Compr. ratio 18:1 18:1 17:1 18:1 16:1 16:1
Output kW DIN 36/2350 39/2350 44,5/2350 45/2350 49/2350 53/2350
Torque Nm/rpm 175/1450 195/1400 220/1400 220/1450 240/1450 260/1450
Idling speed rpm 650 650 750 650 750 750
Valve clear. mm 0,30 0,30 0,30 0,30 0,30 0,30
Compr. press. bar24 1) 24 1) 24 1) 24 1) 24 1) 24 1)
1) Minimum value at starter motor speed (warm engine). The greatest allowable difference between cylinders is 0,3 bar.
Note!
From tractor no 656316 tractors 355, 455 and 555 have new 20---series engines. See sections 21A, 22A
and 23 A.
20
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 3
10. 1. 1992
Valves, rocker arms and tappets (205---555)

Valve timing
At a valve clearance of 0,30 mm:
--- inlet valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10˚ B.T.D.C.
--- inlet valve closes at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42˚ A.B.D.C.
--- exhaust valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42˚ B.B.D.C.
--- exhaust valve closes at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10˚ A.T.D.C.
Valve clearance, cold or warm engine:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm
Seat angle in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30˚±5’
Seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0---1,5 mm
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29_30’±5’
Valve head diameter:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 mm (45 mm, 355,455, 555)
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 mm (40 mm, 355, 455, 555)
Stem diameter, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.465---9.480 mm
Stem diameter, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.445---9.460 mm
Clearance, valve stem ---guide, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040---0.070 mm
Clearance, valve stem ---guide, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060---0.090 mm
Maximum wear limit, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm
Maximum wear limit, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm
Valve guide I.D. (before fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.520---9.535 mm
Valve guide O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.028---16.039 mm
Bore in cylinder head for valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.000---16.018 mm
Height of valve guide above cylinder head face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Distance between cylinder head and valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2---1.4 mm
Valve spring, free length:
--- inner spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 mm
--- outer spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 mm
Loading when valve spring is compressed to:
--- inner spring, 41.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70---90 N
--- outer spring, 47 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190---210 N
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.959---19.980 mm
Rocker arm bushing I.D. (bushing fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.990---20.010 mm
Rocker arm bushing O.D. (before fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.035---23.048 mm
Rocker arm hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.000---23.021 mm
Pushrod length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 ---1 (238 ---1, 455)
Pushrods must be straight to within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm
Rocker arm shaft spring, free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Loading when rocker arm shaft spring is compressedto 58 mm . . . . . . . . . . . . . . . . . . . . . . . . . 80---100 N
Tappet O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.939---29.960 mm
Bore in cylinder block for tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000---30.021 mm
Camshaft (205, 305, 405)
Bearing journal no. 1, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.925---49.950 mm

Bearing journal nos 2---4, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.885---49.910 mm
Bearing no. 1, bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.040---50.060 mm
Bearings nos 2---4, bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.000---50.025 mm
Radial clearance no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090---0.135 mm
Radial clearance nos. 2---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090---0.140 mm
Tolerance, 1st bushing in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025---0.080 mm
Camshaft end float (with 0.5 mm gasket betweencylinder block and timing gear
casing and betweentiming gear casing and front cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045---1.550 mm
Cam height (distance between cam lobe top and opposite side).41.44 mm
Cam lift (lobe top height above the “circle”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44 mm
Max. permissible figure for out---of ---roundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
21
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 4
10. 1. 1992
Camshaft (355, 455, 555)

Bearing journal no. 1, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.905---49.930 mm
Bearing journal nos 2---4, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.885---49.910 mm
Bearing bores, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.000---50.025 mm
Radial clearance no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070---0.120 mm
Radial clearance nos 2---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09---0.140 mm
Tolerance, 1st bushing in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.023---0.072 mm
Camshaft end float (with 0.5 mm gasket between cylinderblock and timing gear
casing and between timing gearcasing and front cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.450---1.550 mm
Cam height (distance between cam lobe top and opposite side) . . . . . . . . . . . . . . . . . . . . . . . . 41.44 mm
Cam lift (lobe top height above the “circle”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44 mm
Max. permissible figure for out---of ---roundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
Cylinder liners (205, 305, 405)

Height above block face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030---0.080 mm
Max. height difference between cylinder liners under thesame cylinder head . . . . . . . . . . . . . . 0.020 mm
Cylinder liner I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.015---100.037 mm
Liner flange height, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.03---8.05 mm
Liner flange height, 1st oversize, part no 8365 36828 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.08---8.10 mm
Liner flange height, 2nd oversize, part no 8365 36829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13---8.15 mm
Liner flange height, 3rd oversize, part no 8365 36830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23---8.25 mm
Cylinder liner flange, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.90---122.00 mm
Cylinder liners (355, 455, 555)

Height above block face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030---0.080 mm
Max. height difference between cylinder liners under thesame cylinder head . . . . . . . . . . . . . . 0.020 mm
Cylinder liner I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.000---108.022 mm
Liner flange height, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.03---9.05 mm
Liner flange height, 1st oversize, part no 8353 29829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.08---9.10 mm
Liner flange height, 2nd oversize, part no 8353 29830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13---9.15 mm
Liner flange height, 3rd oversize, part no 8353 29831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23---9.25 mm
Cylinder liner flange, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.700---131.800 mm
Piston, piston rings and piston pin (205, 305, 405)
Minimum distance between piston and cylinder head, measured with a piece of lead
wire through the injector location hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.900---1.150 mm
Piston diameter: --- 26 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.873---99.887 mm
Piston pin hole, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.003---36.009 mm
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.995---36.000 mm
Ring groove width:
--- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.580---2.600 mm
--- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.040---3.060 mm
--- groove 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.040---4.060 mm
Piston ring clearances in grooves:
--- upper compression ring, hard chromed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09---0.122 mm
--- 2nd compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.082 mm
--- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.082 mm
--- maximum wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm
Piston ring widths:
--- ring 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.478---2.490 mm
--- ring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.978---2.990 mm
--- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.978---3.990 mm
Piston ring gap:
--- compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4---0.6 mm
Max permissible weight difference between pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 g
Heat piston to 100_C before fitting piston pin.
22
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 5
10. 1. 1992
Piston, piston rings and piston pin (355, 455, 555)

Piston diameter:
--- 19 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.853---107.867 mm
--- 75 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.742---107.757 mm
--- 93.5 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.580---107.600 mm
--- 108.5 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.510---107.530 mm
Piston pin hole, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.006 mm
Piston pin, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.995---40.000 mm
Ring groove widths:
--- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.560---2.580 mm
--- groove 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.030---3.050 mm
--- groove 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.040---5.060 mm
Piston ring clearance in grooves:
--- upper compression ring, hard chromed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07---0.102 mm
Piston ring width:
--- ring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.478---2.490 mm
--- ring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.978---2.990 mm
--- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.978---4.990 mm
Piston ring gap, new ring kit no. 8363 39201:
--- upper compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3---0.55 mm
--- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3---0.6
--- maximum wear limit, ring 1 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm
--- maximum wear limit, ring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 mm
Max. permissible weight difference between pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 g
Heat piston to 100_C before fitting piston pin.The combustion chamber should be turned towards the injectors.
Connecting rod (205, 305, 405)
Connecting rod bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.025---36.040 mm

Connecting rod bushing O.D. (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.060---40.076 mm
Connecting rod bushing, (oversize 8360 38605) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.580---40.620 mm
Interference fit: connecting rod bushing/connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035---0.120 mm
Connecting rod bushing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.025 mm
Connecting rod bushing location, diameter (oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.500---40.525 mm
Big end bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.730---65.749 mm
Connecting rod (355, 455, 555)
Connecting rod bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.025---40.040 mm

Connecting rod bushing O.D. (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.082---44.120 mm
Connecting rod bushing O.D. (oversize 8353 28326) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.580---44.620 mm
Interference fit: connecting rod/connecting rod bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.057---0.120 mm
Connecting rod bushing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.000---44.025 mm
Big end bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.730---71.749 mm
Connecting rod end ---float on crank shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.200---0.312 mm
Weight marking (letter) at lower end.
Max. permissible weight difference between connectingrods in the same engine . . . . . . . . . . 20 g
23
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 6
10. 1. 1992
Crankshaft (205, 305, 405)

Big end journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.981---62.000 mm
--- 1st undersize, 0.25 mm (bearing 8360 97266) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.731---61.750 mm
--- 2nd undersize, 0.50 mm (bearing 8360 97267) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.481---61.500 mm
--- 3rd underside, 1.00 mm (bearing 8360 97269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.981---61.000 mm
--- 4th undersize, 1.50 mm (bearing 8360 97271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.481---60.500 mm
Big end journals, length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.160 mm
Big end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.046---0.098 mm
Main bearing journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.988---70.018 mm
--- 1st undersize, 0.25 mm (bearing 8360 97273) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.738---69.768 mm
--- 2nd undersize, 50 mm (bearing 8360 97274) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.488---69.518 mm
--- 3rd undersize, 1.00 mm (bearing 8360 97276) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.988---69.018 mm
--- 4th undersize, 1.50 mm (bearing 8360 97278) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.488---68.518 mm
Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051---0.101 mm
Width of thrust bearing journal on crankshaft (nearest flywheel):
--- standard (2 std thrust bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.000---47.080 mm
--- 1st undersize (one std and one 0.2 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . 47.200---47.280 mm
--- 2nd oversize (two 0.2 mm oversize thrust washers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.400---47.480 mm
Other bearing journals must not be ground so as to make them longer.
Crank shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100---0.320 mm
Big end and main bearing journals, max. permissible figure for
out---of ---roundness or other deformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
Crankshaft balancing accuracy, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Ncm Max
Crankshaft (355, 455, 555)

Big end journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.981---68.000 mm
--- 1st undersize, 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.731---67.750 mm
--- 2nd undersize, 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.481---67.500 mm
--- 3rd undersize, 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.981---67.000 mm
--- 4th undersize, 1.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.481---66.500 mm
Big end journals, length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.160 mm
Big end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.046---0.098 mm
Main bearing journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.985---85.020 mm
--- 1st undersize, 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.735---84.770 mm
--- 2nd undersize, 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.485---84.520 mm
--- 3rd undersize, 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.985---84.020 mm
--- 4th undersize, 1.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.485---83.520 mm
Main bearing location (in block), diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.000---91.022 mm
Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050---0.127 mm
Width of thrust bearing journal on crankshaft (nearest flywheel):
--- standard (2 std thrust bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.000---45.080 mm
--- 1st oversize (one std and one 0.1 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . . . 45.100---45.180 mm
--- 2nd oversize (one std and one 0.2 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . . 45.200---45.280 mm
--- 3rd oversize (one 0.1 mm and one 0.2 mm oversize thrust washer . . . . . . . . . . . . . . . . . . . . . 45.300---45.380 mm
--- 4th oversize (two 0.2 mm oversize thrust washers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.400---45.480 mm
Other bearing journals must not be ground so as to make them longer.Crankshaft end float . 0.100---0.350 mm
Big end and main bearing journals, max. permissible figure
for out---of ---roundness or other deformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
Crankshaft balancing accuracy, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Ncm Max
Flywheel (205---555)
Flywheel ring gear, number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Interference fit: ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.422---0.600 mm
When fitting the ring gear should be heated to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150---200_C
Flywheel balancing accuracy, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Ncm Max
Permissible throw of flywheel friction surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06:ø200
24
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 6.1
10. 1. 1992
Timing gears (205---555)

Tooth backlash:
--- Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
--- Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
--- Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
All timing gears, max. radial throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.951---54.970 mm
Idler gear bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000---55.030 mm
Timing gear markings:
When the timing gear markings are opposite each other the piston in the first
cylinder is at T.D.C. between the compression and power stroke.
On the crankshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 punch marks on teeth.
On the idler gear:
--- against the crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 on a tooth
--- against the camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark on a tooth
--- against the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark at a tooth gap
On the camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark at a tooth gap
On the fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark on a tooth
Crankshaft must be rotated 6 turns before all gear markings fall into line again.
Lubrication (205---555)
Lubricating oil pressure at working temperature:
--- at low idling speed, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 kPa (1.5 kp/cm@)
--- at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300---500 kPa (3---5 kp/cm@)
Spring for oil relief valve, free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring for oil relief valve, loading when 52 mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54+5 N (5.4+0.5 kp)
Oil relief valve, diameter of valve cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.602---19.635 mm
Oil relief valve, diameter of hole in insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.700---19.752 mm
Oil filter by ---pass valve opens at a pressure difference of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 bar
Lubrication oil pump (205---555)
Tooth backlash when crankshaft is resting on the main bearings:

--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16---0.26 mm
Drive shaft clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.016---0.052 mm
Holes in body and cover, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.000---18.018 mm
Gear wheel I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.060---18.078 mm
Gear clearance on fixed drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.021---0.050 mm
Clearance of fixed shaft end ---face of body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5---1.0 mm
Gasket thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06---0.08 mm
Pump gear O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.486---43.525 mm
Gear clearance in body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.125---0.264 mm
Gear location in body, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.650---43.750 mm
Width of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.000---18.027 mm
Gear wheel end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03---0.11 mm
Oil pump body, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.000---18.043 mm
Number of teeth on gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
25
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 6.2
10. 1. 1992
Coolant pump (205---555)

Bearings O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.087---38.100 mm
Bearing location, diameter (in pump body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.058---38.083 mm
Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.907---15.920 mm
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.881---15.899 mm
Seal location, diameter (in pump body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.450---36.489 mm
The impeller should be mounted on the shaft so thatthe distance between
the rear face of the impeller and therear face of the pump body is . . . . . . . . . . . . . . . . . . . . . . . 1---1.7 mm
The hub should be mounted on the shaft so that the distance
between the contact face for the fan and the rear face of the pump body is . . . . . . . . . . . . . . . 157 mm
Fan guide (shoulder) on hub, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.00---25.20 mm
Fan, max. balancing accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 Ncm max
Fan, max. throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm
At correct belt tension it should be possible to deflect the belts . . . . . . . . . . . . . . . . . . . . . . . . . . 15---20 mm
Thermostat (205---555)
Spare part number Diam./Type Opening Fully Max. stroke

commences open mm
8360 15156 ø54/79˚ C 80˚ ---3˚C 94˚ C 7,5
8360 15486 ø54/83˚ C 83˚ ---3˚ C 95˚ C 7,5
Cylinder block (205, 305, 405)
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.000---13.043 mm

Main bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.000---76.019 mm
Cylinder liner location, diameter:
--- at upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.012---116.047 mm
--- at lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115.000---115.035 mm
Camshaft bearing bushing, I.D. when fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.040---50.060 mm
Cylinder block (355, 455, 555)
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.000---13.043 mm

Main bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.000---91.022 mm
--- at upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.514---123.554 mm
--- at lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.000---122.040 mm
Camshaft bearing bushing, I.D. when fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.000---50.025 mm
Cylinder head (205---555)
Seat for copper sleeve, diameter:

--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.000---28.033 mm
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.000---27.033 mm
Copper sleeve O.D.:
--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.979---28.000 mm
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.073---27.090 mm
Cylinder head thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.90---105.10 mm
Cylinder head minimum thickness after machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.70 mm
Cylinder head bolts, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
26
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 7
10. 1. 1992
Turbocharger Holset H1D (not 205 and 355)

Oil pressure at rated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 2 bar
Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10---0.16
Shaft running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30---0.46
Turbine housing mounting bolts (M8x12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Nm
Compressor housing mounting bolts (M6x12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Nm
Bearing housing mounting bolts (M6x16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Nm
Nut at end of shaft (LH thread on shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.0 Nm
Turbocharger Schwitzer S2A (not 205 and 355)
Oil pressure at rated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 2 bar

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.12 mm
Shaft running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 1.0 mm (dry)
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Nm
V ---band nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Nm
Partial vacuum and counter pressure

Partial vacuum at air cleaner, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 kPa (500 mm, water gauge)
Counter pressure at exhaust pipe, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 kPa (600 mm, water gauge)
Tightening torques
Engine fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (8 kpm)
Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (6 kpm)
Exhaust pipe ---turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (2.3 kpm)
Big end bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm (9 kpm)
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm (16 kpm)
Crankshaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm (60 kpm)
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm (12 kpm)
Idler gear bolts:
---M 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (6 kpm)
---M 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Nm (14 kpm)
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm (16 kpm)
Flywheel housing bolts:
--- outer ring, M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm (11 kpm)
--- inner ring, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (6 kpm)
Special tools
21. Engine A
Part number Description

1. 8360 97532 Lever for compressing valve spring (505---905)
2. 8360 97336 Counterhold nut for above (505---905)
3. 8361 97470 Milling tool for injector seat (505---905)
4. 8360 97463 Drift for fitting injector sleeve (505---905)
5. 8360 86085 Extractor for injector sleeve (505---905)
6. 8360 97315 Drift for fitting crankshaft rear seal (505---905)
7. 9030 15200 Drift for fitting crankshaft front seal (505---905)
8. 8360 85499 Puller for coolant pump impeller (505---905)
9. 8360 13091 Puller for coolant pump hub (505---905)
10. 9025 58000 Cylinder head spanner (505---905): earlier number 8360 97328
21. Engine B
Part number Description

11. 8360 97337 Drift for removing valve guide (505---905)
12. 8360 97457 Drift for fitting valve guide (505---905)
13. 8360 97434 T ---handle for valve seat milling cutter (505---905)
27
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 8
10. 1. 1992
14. 8360 97435 Milling cutter for facing exhaust and inlet valve seat(505---905)
15. 8360 97436 Milling cutter for exhaust and inlet valve seat (505---905)
16. 8360 97437 Inner milling cutter for exhaust and inlet valve seat (505---905)
17. 8361 97468 Drift for fitting 16 mm cap plug (505---905)
19. 8360 97327 Puller for crankshaft gear (505---905)
20. 9025 79200 Holder for dial gauge (505---905)
21. 9025 78100 Press tool for cylinder liner (505---905)
22. 9025 98900 Drift for fitting dust cover, crankshaft front seal (505---905)
23. 9051 40200 Drift for fitting coolant pump seal (505---905)
24. 9025 98800 Drift for fitting tubular pin in timing gear casing (505---905)
26. 9051 73100* Puller for cylinder liner
26A. 8365 39293 Puller flange, 205, 305, 405
26B. 8353 39292 Puller flange, 355, 455, 555
27. 9051 72900* Milling cutter for fitting cylinder liner, 205, 305, 405
27A. 9051 72800 Milling cutter for fitting cylinder liner, 355, 455, 555
28. 9051 71300* Puller for injector
Locally prepared tools

29. 9051 64900 Drift for fitting coolant pump shaft (505---905)
30. ET(893 760) Support between front end and front axle to prevent oscillation
3 4 5
7
6
8
10
28
Model Code Page
21. Engine 205 -- 555 210 9
1. 12. 1986
13 19
14
15
12
11
16
17 18
21
20
22
23
26
25
24
27
26A
28
29
Model Code Page
21. Engine 205 -- 555 210 10
1. 12. 1986
29
30
30
Model Code Page
21. Engine 205 -- 555 210 11
1. 12. 1986
Engine, description
The engine on tractors 305---555 is a liquid ---cooled, four ---
stroke, turbocharged, direct---injection diesel engine. The
peripherals of the engine are shown in Figs. 210 1 and 210---2.
309 left side

1. Turbocharger
2. Injector
3. Fuel filter
4. Water trap
5. Oil pressure gauge sender
6. Oil dipstick
7. Oil filter
8. Oil pressure relief valve
9. Engine heater
10. Timing indicator
11. Fuel feed pump
12. Fuel injection pump
13. Oil filler
14. Thermostat housing
15. Serial number
31
Model Code Page
21. Engine 205 -- 555 210 12
1. 12. 1986
309 right side

1. Thermostart device fuel reservoir
2. Thermostart glow plug
3. Breather hose
4. Temperature gauge sender unit
5. Coolant pump
6. Timing gear casing cover
7. Alternator
8. Starter motor
32
Model Code Page
21. Engine 205 -- 555 210 13
1. 12. 1986
Longitudinal section of engine 309
33
Model Code Page
21. Engine 205 -- 555 210 14
1. 12. 1986
Cylinder block
Figure 210 4
1. Cylinder block
2. Cylinder liner
3. O ---ring
4. Bearing sleeve
5. Bearing cap
6. Bearing cap with thrust bearing
7. Guide sleeve
8. Bolt
9. Plug
10. Threaded plug
11. Guide pin
12. Threaded connection
13. Cylinder head bolt
14. Plug (camshaft end)
15. Pressure sender unit
16. Sealing ring
17. Plug
18. Pipe for oil dipstick
The cylinder block is the main body of the engine, to which

other engine parts are attached. The cylinder liners are so
called wet liners, which means that the coolant is in direct con- The camshaft is located in the cylinder block. The camshaft
tact with the outer surface of the liners. The seal between the front bearing location is provided with a separate bearing
cylinder liner lower part and the cylinder block is achieved by sleeve (4). The remaining bearing locations are machined
two O ---rings (3), which are fitted in grooves in the liner. The directly in the cylinder block. The drilling for the camshaft rear
upper part is sealed by the cylinder head gasket. The distance end is covered with a plug.
between the cylinder liner flange and the face of the cylinder
block plays a major role in sealing the upper part. Bear this in There is space on both sides of the rear main bearing for guide
mind when fitting the cylinder liner. bearing shims (the camshaft thrust bearing).
Flywheel housing
Figure 210 5
1. Flywheel housing
2. Bolt M12x35
3. Socket head bolt M10x30
4. Crankshaft oil seal
5. Rubber plug
6. Tubular pin
7. Screw stud 10x25
8. Washer
9. Nut M10
The flywheel housing is fitted to the rear end of the cylinder

block. The starter motor and the crankshaft rear oil seal are
also fitted in the flywheel housing. There is also a hole in the
flywheel housing for inserting a tool in order to crank the
engine. The return oil flow from the engine lubricating system
is channelled through the flywheel housing. The lower face of the flywheel housing fits up against the oil
sump and its front face against the cylinder block. This has to
be taken into account when fitting the flywheel housing, which
is guided partly by the guide pin (6).
34
Model Code Page
21. Engine 205 -- 555 210 15
1. 12. 1986
Cylinder head
Figure 210 6
1. Cylinder head
2. O ---ring
3. Sleeve for injector
4. Plug
5. Valve guide
6. Plug
7. Valve cover
8. Gasket
9. Nut
10. Washer
11. Rubber seal
12. Breather hose
13. Lifting bracket
14. Screw stud
15. Sealing ring
16. Hose coupling
17. Bolt
18. Cylinder head gasket
The cylinder head is made of cast iron, and each cylinder has
its own inlet port and common exhaust port. The stiffness and The inlet and exhaust valve guides (1) are identical and can
even spread of attaching bolts give a good seal for the cylin- be interchanged. The injectors are surrounded by replace-
der head gasket. The directed flow of the coolant ensures that able copper sleeves (2) which are in contact with the coolant,
the valve seats are effectively. thus the injectors are effectively cooled.
Cross---section of cylinder head
1. Valve guide
2. Injector sleeve
3. O ---ring seals
35
Model Code Page
21. Engine 205 -- 555 210 16
1. 12. 1986
Valve mechanism
1. Circlip
2. Shim
3. Nut
4. Rocker arm
5. Bearing sleeve
6. Adjusting screw
7. Holder
8. Spring
9. Shaft
10. Plug
11. Pushrod
12. Tappet
13. Valve keepers
14. Spring guide
15. Valve spring
16. Valve spring
17. Spring guide
18. Exhaust valve
19. Inlet valve
20. Gear wheel
21. Key
22. Camshaft
23. Threaded plug
The valve mechanism is operated by the camshaft (22) which

is located in the cylinder block. The drive is transferred with
the help of tappets (12) and pushrods (11). The camshaft gear
wheel (20) is fitted with a press fit and fixed with a key (21).
Each bearings is lubricated by the force feed lubrication sys-
tem through drilled oilways in the camshaft.
Crank mechanism
1. Crankshaft
2. Key
3. Cylindrical pin
4. Main bearing
5. Thrust bearing
6. Flywheel
7. Ring gear
8. Bolt
9. Hub
10. Shaft seal boot
11. Deflector ring
12. Gear wheel
13. Gear wheel
14. V ---belt pulley
15. Nut
17. Piston
18. Piston rings
19. Piston pin
20. Retaining ring
21. Connecting rod
22. Bearing bushing
23 Bolt
24. Nut
25. Crankshaft bearing
The crankshaft (1) is forged from chrome alloy special steel shaft has splines for the hub (9) of the V ---belt pulley (14). An
and is induction hardened at the bearing and sealing sur- oil deflector ring (11) is fitted between the hub and the gear
faces. Gear wheels (12 and 13) are located at the front end of wheel, and a dust shield (10) is fitted to the hub in order to seal
the crankshaft. They are fitted with a press fit, and drive the the shaft.
idler wheel and oil pump. In addition, the front end of the
crank ---
36
Model Code Page
21. Engine 205 -- 555 210 17
1. 12. 1986
The flywheel (6) is fitted to the rear end of the crankshaft. The
ring gear (7) is fitted to the flywheel with a press fit. The forged
connecting rod has an I ---shaped cross---section. The bear-
ing location at the bottom end of the connecting rod is split,
and the bearing cap is secured by two special bolts (23) and
nuts (24). The upper end of the rod has a fixed bearing loca-
tion, in which the piston pin bearing bushing (22) is fitted with
a press fit.
Piston
1. Combustion chamber
2. Circlip
3. Piston pin
4. Bearing bushing
5. Connecting rod
6. Chromed compression ring
Bearing shell 7. Compression ring
8. Spring loaded oil control ring chromed slide surfaces
1. Indium ---lead alloy The piston is made of an eutectic aluminium alloy. In the upper
2. Lead ---bronze part of the piston there is a combustion chamber (1). The
3. Steel shell shape of the chamber is intended to maximise the mixture of
air and fuel. The number of piston rings is three, of which the
The crankshaft has four main bearings, one on either side of upper (6) has a barrel face, chromed slide surface. The sec-
each cylinder. The thrust bearing is located on either side of ond compression ring (7) is tapered at an angle of 1,5˚, and
the rear main bearing journal. The main and big ---end bear- the third ring is a spring loaded oil control ring (8). The piston
ings are three ---layer bearings, which have a tough lead pin (3) has a close tolerance in the piston and a floating fit in
bronze alloy, with good heat dissipating properties, inside the the connecting rod.
steel shell. The actual sliding surface is covered by a layer of
indium ---lead, which makes the running ---in period easier.
37
Model Code Page
21. Engine 205 -- 555 210 18
1. 12. 1986
Timing gear casing
1. Timing gear casing

2. Bolt
3. Gasket
4. Screw stud
5. Tubular pin
6. Gasket
7. Front cover
8. Sealing ring
9. Protective ring
10. Nut
11. Gasket
12. Filler pipe
13. O ---ring
14. Cap
15. Washer
16. Spacer ring
17. Bearing housing
18. Gasket
19. Bearing
20. Circlip
21. Shaft
22. Plug
23. Sealing washer
24. Timing indicator
25. Attaching plate
26. Rubber plug
The timing gear train consists of hardened, helically cut gear timing gear casing. Sealing ring (8) is fitted to the front end of
wheels. The gears are encased by the timing gear casing (1) the crankshaft and the protective ring (9) is positioned inside
which is fitted to the front of the engine. The fuel injection the location in the front cover. The timing gears drive the cam-
pump, alternator and hydraulic pump with its drive are fitted shaft, fuel injection pump and oil pump.
to the timing gear casing. The front cover (7) is fitted to the
Idler gear with securing parts
1. Bolt M10x55
2. Bolt M14x65
3. Locking flange
4. Bearing bushing
5. Gear wheel
6. Shaft stud
The bearing for the idler gear (5) is a sliding bearing (4) and
is located on the axle (6). It is fitted to the cylinder block with
two bolts (1 and 2). The crankshaft and camshaft gears are
fitted to the shafts with a press fit and key. The fuel injection
pump gear is fitted on the pump shaft, which is tapered, with
a nut and key. In order to ensure the correct timing of the
gears, there are punch marks on each gear.
38
Model Code Page
1. 12. 1986
21. Engine 205 -- 555 210 19
1. 7. 1989
Lubrication system, 305---405

1. Oil pump
2. Suction strainer
3. Pressure relief valve
4. Oil filter
5. Main oil gallery
6. Main bearing oilway
7. Turbocharger
8. Camshaft
9. Idler gear
10. Valve mechanism
39
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 20
10. 1. 1992
The engine has a pressure lubricating system, in which the oil Oil is also taken from the main gallery to the injection pump
pump (1) pumps the oil to the different lubricating points. The and turbocharger (7), and via oilways in both ends of the cylin-
oil is sucked up by the pump through a suction strainer (2). der block, to the camshaft (8). The remaining camshaft bear-
After the pump the oil is ducted through an oilway to the relief ings are lubricated through drillings in the camshaft. Oil is also
valve (3) and the oil filter (4). After the filter, the oil is supplied fed from the oilway in the front of the cylinder block, to the idler
through the main oil gallery (5) from which the oilways for the gear (9) bearing. The oilway at the rear end of the camshaft
main bearings branch out. Through the oilways in the crank- leads to the valve mechanism (10). The oil returns from the
shaft the oil is supplied to the big ---end bearing. cylinder head through the pushrod bores to the oil sump.
Oil pump with oil sump

1. Nut
2. Washer
3. Gear wheel
4. Body
5. Key
6. Gear wheel
7. Gear wheel
8. Shaft
9. Gasket
10. End cover
11. Bolt
12. Pipe union
13. Compression ring
14. Nut
15. Suction pipe
16. Supply pipe
17. Socket head bolt
18. Shims
The oil pump is a gear pump and is attached to the lower face gears can be adjusted by varying the number of gaskets (9)
of the cylinder block. It is driven by the gear at the front end between the body and the cover. The tooth backlash between
of the crankshaft. The gear wheels (6 and 7) and their shafts the pump gear and the crankshaft gear can be adjusted with
are carried in bearings in the body (4). An end cover (10), to shims (18) between the pump body and cylinder block. The
which suction pipe (15) and supply pipe (16) are connected, flow is 45 litres/min at an engine speed of 2350 rpm.
is bolted to the body. The end float of the
Relief valve
1. Screw stud
2. Washer
3. Cover
4. Gasket
5. Washer
6. Spring
7. Valve cone
8. Cylinder insert
9. o---ring
10. Nut
The oil pressure relief valve is located in the cylinder block

below the oil filter (205, 305, 405) or in the timing gear casing
(355, 455, 555). The valve regulates the engine lubricating oil
pressure so that it is kept constant, regardless of the engine
speed. The “O” ring (9) seals against the cylinder insert (8).
The valve cone (7) closes the front end of the lower oil pass-
age. When the oil pressure exceeds the force exerted by the
spring (6), some of the oil is allowed to flow back to the sump.
Normal pressure is 3 ---5 kgf/cm@ depending on the prop-
erties of the oil; at low idling speed the pressure is 1.5 kgf/
cm@.
40
Model Code Page
21. Engine 205 -- 555 210 21
1. 12. 1986
Oil filter
The oil filter is of the disposable type and is a full---flow filter.

A by ---pass valve is located at the bottom of the filter to allow
for cold ---starting and if the filter should become clogged. In
addition, there is a non ---return valve which stops the filter
from being completely emptied of oil.
Induction and exhaust system
Induction system
1. Cyclone type precleaner

2. Dust collector
3. Nut
4. Main filter element
5. Sealing washer
6. Safety filter
7. Air cleaner housing
8. Clamp
9. Rubber hose
10. Inlet pipe
11. Induction manifold
12. Gasket
13. Bolt
The filter system for the engine induction air comprises a cyc- be cleaned when necessary. The inner, safety filter (6) pre-
lone type precleaner and a paper filter which acts as the main vents impurities from entering the engine, should the main
filter. The incoming air is made to rotate in the cyclone (1). This filter element break, or be fitted incorrectly. The safety filter
causes most of the impurities to separate out and collect in the should not be removed except when being changed. The inlet
cyclone precleaner dust collector (2). The paper filter com- system also includes the pipes between the air cleaner and
prises two replaceable filter elements. The impurities in the air the turbocharger and the turbocharger and the induction
collect on the outside of the large filter element (4) which can manifold (11).
41
Model Code Page
21. Engine 205 -- 555 210 22
1. 12. 1986
Turbocharger
1. Turbocharger
2. Gasket
3. Manifold
4. Screw stud M10x25
5. Nut M10
8. Bolt M8x30
9. Gasket
10. Pressure oil pipe
11. Sealing washer
12. Banjo bolt
13. Gasket
15. Return oil pipe
16. Hose
17. Clamp
18. Nut M6
19. Clamp for oil pipe
20. Bolt M6x30
The turbocharger (1) which is connected to the exhaust mani-

fold (3), is lubricated by the engine pressure lubricating sys-
tem, via a pressure oil pipe (10) and return oil pipe (15).
Function of turbocharger
The principle of the turbocharger is that is uses the energy in

the exhaust gases in order to force more air into the combus-
tion chambers. The turbocharger is fitted directly to the
exhaust manifold. The energy in the exhaust gases causes
the turbine wheel to rotate, which in turn drives the com-
pressor wheel. The rotating compressor wheel forces air into
the combustion chambers under pressure. Thus more air
enters the cylinders, allowing more fuel to be burnt and
thereby increasing the output. As the turbine wheel is driven
by the engine exhaust gases, the turbocharger automatically
adjusts itself to the workload and speed of the engine.
The turbine shaft runs in bearings with two floating bearing

bushings located in the bearing housing. The bearings are
lubricated and cooled by the engine pressure lubricating sys-
tem. Piston ring type sealing rings prevent oil leakage from the AIR
bearing housing.
GAZ D’ECHAPPEMENT
HUILE
42
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 211 1
10. 1. 1992
Repair instruction B. Removing cylinder liners
1. If the cylinder liners are to be used again they should be

Cylinder block and flywheel housing (Op. marked so that they can be fitted in the same position.
no. 211)
1. Cylinder block and cylinder liners

9051 73100
A. Measuring cylinder liner wear
1. Zero the cylinder bore gauge to the original dimension

100.015 mm (205, 305, 405) or 108.00 mm (355, 455, 555)
using a micrometer or a new cylinder liner.
2. Remove the cylinder liners using cylinder liner puller 9051

73100.
2. Clean the cylinder bore. C. Checking cylinder block

3. Measuring should be done in both the transverse and the 1. Clean the cylinder block. Do not forget the oilways.
longitudial direction of the engine, at both the top and bottom
dead centre positions as well as in the middle. 2. Check the cooling channels and remove any scale.
4. Note the wear and out---of ---roundness. Compare with the 3. Check the cylinder block for cracks and the sealing of
Technical Data. plugs. Check all sealing surfaces.
4. Measure the camshaft bearings and compare with Techni-

cal Data.
D. Changing camshaft bushing
1. Extract the bushing with an internal puller, for example

Sykes 854. If the camshaft rear end plug is removed the bush-
ing can be forced out with a long drift.
2. Clean the bushing location.
43
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 211 2
10. 1. 1992
F. Fitting plug at camshaft rear bearing
1. Clean the seat for the plug.
2. Apply sealing compound, part no. 6909 30008, on the con-

tact surface.
3. Press in the new bushing. Note the position of the oil hole.
The bushing is of nominal size and does therefore not have
to be reamed.
E. Oversize bushings for camshaft 9025 87400

If the location of the camshaft bushing (front bearing) is dam-
aged, an oversize bushing can be fitted. Bushings are also
available for other camshaft bearings which are not normally
fitted with bushings. Part numbers and machining dimen- 3. Drive in the plug with fitting drift 9025 87400 which ensures
sions for the bushing locations are shown in Fig. 211 4. the correct fitting depth.
The bushings can be fitted using “locally prepared tool” no.
8359 7536. N.B. If the plug is driven in too far it will affect the camshaft end
float.
75,5 213,5
6+0,2
+0,030
+0,030
+0,030
+0,030
G. Fitting pipe for oil dipstick

ø56,02
ø55,62
ø55
ø55
1. Clean the seat for the pipe.

8363 22610
8363 24661 2. Apply locking fluid part no. 6909 30012, on the lower end
8363 22609
of the pipe.
Oversize bushings for camshaft 205, 305,

405
75,5 213,5
6+0,2
45
+0,030
+0,030
+0,030
+0,030
ø55,60
ø55
ø55
ø61
8363 22610
8353 36463
8363 22609
Oversize bushings for camshaft 355, 455,

555
3. Tap in the pipe to the correct fitting height as shown in the

NOTE: When pressing in the new front and rear bushings, en- figure.
sure that the oil holes in the bushings align with the oilways in
the cylinder block. Shorten the threaded part of the plug at the
rear camshaft bearing by 1.5 mm. The plug for the rear end
of the camshaft is, after machining, replaced by plug 8363
24391 and “O” ring 6146 05125.
44
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 211 3
10. 1. 1992
H. Fitting cylinder liners 6. If the cylinder liner height is too low, a liner with a higher
flange is fitted.
1. Clean the cylinder liner and its recess in the cylinder block.
Without o---rings the liner should rotate easily in its recess.
2. Apply a thin layer of marking paint on the underside of the

cylinder liner flange. Fit the cylinder liner without o---rings and
turn it forwards and backwards. Lift out the liner and check
that paint has been deposited on the whole contact surface.
3. If the recess is damaged, or the cylinder liner height needs

to be adjusted, use milling cutter 9051 72900 (205, 305, 405)
7. Cylinder liners with oversize flanges (higher flanges) are
or 9051 72800 (355, 455, 555). If necessary, light lapping can
marked with grooves on the outer circumference of the flange,
be executed after milling with the help of the cylinder liner.
as follows (standard liners have no grooves):
Apply lapping paste to the underside of the cylinder liner
flange, and twist the liner with twisting tool 9051 73100. Lap-
1st oversize, 0,05 mm = 1 marking groove
ping is not suitable for adjusting the cylinder liner.
2nd oversize, 0,10 mm = 2 marking grooves
3rd oversize, 0,20 mm = 3 marking grooves
4. Clean the contact surfaces.
0,03---0,08 mm
8. If the liner height of a cylinder liner is not the same all the way
round, the cylinder liner flange and the cylinder block recess
depth should be checked. Cylinder liners with warped flanges
should be discarded. Recess depth is adjusted with a cylinder
9025 79200
liner recess cutter, see point 3.
9025 78100
5. Fit the cylinder liners and fix each liner with two press tools
9025 78100. Measure the cylinder liner height with a dial
gauge and holder 9025 79200. Zero the dial gauge against a
flat surface, for example, the cylinder block face. Measure
each liner in four places. The height of the liner above the cyl-
inder block face should be 0,03 ---0,08 mm. The height differ-
ence between cylinder liners under the same cylinder head
must not exceed 0,02 mm, nor must an intermediate cylinder
liner lie lower than an outer one.
9. Fit the “O” rings in the grooves on the cylinder liners and
lubricate them with a solution of soft soap.
45
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 211 4
10. 1. 1992
4. Centre the housing and fit the tubular pins with drift 9025
98700.
5. Tighten the bolts, the inner ring of socket head bolts (8 mm)
to 60 Nm and the outer ring of hexagonal bolts (19 mm) to 110
Nm.
Ø 3 musta/svart/black
schwartz/noir
B. Changing crankshaft rear oil seal
Ø 3 vihreä/green/grön
grün/vert 1. Part the tractor at clutch and remove the clutch assembly
(Op no. 411 1A).
Fitting the “O” rings to the cylinder liner. 2. Loosen the bolts (19 mm) and remove the flywheel.
N.B. Fit the o---rings from beneath and ensure that they are 3. Prize out the seal. Ensure that the crankshaft is not dam-
not stretched too much. If they are stretched more than 6 % aged.
they will not return to their original length.
4. Clean the sealing location and grind off any burrs.
Fit the cylinder liners in the cylinder block. They should fall into
place under fairly light pressure. Check that they do not rise 8360 20054
up again.
N.B. With effect from engine number 88946 has cylinder liner
lower end three o---rings. The two upper o---rings are black
and the lowest is green. As a spare part is delivered only liners
with three o---ring grooves.
2. Flywheel housing
A. Fitting flywheel housing
The flywheel housing is centred on the cylinder block by two

tubular pins. Even the flywheel housings which are delivered
as spare parts have pre ---drilled holes for the tubular pins.
1. Clean the sealing surfaces between the cylinder block and

the flywheel housing.
N.B. If the crankshaft is worn at the sealing location, a 2 mm

spacer ring, part no. 8360 20054, can be fitted inside of the
crankshaft rear oil seal.
2. Apply sealing glue as shown in the figure.
3. Lift the flywheel housing into place and fit all the bolts.
46
Model Code Page
21. Engine 205 -- 555 211 5
1. 12. 1986
8360 97315
5. Lubricate the sealing surfaces on the crankshaft and on the

seal.
Place the seal on the crankshaft and drive it until it bottoms
using drift 8360 97315. Other tools may cause the seal to be
damaged or mounted askew, resulting in leakage.
47
48
Model Code Page
21. Engine 205 -- 555 212 1
1. 12. 1986
Cylinder head and valve mechanism (Op.

no. 212)
8360 97336
1. Cylinder head
A. Removing cylinder head

1. Clean the engine externally and drain the coolant . Undo the
water hoses from the cylinder head and thermostat housing.
2. Remove the inlet pipes between the air filter and turbo-
charger and also the pipes between the turbocharger and the
induction manifold.
3. Remove the turbocharger pressure and return oil pipes (13

8360 97532
mm, 22 mm and socket head bolt 6 mm).
4. Remove the pipes to the thermostarter fuel reservoir.

2. Compress the valve springs using lever 8360 97532. Re-
5. Remove the bolt (socket head 8 mm), which holds the move the valve cotters, spring guide and spring. Remove the
engine compartment partition wall against the cylinder head. valves and place them in a valve stand.
Also remove the attaching bolts between the supports and the
induction manifolds.
6. Remove the injector leak ---off fuel pipes (10 mm) and the
delivery pipes (17 mm). Remove the injectors (13 mm). Fit
blanking ---off caps on all open connections.
C. Checking cylinder head
7. Remove the induction manifold (13 mm), exhaust manifold
(17 mm), thermostat housing (8 mm socket head) and the 1. Remove carbon deposits from the exhaust ports, clean the
front end lifting eye (17 mm). sealing surfaces and wash the cylinder head.
Note! The cylinder head can be removed with these parts still 2. Check for cracks and other damage.
in place.
8. Remove the valve cover (17 mm) and the breather hose.
9. Remove the rocker arm mechanism (17 mm) and the push-
rods.
10. Loosen the cylinder head bolts first by a 1/4 turn and then
remove them. Remove the cylinder head.
B. Removing valves
Ensure that valves which are to be re ---used are marked, so

that they are fitted in their original locations.
1. Thread the counterhold nuts 8360 97336 onto a screw stud

for the rocker arm mechanism. On the 309---engines there is
not a screw stud at the valves for the centre cylinder. A bolt of
suitable length should be used instead. 3. Check the flatness of the cylinder head by using a straight
edge. An uneven or warped surface should be surface
ground. The height of the cylinder head, after grinding, should
not be less than 104,70 mm (equivalent to a machinery allow-
ance of 0,20 mm. If further machining is required the piston
should be shortened correspondingly, i.e. 0,20 mm. However,
the height of the cylinder head must not be less than 104,50
mm.
49
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 212 2
10. 1. 1992
8360 97457
4. Measure the clearance between the valve stem and the 2. Lubricate the outside of the new guides and fit them using
valve guide with a dial gauge. Lift the valve so that the valve drift 8360 97457.
head is 15 mm from the face of the cylinder head, and
measure the clearance. It must not be greater than 0,30 mm Note! Earlier the fitting height of the valve guides was 18 mm
for the inlet valves and 0,35 mm for the exhaust valves. In and that was reached by using above mentioned drift. Now
order to establish the valve guide wear, a new valve should be the fitting height is 21 mm and thus a 3 mm thick spacer ring
used when measuring. must be used with tool 8360 97457.
D. Changing valve guides

21
3. The guides are the same for the inlet and outlet valves. En-
sure that the steepest chamfer on the guide, faces the valve
head. Check that the valves do not bind in the guides.
1. Press or knock out the old guides using drift 8360 97337.
Clean the valve guide locations.
50
Model Code Page
21. Engine 205 -- 555 212 3
1. 12. 1986
E. Changing copper sleeve for injector
8360 97463
8360 86085
4. Apply sealing compound 6909 30008 to the lower end of

the sleeve. Lubricate the O ---rings and fit them on the sleeve.
Drive in the sleeve with drift 8360 97463.
1. Tighten the threaded tap part of the extractor for injector
sleeve 8360 86085 in the copper sleeve.
8361
97470
8360 86085
5. If necessary, clean and adjust the seat (the lowest surface

inside the sleeve) using milling tool 8361 97470.
2. Fit the support sleeve and nut, and extract the copper
sleeve. N.B. If required, the ordinary copper sleeve can be replaced
by a sleeve with an oversize of 0,4 mm at the upper end of the
3. Clean the seat for the copper sleeve and check that the sleeve. Before fitting the oversize sleeve, the location in the
upper edge of the hole is not sharp enough to damage the cylinder head has to be enlarged by 0,4 mm. The order
O ---rings when fitting the new sleeve. number for the oversize copper sleeve is 8360 38723.
51
Model Code Page
21. Engine 205 -- 555 212 4
1. 12. 1986
F. Machining valve seats
4. Lap the valves with lapping paste and check the contact
surface with marking paint.
1. Machine the damaged valve seats with cutters 8360 5. Clean the cylinder head and valves of any remaining lap-
97434---97437, or with grind stones. If the width of the seat ping paste.
exceeds 1,5 mm it should be reduced, primarily at the outer
edge. The seat angle is 30˚.
G. Grinding valves H. Fitting valves

1. Check the valve springs for straightness, length and tension
using a spring tester. Compare with Technical Data.
2. Lubricate the valve stems and fit the valves in the correct
order in the cylinder.
3. Fit the springs, spring guides and valve keepers with the aid
of a lever for compressing valve springs, 8360 97532.
4. Tap the end of the valve stems lightly after fitting the valve
in order to ensure that they are secure.
I. Fitting cylinder head

1. Check that the two screw studs are fitted in the cylinder
block. Fit the valve tappets if the have been removed.
In order to ensure that there is a proper seal around the valves,
there is a difference in the sealing surface angles of 0,5˚. Thus 2. Check that the sealing surfaces are clean and position the
there is a very narrow sealing surface which seals effectively cylinder head gasket.
even after prolonged running.
3. Position the cylinder head. Clean, lubricate and fit the bolts.
1. Grind damaged valves clean in a valve grinding machine.
The angle should be 29,5˚.
2. If the edge of the valve head is less than 1,5 mm after it has
been ground, or if the valve stem is bent, the valve should be
discarded.
3. If necessary, grind the end of the valve stem.
52
Model Code Page
10. 1. 1992
21. Engine 205 -- 555 212 5
31. 8. 1995
205, 305, 405
355, 455, 555

2. Check the straightness of the pushrods by rolling them on
a surface table. Check also the spherical surfaces at the ends.
3. Dismantle and clean the rocker arm mechanism. Check the

shaft for wear and that the oilways are clean.
4. Tighten the bolts in stages. The tightening sequence is

shown in figures above. It is also marked on the cylinder head.
Tighten all bolts to 80 Nm in the first stage, to 140 Nm in the
second stage and to 160 Nm in the third and final stage.
5. Fit the pushrods and rocker arm mechanism. Tighten the

rocker shaft bearing brackets so that the washers on the in-
side of the circlips on the rocker arm shaft can rotate freely.
6. Adjust the valve clearance, see Op. no. 212 2C.
7. Fit the remaining parts, see Op. no. 212 1A.

4. Check that the rocker arm bushes are not worn. Ensure that
8. Run the engine until it is warm and check tighten the cylin- the oil hole is positioned correctly when pressing in new
der head. Follow the tightening diagram and loosen each bolt bushes. After pressing in the bushes they should be reamed
slightly, before finally tightening to the correct torque while the to 19,990 ---20,010 mm. Where necessary grind the rocker
bolts is in motion. Adjust the valve clearance. arm valve contact surface to the correct shape. Do not grind
more than necessary as the hardened layer is thin.
5. Lubricate the bearing surfaces and assemble the rocker

arm mechanism. Check that the plugs at either end of the
shaft are secure.
2. Valve mechanism
A. Reconditioning rocker arm mechanism
1. Check the valve tappets, especially the contact surface

against the camshaft. Worn or damaged tappets should be
discarded.
53
Model Code Page
10. 1. 1992
21. Engine 205 -- 555 212 6
15. 4. 1994
bands to prevent them from falling through. Crank the engine

so that all the tappets are in their upper positions.
Note! Do not connect the pushrods too tightly as this might

cause them to bend or snap.
6. Crank the engine until the aligning marks on the idler gear
and camshaft gear are facing each other. Extract the cam-
shaft.
N.B. The rocker shaft lubrication system has been improved

by adding lubricating holes which are drilled obliquely (60˚)
to the valve side (see point 3). At the same time marking
grooves A have been removed (point 2). In connection with
repairs, it is recommended that these new oil holes are drilled
in rocker shafts which have downwards directed holes (point
2).
The drilling is unnecessary if shafts which have horizontally 7. Separate the camshaft from the gear wheel using a press
drilled holes (point 1). Point 3 shows the later shaft which has or suitable drift.
ready ---made oblique holes.
8. Clean the parts which are to be refitted.
B. Changing camshaft/camshaft gear 9. Fit the threaded plug in the rear end of the camshaft and fit
the key in its groove. Heat the camshaft gear to 200˚ C
(392˚F) in an oven and fit it on the shaft.
1. Remove the inlet pipe between the turbocharger and the
induction manifold. Remove the valve cover (17 mm) and the 10. Lubricate bearing surfaces and lobes and insert the shaft
breather pipe. Remove the rocker arm mechanism (17 mm). in the cylinder block. Ensure that the aligning marks on the
gears agree.
2. Remove the cooling fan (13 mm) and the alternator (13 mm)
including the stay and belt. 11. Fit the timing gear casing cover and the crankshaft V ---belt
pulley and hub, see Op. no. 214 1B.
3. Remove the crankshaft nut using spanner 9024 74200.
Remove the V ---belt pulley including the hub. 12. Free the pushrods and fit the rocker arm mechanism, see
Op. no. 212 1J 5. Fit the valve cover, the breather pipe and
4. Remove the timing gear casing cover (13 mm). the inlet pipe between the turbocharger and the induction
manifold.
13. Fit the alternator with stay and belt, and fit the cooling fan.
5. Connect the pushrods in pairs, using o---rings or elastic
54
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 212 7
10. 1. 1992
C. Adjusting valves
The valve clearance, which can be adjusted on a hot or cold

engine, is 0,30 mm (0,012 in) for both inlet and exhaust valves.
The clearance is adjusted when the respective piston is at
T.D.C. in the compression stroke. The valves for the different
cylinders are adjusted in the same sequence as the order of
injection.
1. Remove the valve cover (17 mm) and the breather pipe.
Remove the rubber plug in the flywheel housing.
2. Crank the engine using a screwdriver against the flywheel

ring gear, until the exhaust valve of no. 3 cylinder (valve no. 5)
is completely open. Adjust the valves of no. 1 cylinder.
A6181--- 106
205, 305, 405
3. Crank the engine in the direction of rotation until no. 1 cylin-

der exhaust valve (valve no. 2) is completely open. Adjust the
valves of no. 2 cylinder.
4. Continue cranking the engine in the direction of rotation

until no. 2. cylinder exhaust valve (valve no. 4) is completely
open. Adjust the valves of no. 3 cylinder.
355, 455, 555
3. Crank the engine in the direction of rotation until no. 1 cylin-

der exhaust valve (valve no. 1) is completely open. Adjust the
valves of no. 2 cylinder.
4. Continue cranking the engine in the direction of rotation

until no. 2 cylinder exhaust valve (valve no. 3) is completely
open. Adjust the valves of no. 3 cylinder.
55
56
Model Code Page
21. Engine 205 -- 555 213 1
1. 12. 1986
Crank mechanism (Op. no 213)
1. Crankshaft
A. Removing crankshaft
1. Disconnect all leads, lines and controls from the engine
according to Op. no. 219 1A or 2A.
2. Free the oil pump pressure pipe (6 mm socket head) from

the cylinder block. Remove the oil pump (8 mm socket head)
together with suction and delivery pipes.
3. Remove the flywheel (19 mm) and the flywheel housing (19
mm and 8 mm socket head).
4. Remove the timing gear casing Op. no. 214 1A.
5. Remove the crankshaft bearing caps (19 mm) and push the
connecting rods out of the way of the crankshaft.
6. Remove the main bearing caps (24 mm) and lift out the
crankshaft. 3. Refit the bearing caps with new bearing shells and tighten
them to the correct torque. Measure the I.D. with a dial gauge
which has been zeroed to the dimensions obtained in point 2.
With this method the indicator shows the actual bearing clear-
B. Checking crankshaft ance.
1. Clean the crankshaft. Do not forget the oilways. 4. If the bearing clearance exceeds 0,18 mm for main bear-
ings or 0,14 mm for connecting rod big ---end bearings with
new bearing shells, the bearing journals on the crankshaft
should be ground. Refer to the specifications for the relevant
correct undersize and the corresponding bearings. Ensure
that the radii are not changed when grinding.
C. Changing crankshaft gears

8360 97327
2. Measure both the crank and main bearing journals in sev-

eral places. Out---of ---round, taper or other wear must not ex-
ceed 0,03 mm.
1. Apply puller 8360 97327 for the crankshaft gears and pull
off both gears.
57
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 213 2
10. 1. 1992
2. Clean the seat on the crankshaft with, for example, a wire

brush.
3. Heat the new gears to 200˚C in an oven. Tap them onto the
shaft with a suitable sleeve or soft drift. Note the position of the 0,10-- 0,35 mm
key and ensure that the aligning marks on the front gear are
visible. Leave it to cool.
D. Fitting crankshaft
1. Clean the oilways, bearing shells and bearing locations.

Check that the crankshaft is clean. If it is ground, the oil holes
should be checked.
2. Fit the correct size shell bearings. Ensure that guide pins
and oil holes are fitted facing their respective sockets and
holes.
3. Lubricate the bearing surfaces and fit the crankshaft. Fit the
crankshaft thrust bearings with the lubricating grooves facing
the crankshaft.
5. Check that the crankshaft can rotate without binding.

Check the end float using a dial gauge. The correct end float
is 0,10 ---0,35 mm. If the end float is too large, oversize thrust
bearings should be fitted.
4 N.B. Bearing shells should never be reamed or machined in

any other way, nor should the sides of the bearing caps be
filed.
4
3 4
2. Connecting rods and pistons
3 4 A. Removing piston together with con-

necting rod.
1. Disconnect all leads, lines and controls from the engine ac-
cording to Op. no. 219 1A and 2A.
2. Remove the cylinder head, see Op. no. 212 A.
3. Scrape off the carbon edge in the cylinder liner. If the turning
edge is clearly marked, smooth it down carefully with a
scraper. Take care not to damage the slide surface of the liner.
4. Remove bearing caps and bearing shells. Place the shells

4. Fit the main bearing caps in the order indicated by the in order if they are to be re ---used.
numbering; the rear bearing cap should be fitted with thrust
bearings provided with guide lugs. Lubricate the bolts and 5. Push up the piston and connecting rod with the shaft of a
tighten them to 160 Nm (205, 305, 405) or 200 Nm (355, 455, hammer or similar wooden tool.
555).
6. Remove the piston pin circlips and push out the piston pin.
Where a piston is to be re ---used, the piston pin should not be
knocked out. If the piston pin does not become loose under
thumb pressure the piston should be heated to 100˚C.
58
Model Code Page
1. 7. 1989
21. Engine (11---series) 205 -- 555 213 3
10. 1. 1992
B. Changing connecting rod bearing NOTE: When necessary, an oversize bushing, part no. 8360
38605 (205, 305, 405) or 8353 28326 (355, 455, 555) is avail-
able. Before driving this bushing in, the connecting rod should
1. Clean the connecting rod and bearing shells. Fit them to- be machined to 40.500...40.525 mm (205, 305, 405) or
gether and tighten the bolts to 90 Nm. 44.500...44.525 mm (355, 455, 555). After fitting, the oversize
bushing should also be reamed to the correct size.
C. Checking connecting rod
The connecting rod is checked in a special fixture, intended

for the purpose (e.g. Carl Larsson).
1. Fit the bearing caps and tighten the bolts (19 mm) to 90
Nm.
2. Fit the connecting rod in the fixture and fit the piston pin
which corresponds to that connecting rod.
2. Measure the I.D. using a cylinder gauge which has been

zeroed to the diameterof the appropriate bearing journal. If
the clearance exceeds 0.14 mm with new bearing shells, the
big end journals require grinding. Refer to the Technical Data
section for the correct undersize and the corresponding bear-
ing. Ensure that the radii at the end of the bearing journals are
not altered when grinding.
3. If the small---end bearing bushing is worn, it should be

driven out using a suitable drift.
3. Check that the connecting rod is not twisted by positioning

the measuring tool with the horizontally placed measuring
points against the face of the fixture.
4. Drive in the new bushing and ensure that the oil hole is in
the correct position. Ream the bushing after it is fitted to
36.025...36.040 mm (205, 305, 405) or 40.025...40.040 mm
(355, 455, 555).
59
Model Code Page
10. 1. 1992
21. Engine (11---series) 205 -- 555 213 4
15. 9. 1995
The connecting rods are divided into weight classes with in-
tervals of 20 g. The weight class (indicated by a letter) is
stamped on the side face of the connecting rod. The se-
quence number of the cylinder is stamped next to the letter
(but not on the latest connecting rods). All the connecting rods
in an engine should be of the same weight class; in other
words the greatest permissible weight difference is 20 g.
Note! Connecting rods of the 20---series engines replace as

a spare part the connecting rods of the 11---series engines.
Connecting rod bolts of the 20---series engines should be
tightened progressively, 40 Nm+90˚. When ordering sepa-
rate connecting rods, the weights classes of the rods must be
observed. Table below shows the equivalents of the weight
classes on the 11---, and 20---series engines:
The letters show the weight classes as follows:
205, 305, 405 (309 ---engines):

Weight Part number
H 1990---2010 g 8360 36562
I 2010---2030 g 8360 36563
J 2030---2050 g 8360 36564
K 2050---2070 g 8360 36565
L 2070---2090 g 8360 36566
M 2090---2110 g 8360 36567
N 2110---2130 g 8360 36568
O 2130---2150 g 8360 36569
P 2150---2170 g 8360 36570
R 2170---2190 g 8360 36571
4. Turn the measuring tool round with the vertically placed S 2190---2210 g 8360 36572
measuring points against the face, and check the straight- T 2210---2230 g 8360 38116
ness of the connecting rod. U 2230---2250 g 8360 38117
V 2250---2270 g 8360 38118
355, 455, 555 (11 ---series engines on which are used the
connecting rods of the 20 ---series engines):
Letter of Weight Letter of Part number
11 ---series 20 ---series
2170---2189 A 8366 52104
H 2190---2209 B 8366 52105
I 2210---2229 C 8366 52106
J 2230---2249 D 8366 52107
K 2250---2269 E 8366 52108
L 2270---2289 H 8366 52109
M 2290---2309 I 8366 52110
N 2310---2329 J 8366 52111
O 2330---2349 K 8366 52112
P 2350---2369 L 8366 52113
R 2370---2389 M 8366 52114
S 2390---2409 N 8366 52115
T 2410---2429 O 8366 52116
U 2430---2449 P 8366 52117
V 2450---2469 R 8363 52118
5. Also check the S ---bending of the connecting rod by using X 2470---2489 S 8366 52119
sliding calipers to measure the distance between the edge of Z 2490---2509 T 8366 52120
the small---end bearing bushing and the face of the fixture. A 2510---2529 U 8366 52121
Turn the connecting rod round so that the other side of the
connecting rod faces the fixture. Then measure the same dis-
tance. The accepted deviation is 0,6 mm.
E. Changing piston rings
D. Connecting rods, weight classes
1. Remove the piston rings. Do not open the rings more than
necessary. If the rings are to be used again ensure that they
are fitted in the same groove.
2 2 L
60
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 213 5
10. 1. 1992
4. Fit the piston rings on the piston using the piston ring pliers.
Ensure that the rings are fitted in the correct groove and that
”TOP”, or the manufacturer’s designation, faces upwards.
2. Clean the piston ring groove and measure the piston ring F. Fitting piston pin
clearance, which must not exceed 0,15 mm. Determine
whether too large a clearance is due to worn rings or a worn
groove. Change worn parts.
1. Heat the piston to 100˚C. Fit the connecting rod and press
3. Measure the piston ring gap by pushing one piston ring at in the piston pin.
a time into the cylinder bore using an inverted piston. The gap
should be measured above the upper turning point or below N.B. The combustion chamber in the piston and the se-
the lower turning point. The piston ring gap must not exceed quence number on the connecting rod should be on opposite
1.0 mm (except for the 2nd compression ring on 355, 455 and sides, facing away from each other!.
555: 1.4 mm).
2. Fit the circlips for the piston pin.
61
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 213 6
1. 12. 1986
G. Fitting piston and connecting rod

1. Check that the bearing locations are clean and place the
bearing shells in the connecting rod and bearing cap. Note
the position of the bearing shells.
2. Lubricate piston, rings and cylinder bore. Ensure that the

piston ring gaps are spread around the piston.
3. Fit the piston with the marking on the connecting rod

(weight class) facing the camshaft (an arrow on the piston
must point forward).
4. Lubricate the big ---end bearing journal and bearing shells,

and push the piston down. Fit the bearing cap so that the
notches for the guide lugs are in the same side. Tighten the
connecting rod bolts to 90 Nm.
5. Check that the connecting rod has sufficient end float on the
big ---end bearing journal.
62
Model Code Page
21. Engine 205 -- 555 214 1
1. 12. 1986
9. Remove the timing gear casing (13 mm). Ensure that all
Engine timing gears (Op. no. 214) sealing surfaces are not damaged.
10. Remove the sealing ring and clean all the parts that have
1. Timing gear casing been removed.
A. Removing timing gear casing

B. Fitting timing gear casing
As the timing gear casing forms a seal against the oil sump,
the casing cannot be removed without first removing the oil The position of the timing gear casing and cover is deter-
sump. mined by two tubular pins. Therefore centring should not be
undertaken in connection with fitting. However, the tooth
1. Remove the engine, see Op. no. 219 1A or 2A. backlash between the different gears should be checked.
casing and covers that are delivered as spare parts also have
2. Remove the fan (13 mm) and the alternator (13 mm) includ- holes for the tubular pins already machined.
ing the stay and belt.
1. Fit the casing with a new gasket against the cylinder block.
Drive in the tubular pins with drift 9025 98700. Tighten bolts
and nuts (13 mm).
2. Fit the injection pump together with gear wheel.
3. Lubricate the camshaft bearings and insert the shaft in the

cylinder block. Release the pushrods and tappets if they have
been suspended in some way.
3. Loosen the crankshaft nut with key (socket) 9024 74200.

Remove the V ---belt pulley hub.
4. Remove the transmission casing cover (13 mm). Ensure

that the sealing surfaces are not damaged.
5. Remove the oil deflector ring.
6. Remove the injection pump, see Op. no. 223 1C.

1. Crankshaft gear
N.B. If the timing gear casing is not to be changed, the injec- 2. Lubricating oil pump gear
tion pump remain in place. In which case disconnect all leads 3. Camshaft gear
and pipes from the pump. 4. Idler gear
5. Injection pump gear
7. Remove the idler gear (17 and 22 mm), flange and bearing
journal. 4. Fit the idler gear with shaft stud and ensure that the mark-
ings are in the correct position. Fit the washer and tighten the
8. Extract the camshaft. bolts to 60 Nm and 180 Nm respectively.
N.B. If the cylinder head and valve mechanism have not been
removed, the tappets must be prevented from falling down,
see Op. no. 212 2B 5.
63
Model Code Page
21. Engine 205 -- 555 214 2
1. 12. 1986
9030 15200
5. Check that the tooth backlash is 0,05 ---0,25 mm.

7. Fit the oil deflector ring and then the crankshaft oil seal with
drift 9030 15200.
9025 98700
9025 98800
9025 98900
6. Fit the oil deflector ring on the crankshaft and fit the timing
gear casing cover using a new gasket. Drive in the tubular
pins with drifts 9025 98700 and 9025 98800 respectively (the 8. Fit the dust shield on the crankshaft V ---belt pulley hub, if it
tubular pin round the screw stud). has been removed. Use drift 9025 98900.
9. Lubricate both the seal and sealing surfaces and fit the
crankshaft V ---belt pulley with hub.
10. Tighten the crankshaft nut with key (socket) 9024 74200
to 600 Nm.
11. Fit the alternator and the belt.
12. Fit the breather hose and the fan (13 mm).
64
Model Code Page
21. Engine 205 -- 555 214 3
1. 12. 1986
C. Changing crankshaft front oil sea
1. Remove the fan belt.
2. Loosen the crankshaft nut with key (socket) 9024 74200

and remove the V ---belt pulley and hub.
3. Remove the old seal and clean the sealing location. Tap on
the new seal with drift 9030 15200.
4. Lubricate both seal and sealing surfaces and fit the crank-
shaft V ---belt pulley and the hub. Tighten the crankshaft nut to
600 Nm.
5. Fit the alternator and the belt.
65
66
Model Code Page
21. Engine 205 -- 555 215 1
1. 12. 1986
Lubricating system (Op no 215) B. Removing and dismantling lubricating

oil pump
A. Reconditioning of oil relief valve for
1. Remove the oil sump.
lubricating oil pressure
2. Remove the oil pump suction pipe (13 mm).
If the engine lubricating oil pressure is insufficient or if it varies,
the relief valve should be checked after first checking the oil 3. Remove the oil pump pressure pipe (6 mm socket head)
level. and pipe union.
4. Remove the oil pump (8 mm socket head) together with any

shims.
5. Open the oil pump (13 mm) and remove the loose pump
wheel (gear wheel).
6. Clamp the pump gear across the teeth in a vice fitted with
soft jaws, and loosen nuts (17 mm). Knock the gear wheel off
by hitting the end of the shaft with a soft hammer.
7. Clean the parts and check for wear and other damage.
Compare with the Technical Data. Change damaged parts
and all seals.
1. Remove the cover over the valve (13 mm) and spring. Take
care of the washer between the cover and spring. Remove the
valve insert together with the valve cone and ensure that the
o---ring is also removed.
2. Clean the parts and check that the valve cone slides freely
in the insert and that the sealing surface are undamaged. Mi-
nor damage can be adjusted, but in general, damaged parts
should be changed. Scrape off any remains of the gasket.
3. Assemble the valve with a new o---ring and insert it in the

cylinder block. Place the washer and spring in the cover and
fit it with a new gasket. C. Assembling and fitting lubricating oil
pump
1. Fit the gear wheels in the pump body. Fit the cover using
a new gasket. Partly tighten the bolts. Rotate the pump shaft
and tap the side of the cover lightly until the position is reached
where the shaft rotates most freely. Tighten the bolts and
check that the shaft still rotates.
2. Fit the pump gear on the shaft together with a key. Position
a locking washer and tighten the nut.
4. Note that the relief valve cover is not symmetrical. The

greater distance between the spring housing and bolt should
be turned downwards.
67
Model Code Page
21. Engine 205 -- 555 215 2
1. 12. 1986
E. Changing lubricating oil filter
The lubricating oil filter is usually changed in connection with

changing the oil. See the Operator’s Manual.
1. Clean the filter externally. Remove the filter and wipe off any
spilt oil.
3. Fasten the oil pump in a vice and check the end float be-
tween gear and pump housing. The clearance which should
be 0,03 ---0,11 mm, is adjusted by the number of gaskets be-
tween the cover and body.
2. Clean the sealing surfaces and lubricate the new filter seal.
Tighten the filter by hand.
3. Start the engine and check that there is no leakage.
N.B. The guarantee of the engine is only valid on the assump-

tion that a Valmet original oil filter is used.
4. Fit the pump and check the tooth backlash against the
crankshaft gear. The clearance, which should be 0,05 ---0,25
mm, is adjusted with shims between the pump body and the
cylinder block (shims 0,2 mm, order no 8360 07871). One
shims increases/decreases the backlash about 0,07 mm.
Note! When measuring the tooth backlash, the engine should

be the correct way up as the crankshaft bearing clearance af-
fects the tooth backlash.
5. Connect suction and pressure pipes together with new

seals.
6. Fit the engine (or the oil sump).
68
Model Code Page
21. Engine 205 -- 555 215 3
1. 12. 1986
E. Lubricating oil quality requirements
1. QUALITY (API ---CLASS)
--- naturally aspirated engines CCMC D2 API CC 1)

--- turbocharged engines CCMC D4/D5 API CD
TEMPERATURE ˚C
---30 ---20 ---10 0 +10 +20 +30
5W---20
5W---30
5W---40
10W
10W---20
SAE---CLASS
10W---30
10W---40
15W---30
15W---40
20W---20
20W---30
20W---40
30
1) After running ---in period, API ---CD can also be used in conventionally aspirated engines.
69
70
Model Code Page
21. Engine 205 -- 555 216 1
1. 12. 1986
Inlet and exhaust system, turbocharger B. Checking inlet and exhaust system
(Op no 216)
Important! Leaks in the inlet or exhaust system markedly
1. Inlet and exhaust systems lower the effect of the turbocharger. Because of the pressure,
An engine that is equipped with a turbocharger is a great deal even small leaks in the manifold or in the turbine inlet contact
more sensitive to disturbances and impurities in the inlet and flange quickly increase in size. For this reason all leaks must
exhaust systems than a conventionally aspirated engine. be dealt with immediately.
Therefore special attention should be given to the whole inlet
and exhaust system. 1. Inspect the pipes and sealing surfaces between the air
cleaner and the turbocharger, as well as between the turbo-
A. Checking air cleaner charger and the induction manifold. If the induction manifold
The engine performance and length of service life depend to is dusty on the inside, there is a leak in either the air cleaner
or the induction pipes. Remedy the leak.
a great extent on the state of the air cleaner. A defective air
cleaner allows impurities to pass through, which in time dam-
2. Clean the induction manifold sealing surface. Check that
age the turbocharger and the engine. A blocked air cleaner
the sealing surface is flat using a straight ruler.
lowers the engine output and also causes oil leakage through
the sealing ring on the turbocharger shaft.
3. Fit a new gasket and fasten the induction manifold. Tighten
the manifold fixing screws to a torque of 30 Nm..
4. Check that the exhaust manifold is air tight. Tighten the

bolts to 60 Nm and inspect for any damage (cracks, deforma-
tion, corrosion etc.). Check also the connection between the
turbocharger and the exhaust manifold.
5. Remove the manifold if necessary. Clean the sealing sur-

faces and remove any carbon deposits. Check that the seal-
ing surfaces are flat.
6. Fit new gaskets on the exhaust manifold. Check the tighten-

ing torque (60 Nm) after the engine has been run warm.
7. Ensure that no loose objects or impurities have entered the

exhaust pipe or the silencer.
2. Turbocharger
1. Remove the main filter element by loosening the nut (13
mm) at the end of the filter housing, and pull out the element. A. Checking turbocharger
The safety filter inside the main filter should only be removed
when it is to be changed. It should not be removed for clean-
ing. In order for the turbocharger to obtain trouble ---free perform-
ance, it is important that the engine lubricating and inlet sys-
2. Clean the filter element with either a vacuum cleaner or with tems are serviced according to the given instructions. Ensure
compressed air (max. 500 kPa), directed fron the inside, out. that lubricating oil of the correct type is used and, likewise,
The main filter element should be changed after it has been original filters.
cleaned five times or if it shows any signs of damage.
1. Visually inspect the turbine and compressor wheels. The
3. Insert a lamp inside the filter element and inspect the filter. vanes must not show any signs of damage, deformation or
If there are any holes in the filter element or if it is damaged wear caused by foreign objects.
(lighter parts which let the light shine through), it should be
changed.
4. Clean the inside of the air cleaner housing so that it is free

of dust and dirt. Check that the seals are not damaged and
that the contact surfaces are clean. Insert the filter element in
the housing and check that it is fitted in pace correctly. Tighten
the locking nut (13 mm) approx. 1---1,5 turns after there is con-
tact between the seal and the bottom of the filter housing.
Note! The safety filter inside the main filter should not be re-
moved unnecessarily, for checking or cleaning. The safety
filter must not be cleaned, but should be changed once a year
or when necessary (see Operator’s Manual).
71
Model Code Page
21. Engine 205 -- 555 216 2
1. 12. 1986
2. Investigate any oil leaks through the sealing rings on the If the engine does not work correctly and the turbocharger is
shaft in the turbine and compressor housing. not defective or too worn, the fault could be traced to one of
the following items:
N.B! At low idling there is always a certain amount of oil leak-
age on the compressor side. However, this should not cause --- Blocked air filter
too much concern unless the oil consumption is too great. --- Leakage in the inlet or exhaust systems. Leaking flange
seal
--- Defective or wrongly adjusted injection pump.
--- Wrongly adjusted throttle linkage
--- Defective or wrongly adjusted injectors
--- Low fuel pressure (e.g. blocked fuel filter)
--- Low compression, wrong valve clearance
B. Removing turbocharger
1. Loosen the attaching bolts for the exhaust pipe and remove
it. Loosen the inlet pipe to the turbocharger.
2. Loosen the pipe clamp attaching bolt (10 mm) which holds
the oil pipe. Loosen the attaching bolts (13 mm) for the pres-
sure oil pipe and the lower banjo bolt (22 mm). Remove the
pressure oil pipe. Remove the return oil pipe (6 mm socket
head).
3. Check the turbine shaft running clearance. Place the stylus
of a dial gauge against the shaft and move the shaft sideways. 3. Remove the attaching bolts (17 mm) and lift off the turbo-
refer to the clearance given in the specifications on page charger.
210/9.
4. Fit protective plugs in the holes of all connections.
C. Reconditioning turbocharger
N.B! The same degree of cleanliness should be observed

when removing the turbocharger as with repairing the fuel
system. Only remove the compressor and turbine covers if
the requisite special tools, e.g. for adjusting the balance, are
not available. In general, when the turbocharger is dam-
aged it is more economical to fit a factory reconditioned
turbocharger.
4. Check the shaft end float. Place the stylus of the dial gauge
against the end of the shaft and move the shaft axially. Refer
to the clearance given in the specifications on page 210/9.
If any defects or wear are confirmed, the turbocharger should

be reconditioned.
N.B. In terms of cleanliness and accuracy, the reconditioning

of the turbocharger can be compared to repairing the fuel sys-
tem. In addition, special tools are needed, e.g. for balancing
rotating parts. In general, when the turbocharger is damaged
it is more economical to use a factory reconditioned turbo-
charger.
72
Model Code Page
1. 12. 1986
21. Engine 205 -- 555 216 3
1. 7. 1989
6. Remove the bolts (22) which keep the back plate and the
bearing housing together and remove the locking strips (21).
Remove the back plate (4) and the oil deflector ring (10) from
the shaft. Press out the oil deflector ring from the thrust collar
and remove the sealing ring (5) from the back plate. Remove
the oil deflector (11).
7. Remove the thrust bearing locking bolts (12). Remove the

oil deflector (11).
7. Remove the thrust bearing locking bolts (12). Remove the

thrust collar (13) and the thrust bearing (14).
8. Remove the turbine wheel and the shaft (25), together with
the sealing ring (24), and lift the turbine protective cover (23)
off the shaft. Remove the outer locking rings (16) which fix the
bearing housing. Insert a finger into the bearing (15) and pull
out both bearings. Remove the inner locking rings (16).
Turbocharger (Holset)
1. Compressor housing 14. Thrust bearing
2. Nut for compressor wheel 15. Bearing
3. Compressor wheel 16. Locking ring
4. Back plate 17. Bearing housing Cleaning parts of turbocharger
5. ”SQ” ---sealing ring 18. Socket head bolt
6. Locking strip 19. Locking strip N.B. Use conventional cleaning agents. Do not clean with cor-
7. Washer 20. Attaching strip rosive substances as parts of the turbocharger may be dam-
8. Socket head bolt 21. Locking strip aged.
9. Sealing ring 22. Socket head bolt
10. Oil deflector ring 23. Protective cover 1. Wash off all dirt with a detergent solution. Use plastic tools
11. Oil deflector 24. Sealing ring or brush when cleaning aluminium parts.
12. Bolt 25. Turbine wheel and shaft
13. Thrust collar 26. Turbine housing 2. Clean all oilways with compressed air. Check that all contact
surfaces are clean and in good condition.
Checking parts of turbocharger

Dismantling Holset turbocharger
1. Shaft and turbine wheel unit:
NOTE: The construction of the Schwitzer turbo unit differs in --- Inspect the bearing surfaces for wear and scoring. Minor
certain details from that of the Holset turbo. Nevertheless gen- scoring is permissible
eral repair instructions also concern the Schwitzer turbo. See --- Inspect the walls of the sealing ring seat for scoring. Minor
Technical Data page 210/7. scoring is permissible.
--- Inspect the vanes of the turbine wheel for damage, defor-
mation and breakage. On no account must the vanes be
1. Clean the turbocharger externally and fix it by the outlet bent.
flange in a vice fitted with soft jaws.
2. Thrust bearing set:
2. Mark the compressor housing (1), back plate (4), bearing --- Change worn or defective parts
housing (17) and turbine housing (26) in relation to each other. --- The oil grooves should be clean
Bend down the locking strips (19 and 21).
3. Compressor wheel:
3. Remove the attaching bolts (8) for the compressor housing. --- Inspect the compressor wheel for damage, deformation
Remove the washers (7) and the locking strips (6) and lift off and breakage. On no account must the vanes be bent!.
the compressor housing.
4. Bearings:
4. Remove the attaching bolts (18) for the turbine housing. Re- --- Change worn or scored bearings
move the locking strips (19) and the strips (20) and lift the
bearing housing out of the turbine housing. 5. Bearing housing:
--- Change the bearing housing if the bearing surfaces or the
5. Hold the turbine wheel and remove the nut (2) for the com- grooves for the sealing rings are considerably worn or scored.
pressor wheel. Pull the compressor wheel (3) off the shaft.
6. Rotating parts:
N.B. The nut has a left---hand thread. --- Check the balance of rotating parts
7. ”SQ” ---sealing ring

--- Change the sealing rings.
73
Model Code Page
21. Engine 205 -- 555 216 4
1. 12. 1986
8. Compressor and turbine housing 8. Place the stylus of a dial gauge against the end of the shaft
--- Check for damage and scoring caused by contact with the and measure the end float. The float should be within
compressor or turbine wheels, and defects caused by over- 0,10 ---0,16 mm.
heating. Minor damage is acceptable. If the damage is exten-
sive, the housing should be changed. 9. Place the stylus of a dial gauge against the side of the shaft
and measure the running clearance. The clearance should be
within 0,30 ---0,46 mm.
Assembling turbocharger 10. Tighten the bolts (22 mm) between the bearing housing
and the back plate (4) to 5,7 Nm, the compressor housing
attaching bolts (8) to 5,7 Nm and the turbine housing attach-
When the parts of the turbocharger have been carefully ing bolts (18) to 11,3 Nm.
cleaned, inspected, and any defective parts changed, the
turbocharger can be assembled. The assembling of the 11. Check that the shaft rotates freely.
turbocharger is carried out in the reverse order to dismantling.
Make note of the following: 12. Fix the locking washers (19 and 21).
1. Rotating parts should be balanced to within 1,44 grammes

at both ends. Ensure that the parts are fitted in the same posi-
tion relative to each other, as before (according to the mark-
ings).
2. Fit the locking rings with the chamfered side facing the D. Fitting turbocharger
bearing.
3. Lubricate all bearings, pressure and sealing surfaces with Locate the cause of the defects on the turbocharger. Remedy
clean engine oil. the fault before fitting the new turbocharger.
4. Great care should be exercised when fitting the shaft in the In order for the turbocharger to work satisfactorily, it is import-
bearing housing. The seals are easily damaged when fitting. ant that the engine oil is in good condition. Likewise the cor-
rect oil quality should be used, according to the Technical
5. Tighten the bolts in the thrust bearing to 4,5 Nm. Data. Even the oil filter and air filter should be cared for accord-
ing to the instructions.
6. Take care not to damage the ”SQ” ---sealing ring when fitting
the end cover in the bearing housing. The setting of the injection pump critically affects the function
of the turbocharger. The injection pump should be adjusted
according to the manufacturers instructions.
1. Check the seals on the induction and exhaust pipes, and

that they are securely fastened. Ensure that there are no loose
carbon or rust particles, or other foreign objects in the pipes.
2. Connect the turbocharger to the exhaust manifold and

tighten down using new gaskets.
3. Connect the induction pipe and the silencer.
4. Pour clean engine oil into the bearing housing through the
in ---going oilway. This is very important in order to ensure that
the turbocharger is lubricated at the time of starting.
5. Connect the pressure and return oil pipes. Use new seals.
Check that there are no tensions in pipes when tightening.
6. Before starting, pull out the stop control and crank the
engine round with the starter motor so that the oil pressure
rises. Start the engine and check that there are no leaks.
1. Compressor housing
2. Back plate
3. O ---ring 6146 12114
4. ”SQ” ---seal
7. Tighten the lock nut for the turbine wheel to 14,0 Nm.
N.B. The nut has a left---hand thread. Take care that the shaft
is not bent. Use a suitable T ---handle or a torque wrench.
74
Model Code Page
21. Engine 205 -- 555 219 1
1. 12. 1986
Removing and fitting engine (Op. no. 219)
1. Removing and fitting engine by parting

tractor
N.B. It is easier to remove the engine if the tractor is parted at

the clutch. The engine can also be removed without parting
the tractor, it is fitted with equipment which makes parting diffi-
cult.
A. Removing engine
1. Remove the exhaust pipe and all engine hood plates. Drain
the coolant (10 litres). 4. Disconnect the lower and the upper radiator hoses at the
radiator and disconnect the induction pipe from the turbo-
charger.
2. Open the radiator cowl and disconnect the leads for the
5. Unscrew the bolts for the fan guard ring.
horn and the headlights. Pull the leads into the engine com-
partment.
6. Unscrew the engine attaching bolts (19 mm).
7. Remove the battery and the battery shelf.

3. Disconnect the radiator frame support (13 mm).
8. Split the tractor frame at the clutch (see Op. no. 411 1A
points 2 ---11).
75
Model Code Page
21. Engine 205 -- 555 219 2
1. 12. 1986
80 Nm
9. Disconnect the oil pipes for the steering cylinder (on the 3. Tighten the engine attaching bolts to 80 Nm.
right side of the engine) (13 mm).
4. Connect the pipes for the steering cylinder on the right---
hand side of the engine and clamp the oil pipes and the leads
together with a strip clamp.
5. Connect the lower and the upper radiator hoses and the
induction pipe for the turbocharger.
10. Attach lifting hooks to the lifting points on the engine (eylet
at the front and hole in plate at the rear) and lift the engine
straight up.
N.B. Attach the rear hook so the plate does not bend.
6. Connect the radiator frame support (13 mm) and secure the
fan guard ring.
7. Connect the leads for the horn and headlights.
8. Fill with coolant (10 litres) and with hydraulic oil (35 litres).
B. Fitting engine Air ---bleed the fuel system. Fill with engine oil (7 litres).
9. Tighten the exhaust pipe to 23 Nm and fit all engine hood

1. Lift the engine into the frame and guide the guide pins into plates. Connect the windscreen washer hose to the nozzle at
the holes. the upper hood plate.
N.B. Position the guard ring for the fan over the fan blades 10. Start the engine and check that the indicator lamp for the
before lifting the engine into place. engine oil pressure goes out. Test---run the tractor.
2. Push the tractor frame together at the clutch (see Op. no.
411 1C, points 1 ---10).
76
Model Code Page
21. Engine 205 -- 555 219 3
1. 12. 1986
2. Removing and fitting engine without 6. Attach lifting hooks to the lifting point on the engine (eyelet
at the front and plate with hole at the bac) and lift up the engine
parting tractor out of the engine compartment. N.B. Connect the rear hooks
so that it does not bend the plate.
A. Removing engine
1. Remove the PTO and the long PTO shaft (Op. no. 462 1A).
Pull the clutch shaft out of the clutch through the hole in the B. Fitting engine
cab floor (Op. no. 411 2A, points 1 ---13).
N.B. On tractors fitted with a low gear, the clutch should pre-
2. Carry out the instructions for removing the engine accord-
ing to 1A, points 1 ---6 and 411 1A, points 3 ---7. ferably be fitted to the flywheel before fitting the engine.
N.B. Position the fan guard ring before lifting the engine into
position.
80 Nm
3. Disconnect the delivery pipe for the hydraulic lift at the joint
on the RH side of the engine (27 mm and 26 mm). Disconnect
the engine breather pipe under the front edge of the cab.
1. Lift the engine into position and guide the guide pins into
the holes.
2. Tighten the engine attaching bolts to 80 Nm.
3. Fit the clutch shaft and clutch through the hole in the cab
floor (Op. no. 411 2B, points 1 ---16).
4. Push the hydraulic system suction pipe in under the cab

floor and connect the pipe at its rear end.
5. On the right---hand side of the engine connect and secure:
--- hydraulic system suction pipe at pump (45 Nm).

--- hydraulic system delivery pipe at pump (45 Nm)
--- pipes for steering cylinder (60 Nm)
--- pipe clamps and leads using a strip clamp
4. Disconnect the pipes for the steering cylinder on the RH

side of the engine.
5. Disconnect the hydraulic system suction pipe under the

cab. Loosen the pipe clamps and pullout the pipe from the
front of the cab.
77
Model Code Page
21. Engine 205 -- 555 219 4
1. 12. 1986
6. Fit the PTO (Op. no. 462 1E). Fill the gearbox with oil (23
litres).
7. Secure the lower part of the engine heater pipe. Connect

the electrical leads to the front wall of the cab.
8. Carry out the instructions for fitting the engine (Op. no. 1B,
points 5 ---10)
78
Model Code Page
22. Fuel system 205-- 555 220 1
1. 12. 1986
Contents
General (Op. no. 220)

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
--- Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
--- Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
--- Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
--- Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
--- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
--- Fuel reservoir for thermostart device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
--- Table of fuel metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
--- Table of fuel equipment parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair instructions
Fuel feed pump and fuel filter (Op. no. 222)

1. Checking and repairing fuel feed pump:
A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Measuring fuel system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Removing fuel feed pump and checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Fuel filter
A. Changing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel injection pump and injectors (Op. no. 223)

1. Adjusting fuel injection pump:
A. Checking injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Removing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fitting injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Checking/changing delivery valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Checking/reconditioning injectors:
A. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
D. Fitting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Delivery pipes for injectors:

A. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
79
Model Code Page
1. 7. 1986
22. Fuel system 205-- 555 220 2
10. 1. 1992
Technical Data
Fuel injection pump
Type (pump/governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch PES ---A/RSV

Order of injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---3
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Pump plunger, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,5 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm
Pump timing:
--- 305, 405, 455, 555 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21˚ B.T.D.C.
--- 205, 355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24˚ B.T.D.C.
Oil capacity 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 litres
Fuel feed pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch FP/KS 22 AD 6/2

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston pump with separate hand
priming pump
Fuel feed pressure (overflow valve opening pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60---100 kPa
Pressure from fuel feed pump (without overflow valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 kPa
Injectors 305, 405

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch, four ---hole nozzle
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200±5 bar (19.6 MPa)
Setting pressure @) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210±5 bar (20.6 MPa)
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495
Injectors 205, 355, 455, 555
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch, five ---hole nozzle

Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230±5 bar
Setting pressure @) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235+5 bar
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495
!) When fitting fuel injection pump

@) Value to be used when adjusting the opening pressure of a new or used injector.
Tightening torques
Nut for fuel injection pump gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Delivery valve retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector securing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
80
Model Code Page
22. Fuel system 205-- 555 220 3
1. 12. 1986
Special tools
22. Fuel system A

Order no. Description
(8360 13091) Puller for injection pump drive gear (see Engine A)
8360 97339 Control (calibrating) pipe for injection timing (505---905)
9025 99000 Sleeve for limiting control rod travel (505---905)
22. Fuel system B

6541 30600 Pressure gauge for checking delivery valve (505---905)
8360 83288 Cleaning tools for injectors (505---905)
8360 13091
6541 30600 8360 97339 9025 99000
8360 83288
81
Model Code Page
22. Fuel system 205-- 555 220 4
1. 12. 1986
Fuel system, description
Design and function
2 1
1. Fuel tank 2. Water trap 3. Fuel feed pump 4. Filter 5. Fuel

injection pump 6. Injector 7. Fuel reservoir, Thermostart
device 8. Glow plug 9. Overflow valve
Fuel feed pump (3) draws fuel from tank (1) through water trap
(2) and forces it through filter (4) to fuel injection pump (5) at
the so called feed pressure. The injection pump pumps fuel
at high pressure through the delivery pipes to injectors (6)
which inject the fuel in the form of a fine mist into the combus-
tion chambers.
Excess fuel lubricates the nozzle valve (needle) and flows in

return through the thermostart device reservoir (7) and then
on back to the fuel tank. When the thermostart is on (glowing)
fuel runs from reservoir (7) through glow plug (8) and is ignited
in the induction manifold. Excess fuel returns from the fuel
injection pump through overflow valve (9) back to the fuel
tank.
82
Model Code Page
22. Fuel system 205-- 555 220 5
1. 12. 1986
Fuel injection pump The purpose of the fuel injection pump is to meter fuel to the
combustion chamber at the correct time. Plunger (3) which is
8 1 driven by the pump camshaft (7) via roller tappet (6) forces the
fuel through delivery valve (2) and further through the delivery
pipe to the injector.
3 4 5
6
2
7 2
6
3
5 7
4
1. Oil filter 2. Governor control lever 3. Hand pump 4. Lubricat-

ing oil for injection pump 5. O ---ring 6. Return of lubricating oil A B C
to engine 7. Drive gear 8. Type plate.
Two---hole pump element (maximum feed)
The fuel injection pump is of the in ---line type made by Bosch.
It is flange mounted and sealed by one O ---ring (5) in the tim-
A. Bottom dead centre
ing gear casing. The injection pump is driven from the crank-
B. Fuel injection begins
shaft through an idler gear. The injection pump is connected
C. Fuel injection ends
to the engine forced ---feed lubrication system through an
external hose (4).
1. Inlet passage 2. Cylinder 3. Starting groove 4. Release
passage 5. Plunger 6. Metering edge 7. Vertical groove
The pump element consists of one plunger (5) and one cylin-
der (2) which are a matched pair and because of the fine toler-
ances the whole element should be changed as a complete
unit.
The cylinder has two passages: inlet passage (1) and release
passage (4). Both passages allow fuel to enter the pressure
space. The side of the plunger has one vertical groove (7) and
one metering edge (6) which are used for adjusting the
amount of fuel injected into the combustion chamber of the
engine.
The top of the plunger is provided with a starting groove

(delay groove) which delays the injection timing by approx.
7---8˚. (This should be borne in mind when checking the fuel
injection timing). This groove improves the cold starting prop-
erties of the engine. It works fully automatically. When the en-
gine has stopped the control rod in the injection pump turns
the plungers so that the starting groove faces towards the re-
lease passage. When the engine has started and when the in-
jection pump has reached a certain speed, the governor pulls
the control rod back into running position.
1. Retainer for delivery valve 2. Delivery valve 3. Pump

element 4. Control rod 5. Return spring for pump plunger 6.
Roller tappet 7. Camshaft.
83
Model Code Page
1. 7. 1986
22. Fuel system 205-- 555 220 6
10. 1. 1992
Delivery valve
Governor
2
5
6
4 7
1. Holder for delivery valve 2. Valve spring 3. Valve cone 4.

Valve guide 5. Valve head 6. Pressure ---reducing piston 7.
Vertical groove
The delivery valve is fitted on top of the pump element and its
purpose is to close the connection between the pump el-
ement and the delivery pipe to the injector. This happens
when the metering edge of the plunger passes the lower edge
of the release passage, and the pressure begins to drop. Its
second purpose is to reduce the pressure in the delivery pipe.
This is important as it enables the nozzle valve (needle) to
close more quickly. 1. Governor weight 2. Control rod 3. Starting spring 4. Main
lever 5. Idler screw 6. Governor spring 7. Additional spring,
Delivery valve cone (3) contains a pressure ---reducing piston
idling 8. Spring for equalizer 9. Governor control arm
(6) which, when the valve closes, is first lowered into guide (4)
and then closes the connection between the delivery pipe and
the pump element. Then valve head (5) is pressed against its
The governor is of the centrifugal type and is fitted at the rear
seat and the fuel in the delivery pipe is given the same space
end of the injection pump. The governor controls the rota-
as the displacement of the pressure ---reducing piston.
tional speed of the engine throughout the whole speed range,
and identifies the rotational speed by means of the governor
Fuel injection pump type plate weights (1). The position of the governor control and of the
governor weights is transferred through the governor lever
linkage to control rod (2). The governor has one governor
spring (6). Starter spring (3), which is attached to the upper
end of control lever (9), pulls control rod (2) to the starting posi-
tion when the engine stops. This means that the amount of
fuel injected when the engine is started automatically be-
comes greater.
The injection pump type plate shows one particular letter indi-
cating the user application, see figure above. This letter
should always be quoted when ordering a replacement pump
or when looking for setting values.
Concerning letter indications for different models , see pages

220/10 ---11.
84
Model Code Page
1. 7. 1986
22. Fuel system 205-- 555 220 7
10. 1. 1992
Fuel feed pump (earlier model)
1. Manual priming pump 2. Pipe union 3. Sealing ring 4. A. Pressure stroke

Spring 5. Valve 6. Washer 7. Tappet 8. Body 9. “O” ring 10. B. Intermediate stroke
Nut 11. Piston 12. Spring 13. Sealing ring 14. Plug 15.
Gasket 1. Injection pump camshaft 2. Tappet 3. Pressure valve 4.
Pressure chamber 5. Piston 6. Suction valve 7. Suction
Fuel feed pump (later model) chamber
The eccentric (cam) on the injection pump camshaft (1)

pushes down piston (5) of the fuel feed pump. This makes the
fuel flow from suction chamber (7) through pressure valve (3)
into pressure chamber (4), at the same time as the spring
under the piston is compressed. This is called the intermedi-
ate stroke.
When the highest point of the eccentric has passed, it is fol-

lowed by the piston and the tappet (2), which is pushed up-
wards by the piston spring. The fuel above the piston is then
delivered through the filter to the fuel injection pump. At the
same time new fuel is sucked through suction valve (6) into
the suction chamber of the fuel feed pump. This stroke is
called the pressure stroke.
Nearly the whole output from the fuel feed pump takes place
during the pressure stroke. During the intermediate stroke the
amount of fuel supplied is only small, and corresponds to the
volume of the pushrod within the pressure chamber.
When the pressure in the fuel feed pipe exceeds the force of
1. Manual priming pump 2. Sealing ring 3. Pipe union 4. “O”
the spring, the piston moves only as far as is required to main-
ring 5. Body 6. Plug 7. Gasket 8. Washer 9. Nut 10. Spring
tain the pressure in the system. Thus it is the force of the spring
plate 11. Spring 12. Valve 13. Sealing ring 14. Piston 15.
that determines the system pressure.
Tappet body 16. Tappet
NOTE: With effect from engine no. 77340 tractors 205---555 Injectors
are fitted with a new fuel feed pump. This new pump is ex-
changeable as a complete unit with the earlier type pump. In The main components of the injectors are the nozzle body
the same manner the manual pumps are exchangeable. and the holder. The purpose of the injectors is to inject the fuel
so that it atomizes (forms a mist) in the combustion chamber.
This is done through four (305, 405) or five (205, 355, 455, 555)
The fuel feed pump pressure which fills the high pressure small holes in the nozzle. It is extremely important that the in-
pump elements with fuel is created by a piston pump which jector is opened and closed rapidly to achieve the best poss-
is attached to the side of the fuel injection pump. The piston ible combustion of the fuel. The operation of the injectors is
pump is driven from an eccentric on the camshaft of the injec- controlled entirely by the pressure from the injection pump.
tion pump. The fuel feed pump supplies more fuel than the in-
jection pump needs. The excess fuel is conducted through
the overflow valve back to the fuel tank. The fuel cools the in-
jection pump and also takes any air bubbles with it back to the
tank.
85
Model Code Page
22. Fuel system 205-- 555 220 8
1. 12. 1986
1 The filter consists of a filter head which is provided with inlet

and return passages for the fuel, and a filtering part which con-
sists of a paper element (3) in a filter casing (5). The internal
pipe in the filter cartridge is threaded at the top for securing the
filter to the filter head.
2
Fuel reservoir for thermostart device
3
4
6
7
8
9
1. Fuel inlet 2. Leak ---off fuel connection 3. Shims 4. Spring 5.

Valve stop spacer 6. Nozzle body 7. Nozzle valve 8. Pressure
chamber 9. Nozzle hole
The fuel pressure acts on the tapered part of nozzle valve (7)
inside pressure chamber (8). When the pressure exceeds the
force of spring (4), it lifts the nozzle valve from its seat and the
fuel is forced out through holes (9) of nozzle (6), into the com-
bustion chamber of the engine cylinder. 1. Supply port to reservoir 2. To glow plug 3. Return to fuel
The force of spring (4) which determines the injector opening
tank 4. Breather valve
pressure, can be adjusted with shims (3).
Excess fuel is conducted up through the injector and lubri-
cates the moving parts before it leaves through the leak ---off
The leak ---off fuel from the injectors is pipes into the fuel reser-
connection (2).
voir for the thermostart device. The fuel required for cold ---
starting is stored in this reservoir. The excess fuel is piped
Fuel filter back to the fuel tank.
N.B. As the breather valve on the thermostart fuel reservoir is

the only passage through which the fuel tank is ventilated, it
is important that it does not become clogged up.
1. Filter head 2. Sealing ring 3. Paper element 4. Internal pipe

5. Filter casing 6. Bleeder screw
86
Model Code Page
22. Fuel system 205-- 555 220 9
1. 12. 1986
87
Model Code Page
22. Fuel system 205-- 555 220 10
1. 12. 1986
Table of fuel metering 309

Test equipment ISO 4008, Fluid ISO 4113, Nozzle ISO 4010
173 bar (S), Pipe diam. ø6x2x600 ISO 4093
Engine Tractor Injection pump Governor Pump timing˚ Injected amo- RW mm Control Control
Max. output r/min unt rod at rod pos.
Low idling r/min mm3/isku least 4 mm
1 mm rpm
rpm mm3 rpm
309 DS3 305 PES 3A 95 D RSV 21 1175 63---65 8,3 1225 1270
320 RS 2655 325---1200 2350 1000 62---64 8,4
/R AOC 2178 650 900 62---64
700 64---67 9,2
600 64---67 9,3
325 11---13
309 DS4 405 PES 3A 95 D RSV 21 1175 72---74 9,0 1225 1280
320 RS 2655 325---1200 2350 1000 71---73 9,1
/J AOC 2178 650 900 74---76 9,4
700 78---80 9,9
600 75---78 9,9
325 11---13
Table of fuel equipment parts (part numbers)

Engine Injection Element Delivery Governor Injector Nozzle Nozzle hol-
Tractor pump valve spring compl. der
309 DS 3 8365 8353 8353 8353 8353 8353 8353
Valmet 305 31793 31161 31162 31780 31100 31101 31102
309 DS 4 8365 8353 8353 8353 8353 8353 8353
Valmet 405 31752 31161 31162 31780 31100 31101 31102
Note! Both tables above apply to earlier production tractors
Table of fuel metering

Test equipment ISO 4008, Fluid ISO 4113, Nozzle ISO 4010 173 bar (S), Pipe diam. ø6x2x600 ISO 4093.
Engine Tractor Injection pump Governor Pump timing˚ Injected amo- RW mm Control Control
Max. output r/min unt rod at rod pos.
Low idling r/min mm3/isku least 4 mm
1 mm rpm
rpm mm3 rpm
309 DS3 305 PES 3A 95 D RSV 21 1175 65---67 9,5 1250 1330
320 RS 2711 325---1175 2350 985 +0,6---0,8
/A AOC 650 500 +1,0---1,1
2178---3R 325 12---15 5,4
309 DS4 405 PES 3A 95 D RSV 21 1175 76---78 10,2 1325 1330
320 RS 2711 325---1175 2350 985 +0,6---0,8
AOC 650 500 +1,0---1,1
2178---3R 325 12---15 5,4
Table of fuel equipment parts (part num-

bers)
309 DS 3 8365 8353 8353 8353 8353 8353 8353
Valmet 305 39091 31161 39126 31780 31100 31101 31102
309 DS 4 8365 8353 8353 8353 8353 8353 8353
Valmet 405 31796 31161 39126 31780 31100 31101 31102
88
Model Code Page
22. Fuel system 205-- 555 220 11
1. 12. 1986
Table of fuel metering 205---555

(With effect from serial no 610312)
Test equipments ISO 4008

Fluid ISO 4113
Nozzle ISO 4010 173 bar (S)
Pipe diam. ø6x2x600 ISO 4093
Engine Tractor Injection Governor Pump timing ˚ Injected RW mm Control Control rod
pump Max. output r/min amount rod at position 4
Low idling r/min mm3 / stroke least mm
1 mm:n
r/min mm3 r/min r/min
309 D 205 PES 3A 95 D RSV 325--- 1175 24˚ 1175 52--- 54 8,1--- 8,3 1190--- 1250---
320 RS 2711 A0C 2178 R 2350 1000 +0,5--- 0,7 1210 1270
/N 650 800 +1,2--- 1,4
700 +1,4--- 1,5
500 +1,4--- 1,6
325 11--- 14 4,7--- 4,9
309 DS 3 305 PES 3A 95 D RSV 325--- 1175 21˚ 1175 65--- 67 9,5--- 9,6 1225--- 1330---
320 RS 2711 AOC 2178--- 3R 2350 985 +0,6--- 0,8 1255 1360
/A 650 500 +1,0--- 1,1
325 12--- 15 5,3--- 5,5
309 DS 4 405 PES 3A 95 D RSV 325--- 1175 21˚ 1175 76--- 78 10,2--- 10,3 1225--- 1330---
320 RS 2711 AOC 2178--- 3R 2350 985 +0,6--- 0,8 1255 1360
650 500 +1,0--- 1,1
325 12--- 15 5,3--- 5,5
311 D 355 PES 3A 95 D RSV 325--- 1175 24˚ 1175 71--- 73 8,9--- 9,0 1215--- 1280---
355 320 RS 2655 A2C 2178--- 1R 2350 1000 +0,3--- 0,4 1230 1300
/BA 750 800 +0,6--- 0,9
700 +0,7--- 0,9
600 +0,7--- 0,9
375 11--- 13 4,5--- 5,0
311 DS 455 PES 3A 95 D RSV 325--- 1175 21˚ 1175 74--- 76 9,1--- 9,3 1215--- 1270---
320 RS 2655 A2C 2178 1R 2350 1000 +0,4--- 0,6 1230 1285
/ AP 750 800 +0,9--- 1,1
700 +1,1--- 1,2
600 +1,1--- 1,2
375 11--- 13 4,5--- 4,7
311 DS 555 PES 3A 95D RSV 325--- 1200 21˚ 1175 72--- 74 9,0--- 9,2 1200--- 1265---
555 320 RS 2655 A2 C 2178 1R 2350 1000 +0,3--- 0,5 1220 1280
/BI 650 800 +0,9--- 1,1
700 +1,1--- 1,3
500 +1,2--- 1,4
375 11--- 13 4,5--- 4,7
Table of fuel equipment parts (part numbers)

205 -- 555
(With effect from serial number 610312)
309 D 8365 8365 8353 8353 8363 8363 8366
Valmet 205 39910 39944 39126 31780 40034 39985 39971
309 DS 3 8365 8365 8353 8353 8353 8353 8353
Valmet 305 39091 39944 39126 31780 31100 31101 31102
309 DS 4 8365 8365 8353 8353 8353 8353 8353
Valmet 405 31796 39944 39126 31780 31100 31101 31102
311 D 8364 8353 8353 8353 8363 8363 8353
Valmet 355 39958 31161 31162 31163 39088 39087 31102
311 DS 8364 8353 8353 8353 8363 8363 8353
Valmet 455 39895 31161 31162 31163 39088 39087 31102
311 DS 8364 8353 8353 8353 8363 8363 8366
Valmet 555 40134 31161 31162 31163 40034 39965 39971
89
90
Model Code Page
1. 12. 1986
22. Fuel system
1. 7. 1989 205 -- 555 222 1
Repair instructions
N.B. This text deals only with the general repair and service
measures which may have to be carried out on the fuel sys-
tem. This applies in particular to the fuel injection pump which
may only be repaired by a specially trained person. Work on
the fuel injection pump requires special tools and testing de-
vices. Special cleanliness must be exercised during service
and repair work.
Fuel feed pump and fuel filter

(Op. no. 222)
1. Checking and repairing fuel feed pump
A. Bleeding fuel system

3. Slacken the injection pump overflow valve (19 mm). Pump
with the hand priming pump until the fuel flowing out is free
from air bubbles. Tighten the overflow valve and screw down
1. Unscrew the manual priming pump piston (on the latest fuel the hand priming pump piston.
feed pumps the piston is not locked).
4. Wipe off fuel from the engine
B. Measuring fuel system pressure
1. Clean the injection pump and the filter carefully.
2. Slacken the bleeder screw (10 mm) on the filter head. Pump
with the hand priming pump until the fuel flowing out at the
bleeder screw is free from air bubbles. Then tighten the
bleeder screw.
2. Fit the gauge at the banjo connection on the pump, as

shown above.
91
Model Code Page
22. Fuel system 205-- 555 222 2
1. 12. 1986
3. Run the engine at low idling for a while and compare the 5. Remove the valve springs and the valves from the pump
gauge reading with the prescribed value (0,6 ---1,0 bar). body. Check the sealing surfaces of the valves. Change any
damaged or worn parts.
N.B. If the measured pressure is below the prescribed value,
this may be caused by: 6. Fit valves and springs. The suction and pressure valves are
--- faulty overflow valve identical. Secure the hand pump and the plug, or the union,
--- clogged fuel filter using new seals.
--- faulty fuel feed pump
--- blocked or leaking fuel pipes or unions 7. Clean the contact surface between the fuel feed pump and
the injection pump and fit the feed pump together with a new
gasket.
C. Checking overflow valve
If the fuel feed pressure deviates from the prescribed value,

check the opening pressure of the overflow valve.
1. Connect a pressure gauge to the banjo union at the supply 1. Fuel filter
connection from the fuel feed pump, (see instructions under
222 B).
A. Changing fuel filter
2. Pump with the hand pump until the overflow valve opens.
Compare the reading on the gauge at the moment the valve
1. Carefully clean the outside of the fuel filter and the area
opens with the prescribed value (0,6 ---1,0 bar).
around it.
3. If the recorded opening pressure deviates from the pre-
scribed value, the valve should be changed. 2. Remove the filter using a suitable tool.
N.B. If the recorded pressure is considerably lower than the

prescribed value, there may be a fault in the hand pump or the
fuel feed pump valves.
D. Removing fuel feed pump and checking

valves
1. Clean the outside of the injection pump and the fuel feed
pump.
2. Disconnect the fuel pipes (19 mm) at the fuel feed pump.
3. Unscrew the fuel feed pump attaching nuts (10 mm).
4. Secure the pump in a vice provided with soft jaws. Remove

the hand pump and the union from the fuel feed pump.
3. Check that the sealing ring of the new filter is correctly posi-
tioned. Moisten the seal with fuel. Screw on the filter until the
seal just touches the sealing surface and then tighten the filter
further 1/4 of a turn.
4. Open the bleeder screw (10 mm) on the filter head and
pump with the hand pump until the fule flowing out is free from
air bubbles. Tighten the bleeder screw.
5. Start the engine and check for any leaks.
92
Model Code Page
61. Fuel system 205-- 555 223 1
1. 12. 1986
Fuel injection pump and injectors (Op. no. 5. Disconnect the delivery pipe for the number one cylinder
injector at the pump.
223)
6. Clean the delivery valve of fuel. Slowly turn the crankshaft
1. Adjusting fuel injection pump in the correct direction of rotation until the fuel level in the deliv-
ery valve just begins to rise.
A. Checking injection timing
N.B. The exact time at which the fuel should be injected into
the number one cylinder (21˚ B.T.D.C) is marked on the
crankshaft belt pulley. The mark has been positioned on the
assumption that the cold ---starting device has been disen-
gaged. Therefore this has to be done first so that the control
rod is moved to the ”running position”, otherwise the injection
timing will be incorrect.
Checking procedure
1. Carefully clean the outside of the injection pump.
2. Remove the inspection hole rubber plug fron the flywheel

housing.
7. Check if the mark on the crankshaft belt pulley is at the point

of the indicator. If it is, the injection timing is correct. If the injec-
tion pump needes to be adjusted, follow the instructions
under B.
8. After checking or adjusting, fit the delivery pipe and the pro-
tecting cap for the control rod on the injection pump front face
after having removed the adjusting tool which was used to
limit the control rod travel. Start the engine and let it run for a
few minutes. This will remove any air which may have been
left in the system and which may cause incorrect timing.
3. Turn the crankshaft until the piston in the number one cylin-
der has reached its T.D.C. when in its compression stroke.
Then turn the crankshaft backwards approx. 1/2 of a turn.
9025 99000
4. Remove the protecting cap for the control rod on the injec-
tion pump front face. Fit adjusting tool (sleeve for limiting con-
trol rod travel) 9025 99000. The tool moves the control rod to
the ”running position”.
93
Model Code Page
22. Fuel system 205-- 555 223 2
1. 12. 1986
B. Adjusting injection timing

C. Removing injection pump
1. Slacken the injection pump attaching nuts (17 mm) and dis-
connect the delivery pipes for the injectors (17 mm). 1. Clean the outside of the pump and all connections and
pipes.
2. Remove the delivery pipes (17 mm). Remove the banjo

bolts at the supply and return fuel connections (19 mm). Dis-
connect the lubricating oil line (14 mm). Plug all connections.
A=Earlier point of injection

M=Later point of injection
2. If the injection occurs too early, turn the pump clockwise, as

seen from the front. If the injection occurs too late, turn the
pump anti ---clockwise, as seen from the front of the pump.
3. Again check the injection timing and adjust if necessary.
4. When the injection timing is correct, tighten the pump

attaching nuts and connect the delivery pipes.
94
Model Code Page
22. Fuel system 205-- 555 223 3
1. 12. 1986
3. Unscrew the oil filler pipe nuts (13 mm) and remove the 2. Lubricate the O ---ring and turn the injection pump camshaft
pipe. Remove the oil filler pipe attaching lugs (not necessary to the position where the key on the shaft and the key in the
when using the new puller). gear align. Fit the pump and tighten the attaching nuts (17
mm).
4. Remove the nut for the injection pump drive gear (22 mm).
3. Tighten the nut for the pump drive gear (22 mm) to 90 Nm.
8360 13091
4. Fit the attaching lugs for the oil filler pipe. Apply silicone
sealing compound to the screw studs and secure the filler
pipe.
5. Connect the supply and return fuel lines (19 mm) and the
lubricating oil line (14 mm). Use new sealing washers.
6. Bleed the fuel system, see instructions no. 222 1A.
7. Adjust the injection timing, see instructions no 223 1B.
8. Connect the delivery pipes for the injectors.
5. Use puller 8360 13091 and loosen the gear from the injec-
tion pump camshaft.
6. Remove the injection pump attaching nuts (17 mm).

Remove the injection pump.
N.B. If the engine is not to be disturbed while the pump is

removed, there is no need to secure the pump gear. The gear
rests against the idler gear.
D. Fitting injection pump

9. After fitting the fuel injection pump it should always be filled
with oil. This is done by removing the hexagon socket plug (10
1. Check the O ---ring on the pump attaching flange. If necess- mm) from the pump. The amount of oil required is 0,3 litres.
ary change it.
E. Checking/changing delivery valve
The checking and changing of delivery valves should be car-

ried out by specially trained personnel using tools and equip-
ment specially required for this work. The requirements on
cleanliness are high if this work is to be carried out satisfactor-
ily.
95
Model Code Page
22. Fuel system 205-- 555 223 4
1. 12. 1986
6. Screw in the damping spring adjusting screw so that the

F. Adjusting low idling speed idling speed increases to the value given in the Technical
Data. Lock the adjusting screw (17 mm) in this position.
If the low idling speed of the engine deviates from the value 7. Fit the adjusting screw protective nuts.
given in the Technical Data, adjust as follows:
N.B. Other adjustments, such as output and high idling speed
1. Remove the protective nut (10 mm) for the idling screw and must only be done by a specially trained person with access
the protective nut for the damping spring (17 mm). to the necessary special tools and measuring devices.
2. Set the engine speed control to the low idling speed posi-
tion.
3. Start the engine and unscrew the damping spring adjusting

screw so that it no longer affects the speed.
4. Adjust the idling screw until the engine speed is approx. 20

revolutions below the prescribed value. Lock the screw in this
position.
5. Rev up the engine a couple of times and check that the

idling speed has not changed.
96
Model Code Page
22. Fuel system 205-- 555 223 5
1. 12. 1986
2. Checking/reconditioning injectors B. Checking injectors
N.B. When pressure testing the injectors, it is important to

A. Removing injectors avoid the nozzle end as the fuel jetting out easily penetrates
the skin. Also bear in mind that the fuel ”mist” is dangerous to
1. Clean the injectors and the area around them. inhale.
2. Disconnect the delivery pipe (17 mm) and the leak ---off line 1. Clean the injector with cleaning fluid and a soft brush. The
(10 mm) from the injectors. carbon deposits must not be knocked off or removed in any
other way which may damage the nozzle.
3. Remove the injector attaching nuts (13 mm) and remove

the injector from the cylinder head. Fit protective plugs to all 2. Secure the injector in a test bench and check the following:
connections. --- injector opening pressure
--- the properties of the chattering (creaking) sound and the
4. Remove the sealing washers from the injector location in form of the spray pattern.
the cylinder head if they do not come out with the injector --- sealing of nozzle valve against its seat
B1. Opening pressure
Pump a few times to fill the injectors. Increase the pressure in

the injector until the chattering (creaking) sound becomes
audible. Read off the opening pressure of the injector. See the
Technical Data. If the opening pressure is too low, the injector
should be taken apart and checked.
97
Model Code Page
1. 7. 1989
22. Fuel system 205-- 555 223 6
10. 1. 1992
Adjustment is carried out by changing the shims (item 2 in fig. 1. Secure the injector in a suitable way.
223 16). The thickness of the shims varies from 1.00---1.98
mm and they are available in increments of 0.02 mm. A thicker 2. Remove the nozzle cap nut (19 mm). Remove the nozzle
shim raises the opening pressure while a thinner one lowers and the parts inside the holder.
it. A difference in shim thickness of 0.02 mm changes the
opening pressure by approx. 3 bar. As the opening pressure
of the injector drops slightly after adjustment, it should be ad-
justed to approximately 210±5 bar (305, 405) or 235+5 bar
(205, 355, 455, 555) above the value given in the Technical
Data section. These values apply to both new and used injec-
tors.
B2. Chattering (creaking) sound properties
Testing with a hand powered pump does not create the same
circumstances as when the injector is fitted in the engine. Only
with new nozzles are the test results reliable. With used
nozzles , there is no chattering sound when the tester is
pumped at a certain rate. This has to do with the design of the
nozzles.
However, with a rapid pumping on the tester handle, it should

be possible to hear the chattering sound or see a mist of the
fuel jetting out. When there is no creaking sound, there is more
of a jet than a mist of fuel.
3. Clean the nozzle in cleaning fluid both inside and outside.

B3. Tightness of nozzle valve
Press down the tester pump lever gradually until the pressure
rises to approx. 20 bar below the adjusting value. Maintain this
pressure for approximately 10 seconds and check whether
drops of fuel are formed on the point of the nozzle. If the injec-
tor leaks, it should be cleaned or the nozzle should be
changed
C. Reconditioning injectors
4. Clean the nozzle holes with a needle (included in cleaning

set 8360 83288).
1. Nozzle holder 5. Valve stop spacer

2. Shims 6. Nozzle body
3. Spring 7. Nozzle cap nut
4. Spring guide
98
Model Code Page
22. Fuel system 205-- 555 223 7
1. 12. 1986
D. Fitting injectors
5. Test the movement of the nozzle valve as follows:

Rinse the parts thoroughly in fuel or testing fluid. Pull the valve 1. Attaching clamp
out of the nozzle body to 1/3rd of its length. If the fit is correct, 2. Washer
the valve should be able to slide down in the nozzle body 3. Rubber seal
under its own weight. Turn the valve slightly and repeat the 4. Sealing washer
test. Should the nozzle valve bind slightly, it should be
changed. 1. Clean the injector sealing surface in the cylinder head. If
necessary use a reamer 8361 97470.
6. Before assembling, all parts should be carefully cleaned in
clean fuel or testing fluid. 2. Fit the injector in the cylinder head using a new sealing
washer.
7. Put the same number of shims back as were fitted earlier.
Assemble the rest of the injector. Note the position of the N.B. The spray pattern from the injectors is not symmetrical
spring guide and the valve stop spacer. on purpose. It is therefore important that the injector is fitted
correctly in the cylinder head. The connection for the leaf ---off
8. Tighten the nozzle cap nut by hand and then to 60 Nm. line should be facing the valve mechanism.
3. Fit the attaching clamp and tighten the nuts (13 mm) evenly
to 15 Nm.
4. Connect the leak ---off oil line (10 mm) together with new
sealing washers and connect the delivery pipes (17 mm).
N.B. The screw studs in the cylinder head for the injectors
should only be finger tight. If tools have to be used the studs
should be tightened only lightly.
3. Delivery pipes for injectors
A. Fitting delivery pipes
1. Check the state of the pipes. If there are kinks, damage by

chafing, or if the tapered sealing end is damaged, the pipes
should be changed.
2. Fit the pipes without tension and check that they are at right
angles to the union.
3. Fit the clamps for the pipes.
99
100
Model Code Page
23. Cooling system 205-- 555 230 1
1. 12. 1986
Contents
Technical Data, see code 210 page 6
Special tools, see code 210 page 7
Description and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Repair instructions (Op. no. 231)

1. Thermostat:
A. Removing and checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Coolant pump:
A. Removing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reconditioning coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Fitting coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
101
Model Code Page
23. Cooling system 205-- 555 230 2
1. 12. 1986
Description and function

Coolant pump
1. Hub
2. Circlip
1. Thermostat 3. Shaft
2. By ---pass passage 4. Pump body
3. Radiator 5. Sealing ring and ceramic washer
4. Coolant pump 6. Impeller
A cross---section of the cooling system is shown in figure The coolant pump is of the centrifugal type and is fitted at the
above. Coolant pump (4) draws coolant from the lower part of front end of the cylinder block. The pump is driven by a V ---belt
radiator (3) and delivers the coolant to the water jackets round from a belt pulley on the crankshaft. The pump shaft and the
the cylinders in the cylinder block. The coolant rises through bearing are built together to form one unit (3). One ball bear-
the passages in the upper part of the cylinder block to the cyl- ing and one roller bearing are used (for the belt pulley).
inder head, and further towards the thermostat (1). Impeller (6) is pressed onto the shaft. Sealing is achieved
between one sealing ring (5) fitted in the pump body (4), and
While the coolant temperature is below the opening tempera- a ceramic washer (5). The pump body has connections for
ture of the thermostat, the coolant flows through the by ---pass coolant hoses to the cab heater and engine heater.
passage direct to the coolant pump, and back into the engine.
As the coolant temperature rises to the opening temperature The flow through the coolant pump is 150 litres at 2350 rpm.
of the thermostat, it will open and some of the coolant will
circulate through the radiator and some through the by ---pass
passage. Because of the by ---pass passage, the engine cool-
ant can be kept at a constant temperature regardless of the
ambient air temperature.
102
Model Code Page
23. Cooling system 205-- 555 230 3
1. 12. 1986
Thermostat
1. Hexagon socket bolt

2. Hose connection
3. Gasket
4. Thermostat
5. Thermostat housing
6. By ---pass passage
7. Rubber seal
8. Temperature sender unit
9. Sealing washer
Thermostat (4) is of the single ---acting type and distributes the

flow of coolant between the engine and the radiator. The ther-
mostat is positioned in thermostat housing (5) at the front end
of the cylinder head. There is a by ---pass passage (6) with
seals (7) between the thermostat housing and the coolant
pump. The thermostat opens at 79˚C (174 ˚F). During the
cold season, a thermostat with an opening temperature of
83˚C (181 ˚F), can be used.
Coolant
A mixture of a glycol based anti ---freeze (30---50 %) and water

is used as a coolant. In order to obtain sufficient corrosion
protection, also use the anti ---freeze mixture during the warm
season. The coolant should be changed every second year.
103
104
Model Code Page
23. Cooling system 205-- 555 231 1
1. 12. 1986
Repair instructions B. Reconditioning coolant pump
Cooling system (Op. no. 231)
1. Thermostat
A. Removing and checking thermostat 8360 13091

1. Drain sufficient coolant to lower the level to below the ther-
mostat housing.
2. Disconnect the upper coolant hose from its connection.

Unscrew the attaching bolts (8 mm socket head) and remove
the hose connection and the thermostat.
3. Lower the thermostat into a vessel containing water, making

sure that the thermostat does not touch the sides or the bot-
tom of the vessel.
4. Slowly heat the water and check with a thermometer when

the thermostat begins to open and when it is fully open, and
compare the readings with the Technical Data.
5. If the thermostat binds or does not open at the prescribed

temperatures, it should be changed.
6. Clean the contact surfaces. Fit the thermostat and the hose
connection together with a new gasket. Connect the upper
coolant hose.
1. Pull of fan hub (4) using puller 8360 13091. Remove circlip
7. Fill with coolant. Start the engine and check for leaks. Run (2).
the engine at light loading until it can be established that the
thermostat works normally.
8360 85499
2. Coolant pump
A. Removing coolant pump

1. Drain the coolant. Disconnect the upper and the lower cool-
ant hoses. Unscrew the attaching bolts (8 mm hexagon
socket) for the thermostat housing. Remove the thermostat
housing and the by ---pass passage.
2. Disconnect the connection for the cab heater and the

engine heater (27 mm) from the coolant pump.
3. Slacken the alternator attaching bolts (13 mm). Unscrew

the attaching bolts (13 mm) for the fan and remove the fan, the
belt pulley on the pump and the V ---belt.
4. Unscrew the attaching bolts (13 mm) and remove the

pump. Remove the plate and the gasket between the pump
and the cylinder block and clean the contact surfaces.
2. Pull the impeller (6) off the shaft using puller 8360 85499.
3. Press the shaft out of the housing towards the fan side.
105
Malli Koodi Sivu
23. Cooling system 205-- 555 231 2
1. 12. 1986
4. Drive the shaft seal out of the pump housing using a drift.
Clean and check the parts. Change faulty or worn parts. C. Fitting coolant pump
5. Press the shaft into the pump housing, applying the force 1. Fit a new gasket between the pump and the cylinder block.
on the outer circumference, and then fit the circlip Align the pump and tighten the attaching bolts evenly and
ET 9051 64900 (on shaft 8353 30994). alternately on both sides.
2. Fit the belt pulley, the V ---belt and the fan. Tighten the alter-
nator attaching bolts.
3. Fit the connections for the cab heater and the engine heater.
4. Fit the by ---pass passage together with new seals on the

9051 40200 pump. Align the thermostat housing to the cylinder head and
at the same time fit the by ---pass passage between the pump
and the thermostat housing.
5. Connect the upper and the lower coolant hoses. Fill with
coolant, start the engine and check for leaks.
N.B. If the coolant pump has been fitted with a new seal and
circlip, coolant may drip from the draining hole under the
pump during the first hours of operation. This leak should stop
once the sealing surfaces have run against each other for a
while.
6. Clean the shaft and the surface for the seal in the pump
housing. Fit the saling ring and the ceramic washer together
with plastic ring on the shaft.
Lubricate with coolant. Tap the seal into position using drift
9051 40200. If the plastic ring does not come away with the
drift afterwards, it must be removed before fitting the impeller.
1---1,7
7. Press impeller and hub onto the shaft whilst guiding the
shaft from the other hand. Check that the shaft can rotate
freely.
106
Model Code Page
10. 1. 1992
21A. Engine (20---series) 255-- 865 210A 1
1. 9. 1992
Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Repair instructions
Cylinder block and flywheel housing (Op. no. 211):
1. Cylinder block and cylinder liners:

A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Fitting plug at rear end of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H. Fitting cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Flywheel housing:
A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Changing flywheel starter gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder head and valve mechanism (Op. no. 212):
1. Cylinder head:
A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Changing valve seat inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.Valve mechanism:
A. Reconditioning rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Changing camshaft/camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crank mechanism (Op. no. 213):
1. Crankshaft:
A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing crankshaft ring gear (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Connecting rods and pistons:

A. Removing piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
107
Model Code Page
10. 1. 1992
21A. Engine (20---series) 255-- 865 210A 2
1. 9. 1992
D. Connecting rods, weight classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

E. Changing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. Fitting piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
H. Fitting piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Balancer unit, 420 ---engines:

A. Removing and dismantling balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Reconditioning balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Fitting balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine timing gears (Op. no. 214)

A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reconditioning idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lubrication system and oil sump (Op. no. 215):
A. Reconditioning oil relief valve for lubrication oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inlet and exhaust system, turbocharger (Op. no. 216):
A. Checking air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Checking inlet and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Reconditioning turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Working orders (Op. no. 219) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
108
Model Code Page
15. 4. 1999
21A. Engine (20---series) 255-- 900 210A 3
1. 9. 2001
Technical Data
Note! With effect from tractor ser. no 656316 tractors below have 20---series engines.
Tractor 255 355 365 455 465 555 565 665 865
Engine type 320 D 320 D 320D 320 DS 320 DS 320 DS 320DS 420 D 420 DS
Turbo no no no yes yes yes yes no yes
No of cylinders 3 3 3 3 3 3 3 4 4
Displacement (dm3) 3,3 3,3 3,3 3,3 3,3 3,3 3,3 4,4 4.4
Cyl. diam. (mm) 108 108 108 108 108 108 108 108 108
Stroke (mm) 120 120 120 120 120 120 120 120 120
Compr. ratio 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1 16.5:1
Output (kW/r/min DIN) 39/2350 45/2350 45/2350 49/2350 51/2350 53/2350 55/2350 59/2350 64/2350
Torque (Nm/r/min) 200/1400 220/1400 220/1400 240/1450 260/1450 260/1450 275/1450 290/1450 310/1450
Torque rise % 26 20 20 22 24 21 23 21 21
Idling speed (r/min) 750 750 750 750 750 750 750 750 750
Max. idling (r/min) 2550 2550 2550 2550 2550 2550 2550 2550 2550
Compr. pressure (bar) 24 1) 24 1) 241) 24 1) 24 1) 24 1) 24 1) 24 1) 24 1)
1) Minimum value at operating temperature and starting revs. Max permitted difference between cylinders 3,0 bar.
600 600 700 700 800 800 900 900

Engine type 320D 320DE 320DS 320DSRE 420DR 420DSRE 420DSR 420DSRE
Turbo no no yes yes no yes yes yes
No of cylinders 3 3 3 3 4 4 4 4
Displacement (dm3) 3,3 3,3 3,3 3,3 4,4 4,4 4,4 4,4
Cyl. diam. (mm) 108 108 108 108 108 108 108 108
Stroke (mm) 120 120 120 120 120 120 120 120
Compr. ratio 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1 16,5:1
Output (kW/r/min DIN) 44/2270 44/2270 51/2270 51/2270 59/2270 59/2270 66/2270 66/2270
Torque (Nm/r/min) 220/1400 220/1400 290/1400 290/1400 290/1400 315/1400 330/1400 350/1400
Idling speed (r/min) 750 750 750 750 750 750 750 750
Torque rise % 19 19 34 34 17 27 18 26
Max. idling (r/min) 2470 2470 2470 2470 2470 2470 2470 2470
Compr. pressure (bar) 241) 241) 241) 241) 241) 241) 241) 241)
Valves, rockers and tappets

With a valve clearance of 1,0 mm:
--- inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0˚±2˚ B.T.D.C
--- inlet valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16˚±2˚ A.B.D.C
--- exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39˚±2˚ B.B.D.C
--- exhaust valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1˚±2˚ A.T.D.C
Valve clearance cold and hot:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
Angle of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚+20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚+20’
Width of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm
Angle of valve face:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚ ---20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚ ---20’
Outside diameter of valve head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 mm
Max valve movement:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,9 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,1 mm
Inlet valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,960...8,975 mm
Exhaust valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,925...8,940 mm
Inlet valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,055 mm
--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm
109
Model Code Page
1. 1. 1998
21A. Engine (20---series) 255-- 900 210A 4
1. 6. 1998
Exhaust valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,090 mm

--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
Inside diameter of valve guide before fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000...9,015 mm
Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm
Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm
Protrusion of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Depth of valve face below cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,8 mm
Spring pressure when spring compressed to a length of:
--- 48,6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327±17 N
--- 37,4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500±23 N
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,959...19,980
Inside diameter of rocker arm bearing bush:
--- (when fitted in position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,990...20,010 mm
Outside diameter of rocker arm bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,035...23,075 mm
Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000...23,021 mm
Max. permissible push rod deflection (when free) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 mm
Free length of rocker arm spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring pressure when spring compressed to a length 58 mm . . . . . . . . . . . . . . . . . . . . . . . 80...100 N
Outside diameter of tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29,939...29,960 mm
Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,000...30,043 mm
Engines from week 34 1996:
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,970...22,990 mm
Rocker arm hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000...23,021 mm
Camshaft
Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,925...49,950 mm

Diameter of camshaft bearing journals (others that no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,885...49,910 mm
Inside diameter of camshaft bearing bushes (when fitted in position) . . . . . . . . . . . . . . . . . 50,010...50,070 mm
Diameter of camshaft bearing bores (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,000...50,025 mm
Camshaft clearance in bearing bush no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,145 mm
Camshaft clearance in bearing bushes (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . 0,090...0,140 mm
Bearing bush tolerance in block (press fit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,080 mm
Diameter of bearing bush bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,620...55,650 mm
Camshaft end play with 0,5 mm gasket between cylinder block and timing gear
housing and between timing gear housing and front cover . . . . . . . . . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Cam height (distance between back of cam and tip of cam):
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,180...41,430 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,080...40,330 mm
Cam lift:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,38 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,28 mm
Camshaft max permissible deflection (total indicator reading) . . . . . . . . . . . . . . . . . . . . . . . 0,03 mm
Cylinder liners
Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,030...0,080 mm
Max. permissible height difference between liners (under same head) . . . . . . . . . . . . . . . . 0,02 mm
Outer diameter of cylinder liner guide:
--- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,475...124,500 mm
--- at lower end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122,961...122,986 mm
Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108,000...108,022 mm
Height of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,03...9,05 mm
Height of cylinder liner flange, 1st oversize, part no 8366 47933 . . . . . . . . . . . . . . . . . . . . . 9,08...9,10 mm
Height of cylinder liner flange, 2nd oversize, part no 8366 47934 . . . . . . . . . . . . . . . . . . . . 9,13...9,15 mm
Height of cylinder liner flange, 3rd oversize, part no 8366 47935 . . . . . . . . . . . . . . . . . . . . . 9,23...9,25 mm
Outer diameter of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131,700...131,800 mm
Piston, rings and gudgeon pin

Minimum distance between piston and cylinder head (measured with a piece
of lead wire thought the injector location hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,900...1,150 mm
Piston diameter:
--- 17 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107,873...107,887 mm
--- 64,4 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107,761...107,779 mm
--- 97,5 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107,500...107,520 mm
110
Model Code Page
10. 1. 1992
21A. Engine (20---series) 255-- 865 210A 5
1. 9. 1992
Pin bore in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,003...40,009 mm

Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,991...40,000 mm
Width of ring grooves:
--- 1st groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,560...2,580 mm
--- 2nd grove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,520...2,540 mm
--- 3rd groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,040...4,060 mm
Side clearance of piston rings in their grooves:
--- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,07...0,102 mm
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,062 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,082 mm
--- reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 mm
Piston ring height (in direction of cylinder):

--- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,478...2,490 mm
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,478...2,490 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,975...3,990 mm
Piston ring gap (with piston fitted in cylinder)

--- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30...0,45 mm
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,60...0,80 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30...0,60
--- reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 mm
Max. permissible weight difference between pistons in same engine . . . . . . . . . . . . . . . . . . . . . 25 g

Piston to be heated up to 100˚C before fitting gudgeon pin.
Piston position in cylinder: combustion chamber of piston to face towards injector.
Connecting rod
Inside diameter of piston pin bush (with bush pressed into connecting rod) . . . . . . . . . . . . . . . 40,025...40,040 mm
Outside diameter of piston pin bush . . . . . . . . . . . . . . . . . . . 44,082...44,120 mm
Interference fit: connecting rod small end bushing ---connecting rod . . . . . . . . . . . . . . . . . . . . . . 0,057...0,120 mm
Connecting rod small end bore . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025
Connecting rod big end bore . . . . . . . . . . . . . . . . . . . . . . . . . 71,730...71,749 mm
Big end bearing shell thickness:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835...1,842 mm
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,960...1,967 mm
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,085...2,092 mm
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,335...2,342 mm
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,585...2,592 mm
Big ---end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0,046...0,098 mm
End float (side clearance) at big ---end on crankshaft . . . . . . 0,200...0,410 mm
Piston pin bushing location perpendicular to longitudinal axis of connecting
rod to be within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15:100
Piston pin bushing location and big ---end bearing location to be parallel to within . . . . . . . . . . 0,05:100
Weight marking (letter) at lower end.
Max. permissible weight difference between connecting rods in the same engine . . . . . . . . . . 20 g
Position of connecting rod; order no at valve mechanism side
(away from the combustion chamber in the piston)
Crankshaft
Crankpin diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,981...68,000 mm
--- 1. undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,731...67,750 mm
--- 2. undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,481...67,500 mm
111
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 210A 6
1. 6. 1998
--- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,981...67,000 mm

--- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,481...66,500 mm
Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000...40,160 mm
Main bearing journal diameter:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,985...85,020 mm
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,735...84,770 mm
--- 2nd undersize 0,50mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,485...84,520 mm
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,985...84,020 mm
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,485...83,520 mm
Main bearing location diameter (in cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm
Main bearing shell thickness:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,955...2,965 mm
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,080...3,090 mm
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,205...3,215 mm
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,455...3,465 mm
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,705...3,715 mm
Bearing 8361 40950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,705...3,715 mm
Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,050...0,127 mm

Length of thrust bearing journal (journal nearest to flywheel):
--- standard (2 standard thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,000...45,080 mm
--- 1st oversize (one std and one 0,1 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . . . . . 45,100...45,180 mm
--- 2nd oversize (one std and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . . . . . 45,200...45,280 mm
--- 3rd oversize (one 0,1 mm and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . 45,300...45,380 mm
--- 4th oversize (two 0,2 mm overthick thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,400...45,480 mm
Other crankshaft journals may not be ground longer.
Crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,100...0,380 mm

Max. permissible ovality and other deformity of crankpins or journals . . . . . . . . . . . . . . . . . . . . 0,03 mm
Crankshaft unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm Max.
Balancing unit ring gear location, diameter (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150,220...150,260 mm
Balancing unit ring gear I.D. (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150,000...150,040 mm
Flywheel
Flywheel ring gear no. of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 pcs

Interference fit between ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,425...0,600 mm
Before fitting the ring gear, heat up to a temperature of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150...200˚C
Flywheel unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm Max
Max permissible axial wobble of flywheel clutch face, measured at inner edge
of clutch face on diameter 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06:ø200
Timing gears
Tooth backlash:
Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Max. permissible side wobble of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm
Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,951...54,970 mm
Inner diameter of idler gear bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,000...55,030 mm
Inner diameter of Idler gear hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,000...60,030 mm
Camshaft gear hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,025 mm
Camshaft end diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,043...32,059 mm
112
Model Code Page
15. 4. 1994
21A. Engine (20---series) 255-- 865 210A 7
1. 6. 1998
Timing marks:
Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre between compression and power
strokes.
On crankshaft gear . . . . . . . . . . 2 dots on tooth
On idler gear:
--- against crankshaft gear mark 0 on tooth
--- against camshaft gear mark 1 dot on tooth
--- against fuel injection pump gear mark . . . . . . . . . . 1 dot on notch
On camshaft gear . . . . . . . . . . . 1 dot on notch
On injection pump gear . . . . . . 1 dot on tooth
Crankshaft must be rotated 6 turns before all gear markings fall into line again
Cylinder block
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,250...13,320 mm

Main bearing location diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm
--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,514...124,554 mm
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,000...123,040 mm
Inner diameter of camshaft bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,010...50,070 mm
Distance between piston and top dead centre at different crank shaft angle
Angle Distance mm Angle Distance mm

320/ 420 320/ 420
10˚ 1,173 21˚ 5,100
11˚ 1,418 22˚ 5,587
12˚ 1,686 23˚ 6,095
13˚ 1,976 24˚ 6,624
14˚ 2,289 25˚ 7,173
15˚ 2,625 26˚ 7,742
16˚ 2,983 27˚ 8,331
17˚ 3,363 28˚ 8,939
18˚ 3,765 29˚ 9,567
19˚ 4,188 30˚ 10,213
20˚ 4,633
Cylinder head
Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,800...105,000 mm
Height of cylinder head after repair machining (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,000 mm
Straightness of cylinder head:
--- lateral direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0,05 mm
--- longitudinal direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0,1 mm
Valve guide I.D. (not fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000---9,015 mm
Valve guide O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm
Valve guide fixing hole I.D. in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm
Height of valve guide upper end from cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Valve disc depth from cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm (max. 1,70 mm)
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm (max. 1,60 mm)
Seat surface angle:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚+20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚+20’
Seat surface width:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm
Exhaust valve seat ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,070...44,132 mm

Exhaust valve seat ring location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025 mm
Exhaust valve seat diameter (repair part 8366 52269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,270...44,332 mm
Exhaust valve seat location, diameter (repair part 8366 52269) . . . . . . . . . . . . . . . . . . . . . . . . . . 44,200...44,225 mm
Inlet valve seat ring diameter (8366 47936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,570...48,632 mm

Inlet valve seat ring location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,500...48,525 mm
Inlet valve seat ring diameter (repair part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,770...48,832 mm
Inlet valve seat ring location, diameter (repair part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . . . . 48,700...48,725 mm
113
Model Code Page
21A. Engine (20---series) 255-- 865 210A 8
1. 9. 1992
Lubricating system
Oil pressure at normal running temperature:

--- at idling speed (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa (1,0 kp/cm2)
--- at running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250---400 kPa (2,5---4,0 kp/cm2)
Free length of oil pressure valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring pressure when valve spring is compressed to a length of 52 mm . . . . . . . . . . . . . . . . . . 54+5 N (5,4+0,5 kp)
Diameter of oil pressure valve plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,602...19,635 mm
Diameter of oil pressure valve cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,700...19,752 mm
Oil filter by ---pass valve opens at a pressure difference of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2±0,5 kp/cm2
Oil pump
Backlash between gears when crankshaft lies firmly against the lower side of main bearings:
--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,16...0,26 mm
Diameter of drive shafts:
--- at bearings for body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
--- at gear wheel pressed on shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,099...18,109 mm
Diameter of shaft holes on body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000...18,018 mm
Diameter of gear wheel holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,060...18,078 mm
Drive shaft gear (press fit), distance between side gear (thread side) and first shoulder . . . . . 14,80...15,20 mm
Fixed shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,028...18,039 mm
Protrusion of fixed shaft end below pump body face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Thickness of cover gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06...0,08 mm
Outside diameter of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,486...43,525 mm

Housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,650...43,750 mm
Thickness of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,000...24,027 mm
End play of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,11 mm
Depth of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,000...24,043 mm
Number of teeth on drive gear (320 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 pcs
Number of teeth on drive gear (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 pcs
114
Model Code Page
1. 6. 1998
21A. Engine (20---series) 255-- 900 210A 9
15. 4. 1999
Balancing unit (420 engines)
Tooth backlash:
--- crankshaft ring gear ---balancer weight gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,3 mm
--- between the balancer weights gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,250 mm
Balancing weights end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,5 mm
Shaft diameter at bearing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,000...36,016 mm
Bearing bushing inner diameter (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,050...36,075 mm
Diameter of holes in body for shafts, rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,058...36,083 mm
Diameter of holes in body for shafts, front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35,958...35,983 mm
Shim thickness, cylinder block ---balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 mm
Turbocharger
Schwitzer S1A (320-- engines)

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0,14 mm
Shaft radial clearance 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0,61 mm
Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,8 Nm
Schwitzer S1B (420 DS-- engines)

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0,14 mm
Shaft radial clearance1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0,51 mm
Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Slotted nut---end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,1 Nm
1) Measured at nut at end of shaft.
Tightening torques
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm+90˚+90˚+60˚

Cylinder head studs to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm + 90˚
Crankshaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm
Flywheel bolts:
--- 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Nm
--- 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
Flywheel housing bolts:
--- outer ring M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
--- inner ring M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Idler gear bolts:
--- M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
--- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Coolant pump v ---belt pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Balancing weights, 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Balancing weights, 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Inlet manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Oil sump fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Nut for lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Lubricating oil pump fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
115
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 210A 10
15. 4. 1994
Special tools
Order no Description
1 9051 73100 Puller for cylinder liner
2 9101 65600 *) Milling cutter for cylinder liner seat
3 9052 46400 Centring tool for flywheel housing
4 9052 46300 Drift for fitting rear crankshaft seal
5 9030 15200 Drift for fitting front crankshaft seal
6 9052 46620 Drift for 40 mm cap plug

8 9025 87400 Drift for fitting camshaft cup plug
9 9101 66300 *) Press tool for cylinder liner
10 9025 79200 Holder for dial gauge
11 9101 66100 *) T ---handle for valve seat milling cutter

12 9101 71100 *) Milling cutter for facing exhaust valve seat
13 9101 65502 *) Milling cutter for exhaust valve seat
14 9101 65503 *) Inner milling cutter for exhaust valve seat
15. 9101 75800 *) Milling cutter for facing inlet valve seat
16 9101 65505 *) Milling cutter for inlet valve seat

17 9101 65506 *) Inner milling cutter for inlet valve seat
18 9101 66200 *) Lever for compressing valve spring
19 9052 47200 Counter nut for lever above
20 9101 66000 *) Milling tool for injector seat
21 9052 46660 Drift for 36 mm cup plug
22 9101 65800 *) Drift for removing valve guide
23 9101 65900 *) Drift for fitting valve guide
25 9101 65700 *) Spanner for crankshaft nut
26 9052 48800 Puller for crankshaft gears

27 9020 01100 Conical sleeve for fitting pistons
28 9025 98900 Drift for fitting dust cover, crankshaft front seal
29 9025 98800 Drift for fitting tension pin in timing gear casing
30 9025 98700 Drift for fitting tension pins in timing gear casing and flywheel housing
*) New tools for 20---series engines. Other tools are the same as for 11---series engines.
6 7 8
1 2 4
5
10
116
Model Code Page
21A. Engine (20---engines) 255-- 865 210A 11
1. 9. 1992
11
12 15
18
19
13
16
14 17
21 22
20
26
23 24 25
27 28 29 30
31
117
Model Code Page
21A. Engine (20---series) 255-- 865 210A 12
1. 9. 1992
Engine, description
When fitting the flywheel housing, its position is determined
by tension pins.
General
The Valmet 20---series engines (3---, 4---, or 6---cylinders) are
water ---cooled, four stroke, turbocharged (not 355 and 665),
direct---injection in ---line diesel engines. Technical values, see
page 210/3.
The engines have a rigid and ribbed cylinder block. The crank
mechanism is designed for supercharging. The cylinder
liners are wet and supported at the middle, the cylinder head
bolts are high tensile bolts.
Cylinder block
The cylinder block is the main body of the engine, to which

other engine parts are attached. Wet and replaceable cylinder
liners are supported at the middle which reduces vibrations
and directs coolant circulation mainly to the upper part of the
liners.
The seal between the cylinder liner lower part and the cylinder
block is achieved by three o---rings, which are fitted in grooves
in the liner. The upper part is sealed by the cylinder head
gasket.
The camshaft is located in the cylinder block. The camshaft

front bearing location is fitted with a separate bearing sleeve.
The remaining bearing locations are machined directly in the
cylinder block. The drilling for the camshaft rear end is cov-
ered with a plug.
There are spaces on both sides of the rear main bearing for
guide bearing shims (the crankshaft thrust bearings).
Flywheel housing
The flywheel housing is fitted at the rear end of the cylinder

block. The seal for the crankshaft rear end is placed in a bore
in the housing. The starter motor fixing point is fitted in the fly-
wheel housing.
118
Model Code Page
21A. Engine (20---series) 255-- 865 210A 13
1. 9. 1992
Crank mechanism
The crankshaft is forged from chrome alloy special steel and

is induction hardened at the bearing and sealing surfaces.
This makes it possible to grind bearings four times without a
new heat treatment. Gear wheels are located at the front end
of the crankshaft. They are a press fit, and drive the idler wheel
and oil pump. In addition, the front end of the crankshaft has
splines for the hub of the V ---belt pulley. An oil deflector ring
is fitted between the hub and gear wheel, and a dust shield is
fitted on the hub in order to protect the seal. The v ---belt pulley
has a timing mark. Thus the pulley must be fitted in right posi-
tion which is determined by a guide pin.
The crankshaft is supported on the cylinder block by main

bearings which are placed on both sides of each cylinder.
Thus there is one main bearing more than cylinders. The
crankshaft thrust washers are placed in both sides of the rear-
most main bearing.
At the rear end of the crankshaft there is fitted a flywheel on

which is a press fit a starter ring gear. The forged connecting
rod has an I ---section cross---section. The bearing location at
the bottom end of the connecting rod is split, and the bearing
cup is secured by two special bolts and nuts. The upper part
has a wedge ---shaped bearing location, in which the piston
pin bearing bushing is fitted with a press fit.
Cylinder head The piston is made of an eutectic aluminium alloy. In the
upper face of the piston there is a combustion chamber. The
shape of the chamber is intended to maximise the mixture of
320--- and 420---engines have one cylinder head. Each cylin- air and fuel. The piston has three rings. The middle ring is tap-
der has its own inlet and exhaust ports located on either side ered and it fits into its groove so the taper taking up the clear-
of the head. Between hot exhaust valves a cool inlet valve is ance. The oil control ring is spring loaded and it has a two---
fitted to balance the thermal load. stage, chromed scraping edge.
Cylinder head bolts are high tensile bolts which are tightened
up to yield limit using angle tightening principle. Due to the
large stretch the tightening forces are kept constant during the On the turbocharged engines the piston sides are graphitized
whole lifetime and retightening is unnecessary. to ensure correct running ---in.
The injector locations are machined directly into the cylinder

head. The inlet and exhaust valve guides are identical and can Four ---cylinder engines (420) are equipped with a balancer
be interchanged. In addition, the exhaust valves are equipped unit. The eccentric weights, which rotate at twice the engine
with replaceable valve seat inserts. speed, even out the vibration forces exerted by the movement
of the pistons and the crank mechanism.
Valve mechanism
The valve mechanism is operated by the camshaft which is lo-

cated in the cylinder block. The drive is transferred with the
help of tappets and pushrods. The camshaft gear wheel is
fitted with a press fit and fixed with a key. Each bearing is lubri-
cated by the force feed lubrication system through drilled oil-
ways in the motor block.
119
Model Code Page
21A. Engine (20---series) 255-- 865 210A 14
1. 9. 1992
Timing gears
The timing gear train consists of hardened, helically cut gear

wheels. The gears are encased by the timing gear casing
which is fitted to the front of the engine. The timing gear drives
the camshaft, fuel injection pump, lubricating oil pump an the
hydraulic pump on the engine RH side.
The hydraulic pump is driven by a gear at the camshaft front
end.
The idler gear is supported with a bearing sleeve on the shaft

on the front face of the cylinder block.
120
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 900 210A 15
1. 1. 1998
Lubricating system (3--- and 4---cylinder engines have

similar lubricating systems).
1. Lubricating oil pump

2. Pressure ---relief valve
2a. Draining hole downwards
3. Oil filter
Lubricating system 4. Turbocharger (if fitted)
5. Main oil gallery
6. Lubricating oil to fuel injection pump (in ---line pump)
7. Lubrication of hydr pump drive mechanism (665, 800)
The engine has a pressure lubricating system in which the oil 8. Balancer unit (4---cyl. engines)
pump (gear pump) is attached to the cylinder block lower 9. Oil pressure sensor
face. The oil is sucked up by the pump through a suction
strainer. After the pump the oil is led through an oilway to the The oil pressure relief valve is located under the oil filter on the
relief valve and to the oil filter. After the filter, the oil is led left hand side of the engine. The valve regulates the lubricat-
through the main oil gallery from which oilways branch out. ing oil pressure so that it is kept constant, regardless of the
The oil is led through the oilways in the main bearings and engine speed. Oil pressure is about 2,5 ---4 bar depending on
through the crankshaft to the big ---end bearings. revs, oil quality and temperature, and at engine idling speed
the pressure is min 1,0 bar.
The oil is further directed from the main gallery to the injection The oil filter is full---flow disposable type and is fitted on the
pump, turbocharger, balancing unit (420) and to a possible left---hand side of the engine. A by ---pass valve is located at
compressor. In addition, the idler gear bushing, the camshaft the base of the filter to ensure safe cold ---starting or to ensure
bearing points and the valve mechanism get their lubrication adequate lubrication in case the filter becomes blocked. In
oil via the main oil gallery. addition, there is a non ---return valve which stops the filter
from being emptied of oil.
121
Model Code Page
1. 6. 1998
21A. Engine (20---series) 255-- 900 210A 16
15. 4. 1999
1. Cyclone (not 865, 600---900)

2. Air filter
3. Safety filter
4. Turbo (not 205, 355, 665, 600 and 800)
5. Intake manifold
5a. Glow plug
6. Exhaust manifold
7. Exhaust pipe
8. Vacuum switch
Induction and exhaust system

The filter system for the engine inlet air comprises a cyclone
type precleaner (205---665), and a paper filter which acts as The exhaust manifold is attached to the cylinder head with
the main filter. The incoming air is made to rotate in the cyc- high tensile bolts without a separate gasket. Retightening of
lone precleaner. This causes most of the impurities to settle the manifold bolts is unnecessary.
out and collect in the cyclone precleaner dust collector. The
paper filter comprises two replaceable filter elements. The The turbocharger is small and thus it reacts sensitively at low
paper is corrugated and surrounded by a metal support. engine revs. The turbocharger gets lubricating oil and cooling
from the engine lubricating and cooling system.
The impurities in the air collect at the larger filter element Note! 865, 800 and 900 tractors have not a cyclone but an
which can be cleaned when necessary. The inner safety filter ejector pipe, which removes impurities from the filter with the
prevents impurities form entering the engine should the main aid of the suction created by exhaust gas flow. On the 600,
filter element break, or be fitted incorrectly. 700. 865, 800 and 900, there is also a warning light in the dash-
board for a blocked engine air filter. On 600---900 tractors the
The inlet system also includes the hoses between the air air filter housing is the same. On 600---700 there is a valve in
cleaner and the turbocharger and the turbocharger and the place of the ejector pipe, through which impurities are remo-
induction manifold. ved. The valve does not require service. In connection with
maintenance work, the valve/ejector pipe connection must be
directed downwards.
122
Model Code Page
21A. Engine (20---series) 255-- 865 211A 1
1. 9. 1992
Repair instructions
9051 73100
Cylinder block and flywheel housing (Op
no 211)
1. Cylinder block and cylinder liners
A. Measuring cylinder liner wear
Note! Cylinder liner wear can be measured when the engine

is attached to the tractor. Remove only the cylinder head and
crank the engine so that the piston is in the lower position.
1. Using a micrometer, set the dial gauge to zero using a new

cylinder liner indicating the initial dimension of the bore:
108,00 mm.
2. Clean the inner surface of the cylinder liner thoroughly

before measurement.
C. Checking cylinder block
1. Clean the cylinder block and all oilways.
2. Check the cooling channels and remove the scale and sedi-
ment to ensure engine cooling.
3. Check the tightness of the cup plugs and threaded plugs

in the cylinder block as well as the condition of the cylinder
block and sealing faces.
4. Measure the wear of the camshaft bearing points (compare

with rating on page 210/4).
Note! If it is necessary to machine the upper face of the cylin-

der block, the pistons must be shortened by the same dimen-
sion. Observe the valve disc spaces on the piston upper face.
3. Perform the measurement crosswise at the liner top end,

lower end and middle. D. Changing camshaft bushing
4. Check the gauge reading for maximum wear and ovalness Note! Working order, see page 219/2.
(compare with rating on page 210/4).
1. Extract the bushing with an internal puller, for example
Sykes 854. If the camshaft rear end plug is removed the bush-
B. Removing cylinder liner ing can be forced out with a long drift.
Note! See also page 219/1 for working order.
2. Clean the bushing location.
1. If the cylinder liners are to be used again they should be

marked so that they can be fitted in the same position.
2. Remove the cylinder liners using cylinder liner puller 9051

73100.
123
Model Code Page
21A. Engine (20---series) 255-- 865 211 2
1. 9. 1992
0,1---0,4 mm
3. Press in a new bushing. Note the position of the oil hole. It

is unnecessary to ream the bushing because it has a correct
inner diameter when it is fitted in place.
E. Oversize bushings for camshaft

140 mm 134 mm
If the location of the camshaft bushing (front bearing) is dam- 6---7 mm
aged, a bushing with a 0,4 mm oversize outer diameter can
be fitted. Bushings are available even for other camshaft bear-
ings which do not normally have bushings. Part numbers and
machining dimensions for the bushing locations are shown in
the figure.
4 3 2 1
Observe the position of the bushing oil holes. It is unnecess-
ary to ream the bushings after fitting.
Oversize camshaft bushings for 320---engines. Numbering
begins from the front end of the engine.
Order no Hole diameter
1. 8363 24661 56,02...56,05

2. 8368 52460 55,40...55,43
3. 8368 52460 55,40...55,43
4. 8368 52461 55,62...55,65
124
Model Code Page
21A. Engine (20---series) 255-- 865 211 3
1. 9. 1992
272 mm 134 mm
6---7 mm
4 3 2 1
Order no Hole diameter
1. 8363 24661 56,02...56,05

2. 8368 52460 55,40...55,43
Camshaft oversize bearing bushings for 420---engines. 3. 8368 52460 55,40...55,43
Numbering begins from the front end of the engine. 4. 8368 52461 55,62...55,65
F. Fitting plug at camshaft rear end

1. Clean the seat for the plug.
2. Apply sealing compound to the contact surface of the plug
The camshaft rear end plug is replaced with plug 8363 24391 3. Drive in the plug with fitting drift 9025 87400.
and o---ring 6146 05125 after machining.
Note! Do not drive in the plug too far because it will affect the
camshaft end float.
125
Model Code Page
21A. Engine (20---series) 255-- 865 211A 4
1. 9. 1992
G. Fitting pipe for oil dipstick

9101 65600
1. Clean the seat for the pipe.
2. Apply locking fluid Loctite 601 to the lower end of the pipe.
116 mm
3. Tap the pipe in to the correct fitting height shown in figure

above.
Note! The position of the pipe affects an oil level in the engine.
0,03---0,08 mm
9025 79200
H. Fitting cylinder liner
1. Clean the cylinder liner and its recess in the cylinder block.
Without o---rings the liner should rotate easily in its recess.
2. Apply a thin layer of marking paint on the underside of the

cylinder liner flange. Fit the cylinder liner without o---rings and
turn it forwards and backwards. Lift out the liner and check
that paint has been deposited on the whole contact surface.
9101 66300
3. If the recess is damaged, or the cylinder liner height (see
point 5) needs to be adjusted, use milling cutter 9101 65600.
If necessary, a light lapping can be executed after milling with
the help of the cylinder liner. Apply lapping paste to the under-
side of the cylinder liner flange, and twist the liner with twisting 5. Fit the cylinder liners and fix each liner with two press tools
tool. Lapping is not suitable for adjusting the cylinder liner 910166300. Measure the cylinder liner height with a dial
height. gauge and holder 9025 79200. Zero the dial gauge against a
flat surface, for example, the cylinder block face. Measure
4. Clean the contact surfaces. each liner in four places. The height of the liner above the cyl-
inder block face should be 0,03 ---0,08 mm. The height differ-
ence between cylinder liners under the same cylinder head
must not exceed 0,02 mm, nor must an intermediate cylinder
liner lie lower than an outer one.
126
Model Code Page
21A. Engine (20---series) 255-- 865 211A 5
1. 9. 1992
6. If the cylinder liner height is too low, a liner with a higher

flange is fitted.
Order no H Marking grooves

pcs
8266 47420 9,03+0,02 --- (norm)
8366 47933 9,08+0,02 1
9. Press the cylinder liners into the cylinder block. It should be
8366 47934 9,13+0,02 2
8366 47935 9,23+0,02 3 easy to press them fully home. Make sure that the liners do not
rise up after fitting.
Cylinder liners with oversize flanges (higher flanges) are

marked with grooves on the outer circumference as follows:
1st oversize, 0,05 mm = 1 marking groove

2nd oversize, 0,10 mm = 2 marking grooves
3rd oversize, 0,20 mm = 3 marking grooves
Note! Recess depth is adjusted with a cylinder liner recess

cutter 9101 65600.
7. If the liner height of a cylinder liner is not the same all the way
round, the cylinder liner flange and the cylinder block recess
depth should be checked. Cylinder liners with warped flanges
should be discarded.
Musta/Black/Svart/Noir
Schwartz/Juodi
Vihreä/Green/Grön/Vert
Grün/Žalias
8. Fit the o---rings into the grooves in the cylinder lower part
and lubricate them with a liquid soap (not with engine oil).
Note! Stretch the o---rings as little as possible when fitting

them. Max allowable stretching is 6 %.
127
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 211A 6
1. 3. 1997
8360 20054
2. Flywheel housing
A. Fitting flywheel housing
The flywheel housing is centred on the cylinder block by two

tension pins. Even the flywheel housings which are delivered
as spare parts have ready ---made holes for the pins.
1. Clean the sealing surfaces between the cylinder block and

the flywheel housing.
Note! If the crankshaft is worn at the sealing location, a 2 mm

spacer ring, part no 8360 20054, can be fitted in front of the
crankshaft rear oil seal.
2. Apply silicone sealant as shown in figure above.
3. Lift the flywheel housing into place and fit all the bolts.
4. Centre the housing and fit the tension pins with drift 9025
98700.
5. Tighten the fixing bolts, the inner ring socket head bolts to
60 Nm and outer ring hexagonal bolts to 110 Nm.
9052 46300
B. Changing crankshaft rear oil seal
1. Split the tractor at clutch. Remove the clutch assembly.

5. Lubricate the sealing surfaces on the crankshaft and on the
2. Remove the flywheel. seal. Place the seal on the crankshaft and drive it in until it bot-
toms using drift 9052 46300. Other tools may cause the seal
3. Remove the oil seal. Do not damage the crankshaft. to be damaged or mounted askew, resulting in leakage.
4. Clean the seal location and grind off any burrs. Note! The cranckshaft rear oil seal has been changed to a
Teflon type. The spare part seals have a mounting sleeve,
which must not be removed before fitting. The spare part
numbers do not change. When fitting the seal, place the plas-
tic sleeve on the crankshaft and push the seal on the sleeve
into place. Remove the sleeve and fit the seal with the special
tool. The seal must be fitted as dry.
128
Model Code Page
1. 6. 1998
21A. Engine (20---series) 255-- 900 211A 7
15. 4. 1999
C. Changing starter ring gear on flywheel Note! If a flywheel must be changed on the E ---engines, an in-
jection timing mark must be made on a new flywheel as fol-
If the ring gear is worn, change it with a new one. The ring gear lows:
cannot be turned around because its teeth are chamfered and
hardened on the starter motor side. --- Rotate the crankshaft so that the piston in the first cylinder
is in the top dead centre. Drop a valve down against the piston
1. Split the tractor at clutch (see Op 411 1A). Detach the clutch top. Place a dial gauge stylus against the valve upper end and
assembly and the flywheel. zero the gauge to the top dead centre. Rotate the crankshaft
in the running direction until the dial gauge shows value 4,633
1. Detach the earlier ring gear by tapping it with a drift. Clean mm after the top dead centre).
the ring gear seat on the flywheel with a steel---wire brush.
--- Drill the injection timing mark in the flywheel with the aid of
a drill shown below.
7
5 mm drill
8 mm guide
2. Warm the ring gear to the temperature of 150 ---200˚C. Fit

the ring gear with the inner diameter chamfering turned
against the flywheel and the teeth chamfering against the
starter motor.
3. Allow the ring gear to cool freely without using any coolant.
D. Fitting the flywheel

1. Clean the contact surfaces on the crankshaft rear flange
and on the flywheel.
Note! In the E ---engines there is an injection timing register

mark on the flywheel and the flywheel has been positioned
with a guide sleeve to the crankshaft.
2. Fasten the flywheel to the crankshaft rear end. As a guide

pins can be used screws M12 (2 pcs) which are screwed in to
the flywheel fixing bolt holes.
3. Tighten the flywheel fixing bolts evenly to a torque of 140

Nm (10.9) or 160 Nm (12.9).
129
130
Model Code Page
10. 1. 1992
21A. Engine (20---series) 255-- 865 212A 1
1. 9. 1992
Cylinder head and valve mechanism (Op 2. Compress the valve springs using lever 9101 66200. Re-
no 212) move the valve cotters, spring guide and spring. Remove the
valves.
1. Cylinder head
C. Checking cylinder head
A. Removing cylinder head
1. Remove carbon deposits from the exhaust ports, clean the
sealing surfaces and wash the cylinder head.
1. Remove the engine hood plates. Clean the engine exter-
nally and drain the coolant. Disconnect the coolant hoses 2. Check for cracks and other damage.
from the cylinder head and the thermostat housing.
2. Remove the suction hoses between the turbocharger and

the air filter and between the turbocharger and the inlet mani-
fold (turbocharger only on 455---565 tractors).
3. Disconnect the turbocharger pressure and return oil pipes.
4. Remove the pipes to the thermostart fuel reservoir.
5. Remove the injector leak ---off fuel pipes and the delivery
pipes. Remove the injectors. Fit blanking ---off caps on all
open connections.
6. Remove the inlet and exhaust manifolds and the thermostat

housing.
Note! It is possible to remove the cylinder head even thought

these parts are attached to the head.
7. Remove the valve cover and the breather hose. 3. Check the flatness of the cylinder head by using a straight
edge. An uneven or warped surface should be surface
8. Remove the rocker arm mechanism and the push rods. ground. The height of the cylinder head, after grinding, should
not be less than 104,00 mm. The valve disc depth from the
9. Loosen all the cylinder head bolts first by a 1/4 turn and then cylinder head surface should be 0,60 mm for the exhaust
remove them. Remove the cylinder head. valves and 0,70 mm for the inlet valves.
B. Removing valves
Ensure that valves which are to be re ---used are marked, so 9101 66000
that they are fitted in their original locations.
9052 47200
1. Thread the counterhold nuts 9052 47200 onto a screw stud

for the rocker arm mechanism. On the 320---engines there is
not a screw stud at the valves for the centre cylinder. A bolt of
suitable length should be used instead. 4. Straighten and clean the injector location seat in the cylin-
der head with cutter 9101 66000.
131
Model Code Page
10. 1. 1992
21A. Engine (20---series) 255-- 865 212A 2
1. 9. 1992
9101 65900
5. Measure the clearance between the valve stem and the

valve guide with a dial gauge. Lift the valve so that the valve
21 mm
head is 15 mm from the face of the cylinder head, and
measure the clearance. It must not be greater than 0,20 mm
for the inlet valves and 0,25 mm for the exhaust valves. In
order to establish the valve guide wear, a new valve should be
used when measuring.
D. Changing valve guides
9101 65800 3. The guides are the same for the inlet and exhaust valves.
Ensure that the steepest chamfer on the guide, faces the valve
head. Check that the valves do not bind in the guides.
E. Machining valve seat
1. Press or knock out the old guides using drift 9101 65800.
Clean the valve guide locations.
2. Lubricate the outside of the new guides and fit them using
drift 9101 65900, which ensures the correct fitting height (21
mm over the spring face)
Machine the damaged valve seat with milling cutter (see page
210/10). If the width of the seat exceeds 2,3 mm in exhaust
and 3,7 mm in intake, it should be reduced primarily at the
outer edge.
The valve seat angle is 45˚+20’ for exhaust valve and

35˚+20’ for inlet valve.
132
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 212A 3
1. 3. 1997
F. Changing valve seat inserts
Exhaust valves are fitted with separate valve seat inserts. If the
sealing surface is damaged so badly that it cannot be repaired
B
with machining, the seat inserts should be changed.
A
1. Grind the valve head on a discarded valve so that it sits
down in the valve seat. Fit the valve and weld it in place in the
seat. Cool with water.
2. Turn the cylinder head over and knock out the valve and
seat.
3. Clean the valve seat location. Cool the new seat in liquid ni-
trogen until it stops bubbling, or alternatively place it in dry ice. A B
INLET 35˚ ---20’ 35˚+20’
4. Fit the seat with a suitable drift. Machine the seat. EXHAUST 45˚ ---20’ 45˚+20’
N.B. Where necessary, standard size seats can be replaced

by inserts with a larger outer diameter. See Specifications.
1. Grind the damaged valve disc with a valve refacer. Adjust
angles to 45˚ ---20’ for exhaust valves and 35˚ ---20’ for inlet
valves.
11±0,1
2. If the edge of the valve head is less than 1,5 mm after it has
been ground, or if the valve stem is bent, the valve should be
discarded.
3. If necessary, grind the end of the valve stem.
4. Lap the valves with lapping paste and check the contact
surface with marking paint.
48,500...48,525
5. Clean the cylinder head and valves of any remaining lap-
ping paste.
The inlet valve seat machined direct on the cylinder head, can
be provided with a separate valve seat insert, order no 8366
47936. Machine the seat insert location on the cylinder head
(see figure above). Fit the insert like a seat of the exhaust
valve. H. Fitting valves
Note! From March 96 the V ---marked cylinder heads have the
1. Check the valve springs for straightness, length and ten-
valve seat inserts also on the inlet valves. The V is stamped on
sion using a spring tester. Compare with specifications.
the cylinder head front upper surface on the exhaust side. As
a spare part these heads can be fitted on all engines. The
2. Lubricate the valve stems and fit the valves in the correct
V ---marked cylinder heads are also available for the 4---cylin-
order in the cylinder.
der engines.
3. Fit the springs, spring guides and valve keepers with the aid
G. Grinding valves of a lever for compressing valve springs, 9101 66200.
4. Tap the end of the valve stems lightly after fitting the valve
In order to ensure that there is a proper seal around the valves,
in order to ensure that they are secure.
there is a difference in the sealing surface angles. Thus there
is a very narrow sealing surface which seals effectively even
after prolonged running.
133
Model Code Page
1. 6. 1998
21A. Engine (20---series) 255-- 865 212A 4
15. 4. 1999
I. Fitting cylinder head
1. Measure the length of the cylinder head bolts. Compare 14 10 7 5 9 15

with dimensions shown in figure below. Change too long
16 3 1 17
bolts.
2 4
max. 142 12 13
8 6 11
320
max. 188,5
22 19 12 6 4 11 14 17
21 10 7
2 16
8 1 9
2. Screw the cylinder head stud bolts in to the cylinder block 20 15

to a torque of 30 Nm. Fit the valve tappets if removed. 18 3 5 13
3. Check that the sealing surfaces are clean and fit the cylinder 420
head gasket. Clean and lubricate and fit the bolts.
Note! The spare part number of the cylinder head gasket is 4. Pictures above show the correct tightening order of the cyl-
8366 46351 (320---engines) and 8367 46354 (420---engines). inder head bolts. The order has also been marked on the cyl-
inder heads.
5. Tighten the cylinder head bolts progressively as follows:
1. First tightening to 80 Nm
2. Tightening a further 90˚
3. Tightening a further 90˚
4. Adjust valve clearances
5. Warm engine to normal operating temperatur with light
load (up to about +75˚C)
6. Tightening a further 60˚.
7. Adjust valves.
Note! Tighten the exhaust manifold bolts to the cylinder head

to a torque of 50 Nm. Do not tighten more.
134
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 212A 5
1. 9. 1995
2. Valve mechanism 60˚
A. Reconditioning rocker arm mechanism
1. Check the valve tappets, especially the contact surface

against the camshaft. Worn or damaged tappets should be
discarded.
5. Fit the plug to the other end of the rocker arm shaft. Lubri-
cate the shaft and fit various parts in a correct order. Note the
correct position of the shaft and the bearing brackets. The split
side of the bracket and the shaft oil holes must be turned to
the valve side (see figure above). Fit the other end plug.
B. Changing camshaft/camshaft gear

Note! Working order, see page 219/2.
2. Check the straightness of the pushrods by rolling them on 1. Remove the inlet pipe between the turbocharger and the
a surface table. Check also the spherical surfaces at the ends. induction manifold. Remove the valve cover and the breather
pipe. Remove the rocker arm mechanism.
3. Dismantle and clean the rocker arm mechanism. Check the
shaft for wear and that the oilways are clean. 2. Remove the radiator, cooling fan, alternator and the v ---belt.
3. Remove the crankshaft nut. Remove the V ---belt pulley in-

cluding the hub.
4. Remove the timing gear casing cover (engine front cover).
5. Connect the pushrods in pairs, using o---rings or elastic

bands to prevent them from falling through.
19,990...20,010
4. Check that the rocker arm bushes are not worn. Ensure that
the oil hole is positioned correctly when pressing in new
bushes. After pressing in the bushes they should be reamed
to 19,990 ---20,010 mm. Where necessary grind the rocker
arm valve contact surface to the correct shape. Do not grind
more than necessary as the hardened layer is thin.
Note! Do not connect the pushrods too tightly as this might

cause them to bend or snap.
135
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 212A 6
15. 9. 1995
6. Crank the engine until the aligning marks on the idler gear 320 ---engines
and camshaft gear are facing each other. Extract the cam-
shaft. Check the valve clearances in the injection order of the en-
gine. Injection order is 1---2---3.
7. Separate the camshaft from the gear wheel using a press --- check valves in the 1st cylinder, when the exhaust valve of
or suitable drift. no. 3 cylinder is completely open (valve no. 6)
--- check valves in the 2nd cylinder, when the exhaust valve of
8. Clean the parts which are to be refitted. no. 1 cylinder is completely open (valve no. 2).
--- check valves in the 3rd cylinder, when the exhaust valve of
9. Fit the key in its groove. Heat the camshaft gear to 200˚C no. 2 cylinder is completely open (valve no. 4).
in an oven and fit it on the shaft.
10. Lubricate bearing surfaces and lobes and insert the shaft 420 ---engines
in the cylinder block. Ensure that the aligning marks on the
gears agree. --- rotate the crankshaft in the running direction until the valves
in the 4th cylinder are rocking (exhaust closes, inlet opens).
11. Fit the timing gear casing cover and the crankshaft V ---belt Check the valve clearance of the 1st cylinder
pulley and hub. --- Rotate the crankshaft by 1/2 of a turn in the running direc-
tion so that valves in the 3rd cylinder are rocking. Check
12. Free the pushrods and fit the rocker arm mechanism. valves in the 2nd cylinder
Adjust the valves. Fit the valve cover and the breather pipe --- continue according to the order of injection:
and the inlet pipe between the turbocharger and the induction
manifold.
13. Fit the alternator. Fit the fan and the fan belt. Fit the radiator. Injection order 1 2 4 3
Valves rock in cyl. no 4 3 1 2
C. Adjusting valves
I P I P I P
320
0,35
I P I P I P I P
420
I=inlet P=exhaust
The valve clearance, which can be adjusted on a hot or cold
engine, is 0,35 mm for both inlet and exhaust valves. The
clearance is adjusted when the respective piston is at T.D.C. Note! From engine number C6828, the support strips have
in the compression stroke. The valves for the different cylin- been added onto the valve covers. These strips prevent the
ders are adjusted in the same sequence as the order of injec- gasket from moving inwards. At the same time the cover
tion. manufacturing accuracy has been improved. Spare part
numbers of the covers do not change.
--- slacken the lock nut of the adjusting screw
--- measure clearance with a feeler gauge. The clearance is
correct when a 0,35 mm feeler gauge is slightly tight---fitted
between the rocker arm and the valve stem end. Adjust clear-
ance by rotating the adjusting screw.
--- tighten the locking nut and check the clearance
136
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 213A 1
1. 3. 1997
Crank mechanism (Op. no 213) 3. Refit the bearing caps with new bearing shells and tighten
them to the correct torque. Measure the I.D. with a dial gauge
which has been zeroed to the dimensions obtained in point 2.
1. Crankshaft With this method the indicator shows the actual bearing clear-
ance. Measure in several points in case the worn bearing
housing is not round.
A. Removing crankshaft
1. Split the tractor at the clutch, remove the clutch assembly

and the flywheel. Remove the engine (see also page 219/1).
2. Disconnect the balancing unit lubricating oil pipe from the

cylinder block and unscrew the balancing unit fixing bolts.
Remove the balancing unit and the lubricating oil pipe (only
420---engines).
3. Unscrew the lubricating oil pump pressure pipe fixing

screws from the cylinder block. Remove the oil pump and the
suction and pressure pipes.
4. Remove the flywheel housing.
5. Detach the belt pulley/hub from the crankshaft front end

(see instr. timing gears).
6. Remove the connecting rod bearing caps and push the

connecting rods out of the way of the crankshaft.
7. Remove the main bearing caps and lift out the crankshaft. 4. If the bearing clearance exceeds 0,18 mm for main bear-
ings or 0,14 mm for connecting rod big ---end bearings with
new bearing shells, the bearing journals on the crankshaft
should be ground. Refer to the specifications for the relevant
B. Checking crankshaft correct undersize and the corresponding bearings. Ensure
that the radii are not changed when grinding.
1. Clean the crankshaft. Do not forget the oilways.
Note! Main bearings are available, which are 1,0 mm oversize
(outer diameter) and 0,5 mm undersize (inner diameter). The
cylinder block must then be machined to a dimension of
92,000---92,025 mm. The crankshaft must be machined to a
dimension of 84,485---84,520 mm. The bearing shell with a
hole and an oil groove must be fitted to the cylinder block and
the other shell to the bearing cap.
C. Changing crankshaft gears
9052 48800
2. Measure the journal wear in several points. Out---of ---round,

taper or other wear must not exceed 0,03 mm.
1. Apply puller for the crankshaft gears and pull off both gears.
137
Model Code Page
15. 9. 1995
21A. Engine (20---series) 255-- 865 213A 2
1. 6. 1998
2. Fit the bearing shells with the oil hole/groove into the cylin-
2. Clean the seat on the crankshaft with, for example, a wire der block and the shells without groove into the bearing caps.
brush. Ensure that the bearing shell clamping claws fit into their
notches and that the shell holes coincide with the oil ports.
3. Heat the new gears to 200˚ C. Tap them onto the shaft with
a suitable sleeve or soft drift. Note the position of the key and 3. Lubricate the bearing surfaces and fit the crankshaft. Fit the
ensure that the aligning marks on the front gear are visible. crankshaft thrust bearings with the lubricating grooves facing
Leave it to cool. the crankshaft.
D. Changing camshaft ring gear

(420---engines only)
20˚
200 Nm
4. Fit the main bearing caps according to their numbering, the

rear with thrust bearings provided with guide lugs. Lubricate
the bolts and tighten them to 200 Nm.
Note! The figure above shows a rear view of the crankshaft

and no 2 cylinder big end bearing journal.
1. Mark the position of the ring gear on the shaft.

0,10-- 0,35 mm
2. Heat the ring gear with a welding torch and drive it off using
a suitable drift.
3. Heat the new ring gear to max. 250˚C. Fit the ring gear with
the chamfer facing the crankshaft flange, and with the teeth
according to markings or according to figure above. Tap the
ring gear down and leave it to cool.
E. Fitting crankshaft
1. Clean the oilways, bearing shells and bearing locations.

Check that the crankshaft is clean.
Note! From engine no. E1619 incl. the main bearing shells
have been changed by deleting the oil grooves on the lower
shell. When fitting the bearing shells, it is necessary to note the 5. Check that the crankshaft can rotate without binding.
places of the shells. The shell without groove must be fitted Check the end float using a dial gauge. The correct end float
onto the bearing cup i.e. to the lower side and the shell with is 0,10 ---0,35 mm. If the end float is too large, oversize thrust
the groove to the upper side i.e. on the cylinder block. The bearings should be fitted.
order number of the bearing shells (in pairs) is 8366 55514.
The new bearing shells are fully interchangeable with the Note! Bearing shells should never be reamed or machined in
earlier ones. any other way, nor should the sides of the bearing caps be
filed.
138
Model Code Page
1. 9. 1995
21A. Engine (20---series) 255-- 865 213A 3
1. 6. 1998
3. If the piston pin bushing is worn, it should be driven out

2. Connecting rods and pistons using a suitable drift.
A. Removing pistons together with con-

necting rods
5
Note! Pistons and connecting rods can be removed from the
40,025...
engine when the engine is attached to the tractor by removing
the propeller shaft guard and the shaft and then the oil sump 40,040
(see page 219/1).
1. Detach the oil sump and the lubricating oil pressure and
suction pipes.
2. Detach the cylinder head.
3. Scrape off the carbon edge in the cylinder liner. If the turn-
ing edge is clearly marked, smooth it down carefully with a
scraper.
4. Remove the big ---end bearing caps and bearing shells.

Place the shells in order if they are to be re ---used.
4. Drive in the new bushing and ensure that the oil hole aligns
5. Push up the piston and connecting rod with the shaft of a with the corresponding hole in the connecting rod. After fit-
hammer or similar wooden tool. ting, drill the oil hole with ø 5 mm drill. Ream the bushing after
fitting to a correct dimension.
6. Remove the piston pin snap rings. Push out the pin.
Note! If the piston pin does not move under thumb pressure
the piston should be heated to 100˚C. C. Checking connecting rod
The connecting rod is checked in a special fixture, intended

for the purpose (e.g. Carl Larsson).
B. Changing connecting rod bearings
1. Clean the connecting rod and bearing shells. Fit them

together and tighten the bolts to 40 Nm+90˚.
208,00
40 Nm+90˚
1. Fit the big ---end bearing caps and tighten the bolts to 40
Nm+90˚.
2. Fit the connecting rod in the fixture and fit the piston pin
which corresponds to that connecting rod.
2. Measure the I.D. using a cylinder gauge which has been

zeroed to the diameter of the respective bearing journal. If the
clearance exceeds 0,14 mm with new bearing shells, the
big ---end journals require grinding. Refer to the specifications
for the correct undersize and the corresponding bearing. En-
sure that the radii at the end of the bearing journals is not al-
tered when grinding.
139
Model Code Page
21A. Engine (20---series) 255-- 865 213A 4
1. 9. 1992
3. Check that the connecting rod is not twisted by positioning 5. Also check the S ---bending of the connecting rod by using
the measuring tool with the horizontally placed measuring sliding calipers to measure the distance between the edge of
points against the face of the fixture. the small---end bearing bushing and the face of the fixture.
turn the connecting rod round so that the other side of the con-
necting rod faces the fixture. Then measure the same dis-
tance. The accepted deviation is 0,6 mm.
max 86,50
6. Measure the length of the connecting rod bolts. The length

should be max 86,50 mm. If the bolt is longer, change it with
a new one. It is recommended that the bolts are always
changed when they are unscrewed.
D. Connecting rod weight classes
The connecting rods are divided into weight classes with in-
tervals of 20 g. The weight class (a letter) is stamped on the
side face of the connecting rod. All the connecting rods in one
engine should be of the same weight class, that is to say the
greatest permissible weight difference is 20 g.
4. Turn the measuring tool round with the vertically placed

measuring points against the face, and check the straight-
ness of the connecting rod
140
Model Code Page
21A. Engine (20---series) 255-- 865 213A 5
1. 9. 1992
The letters show the weight classes as follows:
Weight Part no
A 2170---2189 g 8366 52104
B 2190---2209 g 8366 52105
C 2210---2229 g 8366 52106
D 2230---2249 g 8366 52107
E 2250---2269 g 8366 52108
H 2270---2289 g 8366 52109

I 2290---2309 g 8366 52110
J 2310---2329 g 8366 52111
K 2330---2349 g 8366 52112
L 2350---2369 g 8366 52113
M 2370---2389 g 8366 52114

N 2390---2409 g 8366 52115
O 2410---2429 g 8366 52116
P 2430---2449 g 8366 52117
R 2450---2469 g 8366 52118
S 2470---2489 g 8366 52119

T 2490---2509 g 8366 52120
U 2510---2529 g 8366 52121
3. Measure the piston ring gap by pushing one piston ring at

a time into the cylinder bore. The piston ring gap must not
exceed 1 mm on 1. and 3. piston rings and 1,5 mm on 2. pis-
E. Changing piston rings ton ring.
4. Fit the piston rings on the piston using the piston ring pliers.
1. Remove the piston rings with piston ring pliers. Do not open Ensure that the rings are fitted in the correct groove and that
the rings more than necessary. If the rings are to be used ”TOP”, or the manufacturer’s designation, faces upwards.
again ensure that they are fitted in the same groove.
Picture above shows the piston rings.
2. Clean the piston ring groove and measure the piston ring
clearance, which must not exceed 0,15 mm. Determine
whether too large a clearance is due to worn rings or a worn
groove. Change worn parts.
141
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 213A 6
1. 9. 1995
F. Checking pistons
H. Fitting piston together with connecting
Check the condition of the pistons and piston pins. Pay rod.
special attention to possible cracks on the edge of the com-
bustion chamber and on the upper edge of the piston pin 1. Check that the bearing locations are clean and place the
hole. Measure the diameter of the piston at the point shown bearing shells in the connecting rod and bearing cap. Note
in the figure below. Renew a piston if needed. the position of the bearing shells.
2. Lubricate piston, rings and cylinder bore. Ensure that the

piston ring gaps are spread around the piston.
320, 420
620:
G. Fitting piston pin
1. Place the connecting rod inside the piston and push the pis-
ton pin in to place.
3. Fit the piston with the marking on the connecting rod

(weight class) facing the camshaft (an arrow on the piston
must point forward).
4. Lubricate the big ---end bearing journal and bearing shells,

and push the piston down. Fit the bearing cap so that the
notches for the guide lugs are in the same side. Tighten the
connecting rod bolts to 40 Nm+90˚.
5. Check that the connecting rod has sufficient end float on the
big ---end bearing journal.
Note! The combustion chamber and the weight class letter

should be on opposite sides!
2. Fit the piston pin circlips. Ensure the circlips are pressed
correctly into the grooves. The circlip ends must point
upwards.
142
Model Code Page
1. 9. 1995
21A. Engine (20---series) 255-- 900
213A 7
1. 4. 2004 A75-- A95
3. Balancer unit, 420---engines 3. Place the weights in the body, observing the notch mark-
ings. The gear wheel with the punch mark runs against the
crankshaft and should therefore be placed highest. Insert the
A. Removing and dismantling balancer shafts, remembering the thrust bearings. Apply thread lock
fluid Loctite 270 to the locking screws, and lock the shafts.
unit
Note! Working order, see page 219/1.
1. Remove the engine (Note! The balancer unit can also be

detached when the engine is attached to the tractor. In this
case, remove the oil sump).
2. Disconnect the lubricating oil pipe of the balancer unit.
3. Remove the balancer unit. Take care of any shims.
4. Loosen the locking screws and press out the shafts in the
direction of the locking screws. Remove the counterweights
and thrust washers.
5. Clean all parts.
0,1---0,5 mm
B. Reconditioning balancer unit
Check the shafts, gear wheels and bushings for wear and
damage.
1. If one of the gear wheels is damaged, change both counter

weights as a complete unit. The gear wheels are not available
separately as a spare part.
4. Check that the tooth backlash is 0,05 ---0,25 mm and that
2. Remove, if necessary, the old bearing bushings with a suit- the end float is 0,1 ---0,5 mm
able drift. Before removing them, mark the position of the
bushing oil groove on the counter weight. Press in new bush-
ings in the correct position. After fitting, the bushings should
be reamed to a correct dimension, see Specifications.
1. Synchronization marking (notch)

2. Marking against crankshaft (punch mark)
143
Model Code Page
21A. Engine (20---series) 255-- 865 213A 8
1. 9. 1992
C. Fitting balancer unit

Changing crankshaft gear rim
1. Fit the tension pins in the balancer unit body.
1. Mark the position of the gear rim on the shaft.
2. Heat the gear rim with a welding torch and drive it off
using a suitable drift.
3. Heat the new gear rim to max. 250°C. Fit the gear rim with
the chamfer facing the crankshaft flange, and with the
teeth according to markings or according to figure above.
Tap the gear rim down and leave it to cool.
20˚
2. Turn the crankshaft and weights so that the markings agree,

and lift the unit into place.
3. Tighten the bolts to 45 Nm. Check that the tooth backlash

between the crankshaft and counterweight is 0,1 --- 0,3 mm.
The backlash can be increased by placing shims 0,2 mm thick
(order no 8361 19920) between the cylinder block and ba-
lancer unit body. One shims (0,2 mm) changes tooth back-
lash about 0,07 mm.
4. Fit the lubricating oil pipe, using new seals. Note! The picture above shows a rear view of the crank-
shaft and no. 2 cylinder big end bearing journal.
5. Fit the engine or the oil sump.
144
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 214A 1
15. 9. 1995
Timing gears (Op no 214) 6. Unscrew the idler gear bolts (17 and 22 mm). Remove the
flange, gear wheel and bearing journal.
A. Removing timing gear casing 7. Extract the camshaft.
Note! If the cylinder head and valve mechanism have not

Note! Working order, see page 219/2. been removed, the tappets must be prevented from falling
down, see Op. 212 2B.
As the timing gear casing forms a seal against the oil sump,
the casing cannot be removed without first removing the oil 8. Remove the timing gear casing (13 mm). Ensure that all
sump. sealing surfaces are not damaged.
1. Detach the engine (or the oil sump). 9. Remove the crankshaft front sealing ring from the front cas-
ing and clean all the parts that have been removed.
2. Remove the cooling radiator, alternator and the fan belt (if
not removed earlier).
B. Reconditioning idler gear
If the idler gear bushing is changed, press in a new bushing

so that its rear edge is 0,1 ---0,25 mm inside the gear wheel
rear edge (see picture on next page).
1
2
9101 65700
3. Loosen the crankshaft nut (special tool 9101 65700) and

remove the belt pulley/hub.
4. Remove the timing gear casing cover and the oil deflector 1. Chuck of lathe
ring at the front end of the crankshaft. 2. Roller ø=5 mm
5. Remove the injection pump. Machine the idler gear bushing inner diameter to a correct
dimension after fitting. Centre the idler gear according to fig-
Note! If the timing gear casing is not to be changed, the injec- ure above so that tooth backlash is kept the same.
tion pump can remain in place. In which case disconnect all
leads and pipes from the pump. Note! Tractors that have a hydraulic oil pump of 54 litres, the
idler gear bearing has been reinforced with effect from serial
number 662885 (engine number D2187). To standardize the
production, this same modification has been carried out on all
tractors from ser. no. 663410 incl. (engine no. D3397). The
modification can be recognized by a sheet metal housing in
the middle part of the timing gear casing. The new parts are
not interchangeable separately. As a spare part both new and
earlier parts are supplied.
145
Model Code Page
21A. Engine (20---series) 255-- 865 214A 2
1. 9. 1992
C. Fitting timing gear casing

4. Fit the idler gear with shaft stud and ensure that the mark-
The position of the timing gear casing and cover is deter- ings are in the correct position. Fit the washer and tighten the
mined by two tension pins. Therefore centring should not be bolts to the correct torque.
undertaken in connection with fitting. However, the tooth
backlash between the different gears should be checked.
Casing and covers that are delivered as spare parts also have
holes for the tension pins already machined.
1. Fit the casing with a new gasket against the cylinder block.
Drive in the tension pins with drift 9025 98700. Tighten bolts
and nuts.
2. Fit the injection pump together with gear wheel (if

removed).
3. Lubricate the camshaft bearings and insert the shaft in the

cylinder block. Release the pushrods and tappets if they have
been suspended.
5. Check the tooth backlash which should be 0,05 ---0,25 mm.
146
Model Code Page
21A. Engine (20---engines) 255-- 865 214A 3
1. 9. 1992
9025 98700
9025 98800
9025 98900
6. Fit the oil deflector ring on the crankshaft and fit the timing
gear casing cover using a new gasket. Drive in the tension
pins with drifts 9025 98700 and 9025 98800 respectively (the
tubular pin round the screw stud). Tighten bolts and nuts.
8. Fit the dust shield on the crankshaft V ---belt pulley hub, if it
has been removed. Use drift 9025 98900.
9030 15200
600 Nm (320, 420)
1000 Nm (620, 634)
7. Fit the protective plate into the seal location and fit the
crankshaft front seal with special tool 9030 15200.
9. Lubricate both the seal and sealing surfaces and fit the
Note! The crankshaft front oil seal can be changed while the crankshaft V ---belt pulley with hub.
engine is attached to the tractor. In this case, remove the cool-
ing radiator and belt pulley/hub at the front end of the crank- 10. Lubricate the crankshaft nut threads. Tighten the nut (with
shaft. tool 9101 65700) to 600 Nm.
11. Fit the other detached parts.
147
148
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 900 215A 1
1. 9. 2001
Lubricating system (Op no 215) Latest lubricating oil pressure relief valve
(J7589---).
A. Reconditioning of oil relief valve for
lubricating oil pressure
2 3
Loctite 638 25 Nm
If the engine lubricating oil pressure is insufficient or if it varies,
the relief valve should be checked after first checking the oil
level.
1
4
5
6
1. Valve seat insert

2. Valve head
3. Spring, dark colour
Note! The spring expanded end towards the valve head. In
autumn 99, the spring end shape will be changed to prevent
wrong mounting of the valve.
4. Gasket
5. Cover
6. Bolt, 2 pcs
1. Remove the cover over the valve (13 mm) and spring. Take Note! As a spare part the earlier complete valve can be repla-
care of the washer between the cover and spring. Remove the ced with the new valve fitting kit.
valve insert together with the valve cone and ensure that the
o---ring is also removed.
2. Clean the parts and check that the valve cone slides freely
in the insert and that the sealing surface are undamaged. Mi-
nor damage can be adjusted, but in general, damaged parts
should be changed. Scrape off any remains of the gasket. B. Removing and dismantling lubricating
3. Assemble the valve with a new o---ring and insert it in the oil pump
cylinder block. Place the washer and spring in the cover and
fit it with a new gasket. 1. Detach the oil sump, see page 219/1.
2. Remove the oil pump suction and pressure pipe.
3. Remove the oil pump together with any shims between the
pump and the cylinder block.
4. Remove the pump cover and the gasket. Remove the gear
on the dead axle.
5. Clamp the pump gear across the teeth in a vice fitted with
soft jaws, and loosen the drive gear nut. Knock the gear wheel
off by hitting the end of the shaft with a soft hammer. Pull out
the drive shaft---gear wheel
6. Clean the parts and check for wear and other damage.
Compare with the specifications. Change damaged parts and
all seals.
4. Note that the relief valve cover is not symmetrical. The
greater distance between the spring housing and bolt should
be turned downwards.
149
Model Code Page
1. 9. 1992
21A. Engine (20---series) 255-- 865 215A 2
15. 9. 1995
C. Assembling and fitting lubricating oil

pump
1. Fit the gear wheels in the pump body. Fit the cover using
a new gasket. Partly tighten the bolts. Rotate the pump shaft
and tap the side of the cover lightly until the position is reached
where the shaft rotates most freely. Tighten the bolts and
check that the shaft still rotates freely.
2. Fit the key (not on the latest pumps) and drive gear onto the
shaft. Apply Loctite 242 onto nut threads and tighten the nut
to 60 Nm. Remember the washer under the nut.
Note! With effect from engine ser. no. C1474 (320) and C1328
(420), the engine lubricating oil pump has been modified. The
fitting between the gear and the shaft has been changed from
a cylindrical type with key to a taper type without key.
As a spare part the complete new pump is exchangeable with
the earlier pump. The new drive gear and the shaft can be
fitted in pairs on the earlier pump.
4. Fit the pump and check the tooth backlash against the
crankshaft gear. The clearance, which should be 0,05 ---0,25
mm, is adjusted with shims between the pump body and the
cylinder block (shims 0,2 mm, order no 8360 07871). One
shims increases/decreases the backlash about 0,07 mm.
Note! When measuring the tooth backlash, the engine should

be the correct way up as the crankshaft bearing clearance af-
fects the tooth backlash.
5. Connect suction and pressure pipes together with new

seals.
6. Fit the engine (or the oil sump).
3. Fasten the oil pump in a vice and check the end float be-
tween gear and pump housing. The clearance which should
be 0,03 ---0,11 mm, is adjusted by the number of gaskets be-
tween the cover and body.
150
21A. Engine 255-- 865 215A 3
1. 4. 1999
E. Lubricating oil quality requirements (see also page 130/4)

1. QUALITY (API ---CLASS)
--- naturally aspirated engines CCMC D2 API CC 1) ACEA E2 ---96

--- turbocharged engines CCMC D4/D5 API CD ACEA E2 ---96/E3 ---96
1) API ---CD can also be used in conventionally aspirated engines.
Note! Valtra Engine oil is recommended for use in Valmet engines.
TEMPERATURE ˚C
---30 ---20 ---10 0 +10 +20 +30
5W---20
5W---30
5W---40
10W
10W---20
SAE---CLASS
10W---30
10W---40
15W---30
15W---40
20W---20
20W---30
20W---40
30
151
152
Model Code Page
21A. Engine (20---series) 255-- 865 216A 1
1. 9. 1992
Inlet and exhaust system, turbocharger

4. Check that the exhaust manifold is air tight. Tighten the
(Op no 216) bolts to 50 Nm and inspect for any damage (cracks, deforma-
tion, corrosion etc.). Check also the connection between the
turbocharger and the exhaust manifold.
An engine that is equipped with a turbocharger is a great deal
more sensitive to disturbances and impurities in the inlet and
5. Remove the manifold if necessary. Clean the sealing sur-
exhaust systems than a conventionally aspirated engine. faces and remove any carbon deposits. Check that the seal-
Therefore special attention should be given to the whole inlet
ing surfaces are flat. If the fastening flanges are twisted or
and exhaust system.
there are scratches on the sealing surfaces, machine the
flanges or renew the exhaust manifold.
6. Ensure that no loose objects or impurities have entered the

exhaust pipe or the silencer. Any such loose objects or impu-
rities can increase the back pressure for the exhaust gases
from the turbine wheel.
A. Checking air cleaner
The engine performance and length of service life depend to C. Checking turbocharger
a great extent on the state of the air cleaner. A defective air
cleaner allows impurities to pass through, which in time dam-
age the turbocharger and the engine. A blocked air cleaner If a fault is suspected in the turbocharger it can be located in
lowers the engine output and also causes oil leakage through the following way:
the sealing ring on the turbocharger shaft.
1. Visually inspect the turbine and compressor wheels. The
Note! The safety filter inside the main filter should not be re- vanes must not show any signs of damage, deformation or
moved unnecessarily, for checking or cleaning. The safety wear caused by foreign objects.
filter must not be cleaned, but should be changed once a year
or when necessary (see Operator’s Manual) 2. Investigate any oil leaks through the sealing rings on the
shaft in the turbine and compressor housing.
N.B! At low idling there is always a certain amount of oil leak-

age on the compressor side. However, this should not cause
too much concern unless the oil consumption is too great.
B. Checking inlet and exhaust system
Important! Leaks in the inlet or exhaust system markedly

lower the effect of the turbocharger. Because of the pressure,
even small leaks in the manifold or in the turbine inlet contact
flange quickly increase in size. For this reason all leaks must
be dealt with immediately.
1. Inspect the pipes and sealing surfaces between the air

cleaner and the turbocharger, as well as between the turbo-
charger and the induction manifold. If the induction manifold
is dusty on the inside, there is a leak in either the air cleaner
or the induction pipes. Remedy the leak.
2. Clean the induction manifold sealing surface. Check that

the sealing surface is flat using a straight ruler. If the surface
is not flat or it has scratches, machine or renew the induction
manifold.
3. Fit a new gasket and fasten the induction manifold. Tighten

the manifold fixing screws to a torque of 30 Nm. Fasten the air
pipes carefully..
3. Check the turbine shaft running clearance. Place the stylus

of a dial gauge against the shaft and move the shaft sideways.
refer to the clearance given in the specifications on page
210/9.
153
Model Code Page
21A. Engine (20---series) 255-- 865 216A 2
1. 9. 1992
4. Check the shaft end float. Place the stylus of the dial gauge
against the end of the shaft and move the shaft axially. Refer
to the clearance given in the specifications on page 210/9.
If any defects or wear are confirmed, the turbocharger should

be reconditioned.
If the engine does not work correctly and the turbocharger is

not defective or too worn, the fault could be traced to one of
the following items:
--- Blocked air filter

--- Leakage in the inlet or exhaust systems. Leaking flange
seal
--- Defective or wrongly adjusted injection pump.
--- Wrongly adjusted throttle linkage
--- Defective or wrongly adjusted injectors
--- Low fuel pressure (e.g. blocked fuel filter)
--- Low compression, wrong valve clearance
154
Model Code Page
1. 9. 1995
21A. Engine (20---series) 255-- 865 216A 3
1. 5. 1996
D. Reconditioning turbocharger
(Schwitzer S1A and S1B)
N.B! The same degree of cleanliness should be observed

when removing the turbocharger as with repairing the fuel
system. Only remove the compressor and turbine covers if
the requisite special tools, e.g. for adjusting the balance, are
not available. In general, when the turbocharger is dam-
aged it is more economical to fit a factory reconditioned
turbocharger.
Dismantling turbocharger 5. Hold the turbine wheel at hub and unscrew the compressor
wheel nut (left---hand thread). Remove the compressor wheel.
1. Mark the compressor housing, turbine housing and the
bearing housing in relation to each other. 6. Remove the turbine wheel/shaft carefully by tapping at the
shaft end with a soft hammer. Do not bend the shaft.
2. Fix the turbocharger by the outlet flange in a vice fitted with
soft jaws. 7. Place the bearing housing on a table so that the turbine side
is against the table. Remove the support flange circlip.
3. Remove the compressor housing circlip and remove the
housing. 8. Remove the support flange and the oil deflector ring by pry-
ing with two levers behind the support flange grooves. Press
4. Unscrew the turbine housing fixing screws and remove the
the deflector ring out of the support ring.
fixing plate. Detach the bearing housing from the turbine
housing.
9. Remove the oil deflector plate, thrust bearing and thrust
sleeve from the bearing housing. Remove the bearing outer
circlips and remove the bearings and the inner circlips.
155
Model Code Page
21A. Engine (20---series) 255-- 865 216A 4
1. 9. 1992
Cleaning parts of the turbocharger Assembling the turbocharger
N.B. Use conventional cleaning agents. Do not clean with cor- It is recommended to use a repair kit when assembling the
rosive substances as parts of the turbocharger may be dam- turbocharger. This kit includes necessary seals and parts
aged. which are exposed to wear.
1. Wash off all dirt with a detergent solution. Use plastic tools 1. Fit the inner circlips into the bearing housing. Lubricate the
or brush when cleaning aluminium parts. bearing points. Push the bearings into place and fit the outer
circlips.
2. Clean all oilways with compressed air. Check that all contact
surfaces are clean and in good condition. 2. Fit a new sealing ring into the groove and push the rear plate
onto the shaft against the turbine wheel.
3. Lubricate the shaft bearing points and the sealing ring.

Push the shaft into the bearing housing. Do not damage the
sealing ring.
4. Place the bearing housing vertically resting on the turbine

housing.
Checking parts of the turbocharger
5. Fit the thrust sleeve into the thrust bearing and place the
1. Bearing housing parts into the bearing housing according to the position of the
--- Inspect the bearing surfaces for damages and wear. guide pins. Place the oil deflector plate onto the thrust bear-
--- make sure that the turbine side sealing surface is undam- ing.
aged.
6. Fit a new o---ring into the groove of the support flange. Fit
2. Compressor wheel a new o---ring onto the deflector ring. Press the deflector ring
--- check for bends, cracking or corrosion and possible wear into the middle of the support flange. Do not damage the seal-
on the wheel rear face. Small faults can be accepted. Change ing ring and its counter surface.
the wheel if damages affect on balancing accuracy. Never
bend the vanes. Check the balancing accuracy (0,21 gm 7. Lubricate the o---ring and push the support flange into the
mm). bearing housing. Fit the circlip the chamfered side outwards.
3. Shaft and turbine wheel unit 8. Push the compressor wheel onto the shaft. Tighten the shaft
--- check the bearing point wear, min diameter is 7,615 mm. nut to a torque of 7 Nm. Secure the nut with locking fluid Loc-
--- check the width of the sealing groove, max 1,630 mm. tite 601.
--- measure the shaft ovality, max 0,005 mm.
--- check balancing accuracy (0,21 gm mm), change the part 9. Pass the compressor housing circlip over the bearing hous-
if given values are exceeded. ing the circlip chamfered side towards the turbine housing.
Fit the o---ring into the groove on the bearing housing. Fit the
4. Compressor and turbine housing compressor housing according to the markings. Fit the circlip
--- check if there are damages, cracks or overheating faults into groove.
caused by wheel contact in the housings. Small damage can
be accepted, otherwise change the housing. 10. Fit the bearing housing and the turbine housing according
to the markings. Fit the fixing plate and tighten the screws to
5. Turbine side rear plate 22 Nm.
--- change the rear plate if it is bent or cracked.
6. Oil deflector ring

--- check the groove width on the sealing ring, max 1,226 mm.
Check also for other possible damage and wear. Reject worn
part.
7. Support flange
--- Check wear and cracking of the seal ring counter surface.
Only small wear can be accepted. In general, even a small
wear causes sealing problems.
156
Model Code Page
21A. Engine (20---series) 255-- 865 216A 5
1. 9. 1992
E. Fitting turbocharger
Locate the cause of the defects on the turbocharger. Remedy

the fault before fitting the new turbocharger.
In order for the turbocharger to work satisfactorily, it is import-

ant that the engine oil is in good condition. Likewise the oil
should be to the correct quality specification. The air filter and
oil filter should be serviced according to the handbook specifi-
cation.
The setting of the injection pump critically affects the function

of the turbocharger. The injection pump should be adjusted
according to the manufacturers instructions.
1. Check the tightness of the induction and exhaust mani-

folds, and that they are securely fastened. Ensure that there
are no loose carbon or rust particles, or other foreign objects
in the manifolds.
2. Connect the turbocharger to the exhaust manifold and

tighten down using a new gasket.
3. Connect the induction pipe and the silencer.
4. Pour clean engine oil into the bearing housing through the
inlet oilway. This is very important in order to ensure that the
turbocharger is lubricated at the time of starting.
5. Connect the pressure and return oil pipes. Use a new seal.
Check that there are no tensions in the pipes when tightening.
6. Before starting, pull out the stop control and crank the en-
gine over with the starter motor so that the oil pressure rises.
Start the engine and check that there are no leaks.
157
158
Model Code Page
21A. Engine (20---series) 665-- 4 MOD 217 1
31. 1. 1996
Sentinel diesel engine protection system
On the engine there is an automatic stopping system. If the

engine oil pressure lowers or engine cooling liquid tempera-
ture rises too much, the automatic system will stop the engine
in about 40 seconds. The stopping time depends on the
engine load (= fuel consumption).
If the engine has stopped through this system, find and repair
the fault before starting. After repairing turn the fuel valve lever
(G), on the master control unit 180_ clockwise on the left side
of the engine. After the engine starts the lever rotates auto-
matically 180_ anticlockwise to the normal position.
Fig. 1 LH side of engine
Fig. 2. Sentinel Protection System on Valmet

C
A. Master Control
B. Heat Valve
C. Fuel from filter into Master Control
D. Fuel from Master Control into fuel injection pump
E. Engine oil pressure into Master Control
F. Engine oil pressure into Heat Valve D
G. Fuel valve lever A
G
E
159
Model Code Page
31. 1. 1996
Operation of engine protection system
Fuel valve
Fuel in
Fuel out
Vent filter
Dump
Engine oil pressure

from Master Con-
trol Engine
oil
pressure
Oil to
crankcase
HEAT VALVE MASTER CONTROL
(closed position) (open position)
Fig.3. Operation of engine protection system
Under normal operation conditions, oil pressure from the When engine coolant temperatures exceeds the setting of the
engine will keep the fuel valve of the Master Control in the Heat Valve, the seal will open and dump oil pressure from
raised position allowing the fuel to flow through to the engine. under the Master Control piston. This in turn will cause the fuel
Loss of oil pressure will automatically cause the fuel valve to valve to fall and block fuel flow to the engine.
drop, shutting off the fuel flow and the engine will stop.
160
Model Code Page
31. 1. 1996
A. Servicing C. Trouble shooting

a) If engine will not start, or stops during operation, make a
The Sentinel System should be checked at every engine oil careful inspection of the engine and Sentinel System:
change and serviced as required.
--- Check engine oil and coolant levels
Visually inspect the complete system for leaks, worn hoses, --- Check coolant temperature
correct plumbing etc. --- Check oil, coolant and fuel lines for leaks or damage
--- Check sentinel system for leaks or damage
Inspect the vent filter on the Master Control for fuel or engine
oil leakage. Replace vent filter if dirty. Important! Coolant thermometer in the dashboard. Engine
oil pressure warning light in the dashboard.
b) If completely satisfied that everything is in good order, and

engine will not start, check Sentinel operation:
B. Other information
The Sentinel engine protection units monitors directly from Master Control
the engine and are normally very accurate and superior to housing
gauges in their response to abnormalities.
Master Control (Model DTF-- 15)
Monitors engine oil pressure in lower chamber. Activates

shutdown when oil pressure falls below unit setting, normally Cam lever
10/15 psi.
Heat Valve (Model HM -- 212)
Monitors coolant temperature. Activates when temperature --- Turn cam lever on the Master Control 180˚ clockwise and
rises above unit setting, normally 212˚ F. back several times to check piston moving freely.
--- Override Sentinel by turning cam lever 180˚ clockwise.
Master Control serial no.: 9401790 Watch lever and try for engine start. If engine starts and lever
Heat Valve serial number: 9310592 returns 180˚, Sentinel system operative.
--- If lever does not return in 30 seconds, stop engine.
N.B. Master Control unit and Heat Valve should be changed

as a complete unit. When changing Master Control unit, pre-
vent dirt from entering into the fuel system, when you open the
fuel line unions. Clean pipes, unions and Master Control
housing before work.
c) If engine stops shortly after starting, bring rpm up to about

1200 rpm for three seconds. This will increase oil pressure
enough to open Master Control.
161
162
Model Code Page
21A. Engine (20---series) 255-- 865 219A 1
1. 9. 1992
Working orders
D. Lubricating oil pump
A. Crankshaft seals
(Lubricating oil pump, see page 215/1)
(Rear seal, see page 211/6).
(Front seal, see page 214/3). --- Drain the engine oil.
--- Before changing the crankshaft rear oil seal, split the tractor --- Remove the propeller shaft guard and the propeller shaft.
at the clutch (see Op 411 1A) and detach the clutch assembly Unscrew the oil sump fixing bolts and remove the oil sump.
and the flywheel.
--- When changing the crankshaft front seal, drain the coolant --- The oil pump can now be removed from the lower face of
from the cooling system. Remove the cooling radiator and the the cylinder block.
belt pulley/hub at the front end of the crankshaft.
E. Balancer unit (only 420---engines)

(Balancer unit, see page 213/7)
B. Cylinder head and valve mechanism --- Drain the engine oil.
(Cylinder head and valves, see page 212/1) --- Remove the propeller shaft guard and the propeller shaft.
(Rocker arm mechanism, see page 212/5) Unscrew the oil sump fixing bolts and remove the oil sump.
--- Before removing the cylinder head, remove the engine

--- The balancer unit is now accessible and can be detached
hood plates, engine coolant and detach all parts which are
from the cylinder block lower face.
attached to the cylinder head. After that the cylinder head can
be removed.
--- Rocker arm mechanism is accessible after removing the

valve cover. F. Crankshaft
--- Pushrods can be removed after removing the valve cover (Crankshaft, see page 213/1)
and the rocker arm mechanism.
--- Split the tractor at the clutch. Remove the clutch assembly
and the flywheel and the flywheel housing.
--- Drain the engine coolant and engine oil and remove the
C. Pistons and connecting rods radiator. Detach the engine and the oil sump.
(Pistons and connecting rods, see page 213/3) --- Remove the timing gear casing cover.
If only pistons/connecting rods are to be changed, the

simplest working order is as follows:
G. Cylinder liners
--- Drain the engine coolant and the engine oil.
(Cylinder liners, see page 211/1)
--- Remove the propeller shaft guard and the propeller shaft.
Unscrew the oil sump fixing bolts and remove the oil sump. --- Drain the engine coolant and the engine oil.
--- Remove the cylinder head. --- Remove the propeller shaft guard and the propeller shaft.
Unscrew the oil sump fixing bolts and remove the oil sump.
--- Loosen the connecting rod big ---end bearing caps and
push the pistons together with connecting rods upwards and --- Remove the cylinder head.
remove them through the cylinder bore.
--- Loosen the connecting rod big ---end bearing caps and
push the pistons together with connecting rods upwards and
remove them through the cylinder bore.
--- Remove the cylinder liners upwards.
163
Model Code Page
21A. Engine (20---series) 255-- 865 219A 2
1. 9. 1992
H. Timing gears I. Camshaft
(Timing gears, see page 214/1) (Camshaft, see page 212/5)
As the timing gear casing forms a seal against the oil sump, Before removing the camshaft the following steps should be
the casing cannot be removed without first removing the oil taken:
sump. The timing gear casing cover, however, can be
removed without removing the oil sump.
--- Remove the timing gear casing cover (see under previous
--- Remove the oil sump if the timing gear casing is to be heading H Timing gears).
removed. Remove the cooling radiator.
--- Remove the valve cover and the rocker arm mechanism.
--- Remove the fan, alternator and the v ---belt.
--- Support the pushrods (at the same time tappets which are
--- Unscrew the crankshaft nut and remove the belt pulley/
against the camshaft) to the upper position in pairs by using
hub.
--- Remove the timing gear casing front cover and remove the for instance o---rings (see picture on page 212/5).
oil deflector ring at the front end of the crankshaft.
--- Rotate the crankshaft so that the timing markings on the
--- Remove the fuel injection pump if the timing gear casing idler gear and the camshaft gear become opposite each other
(see picture on page 214/2).
is to be removed. Otherwise disconnect all the pipes from the
fuel injection pump.
--- Pull out the camshaft from the cylinder block.
--- The timing gears are now accessible.
In addition, the following steps should be taken if the entire Note! Take care when fitting the camshaft that the timing
timing gear casing has to be changed: marks align.
--- Unscrew the idler gear fixing bolts and remove the idler
gear.
--- Pull out the camshaft from the cylinder block.
Note! If the cylinder head and valve mechanism have not

been removed, the tappets must be prevented from falling
down when the camshaft is removed, see page 212/5.
--- The timing gear casing can now be removed.
164
Model Code Page
15. 4. 1999
22. Fuel system (20---series) 255-- 900 220A 1
1. 4. 2004
Contents
General (Op no 220):
Bosch in ---line injection pump:

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stanadyne distributor pump:

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bosch VE distributor pump:

Repair instructions
Fuel feed pump and fuel filters, Bosch in-- line pump (Op no 222):
A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Bleeding Thermostart system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Checking overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Changing fuel feed pump valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel injection pump and injectors, Bosch in-- line pump (Op no 223):
A. Checking fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Removing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fitting injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Checking/changing delivery valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
H. Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
J. Fitting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
K. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Stanadyne rotary distributor pump

A. Removing distributor pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Fitting pump and adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
D. Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E. Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
G. Bleeding Themostart---system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
H. Checking dynamic injection advance, E ---engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bosch VE rotary distributor pump (Op no 224)

A. Removing fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting pump and adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F. Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
H. Fitting injector in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
I. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
165
Model Code Page
15. 4. 1999
1. 9. 2001
Specifications, Bosch in ---line injection pump

Note! Stanadyne rotary distributuon pump, see page 220A/9.
Bosch fuel injection pump
Type (pump/governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch PES...A/RSV

Injection order:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---3
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---4---3
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Diameter of pump piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,5 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm
Injection advance:
--- 255, 355, 365, 665, 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21˚
--- 455---565, 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19˚
--- 600 with E ---engine 320DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17˚
Oil fillings 1):

--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 l
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 l
Fuel feed pump
Type:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch FP/KSG 24 AD 207
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch FP/KEG 24 AD 504
Construction: piston pump, separate hand pump
Fuel feed pressure (overflow valve opening pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7---1,2 bar (70---120 kPa)
Pressure from fuel feed pump (without overflow valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7 bar (270 kPa)
Injectors (see also page 220/14)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle

Opening pressure:
--- 255---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 bar (23 MPa)
--- 600, 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 bar (27 MPa)
Setting pressure 2):
--- 255---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235+5 bar (23,5 MPa)
--- 600, 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270+8 bar (27,8 MPa)
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495
1) When fitting fuel injection pump.

2) Value to be used when adjusting the opening pressure of a new or used injector.
Tightening torques
Injection pump gear nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

166
Malli Koodi Sivu
1. 3. 1997
22A. Fuel system (20---series) 255-- 900 220A 3
15. 4. 1999
Special tools
Note! Measuring equipment for fuel feed pressure, see page 101/4C.
9052 47800 *) Pressure gauge for checkinh delivery valve.

9052 48900 *) Puller for injection pump drive gear.
9052 47600 *) Control pipe for injection timing
9025 99000 *) Sleeve for limiting control rod travel
9051 71300 *) Extractor for injectors.
8366 62022 Tester (TimeTrac) to check dynamic injection advance, E ---engines:
1. 836662121 Magnetic detector
2. 836662122 Cable
3. 836662123 Fastening part
4. 836662120 Timing light (not illustrated)
5. 836859466 TimeTrac in ---line sensor (not illustrated)
6. 836662124 Clamp ---on Transducer 4,5 mm (not ill.)
7. 836662125 ---” ---, 5,0 mm (not ill.)
8. 836662126 ---” --- ,6,0 mm (not ill.)
9. 836662127 ---” --- ,8,0 mm (not ill.)
10. 836662128 ---” --- ,1/4 inches (not ill.)
*) Same tool as for fuel system on 11---series engines.
905248900
15±1
9052 47800 902547600 9025 99000 9051 71300

3
8366 62022
1
167
Model Code Page
1. 9. 1992
1. Fuel tank
2. Fuel feed pump
4 3. Fuel filter
4. Fuel injection pump
5. Injector
6. Thermostart fuel reservoir
7. Glow plug
8. Overflow valve
2
Fuel system, description Fuel tank:

--- Empty/clean the fuel tank at every 1000 running hours or
Fuel feed pump (2) draws fuel from tank (1) and forces it yearly.
through combined water trap/filter (3) to fuel injection pump
(4). The fuel injection pump pumps fuel at high pressure Injectors
through the delivery pipes to injectors (5) which inject the --- Reconditioning of the injector should be carried out by
fuel in the form of a fine mist into the combustion chamber. an authorised workshop.
Excess fuel lubricates the nozzle valve (needle) and flows in
return through the thermostart device reservoir (6) and Symptoms of dirty or faulty injectors are:
then on to the fuel tank. When the thermostart is on (glow- --- Knocking is an indication that one of the injectors is
ing) fuel runs from reservoir (6) through glow plug (7) and is faulty. When a cold engine ticks over a certain amount of
ignited in the induction manifold. Excess fuel returns from knocking is unavoidable. If the engine knocks after it has
the fuel injection pump through overflow valve (8) to the reached normal operating temperature, it is very likely that
fuel tank. one of the injectors is faulty. Air in the fuel system can also
cause knocking (which should disappear after the system
has been bled of air).
--- Smoky exhaust gases may indicate impaired perform-
Maintenance ance of the injectors. However, this can also be caused by
Fuel filter/water trap: other faults such as a blocked air cleaner.
--- Empty the water trap at every 50 running hours/weekly.
--- Change the fuel filter at intervals of 1000 running hours or The fuel system should always be bled when the fuel sys-
yearly. tem has been emptied (e.g. the fuel tank has been emptied
during driving, in connection with maintenance or repair
work or after a long idle period).
168
Model Code Page
22. Fuel system (20---series) 355-- 665 220 5
1. 9. 1992
Fuel injection pump 1
8
Valmet 355---665 tractors have a Bosch ---make injection
pump which is an in ---line pump and its basic construction
is similar on engines with the different number of cylinders.
2
7
Fuel injection pump
1. Oil filling plug

2. Governor control lever
3. Hand pump on fuel feed pump
4. Lubricating oil into injection pump
5. O ---ring
6. Return of lubricating oil to engine
7. Drive gear
6
3
The fuel injection pump is flange mounted and sealed by 4

one o---ring (5) in the timing gear casing. The injection
pump is driven from the crankshaft through an idler gear.
The injection pump is connected to the engine force ---feed
lubrication system through an external pipe (4). Lubricating
oil returns to the engine via the hole (6) at the front end of
the injection pump.
The fuel feed pressure which fills the high pressure pump
elements with fuel is created by a piston pump which is
attached to the side of the fuel injection pump. The piston
pump is driven from an eccentric on the camshaft of the
injection pump. The fuel feed pump supplies more fuel than
the injection pump needs. The excess fuel flows through
the overflow valve back to the fuel tank. The fuel cools the
injection pump and also takes any air bubbles with it back
to the tank.
169
Model Code Page
22. Fuel system (20---series) 355-- 665 220 6
1. 9. 1992
The pump element consists of one plunger and one cylinder

which are a matched pair and because of the fine tolerances
the whole element should be changed as a complete unit.
The cylinder has two passages: inlet passage and release

passage. Both passages allow fuel to enter the pressure
space. The side of the plunger has one vertical groove and
one metering edge which are used for adjusting the amount
of fuel injected into the combustion chamber of the engine.
The top of the plunger is provided with a starting groove

(delay groove) which delays the injection timing by approx.
8˚. (This should be borne in mind when checking the fuel in-
jection timing). This groove improves the cold starting prop-
erties of the engine. It works fully automatically. When the en-
gine has stopped the control rod in the injection pump turns
the plungers so that the starting groove faces towards the re-
lease passage. When the engine has started and when the in-
jection pump has reached a certain speed, the governor pulls
the control rod back into running position.
1
1. Retainer for delivery valve
2. Delivery valve 2
3. Pump element 5
4. Control rod
5. Return spring for pump plunger 3
6. Roller tappet
7. Camshaft 6
4 7
The purpose of the fuel injection pump is to meter out fuel to
the combustion chamber at the correct time. Plunger (3)
which is driven by the pump camshaft (7) via roller tappet (6)
forces the fuel through delivery valve (2) and further through
the delivery pipe to the injector.
Delivery valve
3 4 5
6
2 1. Holder for delivery valve
2. Valve spring
3. Valve cone
4. Valve guide
5. Valve head
1 6. Pressure ---reducing piston
7. Vertical grooves
7 The delivery valve is fitted on top of the pump element and its
purpose is to close the connection between the pump el-
ement and the delivery pipe. This happens when the metering
edge of the plunger passes the lower edge of the release
passage, thus reducing the pressure in the space above the
plunger. Its second purpose is to reduce the pressure in the
A B C delivery pipe. This is important as it enable the nozzle valve
(needle) to close more quickly.
Two---hole pump element (maximum feed) Delivery valve cone contains a pressure ---reducing piston
which, when the valve closes, is first lowered into the guide
A. Bottom dead centre 1. Inlet passage and then closes the connection between the delivery pipe and
B. Fuel injection begins 2. Cylinder the pump element. The valve head is then pressed against its
C. Fuel injection ends 3. Starting groove seat and the fuel in the delivery pipe is given the same space
4. Release passage as the displacement of the pressure ---reducing piston.
5. Plunger
6. Metering edge
7. Vertical groove
170
Model Code Page
1. 9. 1992
Governor
Fuel injection pump type plate
The injection pump type plate shows one particular letter indi-
cating the user application, see figure below. This letter
should always be quoted when ordering a replacement pump
or when looking for setting values.
The letters for different pumps on 6100---8100 tractors can be

found in the table on next page.
1. Governor weight
2. Control rod
3. Starting spring
4. Main lever
5. Idler screw
6. Governor spring
7. Additional spring, idling
8. Spring for equalizer
9. Governor control arm
The governor is of the centrifugal type and is fitted at the rear

end of the injection pump. The governor controls the rota-
tional speed of the engine throughout the whole speed range,
and identifies the rotational speed by means of the governor
weights. The position of the governor control and of the gov-
ernor weights is transferred through the governor lever link-
age to the control rod. The governor has one governor spring.
Starter spring, which is attached to the upper end of the con-
trol lever, it pulls the control rod to the starting position when
the engine stops. This means that the amount of fuel injected
when the engine is started automatically becomes greater.
171
22A. Fuel system (20---series) 255-- 700 220 8
10. 10. 2003
Table of fuel metering, Bosch in ---line pump, 255---700

Koevarustus ISO 4008, Neste ISO 4113, Suutin ISO 4010 173 bar, Putket ø6x2x600 ISO 4093
Engine Tractor Injection Governor Pump timing ˚ Injected RW mm Control Control rod
pump Max. output r/min amount rod at le- position
Low idling r/min mm3 / stroke ast 1 mm 4 mm
rpm mm3 rpm rpm
320 D 255 PES 3A 95 D RSV 375--- 1175 21˚˚ 1150 75--- 77 9,8±0,2 1200--- 1270---
355 320 RS 2810 A2C 2178--- 10R 2350 1000 +0,3--- 0,5 1220 1300
365 /B 750 800 +0,5--- 0,7
500 +0,5--- 0,7
325 12--- 15 4,4±0,3
320 DS 455 PES 3A 95 D RSV 375--- 1175 19˚˚ 1150 79--- 81 10,2±0,2 1200--- 1270---
320 RS 2810 A2C 2178--- 10R 2350 1000 +0,2--- 0,3 1220 1300
/A 750 800 +0,5--- 0,6
500 +0,5--- 0,6
325 10--- 15 4,4±0,3
320 DS 555 PES 3A 95 D RSV 375--- 1175 19˚˚ 1175 88--- 90 11,1--- 10,8 1200--- 1255---
465 320 RS 2810 A2C 2178--- 10R 2350 990 +0,2--- 0,3 1225 1285
750 800 +0,5--- 0,6
500 +0,5--- 0,6
375 10--- 15 4,4±0,3
320 DS 565 PES 3A 95 D RSV 375--- 1175 19˚˚ 1150 95--- 97 11,4--- 11,8 1200--- 1270---
320 RS 2810 A2C 2178--- 10R 2350 1000 +0,3--- 0,5 1220 1300
/P 750 800 +0,5--- 0,7
500 +0,5--- 0,7
375 12--- 15 4,4±0,3
420 D 665 PES 4A 95 D RSV 375--- 1175 21˚˚ 1150 73--- 74 10.0±0,2 1195--- 1270---
320 RS 2807 A2C 2178--- 7R 2350 1000 +0,4--- 0,5 1205 1285
/ BE 750 900 +0,8--- 0,9
600 +0,8--- 0,9
375 11--- 15 4,2±0,3
320 D 600 PES 3A 95D RSV 375--- 1175 21˚ 1150 88--- 90 9,3±0,2 1170--- 1240---
320 RS 2810 A2C 2178--- 10R 2270 1000 9,6±0,2 1190 1260
/AR 750 950 90--- 92 9,8±0,2
800 90--- 92 10,0±0,2
700 10,2±0,2
600 10,2±0,2
400 12--- 16 4,4±0,3
320 DE 600 PES 3A 95D RSV 375--- 1175 17˚ 1135 96--- 98 12,1±0,2 1170 1230---
46kW 320 RS 2810 A2C 2178--- 10R 2270 950 100--- 101 12,4±0,2 1238
/BA 850 800 99--- 100 12,6±0,2
500 12,6±0,2
425 10--- 15 4,4±0,3
320 DS 700 PES 3A 95D RSV 375--- 1175 19˚ 1135 99--- 101 12,6±0,2 1160 1235---
320 RS 2810 A2C 2178--- 10R 2270 950 13,0±0,2 1265
/AO 750 800 13,3±0,2
500 13,3±0,2
375 16 5,5±0,2
Table of fuel equipment parts, 355---700

Engine/Tractor Injection pump Element Delivery valve Governor spring Injector compl. Nozzle Nozzle holder
320 D 8366 8353 8353 8353 8366 8366 8366
Valmet 255 40198 31161 39126 31163 39956 39957 39971
Valmet 355
Valmet 365
320 DS 8366 8353 8353 8353 8366 8366 8366
Valmet 455 40197 31161 39126 31163 39956 39957 39971
320 DS 8366 8353 8353 8353 8366 8366 8366
Valmet 465 40156 31161 39126 31163 39956 39957 39971
Valmet 555
320 DS 8366 8353 8353 8353 8366 8366 8366
Valmet 565 40438 31161 39126 31163 39956 39957 39971
420 D 8367 8353 8353 8353 8366 8366 8366
Valmet 665 40392 31161 39126 31163 39956 39957 39971
320 D 8366 8353 8353 8353 8368 8368 8366
Valmet 600 54789 31161 39126 31163 54755 54757 39971
320 DE 8366 8353 8353 8353 8368 8368 8368
Valmet 600 54886 31161 39126 31163 54755 54757 54756
320 DS 8366 8353 8353 8353 8368 8368 8366
Valmet 700 54781 31161 39126 31163 54755 54757 39971
172
Model Code Page
15. 4. 1999
22A. Fuel system (20---series) 865, 700
1. 9. 2001 800, 900 220A 9
Specifications with Stanadyne distributor pump

Note! 865, 800 and 900 tractors have Stanadyne rotary distributor pump. The pump is equipped with an an electric running sole-
noid (ignition switch stop) and with an automatic bleeding system. Stanadyne pump is lubricated by fuel. A separate fuel feed
pump is of a membrane type and it is driven by the engine camshaft. The system includes also the Thermostart glow plug.
Note! 700, 800 and 900 tractors with E ---engines (DSRE) have also the Stanadyne rotary distributor pump.
Picture. Stanadyne distributor pump (conserning

E ---engines, see picture on page 12A).
1. Sealing ring 8368 40858

2. Type plate with pump part number (836754665)
3. Timing marks under the cover
4. Fuel inlet
5. Return fuel/overflow valve
6. Revolution lever
7. Connector for wire to electric stop solenoid
Stanadyne distributor pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DB 4 (four pumping plungers)

Injection order:
--- 420---engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---4---3
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Injection advance, see table on page 220/13:
Tightening torque of pump gear wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Fuel feed pump
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . membrane pump, separate

hand pump
Fuel feed pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar (48 kPa)
Injectors (see also page 220/14)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stanadyne five hole nozzle

Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no 8999 01495
Injector nozzle sleeve, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
173
Model Code Page
1. 3. 1997
22A. Fuel system (20---series) 865
220A 10
1. 1. 1998 800, 900
Fuel system with distributor pump
1. Fuel tank Stanadyne water trap on 865 from Spring

2. Water trap ---97 and on 800 and 900 tractors.
3. Fuel feed pump
4. Fuel filter
5. Distributor pump
A
6. Injector
7a,b,c. Return fuel to tank
8. Thermostart reservoir
9. Glow plug B
10. Bleeding screw
In this fuel system, there is a separate fuel feed pump (3) on when securing band (B) is rotated for hand and the filter is pul-
the RH side of the engine. led downwards. When fitting a new filter, rotate the securing
band until it locks the filter (click).
The system includes a separate water trap (2) and a fuel filter
(4). The lower part of the fuel filter housing has a space for Maintenance
possible impurities and there is a drain tap under the filter hou- --- Check/empty the water trap weekly/every 50 running
sing. hours.
--- Open and clean the water trap at every 500 running hours
The fuel feed pump has a washable metal gauze filter. There (not 865, 800 and 900 with Stanadyne water trap). At the same
is also a tapered metal net filter inside the distributor pump in time open the tap under the filter housing and allow possible
the inlet line before the pump transfer pump. impurities to run out.
--- Clean the fuel tank every 1000 running hours/yearly and
Important! The Stanadyne water trap also includes a filter. change the fuel filter (on 865, 800 and 900, change the Stana-
There is a draining tap (C) in the bottom of the housing. Before dyne water trap filter).
emptying this water trap, slacken the bleeding screw (A) . --- Check/clean injectors at every 2000 running hours/every
After emptying, close the screws and pump fuel with the feed other year. Faulty injectors cause knocking, smoky exhaust
pump (3) lever, until the water trap is full of fuel. The Stanadyne gases and loss of engine power.
water trap filter loosens,
174
Model Code Page
22A. Fuel system (20---series) 865 220A 11
1. 5. 1996
1. Drive shaft
2. Governor weights
3. Governor spring
4. Stop solenoid
5. Overflow valve
6. Metering valve
7. Cam ring rollers
8. Hydraulic head
9. Pressure regulator valve
10. Transfer pump blades
11. Distributor rotor
12. Delivery valve
13. Cam ring
14. Automatic advance
15. Centrifugal governor
16. Pumping plungers (4 pcs in
picture. 865 has 2 pcs).
The main rotating components are the drive shaft, transfer

pump blades, distributor rotor and governor. The distributor rotor incorporates two charging ports and a
single axial port (pressure chamber), in which is placed the
The drive shaft engages the distributor rotor in the hydraulic delivery valve. After the delivery valve, there is one discharge
head. The drive end of the DB4 rotor incorporates four pump- port to serve all head outlets to the fuel injection pipes.
ing plungers.
The hydraulic head contains the bore in which the rotor
The plungers are actuated toward each other simultaneously revolves, the metering valve bore, the charging ports and the
by an internal cam ring through rollers and shoes which are connections to the fuel injection pipes.
carried in slots at the drive end of the rotor. The numbers of
cam lobes normally equals the number of cylinders (not The pump contains a mechanical governor. The centrifugal
3---cyl. engines). force of the weights is transferred to the metering valve via a
linkage. The metering valve can be closed electrically with aid
The transfer pump at the rear of the rotor is of the positive dis- of the solenoid in the pump housing.
placement vane type and is enclosed in the end cap. The end
cap also houses the fuel inlet strainer and transfer pump pres- The automatic advance is a hydraulic mechanism which
sure regulator. The face of the regulator assembly is com- turns the cam ring and advances or retards the beginning of
pressed against the distributor rotor and forms an end seal for the fuel delivery from the pump.
the transfer pump.
The pump axial force acts against the pressure regulator valve
front face.
175
Model Code Page
22A. Fuel system (20 series) 865 220A 12
1. 5. 1996
Housing pressure
Transfer pump pressure Injection pressure
1. Fuel tank 10. Regulator spring

2. Water trap 11. Centrifugal weights
3. Fuel feed pump 12. Overflow valve
4. Fuel filter 13. Hydraulic head connecting passage
5. Transfer pump 14. Metering valve
6. Pressure regulator valve 15. Hydraulic head charging pasage
7. Automatic advance 16. Distributor rotor
8. Air vent passage 17. Delivery valve
9. Stop solenoid 18. Injector
Function
The fuel feed pump draws fuel from the tank via the water trap While the discharge post is opened, the rollers contact the
and the filter into the fuel injection pump. cam lobes forcing the plungers together. Fuel trapped
between the plungers is then pressurised and delivered by
In the pump fuel flows through the inlet filter screen into the the nozzle to the combustion chamber.
vane type fuel transfer pump. Some fuel is bypassed through
the pressure regulator assembly to the suction side. The injection pump is self ---lubricating, and it has not been
connected to the engine lubrication system.
Fuel under transfer pump pressure (1---6 bar) flows through
the center of the transfer pump into the circular groove on the As fuel at transfer pump pressure reaches the charging ports,
rotor. It then flows through a connecting passage in the head slots on the rotor shank allow fuel and any entrapped air to
to the automatic advance and up through a radial passage flow into the pump housing cavity. In addition, an air vent
and then through a connecting passage to the metering passage in the hydraulic head connects the outlet side of the
valve. The metering valve adjusts amount of injected fuel and transfer pump with the pump housing. This allows air and
position of the metering valve is controlled by the governor some fuel to be bleed back to the fuel tank via the overflow
(revolution lever) and the stop solenoid. From the metering valve.
valve fuel flows to the radial charging passage and further to
the head charging ports. The fuel thus bypassed fills the housing, lubricates the inter-
nal components, cools and carries off any small air bubbles.
As the rotor revolves, the two rotor inlet passages register The pump operates with the housing completely full of fuel;
with the charging ports in the hydraulic head, allowing fuel to there are no dead air spaces anywhere within the pump.
flow into the pumping chamber. With further rotation, the inlet
passages close and port to the injectors opens.
176
Model Code Page
15. 4. 1999
22A. Fuel system 865,
220A 12A
1. 9. 2001 700-- 900
1. Type plate with ordering number

2. Timing marks under the cover
3. Fuel inlet
4. Fuel return flow/overflow valve
5. Revolution lever
6. Connector for wire to electric stop solenoid
Possible equipment on Stanadyne distributor pump (e.g. E-- engines)
A. Interrupted screw (ordering no. 8366 59038) G. Compact cold advance CCA
Electric advancing of the injection during starting and at low
B. Detector for injection timing
engine revs (below 1100 rpm) in order to decrease the cold
C. Fuel limiter FL smoking. In addition to the injection pump solenoid, the
The fuel limiter limits the amount of injected fuel at low pump has a separate control unit, which follows up the engine
engine revs, when the air coefficient is too small. revs.
D. Light load advance LLA H. Torque screw TS (inside the housing).
Adjustment of the injection advance according to the en-
gine revs and loading. This is controlled by the fuel feed With this screw the engine specific curves for output and
pressure after the quantity governing valve. torque can be canged into desired form.
E. Aneroid control AC
Aneroid control (limitation of acceleration smoke) allows I. Vented metering valve VMV (inside the pump housing).
a full fuel injection during acceleration just when the
boost pressure has risen enough. The valve makes the inner bleeding of the pump better.
F. Boost pressure
177
178
22A. Fuel system (20---series)
Valtra---tractors with Stanadyne rotary distributor pump and delivery pipes
Trac- Engine Fuel injection pump Static in- Dynamic injection advance (°/rpm) Extra equipment **) Delivery pi-
tor jection ad- pe inner
vance diameter
***)
Type Type Order no. Low idling Max. 1400 rpm 2200 rpm
revs (full loa- (full loading)
ding)
±1,0° ±1,0°
±1,0°
800 420 DR DB 4429---5375 8367 54776 22˚ --- --- --- --- TS ø 1,5 mm
865 420 DSR DB 4427---5218 8367 54665 14˚ --- --- --- --- TS ø 2.0 mm
900 420 DSR DB 4427---5218 /F 8367 54780 14˚ --- --- --- --- TS ø 2.0 mm
(8367 54665) *)
700 320 DSRE DB4327---5575/B 8366 54861 15° >4° 16,5° 14° 15° (2270 rpm) TS, LLA ø 1,75 mm
L24101--- (8366 54724) *)
800 420 DSRE DB4429---5375/C 8367 54853 15° 8° 11° 15° 17,5° (2270 rpm) TS ø 1,75 mm
L24101--- (8367 54776) *)
900 420 DSRE DB 4429---5375/E 8367 54885 14° 7° 11° 13° 17° (2270 rpm) TS ø 1,75 mm
L24101--- (8367 54776) *)
10. 10. 2003
1. 9. 2001
’) Base pump niumber, marked on the pump type plate. Ø ***) Delivery pipe inner diameter
Note! Adjusting values of Bosch in ---line pumps, see pages 220/2 and 220/8
**) Extra equipment 220/12A. without notch, Ø 1,5 mm The latest pipes have numbers on nut.
1 notch, Ø 1,75 mm without numbers, Ø 1,5 mm
2 notches, Ø 2,0 mm 1.8, Ø 1,75 mm
2.0, Ø 2,0 mm
Model
700-- 900
865,
Code
220A
Page
13
179
ValtraValmet ---tractors, Stanadyne injectors
Tractor Type of Order no of Nozzle order Opening Adjusting pres- Shim no Code C
injector compl. in- no pressure, sure, bar 1)
jector bar
305, 405 (311--- and 411---engines) --- 8353 31100 8353 31101 205+10 215 --- ---
205, 555 (610312---656315), S/655 8363 40034 8363 39985 230+10 240 8366 40104...8366 40122 655
865, 900 (Stanadyne ---pump, not E ---engine)
355, 455 (610312---656315. 311--- and 411---engines) --- 8363 39088 8363 39087 230+10 240 --- ---
255, 355, 365, 455, 465, 555, 565, 665 (656316---) S/736 8366 39956 8366 39957 230+10 240 8366 40104...8366 40122 736
600, 700 (Bosch ---inline pump, not E ---engine) M/423 8368 54755 8368 54757 270+8 278 8368 62000...8368 62020 423
800 (Stanadyne ---pump, not E ---engine)
600 (Bosch ---inline pump, E ---engine)
10. 10. 2003

700R,, 800,, 900 ((L24101---)) M/358
/ 8366 59808 8366 59902 270+8 278 8368 62000...8368 62020 358
1. 9. 2001
(E ---engine, S
Stanadyne ---pump)
1) Value to be used both with new and used nozzles.
Model
255-- 900
Code
220A
Page
14
180
22A. Fuel system (20 series) A75-- A95 220A 15
23. 8. 2004
Technical specifications
Injection pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch VE rotary pump
Fitting position º BTDC (static): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5º
Piston distance of the injection pump (in assembling):
--- A75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm
--- A85 and A95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm
Direction of rotation from the engine front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Injection order:
- 44-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4-3
- 66-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Fuel system
VE ---pump:
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The fuel must be according to norm EN 590
Fuel filters:
- Pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stanadyne 30 μ, element no. 8368 66575
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stanadyne 5 μ, element no. 8368 66577
Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diaphragm pump, separate hand lever
Fuel feed pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar
Fuel feed pressure min. (used pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 bar / max. rpm
Injectors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 bar
Setting pressure* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 bar
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 899901495
*) Value to be used when adjusting the opening pressure of a new or used injector.
Tightening torques
VE ---pump:
Injection pump retaining nuts M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Injection pump gear retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Injection pump coupling flange retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92,5 Nm
Delivery pipe attaching nut to pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
181
Model Code Page
22A. Fuel system (20 series) A75-- A95 220A 16
1. 4. 2004
Fuel system, description
7 2
9 3
Fuel system (Injection pump Bosch VE)

1. Fuel tank 6. Injection pump
2. Pre ---filter 7. Injector
3. Water separator (optional) 8. Overflow valve
4. Feed pump 9. Feed pressure sensor (0,05-0,2 bar)
5. Fuel filter
The fuel is pumped by feed pump from the tank via a pre- The fuel system is equipped with a pressure sensor that
filter, through the filter to the injection pump. The injection alarms before interference has developed. An option the
pump forces the fuel into the injector with feeds fuel into the pre-filter can be equipped with a see-trough water trap and
combustion space in a fine spray. Excess fuel returns from with an electronic water in fuel sensor.
the fuel injection pump through an overflow valve to the fuel
tank. The overflow pipe between filter and injectors helps
the automatic bleeding of the system.
182
Model Code Page
1. 3. 1997
1. 9. 2001
Repair instructions B. Bleeding thermostart system

355---700)
Fuel feed pump and fuel filter (Op no 222)
Always remove air from the glow plug fuel pipe when the pipe
A. Bleeding fuel system or reservoir has been emptied during repair work etc. This
prevents damages to the glow plug caused by lack of fuel dur-
(Bosch in ---line pump) ing starting.
1. If the reservoir is empty, fill it e.g. with a drip pot through the
breather hole on the reservoir.
2. Open the glow plug pipe connector and drain fuel from the
pipe. Connect the pipe.
Note! From engine no. H16734 incl. the outer diameter of the
glow plug fuel pipe has been enlarged from 4,76 mm to 5,0
mm. These new pipes can be used on earlier manufactured
tractors, when simultaneously is fitted a new connector nut
and a new sealing cone. The new nut can be recognized by
grooves on the outer circumference.
C. Measuring fuel feed pressure
Note! Pressure measuring equipment, see page 101/4C.
1. Clean the fuel injection pump and the filter and the pipes
between them.
1. Slacken the bleeder screw on the filter head. Pump with the
hand pump until the fuel flowing out at the bleeder screw is
free from air bubbles. Then tighten the bleeder screw.
2. Fit the gauge at the banjo connection on the pump, as

shown above (between filter and injection pump).
3. Run the engine at low idling for a while and compare the
gauge reading with the prescribed value (0,6 ---1,0 bar).
3. Slacken the injection pump overflow valve. Pump with the N.B. If the measured pressure is below the prescribed value,
hand pump until the fuel flowing out is free from air bubbles. this may be caused by:
Tighten the overflow.
--- faulty overflow valve
4. Wipe off any fuel from the engine. --- blocked fuel filter
--- blocked or leaking fuel pipes or unions
183
Model Code Page
1. 9. 1992
D. Checking overflow valve E. Changing fuel feed pump valves
If the fuel feed pressure deviates from the prescribed value, 1. Clean the feed pump. Disconnect fuel pipes to the feed
check the opening pressure of the overflow valve. pump. Remove the feed pump.
1. Connect a pressure gauge to the banjo union in the same

way as in previous instruction C.
2. Pump with the hand pump until the overflow valve opens.
Compare the reading on the gauge at the moment the valve
opens with the prescribed value (0,6 ---1,0 bar).
3. If the recorded opening pressure deviates from the pre-

scribed value, the overflow valve should be changed.
N.B. If the recorded pressure is considerably lower than the

prescribed value, there may be a fault in the hand pump or
the fuel feed pump valves.
2. Secure the pump in a vice provided with soft jaws. Loosen

the tappet body from the pump and remove the piston, seal
rings, suction valve and the spring.
3. Detach from the pump body the outlet side threaded con-
nector, in which is placed the pressure valve.
4. Rinse the valves with clean fuel and check the function and
possible wear.
5. Change the valve if needed and assemble the pump using

new o---rings and gasket
184
Model Code Page
10. 1. 1992
1. 9. 1992
Fuel injection pump and injectors (Op no

223)
A. Checking injection timing

9025 99000
Note! The exact time at which the fuel should be injected into
no. 1 cylinder is marked on the crankshaft belt pulley. Due to
the excess fuel flowing into the injection pump the control rod
must be moved to the drive position when checking the injec-
tion timing. Otherwise the timing will be incorrect!
IMPORTANT! Governors of the Bosch in ---line pumps have

been changed with effect from engine no. G4720 (320 D, DS)
and G2358 (420 D, DS). These modified pumps can be
recognized by a plug in the governor housing (the same as on
Valtra 6800 and 8750 tractors) and they are exchangeable
with the earlier pumps. Spare part numbers of the pumps are
not changed. Checking/adjusting injection timing on these
modified pumps, see page 223A/4A.
Checking method: 4. Remove the control rod cover from the injection pump. Turn
the control rod to drive position with tool 9025 99000.
1. Clean the injection pump and its surroundings carefully.
5. Disconnect the injection pipe (at the pump) for the 1st cylin-
2. Remove the inspection hole rubber plug from the flywheel der (nuts 17 mm and support piece 8 mm).
housing.
6. Wipe off the fuel on top of the delivery valve. Turn the crank-
shaft in the correct direction of rotation until the fuel level in the
delivery valve just begins to rise.
3. Turn the crankshaft until the piston in the number one cylin-
der has reached its T.D.C. when in its compression stroke. The 7. Check if the mark on the crankshaft belt pulley is at the point
turn the crankshaft backwards until the timing mark on the belt of the indicator. If it is, the injection timing is correct. If the injec-
pulley passes by the point of the indicator. tion pump needs to be adjusted, follow the next instruction.
8. After checking and if necessary adjusting the timing install

the injection pipe and the control rod cover. Run the engine
for a few minutes and recheck. Thus you can ensure that there
is no air left in the fuel system which might affect the timing.
185
Model Code Page
10. 1. 1992
1. 9. 1992
B. Adjusting injection timing 9052 48900
1. Loosen the retaining nuts (17 mm) of the injection pump

and remove the injection pipes (17 mm).
5. Use puller 9052 48900 and loosen the gear from the injec-
tion pump camshaft front end.
M 6. Remove the injection pump attaching nuts (17 mm).

Remove the injection pump.
2. If the injection timing is retarded, turn the pump anti ---clock-
wise (viewed from the front end of the pump). If the timing is
N.B. If the engine is not to be disturbed while the pump is re-
advanced, turn the pump clockwise.
moved, there is no need to secure the pump gear. The gear
rests against the idler gear.
3. Check once again the injection timing and set again if
needed.
4. When the timing is correct tighten the retaining nuts of the

pump and fix the delivery pipes. D. Fitting fuel injection pump
1. Check the condition of the o---ring between the pump and

the timing gear casing. Change the o---ring if necessary.
C. Removing fuel injection pump
1. Clean the injection pump and surrounding engine parts

and the pipes and connectors on the injection pump.
2. Disconnect the delivery pipes and the banjo bolts at the

supply and return fuel connections. Disconnect the lubricat-
ing oil line. Plug all connections.
3. Detach the oil filler pipe/cover from the front cover. Unscrew
the pump drive gear nut.
2. Lubricate the o---ring and place the injection pump so that

the key on the pump shaft aligns with the key slot inside the
gear. Tighten the pump attaching nuts.
3. Tighten the gear nut to 90 Nm . Fix the oil filler pipe/cover.
4. Connect the supply and return fuel lines. Connect the lubri-
cating oil line. Use new sealing washers.
186
Model Code Page
1. 9. 1992
5. Bleed the fuel system (Op no 222 A). E. Checking/changing delivery valve
6. Adjust the injection timing (Op B).
1. Clean the injection pump, injectors and surrounding parts.
7. Fit the delivery pipes. Disconnect the delivery pipes.
9052 47800
8. If the injection pump is changed or if the lubricating oil has

been drained from the pump, fill the pump with lubricating oil
before starting the engine. Open the hexagonal socket plug
on the governor housing and pour in oil.
Filling quantity: 320---engines 0,3 l

420---engines 0,4 l
Same oil specification as in the engine.
2. Connect the pressure gauge 9052 47800 to the delivery

valve holder which is to be checked.
3. Rotate the engine with the starter motor, until the gauge
reading is about 330 bar.
Note! Pressure rises fast, do not damage the gauge. Get

ready to pull the stop control out as soon as the gauge reading
reaches an adequate pressure value.
4. Let the gauge reading lower at first about 30 bar. When the
gauge shows 300 bar, observe the reading during one min-
ute. During this time the gauge reading must not lower too
much (max 30---50 bar). If the pressure lowers faster than
specified, the delivery valve must be cleaned or replaced.
Note! The delivery valve plunger and guide should always be

replaced in pairs.
5. Open the delivery valve holder locking and holder. Remove

the valve spring, plunger and the guide.
6. Rinse the plunger and guide in clean fuel or test liquid and
at the same time rotate the plunger in its guide and press the
sealing surfaces against each other.
187
Model Code Page
1. 9. 1992
2. Ensure that the throttle lever is in the idling position and that
the engine is at normal operating temperature.
3. Start the engine and loosen the adjusting screw of the addi-
tional spring so that it does not affect the idling speed.
7. Fit the delivery valve into the fuel injection pump. Place the
4. Adjust the idling speed using the adjusting screw to about
spring in place and tighten the holder.
20 RPM below rated speed and lock the adjusting screw (10
mm).
Note! Renew the sealing ring and o---ring.
5. Run the engine a few times and ensure that the idling speed
8. Tighten the holder as follows:
remains as set.
--- Tighten first to 30 Nm.
6. Tighten the adjusting screw of the additional spring until the
--- Open the holder about 1/2 a turn and tighten to 40 Nm.
idling speed rises to the rated value. Lock the adjusting screw
--- Open the holder about 1/2 a turn and tighten to 45 Nm.
(17 mm) in this position.
7. Fix the safety caps of the adjusting screws.
Note! Other adjustments (output and max. speed) of the in-

F. Adjusting low idling speed jection pump can only be performed by a specially trained
person who has the necessary special tools and gauges avail-
able.
If the idling speed of the engine deviates from the value given
in the specifications or if the engine revs vary at the idling
speed, adjust the idling speed as follows:
1. Unscrew the idling speed adjusting nut cap (1) and the cap
(2) on the idling speed additional spring adjusting screw.
188
Model Code Page
22A. Fuel system (20---series) 255-- 665
1. 6. 1998 600, 700 223A 4A
F.1. Adjusting injection timing on modified

Bosch in ---line pumps
IMPORTANT! Governors of the Bosch in ---line pumps have

been changed with effect from engine no. G4720 (320 D, DS)
and G2358 (420 D, DS). These modified pumps can be
recognized by a plug in the governor housing (the same as on
Valtra 6800 and 8750 tractors) and they are exchangeable
with the earlier pumps. Spare part numbers of the pumps are
not changed.
Note! On these modified pumps the injection starting point in

the 1st cylinder has been positioned with aid of an indicator
pin in the pump governor housing.
2. Unscrew the plug on the side of the injection pump. Take

out the indicator pin.
3. Turn the indicator pin and push it into the hole so that the
groove at the end of the pin points towards the pump.
4. If the pin groove fits on the boss on the governor weight

assembly, the injection timing is correct. Otherwise, turn the
pump to a position where the boss and the pin groove align.
Warning! Do not rotate the crankshaft when the groove end

of the pin is inside the pump, since the pin end damages eas-
ily and metal pieces remain in the governor housing.
5. When the adjustment is correct, turn the indicator pin so that

the groove points outwards (running position) and push the
pin into the hole. Refit the plug.
1. Turn the crankshaft to a position where the 1st cylinder pis-

ton reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the timing mark on the belt
pulley is at the point of the indicator.
189
190
Model Code Page
1. 9. 1992
G. Removing injectors
1. Clean the injectors and the area around them. Disconnect

the delivery pipes and the leak ---off pipes.
9051 71300
2. Secure the injector in a test bench and check the follow-

ing:
--- injector opening pressure
--- the properties of the chattering (creaking) sound and the
form of the spray pattern
--- sealing of nozzle valve against its seat
3. Remove the injector attaching nuts (13 mm) and remove Opening pressure
the injector from the cylinder head. Fit protective plugs to all
connections. If the injector does not rise by hand, use puller Pump a few times to fill the injector. Increase the pressure in
9051 71300. the injector until the chattering (creaking) sound becomes
audible. Read off the opening pressure of the injector. If the
4. Remove the sealing washers from the bottom of the injector opening pressure deviates from the given value (230±5 bar),
location in the cylinder head if they do no come out with the the injector should be taken apart and checked.
injector
Adjustment is achieved by changing the shims. The thickness
of the shims varies from 1.00---1,90 mm and they are available
in increments of 0,05 mm. A thicker shim will raise the opening
pressure while a thinner one lowers it. A difference in shim
thickness of 0,05 mm changes the opening pressure by ap-
prox. 5,0 bar. As the opening pressure of the injector drops
slightly after adjustment, the opening pressure should be set
to approximately 10 bar above the value given in the specifica-
tions. This value applies both to new and used injector.
H. Inspecting injectors
Chattering sound properties
N.B. When pressure testing the injectors, it is important to
Testing with a hand powered pump does not create the same
avoid the nozzle end as the fuel jetting out easily penetrates
circumstances as when the injector is fitted in the engine. Only
the skin. Also bear in mind that the fuel ”mist” is dangerous to
with new nozzles are the test results reliable. With used
inhale.
nozzles, there is no chattering (creaking) sound when the
tester is pumped at a certain rate. This has to do with the de-
sign of the nozzles.
1. Clean the injector with cleaning fluid and a soft brush.
The carbon deposits must not be knocked off or removed in
However, with a rapid pumping on the tester handle, it should
any other way which may damage the nozzle.
be possible to hear the chattering (creaking) sound or/and
see a mist of the fuel jetting out.
191
Model Code Page
1. 9. 1992
1
Tightness of nozzle
Press down the tester pump lever until the pressure rises to
approx. 20 bar below the adjusting value. Maintain this pres-
sure for approximately 10 seconds and check whether drops
of fuel are formed on the point of the nozzle. If the injector
leaks, it should be cleaned or the nozzle should be changed. 2
I. Reconditioning injectors
1. Secure the injector in a suitable way.
3
2. Unscrew the nozzle cap nut. Remove the nozzle and the
parts inside the holder.
4
4. Clean the nozzle holes with a needle (including in cleaning

set 8360 83288).
5. Test the movement of the nozzle valve as follows: 5
Injector
1. Fuel inlet 6. Nozzle body

2. Leak ---off fuel 7. Pressure chamber
3. Shims 8. Nozzle valve
4. Pressure spring 9. Nozzle hole
5. Valve stop spacer
Rinse the parts thoroughly in fuel or testing fluid. Pull the valve 6. Before assembling, all parts should be carefully cleaned in
out of the nozzle body to 1/3rd of its length. If the fit is correct, clean fuel or testing fluid.
the valve should be able to slide down in the nozzle body
under its own weight. Turn the valve slightly and repeat the 7. Put the same number of shims back as were fitted earlier.
test. Should the nozzle valve bind slightly, it should be Note possible adjustment of the opening pressure. Assemble
changed. the rest of the injector. Note the position of the spring guide
and the valve stop spacer.
8. Tighten the nozzle cap nut by hand and then to 60 Nm.
192
Model Code Page
1. 9. 1992
K. Fitting delivery pipes

J. Fitting injector in engine 1. Check the state of the pipes. If there are kinks, damage by
chafing, or if the tapered sealing end is damaged, the pipes
1. Clean the injector sealing surface in the cylinder head. If should be changed.
necessary use a reamer 9101 66000.
2. Fit the pipes without tension and check that they are at right
angles to the union.
1. Washer
2. Rubber ring
3. Sealing washer
2. Fit the injector in the cylinder head using a new sealing

washer.
N.B. The spray pattern from the injector is not symmetrical on

purpose. It is therefore important that the injector is fitted cor-
rectly in the cylinder head. The connection for the leak ---off
line should be facing the valve mechanism.
3. Fit the attaching clamp and tighten the nuts (13 mm) evenly
to 15 Nm.
4. Connect the leak ---off line (10 mm) together with new seal-
ing washers and connect the delivery pipes (17 mm).
N.B. The screw studs in the cylinder head for the injectors
should only be finger tight. If tools have to be used the studs
should be tightened only lightly.
Note! Make sure, that the injector is of a correct type. Wrong

injectors cause malfunctions and can damage the engine.
193
Model Code Page
15. 4. 1999
22A. Fuel system (20---series) 865, 700-- 900 223A 8
1. 9. 2001
2. Stanadyne distributor pump
A. Removing pump
1. Make the procedures shown i paragraph 1 below. Clean

the pump and the surrounding parts carefully. Remove the
delivery pipes, the throttle cable wire from the revolution
lever and the stop solenoid wire from the pump. Fit protec-
tive caps on the delivery pipe unions.
2. Remove the cover (+oil filler tube) of the front plastic

covering so that the pump gear wheel becomes accessible.
4. Unscrew the gear wheel attaching nut. Detach the gear

wheel by using puller 9052 48900.
Note! If the timing gear casing has not been removed, the
injection pump gear wheel remains in contact with the idler
gear and it is unnecessary to mark the positions of the
gears.
Note! In the E ---engines one injection pump fixing bolt is so

called interrupted screw (i.e, it cuts off when it is tightened).
2. Remove the small cover plate on the side of the injection
Open this bolt by striking to the bolt outer edge with a chi-
pump. Rotate the pump shaft until the timing marks align
sel (strike to the opening direction).
(see arrow in picture above).
5. Detach the injection pump from the timing gear casing.
Note! In 420---engines the side cover bolts are special
Clean the sealing surfaces.
bolts, which require special key. Cover seal no. is 8366
62296.
3. Place a new sealing ring on the pump flange. Push the

B. Fitting injection pump and adjusting pump into place so that the key on the shaft engages with
the key slot on the gear wheel.
injection timing
4. Tighten the pump into position, where the timing marks
align.
5. Tighten the gear wheel nut to a torque of 90 Nm. Fit the

small cover onto the side of the pump. Fasten the pump
gear wheel covering (+oil filler tube).
6. Remove the protective caps from the delivery pipe uni-

ons and fasten the delivery pipes. Fit the overflow pipe,
throttle cable wire and the stop solenoid wire. Bleed the fuel
system (see instruction C).
Note! Lubrication is not needed in the distributor pump as

fuel in the pump lubricates the internal parts.
1. Turn the crankshaft until the piston in the number one

cylinder has reached its T.D.C when in its compression
stroke and then turn the crankshaft a little so that the timing
mark on the belt pulley is at the point of the indicator (injec-
tion in no. 1 cylinder begins).
Note! Distance between the piston top face and the top
dead center with different crankshaft angles, see page
210/7.
194
Model Code Page
1. 3. 1997
22A. Fuel system (20--- series) 865, 800, 900 223A 9
1. 6. 1998
C. Bleeding fuel system D. Fuel feed pump

Note! This fuel system removes automatically small
Separate spare parts are not available for the membrane
amounts of air bubbles from the filter and the pump. How-
ever, bleed the system always, when the system has been type fuel feed pump. The feed pump must be changed for
a new one, if the feed pressure has dropped noticeably
opened or fuel has been exhausted during driving (to
(rated feed pressure is 0,2 ---0,5 bar at low idling speed and
avoid long starting time).
max 0,2 bar less when engine is accelerating) or if the fuel
feed pump has damaged.
Metal gauze filter Measuring fuel feed pressure

under the cover
Pressure measuring equipment, see page 101/4C.
Note! If the feed pressure value is below the rated value,

possible reason can be:
--- blocked fuel filter/fuel feed pump metal gauze filter

--- blocked or leaked fuel pipes or pipe connections
Important! Under the fuel feed pump cover there is a

washable metal gauze filter. If many impurities have
gathered on this filter, fuel cannot flow to the feed pump
and further to the injection pump and this causes malfunc-
tions in the fuel system. Always when malfunctions appear,
the feed pump cover should be removed and the metal
gauze filter must be checked and cleaned.
1. Pump by hand the fuel feed pump lever. If the pumping
seems to be ineffective, turn the engine a little so that the Note! From manufacturing week G42 incl. the fuel feed
camshaft cam is not at the feed pump lifter. pump gasket no. 836640335 has been removed and the
sealing has been done with sealing glue T61050 (Weicon
Lock AN 305---10 TAI 75), which must also be used in con-
10a
nection with possible leakages.
Run the engine, until the cylinder block temperature is at
least +60˚C. Clean the sealing surfaces well by using sui-
table solution. Apply sealing glue onto the pump sealing
face and fasten the pump. Let the sealing glue dry about
one hour before the engine is started (if a fuel feed pump,
which has been tightened with the sealing glue, should be
changed, the pump fastening flange must be warmed up to
about +200˚C before removing the pump).
New fuel feed pump
In the tractor production has been started to fit a new fuel

feed pump (420: H7663 ---), which has an o---ring seal and
2. Loosen the bleeding screw (10a) on the filter. Pump with four fixing bolts. This pump can be fitted also on earlier
the hand pump until no air bubbles flow out of the bleeding manufactured tractors, although they should have the ear-
lier, with two bolts attached pump (mounting kit no. 8366
screw hole. Tighten the bleeding screw.
62052). In the cylinder block there are four fixing holes from
3. Pump further with the hand pump and loosen the fuel the beginning of the year 98. The Spare Part Centre dispat-
ches only the new pump.
inlet connection (10b) on the pump, until the fuel coming
out is free from air bubbles. Tighten the connection.
On the next page there is an instruction on, how to fit the
new pump.
Note! When the bleeding is done in this way, fuel flows
immediately into the internal transfer pump when the starter
motor is rotating and the distributor pump housing is filled
quickly with fuel. In the pump housing there is a stop sole-
noid, which must not be switched on for longer periods
when the pump housing is empty of fuel.
4. Start the engine and assure, that no leaks exist.
195
Model Code Page
1. 6. 1998
22A. Fuel system (20---series) 865, 700-- 900 223A 10
1. 9. 2001
Fitting new fuel feed pump (H7663-- ) F. Adjusting low idling speed
Revolution lever
Max. revs
Low idling speed
--- Remove the old feed pump and fuel pipes

--- Clean the sealing surface on the cylinder block
--- Place an o---ring into the groove on the pump.
--- Engines with two fixing bolts: apply sealing compound
T61050 (Weicon Lock AN ---305---74) on the cylinder block
side of the flange 4 (if four fixing holes the flange is not fitted) The low idling speed can be adjusted with a limiting screw in
--- Apply sealing compound also on the threads of the bolts front of the revolution lever. The adjusting screw for max. revs
(2 pcs or 4 pcs) and fasten the pump. Tightening torque is 30 has been sealed. This adjustment has been done in the fac-
Nm. tory, and adjustment of max. revs afterwards is prohibited.
--- Bend the pipe between the filter ---pump or use a flexible
pipe which incl. in the kit. Note! The throttle cable is attached to the revolution lever
lower hole. To the upper hole is fastened a return spring.
Note! If the cylinder block has already four threaded bolt
holes, remove plugs from points A, and fasten the pump with Other information
four bolts (sealing compound on the threads of all bolts)
without the intermediate flange (4). The injection pump housing upper cover has been sealed to
prevent adjustment of engine output afterwards. Also the stop
Sealing compound (50 ml) 6909 30030 solenoid is fitted under this cover. If the injection pump is dam-
Sealing compound (250 ml) 6909 30016 aged during the warranty period, replace with a new spare
part pump. After the warranty period it is recommended, that
all pump repairs are made by an authorised Stanadyne work-
shop.
E. Injectors
G. Bleeding Thermostart system
Injectors are checked and serviced according to instructions
G ---J on pages 223/5 ---7.
Always remove air from the glow plug fuel pipe when the pipe
or reservoir has been emptied during repair work etc. This
Opening pressure of the injectors, see pages 220/14.
prevents damage to the glow plug caused by lack of fuel dur-
ing starting.
Adjustment is achieved by changing the shims. The thickness
of the shims varies from 1.00---1,90 mm and they are available
1. If the reservoir is empty, fill it e.g. with a drip pot through the
in increments of 0,05 mm. A thicker shim will raise the opening
breather hole on the reservoir.
pressure while a thinner one lowers it. A difference in shim
thickness of 0,05 mm changes the opening pressure by ap-
2. Open the glow plug pipe connector and drain fuel from the
prox. 5,0 bar. As the opening pressure of the injector drops
pipe. Connect the pipe.
slightly after adjustment, the opening pressure should be set
to approximately 10 bar above the value given in the specifica-
Note! From engine no. H16734 incl. the outer diameter of the
tions. This value applies both to new and used injector.
glow plug fuel pipe has been enlarged from 4,76 mm to 5,0
mm. These new pipes can be used on earlier manufactured
tractors, when simultaneously is fitted a new connector nut
and a new sealing cone. The new nut can be recognized by
grooves on the outer circumference.
196
Model Code Page
15. 4. 1999
22A. Fuel system 700, 800 223A 11
1. 9. 2001
I. Dynamic adjustment of injection timing
1. Let the engine run to a normal working temperature befo-

re adjustment. Note! Ensure before engine start that the wires do not to-
uch the exhaust manifold or movable parts.
Note! Stop the engine before connecting and disconnec-
ting the adjusting device. 8. If the revolution reading is correct, press ENTER after
which text ”Calibrating...”. is visible in the display
2. Remove the protective plug on the fly wheel housing on
the LH side of the engine and fit the magnetic sensor A Note! If the revs signal disapperas or engine stops , in the
into the 8 mm hole. Press the sensor against the fly wheel . display flashes text ”Eng. Not running” and the device re-
The sensor must not touch the fly wheel so pull it a little out turns to the revs mode. Start again by pressing button
(0,5...1,0 mm) . Connect the sensor connector to the test MAG PROBE (return to point 5).
device plug MP.
9. If the engine is running at 850 r/min and the pump ad-
3. Fit fastener B on the brass ring between the pump and vance is 6˚ btdc, in the display there is visible ”R=850 MP
pipe and tighten the screw. Ensure, that the screw end + 6.0”. Now the device is ready for adjustment.
touches the brass ring. Connect the injection sensor con-
nector to the test device plug SR. Connect the earth wire Note! If the magnetic sensor signal is cut or the sensor is
to the clean metal surface on the engine or fuel system. lacking, in the display there is text ”R=850 No Probe”.
When the signal returns, the device shows again the injecti-
4. Switch on the test device by pushing ON/CLEAR but- on advance.
ton. In the display is visible ”Time Trac” and ”Model TT
1000” and then i ”R= 0”. Now the device can be used as 10. The injection time is checked at high idling revs [TT
a rpm counter without other procedures. (HI)]. Adjust if necessary. The function of the pump injecti-
on advance governor is assured by checking the injection
5. Press button MAG PROBE. In the display appears ”Trig timing at a low idling speed [TT (LI)].
Level 30%”. Confirm by pushing ENTER.
Adjusting values, see pages 220/13 and 14.
6. In the display is visible ”Offset 20.0˚”. Confirm by pus-
hing ENTER. See also instructions of the device manufacturer.
7. In the display is visible ”Calibrate?”. Start the engine

and let it run at low idling. Press ENTER so that in the disp-
lay is visible ”R=Set RPM”. Compare the revs to the speci-
fications, see page 210/3.
197
Model Code Page
22A. Fuel system 700, 800 223A 12
15. 4. 1999
Possible disturbances
If the injection timing deviates much from the specified value,

check the following points:
1. Vibrating delivery pipe, hold to the pipe with one hand.
2. The distance between the magnetic sensor and the flyw-

heel is incorrect, reposition the sensor.
3. Offset or Trig Level value incorrect, reset the values.
4. Disturbing grooves on the flywheel.
5. The mutual position of the flywheel and the crankshaft

incorrect, remove the flywheel and fit it to the correct position
in relation to the crankshaft.
8366 62022 Electronic device for injection timing
198
Model Code Page
1. 4. 2004 A75 -- A95 224A 1
Bosch VE distributor pump (Op no 224)

A. Removing fuel injection pump
5. Unscrew the retaining screws of the gear (4 pcs)
1. Turn the crankshaft to a position where the 1st cylinder

piston reaches its compression stroke top dead centre.
Turn the crankshaft backwards until the mark on the
pulley passes the timing indicator. Then rotate the crank-
shaft slowly in the running direction until the mark on the
pulley is at the point of the timing indicator.
2. Clean the injection pump and surroundings.
3. Remove the fuel delivery pipes, the throttle cable wire
from the lever and the stop solenoid wire from the pump.
Fit protective caps on the delivery pipe unions.
Note! If the front cover of the timing housing has not been
removed, the pump gear and the idler gear will stay in
mesh with each other.
Note! Do not remove the coupling flange from the shaft of

the pump.
4. Remove the injection pump gear cover. Don’t open the

nut of the coupling flange.
6. Unscrew the retaining nuts of the pump (3x13 mm).
199
Model Code Page
1. 4. 2004 A75 -- A95 224A 2
B. Fitting the injection pump and adjust-

ing injection timing
7. Remove the injection pump.
1. If the coupling flange is separate: Clean the conical con-

nection between the shaft of the injection pump and
coupling flange. Fit the separate coupling flange into the
timing gear housing.
8. Don’t open the nut of the coupling flange.

Note! Injection pump delivered as exchange part includes
coupling flange for the gear (1) and banjo bolt (2) for fuel
overflow. Those must be included also when returning in- 2. Tighten the screws of the flange to 35 Nm (4 pcs).
jection pump core.
200
Model Code Page
1. 4. 2004 A75 -- A95 224A 3
3. Check the marks. The groove and the mark must be in the Note! The shaft of the injection pump is locked by a lock
same line. screw. If the shaft slips when tightening the flange nut, the
injection pump will be damaged and must be replaced!
Prevent crankshaft from rotating by locking the flywheel.
7. Fix and pretighten the nut to 15 Nm.
4. Remove the nut and washer

5. Check the condition of the o-rings between the pump and 1
the timing housing. Change the o-rings if needed. Lubri-
cate the o-rings and fit the assembling ring into the timing
housing.
Note! Use gasket sealant on the surfaces against the timing 8. Open the lock screw (1) a little and fit the plate (2), that
housing. came with the pump, under the screw. Tighten the screw
to 12,5 Nm. The shaft of the injection pump is free now.
6. Place a new seal on the pump flange. Push the injection 9. Prevent crankshaft from rotating by locking the flywheel.
pump into place (to the middle of the adjusting holes) on
the timing gear housing. Pretighten the retaining nuts of 10. Tighten the nut of the coupling flange to 92,5 Nm.
the pump (3x13 mm).
201
Model Code Page
1. 4. 2004 A75 -- A95 224A 4
ETV 894 580
Setting tool for the injection pump. Adapter 8366 62521 and
dial gauge (1/100 mm).
14. When distance of the pump piston is correct, tighten the

retaining nuts of the injection pump (3x13 mm).
11. Remove the screw (tool size 12 mm), in the middle of the
back of the pump and fit the dial gauge into position.
12. Rotate the crankshaft opposite to the running direction
until the movement of the dial gauge stops (piston of the
injection pump is in bottom dead centre). Set the dial
gauge to zero.
15. Fit the injection pump gear cover.

16. Fit the injection pipes. Check that they are in the correct
angles to the unions. Tighten the delivery pipe attaching
nuts to 25 Nm. Do not overtighten!
17. Fit the fuel pipes, throttle cable and the electric wire.
18. The fuel system bleeding starts with opening the fuel re-
turn pipe connection and pumping with the hand pump
until the injection pump housing is filled with fuel. Tighten
the connection. Open the injection pipe connections
13. Rotate the crankshaft slowly in the running direction until from the injector end (only about half a turn, not more).
the mark on the crankshaft pulley is at the point of the tim- Crank the engine for about 5 seconds, until fuel comes
ing indicator. Read the distance of the injection pump pis- out from every injection pipe. Tighten the injection pipe
ton from the dial gauge, it should be: connections and start the engine. Clean off the over flown
--- In A75 model 0,20 mm fuel.
--- In A85 and A95 models 0,25 mm
Note! If needed, a vacuum pump can be connected to the
If the dial gauge shows a different distance, turn the injec- fuel return connection. The pump sucks the fuel from the
tion pump, accordingly and check again. tank via the injection pump. Connect the return pipe when
fuel flows out from the return connection.
202
Model Code Page
1. 4. 2004 A75 -- A95 224A 5
C. Bleeding the fuel system

Note! This fuel system bleeds automatically small amounts
of air bubbles from the filter and the pump when the engine
is running. However, bleed the system always, when the
fuel filters have been replaced or fuel has run out during
driving.
1 Crank the engine (about 5 seconds), until fuel comes out

from every injection pipe.
2 Retighten connections and start the engine. Clean off the

over flown fuel.
D. Measuring fuel feed pressure

1. Pump by hand the fuel feed pump lever. If the pumping
seems to be ineffective, turn the engine a little so that the 1. Clean up the pre-filter and the fuel filter and related fuel
camshaft cam is not at the feed pump lifter. pipes from outside.
2. Start the engine to idling speed, do not race. If the engine
is not starting, loosen the connection of the bleeding pipe
from the fuel filter to the injector. Pump with the hand
pump until fuel flows out of the connection. Tighten the
connection and clean off the over flown fuel.
3. Start the engine and make sure that there are no leaks.
2. Disconnect the pressure switch from the fuel filter and

connect the gauge instead (the thread is M14x1,5).
3. Run the engine at low idling for a while and compare the
gauge reading with the prescribed value (0,48 bar, mini-
mum 0,20 bar at max. rpm).
Note! In connection with service- or repair work (like Note! If the measured pressure is below the prescribed
change of injection pump), there might be a situation where value, this may be caused by:
bleeding the air requires special measures. In this case
open the injection pipe connections from the injector end • Clogged fuel filters.
(only about half a turn, not more). • Malfunction of the feed pump.
• Suction piping clogged or leaking air.
• Empty fuel tank or unsuitable fuel (e.g. summer fuel in
the winter).
203
Model Code Page
1. 4. 2004 A75 -- A95 224A 6
E. Removing injectors
1. Clean the injectors and the area around them. Discon- Opening pressure
nect the delivery pipes and the leak-off pipes.
Pump a few times to fill the injector. Increase the pressure
in the injector until the chattering (creaking) sound be-
9051 71300 comes audible. Read off the opening pressure of the injec-
tor. If the opening pressure deviates from the given value,
the injector should be taken apart and checked.
Adjustment is achieved by changing the shim. The thick-

ness of the shims varies from 1,00...1,90 mm and they are
available in increments of 0,05 mm. A thicker shim will raise
the opening pressure while a thinner one lowers it. A differ-
ence in shim thickness of 0,05 mm changes the opening
pressure by approx. 5,0 bar. As the opening pressure of the
injector drops slightly after adjustment, the opening pres-
sure should be set to approximately 10 bar above the value
given in the specifications. This value applies both to new
and used injector.
Chattering sound properties

2. Remove the injector attaching nuts and remove the injec- Testing with a hand powered pump does not create the
tor from the cylinder head. Fit protective plugs to all con- same circumstances as when the injector is fitted in the
nections. If the injector does not withdraw by hand, use engine. Only with new nozzles are the test results reliable.
puller 9051 71300. With used nozzles, there is no chattering (creaking) sound
3. Remove the sealing washers from the bottom of the injec- when the tester is pumped at a certain rate. This has to do
tor location in the cylinder head if they do no come out with the design of the nozzles.
with the injector.
However, with a rapid pumping on the tester handle, it
should be possible to hear the chattering (creaking) sound
F. Inspecting injectors or/and see a mist of the fuel jetting out.
Note! When pressure testing the injectors, it is important to

avoid the nozzle end as the fuel jetting out easily penetrates Tightness of nozzle
the skin. Also bear in mind that the fuel ”mist” is dangerous
to inhale. Press down the tester pump lever until the pressure rises to
approx. 20 bar below the adjusting value. Maintain this
1. Clean the injector with cleaning fluid and a soft brush.The pressure for approximately 10 seconds and check whether
carbon deposits must not be knocked off or removed in drops of fuel are formed on the point of the nozzle. If the
any other way which may damage the nozzle. injector leaks, it should be cleaned or the nozzle should be
changed.
G. Reconditioning injectors
1. Secure the injector in a suitable way.
2. Unscrew the nozzle cap nut. Remove the nozzle and the
parts inside the holder.
4. Clean the nozzle holes with a suitable needle.
2. Secure the injector in a test bench and check the follow-

ing:
• injector opening pressure
• the properties of the chattering (creaking) sound and
the form of the spray pattern
• sealing of nozzle valve against its seat.
204
Model Code Page
1. 4. 2004 A75 -- A95 224A 7
H. Fitting injector in engine

5. Test the movement of the nozzle valve as follows:
9101 66000
Rinse the parts thoroughly in fuel or testing fluid. Pull the

valve out of the nozzle body to 1/3rd of its length. If the fit is 1. Clean the injector sealing surface in the cylinder head. If
correct, the valve should be able to slide down in the nozzle necessary use a reamer 9101 66000.
body under its own weight. Turn the valve slightly and re-
peat the test. Should the nozzle valve bind slightly, it should
be changed.
1. Washer
1 2. Rubber ring
3. Sealing washer
9 2
Injector
1. Fuel inlet
2. Leak off pipe connection 1
3. Adjusting shim
4. Pressure spring
5. Pressure pin 2
6. Nozzle body
7. Pressure chamber
8. Injector needle 3
9. Number code
4
5
3
6
7
2. Fit the injector in the cylinder head using a new sealing
washer.
8
Note! The spray pattern from the injector is not symmetrical
on purpose. It is therefore important that the injector is fitted
correctly in the cylinder head. The connection for the leak-
6. Before assembling, all parts should be carefully cleaned
off line should be facing the valve mechanism.
in clean fuel or testing fluid.
7. Put the same thickness of shim back as were fitted earlier. 3. Fit the attaching clamp and tighten the nuts evenly to 15
Note possible adjustment of the opening pressure. As- Nm.
semble the rest of the injector. Note the position of the 4. Connect the leak-off line together with new sealing
spring guide and the valve stop spacer. washers and connect the delivery pipes.
8. Tighten the nozzle cap nut by hand and then to 60 Nm.
Note! The screw studs in the cylinder head for the injectors
should only be finger tight. If tools have to be used the
studs should be tightened only lightly.
Note! Make sure, that the injector is of a correct type.

Wrong injectors cause malfunctions and can damage the
engine.
205
Model Code Page
1. 4. 2004 A75 -- A95 224A 8
I. Fitting delivery pipes

1. Check the state of the pipes. If there are kinks, damage
by chafing, or if the tapered sealing end is damaged, the
pipes should be changed.
2. Fit the pipes without tension and check that they are at
right angles to the union. Tighten the delivery pipe attach-
ing nuts to 25 Nm. Do not overtighten!
206
Model Code Page
10. 1. 1992
23A. Cooling system (20---series) 255-- 865 230A 1
1. 9. 1992
Contents
General (Op no 230):

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cooling system, description and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Repair instructions (Op no 231):
A. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reconditioning coolant pump (320---, and 420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Quality requirements of engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
207
Model Code Page
1. 5. 1996
1. 1. 1998
Specifications
Coolant pump (320, 420 engines)
Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,087...38,100 mm

Inside diameter of bearing housing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,058...38,083 mm
Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,910...15,920 mm
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,881...15,899 mm
Diameter of the seal recess in the pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,450...36,489 mm
The impeller is pressed onto the shaft until the distance between the rear face of impeller
and the rear face of the pump body is . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8---2,2 mm
Distance of belt pulley from rear face of body:
--- 320D/DS; ---E7535, 420D/DS; ---E7054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178,3...178,7 mm
--- 320D/DS; E7536---, 420D/DS; E7055--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174,4---174,6
Fan guide diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,00...25,20 mm
Balancing precision of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 Ncm max
Max. permissible eccentricity of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0,3 mm
Belt deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15...20 mm
Fan diameter
255---565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 430 mm, 6 fan blades

665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 460 mm, 6 fan blades
600---700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 432 mm, 6 fan blades
800---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 483 mm, 8 fan blades
600---900 tractors have new and more effective cooling radiators (600---700: four ---line radiator. 800---900: five ---line radiator). The
larger radiator and fan are also fitted on 600---700 tractors, if they are equipped with an air conditioning.
Thermostat
Spare part number Type Opening Fully Max stroke
begins at open at mm
8361 15646 ø67/79˚C 79˚±2˚C 94˚C 8
8361 15718 ø67/83˚C 83˚±2˚C 97˚C 8
208
Model Code Page
23A. Coolant pump (20---series) 255-- 865 230A 3
1. 9. 1992
Special tools
9022 03500 *) Puller for coolant pump impeller (earlier no 8360 85499)
9051 40200 *) Drift for fitting coolant pump seal (seal no 8353 31202)
9051 64900 *) Drift for fitting coolant pump shaft, 320--- and 420---engines
9052 48900 *) Puller for fan hub (see Fuel system)
*) Same tool as for engines on 305---405 tractors.
905140200 905179300
9022 03500
905164900 9052 48900
209
Model Code Page
1. 9. 1992
1. 5. 1996
Cooling system, 4---cylinder engine
1. Coolant pump
2. Thermostat
3. By ---pass passage
4. Radiator
Caution! Open the radiator cap carefully, if the coolant is hot
as there will be overpressure in the system. Carefully turn the
Description radiator cap to the first stop. This will allow the overpressure
to be released from system.
The belt driven, centrifugal type coolant pump is attached at
the front end of the cylinder block and the thermostat housing N.B! The coolant pump is provided with a drainage hole on
is fitted above the pump. The system has an internal coolant its underside. This hole must not be blocked. If coolant drips
circulation via the by ---pass passage and the circulation is out of the hole, the pump seal is faulty. There may be slight
controlled by a two---way thermostat. With this is achieved a leakage on a new engine before the pump has been run in.
even warming in all conditions.
The pump shaft and the bearings are built together to form Freezing point of coolant
one unit (320--- and 420 engines).
Check the freezing point of the coolant at the beginning of the
The thermostat opens at 79˚C. During a cold season, a ther- cold season. If the freezing point is too low, drain off some of
mostat with the opening temperature of 83˚C can be use. the coolant and top up with anti ---freeze. Run the engine for
a while until the anti ---freeze has been mixed in, then re ---
Maintenance check the freezing point of the coolant. Drain the cooling sys-
tem completely every second year and refill with new coolant.
Never use just water as a coolant.
Check the coolant level daily.
The level of the coolant should be slightly above the radiator
core. Check the condition of the fan belt since it drives the Clean regularly the radiator externally from insects and other
coolant pump. Stop the engine immediately if the coolant impurities.
temperature rises too much.
210
Model Code Page
15. 4. 1999
Temperature sensor, engine coolant temperature
The sensor is placed on the engine beside the thermostat housing:
Temperature gauge pin

Warning light
Resistance value, temperature

gauge side:
60˚C=134± 13,5 Ω
90˚C=51,2± 4,3 Ω
19 mm 100˚C=38,5± 3,0 Ω
40
M14x1,5
11
40
Order no Alarm temperature

6542 71208 98 ± 3˚C (used on Valtra ---tractors)
8366 40772 106 ± 3˚C (used on Valtra ---tractors)
211
212
Model Code Page
23A. Coolant system (20---series) 255-- 865 231A 1
1. 9. 1992
Repair instructions (Op no 231)

B. Reconditioning coolant pump
A. Thermostat 1. Drain the engine coolant. Disconnect the water hoses from
the thermostat housing and from the coolant pump. Remove
the thermostat housing and the by ---pass hose.
2. Slacken the alternator fixing bolts. Remove the fan and the
pump belt pulley. Remove the v ---belt.
3. Detach the coolant pump. Remove the pump rear plate and
clean the sealing surfaces.
9052 48900
4. Remove the fan hub using puller 9052 48900. Remove the
circlip from the pump body.
9022 03500
The thermostat is of a two---way type. Its opening temperature
is 79˚C. In winter a thermostat can be used with an opening
temperature of 83˚C.
Check the function of the thermostat as follows:
--- lower the thermostat into a vessel off boiling water so that
the thermostat does not touch the sides or bottom.
--- opening must begin under 20 seconds.
--- The thermostat must be fully open under 50 seconds.
Stroke, see specifications.
5. Remove the impeller using puller 9022 03500. Press the

shaft out of the pump body in the direction of the fan. Use a
hydraulic press. Support the body so that the shaft bearing
unit has enough space for releasing.
213
Model Code Page
15. 9. 1995
1. 5. 1996
6. Tap out the shaft seal in the body using a suitable drift. 178,5 mm
Clean all parts and inspect their condition. Replace damaged 174,5 mm
parts with new ones. 320 DS: E7536---
420 D/DS: E7055---
N.B. If the pump shaft has to be changed, use a recondition-
ing kit. This kit also contains all seals (see Parts Catalogue).
7. Press the shaft into its location in the body using special tool
1,8---2,2 mm
9051 64900 and fit the circlip.
320
420
9051 79300
905140200
D. Quality requirements of coolant
The coolant used must meet the standards ASTM

D3306---86a or BS 6580:1985.
--- Mixing proportion should be 40---60 % of ethyls---glycol

based coolant and the rest water. The best ratio is 50/50 %.
8353 39425 --- In warm climates the 30 % mixture ratio gives enough good
8353 31202 protection against corrosion.
--- Water used should be clean and soft water i.e. that it does
not include metals and their salts.
8. Fit the shaft seal. Use as a ”lubricating liquid” coolant
between the shaft and the seal. Two different seal types are --- Check the coolant frost resistance every now and then.
used. Both these seals are fitted with their own drift (see figure Change the coolant every other year. Never use just water as
above). a coolant.
9. Press the impeller and the hub to the correct depth (see fig-
ure) and support the shaft at the other end. Ensure that the
shaft can rotate freely. Fit the rear plate using a new gasket.
Note! The coolant pumps (and crankshaft belt pulleys) have

been modified from the following engine numbers incl.:
--- 320 D/DS ---engines: E7536 ---.
--- 420 D/DS ---engines: E7055 ---.
This modification must be observed, when ordering spare

parts. The distance between the belt pulley hub and the pump
body rear face has been changed, see the next picture.
214
Model Code Page
23A. Engine cooling system (20---series) 600-- 900 231 3
1. 9. 2001
E. Cooling system with expansion tank --- Drain the water pump by cranking the engine a few revs
with the drain plugs removed.
1
1
3
2
69--- 84,2
Draining the cooling system:

Filling
---Always stop the engine before draining the coolant.
DANGER: The radiator cap can not be Mix the antifreeze and water according to the manufac-
opened when the system is hot, because the turer’s instructions.
cap has not the clamp position, which should
remove the pressure before opening. --- Fill up the radiator (1) with a mixture of anti ---freeze fluid
and water completely full, close the filler cap. The expan-
--- sion tank’s cap has to be open when filling.
Open the expansion tank’s cap (1). Open the expansion --- Fill the expansion tank (2) with fluid up to the fluid level
tank cap carefully, if the coolant is hot as there will sign (3).
be over pressure in the system. Carefully turn the NOTE! If the finger shield is removed make sure you
expansion tank cap to the first stop. This will allow re ---fit it.
the overpressure to be released from system. After
this press the cap down and unscrew it. Coolant volume:
--- Loosen the lower water pipe (2) (remove the finger shield
if necessary). The best way to drain the system is to --- 600 ........................................ 13,5 l
loosen the upper end of the pipe and then a little loosen --- 700 ........................................ 13,5 l
the lower end, then the pipe can be bent to the side and --- 800 ........................................ 15,5 l
the fluid drained into a vessel. The radiator has a draining --- 900 ........................................ 15,5 l
plug GR0202 Ensure that a recommended coolant is always used.
WARNING: Never fill up with cold fluid while the engine
is warm. Do not use plain water as coolant.
After changing the fluid run the engine for a time and check
the level of fluid.
69--- 84,3
--- Open the plug (3) (or tap) on the cylinder block
--- Turn on the heater control in cab. Drained the fluid into a
vessel.
215
Model Code Page
1. 9. 2001
F. Modification of coolant pump

There is a new type coolant pump in engines of 600---900 tractors (serial nos below):
--- 10179...10187
--- 10191...10193
--- 12660...12671
--- 16187, 16726, 16747, 16751
--- from ser. no. 17505 incl.
In the modified pump the impeller diameter has been changed from 87 mm to 97 mm and the pump shaft is supported with sepa-
rate ball bearings. The pump is fastened with four fixing bolts onto the rear plate, which is a new part. Output and pressure values
of this new pump are greater, and also the cooling effect.
(left hand threads)
As a spare part the earlier coolant pump can be replaced with

the modified one, when the modified parts are observed:
New part number Earlier part number Description

8367 64215 8367 55471 Coolant pump
8367 64046 8361 20128 Gasket (pump --- rear plate)*)
8367 64045 8361 20109 Rear plate*)
5798 04602 5288 01062 Bolt (fastening of rear plate)*)
5818 04602 --- --- --- --- Bolt (fastening of rear plate)
5298 01420 --- --- --- --- Bolt (fastening of pump, 2 pcs)
5817 05425 --- --- --- --- Bolt (fastening of belt pulley)
8367 64239 --- --- --- --- Guide sleeve (fastening of belt pulley)
8367 64241 8366 59745 Belt pulley ∅191 Valtra Valmet 600
8367 64242 8366 55469 Belt pulley ∅166 Valtra Valmet 700
8367 64243 8366 55468 Belt pulley ∅145 Valtra V. 800 / 900
*) These parts incl. in the earlier pump assy. The gasket between the pump rear plate and the cylinder block has not been changed.
The connection ports for the expansion tank and the boost air and the oil cooler have been observed. The threaded holes are
plugged, when the pump is fitted on engines without this equipment:
Part nos of the plugs:

Plug 6403 25018, M18x1,5+sealing ring 6158 81822, 18x22.
Plug 6400 45022, M22x1,5+sealing ring 6158 82227, 22x27
216
Model Code Page
1. 9. 2001
25 Nm (M8, 8.8)
Loctite 572
Reconditioning the coolant pump:

Note! If the pump ball bearings must be changed, it is best
Disassembling the pump: to fit the pump repair kit, which also includes all seals (see
Spare part Catalogue).
1. Drain the engine coolant. Disconnect the water hoses
from the thermostat housing and from the pump. Remove Assembling the pump:
the thermostat housing and disconnect the side ---circulation
pipe. Remove the fan and the v ---belt. 7. Fit a new shaft seal with the aid of a suitable drift. Place
the bearings together with the intermediate bushing onto
2. Remove the coolant pump and clean the sealing surfa- the shaft. Grease the bearings with heat---resistant ball bea-
ces. ring grease. Fit the shaft and bearings into place so that the
pressing force does not affect the bearing balls. Refit the
3. Unscrew the belt pulley bolts (left---hand threads!). Re- snap ring.
move the guide sleeve and the pulley. When necessary, use
puller 9052 48900. 8. Refit the axial seal, see paragraph 8 in instr. B.
4. Remove the impeller on the shaft using puller 9104 9. Press the impeller into place while supporting the shaft
27700. other end. The impeller fitting depth: distance between the
pump body and the even recess in the impeller should be
5. Remove the snap ring in the pump body. Press the shaft 9,0 ---9,3 mm (see picture on previous page). Ensure, that
together with the ball bearings out of the pump body to the the shaft rotates freely.
fan side (use e.g. a hydraulic press). Support the pump
body so that the bearings can freely move out. 10. Refit the belt pulley and the guide sleeve and tighten
the fixing bolt to a torque of 140 Nm.
6. Tap out the axial seal and the shaft seal by using a suita-
ble drift. Clean the parts and check the condition. Change 11. Refit the assembled pump, connect all detached parts
worn parts. and fill the engine with coolant. Test---run the engine and
check for leaks.
217
218
31. Tractor’s elec---
30. Electrical system trical system
32. AC power lift

ACB power lift
33. Agrodata
AD---instrument
34. Infoline and Agroli-

ne---instrument
219
220
30. Electrical system 205 -- 900 310 1
1. 9. 2001
31. Electrical equipment for engine
Alternator, Magneti Marelli (Lucas) A 115 (up to engine number 65224)

(Order number 8353 31379)
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Max. current, 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A
Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (---) negative
Max. speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15000 rpm
Brush length, new brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm
Brush spring pressure, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3---2,7 N
Stator, no. of poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Stator, no. of phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,092 ohm±5%
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 ohm±5%
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,6---14,4 V
Nut for belt pulley, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Alternator Magneti Marelli (Lucas) A 127/45 (from engine no. 65225)

(part no 8353 39303)
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Max. current, 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A
Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (---) negative
Max. speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15000 rpm
Brush length, new brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Brush spring pressure, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3---2.7 N
Stator, no. of poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Stator, no. of phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ohm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 ohm
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6---14.4 V
Belt pulley securing nut, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Note! Alternator on earlier 600---900 tractors is Magneti Marelli 127/65. Latest 600---900 tractors have alternator Iskra AAK 1333
14 V 65 A as follows: 600 (J7159---), 700 (J6774---), 800 (J8027---), 900 (J6781---)
Starter motor, Magneti Marelli (Lucas) M 127/2,8 12 V

(Order number 8353 31592)
Test values, unloaded:
--- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5500---8000 rpm max.
--- current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 A
--- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
Test values, loaded:
--- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm
--- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,8 Nm
--- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V
Locked rotor:
--- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 rpm
--- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,4 Nm
--- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5V
Brush spring pressure, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,6---15,5 N

Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 mm
Commutator, min. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 mm
Important! Starter motor on 865 and on earlier 800 and 900 tractors is ISKRA 12V 3,6 kW (Stanadyne rotary injection pump).
Starter motor on later 205---665 tractors and on 600 and 700 tractors with Bosch ---in ---line pump: 3---cyl. engines F4506--- and
4---cyl. engines F3792---; ISKRA 12 V 3,1 kW.
Latest 600---900 tractots have starter motor Iskra AZJ 3319 12 V 3 kW as follows: 600 (J7159---), 700 (J6774---), 800 (J8027---),
900 (J6781---).
221
Model Code Page
15. 9. 1995
30. Electrical system 205-- 900 310 2
1. 1. 1998
Battery
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Ah
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (---) negative
Bulbs:
--- headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60/55 W H4
--- working lights (2 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 W H3
--- parking lights, brake lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 W, 5/21 W
--- direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 W
--- cabin lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5W
--- dashboard lights, warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 W --- 1,2 W
A. Fuses on 05---models and on 55---models up to cab no. 75192

The fuse box is located under the instrument panel. It is divided into two parts, in one of which there are eight fuses (A ---box) and
in the other four fuses (B---box). The fuse rating is as follows: 5 A (3 off), 8 A (9 off) and 16 A (2 off).
In the component list the fuses are numbered from right to left.
16 A
16 A
8A
8A
8A
8A
8A
8A
8A
8A
8A
5A
4 3 2 1 8 7 6 5 4 3 2 1
B A
3055--- 121
Fusebox A: Fusebox B:
FA1: Gauges, PTO and oil pressure control lamps (5 A) FB1: Dipped beams (8 A)
FA2: Radio, roof fan, cabin light, cigarette lighter, wiper return (8 A) FB2: Main beams, indicator lamp (8 A)
FA3: Heater unit, windscreen wiper and washer pump (8 A) FB3: Horn, trailer socket, rotating warning light (8 A)
FA4: Brake lights, headlight switch illumination light (8 A) FB4: Thermostart unit (16 A)
FA5: Direction indicator flashers (8 A)
FA6: Left parking lights, instrument light, working light switch (8 A) FC1: Radio, speedometer (5 A) (only on tractors which
FA7: Right parking light (8 A) have a main current switch). This fuse is placed in the
FA8: Working lights (8 A) (603606---, 16 A) engine compartment
F1E: Autocontrol power lift (5 A). This fuse is situated under

the Autocontrol switch panel.
222
Model Code Page
1. 3. 1997
30. Electric system 255 -- 900 310 2A
1. 1. 1998
B. Fuses on 65---models up to ser. no. 670319 and on 55---models from cab number 75193
incl.
Fusebox A Fusebox B
FA1 Gauges, pilot lights, Autocontrol (5A) FB1 Dipped beams (16A)
FA2 Cab light, Cigarette lighter, Agrodata (8A) FB2 Main beams, ---pilot light (16A)
FA3 Fan, wiper+washer, rear window wiper+washer (8A) FB3 Horn, trailer socket, front working lights, hazard
FA4 Brake lights, headlight switch illumination light (8A) warning flashers, Autocontrol (16A)
FA5 Direction indicator flashers, rear buzzer (8A) FB4 Thermostart (16 A)
FA6 LH parking light, instr. light, working light switch (8A)
(FC1) Radio, speedometer (5 A) (in engine
FA7 Right parking light (8A) compartment)
FA8 Rear working lights, rot. warning light, radio (16A) F1E. Autocontrol power lift (5 A). This fuse is situated
under the Autocontrol switch panel.
C. Fuses on 65---models from ser. no. 670320 incl.

5A
5A
5A
5A
5A
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
A B
A3565--- 131,1
Fusebox A
FA1 Illumination of gauges, pilot lights, Fusebox C
Autocontrol, AD ---instrument (5 A)
FA2 Rotating varning light, radio (10 A)
FC1 Brake lights, cigarette lighter, cabin light (10A)
FA3 Fan, wiper+washer,
rear wiper and washer, Agrodata, FC2 Rear working lights (15A)
clock/speedometer (15 A) FC3 Thermostart (15A)
FA4 Front PTO, headlight switch illumination light (5 A) FC4 Left parking light, instrument light, working light
FA5 Direction ind. flashers, reverse buzzer, pneumatic seat switch illumination light (5A)
(15 A) FC5 Right parking light (5 A)
(F1C) Radio, AD ---instrument (5A). In the rear part of

Fusebox B engine compartment.
FB1 Headlights, pilot light (15 A) (F2C) Air conditioning, roof fan (20 A). Under dashboard.
FB2 Parking light (10 A)
FB3 Horn, trailer socket, front working lights,
hazard warning flashers (15 A) Note! Fuses on 600---900 tractors, see page 310/19.
(FB4) Autocontrol (5 A)
FB5 Starter switch, control stop (15 A)
223
Model Code Page
1. 3. 1997
30. Tractor electrical system 865 310 2B
1. 1. 1998
Position of electric components on 865 tractor
224
Model Code Page
1. 1. 1998
30. Tractor electrical system 600, 700 310 2C
15. 4. 1999 800, 900
Positions of electrical equipment on 600---900 tractors
225
Model Code Page
30. Electrical system 600, 700
1. 9. 2001 800, 900 310 2D
600---900, position of electrical components (with Infoline (L26206---) or Agroline

(L22101) ---instrument).
226
Model Code Page
15. 9. 1995
30. Tractor electrical system 205 -- 665 310 3
1. 3. 1997
Position of electrical components on 205---665 tractors
227
Model Code Page
1. 12. 1986
30. Electric system 305, 405 310 4
1. 9. 1992
Wiring diagram 305/405
Note! This diagram concerns tractors 305---405 up to serial

number 603605.
Code C5 H10 Control lamp, rotating warning beacon

C6 A2 Radio (extra equipment) A2 H11 Control lamp, main beam headlights
A6 H12 Control lamp, fan
C2 B1 Sender unit (engine temperature) A6 H13 Control lamp, windscreen washer
C2 B2 Sender unit (fuel gauge) A7 H14 Control lamp, reserve (rear window wiper)
B2 H15 Control lamp, differential lock
C3 E1 Headlight, right
C3 E2 Headlight, left
B1 K1 Auxiliary relay, main switch
C4 E3 Front direction indicator, right
A4 K2 Direction indicator relay
C4 E4 front direction indicator, left
C4 E5 Rear light, right C5 K3 Relay, front working lights (optional)
C3 E6 Rear ight, left C4 K4 Relay, rear working lights
C6 E7 Cab light A3 K5 Headlight dipper switch relay
C1 E8 Thermostart
C4 E9 Rear working light, right B1 M1 Starter motor
C4 E10 rear working light, left C6 M2 Fan motor
C5 E11 Front working light, right (extra equipment) B6 M3 Windscreen wiper motor
C5 E12 front working light, left (extra equipment)
B6 M4 Windscreen washer pump
C3 E13 Light, combination instrument
C3 E14 Light, revolution counter
C7 E15 Cigarette lighter (extra equipment) B2 P1 Engine temp gauge
B2 P2 Fuel gauge
A2 FA1 Instrument light, warning lamps (engine oil pres--- B2 P3 Revolution counter
sure and PTO (5 A) B2 P4 Hour recorder
A6 FA2 Cab light, cigarette lighter, radio, windscreen
wiper return (8 A) B6 R1 Series resistor, fan motor (1,2 ohm.)
A6 FA3 Fan motor, wiper motor and washer pump (8 A)
A3 FA4 Brake lights, warning lamp (headlamps (8 A)
A1 S1 Ignition switch
A5 FA5 Direction indicators (8 A)
A6 S4 Switch, windscreen wiper and washer
B4 FA6 Parking light (left), instrument light, control lamp
(working lights (8 A) A6 S5 Switch, heater fan
B4 FA7 Parking light, right (8 A) A2 S7 Switch, headlights
B5 FA8 Working lights, front and rear (8 A) B4 S8 Switch, rear working lights
B3 FB1 Dipped beams (8 A) B5 S9 Switch, front working lights (optional)
B3 FB2 Full beams (8 A) A4 S10 Combination control
A3 FB3 Horn, trailer socket and rotating warning beacon B1 S12 Starter motor safety switch
(8 A) A3 S13 Brake light switch
B1 FB4 Thermostart (16 A)
C2 S14 Switch, control lamp PTO
C2 S15 Switch, engine oil pressure
C1 G1 Battery
B1 G2 Alternator C2 S17 Switch, control lamp differential lock
A3 S18 Switch, parking brake
B2 H1 Warning lamp, engine oil pressure
B2 H2 Warning lamp, charging X1 Connector, 9---pin (front cab wall, left)
A4 H3 Control lamp, direction indicators X2 Connector, 9---pin (front cab wall, right)
C3 H4 Control lamp, full beams X3 Connector, 1---pin (front working lights)
B2 H5 Control lamp, PTO X4 Trailer socket, 7---pin
B4 H6 Control lamp, rear working lights
X5 Connector, 9---pin (mudguard, right)
B5 H7 Control lamp front working lights (extra equip ---
X6 Connector, 9---pin (mudguard, left)
ment)
A3 H8 Horn X8 Connector, 9---pin (hazard warning lights)
C5 H9 Rotating warning beacon (extra equipment) X9 Conector, 1---pin, reserve (rear window wiper)
1 Earth lead (battery)

2 Earth lead (starter motor)
3 Earth lead (instrument panel)
4 Earth lead (rear, right)
5. Earth lead (front working lights)
228
Model Code Page
1. 7. 1989
1. 9. 1995
Wiring diagram B
(with effect from tractor serial number 603606) 23 (H 7) Indicator lamp, front working lights
16 H8 Horn
NOTE: With effect from ser. no. 609977 the hazard warning 26 (H 9) Rotating warning beacon
flasher switch S16 is fitted as standard on Valmet 205---555 25 (H10) Indicator lamp, rotating warning beacon
tractors. 6 H11 Switch light, headlights
31 H12 Switch light, heater fan
Ref. Sym--- Component 33 H13 Switch light, windscreen washer
no. bol 37 (H14) Switch light, reserve
30 (A2) Radio 7 H15 Indicator lamp, differential lock
9 B1 Sender unit (engine temperature) 4 K1 Auxiliary relay, starter (main switch)

9 B2 Sender unit (fuel gauge) 18 K2 Direction indicator relay
24 (K3) Relay, front working lights
12 E1 Headlight, right 22 K4 Relay, rear working lights
13 E2 Headlight, left 12---14 K5 Headlight dipper switch relay
18 E3 Front direction indicator, left
17 E4 Front direction indicator, right 2 M1 Starter motor
19 E5 Rear light, right 32 M2 Heater fan motor
16 E6 Rear light, left 35 M3 Windscreen wiper
36 E7 Cab light 34 M4 Windscreen washer
5 E8 Thermostart
21 E9 Rear working light, right 9 P1 Temperature gauge (engine)
20 E10 Rear working light, left 9 P2 Fuel gauge
23 (E11) Front working light, right 10 P3 Revolution counter
23 (E12) Front working light, left 11 P4 Hour recorder
14 E13 Light, combination instrument
15 E14 Light, revolution counter 32 R1 Series resistor, fan motor (1.2 ohm)
37 (E15) Cigarette lighter
14 E16 Number plate light, (equipment for Norway). 2 S 1 Ignition switch
33---35 S 4 Switch, windscreen wiper and washer
FA, FB Fusebox 30---32 S 5 Switch, heater fan motor
9 FA1 Instrument light, warning lamps (PTO and en 6---9 S 7 Switch, headlights
gine oil pressure) (5 A) 20---22 S 8 Switch, rear working lights
36 FA2 Cab ventilator, cab light, radio, cigarette lighter, 22---24 (S 9) Switch, front working lights
windscreen wiper return (8 A) 19---22 S10 Switch, combination control
32 FA3 Heater fan, wiper motor and washer pump (8 A) 4 S12 Contact, starter motor safety circuit
15 FA4 Brake lights, headlight switch illuminating lamp 15 S13 Brake light contact
(8 A) 8 S14 PTO warning light contact
FA5 Direction indicator flashers (8 A) 6 S15 Indicator light switch, engine oil pressure
FA6 Left parking lights, instrument light, working 26---29 S16 Switch, hazard warning flashers
light switch illuminating lamp (8 A) 7 S17 Indicator light switch, differential lock
FA7 Right parking lights (8 A) 15 S18 Hand brake contact
FA8 Working lights (16 A)
13 FB1 Dipped beams (8 A) X1 Connector, 9---pin (front cab wall, left)
12 FB2 Main beams, indicator lamp (8 A) X2 Connector, 9---pin (front cab wall, right)
16 FB3 Horn, trailer socket, rotating warning beacon X3 Connector, 1---pin (front working lights)
(8A) 19---20 X4 Trailer socket, 7 pin
5 FB4 Thermostart unit (16 A) X5 Connector, 9---pin (mudguard, right)
X6 Connector, 9---pin (mudguard, left)
1 G1 Battery X8 Connector, 9---pin (hazard warning flashers)
2 G2 Generator X9 Connector, 1---pin (reserve)
6 H1 Warning lamp, engine oil pressure /1 Earth lead, battery

6 H2 Control lamp, charging /2 Earth lead, starter motor
17 H3 Indicator lamp, direction indicators /3 Earth lead, instrument panel
12 H4 Indicator lamp, main beam headlights /4 Earth lead, rear right
8 H5 Warning lamp, PTO ---clutch lever (/5) Earth lead, front working lights
20 H6 Indicator lamp, rear working lights /6 Earth lead, cab ventilator
Optional or alternative equipment shown in brackets.
229
Model Code Page
15. 4. 1994
15. 9. 1995
Wiring diagram C
Sym--- Code
Note! This diagram concerns tractors 365, 565 and 665 up bol Component no
to ser. no. 670319 and 55 ---models from cab no. 75192 incl.
Diagram no. 31005010D. K1 Auxiliary relay, starter (ignition switch) 3
K2 Direction indicator relay 39
Sym--- Code (K3) Relay, front working lights 26
bol Component no K4 Relay, rear working lights 25
K5 Headlight dipper switch relay 29
(A2) Radio 23
(A4) Speedometer/clock M1 Starter motor 2
(A6) Agrodata 19 M2 Heater fan 13
M3 Windscreen wiper 16
B1 Engine temperature sender unit 9 M4 Windscreen washer pump 15
B2 Fuel gauge sender unit 10 (M6) Rear window wiper 21
(B8) Wheel sensor (Agrodata) (M7) Rear window washer 20
E1 Headlight, right 30 P1 Engine temperature gauge 9

E2 Haedlight, left 29 P2 Fuel gauge 10
E3 Front direction indicator, right 37 P3 Rev counter 11
E4 Front direction indicator, left 35 P4 Hour recorder 12
E5 Rear light, right 36
E6 Rear light, left 34 (Q2) Main circuit breaker 1
E7 Cabin light 17
E9 Rear working light, right 24 R1 Resistance, heating fan (1,2 ohm) 13
E10 Rear working light, left 24
(E11) Front working light, right 26 S1 Ignition switch 5
(E12) Front working light, left 25 (S3) Switch, rear window wiper and washer 20
(E15) Cigarette lighter 18 S4 Switch, windscreen wiper and washer 16
(E16) Number plate light 33 S5 Switch, heater fan 14
(E17) Raised headlights, right 28 (S6) Switch, rotating warning light 22
(E18) Raised headlight, left 27 S7 Switch, headlights 29
S8 Switch, rear working lights 25
FA, FB Fuses (S9) Switch, front working lights 27
FA1 5A Instruments, ind.lights, Autocontrol 10 S10 Switch, combination control 33
FA2 8A Cab light, cig. lighter, Agrodata 18 (S11) Toggle switch, raised headlights 29
FA3 8A Fan, wiper+washer, rear wiper+washer 13 S12 Contact, starter interlock 3
FA4 8A Brake lights, light switch illum. light 34 S13 Brake light contact 35
FA5 8A Direction indicators, reverse buzzer 38 S14 PTO warning light contact 8
FA6 8A Left parking light, instr. light, illumin. light in S15 Indicator light switch, engine oil press. 6
working light switch 35 S16 Switch, hazard warning flashers 37
FA7 8A Parking light, right 36 S17 Indicator light switch, diff. lock 7
FA8 16A Rear work. lights, rot. warning light, radio, 24 S18 Hand brake contact 35
S19 Contact, reverse light+buzzer
FB1 8A Dipped beams 29 (S49) Rocker switch, RPM ---/flow meter
FB2 8A Full beams, --- indication light 29 (S50) Rocker switch, km/h, tractor/implement
FB3 16A Horn, socket, front working lights, hazard
warning flashers, Autocontrol 40 X1 Connector, 9---pins, engine
FB4 16A Thermostart 5 X2 Connector, 9---pins, engine
(FC1)16A Radio, speedometer 2 (X3) Connector, 3---pins, front working lights/ raised head-
lights
G1 Battery 1 X4 Connector, 7---pins, trailer socket 37
G2 Alternator 4 X5 Connector, 9---pins, mudguard right
X6 Connector, 9---pins, mudquard left
H1 Warning light, engine oil pressure 6 (X7) Connector, 3---pins, front work. light relay+switch
H2 Control lamp, charging 5 (X9) Connector, 1---pins, rear wiper
H3 Indicator lamp, direction indicators 39 (X53) Connector, 7---pins, Agrodata implement socket
H4 Indicator lamp, main beam headlights 31 (X54) Connector, 9---pins, Agrodata sensors
H5 Warning lamp, PTO clutch lever 8
H6 Switch illumin. light, rear working lights 26 /1 Earth lead, battery
(H7) Switch illumin. light, front working lights 27 /2 Earth lead, cab+headlights (starter)
H8 Horn 40 /3 Earth lead, instrument panel
(H9) Rotating warning light 23 /4 Earth lead, rear right
(H10)Switch illuminating light, rot. warning light 22 /5 Earth lead, front wiper
H11 Switch illuminating light, headlights 28
H12 Switch illuminating lamp, fan 14
H13 Switch illuminating lamp, front wiper 15 Note! Autocontrol power lift, see under code 320.
(H14)Switch illuminating lamp, rear wiper 19
H15 Indicator lamp, differential lock 7 Wire color key
(H16)Switch illumin. lamp, raised headlights 28 VA = WHITE SI = BLUE
(H17)Reverse buzzer HA = GREY LI = LILAC
H18 Ind. light, first trailer 40 KE = YELLOW PU = RED
H19 Ind. light, second trailer 40
VI = GREEN RU = BROWN
MU = BLACK
230
Model Code Page
15. 4. 1994
30. Electric system 355-- 665 310 7
15. 9. 1995
Wiring diagram C
31005010 D
5565--- 1
5565--- 2
231
Model Code Page
15. 9. 1995
1. 3. 1997
Wiring diagram D Sym--- Code

This diagram concerns 65 ---models from ser. no. 670320 bol Component no
incl. Diagram no. 31005020B. (H16) Switch illum. lamp, raised headlights 28
(H17) Back buzzer
H18 Indicator light, dir.ind. trailer 1 40
Sym--- Code
bol Component no H19 Indicator light, dir.ind. trailer 2 40
A1 Current screw, cabin supply 1
(A2) Radio 23 K1 Auxiliary relay, starter (ign. switch) 3
(A4) Speedometer/clock 23 K2 Direction indicator relay 39
(A6) Agrodata 19 (K3) Relay, front working lights 26
K4 Relay, rear working lights 25
B1 Engine temperature sender unit 9 K5 Headlight dipper switch relay 29
B2 Fuel gauge sender unit 10 K6 Auxiliary relay, starter switch 6
(B8) Wheel sensor (Agrodata)
M1 Starter motor 2
E1 Headlight, right 30 M2 Heater fan 13
E2 Headlight, left 29
M4 Windscreen washer pump 15
E3 Front direction indicator, left 37
E4 Front direction indicator, right 35 (M6) Rear window wiper 21
E5 Rear light, right 36 (M7) Rear window washer 20
E6 Rear light, left 34
E7 Cab light 17 P1 Engine temperature gauge 9
E8 Thermostart--- unit 5 P2 Fuel gauge 10
E9 Rear working light, right 25 P3 Rev counter 11
E10 Rear working light, left 25 P4 Hour recorder 12
(E11) Front working light, right 26
(E12) Front working light, left 26 (Q2) Main circuit breaker 1
(E15) Cigarette lighter 18
(E16) Number plate light 33 R1 Resistance, heating fan, 1,2 ohm 13
(E17) Raised headlights, right 28
S1 Ignition switch 5
(E18) Raised headlight, left 27
(S3) Switch, rear w. wiper and washer 20
FA, FB, FC Fuses from right to left S4 Switch, windscreen wiper and washer 16
FA1 5A Instruments, ind.lights, Autocontrol 10,44 S5 Switch, heater fan 14
FA2 10A Rotating light, radio 24 (S6) Switch, rotating warning light 24
FA3 10A Fan, wiper+washer, S7 Switch, headlights 29
rear wiper+washer, Agrodata, clock / S8 Switch, rear working lights 25
speedometer 13 (S9) Switch, front working lights 27
FA4 5A Front PTO, light sw. illum. light 28 S10 Switch, combination control 33
FA5 10A Direction indicators, back buzzer 38 (S11) Toggle switch, raised headlights 29
FB1 15A Dipped beams, high beams, S12 Safety switch 3
--- indicator light 29 S13 Switch, brake lights 35
FB2 10A Parking lights 29 S14 PTO warning light contact 8
S15 Indicator light switch, engine oil press. 6
FB3 15A Horn, rear socket, front working lights
S16 Switch, hazard warning flashers 37
hazard warning flashers 40
(FB4) 5A Autocontrol 42 S17 Indicator light switch, diff. lock 7
FB5 15A Starter switch, electric stop 5 S18 Hand brake contact 35
FC1 10A Brake lights, cigarette lighter, (S19) Switch, back light +buzzer
cabin light 18 (S38) Switch, front PTO 22
FC2 15A Rear working lights 25 (S49) Rocker switch, RPM ---/flow meter
FC3 15A Thermostart 5 (S50) Rocker switch, km/h, tractor/implement
FC4 5A Parking lights L.H, meter lights,
working light switches 35
FC5 5A Parking lights R.H 36 X1 Connector, 9---pins, engine
(F1C) 5A Radio 1 X2 Connector, 9---pins, engine
X4 Connector, 7---pins, trailer socket 37
X5 Connector, 9---pins, mudguard right
G1 Battery 1
X6 Connector, 9---pins, mudquard left
G2 Alternator 4
(X7) Connector, 2---pins, air condition
H1 Warning light, engine oil pressure 6 (X9) Connector, 1---pins, rear wiper
H2 Control lamp, charging 5 (X10) Connector, 1---pin, supply, air condition
H3 Indicator lamp, direction indicators 39 (X53) Connector, 7---pins, Agrodata implement
H4 Indicator lamp, main beam headlights 31 socket
H5 Warning lamp, PTO clutch lever 8 (X54) Connector, 9---pins, Agrodata sensors
H6 Switch illumin. light, rear working lights 26
(H7) Switch illumin. light, front work. lights 27 (Y1) Solenoid, electric stop 4
H8 Horn 40 (Y9) Solenoid, front PTO 22
(H9) Rotating warning light 24
(H10) Switch illum. light, rot. warning light 24 /1 Earth lead, battery
H11 Switch illuminating light, headlights 28 /2 Earth lead, cab+headlights (starter)
/3 Earth lead, instrument panel
H12 Switch illuminating lamp, fan 14
/4 Earth lead, rear right
H13 Switch illuminating lamp, front wiper 15
(H14) Switch illuminating lamp, rear wiper 19 /5 Earth lead, front wiper
H15 Indicator lamp, differential lock 7 /6 Earth lead, front wall of cabin
232
Model Code Page
15. 9. 1995
1. 3. 1997
Wiring diagram D
31005020 B
65--- 1
65--- 2
233
30. Electric system 665-- 4 MOD 310 10
15. 4. 1996
Wiring diagram for some special equipment on Valmet 665---4 MOD
Note! Earlier electrical system with fuse box of two parts
This wiring diagram and components list are for special equipment on Valmet 665---4 MOD. Concerning other special system of
Valmet 665---4 MOD, see pages 310/1 ---9).
Sym---
bol Component
(A7) A/V Warning, loader
(H17) Back Buzzer
(S19) Switch, back buzzer+lights

(S20) Pressure switch, loader 180 bar
(S21) Pressure switch, loader 200 bar
(X8R) 12---pole, Nato socket

(X9R) 2---pole, auxiliary start socket
FA3
234
15. 4. 1996
Wiring diagram for some special equipment on Valmet 665---4 MOD

Note! Later electrical system with fuse box of three parts.
This wiring diagram and component list are for special equipment on Valmet 665---4 MOD. Concerning other electrical system
of Valmet 665---4 MOD, see pages 310/1 ---9.
A1R Current screw 2

A7 A/V Warning, loader 49 K7 Relay, horn 50
F1 80 A Main fuse 2 S19 Switch, back buzzer + lights 47

S20 Pressure switch, loader 155 bar 49
H1 Led, green, A/V Warning 49 S21 Pressure switch, loader 175 bar 49
H2 Led, yellow, A/V Warning 49
H3 Led, red, A/V Warning 49 X8R 12---pole, Nato socket 48
H17 Back Buzzer 47 X9R 2---pole, auxiliary start socket 2
H18 Buzzer, A/V Warning 49
F1C fuse not mounted in 665---4 MOD ---models.
31005020 B
665MOD--- 7
The main fuse (F1) is situated under the instrument

panel. For checking it, loosen the front shield (A) of the
instrument panel.
F1
235
Model Code Page
15. 4. 1996
Front loader overloading indicator
Function
The Green Light:

This light is illuminated at all time when the machine is being operated with a safe and stable
load (pressure in cylinders below 155 bar (earlier below180 bar)).
The Yellow Light:

When this light is illuminated the operating conditions are becoming unstable. The load
should not be raised any further. Take extreme care. The buzzer gives sound on later tractors.
The Red Light and the Alarm signal:
When the red light is illuminated and the horn is sounding, the load is in a dangerous situation.
All operations must be ceased and the load slowly lowered. Operating in these conditions is
very dangerous.
Setting specifications
Yellow light:
The yellow light is illuminated when the Hydraulic pressure exceeds 155 bar ( -- 10 bar)
(earlier 180 bar ( -- 10 bar)) in the lift cylinders. Also buzzer alarms
Red light:
The red light and the horn operated when the pressure is over 175 bar ( -- 10 bar) (earlier
200 bar ( -- 10 bar)) in the lift cylinders.
How to calibrate the front load overloading indicator lights
Place a suitable pressure gauge into the lift cylinder line. Increase the load on the loader until
the pressure rises to 155 bar (earlier 180 bar). The yellow light must be illuminated and the
buzzer must aralm when the pressure is 145---155 bar (earlier 170---180 bar) . The yellow light
will go off when the pressure drops by approx. 30 bar.
The pressure limiting screw in the end of the pressure switch can be adjusted in order to give
these readings.
The red light must be illuminating and the horn must be sounding when the pressure is
165-- 175 bar (earlier 190---200 bar).
After adjusting the pressure switches recheck the functions of the overload indicator.
236
Model Code Page
1. 1. 1998
30. Tractor electrical system 310 13
1. 6. 1998 865
Wiring diagram 865 (No 33202000) Sym--- Code

bol Component no
Note! Also 600---900: H06401 ---H06508. (H12) Warning light, Thermostart *) 5
H13 Warning light, PTO clutch 6
Sym--- Code H14 Warning light, main beams 31
bol Component no H15 Warning light, low fuel level 9
H16 Warning light, charging 4
A1 Current screw, cabin supply 1 H20 Warning light, differential lock 5
(A2) Radio 38 H23 Horn 40
(A3) Control unit, front PTO 22 (H24) Rotating warning light 24
(A5) Pneumatic seat 32 (H27) Back buzzer 58
B1 Engine temperature sender unit 8, 59
B2 Fuel gauge sender unit 9 K1 Auxiliary relay, starter (ign. switch) 2
(B3) Gearbox temperature sender unit*) 49 K2 Direction indicator relay 39
(B6) Sensor, gearbox speed*) 47 (K3) Relay, front working lights 26
K4 Relay, rear working lights 26
E1 Headlight, right 30 K5 Headlight dipper switch relay 29
E2 Headlight, left 29 K6 Auxiliary relay, starter switch 4
E3 Front direction indicator, right 36 (K7) Relay, rear fog light 52
E4 Front direction indicator, left 35 (K8) Relay, roof fan, III speed 56
E5 Rear light, right 37 (K18) Relay, control stop 60
E7 Cab light 18 M1 Starter motor 2
E8 Thermostart---unit 4 M2 Heater fan 12
E9 Rear working light, right 25 M3 Windscreen wiper 15
E10 Rear working light, left 25 M4 Windscreen washer pump 14
(E11) Front working light, right 26 (M5) Roof fan 55
(E12) Front working light, left 26 (M6) Rear window wiper 20
E13 Instrument light 8, 10 (M7) Rear window washer 19
(E15) Cigarette lighter 16
(E16) Number plate light 34 P1 Engine temperature gauge 8
(E17) Raised headlights, right 28 P2 Fuel gauge 9
(E18) Raised headlights, left 27 P3 Rev counter 10
(E19) Rear fog light 52 P4 Hour recorder/AC (.../Speed*)) 11
(E22) Roof panel light 57 (P5) Clock, AC, Dist., Gearbox temp*) 47
Fuse box (From right to left) (Q2) Main circuit breaker 1
FA1 5A Instruments, ind. light, Autocontrol *) 9, 44 R1 Resistance, heating fan, 1,2 ohm 12
FA2 10A Rotating light, radio 24
FA3 15A Fan, wiper+washer S1 Ignition switch 2, 60
rear wiper+washer, Agrodata 12 (S2) Switch, roof fan 55
FA4 5A Front PTO, light sw. illum. light 28 (S3) Switch, rear w. wiper and washer 18
FA5 15A Direction ind., back buzzer, pneum. S4 Switch, windscreen wiper and washer 15
seat 38, 58 S5 Switch heater fan 13
(S6) Switch, rotating warning light 23
FB1 15A Dipped beams, high beams, ---ind. light 29 S7 Switch, headlights 29
FB2 10A Parking lights 29 S8 Switch, rear working lights 25
FB3 15A Horn, rear socket, front working lights (S9) Switch, front working lights 27
hazard warning flashers 40 S10 Switch, combination control 32
(FB4) 5A Autocontrol 43 (S11) Toggle switch, raised headlights 29
FB5 15A Starter switch, control stop 3, 52, 60 S12 Safety switch 2
S13 Switch, brake lights 35
FC1 10A Brake lights, cig. lighter, cab light 17 S14 PTO warning light contact 6
FC2 15A Rear working lights 25 S15 Ind. light switch, engine oil pressure 7
FC3 15A Thermostart 4 S16 Switch, hazard warning flashers 36
FC4 5A Parking lights L.H, meter lights, S17 Indicator light switch, diff. lock 6
working light switches 35
FC5 5A Parking lights R.H. 36 S18 Hand brake contact 35
(F1C) 5A Radio, (Clock*)) 1 (S19) Switch, back buzzer 58
(F2C) 20A Air conditioner, roof fan 56 S20 Warning light switch, engine temp, Stop 8, 56
S21 Warning light switch, engine air filter 6
G1 Battery 1 (S22) Switch, air conditioner 54
G2 Alternator 3 (S23) Switch, compressor pressure 54
(S26) Switch, rear fog light 51
H1 Ind. lamp, direction ind. flashers III 40 (S36) Switch, control stop 61
H2 Ind. lamp, direction ind. flashers II 39 (S37) Switch, cursor+program *) 47
H3 Ind. lamp, direction ind. flashers 39
H4 Warning light, engine air filter 6 (S38) Switch, front PTO 22
H5 Warning light, engine oil pressure 7 (S42) Door switch, cab light, right 18
H6 Warning light, Stop, engine temperature 7, 59 (S43) Door switch, cab light, left 18
(H7) Warning light, gearbox oil pressure
H11 Warning light, parking brake 9
237
Model Code Page
1. 5. 1996
30. Tractor electrical system 865 310 14
1. 1. 1998
Wire colours
X1 Connector, 9---pins, engine
X2 Connector, 9---pins, engine Ru = brown
X4 Connector, 7---pins, trailer socket 37, 53 Pu = red
X5 Connector, 9---pins, mudguard right Ke = yellow
X6 Connector, 9---pins, mudguard left Si = blue
(X7) Connector, 2---pins, air condition Mu = black
(X8) Connector, current socket 53
Vi = green
(X9) Connector, 1---pins, rear wiper 17
Va = white
(X10) Connector, 1---pin, supply, air condition 56
(X15) Connector, 3---pins, air conditioner, diodes 54 Ha = grey
X20 Connector, 9---pins, front direction ind. Li = lilac
(X22) Connector, 2 pins, rotating warn. light
(X25) Connector, 9---pins, AD ---instrument
(X26) Connector, 26 pins, Instrument white
X27 Connector, 26---pins, instrument blue
(X44) Connector, 1 pin, control stop 59
(X49) Connector, 2---pins, pneumatic seat 32
(X56) Connector, 1 pin, Gearbox oil pressure 48
(Y1) Solenoid, electric stop 5, 60

(Y5) Magnetic clutch, compressor 54
(Y9) Solenoid, front PTO 22
GR1 Earth lead, battery

GR2 Earth lead, headlights (starter)
GR3 Earth lead, wiring assy, instrument panel
GR4 Earth lead, rear / right
GR5 Earth lead, roof of cab
GR6 Earth lead, cab front wall
*) AD ---instrument
Note! Autocontrol power lift, see page 320/3C.
238
Model Code Page
1. 3. 1997
1. 1. 1998
Wiring diagram 865

33202000
865
865
239
Model Code Page
1. 5. 1996
30. Tractor eletrical system 865 310 16
1. 1. 1998
865
240
Model Code Page
1. 3. 1997
Control stop
Picture. Wiring diagram of control stop (option, 865)

S1=Ignition switch
S36=Control stop switch in the dashboard Note! The Stop ---light wire must be equipped with a diode.
Y1=Fuel distributor pump stop solenoid Otherwise, when the driver uses the direction indicator lever
K18=Control stop relay (under the dashboard)
S4 or hazard warning flashers, relay K18 becomes earthed
S15=Engine oil pressure sensor
S20=Engine coolant temperature sensor via bulbs E3---E6 causing the engine stop. The diode is
H5=Warning light, engine oil pressure in ---built in the instrument.
H6=Central warning light, Stop
S10=Combination switch The engine oil pressure sensor is fitted on the RH side of
S16=Switch for hazard warning flashers the engine and the temperature sensor on the engine
K2=Direction indicator relay beside the thermostat housing.
GR3=Earth terminal in the cab front wall
Testing the function
Function
The function of the control stop can be tested while the
When switch S36 is in the OFF position (in picture), current engine is running and switch S36 in the ON position. When
can affect the solenoid Y1 when the starter switch is turned a wire of one of the sensors S15 or S20 is connected to the
to the starting position and the engine can be started tractor frame, the warning light must come on and the
(engine does not start, if the switch is in the ON position). engine must stop. Stop light flashes, when the engine tem-
perature sensor becomes earthed.
When the switch S36 is turned ON, current flows to the
solenoid Y1 via relay K18. If one of the sensors S15 or S20
becomes grounded, the relay K18 breaks the circuit and
the engine stops. Warning lights illuminate normally (also
stop ---light flashes).
241
Model Code Page
30. Tractor electrical system 600, 700
310 18
1. 1. 1998 800, 900
242
Model Code Page
1. 1. 1998
310 19
1. 6. 1998 800, 900
Wiring diagram, 600---900 (No 33202000C)

H06206-- (except H06401-- H06508)
Sym--- Code
Sym--- Code bol Component no
bol Component no
H3 Ind. lamp, direction ind. flashers 39
A1 Current screw, cabin supply 1 H4 Warning light, engine air filter 6
(A2) Radio 38 H5 Warning light, engine oil pressure 7
(A3) Control unit, front PTO 22 H6 Warning light, Stop, engine temperature 7, 59
(A5) Pneumatic seat 32 (H7) Warning light, gearbox oil pressure
B1 Engine temperature sender unit 8, 59 (H12) Warning light, Thermostart 5
B2 Fuel gauge sender unit 9 H13 Warning light, PTO clutch 6
(B3) Gearbox temperature sender unit*) 49 H14 Warning light, main beams 31
(B6) Sensor, gearbox speed*) 47 H15 Warning light, low fuel level 9
E1 Headlight, right 30 H20 Warning light, differential lock 5
E2 Headlight, left 29 H23 Horn 40
E3 Front direction indicator, right 36 (H24) Rotating warning light 24
E4 Front direction indicator, left 35 (H27) Back buzzer 58
E7 Cab light 18 K1 Auxiliary relay, starter (ign. switch) 2
E8 Thermostart---unit 4 K2 Direction indicator relay 39
E9 Rear working light, right 25 (K3) Relay, front working lights 26
E10 Rear working light, left 25 K4 Relay, rear working lights 26
(E11) Front working light, right 26 K5 Headlight dipper switch relay 29
(E12) Front working light, left 26 K6 Auxiliary relay, starter switch 6
E13 Instrument light 8, 10 (K7) Relay, rear fog light 52
(E15) Cigarette lighter 16 (K8) Relay, roof fan, III speed 56
(E16) Number plate light 34 K9 Auxiliary relay, starter switch 6
(E17) Raised headlights, right 28 (K18) Relay, control stop 60
(E18) Raised headlights, left 27 (K24) Relay, Hi ---Shift 63
(E19) Rear fog light 52
(E22) Roof panel light 57 M1 Starter motor 2
M2 Heater fan 12
Fuse box (From left to right) M3 Windscreen wiper 15
M4 Windscreen washer pump 14
FA1 5A Instruments, ind. light, Autocontrol 9, 44 (M5) Roof fan 55
FA2 10A Rotating light, radio 24 (M6) Rear window wiper 20
FA3 15A Wiper+washer, rear wiper+washer 12 (M7) Rear window washer 19
FA4 5A Front PTO, light sw. illum. light,
current socket 28 P1 Engine temperature gauge 8
FA5 15A Direction ind., back buzzer, pneum. P2 Fuel gauge 9
seat, roof fan I --- and II ---speed. 38, 58 P3 Rev counter 10
P4 Hour recorder/AC (.../Speed*)) 11
FB1 15A Dipped beams, high beams, ---ind. light 29 (P5) Clock, AC, Dist., Gearbox temp*) 47
FB2 10A Parking lights 29
FB3 15A Horn, rear socket, front working lights (Q2) Main circuit breaker 1
hazard warning flashers 40
(FB4) 5A Autocontrol 43 R1 Resistance, heating fan, 1,2 ohm 12
FB5 15A Starter switch, elecric stop,
rear fog light 3, 52, 60 S1 Ignition switch 2, 60
(S2) Switch, roof fan 55
FC1 10A Brake lights, cig. lighter, cab light 17 (S3) Switch, rear w. wiper and washer 18
FC2 15A Rear working lights 25 S4 Switch, windscreen wiper and washer 15
FC3 15A Thermostart 4 S5 Switch heater fan 13
FC4 5A Parking lights L.H, meter lights, (S6) Switch, rotating warning light 23
working light switches 35 S7 Switch, headlights 29
FC5 5A Parking lights R.H. 36 S8 Switch, rear working lights 25
(S9) Switch, front working lights 27
FD1 10A Fan 12 S10 Switch, combination control 32
FD2 20A Air conditioning, upper fan III ---speed 56 (S11) Toggle switch, raised headlights 29
FD3 10A Hi ---Shift 62---63 S12 Safety switch 2
FD4 25A Current socket 64 S13 Switch, brake lights 35
FD5 5A Radio, (Clock*)) 1 S14 PTO warning light contact 6
S15 Ind. light switch, engine oil pressure 7
G1 Battery 1 S16 Switch, hazard warning flashers 36
G2 Alternator 3 S17 Indicator light switch, diff. lock 6
H1 Ind. lamp, direction ind. flashers III 40
H2 Ind. lamp, direction ind. flashers II 39
243
Model Code Page
310 20
1. 1. 1998 800, 900
Wire colours
Sym--- Code Ru = brown
bol Component no
Pu = red
S18 Hand brake contact 35 Ke = yellow
(S19) Switch, back buzzer 58 Si = blue
S20 Warning light switch, engine temp, Stop 8, 56 Mu = black
S21 Warning light switch, engine air filter 6 Vi = green
(S22) Switch, air conditioner 54 Va = white
(S23) Switch, compressor pressure 54 Ha = grey
(S26) Switch, rear fog light 51 Li = lilac
(S36) Switch, control stop 61
(S37) Switch, cursor+program *) 47
(S38) Switch, front PTO 22
(S42) Door switch, cab light, right 18
(S43) Door switch, cab light, left 18
(S45) Switches, Hi ---Shift 62---63
(S45.1) Extra switches, Hi ---Shift 62
X1 Connector, 37---pins, engine

X2 Connector, 9---pins, head lights 29---30
X4 Connector, 7---pins, trailer socket 37, 53
X5 Connector, 9---pins, mudguard right
X6 Connector, 9---pins, mudguard left
(X7) Connector, 4---pins, air conditioner
(X8) Connector, current socket 38
(X9) Connector, 1---pins, rear wiper 17
(X15) Connector, 3---pins, air conditioner, diodes 54
X20 Connector, 9---pins, front direction ind.
(X22) Connector, 2 pins, rotating warn. light
X25 Connector, 9---pins, AD ---instrument
X26 Connector, 26 pins, Instrument white
X27 Connector, 26---pins, instrument blue
(X49) Connector, 2---pins, pneumatic seat 32
X50 Connector, 3---pin, current socket 64
(Y1) Solenoid, electric stop 5, 60

(Y14) Solenoid valve, Hi ---Shift 62
(Y15) Solenoid valve, Hi ---Shift, retardation 63
GR1 Earth lead, battery

GR2 Earth lead, headlights (starter)
GR3 Earth lead, wire loom, instrument panel
GR4 Earth lead, rear / right
GR5 Earth lead, roof of cab
GR6 Earth lead, cab front wall
*) AD ---instrument
Note! Autocontrol power lift, see page 320/3C.
244
Model Code Page
310 21
1. 1. 1998 800, 900
Wiring Diagram 600---900

33202000C 600--- 900.1
600--- 900.2
245
Model Code Page
310 22
1. 1. 1998 800, 900
600--- 900.3
600--- 900.4
246
30. Tractor eletrical system 600, 700
310 23
1. 9. 2001 800, 900
Wiring diagram 600---900 (No 33202000F), trac- Sym--- Code

bol Component no
tors with ACB power lift.
H5 Warning light, engine oil pressure 7
Sym--- Code H6 Warning light, Stop, engine temperature 7, 59
bol Component no (H7) Warning light, gearbox oil pressure
A1 Current screw, cabin supply 1 H12 Warning light, Thermostart 5
(A2) Radio 38 H13 Warning light, PTO clutch 6
(A3) Control unit, front PTO 22 H14 Warning light, main beams 31
(A5) Pneumatic seat 32 H15 Warning light, low fuel level 9
B1 Engine temperature sender unit 8, 59 H20 Warning light, differential lock 5
B2 Fuel gauge sender unit 9 H23 Horn 40
(B3) Gearbox temp sender unit* 49 (H24)Rotating warning light 24
(B6) Sensor, gearbox speed* 47 (H27)Back buzzer 58
E1 Headlight, right 30 K1 Auxiliary relay, starter (ign. switch) 2

E2 Headlight, left 29 K2 Direction indicator relay 39
E3 Front direction indicator, right 36 (K3) Relay, front working light 26
E4 Front direction indicator, left 35 K4 Relay, rear working lights 26
E5 Rear light, right 37 K5 Headlight dipper switch relay 29
E6 Rear light, left 34 K6 Auxiliary relay, starter switch 5
E7 Cab light 18 (K7) Relay, rear fog light 52
E8 Thermostart---unit 4 (K8) Relay, roof fan , III speed 56
E9 Rear working light, right 25 K9 Auxiliary relay, starter switch 6
E10 Rear working light, left 25 (K18) Relay, control stop 60
(E11) Front working light, right 26 (K24) Relay, HiShift 63
(E12) Front working light, left 26
E13 Instrument light 8, 10 M1 Starter motor 2
(E15) Cigarette lighter 16 M2 Heater fan 12
(E16) Number plate light 34 M3 Windscreen wiper 15
(E17) Raised headlights, right 28 M4 Windscreen washer pump 14
(E18) Raised headlights, left 27 (M5) Roof fan 55
(E19) Rear fog light 52 (M6) Rear window wiper 20
(E22) Roof panel light 57 (M7) Rear window washer 19
P1 Engine temperature gauge 8

Fuse box (from left to right) 0. 0. P2 Fuel gauge 9
FA1 5A Instruments, ind. light, Autocontrol 9, 44 P3 Rev counter 10
FA2 10A Rotating light, radio 24 P4 Hour recorder/AC (.../Speed*) 11
FA3 15A Wiper+washer, rear wiper+washer 12 (P5) Clock, AC, Dist., Gearbox temp* 47
FA4 5A Front PTO, light sw. illum. light, current socket 28
FA5 15A Direction ind., back buzzer, pneum. seat, 38, 58 (Q2) Main circuit breaker 1
FB1 25A Light switch 29 R1 Resistance, heating fan 1,2 ohm 12

FB2 10A Dipped beams 29
FB3 15A Main beams, pilot light 29 S1 Ignition switch 2, 60
FB4 5A Autocontrol 43 (S2) Switch, roof fan 55
FB5 20A Starter switch, eletric stop, rear fog light (S3) Switch, rear w. wiper and washer 18
control stop 3, 52, 60 S4 Switch, windscreen wiper and washer 15
S5 Switch, heater fan 13
FC1 10A Brake lights, cig. lighter, cab light 17 (S6) Switch, rotating warning light 23
FC2 15A Rear working lights 25 S7 Switch, headlights 29
FC3 15A Horn, rear socket, front working lights, S8 Switch, rear working lights 25
hazard warning flashers 40 (S9) Switch, front working lights 27
FC4 5A Parking lights LH, meter lights, working lights swit- S10 Switch, combination control 32
ches 35 (S11) Toggle switch, raised headlights 29
FC5 5A Parking lights RH 36 S12 Safety switch 2
S13 Switch, brake lights 35
FD1 20A Fan, roof fan I and II speeds, S14 PTO warning light contact 6
air conditioning 12 S15 Ind. light switch, engine oil pressure 7
FD2 20A Upper fan III speed 56 S16 Switch, hazard warning flashers 36
FD3 10A HiShift 62---63 S17 Ind. light switch, diff. lock 6
FD4 25A Current socket 64 S18 Ind. lamp, hand brake 35
FD5 5A Radio, (clock*) 1 (S19) Switch, back buzzer 58
S20 Warning light switch, engine temp, (Stop) 8, 59
G1 Battery 1 S21 Warning light switch, engine air filter 6
G2 Alternator 3 (S22) Switch, air conditioning 54
(S23) Switch, compressor pressure 54
H1 Ind. lamp, direction indicator flashers III 40 (S26) Switch, rear fog light 51
H2 Ind. lamp, direction indicator flashers II 39 (S36) Switch, control stop (option in 800 and 900) 61
H3 Ind. lamp, direction indicator flashers 39 (S37) Switch, cursor+program * 47
H4 Warning light, engine air filter 6
247
Model Code Page
15. 4. 1999
30. Tractor eletrical system 600, 700
310 24
1. 9. 2001 800, 900
Sym--- Code Wire colours

bol Component no
VA = white
(S38) Swtch, front PTO 22 HA = grey
(S42) Door switch, cab light, right 18 KE = yellow
(S43) Door switch, cab light, left 18 VI = green
(S45) Switches, HiShift 62---63 SI = blue
(S45.1)Extra switches, HiShift 62 LI = lilac
PU = red
(V5) Diodit, HiShift 62---63 RU = brown
MU = black
Connectors
X1 Connector, 37 pins, engine
X2 Connector, 9 pins, head lights 29---30
X4 Connector, 7 pins, trailer socket 37, 53
X4.1 Connector, 3 pins, rear socket 37, 53
X5 Connector, 9 pins, mudguard right
X6 Connector, 9 pins, mudguard left
(X7) Connector, 4 pins, air conditioning
(X8) Connector, 2 pins, current socket 38
(X9) Connector, 1 pin, rear wiper 17
(X15) Connector, 3 pin, air conditioning, diodes 54
X20 Connector, 9 pins, front direction ind.
(X22) Connector, 2 pins, rotating warning light
X25 Connector, 9 pins, A ---instrument
X26 Conector, 26 pins, instrument white
X27 Connector, 26 pins, instrument blue
(X49) Connector, 2 pins, pneumatic seat 32
X50 Connector, 3 pins, current socket 64
X51 Connector, 1 pin, reversing buzzer
(Y1) Solenoid,electric stop (800, 900) 5, 60

(Y14) Solenoid valve, HiShift 62
(Y15) Solenoid valve, HiShift, retardation 63
Earth points
GR1 Earth cable, Battery
GR2 Earth cable, headlights (starter)
GR3 Earth cable, wire loom, instrument panel
GR4 Earth cable, rear/right
GR5 Earth cable, roof of cab
GR6 Earth cable, cab front wall
*) AD ---instrument 47---49
AC power lift, see code 320.
ACB power lift, see code 321.
Note! Electric stop is a standard equipment on models 800

and 900. Electric stop is not available as an option. Control
stop is an option in models 800 and 900.
248
Model Code Page
15. 4. 1999
30. Tractor electric system 600, 700
310 25
1. 9. 2001 800, 900
33202000F
249
Model Code Page
310 26
15. 4. 1999 800, 900
250
Model Code Page
310 27
1. 9. 2001 800, 900
Wiring diagram 600---900 (No 33202000H) Sym--- Code

bole Component no
(incl. e.g. electric main current switch, PTO ---HiShift)
Sym--- Code H5 Warning light, engine oil pressure 7
bole Component no H6 Warning light, Stop, engine temperature 7, 59
(H7) Warning light, gearbox oil pressure
A1 Current screw, cabin supply 1 H11 Warning light, parking brake 9
(A2) Radio 38 H12 Warning light, Thermostart 5
(A3) Control unit, front PTO 22 H13 Warning light, PTO clutch 6
(A5) Pneumatic seat 32 H14 Warning light, main beams 31
H15 Warning light, low fuel level 9
B1 Engine temperature sender unit 8, 59 H16 Warning light, charging 4
B2 Fuel gauge sender unit 9 H20 Warning light, differential lock 5
(B3) Gearbox temp sender unit* 49 H23 Horn 40
(B6) Sensor, gearbox speed* 47 (H24)Rotating warning light 24
(H27)Back buzzer 58
E1 Headlight, right 30
E2 Headlight, left 29 K1 Auxiliary relay, starter (ign. switch) 2
E3 Front direction indicator, right 36 K2 Direction indicator relay 39
E4 Front direction indicator, left 35 (K3) Relay, front working light 26
E5 Rear light, right 37 K4 Relay, rear working lights 26
E6 Rear light, left 34 K5 Headlight dipper switch relay 29
E7 Cab light 18 K6 Auxiliary relay, starter switch 5
E8 Thermostart---unit 4 (K7) Relay, rear fog light 52
E9 Rear working light, right 25 (K8) Relay, roof fan , III speed 56
E10 Rear working light, left 25 K9 Auxiliary relay, starter switch 6
(E11) Front working light, right 26 (K18) Relay, control stop 60
(E12) Front working light, left 26 (K24) Relay, HiShift 63
E13 Instrument light 8, 10 (K25) Relay, starter interlock, PTO ---HiShift 65
(E15) Cigarette lighter 16 (K51) Relay, pilot light, main current switch 69
(E16) Number plate light 34
(E17) Raised headlights, right 28 M1 Starter motor 2
(E18) Raised headlights, left 27 M2 Heater fan 12
(E19) Rear fog light 52 M3 Windscreen wiper 15
(E22) Roof panel light 57 M4 Windscreen washer pump 14
(M5) Roof fan 55
(M6) Rear window wiper 20
Fuse box (from left to right) 0. 0. (M7) Rear window washer 19
FA1 5A Instruments, ind. light, Autocontrol 9, 44
FA2 10A Rotating light, radio 24 P1 Engine temperature gauge 8
FA3 15A Wiper+washer, rear wiper+washer 12 P2 Fuel gauge 9
FA4 5A Front PTO, light sw. illum. light, current socket 28 P3 Rev counter 10
FA5 15A Direction ind., back buzzer, pneum. seat, 38, 58 P4 Hour recorder/AC (.../Speed*) 11
(P5) Clock, AC, Dist., Gearbox temp* 47
FB1 25A Light switch 29
FB2 10A Dipped beams 29 (Q2) Main circuit breaker 1
FB3 15A Main beams, pilot light 29
FB4 5A Autocontrol 43 R1 Resistance, heating fan 1,2 ohm 12
FB5 20A Starter switch, eletric stop, rear fog light
control stop 3, 52, 60 S1 Ignition switch 2, 60
(S2) Switch, roof fan 55
FC1 10A Brake lights, cig. lighter, cab light 17 (S3) Switch, rear w. wiper and washer 18
FC2 15A Rear working lights 25 S4 Switch, windscreen wiper and washer 15
FC3 15A Horn, rear socket, front working lights, S5 Switch, heater fan 13
hazard warning flashers 40 (S6) Switch, rotating warning light 23
FC4 5A Parking lights LH, meter lights, working lights swit- S7 Switch, headlights 29
ches 35 S8 Switch, rear working lights 25
FC5 5A Parking lights RH 36 (S9) Switch, front working lights 27
S10 Switch, combination control 32
FD1 20A Fan, roof fan I and II speeds, (S11) Toggle switch, raised headlights 29
air conditioning 12 S12 Safety switch 2
FD2 20A Upper fan III speed 56 S13 Switch, brake lights 35
FD3 10A HiShift 62---63 S14 PTO warning light contact 6
FD4 25A Current socket 64 S15 Ind. light switch, engine oil pressure 7
FD5 5A Radio, (clock*) 1 S16 Switch, hazard warning flashers 36
In engine compartment: S17 Ind. light switch, diff. lock 6
(F51) 15 A electrically controlled main current switch 1 S18 Ind. lamp, hand brake 35
(S19) Switch, back buzzer 58
G1 Battery 1 S20 Warning light switch, engine temp, (Stop) 8, 59
G2 Alternator 3 S21 Warning light switch, engine air filter 6
(S22) Switch, air conditioning 54
H1 Ind. lamp, direction indicator flashers III 40 (S23) Switch, compressor pressure 54
H2 Ind. lamp, direction indicator flashers II 39 (S26) Switch, rear fog light 51
H3 Ind. lamp, direction indicator flashers 39 (S36) Switch, control stop 61
H4 Warning light, engine air filter 6 (S37) Switch, cursor+program * 47
251
Model Code Page
310 28
1. 9. 2001 800, 900
Sym--- Code ACB Autocontrol nostolaite

bole Component no
Sym--- Code
bole Component no
(S38) Swtch, front PTO 22
S42 Door switch, cab light, right 18
A1E ACB control unit 42-- 44
S43 Door switch, cab light, left 18
A2E Control switch circuit card 45
(S45) Switches, HiShift 62---63
(S45.1)Extra switches, HiShift 62
(S68) Switch, electric main circuit breaker 67 B1E Position sensor 41
(S69) Switch, PTO ---HiShift 66 B2E Draft sensor 41
(V5) Diodes, HiShift 62---63 E1E Illumination, switch circuit card 45

(V6) Diodes, PTO ---HiShift 65---66 E2E Illumination, position potentiometer 46
Connectors R1E Potentiometer, position control 45

X1 Connector, 37 pins, engine S1E Push button, mudguard, lifting, right 43
X2 Connector, 9 pins, head lights 29---30 S2E Push button, mudguard, lowering, right 43
X4 Connector, 7 pins, trailer socket 37, 53 S3E Push button, mudguard, lifting, left 42
S4E Push button, mudguard, lowering, left 42
S5E Switch, cabin, lifting/lowering 44
X5 Connector, 9 pins, mudguard right
X6 Connector, 9 pins, mudguard left S7E Selector, lowering speed 45
(X7) Connector, 4 pins, air conditioning S8E Selector, transport height 45
(X8) Connector, 2 pins, current socket 38 S9E Selector, position control/draft control 45
(X9) Connector, 1 pin, rear wiper 17 S10E Switch, lift/stop/lowering 45-- 46
(X15) Connector, 3 pin, air conditioning, diodes 54 S11E Switch, forced lowering 44-- 45
X20 Connector, 9 pins, front direction ind. S12E Switch, oscillation damping (DBC) 45
(X22) Connector, 2 pins, rotating warning light
X25 Connector, 9 pins, A ---instrument X2E Connector, 9 pins, supply & rear buttons 42
X26 Conector, 26 pins, instrument white
X27 Connector, 26 pins, instrument blue Y1E Solenoid valve, lowering 41
(X42) Connector, 4 pins, frontPTO supply 22 Y2E Solenoid valve, lifting 41
(X44) Connector, 1 pin, control stop 59 Wire colours
(X49) Connector, 2 pins, pneumatic seat 32
X50 Connector, 3 pins, current socket 64 VA = white
X51 Connector, 1 pin, reversing buzzer HA = grey
KE = yellow
(Y1) Solenoid,electric stop (800, 900) 5, 60 VI = green
(Y5) Magnetic clutch, compressor 54 SI = blue
(Y9) Solenoid, front PTO 22 LI = lilac
(Y14) Solenoid valve, HiShift 62 PU = red
RU = brown
(Y16) Solenoid valve, PTO ---HiShift 65
(Y17) Solenoid, PTO ---HiShift, retarding 66 MU = black
Note! Electric stop is a standard equipment on models 800

Earth points and 900. Electric stop is not available as an option. Control
GR1 Earth cable, Battery stop is an option in models 800 and 900.
GR2 Earth cable, headlights (starter)
GR3 Earth cable, wire loom, instrument panel
GR4 Earth cable, rear/right
GR5 Earth cable, roof of cab
GR6 Earth cable, cab front wall
*) AD ---instrument 47---49
252
Model Code Page
310 29
1. 9. 2001 800, 900
33202000H
69--- 1H
69--- 2H
253
Model Code Page
310 30
1. 9. 2001 800, 900
69--- 3H
69--- 4H
254
Model Code Page
310 31
1. 9. 2001 800, 900
69--- 5H
255
256
Model Code Page
310 33
1. 9. 2001 800, 900
Wiring diagram 600---900 (No 33202000K) Sym--- Code

bol Component no
(Incl. e.g. Infoline (L26206---) and Agroline (L22101---) instru-
ments) H1 Indicator light, direction indicators III 40
Optional or alternative equipment listed in brackets. H2 Indicator light, direction indicators II 39
H4 Indicator light, air filter 6
Sym--- Code H5 Indicator light, engine oil pressure 7
bol Component no H6 Warning light, Stop, engine temperature 7, 59
(H7) Indicator light, gearbox oil pressure
(A1) Current screw, cabin supply 1 H11 Indicator light, parking brake 9
(A2) Radio 38 (H12)Indicator light, Thermostart 5
(A3) Controller, front PTO 22 H13 Indicator light, PTO clutch 6
(A5) Air suspension seat 32 H14 Indicator light, high beams 31
H15 Indicator light, fuel reverse 9
B1 Sensor, engine temperature gauge 8, 59 H16 Indicator light, charging 4, 68
B2 Sensor, fuel gauge 9 H20 Indicator light, differential lock 5
(B3) Sensor, gearbox temperature* 49 H23 Horn 40
(B6) Sensor, gearbox* 47 (H24)Rotating light 24
(H27)Rear buzzer 58
E1 Headlight, right 30 H30 Light alarm buzzer 4
E2 Headlight, left 29 H31 Direction indicator, left 39
E3 Front direction indicator, right 36 H32 Direction indicator, right 35
E4 Front direction indicator, left 35
E5 Rear light, right 37 K1 Auxiliary relay, starter (ignition switch) 2
E6 Rear light, left 34 K2 Direction indicator relay 39
E7 Cab light 18 (K3) Relay, front working lights 26
E8 Thermostart 4 K4 Relay, rear working lights 26
E9 Rear working light, right 25 K5 Headlight dipper switch relay 29
E10 Rear working light, left 25 K6 Auxiliary relay, starter switch 5
(E11) Front working light, right 26 (K7) Relay, rear fog light 52
(E12) Front working light, left 26 (K8) Relay, roof fan III ---speed 56
E13 Instrumentation lights 8, 10 K9 Auxiliary relay, starter switch 6
(E15) Cigarette lighter 16 (K18) Relay, control stop 60
(E16) Number plate light 34 (K24) Reley, HiShift 63
(E17) Raised headlights, right 28 (K25) Relay, PTO ---HiShift 65
(E18) Raised headlight, left 27 (K51) Relay, indicator light, contr. main current switch 69
(E19) Fog light, rear 52
(E22) Lights on roof console 57 M1 Starter motor 2
FA, FB, FC, FD Fuses 1. M2 Heater fan 12
FA1 5A Instruments, ind.lights, Autocontrol M4 Windscreen washer pump 14
fuel gauge 9, 44 (M5) Roof fan 55
FA2 10A Rot. warning light 24 (M6) Rear window wiper 20
FA3 15A Wiper+washer, rear wiper+washer 12 (M7) Rear window washer 19
FA4 5A Front PTO, light switch illum. light, current
socket 28 P1 Engine temperature gauge 8
FA5 15A Direction indicators, reverse buzzer, air P2 Fuel gauge 9
suspen. seat, hazard warning flashers 38, 58 P3 Rev counter 10
P4 Hour recorder/AC (.../speed*) 11
FB1 25A Light switch 29 (P5) Clock, AC, trip, gearbox oil temperature* 47
FB3 15A Full beams, ---indication light 29 (Q2) Main circuit breaker 1
FB4 5A Autocontrol 43
FB5 20A Starter switch, electric---stop, R1 Resistance, heating fan 1,2 ohm 12
rear fog light, control stop, thermostart 3, 52, 60
S1 Ignition switch 2, 60
FC1 10A Braking lights, cigarette lighter, cab light 17 (S2) Switch, roof fan 55
FC2 15A Rear working lights 25 (S3) Switch, rear window wiper and washer 18
FC3 15A Horn, rear socket, front working lights,hazard S4 Switch, windscreen wiper and washer 15
warning flashers 40 S5 Switch, heater fan 13
FC4 5A Left parking light, illumin. light in working (S6) Switch, rotating warning light 23
light switch, light in hazard light switch 35 S7 Switch, headlights 29
FC5 Parking light, right 36 S8 Switch, rear working lights 25
FD1 20A Fan 12 S10 Combined switch 32
(FD2)20A Air ---conditioner, upper fan III-speed 56 (S11) Toggle switch, raised headlights 29
FD3 10A HiShift, PTO ---HiShift, radio 62---63 S12 Contact, starter interlock 2
FD4 25A Current socket 64 S13 Brake light contact 35
FD5 5A Radio, (clock*), light alarm buzzer 1 S14 PTO warning light contact 6
In engine room S15 Indicator light switch, engine oil press. 7
(F51) 15A Electrically controlled main circuit breaker 70
G1 Battery 1
G2 Alternator 3
257
Model Code Page
310 34
1. 9. 2001 800, 900
Sym--- Code
Sym--- Code bol Component no
bol Component no
B1E Position sensor 41
S17 Indicator light switch, diff. lock 6 B2E Draft sensor 41
S18 Indicator light switch, hand brake contact 35
(S19) Contact, reverse buzzer 58 E1E Lightning, switch panel 45
S20 Indicator light switch, engine temperature, E2E Lightning, position control potentiometer 46
(Stop) 8, 59
S21 Indicator light switch, air cleaner 6 R1E Potentiometer, position control 45
Optional or alternative equipment listed in brackets
S1E Push button, RH mudguard, lifting 43
(S22) Switch, air conditioning 54 S2E Push button, RH mudguard, lowering 43
(S23) Switch, compressor pressure 54 S3E Push button, LH mudguard, lifting 42
(S26) Switch, rear fog light 51 S4E Push button, LH mudguard, lowering 42
(S36) Switch, control stop 61 S5E Push button, lift/lower, inside 44
(S37) Switch, cursor+program* 47 S7E Switch, lowering speed 45
(S38) Contact, front PTO 22 S8E Switch, transport height 45
S42 Door switch, cab light, right 18 S9E Switch, position/draft control sensitivity 45
S43 Door switch, cab light, left 18 S10E Rocker switch, lift/stop/lower 45---46
(S45) Switches, HiShift 62---63 S11E Switch, AC---bypass 44---45
(S45.1)Extra switch, HiShift 62 S12E Switch, drive balance control 45
(S68) Switch, controlled main current switch. 70
(S69) Switch, PTO ---HiShift 69 X2E Connector, 9 pins, supply+rear drive switch 42
(V5)Diodes, HiShift 62---63 Y1E Solenoid valve, lowering 41
(V6)Diodes, PTO ---HiShift 65---66 Y2E Solenoid valve, lifting 41
Connectors
X1 37---pins, engine Wire colours
X2 9---pins, head lights 29---30 VA = white
X4 7---pins, trailer socket 37, 53 HA = grey
X4.1 3---pins, trailer socket 37, 53 KE = yellow
X4.2 3---pins, trailer socket 37, 53
VI = green
X5 9---pins, mudguard right
SI = blue
X6 9---pins, mudquard left
(X7) 4---pins, air condition LI = lilac
(X8) 2---pins, current socket 38 PU = red
(X9) 1---pins, rear wiper 17 RU = brown
(X15) 3---pins, air conditioning, diodes 54 MU = black
X20 9---pins, front direction indicators
(X22) 2---pins, rotating light
X25 9---pins, Agrodata ---instrumentation
X26 26---pins, instrumentation, white
X27 26---pins, instrumentation, blue
(X42) 4---pins., front---PTO supply 22
(X44) 1---pin, control stop, optional equipment 59
(X49) 2---pins, air suspension seat 32
X50 3---pin, current socket 64
X51 1---pin, rear buzzer
Y1 Solenoid valve, on electric stop models 5, 60

(Y5) Magnetic clutch, compressor, air condition 54
(Y9) Solenoid valve, front PTO 22
(Y17) Solenoid valve, PTO ---HiShift, retardation 66
Ground leads
GR1 Battery
GR2 Headlights (starter)
GR3 Instrument panel
GR4 Earth lead, rear right
GR5 Cabin roof
GR6 Cabin front wall
*) Agroline ---instrumentation 47---49

ACB Autocontrol power lift
A1E Autocontrol electronic unit 42---44
A2E Switch panel 45
258
Model Code Page
310 35
1. 9. 2001 800, 900
33202000K
259
Model Code Page
310 36
1. 9. 2001 800, 900
260
Model Code Page
310 37
1. 9. 2001 800, 900
261
Model Code Page
1. 4. 2004
Sym--- Code
Wiring diagram 600 --- 900 bol Component no
(No 33202000M)
Incl. e.g. fluid brakes (M21101---) In engine room
(F51) 15A Electrically controlled main circuit breaker 70
Sym--- Code G1 Battery 1

bol Component no G2 Alternator 3
A1 Current screw, cabin supply 1 H1 Indicator light, direction indicators II 40

(A2) Radio 38 H2 Indicator light, direction indicators I 39
(A3) Controller, front PTO 22 H4 Indicator light, air filter 6
(A5) Air suspension seat 32 H5 Indicator light, engine oil pressure 7
H6 Warning light, Stop, engine temperature 7, 59
B1 Sensor, engine temperature gauge 8, 59 (H7) Indicator light, gearbox oil pressure
B2 Sensor, fuel gauge 9 H11 Indicator light, parking brake 9
(B3) Sensor, gearbox temperature* 49 H12 Indicator light, Thermostart 5
(B6) Sensor, gearbox* 47 H13 Indicator light, PTO clutch 6
H14 Indicator light, high beams 31
E1 Headlight, right 30 H15 Indicator light, fuel reverse 9
E2 Headlight, left 29 H16 Indicator light, charging 4, 68
E3 Front direction indicator, right 36 H20 Indicator light, differential lock 5
E4 Front direction indicator, left 35 H23 Horn 40
E5 Rear light, right 37 (H24)Rotating light 24
E6 Rear light, left 34 (H27)Rear buzzer 58
E7 Cab light 18 H30 Light alarm buzzer 47
E8 Thermostart 4 H31 Direction indicator, left 39
E9 Rear working light, right 25 H32 Direction indicator, right 35
(E11) Front working light, right 26 K1 Auxiliary relay, starter (ignition switch) 2
(E12) Front working light, left 26 K2 Direction indicator relay 39
E13 Instrumentation lights 8, 10 (K3) Relay, front working lights 26
(E15) Cigarette lighter 16 K4 Relay, rear working lights 26
(E16) Number plate light 34 K5 Headlight dipper switch relay 29
(E17) Raised headlights, right 28 K6 Auxiliary relay, starter switch 5
(E18) Raised headlight, left 27 (K7) Relay, rear fog light 52
(E19) Fog light, rear 52 (K8) Relay, roof fan III ---speed 56
(E22) Lights on roof console 57 K9 Auxiliary relay, starter switch 6
(K18) Relay, control stop 60
(K24) Reley, HiShift 63
FA, FB, FC, FD Fuses (K25) Relay, PTO ---HiShift 65
(K51) Relay, indicator light, contr. main current switch 69
FA1 5A Instruments, ind.lights, Autocontrol, fuel
gauge 9, 44 M1 Starter motor 2
FA2 10A Rot. warning light, radio 24 M2 Heater fan 12
FA3 15A Wiper+washer, rear wiper+washer 12 M3 Windscreen wiper 15
FA4 5A Front PTO, light switch illum. light, current M4 Windscreen washer pump 14
socket 28 (M5) Roof fan 55
FA5 15A Direction indicators, braking lights, reverse buz- (M6) Rear window wiper 20
zer, air suspen. seat, warning flashers 38, 58 (M7) Rear window washer 19
FB1 25A Light switch 29 P1 Engine temperature gauge 8
FB2 15A Dipped beams 29 P2 Fuel gauge 9
FB3 15A Full beams, ---indication light 29 P3 Rev counter 10
FB4 5A Autocontrol 43 P4 Hour recorder/AC (.../speed*) 11
FB5 20A Starter switch, electric---stop, (P5) Clock, AC, trip, gearbox oil temperature* 47
rear fog light, control stop, Thermostart 3, 52, 60
(Q2) Main circuit breaker 1
FC1 10A Cigarette lighter, cab light 17
FC2 15A Rear working lights 25 R1 Resistance, heating fan 1,2 ohm 12
FC3 15A Horn, rear socket, front working lights, hazard
warning flashers 40 S1 Ignition switch 2, 60
FC4 5A Left parking light, instrumentation lights, working (S2) Switch, roof fan 55
light switches, hazard warning flashers illum. light 35 (S3) Switch, rear window wiper and washer 18
FC5 5A Parking light, right 36 S4 Switch, windscreen wiper and washer 15
S5 Switch, heater fan 13
FD1 20A Fan, upper fan I ---II-speed, Air ---conditioner 12 (S6) Switch, rotating warning light 23
FD2 20A Air ---conditioner, upper fan III-speed 56 S7 Switch, headlights 29
FD3 10A HiShift, PTO ---HiShift, radio 62---63 S8 Switch, rear working lights 25
FD4 25A Current socket 64 (S9) Switch, front working lights 27
FD5 5A Radio, (clock*), light alarm buzzer 1
262
Model Code Page
1. 4. 2004
Sym---
bol Component no
Sym--- Code
bol Component no GR6 Cabin front wall
S10 Combined switch 32 *) AL ---instrumentation 47---49
(S11) Toggle switch, raised headlights 29
S12 Contact, starter interlock 2
S13 Brake light contact 35 ACB Autocontrol power lift
S14 PTO warning light contact 6 A1E Autocontrol electronic unit 42---44
S15 Indicator light switch, engine oil press. 7 A2E Switch panel 45
S17 Indicator light switch, diff. lock 6 B1E Position sensor 41
S18 Indicator light switch, hand brake contact 10 B2E Draft sensor 41
(S19) Contact, reverse buzzer 58
S20 Indicator light switch, engine temperature, (Stop) 8, 59 E1E Lightning, switch panel 45
S21 Indicator light switch, air cleaner 6 E2E Lightning, position control potentiometer 46
(S23) Switch, compressor pressure 54 R1E Potentiometer, position control 45
(S36) Switch, control stop 61 S1E Push button, RH mudguard, lifting 43
(S37) Switch, cursor+program* 47 S2E Push button, RH mudguard, lowering 43
(S38) Contact, front PTO 22 S3E Push button, LH mudguard, lifting 42
S42 Door switch, cab light, right 18 S4E Push button, LH mudguard, lowering 42
S43 Door switch, cab light, left 18 S5E Push button, lift/lower, inside 44
(S45) Switches, HiShift 62---63 S7E Switch, lowering speed 45
(S45.1)Extra switch, HiShift 62 S8E Switch, transport height 45
(S68) Switch, controlled main current switch 70 S9E Switch, position/draft control sensitivity 45
(S69) Switch, PTO ---HiShift 69 S10E Rocker switch, lift/stop/lower 45---46
S11E Switch, AC---bypass 44---45
(V5)Diodes, HiShift 62---63 S12E Switch, drive balance control 45
(V6)Diodes, PTO ---HiShift 65---66
X2E Connector, 9 pins, supply+rear drive switch 42
Connectors Y1E Solenoid valve, lowering 41
X1 37---pins, engine Y2E Solenoid valve, lifting 41
X2 9---pins, head lights 29---30
X4 7---pins, trailer socket 37, 53
Wire colours
X4.1 3---pins, trailer socket 37, 53
X4.2 3---pins, trailer socket 37, 53 VA = white
X5 9---pins, mudguard right HA = grey
X6 9---pins, mudquard left KE = yellow
(X7) 4---pins, air condition VI = green
(X8) 2---pins, current socket 38 SI = blue
(X9) 1---pins, rear wiper 17 LI = lilac
(X15) 3---pins, air conditioning, diodes 54 PU = red
X20 9---pins, front direction indicators
RU = brown
X25 9---pins, Agrodata ---instrumentation MU = black
(Y1) Solenoid valve, electric stop 5, 60

Ground leads
GR1 Battery
GR5 Cabin roof
263
Model Code Page
1. 4. 2004
M21101--->
33202000M
69--- 1
69--- 2
264
Model Code Page
1. 4. 2004
M21101--->
69--- 3
69--- 4
265
Model Code Page
1. 4. 2004
M21101--->
69--- 5
266
Model Code Page
1. 4. 2004
267
Model Code Page
1. 4. 2004 600L -- 900L
Sym--- Code
Wiring diagram 600L --- 900L, open cab bol Component no
(No 33391700G) K1 Auxiliary relay, starter 2
Incl. e.g. fluid brakes (M21101---) K2 Direction indicator relay 39
K5 Headlight dipper switch relay 29
A1 Current screw, cabin supply 1 K6 Auxiliary relay, starter switch 4
(A3) Controller, front PTO 21 (K7) Relay, rear fog light 27
(K18) Relay, control stop 24
B1 Sensor, engine temperature gauge 8, 24
B2 Sensor, fuel gauge 9 M1 Starter motor 2
E1 Headlight, right 30 P1 Engine temperature gauge 8

E2 Headlight, left 29 P2 Fuel gauge 9
E3 Front direction indicator, right 36 P3 Rev counter 10
E4 Front direction indicator, left 35 P4 Hour recorder 11
E5 Rear light, right 37 (P5) Clock, AC, trip, gearbox oil temperature* 11
E8 Heater unit 4 (Q2) Main circuit breaker 1
E9 Rear working light, right 15
E10 Rear working light, left 14 S1 Ignition switch 2, 25
(E11) Front working light, right 19 (S6) Switch, rotating warning light 13
(E12) Front working light, left 18 S7 Switch, headlights 29
E13 Instrumentation lights 8, 10 S8 Switch, rear working lights 16
(E16) Register plate light 34 (S9) Switch, front working lights 18
(E19) Fog light, rear 27 S10 Combined switch 32
S12 Safety switch 2
S13 Switch, brake light contact 35
FA, FB, FC Fuses S14 Indicator light switch, PTO clutch 6
FA1 5A Instruments, ind.lights, fuel gauge 9 S15 Indicator light switch, engine oil press. 7
FA2 10A Rot. warning light, radio 13 S16 Switch, hazard warning flashers 36
FA4 5A Front PTO, ligth for light switch 28 S17 Indicator light switch, diff. lock 6
FA5 15A Direction indicators, braking lights, back buzzer, S18 Indicator light switch,hand brake contact 5
Stop warning light 38 S20 Indicator light switch, engine temperature, (Stop) 8, 24
S21 Indicator light switch, air cleaner 6
FB1 25A Light switch, lower beams/high beams 29 (S26) Switch, rear fog light 27
FB2 15A Light switch, parking lights 29 (S36) Switch, control stop 26
FB3 15A Horn, front working light 40 (S38) Contact, front PTO 21
FB5 20A Starter switch, electric---stop, fog light rear, Connectors
Control stop, Thermostart 3, 25
X1 37---pins, engine 29, 40
FC1 10A Reserve 32 X2 9---pins, head lights 25
FC2 15A Rear working lights 15 X4 7---pins, trailer socket 37
FC3 15A Light alarm buzzer, Hour recorder, Clock 11 X4.1 3---pins, trailer socket 37
FC4 5A Left parking light, instrumentation lights, X4.2 3---pins, trailer socket 37
working light switches, X5 9---pins, mudguard right
illumin. light for hazard warning flasher switch 35 X6 9---pins, mudquard left
FC5 5A Parking light, right 36 X20 9---pins, front direction indicators
In engine room (X42) 4---pins., front---PTO supply 22
G1 Battery 1 (X44) 1---pin, control stop, optional equipment 24
G2 Alternator 3
H1 Indicator light, direction indicators III 40 (Y9) Solenoid valve, front PTO 21
H2 Indicator light, direction indicators II 39
H4 Indicator light, air filter 6
Ground leads
H5 Indicator light, engine oil pressure 7 GR1 Battery
H6 Warning light, Stop, engine temperature 7 GR2 Headlights (starter)
H11 Indicator light, parking brake 5 GR3 Instrument panel
H13 Indicator light, PTO clutch 6 GR4 Earth lead, rear right
H14 Indicator light, high beams 31 GR5 Cab of roof
H15 Indicator light, fuel reverse 9 Wire colours
H16 Indicator light, charging 4
H20 Indicator light, differential lock 5 VA = white
H23 Horn 40 HA = grey
(H24)Rotating light 13 KE = yellow
H30 Light buzzer 11 VI = green
H31 Direction indicator, left 39 SI = blue
H32 Direction indicator, right 38 LI = lilac
PU = red
RU = brown
MU = black
268
Model Code Page
30. Tractor electrical system 600L -- 900L 310 45
1. 4. 2004
M21101--->
33391700G 69L --- 1_2
69L --- 2_2
269
Model Code Page
1. 4. 2004
270
Model Code Page
30. Tractor electrical system 600 -- 900
310 47
1. 4. 2004 A75 -- A95
Sym--- Code
bol Component no
Wiring diagram 600---900 and A75 --- A95
(Nro 33202000P) In engine room
Incl. e.g. drizzle operation (relay K26) and a new combined (F51) 15A Electrically controlled main circuit breaker 70
switch S10 (M49302---)
Sym--- Code G1 Battery 1
bol Component no G2 Alternator 3
A1 Current screw, cabin supply 1 H1 Indicator light, direction indicators II 40

(A2) Radio 38 H2 Indicator light, direction indicators I 39
(A3) Controller, front PTO 22 H4 Indicator light, air filter 6
(A5) Air suspension seat 32 H5 Indicator light, engine oil pressure 7
H6 Warning light, Stop, engine temperature 7, 59
B1 Sensor, engine temperature gauge 8, 59 (H7) Indicator light, gearbox oil pressure
B2 Sensor, fuel gauge 9 H11 Indicator light, parking brake 9
(B3) Sensor, gearbox temperature* 49 H12 Indicator light, Thermostart 5
(B6) Sensor, gearbox* 47 H13 Indicator light, PTO clutch 6
H14 Indicator light, high beams 31
E1 Headlight, right 30 H15 Indicator light, fuel reverse 9
E2 Headlight, left 29 H16 Indicator light, charging 4, 68
E3 Front direction indicator, right 36 H20 Indicator light, differential lock 5
E4 Front direction indicator, left 35 H23 Horn 40
E5 Rear light, right 37 (H24)Rotating light 24
E6 Rear light, left 34 (H27)Rear buzzer 58
E7 Cab light 18 H30 Light alarm buzzer 47
E8 Thermostart 4 H31 Direction indicator, left 39
E9 Rear working light, right 25 H32 Direction indicator, right 35
(E11) Front working light, right 26 K1 Auxiliary relay, starter (ignition switch) 2
(E12) Front working light, left 26 K2 Direction indicator relay 39
E13 Instrumentation lights 8, 10 (K3) Relay, front working lights 26
(E15) Cigarette lighter 16 K4 Relay, rear working lights 26
(E16) Number plate light 34 K6 Auxiliary relay, starter switch 5
(E17) Raised headlights, right 28 (K7) Relay, rear fog light 52
(E18) Raised headlight, left 27 (K8) Relay, roof fan III ---speed 56
(E19) Fog light, rear 52 K9 Auxiliary relay, starter switch 6
(E22) Lights on roof console 57 (K18) Relay, control stop 60
(K24) Relay, HiShift 63
(K25) Relay, PTO ---HiShift 65
FA, FB, FC, FD Fuses K26 Relay, drizzle 15
FA1 5A Instruments, ind.lights, Autocontrol, fuel (K51) Relay, indicator light, contr. main current switch 69
gauge 9, 44
FA2 10A Rot. warning light, radio 24 M1 Starter motor 2
FA3 15A Wiper+washer, rear wiper+washer 12 M2 Heater fan 12
FA4 5A Front PTO, light switch illum. light, current M3 Windscreen wiper 15
socket 28 M4 Windscreen washer pump 14
FA5 15A Direction indicators, braking lights, reverse (M5) Roof fan 55
buzzer, air suspen. seat, warning flashers 38, 58 (M6) Rear window wiper 20
FB1 25A Light switch 29 (M7) Rear window washer 19
FB3 15A Full beams, ---indication light 29 P1 Engine temperature gauge 8
FB4 5A Autocontrol 43 P2 Fuel gauge 9
FB5 20A Starter switch, electric---stop, P3 Rev counter 10
rear fog light, control stop, Thermostart 3, 52, 60 P4 Hour recorder/AC (.../speed*) 11
FC1 10A Cigarette lighter, cab light 17 (P5) Clock, AC, trip, gearbox oil temperature* 47
FC2 15A Rear working lights 25
FC3 15A Horn, rear socket, front working lights, hazard (Q2) Main circuit breaker 1
warning flashers
40 R1 Resistance, heating fan 1,2 ohm 12
FC4 5A Left parking light, instrumentation lights,
working light switches, S1 Ignition switch 2, 60
hazard warning flashers illum. light 35 (S2) Switch, roof fan 55
FC5 5A Parking light, right 36 (S3) Switch, rear window wiper and washer 18
FD1 20A Fan, upper fan I ---II ---speed, Air ---conditioner 12 S4 Switch, windscreen wiper 15
FD2 20A Air ---conditioner, upper fan III ---speed 56 S5 Switch, heater fan 13
FD3 10A HiShift, PTO ---HiShift, radio 62---63 (S6) Switch, rotating warning light 23
FD4 25A Current socket 64 S7 Switch, headlights 29
FD5 5A Radio, (clock*), light alarm buzzer 1 S8 Switch, rear working lights 25
271
Model Code Page
310 48
1. 4. 2004 A75 -- A95
Sym--- Code
bol Component no
Sym--- Code
bol Component no GR6 Cabin front wall
S10 Combined switch 32 *) AL ---instrumentation 47---49
(S11) Toggle switch, raised headlights 29
S12 Contact, starter interlock 2
S13 Brake light contact 35 ACB Autocontrol power lift
S14 PTO warning light contact 6 A1E Autocontrol electronic unit 42---44
S15 Indicator light switch, engine oil press 7 A2E Switch panel 45
S17 Indicator light switch, diff. lock 6 B1E Position sensor 41
S18 Indicator light switch, hand brake contact 10 B2E Draft sensor 41
(S19) Contact, reverse buzzer 58
S20 Indicator light switch, engine temperature, (Stop) 8, 59 E1E Lightning, switch panel 45
S21 Indicator light switch, air cleaner 6 E2E Lightning, position control potentiometer 46
(S23) Switch, compressor pressure 54 R1E Potentiometer, position control 45
(S36) Switch, control stop 61 S1E Push button, RH mudguard, lifting 43
(S37) Switch, cursor+program* 47 S2E Push button, RH mudguard, lowering 43
(S38) Contact, front PTO 22 S3E Push button, LH mudguard, lifting 42
(S42) Door switch, cab light, right 18 S4E Push button, LH mudguard, lowering 42
(S43) Door switch, cab light, left 18 S5E Push button, lift/lower, inside 44
(S45) Switches, HiShift 62---63 S7E Switch, lowering speed 45
(S45.1)Extra switch, HiShift 62 S8E Switch, transport height 45
S62 Switch, windscreen washer 14 S9E Switch, position/draft control sensitivity 45
(S68) Switch, controlled main current switch 70 S10E Rocker switch, lift/stop/lower 45---46
(S69) Switch, PTO ---HiShift 69 S11E Switch, AC---bypass 44---45
S12E Switch, drive balance control 45
(V5) Diodes, HiShift 62---63
(V6) Diodes, PTO ---HiShift 65---66 X2E Connector, 9 pins, supply+rear drive switch 42
Connectors Y1E Solenoid valve, lowering 41

Y2E Solenoid valve, lifting 41
X1 37---pins, engine
X2 9---pins, head lights 29---30
X4 7---pins, trailer socket 37, 53 Wire colours
X4.1 3---pins, trailer socket 37, 53 VA = white
X4.2 3---pins, trailer socket 37, 53 HA = grey
X5 9---pins, mudguard right KE = yellow
X6 9---pins, mudquard left VI = green
(X7) 4---pins, air condition SI = blue
(X8) 2---pins, current socket 38 LI = lilac
(X9) 1---pins, rear wiper 17 PU = red
(X15) 3---pins, air conditioning, diodes 54 RU = brown
X20 9---pins, front direction indicators MU = black
X25 9---pins, Agrodata ---instrumentation

Ground leads
GR1 Battery
GR5 Cabin roof
272
Model Code Page
1. 4. 2004 A75 -- A95
M49302--->
33202000P
69--- 1
69--- 2
273
Model Code Page
1. 4. 2004 A75 -- A95
M49302--->
69--- 3
69--- 4
274
Model Code Page
310 51
1. 4. 2004 A75 -- A95
M49302--->
69--- 5
275
Model Code Page
1. 4. 2004 600L -- 900L
Sym--- Code
Wiring diagram 600L --- 900L, open cab bol Component no
(Nro 33391700H) K1 Auxiliary relay, starter 2
Incl. e.g. a new combined switch S10 (M49302---) K2 Direction indicator relay 39
K6 Auxiliary relay, starter switch 4
A1 Current screw, cabin supply 1 (K7) Relay, rear fog light 27
(A3) Controller, front PTO 21 (K18) Relay, control stop 24
B1 Sensor, engine temperature gauge 8, 24 M1 Starter motor 2

B2 Sensor, fuel gauge 9
P1 Engine temperature gauge 8
E1 Headlight, right 30 P2 Fuel gauge 9
E2 Headlight, left 29 P3 Rev counter 10
E3 Front direction indicator, right 36 P4 Hour recorder 11
E4 Front direction indicator, left 35 (P5) Clock, AC, trip, gearbox oil temperature* 11
E6 Rear light, left 34 (Q2) Main circuit breaker 1
E8 Heater unit 4
E9 Rear working light, right 15 S1 Ignition switch 2, 25
E10 Rear working light, left 14 (S6) Switch, rotating warning light 13
(E11) Front working light, right 19 S7 Switch, headlights 29
(E12) Front working light, left 18 S8 Switch, rear working lights 16
E13 Instrumentation lights 8, 10 (S9) Switch, front working lights 18
(E16) Register plate light 34 S10 Combined switch 32
(E19) Fog light, rear 27 S12 Safety switch 2
S13 Switch, brake light contact 35
S14 Indicator light switch, PTO clutch 6
FA, FB, FC Fuses S15 Indicator light switch, engine oil press. 7
FA1 5A Instruments, ind.lights, fuel gauge 9 S16 Switch, hazard warning flashers 36
FA2 10A Rot. warning light, radio 13 S17 Indicator light switch, diff. lock 6
FA4 5A Front PTO, ligth for light switch 28 S18 Indicator light switch,hand brake contact 5
FA5 15A Direction indicators, braking lights, back buzzer, S20 Indicator light switch, engine temperature, (Stop) 8, 24
Stop warning light 38 S21 Indicator light switch, air cleaner 6
FB1 25A Light switch, lower beams/high beams 29 (S36) Switch, control stop 26
FB2 15A Light switch, parking lights 29 (S38) Contact, front PTO 21
FB3 15A Horn, front working light 40 Connectors
FB5 20A Starter switch, electric---stop, fog light rear,
Control stop, Thermostart 3, 25 X1 37---pins, engine 29, 40
X2 9---pins, head lights 25
FC1 10A Reserve 32 X4 7---pins, trailer socket 37
FC2 15A Rear working lights 15 X4.1 3---pins, trailer socket 37
FC3 15A Light alarm buzzer, Hour recorder, Clock 11 X4.2 3---pins, trailer socket 37
FC4 5A Left parking light, instrumentation lights, X5 9---pins, mudguard right
working light switches, X6 9---pins, mudquard left
illumin. light for hazard warning flasher switch 35 X20 9---pins, front direction indicators
FC5 5A Parking light, right 36 (X22) 2---pins, rotating light
In engine room (X44) 1---pin, control stop, optional equipment 24
G1 Battery 1
G2 Alternator 3 (Y1) Solenoid valve, electric stop 4, 25
H1 Indicator light, direction indicators III 40
H2 Indicator light, direction indicators II 39
Ground leads
H4 Indicator light, air filter 6 GR1 Battery
H5 Indicator light, engine oil pressure 7 GR2 Headlights (starter)
H6 Warning light, Stop, engine temperature 7 GR3 Instrument panel
H11 Indicator light, parking brake 5 GR4 Earth lead, rear right
H13 Indicator light, PTO clutch 6 GR5 Cab of roof
H14 Indicator light, high beams 31 Wire colours
H15 Indicator light, fuel reverse 9
H16 Indicator light, charging 4 VA = white
H20 Indicator light, differential lock 5 HA = grey
H23 Horn 40 KE = yellow
(H24)Rotating light 13 VI = green
H30 Light buzzer 11 SI = blue
H31 Direction indicator, left 39 LI = lilac
H32 Direction indicator, right 38 PU = red
RU = brown
MU = black
276
Model Code Page
1. 4. 2004 600L -- 900L
33391700H M49302---> 69L --- 1_2
69L --- 2_2
277
Model Code Page
1. 4. 2004
278
Model Code Page
10. 1. 1992
32. Electro---hydraulic power lift 355-- 865 320 1
1. 3. 1997
4
6
5
3
2
Picture 1. Electro---hydraulic power lift
1. Hydraulic pump
2. Control valve
3. Lifting cylinder
4. Electronic unit
5. Draft sensor
1 6. Position sensor
7. Switch panel
8. Top link bracket
1. Autocontrol hydraulic lift, electri ---

cal system This unit determines the differences between the two sets of
signals (i.e. from the sensors and switches) and feed the
Note! The Electro---hydraulic power lift on Valmet 355---865 necessary control signal to the control valve solenoid.
tractors is the same as on Valmet Mezzo---series. However,
355---865 tractors have only one draft sensor on the top link The position sensor (6) is in permanent contact with an eccen-
bracket. tric on the lift shaft. When the lower links are lifted or lowered
the eccentric moves the pin, which sends a signal to the elec-
tronic unit; thus the hydraulic lift always ”knows” the position
A. Description
of the lower links.
The Valmet Autocontrol is an electrically controlled hydraulic
The draft sensor (5) is placed on the top link bracket (8). When
lift. All mechanical levers have been replaced with knobs and
the push/pull force in the top link increases the loading on the
switches. Ideal mixing/sensitivity values for draft control have
draft sensor also increases. This loading is then converted
been pre ---programmed and can be controlled with one
into electrical signals by the draft sensor.
switch.
These signals are amplified by an electronic device which is
Operation: built into the the draft sensor.
The pump (1) draws oil from the oil reservoir and delivers it to
the control valve (2). The control valve directs the oil to the lift- The signals are sent to the Autocontrol hydraulic lift. If the draft
ing cylinders (3) for the operation of the lifting arms (lifting, force increases the hydraulic lift will raise the implement, the
lowering and holding functions). The values set on the switch draft control sensitivity depending on the setting of the
panel (7), and the actual values detected by the draft sensors switches in the cab and on the top link fastening point on the
(5) and position sensor (6), are fed into the electronic unit (4). bracket.
283
Model Code Page
15. 9. 1995
1. 3. 1997
Wiring diagram up to cab number 64093
Picture 1. Wiring diagram of Autocontrol
284
Model Code Page
10. 1. 1992
1. 9. 1992
Component list of wiring diagram
A1E . . . . Autocontrol electronic unit

A2E . . . . Switch panel
B1E . . . . Position sensor

B2E . . . . Draft sensor
R1E . . . . Potentiometer, position control
S1E . . . . Push button, RH mudguard, lifting

S2E . . . . Push button, RH mudguard, lowering
(S3E) . . . Push button, LH mudguard, lifting
(S4E) . . . Push button, LH mudguard, lowering
S5E . . . . Push button in cab, lifting
S6E . . . . Push button in cab, lowering
S7E . . . . Switch, lowering speed
S8E . . . . Switch, transport height
S9E . . . . Switch, position/draft control sensitivity
S10E . . . Rocker switch, lift/lower
S17E . . . Limit switch
(X2E) . . . Connector, 3 pins, push buttons on LH side mudguard.

X7E . . . . . Connector, 3 pins, limit switch
Y1E . . . . . Solenoid valve. lowering

Y2E . . . . . Solenoid valve, lifting
Fuses
FA1 (in fuse box; current via starter switch): 5 A, porcelain fuse
FB3 (in fuse box; permanent current): 8 A, porcelain (665: 16 A)
665: F1E (on wire under Autocontrol switch panel): 5 A, flat fuse. Fuse FA9 on tractors 355---565 and on some 665 tractors in same
place as fuse F1E.
Wire colours
Ru = brown
Pu = red
Ke = yellow
Si = blue
Mu = black
Vi = green
Va = white
Li = lilac
285
Model Code Page
32. Electro---hydraulic power lift 355-- 665 320 3A
15. 9. 1995
Wiring diagram on 65---models from cab no. 64094 incl.
65--- 3
286
Model Code Page
32. Electro---hydraulic power lift 355-- 665 320 3B
15. 9. 1995
Component list of wiring diagram

Code
A1E . . . . . . . Autocontrol electronic unit 42---44
A2E . . . . . . . Switch panel 45
B1E . . . . . . . Position sensor 41

B2E . . . . . . . Draft sensor 41
R1E . . . . . . . Potentiometer, position control 45
S1E . . . . . . . Push button, RH mudguard, lifting 43

S2E . . . . . . . Push button, RH mudguard, lowering 43
(S3E) . . . . . . Push button, LH mudguard, lifting 42
(S4E) . . . . . . Push button, LH mudguard, lowering 42
S5E . . . . . . . Push button in cab, lifting 44
S6E . . . . . . . Push button in cab, lowering 44
S7E . . . . . . . Switch, lowering speed 45
S8E . . . . . . . Switch, transport height 45
S9E . . . . . . . Switch, position/draft control sensitivity 45
S10E . . . . . . Rocker switch, lift/lower 45---46
S17E . . . . . . Limit switch 41---42
(X2E) . . . . . . Connector, 3 pins, push buttons

. . . . . . . . . . . . on LH side mudguard. 42
X7E . . . . . . . . Connector, 3 pins, limit switch 41---42
Y1E . . . . . . . . Solenoid valve. lowering 41

Y2E . . . . . . . . Solenoid valve, lifting 41
Fuses
FA1 Current via starter switch (5 A)

FB4 Permanent current (5 A)
Wire colours
Ru = brown
Pu = red
Ke = yellow
Si = blue
Mu = black
Vi = green
Va = white
Li = lilac
287
Model Code Page
1. 5. 1996
32. Electro---hydraulic power lift 865
320 3C
1. 1. 1998 600-- 900
Figure 1B. Autocontrol power lift
Wiring diagram for 865 and 600---900 tractors

288
Model Code Page
1. 3. 1997
32. Electro---hydraulic power lift 865
320 3D
1. 1. 1998 600-- 900
Component list of wiring diagram,

tractors 865 and 600---900
Sym---
bol Component Code
A1E Autocontrol electronic unit 42---44

A2E Switch panel 45
A3E Compensator 42
E1E Switch panel illumination 45

E2E Illumination, position control potentiometer 46
B1E Position sensor 41

B2E Draft sensor 41
R1E Potentiometer, position control 45
S1E Push button, RH mudguard, lifting 43

S2E Push button, RH mudguard, lowering 43
S3E Push button, LH mudguard, lifting 42
S4E Push button, LH mudguard, lowering 42
S5E Rocker switch in cab, lifting/lowering 44
S7E Switch, lowering speed 45
S8E Switch, transport height 45
S9E Switch, position/draft control sensitivity 45
S10E Autocontrol rocker switch, lift/stop/lower 45---46
S11E Switch, forced lowering 44---45
(X2E) Connector, 9 pins, push buttons+supply 42---45

X5 RH mudguard push button connector
X6 LH mudguard push button connector
B1E Position sensor connector
B2E Draft sensor connector
Y1E Solenoid valve, lowering 41

Y2E Solenoid valve, lifting 41
Fuses:
FA1 Current via starter switch (5 A) 44

FB4 Permanent currect (5 A) 43
Wire colours
Ru = brown
Pu = red
Ke = yellow
Si = blue
Mu = black
Vi = green
Va = white
Li = lilac
IMPORTANT! Instructions for 865---tractor under code 320

are also good for 600, 700, 800 and 900 tractors.
289
Model Code Page
10. 1. 1992
7
8
Blue (to fuse FB3)
Brown (to fuse FA1) Connector for LH

665: F1E side mudguar push
buttons (optional)
5
3
10
Figure 2. Electro---hydraulic power lift, Valmet 355---665
1. Control valve (Bosch)

2. Draft sensor (B2E)
3. Top link
4. Electronic unit (A1E)
5. Position sensor (B1E)
6. Switch panel (A2E)
7. Push buttons (in cab)
8. Push buttons (on RH side mudguard)
9. Solenoid valve (2 pcs, Y1E, Y2E)
10. Limit switch (S17E)
290
Model Code Page
32. Electro---hydraulic power lift 865 320 4A
1. 3. 1997
Picture 2a. AC---power lift on 865 tractor
1. Control valve Note! The electric functions of the 865 tractor AC power lift
2. Draft sensor B2E are the same as on 355---665 tractors:
3. Top link sensing
4. Control unit A1E --- Functional check, see pages 320/8 ---9.
5. Position sensor B1E --- Checking switch panel, see pages 320/11 ---12.
6. Autocontrol---switch S10E --- Position sensor, see page 320/6. Adjusting position sensor
7. Position control potentiometer R1E on 865, see page 320/10A.
8. Lowering speed selector S7E --- Draft sensor, see page 320/7.
9. Transport height selector S8E --- Checking position control potentiometer and solenoid val-
10. Position control/draft control selector S9E ves, see page 320/15.
11. Rocker switch, lifting / lowering S5E
12. Push buttons S1E and S2E in the rear mudguards
13. Forced lowering button S11E
14. Indication lights for lifting/lowering
15. Indication lights, position control / draft control
291
Model Code Page
32. Electro---hydraulic power lift 865 320 4B
1. 3. 1997
Picture 2b. Control switch console on the 865 tractor
6. Autocontrol---rocker switch S10E

7. Position control potentiometer R1E
8. Lowering speed selector S7E
9. Transport height selector S8E
10. Position control/draft control selector S9E
11. Rocker switch in cab, lifting/lowering S5E
12. Push buttons S1E and S2E in the rear mudguards (not
illustrated)
14. Indication lights, lifting and lowering
15. Indication lights, position control/draft control
Note! On the 865 tractor the positions of the control switches

have been changed, but their electrical functions are the
same as on 355---665 tractors, see the following page 320/5.
On the 865 the forced lowering button S11E is a standard
equipment. The two push buttons for the lifting/lowering in the
cab have been replaced with one rocker switch.
292
Model Code Page
1. 5. 1996
1. 3. 1997
4 5
Figure 3. Control switches for power lift on 355---665.

a middle position and the both extreme positions have the
1. Position control potentiometer same functions as the push buttons. A spring returns the
--- max. clockwise, lower links at the transport height (with rocker switch to the middle position.
switch 5)
--- max. anti ---clockwise, lower links in the lowest position 4. Lowering speed selector
--- does not function if the system has not been activated with --- six different lowering speeds
switch 2. --- lowering speed is independent of the load
2. Lift/lower switch (Autocontrol switch) 5. Transport height selector

--- activates the control system (after the main power has been --- six different upper position
switched off or if the mudguard push buttons (or rocker switch --- push buttons override these settings
in cab on 865) have been used).
--- lifts to the transport height determined by the switch 5. 6. Position control/draft control
--- lowers to the position determined by the position control --- position P is the position control mode
knob 1 --- positions 1---5 are for the draft control
Note! From the beginning of the year 1994, the lift/lower 7. Lift/lower indicator lights
switch has three positions. The middle position stops the --- lifting (red)
movement of the lower links. The two other positions are the --- lowering (green)
same as earlier.
8. Indicator lights for the position control/draft control
3. Lift/lower push buttons in the mudguards --- light for the position control (position P)
--- in the cabin and on the RH side rear mudguard --- light for the draft control (positions 1---5)
--- lift button raises the lower links to max. upper position
(higher than max transport position with switch 5) 9. Forced lowering switch (see page 320/4B)
--- push button does not function, if the lift/lower switch (2) is
in the lifting position. 865---tractor has as standard a forced ---lowering switch (as on
--- after using the push buttons, the system must be activated some Mezzo---tractors). The switch is a spring returned push
with the switch (2). button beside the position potentiometer. When this button is
depressed, the Autocontrol adjustment is overidden and the
Note! 355---665: The lifting arms are provided with a limit lower links lower as long as the button is depressed. The
switch which limits the max lifting height when push buttons forced ---lowering button does not override the lowering speed
are used (the pick ---up hitch lifting links limit the upper position control. When the button is released, the lower links will find
if they are fitted on the tractor). the position determined by the position potentiometer. The
forced ---lowering button does not lower the lower links, if the
Note! On 865---tractor, the push buttons in the cab have been lift/lower switch is in the transport or in the middle position.
replaced with a three ---position rocker switch. The switch has
293
Model Code Page
10. 1. 1992
1. 3. 1997
USignal
5
USupply
Direction A
Figure 4. Position sensor

1
1. Locking nut (Loctite 270 on threads)
4 2. Permatex Super 300 on threads
3. Eccentric on lifing arm shaft
2 4. Hydraulic housing cover
5. Connector (on RH side under cab)
Note ! The position sensor must be changed if it

is damaged. If the sensor lead is damaged it can
be repaired using three pin connector.
USignal
USupply
10 mm
(max. 13
mm)
Position sensor
USupply=6,3---7,7 Veff (AC) (f4---7kHz)
The position sensor is fitted on the hydraulic housing cover in USignal=33---67 % x USupply (lower links down ---up)
the rear of the tractor. It supplies information on the actual
position of the lower links.
Measuring position sensor signal and supply volt-
The sensor detects the lower link position by means of an ages, see page 320/14.
eccentric fitted to the lifting arm shaft. The construction of the
position sensor can be compared to that of a solenoid. Inside Adjusting the limit switch and the position sensor
the electromagnetic housing there is a pin which moves with
the eccentric on the lifting arm shaft.
Concerning 355---665 tractors with the limit switch, see page
Alternating current is fed to the coil, and the voltage in the 320/10. Adjustment of the position sensor on the 865 tractor,
middle of the coil depends on the position of the pin inside the see page 320/10A.
housing. Thus the voltage is proportional to the position of the
lower links.
294
Model Code Page
10. 1. 1992
15. 9. 1995
F
FILTER OSCILLATOR
Ua
Us
DEMODULATOR
F/2 F/2
2
Figure 5. Draft sensor
1. Draft sensor
2. Top link bracket
A 45 Nm
(8--- 12 V DC)
Draft sensor Measuring signal and supply voltages

See page 320/14.
The draft sensor acts as a lower mounting bolt of the top link
bracket. The sensor converts draft forces into electrical sig- Short circuit in draft sensor line
nals.
The draft sensor is housed in a tube manufactured from a --- Short circuit in the supply line causes deadlock of the whole
special steel. Inside the sensor there is a carrier wave elec- system (current breaks also in the selector panel A2E ). If this
tronics unit, a signal amplifier, and a transformer which pro- short circuit is only momentary, the system starts normally
duces a magnetic field at the measuring point. with the lift/lower switch. If the short circuit is sustained, the
power lift remains locked.
The draft force causes a shearing stress on the sensor and this
changes the magnetic properties of the metal, which causes --- Short circuit in the signal line causes the lifting reaction on
a variation in the voltage in the transformer. the lower links during the short. The system returns automati-
cally to the normal function after the short circuit (”ghost lifts”).
USupply = 8 ---12 V (DC)
USignal = 2,5 ---7,5 V (DC) (max. draft --- max. push) --- Contact between the supply and signal lines causes the full
(signal voltage is 5 V when the sensor is unloaded). lowering reaction on the lower links during the short circuit.
The draft pin must be changed if it is damaged. If the sensor

lead is damaged it can be repaired using three pin con-
nectors.
295
Model Code Page
15. 9. 1995
1. 3. 1997
4 5
Functional checks
A. Checking rear push buttons
If a malfunction should occur, the reasons may be either in the --- Start the tractor
electric control system or in the hydraulic system: --- Set the lift/lower switch (2) in the lowering position
--- Press the buttons on the RH side mudguard and check if
1. Distinguishing between electrical and the lower links actually move upwards and downwards:
hydraulic malfunctions a) If the lower links respond to the push buttons, then this sec-
tion is in working order
---Start the tractor. Apply the parking brake. Ensure that the
lower links are in the working position. b) If the lower links do not move when the buttons are
--- Press the push buttons at the ends of the solenoids on the pressed:
control valve. This moves the valve plunger mechanically (the ---check the power lift fuses FA1 and FB3 in the fuse box (on
rearmost solenoid is for lifting). 665 is also fuse F1E on wire under the switch panel. On
--- If the lower links move upwards and downwards, the 355---565 and on some 665 fuse FA9 in the same place. On
hydraulic circuit is in order the latest 65---models fuse FB4 in the fuse box.
--- If the lower links fail to move when the buttons are --- check the constant current and current passing through the
depressed, check the condition of the pump and oil pipes. If ignition switch from the power lift inlet connection (blue and
necessary, the control valve must be checked (see section brown wires. 865: blue and red wires, connector X2E/1 and 2)
90). --- check the connectors for breaks and repair if necessary
Warning! 355 ---665: Do not lift the lower links to the max. c) If the lower links e.g. lift but will not lower:
upper position with the push buttons at the solenoid --- Change round wires to the solenoids and try the buttons
valve ends because the limit switch could be damaged again:
and the inner lever in the hydraulic lift housing can dam- --- If the lower links still move upwards only, the lower solenoid
age the rear wall of the housing. is defective and must be changed
--- If the lower links move downwards only, the valve is in order,
Note! The 865 tractor has not the limit switch and the warning but the other solenoid is not receiving current. In this case,
above is unnecessary. On this tractor the hydraulic housing check the lead connectors.
resists the force caused by the inner lever.
B. Checking the lift/lower switch
2. Checking the electrical operation
The power lift control system is activated with this switch. (2).
Important! The most likely causes of malfunction are poor
If the unit is not receiving current or information about the posi-
contacts in the connectors and switches. In case of malfunc-
tion of the lower links (e.g. the position sensor lead is dam-
tion, all connectors and switches must be checked and
aged), the control system will not start to function and the
cleaned.
power lift will not respond to the position control knob (1)
296
Model Code Page
10. 1. 1992
1. 3. 1997
If the control system does not start to function, but the lower
links respond to the push buttons: --- rotate selector (4) to position 6 (max lowering speed)
--- connect a suitably heavy load to the three ---point linkage
--- Check the lift/lower switch and the associated connections
(if the power lift is left unused for some time the switch may Put the lift/lower switch (2) in the lifting position, so that the
become oxidized, and the control system will fail to activate). lower links are raised to an upper position. Lower them by put-
--- Check the position sensor and its connector (see pages ting the switch in the lowering position and use a timer to
320/10 ---10A and 320/14) measure the lowering speed. Six different speeds should be
--- Check the electronic unit connector found according to the position of the selector (4) (1=slowest,
6=fastest)
If no defect is found, the whole electronic unit must be
replaced. Note! The lowering speed for the slowest position (1) should
be at least 6 seconds regardless of the load.
C. Checking the position control potentio-
Checking the switch panel, see page 320/11.
meter (1)
--- Activate the control system (switch 2)
--- Turn switch (5) to position 9. G. Checking the draft control operation
--- Rotate the position control knob slowly to its extreme posi-
tions. The movement of the lower links should be steady
(clockwise extreme position=max transport height. Anti --- When the draft control is in use (Eg. during ploughing), the lift
clockwise extreme position=lowest position of lower links. and lower indicator lights will flash. If the draft control is out of
order, the power lift operates in the position control mode (as
Note! The numbers beside the position control knob and the if selector were in position P.
transport height selector correspond to each other.
Quick checking of the draft control ranges
Note! Checking the position control potentiometer, see page
320/15. --- start the engine and activate the power lift (switch 2)
--- use the position control knob (1) to set the lower links to
position 4 (selector (6) in position P)
D. Checking the indicator lights on switch --- stop the engine but leave the ignition on
panel --- turn the draft control selector to position 2
--- use the position control knob to stop the power lift fairly near
--- Check that the position control indicator light (8) is lit when the beginning of the lift cycle, ie. rotate the knob until the lift
the draft control selector (6) is in position P and lowering indicator lights are off, fairly close to the area
--- Check that the draft control indicator light (8) is lit, when the where the lift light is lit
draft control selector is in position 1---5 --- turn the draft control selector to position 3. The lift indicator
--- Raise the lower links by rotating the position control knob light should now be lit
=red lift indicator light (7) is lit --- again use the position control knob to stop the power lift.
--- Lower the lower links =green light (7) is lit --- turn the draft control selector to position 4. Now the lift indi-
cator light should be lit
Note! The lift/lower indicator lights are connected in parallel --- use the position control knob to stop the power lift and turn
with the control valve solenoids. Therefore, if the indicator the draft control selector to position 5. Once again, the lift indi-
lights are lit this means that the solenoids are receiving cur- cator light should be lit.
rent.
Note! The graduation between the areas 3 and 4 is greater
Note! Reconditioning indicator lights, see page 320/13. than elsewhere. It can be tested by turning the draft control in
area 3 a little further to the lowering side. Returning to area 4,
the lift indicator light is lit again.
E. Checking the transport height selector
--- Activate the control system (switch 2) Note! Checking draft control selector (switch panel), see
--- Rotate the transport height selector (5) to position 9 page 320/11.
--- Rotate the draft control selector (6) to position P
--- Rotate the knob (1) max clockwise (to position 9) H. Forced lowering button
The transport height selector (5) should at this point provide As standard on 865, see pages 320/4B and 320/5. When this
6 different upper position for the lower links: the maximum button is depressed, the control unit pin 8 is earthed, see wir-
upper position 9 and five lower positions, but not the lowest ing diagram.
position
--- Activate the power lift. Adjust the lower links to the working
Checking the selector, see instruction on page 320/11. position with the position control potentiometer.
Adjusting max. transport height, see page 320/10 ---10A. --- Depress the forced lowering button at which time the lower
links are lowered to the lowest position.
--- Release the button and the lower links should find a level
F. Checking the lowering speed selector determined by the position control potentiometer.
--- lift the lower links to the transport position with the Autocon-
trol---switch. Now the use of the button must not cause a
Note! The lower links must have load when this check is car- lowering reaction of the lower links. Not even when the Auto-
ried out. control---switch is in the middle position.
--- the lowering speed of the forced lowering button depends
--- Activate the control system (switch 2) on the position of the lowering speed selector.
--- rotate selector (6) to position P
--- rotate selector (5) to position 9
297
Model Code Page
1. 9. 1995
1. 3. 1997
Checking/adjusting limit 2
switch on 355---665
1
Note! The limit switch prevents the lift-
ing arms from rising too high when the
push buttons are used (if the towing
hook lifting links do not limit the lifting
height). If the limit switch has been
detached, it can be readjusted accord-
ing to this instruction:
--- unscrew the position sensor so

much that the eccentric on the lifting
arm shaft does not damage it when the
lifting arms are raised to the max. upper
position.
3
--- detach the lifting links from the lifting
arms.
Figure 5. Hydraulic lift housing
--- disconnect the limit switch connector
1. Limit switch
X7E under the cab floor mat on the LH
2. Position sensor
side rear corner. Connect an ohmmeter 3. Inner lever
to the pins of the connector.
--- raise the lifting arms by hand and
check when the limit switch switches
off.
--- after the limit switch has switched off
the lifting arms must rise about 5 mm
more at the lifting arm ends before the
inner lever touches the hydraulic hous-
ing rear wall.
--- adjust the limit switch and tighten its fixing screws.
--- connect the limit switch connector.
--- start the engine and raise the lifting arms with the push but-
tons until the limit switch stops the lifting movement at the
adjusted level (about 5 mm (at the lifting arm ends) before the
inner lever touches the housing rear wall)
--- adjust the position sensor (see the following instruction).
1
4
Adjusting position sensor on 355---665 2
(=Max. transport height adjustment)
Note! Make sure that the limit switch is correctly adjusted

(see instruction above).
1. Unscrew the position sensor so much that the eccentric on

the lifting arm shaft does not damage the sensor when the
arms are raised to the max. upper position. Start the engine
and raise the lifting arms with the push buttons until the limit
switch stops the lifting movement.
3
3.Turn the position sensor clockwise until it reaches the bot-
tom and then turn it back one turn. Lower the lifting arms with
the lift/lower switch and raise them to the max. transport
height with the same switch (selector 5 in position 9).
4. Check that the push button for lifting raises the lifting arms
about 5 mm higher than the max transport height.
Note! If the lifting arms rise too much with the push button,
screw the sensor carefully clockwise and vice versa. Note that
the push buttons do not function if the lift/lower switch is in the
lifting position.
Figure 6. Position sensor
5. Tighten the position sensor locking nut. Apply Permatex
1. Locking nut (Loctite 270 onto threads)
Super 300 sealant onto the sensor threads. Locking nut is
2. Permatex super 300 onto threads
locked with Loctite 270.
3. Eccentric on the lifting arm shaft
. 4. Hydraulic housing cover
6. Fit and adjust the towing hook lifting links (if fitted) (see
instruction in section 90 on page 920/7).
298
Model Code Page
1. 5. 1996
32. Electro---hydraulic power lift 865 320 10A
1. 3. 1997
Adjusting position sensor on 865 With the new unit the position sensor must be
(Note! The 865 tractor has not a limit switch). adjusted as follows:
Normally the position sensor does not require any adjust- --- remove the lifting links of the towing hook (if fitted).
ment. If the sensor has been removed for repair works, the --- lift the lower links to the max. transport height with the Auto-
sensor must be adjusted. control rocker switch
--- check by lifting the lifting arms, that the lifting links rise
1. Apply sealant to the sensor threads (Permatex Super 300). about 10 mm before the mechanical stop (at the ends of the
Screw in the sensor, but not too deep. lifting arms about 20 mm.
Warning! If the sensor is screwed too deep, the eccentric on

the lifting arm shaft damages the sensor end, when the push Malfunctions of position sensor
buttons are used.
Up to manufacturing date 980331 of the digital unit the posi-
2. Start the engine. Raise the lower links to the max. transport
tion sensor has had malfunctions. The faulty units are used in
height (pos. 9) with the Autocontrol rocker switch. Turn the
the tractor production from week 810 up to tractor serial
sensor and find the position where the pump relief valve is
number H24542. From the unit date 980401 the faulty func-
blowing off *) and turn then the sensor inwards about 1/4 of
tions have been removed.
a turn.
Note! The spare part units 31287220 do not cause the mal-
3. Lower the lower links.
functions.
4. Raise the lower links again to the max. transport height and
If the AC power lift transport height has been adjusted
ensure that the relief valve is not blowing off.
wrongly, the lift activation can disappear and the lower links
remain in the upper position.
5. Check, that the lifting arm ends rise further 5 ---10 mm when
At this time, stop the engine and switch off current. Restart the
using the push button.
engine and lower the lower links downwards by using the
push buttons. After this activate the lift normally. Carry out
6. After adjustment, tighten the sensor locking nut (Loctite
repair by adjusting the position sensor a little outwards, check
270).
the function..
*) When the pump is on, the load on the engine can be heard
easily.
1. Special instructions
A. Control unit A1E
Note! The internal function of the unit has been changed from
analog into digital and the analog units are not manufactured
any more. In addition, in the store, there is a limited number
of the analog units.
The new digital unit replaces the old one. All spare part orders
with number 31287210 (old analog) will be sent with number
31287220 (new digital). Unit 31287220 is suitable for models
365---865 and 600---900.
Note! When the new digital unit is fitted on earlier 865---900

tractors, the compensator A3E (32634500) must be removed
(remove from its connector). The compensator has been
removed in the production on new tractors.
299
300
Model Code Page
10. 1. 1992
1. 3. 1997
1. Checking switch panel circuit card (A2E)

If lowering speed (S7E), transport height (S8E) or draft control
selector (S9E) does not function properly and the malfunction
cannot be localized with the help of the preceding instruction,
the circuit card A2E can be checked as follows:
N.B.! In checking, a voltmeter (measuring scale 0---14 V DC)

is needed.
S7E
S9E
S8E
2
A2E
X6E
4
Figure 6. Switch panel (different on 865), circuit card (A2E) and connectors
--- S7E lowering speed selector
--- S8E transport height selector
--- S9E draft control selector
1. Connector, position control potentiometer
2. Connector, lift/lower ---switch
3. Wires for indicator lights
4. Connector, circuit card
A. Removing the switch panel for checking

on 355---665 tractors
1. Detach the panel for switches and circuit card by unscrew- Note! The terminals of connector 4 have been numbered
ing four fixing screws. from 1 to 12.
Note! The fixing screws have loose nuts. It is easier to Note! On the 865 tractor, the console on the driver’s right
unscrew/screw the screw on the left upper corner by using a must be removed before the circuit card is accessible. When
ring spanner (10 mm) with a washer welded to one side of the removing the console, unscrew the console fixing screws,
ring to keep the nut in place. Also the ring spanner is more one screw in the front part on the lower corner and another in
useful if it has a special long arm. the rear part lower corner. Then raise the console until it
releases from the attachment on the upper part beside the
2. Turn the panel upside down so that the voltage measure- side window.
ments can be done on the circuit card rear side from the tinned
terminals of connector 4. Do not detach the connector from
the circuit card.
301
Model Code Page
15. 9. 1995
1. 3. 1997
B. Voltage measurements Checking transport height selector
Turn the current on with the ignition switch and activate the
control system with the Autocontrol---switch (lift/stop/lower
switch) (do not detach the connector from the circuit card).
Carry out measurements on the rear side terminals according
to the figures a ---d below.
12 1
Checking supply voltage
8
V
12 7 6 1
Figure c) Checking transport height selector: Measure volt-
age between terminals 1 (or any frame contact) and terminal
8 with every selector (S8E) positions.
Position Terminal 8
4 9,5---10,5 V
5 7,6---8,4 V
V 6 5,7---6,3V
7 3,8---4,2 V
8 1,9---2,1V
9 ~0
Figure a) Measuring supply voltage: measure voltage
between terminals 1 and 6
Correct value is 8---12 V

Checking draft control selector
12 5 1
1
11 10 9
V
Checking lowering speed selector
Figure b) Checking lowering speed selector: Measure volt-

Figure d) Checking draft control selector: Measure voltage
age between terminals 1 (or any frame contact) and terminal
between terminals 1 (or any frame contact) and terminals 9,
5 with every selector (S7E) positions:
10 and 11 separately with every selector (S9E) positions:
Position Terminal 5
Pos. Terminal 10 Terminal 9 Terminal 11
1 0,9---1,1 V
P 9,5---10,5 V 0---0,2 9,5---10,5 V
2 1,7---1,9 V
1 3,7---4,1 V 0---0,2 7,7---8,5V
3 2,4---2,8 V
4 4,3---4,9 V 2 1,8---2,0 V 0---0,2 7,7---8,5 V
5 6,0---6,8 V 3 1,8---2,0 V 0---0,2 9,5---10,5 V
6 9,5---10,5 V 4 ~0 0,6---0,8 V 7,7---8,5 V
5 ~0 0,6---0,8 V 9,5---10,5 V
Note! If the supply voltage deviates from the value given

above, a possible fault can be poor contacts in supply con-
nectors (+ or --- side). If other measuring values deviates from
values above, the circuit card is faulty and must be changed
(see instr. C).
302
Model Code Page
10. 1. 1992
C. Changing circuit card

N.B: If the voltage measurements show that the circuit card
is defective the card must be replaced as a complete unit as
follows:
1. Detach the circuit card from the panel by removing selector

knobs and by unscrewing ring nuts and by removing the cup
washers.
2. Remove also the dust seals. Detach the circuit card con-
nector so that the card can be removed.
3. Fit onto new selectors washers with lugs. These washers

limit selector positions. Before fitting the washers turn every
selector anti ---clockwise as far as possible to their extreme
position. After this has been done, fit the washers so that the
lugs engage in the holes at number six on every switch (see
figure above). Make sure by turning the switches that they
have six different positions.
4. Fit the dust covers (317 204 20) onto the switches.
5. Attach the connector to the circuit card. Fit the circuit card
onto the panel by means of the ring nuts (fit the cup washers
JE 9423 under the nuts).
6. Fit the selector knobs and fit the panel into its place.
D. Checking circuit card indicator lights

If Autocontrol power lift functions properly, but indicator lights
on the circuit card do not function correctly the following steps
must be taken:
--- Detach the switch panel (instr. A) and move the connector
on the circuit card so that possible poor contacts disappear.
--- If an indicator light is still out of order the voltage measure-
ments shown in instruction B must be carried out.
--- If voltages are between allowable limits but light is still out of
order the fault is in the bulb and the whole circuit card has to
be changed as a complete unit (see instruction C)
303
Model Code Page
1. 5. 1996
1. 3. 1997
2. Measuring internal voltages of position sensor and draft sensor

The condition of the sensors can be checked by measuring
the sensor supply and signal voltages with the aid of a spe-
cial tool.
Connect the tool into the power lift by opening the position
sensor connector (black) or the draft sensor connector
(white) and by fitting the tool between the lead. Start the
tractor and activate the power lift with lift/lower switch.
The correct values should be:

Special tool
ETV 894 100
Position sensor
Supply voltage = 6,3---7,7 Veff (AC) (f4---7 kHz)

Signal voltage = 1,2...2,5 V --- 3,0...5,0 V (AC)
(lower links down ---up)
The supply voltage is measured between the red and black

connectors and the signal voltage between the blue and
black connectors.
Draft sensor
Supply voltage = 8---12 V (DC)

Signal voltage = 2,5---7,5 V DC (max pull---max push)
Note! The signal voltage should be 5 V DC, when the draft

sensor is unloaded.
Blue The supply voltage is measured between the red and black
black connectors.
Yellow ---green Note! If the sensors do not receive the supply voltage,
check the power lift fuses and the lead connectors. If these
are OK the possible fault may be inside the electronic unit
Brown which should be replaced.
665: F1E
Black (1)
Blue (2) 1 3
2
Red (3)
Figure 1. Tool for measuring sensor signal

and supply voltage
Red = supply voltage=3
Blue = signal voltage=2
Black = earth lead=1
View A
1 3 Sensor connectors (X3E and X4E. 865: B1E and B2E) are
placed under the cab on the RH side. They are accessible
2 when the sensor wire bands are cut and the connectors are
pulled up into the cab through the rubber bellows on the RH
side of the driver’s seat.
304
Model Code Page
1. 3. 1997
1. 6. 1998
3. Checking the position control potentio- 4. Checking control valve and its solenoid
meter valves
If the lifting or lowering speeds do not function correctly, it is

Potentiometer necessary to clear up whether the fault lies in the electric sys-
tem or in the control valve (valve spools can get trapped etc.).
Checking electric system:
1. Stop the engine and switch off current.
2. Detach the switch panel (see page 320/11) and part the
position control potentiometer connector (X6E) under the
panel (865: connector R1E under the side console).
Connect an ampere ---meter in series with control valve sole-
3. Measure resistance (between blue and black leads) in knob noids. Y1E lowering (inner) and Y2E lifting (outer). Use ETV
positions 1, 4 , 7 and 9. Resistance values should be: 894 220 when measuring, see page 101/4F.
Position 1 . . . . . . . . . . . . . . . . . . . . . . ~ 145 ohm Lifting . . . . . . . . . . . . . . . . . . . . . . . . . ~ 3,45 A

Position 4 . . . . . . . . . . . . . . . . . . . . . . ~ 1355 ohm Lowering (yellow buttons) . . . . . . . . ~ 1,96 A
Position 7 . . . . . . . . . . . . . . . . . . . . . . ~ 3215 ohm
Position 9 . . . . . . . . . . . . . . . . . . . . . . ~ 4,5 kilo---ohm Lowering speed positions:
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 1,40 A
4. Then rotate the position control knob slowly from one 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 1,55 A
extreme position to the other and make sure that the resis- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 1,70 A
tance value changes linearly without steps. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 2,15 A
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 2,60 A
6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 3,45 A
Resistance of solenoid . . . . . . . . . . . ~ 1,6 Ω
Checking control valve:
If the measured values agree with the correct values above,

but malfunctions occur in the lowering and lifting functions,
the control valve should be removed and checked (see page
920/6).
Note! The control valve solenoids have been changed. The

new solenoids are round and the coils can be changed sepa-
rately. The electric control of the new solenoids is the same
and ithey are exchangeable with the earlier solenoids. A re-
pair kit is available for the new solenoids, which includes the
coil, seals, fixing nut and the protecting cap.
305
306
Model Code Page
32. ACB power lift 600-- 900 321 1
15. 4. 1999
A. ACB power lift, description

Note! On 600---900 tractors the ACB power lift is the same as on Mezzo---tractors except that 600---900 tractors have only one
draft sensor on the top link bracket. In addition, wires and switches have differences.
--- ACB power lift has a digital control unit (same as on Mezzo tractors).
--- The position sensor is different as on AC power lift, but the same as on Mezzo tractors’ ACB power lift.
--- ACB power lift has as standard a Drive Balance Control, which dampens driving oscillation movements in transport of the
tractor caused by a heavy implement which is attached to the three point linkage unit.
--- The ACB power lift switch panel has a diagnostic light, which indicates self ---testing and locking of the power lift and it indi-
cates by flashing the fault code numbers so that possible faults can be localised.
--- Lowering speed selector, transport height selector and draft control selector have more positions than earlier.
6 1 2
3 4
5
8 B
Picture 1. ACB power lift switch panel
1. Lowering speed selector (9 positions)

2. Transport height selector (9 position)
3. Position control/Draft control selector (position P is for position control. The draft control has 6 different positions)
4. Drive Balance Control
--- OFF; Drive Balance Control switched off
--- Drive Balance Control switched on (situation in picture)
5. Indicator light, Drive Balance Control switched on
6. Diagnostic light
7. Indicator light, lifting
8. Indicator light, lowering
Note! The functions of the position control potentiometer, lifting/lowering switch and the forced ---lowering switch are the same
as earlier (see code 320). The push buttons in the cab have been replaced with one rocker switch, but the function is the
same as earlier (also on AC power lift). There are push buttons on the rear mudguards. The draft sensor is the same as
earlier. Functional check of ACB power lift, see page 321/6.
307
Model Code Page
32. ACB Power lift 600-- 900 321 2
15. 4. 1999
Picture 2. . Control switch console on 600 ---900 tractor
6. Autocontrol ---rocker switch S10E

7. Position control potentiometer R1E
8. Lowering speed selector S7E
9. Transport height selector S8E
10. Position control/draft control selector S9E
11. Rocker switch in cab, lifting/lowering S5E
12. Push buttons S1E and S2E in the rear mudguards (not
illustrated)
14. Indication lights, lifting and lowering
15. Oscillation damping switch S12E
Note! On the 600---900 tractors, the console on the driver’s

right must be removed before the circuit card or control unit
of ACB are accessible. When removing the console,
unscrew the console fixing screws, one screw in the front
part on the lower corner and another in the rear part lower
corner. Then raise the console until it releases from the
attachment on the upper part beside the side window.
308
Model Code Page
32. ACB Power lift 600-- 900 321 3
15. 4. 1999
Picture 3. ACB Power lift on 600 ---900 tractors
1. Control valve (earlier type in picture)

2. Draft sensor B2E 10. Position control/draft control selector S9E
3. Top link sensing 11. Lifting/lowering rocker switch S5E
4. Control unit A1E 12. Push buttons on rear mudguards, S1E and S2E
5. Position sensor B1E 13. Forced lowering button S11E
6. Autocontrol ---switch S10E 14. Ind. lights for lifting/lowering
7. Position control potentiometer R1E 14a,. Diagnostic light
8. Lowering speed selector S7E 15. Oscillation damping switch S12E (+ind. light)
9. Transport height selector S8E 15a. Indication light for oscillation damping
309
Model Code Page
32. ACB---Power lift 600-- 900 321 3A
1. 9. 2001
ACB---Power lift with Bosch EHR5 Control Valve. Com-

pare with picture on page 321/3.
310
311
Model Code Page
15. 4. 1999
32. ACB Power lift 600-- 900 321 4
1. 9. 2001
Wiring diagram, ACB Power lift
312
Model Code Page
15. 4. 1999
32. ACB Power lift 600-- 900 321 5
1. 9. 2001
General
Wiring diagram
Connector X2E for the supply voltage is placed in the lever
A1E ACB control unit 42-- 44 console. If the Power lift does not start and does not res-
A2E Control switch circuit card 45 pond, when the rear push buttons are used, check fuses
FA1 and FB4. If the fuses are OK, check connector X2E
B1E Position sensor 41 (pins 1 and 2). Also check the earth point GR4 on the cab
B2E Draft sensor 41 rear horizontal beam on the RH side (under the mat and the
plate).
E1E Illumination, switch circuit card 45
E2E Illumination, position potentiometer 46 The wires from the LH side push buttons (on the mudgu-
ard) have been drawn via connector X6 (in the cab on the
R1E Potentiometer, position control 45 LH side) and the wires from the RH side push buttons via
connector X5. In addition, the push button wires have been
S1E Push button, mudguard, lifting, right 43 connected to connector X2E.
S2E Push button, mudguard, lowering, right 43
S3E Push button, mudguard, lifting, left 42 If the rear push buttons function, but the Power lift cannot
S4E Push button, mudguard, lowering, left 42 be activated with the Autocontrol---switch , check the wires
S5E Switch, cabin, lifting/lowering 44 of the Autocontrol---switch. If these are OK, the fault can lie
S7E Selector, lowering speed 45 in the control unit A1E, which should be changed.
S8E Selector, transport height 45
S9E Selector, position control/draft control 45 Note! When malfunctions occur, check the connectors.
S10E Switch, lift/stop/lowering 45-- 46 Poor contacts in the connectors is the most common fault
S11E Switch, forced lowering 44-- 45 in this kind of system. The hydraulic system can be tested
S12E Switch, oscillation damping (DBC) 45 by pushing buttons at the end of the control valve sole-
noids.
X2E Connector, 9 pins, supply & rear buttons 42
Note! If the tractor has the earlier type control valve (sole-
Y1E Solenoid valve, lowering 41 noids on the different sides of the valve), the pins 7 and 13
Y2E Solenoid valve, lifting 41 of the control unit have been connected with wire 169 yel-
low. If a new valve is fitted (solenoids on the same side of
the valve, see code 920), the wire has been removed. The
Wire colours: new type valve does not cause other modifications in the
Ru = braun ACB Power lift.
Pu = red
Ke = yellow
Si = blue
Mu = black
Vi = green
Va = white
313
Model Code Page
32. ACB Power lift 600-- 900 321 6
15. 4. 1999
1 8 9 10 15
2
5
3 B
B. Functional check of ACB Power lift

7. Lift the lower links up step by step (1---9) by using the positi-
Note! The Power lift must function in the way shown in this
on control potentiometer (7); The lifting intervals are almost
instruction. the same and the red light (2) is lit when the links move up.
Leave the knob (7) in the max. position; the display shows 100
1. Start the engine. The red diagnostic light (1) comes on.
Ac (in AD ---instrument 99 Ac).
Activate the Power lift with the Autocontrol---switch (6), at
which time the diagnostic light goes out. Leave the Auto-
8. Raise the lower links to the topmost position with switch
control---switch (6) in the lowering position and adjust the
(11), diagnostic light (1) comes on and shows that the Power
lower links with the position control potentiometer (7) to the lift is locked.
lowest position.
Release the towing hook and lower the lower links together
with the towing hook. Check that the mudguard push buttons
2. Set the lowering speed (8) and transport heights (9) to and switch (11) function (the buttons function in all positions
the minimum and position control/draft control switch (10)
of the Autocontrol---switch (6)).
to position P.
9. Turn the Autocontrol---switch (6) to the transport position
3. Turn the Autocontrol---switch (6) into the transport positi-
and immediately back to the middle position; the lower links
on. The standard instrument shows running hours and the start to rise but stop immediately, when the switch is turned to
decimal point is flashing, when the engine is running (The the middle position. The standard instrument shows running
display of AD ---instrument does not change with Autocont-
hours in the middle and transport position (display of AD ---in-
rol---switch, but with a switch of its own). strument does not depend on the position of the switch (6)).
4. Turn step by step the transport height selector (9). The
lower links rise with even intervals, the red lifting ind. light 10. Turn switch (6) to the transport position, at which time the
(2) is lit when the lower links move up. Leave the transport
lower links rise up and the towing hook is locked by the pawl.
height selector to the max. value (pos. 9).
11. Adjust the lower links to horizontal with knob (7) (switch
5. Turn the draft control switch (10) to the max. value (pos
(10) in pos. 6) so that the ind. lights (2 and 3) do not light.
6) and press the Autocontrol switch (6) to the lowering posi- Press the top link bracket, at which time the ind. light (2) co-
tion. When the lower links go down, turn the lowering mes on and the lower links go up.
speed selctor (8) to the max. value. The lowering speed
increases clearly and the green light (3) is lit. Leave the lo- 12. Switch on the position control mode (P). Push switch (13),
wering speed in the max. value.
at which time the lower links go down. Release the switch, at
which time the lower links return to the original position. Check
6. When the lower links are in the bottom position, the the position of the lower links in the Ac---display.
green light (3) is lit (floating position), the standard instru-
ment shows between 0---15 and text Ac (in the AD ---instru-
13. Turn the Autocontrol---switch (6) to the transport position,
ment, the Ac---display must be selected in the upper disp- switch on the drive balance control (DBC) with switch (15).
lay).
The lower links lower then about 4 cm. Switch off the DBC,
at which time the lower links rise up.
314
Model Code Page
32. ACB Power lift 600-- 900 321 7
15. 4. 1999
C. Position sensor
B1E
SIGNAALI
3
SYÖTTÖ
1
Suunta A
Picture 4. Position sensor in ACB Power lift

1. Eccentric on the lifting ram shaft
2. Hydraulic housing cover
3. Permatex Super 300 on the threads
4. Locking nut
5. In ---built amplifier
Connnector A:
1. Earth pin
2. Signal pin
3. Supply pin
Direct current (DC) is fed into the ACB position sensor. Measuring position sensor supply and signal
voltages
USUPPLY = 9,5±0,3 VDC
USIGNAL = 25 ---75 % x USUPPLY (lower links down ---up) Sensor voltages can be measured as earlier by using spe-
cial tool ETV 894 100 and a universal instrument, see page
The position sensor connector is fitted at the end of the 321/9.
sensor.
Measuring values
Note! The positon sensor cannot be repaired but a defect --- Supply voltage . . . . . . . . . . . . . . . 9,2 ---9,8 VDC
sensor must be changed for a new one. --- Signal, lower links down . . . . . . . 2,3 ---2,5 VDC
--- Signal, lower links up . . . . . . . . . . 6,9 ---7,4 VDC
Important! Fault code number 22 indicates, that the posi-
tion sensor does not function. Diagnostic light and fault Adjusting position sensor, see page 321/14.
codes, see instr. E.
315
Model Code Page
32. ACB Power lift 600-- 900 321 8
15. 4. 1999
D. Draft sensor (same as on AC Power lift)
F
FILTER OSCILLATOR
Ua
Us
DEMODULATOR
F/2 F/2
Picture 5. Draft sensor
1. Draft sensor
2 2. Top link bracket
A 45 Nm
(8---12 VDC)
Short circuit in draft sensor line

The draft sensor acts as a lower mounting bolt of the top
link bracket. The sensor converts draft forces into electrical
signals. --- Short circuit in the supply line causes deadlock of the whole
system (current breaks also in the selector panel A2E ). If this
USUPPLY = 8 ---12 V (DC) short circuit is only momentary, the system starts normally
USIGNAL = 2,5 ---7,5 V (DC) (max. draft --- max. push) with the lift/lower switch. If the short circuit is sustained, the
(signal voltage is 5 V when the top link is unloaded). power lift remains locked.
The draft sensor internal voltages can be measured with --- Short circuit in the signal line causes the lifting reaction on
tool ETV 894 100, see the next page. The sensor can be the lower links during the short. The system returns automati-
loaded e.g. with a mounting lever, so that the function of the cally to the normal function after the short circuit (”ghost lifts”).
sensor can be verified.
--- Contact between the supply and signal lines causes the full
A damaged draft pin must be changed . If the sensor wire lowering reaction on the lower links during the short circuit.
is damaged it can be repaired using three pin connectors.
Fault codes 31 and 32 indicate the fault in the sensor.
316
Model Code Page
32. ACB Power lift 600-- 900 321 9
15. 4. 1999
Measuring internal voltages of positi-

on sensor and draft sensors
Open the position sensor connector at the end of the positi-

on sensor or the draft sensor connector under the cab on
the RH side (the draft pin connector is accessible when the
Ordering no plastic bind is cut after which the connector can be pulled
ETV 894 100 up through the rubber bellows). Connect ETV 894100 bet-
ween the sensor connector. During measuring the current
must be switched on and the lift must be activated.
Below are given the correct voltage values (DC):
Position sensor:
--- supply voltage . . . . . . . . . . . . . . . . . . . . . 9,2 ---9,8 VDC

--- Signal, when lower links down . . . . . . . . 2,3 ---2,5 VDC
--- Signal, when lower links up . . . . . . . . . . 6,9 ---7,4 VDC
Draft sensor:
--- supply voltage . . . . . . . . . . . . . . . . . . . . . 8 ---12 VDC

--- signal voltage . . . . . . . . . . . . . . . . . . . . . . 2,5 ---7,5 V VDC
(max. pull --- max. push). Signal voltage is 5 V when the top
link is unloaded.
The supply voltage is measured between the red and black

black connectors.
Blue
Note! If the sensors do not receive the supply voltage,
check the power lift fuses and the lead connectors. If these
Yellowgreen are OK, the possible fault may lie inside the electronic unit
which should be replaced. If the signal voltages are incor-
rect, the fault lies in the sensor or in its adjustment.
Brown
Black (1) 1 3
Blue (2) 2
Red (3)
A
Picture 1. Tool to measure internal voltages of sensors

Black connector = earth=1 (brown wire)
Blue connector= signal voltage=2 (yellowgreen wire)
Red connector= supply=3 (blue wire)
1 3
2
Direction A
317
Model Code Page
32. ACB Power lift 600-- 900 321 10
15. 4. 1999
E. Function of diagnostic light and fault codes
When the current is switched on with the ignition switch, the diagnostic light is lit for a while (book symbol). This is the self ---
testing of the ACD system. After a short time the diagnostic light is lit continuously. This indicates that the power lift is locked.
When the light is on, all functions are locked, but the push buttons function.
The power lift is activated by turning the lift/lower switch first to the lifting and then to the lowering position, at which time the
diagnostic light goes out and the power lift responds to all switches. Immediately after the activating the ACD limits the supply
current to the solenoid valves for safety. This limit delays movements of the lower links. The current supply limit disappears,
when the function limit of the control unit has been achieved or if the lift/lower switch is used anew.
After use of the push buttons the ACB is locked and the diagnostic light is illuminated.
Fault codes
ACB power lift continually monitors possible malfunctions in the system. The faults are divided into three different levels
according to their seriousness as follows:
1. Serious faults:
--- the power lift is locked
--- relay closes (protects outputs)
--- diagnostic light indicates the fault
--- Remedy: Repair the fault, start the tractor and activate the power lift.
2. Medium serious faults:

--- the power lift is locked.
--- diagnostic light indicates the fault
--- Remedy: Repair the fault and activate the power lift with the lift/lower switch
3. Minor faults
--- the power lift continually functions
--- diagnostic light indicates the fault. When the lift/lower switch is turned, the diagnostic light goes out, if the fault has disap-
peared.
A possible fault can be localised with the aid of the diagnostic light, which displays by flashing the number of the fault code.
For example, if the signal wire to the draft control selector is damaged or there is poor contacts in connectors (fault code 36),
the diagnostic lights flashes as follows:
--- Long pause --- three flashes --- short pause --- six flashes.
During momentary faults, the diagnostic light flashes, until the lift/lower switch is turned, although the fault has already disap-
peared.
THE FAULT CODES ARE LISTED ON THE NEXT PAGE.
318
Model Code Page
32. ACB Power lift 600-- 900 321 11
15. 4. 1999
Fault codes of ACB Power lift

1. Serious faults
Fault code Fault Control Description

number unit con-
nector pin
11 Output/lifting 2 Output signal to lifting solenoid faulty or poor contacts in solenoid wire
to pin 6.
12 Output lowering 14 Output signal to lowering solenoid faulty or poor contacts in solenoid
wire to pin 6.
13 Short circuit 6 Measured current in pin 6 too high. Short circuit between pins 2 and 6
or between pins 14 and 6 (solenoid in short circuit)
14 Push button in 10 Signal from push buttons not OK. Push button or its wire damaged.
mudguard, up-
wards
15 Push button in 20 Signal from push buttons not OK. Push button or its wire damaged.
mudguard, down-
wards
16 Supply 12 Control unit supply not in order.
Supply of 9,5 V and earthing not in order
2. Medium serious fault

number unit con-
nector pin
22 Position sensor 19 Signal from sensor faulty
--- Poor contact or position sensor disconnected
--- Possible short circuit or earthing
--- Position sensor faulty adjusted
23 Position control 16 Signal from potentiometer faulty. Poor contacts or wire loose.
potentiometer
24 Transport height 22 Signal from selector faulty. Poor contacts or wire loose.
selector
28 Up/stop/down 8 Signal from switch faulty. Poor contacts or wire loose.
switch
3. Minor faults

numbers unit con-
nector pin
31 *) Draft sensor 18, 17 Signal from sensor faulty:
32 *) --- Poor contact or wire disconnected
--- Possible short circuit or earthing
--- Sensor overloaded
34 Lowering speed 24 Signal from selector faulty. Poor contacts or wire disconnected.
selector
36 Position control/ 4 Signal from selector faulty. Poor contacts or wire disconnected.
draft control selec-
tor
*) The diagnostic light flashes by turns fault codes 31 and 32, since in 100---series tractors the Power lift has only one draft
sensor, but it is connected to two pins (17 and 18) of the control unit.
319
Model Code Page
32. ACB Power lift 600-- 900 321 12
15. 4. 1999
F. Drive Balance Control (DBC) Verifying the function of the DBC
When the tractor is driven in transport driving on an uneven

road or field with an heavy implement attached to the
power lift linkage, the shocks caused by the implement
must light the indicator lights for lifting and lowering. This
indicates that the DBC is functioning (the draft sensors
react to shocks from the implement).
When the DBC is activated, the indicator light for the lower-
ing must light for a while, since the lower links lower about
40 mm to the intermediate limit position.
Note! Checking the function of the DBC switch, see page

Ind. light 321/13.
When a tractor is driven in transport drive and a heavy

implement is attached to the power lift linkage, this causes
oscillation of the tractor (front wheels tend to jump up from
the ground) . ACB power lift has the Drive Balance Control
(oscillation damping), which functions when the power lift is
in the transport position. Shocks from an implement cause
tensions in the draft sensors, and these tensions alter to
electric signals, which in turn cause the linkage to make
small lift and lowering movements.
Drive Balance Control is activated, when:
a) Power lift is activated.
b) Power lift is in the transport position
c) The DBC switch is in the ON position

(indication light is lit).
When these four terms are valid, the lower links lower about
4 % from the upper limit position to the intermediate limit
position.
The lower links can lower 4 % from the intermediate limit
position to the lower limit position. Thus the max. distance
between the upper limit position to the lower limit position is
8 %. All percentages are counted from the total movement
range of the lower links (100 %).
Note! Position of the lowering speed selector does not

affect the Drive Balance Control speed.
The DBC can be switched off with the selector.
320
Model Code Page
32. ACB Power lift 600-- 900 321 13
15. 4. 1999
G. Checking switch panel of ACB 3. Checking transport height selector S8E
Remove the switch panel from the lever console (do not dis-
connect the connector). Switch on currrent and activate the
ACB power lift. Measure from the terminals on the rear side of
the circuit card (DC).
1. Measuring supply voltage
Picture c) Measure voltage between pins 8 and 5 with all

selector positions:
Position Pin 5
1 0
2 0,9---1,2 V
3 1,9---2,3 V
Picture a) Measure supply voltage between pins 21 (---) 4 2,9---3,3 V
and 10 (+): Correct value is 9,2 ---9,8 V (DC). Measure also 5 3,9---4,3 V
voltage between pins 21 and 8. Correct value is about 1,6 6 4,9---5,4 V
V. 7 5,9---6,4 V
8 6,8---7,5 V
Note! If the supply voltage is incorrect, the fault lies in con- 9 7,6---8,2 V
nectors/wires.
2. Checking lowering speed selector S7E 4. Draft control selector S9E
Picture b) Measure voltage between pins 8 and 6 with all

selector positions: Picture d) Measure voltage between pins 8 and 3 with all
Position Pin 6 selector positions:
1 0,3---0,5 V
2 0,7---1,1 V Pos. Pin 3
3 1,1---1,5 V P 7,6---8,2 V
4 1,6---2,0 V 1 4,0---4,4 V
5 2,3---2,9 V 2 3,3---3,6 V
6 3,1---3,7 V 3 2,4---2,9 V
7 4,1---4,7 V 4 1,6---2,6 V
8 5,6---6,0 V 5 0,7---1,0 V
9 7,6---8,2 V 6 0
321
Model Code Page
15. 4. 1999
32. ACB Power lift 600-- 900 321 14
1. 9. 2001
5. Checking DBC selector S12E H. Changing switch panel
Note! If the voltage measurements show that the switch

panel is faulty, the panel should be changed as a complete
unit.
1. Remove the cab RH side console. Remove the circuit

card on the panel by removing the selector knobs and by
unscrewing the ring nuts under the knobs and remove the
lock washers. Remove the dust protectors.
2. Disconnect the connector of the switch

card.
Picture e) Measure voltage between pins 21 and 1 (DBC)

with two selector positions:
Position Pin 1
OFF 2,0---2,4 V
DBC switched on 0
Note! If the measured values in points 2 ---5 deviate from the

given values, the fault lies in the switch panel circuit card
which should be changed.
6. Checking lift/stop/lowering switch S10E
3. Fit onto new selectors washers with lugs. These washers

limit selector positions. Before fitting the washers turn every
selector anti ---clockwise as far as possible to their extreme
positions. After this fit washers so that the lugs engage in
the holes given below:
--- lowering speed selector; hole 9.
--- transport height selector; hole 9.
--- draft control selector; hole 7.
--- Drive Balance Control; hole 2.
4. Ensure by rotating the selectors, that the lowering speed

and transport height selectors have 9 positions, draft con-
trol selector 7 position and DBC selector 2 positions.
5. Connect the connector to the new switch panel. Fit the

dust covers (no 317 204 20) onto the washers and fasten
Picture f. Measure voltage between pins 8 and 9 with all the circuit card to the switch panel with the ring nuts (under
three switch positions: the nuts locking washers JE 9423).
Position Pin 9 6. Fit the knobs and fasten the DPS circuit card. Attach the
Lowering 2,4---2,8 V selector panel onto the lever console.
Middle position (Stop) 3,5---4,0 V
Transport position 4,9---5,4 V 7. Refit the side console in the cab.
Note! If the measured values deviate from the given values,

check the switch connector. If the values are further incorrect,
the fault lies in the circuit card which should be changed.
322
Model Code Page
15. 4. 1999
32. ACB Power lift 600-- 900 321 15
1. 9. 2001
I. Checking switch panel indicator lights L. Adjusting position sensor

(in connection with repairs)
If the ACB functions properly, but the indicator lights on the
switch panel do not function correctly the following steps
must be taken:
--- detach the switch panel and move the connector on the
panel so that possible poor contacts are eliminated.
--- if an indicator light is still out of order the voltage
measurements shown in instruction G must be carried out.
---If the voltages are between allowable limits but the light is
still out of order the fault is in the bulb and the whole switch
panel has to be changed as a complete unit.
J. Checking function of position control

potentiometer
27,2 mm
1. Stop the engine and switch off current.
2. Remove the side console in the cab (see page 321/2)

and disconnect the potentiometer R1E connector near it.
3. Measure the potentiometer resistance (between blue and

black wires) in pos. 1, 4 , 7 and 9. Resistance values
(±20%):
1. Apply sealant (Permatex Super 300) onto the sensor
Position 1 ............................ ~ 145 ohms threads. Screw the sensor into place so deep, that the dis-
Position 4 ............................ ~ 1355 ohms tance between the locking nut lower face (when in contact
Position 7 ............................ ~ 3215 ohms with housing) and sensor end lower side (see picture) is
Position 9 ............................ ~ 4,5 k ---ohms 27,2 mm.
4. Then rotate the position control knob slowly from one Warning! If the sensor is turned too deep, the eccentric on
extreme position to the other and make sure that the resis- the lifting ram shaft damages the sensor, if the lower links
tance value changes linearly without steps. are raised up with the push buttons.
Note! Fault code 23 indicates problems in the position po- 2. Start the engine. Lower the lower links. Raise the lower
tentiometer. links up to the max. trasnport height (pos. 9) with the Auto-
control---switch.
K. Control valve solenoids (Y1E and Y2E). 3. Check that the lifting arm ends rise a further 5 ---10 mm
Note! Control valve EHR4 in picture below. Concerning before the mechanical stop.
control valve EHR5, see page 920/8.
Note! If the arm ends rise more than 5 ---10 mm, turn the
sensor outwards a little and vice versa.
4. After adjustment tighten the locking nut (Loctite 270). Do

not affect the adjusment when tightening the locking nut.
5. Check again the adjustment. Ensure, that the pressure ---

relief valve does not blow off in the transport position.
Note! Fault code 22 indicates problems in the position

sensor.
Important! In the rear side of the ACB hydraulic housing

there is a limiter bolt, see picture on page 920/13 point 5.
The bolt is adjusted so that the lifting arms do not touch the
cabin when the yellow push buttons are used. When using
The diagnostic light indicates faults in the solenoids or in the position potentiometer or the Autocontrol rocker switch
their signals. Fault code 11 indicates, that signal to the lif- the lifting movement must stop before the inner lever in the
ting solenoid Y2E is incorrect (e.g. poor contacts). Code 12 housing touches the bolt.
indicates that the signal to lowering solenoid Y1E is incor-
rect (e.g. poor contacts).
Fault code 13 indicates that one of the solenoids is in short
circuit.
If the solenoid resistance is zero (short circuit) or infinite

(break), change the solenoid coil. The correct resistance
value is about 1,6 ohms.
323
324
Model Code Page
33. Valmet Agrodata 205-- 665 330 1
10. 1. 1992
Agrodata---performance monitor
N.B. These instructions deal with trouble shooting on the
Agrodata unit. Instructions on how to install Agrodata on the
Valmet tractor will be sent for inserting into the Workshop
Manual. For detailed instructions concerning the use of the
Agrodata system, please see the Operator’s Manual.
Number keys (1---9)
Zeroing key for time, area (trip), area (total) and

litres. Also used to input the figure 0
Wheel circumference input key
Working width input key
Function code
Flow meter calibration
Time (hours and minutes)
Speed
Area meter (trip) and distance travelled
Area meter (total)
Engine rpm and application rate (litres per hectare)
Piece counter and total litres consumed
1 2
1. Selects between tractor and implement wheel sensor for
measurement of speed and area.
2. Selects between measurement of engine revs or implement

functions (e.g. piece counter or flow rate).
Figure 1. Agrodata function keys
General
Agrodata can be fitted on Valmet 205---555 tractors as an op- Before the Agrodata unit can be used the following three va-
lues must be input:
tional accessory. Agrodata is meant to be used in agricultural
--- the circumference of the wheel (cm) on which the magnetic
and contract work for measuring tractor and implement func-
sensor is mounted (LH rear wheel of the tractor) divided by the
tions and work performance.
number of magnets used.
--- the effective working width (cm) of the implement.
Agrodata can monitor:
--- Time (h, min) --- the function code (9999 except when measuring flow rate
and total consumption)
--- Area (ha)
--- Speed (km/h)
--- Flow rate (l/ha) Important: Before measuring flow rate and total consump-
tion, the Agrodata unit and flow meter must be calibrated in
--- Total consumption (litres)
order to obtain the correct function code.
--- Revs (rpm)
--- Number of items (piece counter)
The data listed above is retained in the Agrodata unit’s mem-
--- Distance (current metres)
ory even if the battery cables are disconnected from the bat-
tery terminals.
The different keys are pressed to call up a display of a particu-
lar function (for instructions on how to use function keys, see
the Operator’s Manual).
325
Model Code Page
10. 1. 1992
Figure 2. Agrodata unit fitted on 205---555 tractors
326
Model Code Page
1. 9. 1995
1. 3. 1997
Figure 2. Agrodata unit on 205---555 tractors
A6 = display unit and function keys

E7 = supply voltage connector (placed in the cab light)
Note! On the latest models, the supply voltage is taken from
the windscreen wiper motor M3.
B8 = sensor for detecting LH side rear wheel rotation speed
B9 =hydraulic lift linkage sensor, which stops the area meter
when the implement is raised. The sensor is activated by a
magnet on the position control lever (not on the tractors which
have an electro---hydraulic power lift (Autocontrol)
B10 = sensor for detecting engine revs
X49 = socket for connecting sensors on an implement.
X1E = lift/lower ---switch (Autocontrol power lift), which sends
a signal to the display unit when an implement is raised. This
function corresponds to the function of sensor B9.
S50 = rocker switch selects between tractor and implement
wheel sensor for measurement of speed and area.
S49 =rocker switch selects between measurement of engine
revs or implement functions (e.g. piece counter or flow rate).
X47 = connector for sensor wires. Sensor wires are con-
nected according to the picture in the right lower corner of fig-
ure 2.
Note! Position of different component is shown in the side
view of the tractor
Equipment
The Agrodata unit consists of a monitor in the cab, sensors,

leads connecting monitor and sensors and supply voltage
leads (there is a fuse in the fuse box).
On the monitor rear cover there are terminals for sensor leads
and supply voltage leads. The terminals are numbered from
one to nine (1---9) and the leads are numbered correspon-
dingly (lead no 19, however, to terminal 9)
The Agrodata system uses magnetic sensors. When the

magnet and the sensor are in close proximity the sensor is
activated and an electrical signal is transmitted to the monitor
display.
The following sensors are fitted on the tractor:
--- The engine rotation speed sensor; this measures engine

speed from the crankshaft. The sensor magnet is fitted on the
belt pulley at the front end of the crankshaft.
--- The wheel sensor; this is fitted on the LH rear wheel mount-
ing flange. Several magnets can be fitted on the wheel, evenly
spaced, for more accurate measurement of driving speed.
Correct speed measurement is not possible if too few
magnets are used with a big wheel.
--- The power lift linkage sensor is fitted on the position control
lever. Its function includes stopping the area meter when the
implement is raised. Autocontrol hydraulic lift doesn’t have
this sensor but the signal is sent to the display unit from the
lift/lower ---switch.
In addition to the tractor sensors, implement sensors can also

be connected to the Agrodata unit (flow meter, piece counter
etc.). For this purpose a socket is fitted at the rear of the trac-
tor. These sensors are not included in the Agrodata installa-
tion kit. These should be ordered separately from the spare
parts center.
327
Model Code Page
10. 1. 1992
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
--- sign. --- sign. --- + sign. --- +
Linkage Wheel sensor Supply Rotation speed sensor

sensor voltage Implement sensors
Figure 3. Monitor unit rear panel (wires have corresponding

numbers)
Terminals 1 and 2; Hydraulic lift linkage sensor wires (or

wires from lift/lower ---switch on Autocontrol models)
Terminals 3 and 4; Wheel sensor wires.
Terminals 5 and 6; Supply voltage leads (battery voltage).
Terminals 7, 8 and 9; Engine rev sensor wires and wires from
implement sensors (e.g. flow meter, piece counter, rev
counter etc). Terminal 8 is without lead on tractors with a
mechanical hydraulic power lift.
1. Trouble shooting
A. Checking display operation
The Agrodata unit receives its power supply from connector 3. If the power supply is in order, but the monitor fails to oper-
E7 (in the cab light). ate, the defect is in the unit itself. In this case the monitor must
be replaced (the condition of the other leads and sensors is
1. Turn on the ignition. Check that: irrelevant if the monitor is defective).
--- the monitor display is lit
--- the display flashes the word ”AGRO” 4. If the monitor responds to commands (eg. working width,
wheel circumference), it is in working order.
2. If this does not happen:
--- check fuse FA2 in the fuse box (second fuse from right) 5. If the monitor displays or flashes the word ”FEJL”, this indi-
--- disconnect the monitor (not the leads) and make sure that cates that the supply voltage to the unit is not adequate (12
the unit is receiving power (measure voltage between ter- V). Check the condition of the battery and the battery connec-
minals 5 (---) and 6 (+)) tions.
328
Model Code Page
10. 1. 1992
B. Checking the sensors and leads 6. The wheel sensor and the linkage sensor (not Autocontrol)
can also be tested with an ohmmeter:
--- disconnect the monitor (not the leads)
1. Turn on the ignition and: --- disconnect lead 1 from terminal 1
--- measure the resistance between terminal 1 and lead 4.
--- input the working width by pressing the key followed Wheel sensor resistance should be 33 ohms when the
magnet is close to sensor, otherwise 10 kilo---ohms or
by 8888. greater
--- measure the resistance between terminal 1 and lead 2.
Linkage sensor resistance should be 33 ohms when the
--- press the time function key . Following this the display magnet is close to the sensor, otherwise 10 kilo---ohms or
should be clear (this indicates that the unit is in order). greater
--- set switches 1 and 2 for the unit to measure tractor oper- 7. Check the earth connection by measuring the voltage
ations (front side pressed) between leads 8 (---) and 6 (+); this should equal battery volt-
age.
2. Now the unit will display the following symbols:
8. The defects may be either in the sensors or in the leads. First
--- ”h” (only flashes), when the wheel sensor is activated. check the connectors and leads. If the connection is in order,
Activation can be done while driving the tractor the sensor has to be changed. The implement sensors are
--- ”r” (lit), when the hydraulic lift linkage is in the upper posi- checked in the same manner. When this is being done, selec-
tion. On Autocontrol hydraulic lift ”r” is lit when the lift/lower --- tors 1 and 2 must be in implement position (the rear side
switch is in the lifting position. pressed).
--- ”F” (lit), when the engine rotation speed sensor is activated
(rocker switches in tractor position) or when the flow meter
paddle wheel is revolving (rocker switches in implement posi- C. Connecting the leads from the imple-
tion). The engine speed sensor cannot be tested while the
engine is running. ment sensor to the plug poles
3. If the letters listed above do not appear in the display, check Flow meter leads
that the sensors and magnets are correctly fitted. Blue to pole 5 (---)
Black to pole 6 (+)
Brown to pole 2 (signal)
Piece counter leads/rotation speed sensor

Brown to pole 5 (---)
Blue to pole 6 (+)
Black to pole 2 (signal)
Wheel sensor leads

Max. 5 mm Blue to pole 3 (signal)
Brown to pole 1 (---)
4. The distance between the magnet and sensor is max. 5 Sensor for detecting position of part of implement
mm. The magnet must be mounted the right way round (yel- Blue to pole 7 (signal)
low dot points towards the sensor). Brown to pole 5 (---)
5. If the sensors are correctly fitted then:

The numbering of
--- disconnect the monitor (not the leads) 1 poles can be found
--- disconnect the lead 1 from terminal 1 in the plug by the
--- turn on the ignition
6 2 corresponding pole
--- measure the voltage between terminal 1 (---) and the follow-
ing leads;
.7
Note! Figure
--- lead 9 (+) input voltage (approx. battery voltage) 5 3 shows the plug
--- lead 4 (+), wheel sensor: voltage ~ 0 when the magnet is from the lead side.
close to sensor, otherwise 11 ---13,5 V. 4
--- lead 2 (+), linkage sensor: voltage ~ 0 when the magnet
is close to sensor, otherwise 11 ---13,5 V. On Autocontrol lift
voltage is ~ 0 when the lift/lower ---switch is in the lifting posi- Note! The line from the Agrodata unit to the socket can be
tion, otherwise 11 ---13,5 V. checked as follows:
--- lead 7 (+), rotation speed sensor: voltage ~ 0 when the --- input working width of 8888 and press the time key
magnet is close to sensor, otherwise 11 ---13,5 V.
--- shunt between the socket terminals no 5 (---) and 2 (signal)
Note! Voltmeter should have such measuring heads which and the display should show ”F” (flow meter, piece counter)
can be pricked through the cable shoe plastic cover. --- shunt between terminals no 1 (---) and 3 (signal). The dis-
play should show letter ”h” (only flashes) (wheel sensor).
--- then shunt between terminals no 5 (---) and 7 (signal). The
display should show letter ”r”.
329
Model Code Page
10. 1. 1992
Spare part numbers for sensors and plug
Wheel sensor, linkage sensor, sensor for detecting position of

part of implement: 31703200 (2---pole sensor)
Piece counter/rotation speed sensor: 31703000 (3---pole sen-
sor)
Plug: 31702900
C. Further information on Agrodata oper-

ation
--- The linkage sensor should be adjusted so that the symbol
”r” is displayed when the implement is in the upper position. If
the max. height of the implement is re ---set, the position of the
sensor must be adjusted.
--- Any short---circuit device may be used (eg. mechanical re-

lays).
--- Only original magnets should be used. If the magnet is not

strong enough malfunctions will occur.
--- The full supply voltage should not be connected to the sen-
sor, because this may cause damage to the sensors.
--- The unit will not be damaged if the power supply wires are
connected in reverse.
--- The monitor bulbs cannot be changed in the present mo-

dels. They are 10000 hour bulbs, and they not only illuminate
the display but also dry out internal moisture.
330
Model Code Page
1. 3. 1997
33. Agrodata---instrument 865, 600-- 900 331 1
1. 9. 2001
Agrodata---instrument
Note! The AD ---instrument on the 865 and 600---900 trac-
tors is the same as on Mezzo---series. However, on the 865
and 600---900 tractors the AD ---instrument does not show
the PTO shaft revs. AD ---instrument is a factory fitted option
up to chassis no. L21546 after which the Agroline ---instru-
ment replaces the AD ---instrument (see code 340).
The upper digital display A shows:

Agrodata ---instrument includes two digital displays. The
instrument is fitted in place of the standard instrument. The
1. Time (allways when ignition is switched off)
AD ---instrument has in ---built electronics.
2. Position of lower links (0---99) (if AC power lift)
3. Distance travelled (up to1000 km, after which is zeroed)
The AD ---instrument has a rev counter, engine temperature
4. Gearbox temperature (from +40˚C. LO is shown at lower
gauge and fuel gauge and warning lights as in the standard
temperatures).
instrument.
The different functions of the upper display can be changed
In addition, the lower digital display B shows:
by pressing the right edge (spring returned) of the switch C
in the dashboard. The black arrow indicates which function
1. Running hours, when the tractor is stationary (also when
is selected.
the current is switched off).
2. Driving speed, when the tractor is moving (from 0,3
km/h. There is letter L in front of the value, when the driving
speed is slower than 4 km/h).
Note! The AD ---instrument wire loom includes also the indi-

cator light function for the engine glowing.
331
Model Code Page
1. 3. 1997
1. 9. 2001
B3: Sensor, gearbox oil temperature

B6: Sensor, gearbox
P4: Agrodata Instrument: Hour recorder/ Speedometer (in standard mo-
del AC---display)
P5: Agrodata --- instrument: Clock / AC / Trip / gearbox oil temp.
S1: Ignition switch
S37: Switch, AGRODATA ---instrument, cursor+ program
F1C: 5A Radio, (clock), not in models 600---900
X25: 9---os., Agrodata ---instrument (from G27101---> )
X26: 26 pins., instrument, left, white
GR3: Ground, wire loom of dashboard
865
600---900
865 (G27101--- >):

X25, X55
332
Model Code Page
1. 3. 1997
1. 9. 2001
Agrodata---instrument
(see picture on the previous page) Zeroing the travelling distance
--- select travelling distance into the display by pressing the
Note! The AD ---instrument can only be fitted on the 4WD switch right edge.
models. The mounting requires a new undershield for the --- press the switch left edge until the display is zeroed.
propeller shaft.
Current from the ignition switch (12 V) comes to the AD ---in-

strument as on the standard instrument via fuse FA1. AD ---
Time setting
instrument is supplied with permanent current (12 V) for the --- select time into the display by pressing the switch right
clock via fuse F1C (865) or via fuse FD5 (600---900). This edge.
--- press the switch left edge, until the hours are flashing.
voltage can be measured between pins 23 (ground) and 24
(supply) of the connector X26. Voltage via the starter switch --- set the hours by pressing the switch right edge
can be measured on pin 26 of the connector X27. --- press the switch left edge, until the minutes are flashing.
--- set the minutes by pressing the switch right edge
Always when the instrument does not function, check the
fuses. If the fuses and supply voltages are OK, but the --- when the time has been set, press the left edge, until the
instrument does not function, the fault lies in the instrument correct time appears into the display (flashing stops).
section in question.
Calibrating the instrument for different tyres, see page
The rev counter and fuel and temperature gauges can be 331/5.
replaced separately and also the smaller circuit card (or
bigger basis circuit card) which includes the digital dis-
plays. Warning light bulbs and instrument light bulbs can
be changed separately without opening the instrument cas- Wiring diagram, engine glowing indica-
ing.
tor light
Switch S37 earths pin X26/12, when the right edge is
depressed. When depressing the left edge, pin X26/13
gets earthed.
Note! Agrodata ---instrument is accessible after opening the

hatch in the steering wheel console rear face. Unscrew via
the hatch screws on the upper rear corners of the dash-
board and unscrew also the dashboard upper front screws
on the sides of the dashboard. When necessary, unscrew
the lower bolts of the console side plates via the hatch, after
which the AD ---instrument is accessible.
333
Model Code Page
33. Agrodata---instrument 865 331 4
1. 3. 1997
1. Sensors B. Gearbox temperature sensor B3

A. Gearbox speed sensor B6
Note! The sensor resistance should be 1,0 ---1,10 kΩ. It can
be measured on pins 9 and 10 of the white connector
behind the instrument. If the resistance is infinity, it should
be measured from the sensor pins in order to clear up pos-
sible breaks. The sensor is the same as on AD ---instrument
on tractors 6000---8750.
Changing the speed sensor:
Washer
Note! The gearbox oil temperature must be higher than
+40˚C, before the display shows the temperature. At the
lower temperatures the display shows LO.
If the AD ---instrument does not show the gearbox oil tempe-

rature, check the sensor and its wiring. The sensor is the
same as on AD ---instrument for 6000---8750 tractors.
Sensor resistance values:

--- 34 ---40 Ω (~ +120˚ C)
--- Remove the faulty sensor and clean the threads where --- 75 ---90 Ω (~ +90˚ C)
the sensor fits --- 200 ---250 Ω (~ +60˚ C)
--- Screw in a new sensor until its end touches the measu- (resistance value increases when temperature lowers).
ring wheel and open it then, until the clearance is
0,6 ---0,8 mm (use e.g. 0,7 mm feeler gauge). The resistance can be measured between pins 23 and 26 in
--- Secure the sensor with a lock nut and connect the wires the white connector X26 behind the instrument casing. If
--- Carry out a test---drive and assure that the instrument the resistance value is infinity, measure it once again on the
shows the driving speed and the driving distance. sensor pins, so that possible breaks can be cleared up.
--- Connect the connectors to the sensor and protect the
pins with grease UC1913 (vaseline spray HHS 2000 If you doubt that the sensor wiring is faulty, switch on the
(Würth)). ignition. Select the gearbox temperaure into the Agrodata
--- Fold the wire on the sensor and fasten it with a plastic display (follow the black arrow).
cable tie. Detach the wire from the sensor and connect it to the trac-
tor frame. When the wire is earthed, some temperature
Note! If the measuring wheel must be removed, it must values must flash in the display and three lines must be
be centered with a dial gauge when fitting it. Measure visible in the display, if the display and the wiring is OK.
e.g. on every third tooth and rotate the wheel forwards
and zero the dial gauge on the first tooth. The greatest
allowable total throw is 0,2 mm.
334
Model Code Page
1. 3. 1997
33. Agrodata---instrument 865
331 5
1. 1. 1998 600-- 900
2. Calibrating the instrument for different Code numbers with different tyre sizes
tyres
Rear wheel r dyn Code no
1. Remove the switch C by prying it carefully. Do not mm Impulses/m
disconnect the wires. 32 teeth
2. Switch on current with the ignition switch. 14.9---30/8N 665 162
16.9---30/8N 695 155
16.9R30/8M 695 155
16.9---30/8N 695 155
16.9R30/8M 695 155
C 16.9R30/8N 695 155

480/70R30 706 153
13.6---36/8N 715 151
13.6R36/8M 715 151
13.6---36/8N 715 151
13.6R36/8M 715 151
13.6---36/8N 715 151
13.6R36/8M 715 151
18.4R30/8M 720 150
13.6R38/8N 740 146
3. Connect the switch pins 1 and 7 with an auxiliary wire
and press at the same time the switch left edge for over 3 16.9R34/8M 745 145
seconds. ”P” appears in the lower display and the valid
code number (e.g. P143). The first digit is flashing. Remove 16.9---34/8N 745 145
the wire. 480/70R34G 753 143
18.4R34 783 138
16.9R38 800 135
18.4R38 833 129
20.8R38 872 124
Note! If a tractor has tyres which are not listed in the table
above, the code number can be calculated as follows:
YxV
X= in which
vmax
4. Adjust the hundreds by pressing the switch right edge. X= correct code number
Y=actual code number in AD ---instrument
5. When the hundreds are correctly adjusted, press the V= tractor’s constructional speed (30, 40 or 50 km/h)
switch left edge and tens start to flash. Vmax=tractor’s max driving speed which is shown by
AD ---instrument
6. Adjust the tens by pressing the right edge and then Example:
press the left edge, at which time single units start to flash.
In the AD ---instrument the actual code number is 170.
7. Adjust the ones by pressing the right edge. Tractor’s constructional speed is 40 km/h.
AD ---instrument shows the tractor max. driving speed of 38
8. Finally press the left edge for over 2 seconds. Calibrating km/h:
has been carried out and running hours appear in the lower
display. Fit the switch.
170 x 40
Note! The code number value can vary between X= = 179
P100---P299. When pressing the switch right edge, the code 38
value changes from a smaller value to greater one. The
code numbers and corresponding tyres are listed in the
table.
335
336
Model Code Page
34. Infoline and Agroline ---instruments 600-- 900 340 1
1. 9. 2001
General
The manufacturing of the present dasboard instrumet in

600---900 tractors will be finished and a new instrument will
be fitted in place. The new instrument is either a standard
Infoline ---instrument (L26206---) or a factory fitted optional
Agroline ---instrument (L22101---). If the tractor has as stan-
dard the HiShift---buttons, the Agroline instrumet is a stan-
dard equipment. The Agroline ---instrument can only be fit-
ted on 4WD tractors.
In the Agroline ---instrument there is a digital display in place

of a mechanical hour recorder with the Infoline and the Ag-
roline digital display correcponds the earlier AD ---instru-
ment. The other functions are similar in these instruments.
In the dashboard in connection with the instrument change

there are modifications and a part of the dashboard swit-
ches have been moved to the RH side side pillar of the cab.
In addition, some switches have been fitted on the RH side
of the steering wheel console.
Infoline --- and Agroline ---instruments cannot be repaired.

Internal light bulbs and the cover glass can be changed.
The warning lights are LED ---diodes, which cannot be chan-
ged, but the LED ---diodes lifetime is very long. There are
connectors X26 and X27 on the rear face of the instrument
for wire looms.
The Agroline ---instrument is controlled by a microprocessor

and it is programmed according to the tractor type. Recar-
ding service or repairs the instrument program cannot be
changed.
A spare part instrument is ready ---programmed and also
the hour recorder reading can be set to the correct value. In
this case the tractor chassis number, tractor model, possi-
ble front PTO and the actual hour recorder reading must be
notified.
337
Model Code Page
1. 9. 2001
Picture 1. Infoline --- and Agroline ---instruments
338
Model Code Page
1. 9. 2001
Picture 1. Infoline --- and Agroline ---instruments.

Lower row shows:
1. Revolution counter (lower row functions are scanned by pressing the upper
2. Fuel gauge edge of switch17b):
4. Engine temperature gauge --- running hours
5. Tractor dir. ind. flashers --- driving speed (km/h or miles/h)
6. Warning light, blocked engine air filter
7. Not in use When the current is switched on, there is driving speed in
8. First trailer dir. ind. flashers (does not flash if a bulb in the the lower row and driving distance in the upper row.
system has blown).
9. Second trailer dir. ind. flashers (does not flash if a bulb in
the system has blown). Zeroing driving distance:
10. Engine glowing
11. Ind. light, PTO clutch lever --- choose driving distance into the upper row by pressing
12. Ind. light, parking brake the lower edge of switch17b.
13. Low fuel level (<14 l) --- press the upper edge of switch 17b until the display is
14. Charging zeroed.
15. General warning light (not in use)
16. Engine oil pressure
17. Mechanical hour recorder (Infoline) Setting time:
17a. Digital dipsplay (Agroline)
17b. Control switch S37 for Agroline digital display Do not pause for over 10 seconds during setting, since then
18. Controls on the RH side of the steering wheel console. the dispaly is switched into the normal mode.
19. STOP---central warning light:
--- engine temperature --- switch on current, choose time into the upper row by
--- engine oil pressure pressing the lower edge of switch 17b.
23. Indication light, differential lock --- press the upper edge of switch 17b for about 3 seconds,
29. Indication light, high beams minutes start to flash.
---set minutes by pressing the lower edge of switch 17b
Note! When the current is switched on, the following war- ---choose hours in the display by pressing the upper edge
ning lights must come on: of switch 17b.
--- engine oil pressure --- set hours by pressing the lower edge of switch 17b
--- stop ---light is flashing --- time has now been set and the diplay is returned to the
--- charging normal mode after 10 seconds.
If the engine oil pressure warning light comes on, also the
engine air filter light comes on. If the stop ---light starts to Changing units of driving speed and distance travelled
flash alone, the engine temperature is too high. (km/h ---miles/h):
Note! Infoline --- and Agroline instruments are equipped as The setting is done in factory for different market areas.
standard with a buzzer, which alarms, when the head lights This setting cannot be done in Service.
are on and the current is switched off with the ignition
switch. When the head lights are switched off the buzzer
stops. After this the head lights can be switched on without Indication of periodical maintenance:
that the buzzer comes on.
Note! When the tractor running hours reach a service inter-
val, a spanner symbol and the running hours of the service
1. Agroline ---instrument digital display interval in question come on into the diplay.
Agroline ---instrument digital display (17a) shows the follo- If the service is not done, the spanner and the service inter-
wing functions (functions are scanned with switch17b): val are visible for 10 seconds every time the ignition is swit-
ched on.
Upper row shows:
(upper row functions are scanned by pressing the lower Service man can confirm that the maintenance has been
edge of switch 17b): done by pressing switch 17b and at the same time swit-
--- driving distance (km or miles) ching on the ignition. After this the spanner symbol does
--- rear PTO revs (R) (r/min) not come on.
--- front PTO revs (F) (r/min), option
--- time
--- gearbox oil temperature (shows LO, when temperature is
below +40˚C).
--- position of lower links (0---100), with ACB power lift
--- fault code, if sensor damaged
--- indication of time of periodical maintenance
339
Model Code Page
1. 9. 2001
Calibrating Agroline for different tyres 2. Fault codes

Do not pause for over 10 seconds during setting, the dis- Agroline ---instrument can show fault codes, at which time
paly will switch into the normal mode. the spanner symbol is visible in the display.
--- switch on current. Choose driving distance in the upper The fault code can be seen by scanning with switch 17b.
row by pressing the lower edge of switch 17b. The fault code is shown in the upper row of display 17a, if
--- press the upper edge of switch 17b for about 3 seconds, one of the following sensors have malfunctions:
until the display is switched into the setting mode.
--- if symbole m does not start to flash in the display, quickly --- fuel level sensor. First digit of three ---number code.
press the upper edge of the switch, until m is flashing. --- engine temperature sensor. Middle digit of fault code.
--- set a correct code number by pressing the lower edge of --- gearbox temperature sensor. Last digit of fault code.
switch 17b. When the lower edge is kept down, numbers
are changed continually. 0=OK
1= poor contacts
Note! The code number could be between 100---400. By 2 = short circuit
pressing switch 17b the code value is changed from smal-
ler value to greater. The code numbers with various tyres E.g: 200: fuel sensor short circuit
are shown in table below (same as for AD ---instrument). If E.g: 010: engine temperature sensor does not send signal
you pass by the desired code, you must scan with the (wire broken, sensor damage etc.).
switch to the end and start from the beginning. E.g: 001: gearbox temperature sensor does not send sig-
nal (wire broken, sensor damage etc.).
Rear tyre Code
14.9---30 162
Fault tracing:
16.9---30, 16.9R30 155
480/70R30 153 --- If the Infoline --- or Agroline ---instruments have malfuncti-
ons, check that the instrument rear face connectors X26
13.6---36, 13.6R36 151 and X27 are correctly connected. If the instrument is totally
520/R34 132 black although the current is switched on, check the fuse
FA1, supply wires (X27/10) and earth points (X27/5) (see
480/70R34 143
wiring diagrams on pages 310/31 ---33). The position of
18.4---34, 18.4R34 138 different components and connectors can be found on pa-
ge 310/2D.
18.4R30 150
13.6---38, 13.6R38 146 --- When necessary, check various sensors and switches
according to instructions 3 and 4. If wires, switches and
16.9R34, 16.9---34/8N 145
sensors are OK, but the problem still exists, change the
16.9R38 135 instrument. When ordering a spare instrument, tractor chas-
sis no., tractor model, actual running hours and possible
14.9R38 135
front PTO must be notified.
18.4R38 129
20.8R38 124 --- If the instrument rocker switch S37 (17b) has malfuncti-
ons, check the wire connections inside the switch and the
connectors on the rear face of the instrument. When edges
Note! If tractor tyres cannot be found in the table above, of the switch are pressed, certain pins (X26/24, 25)in con-
the code number can be calculate as followsos: nector X26 is earthed.
Exemple:
--- Agroline ---instrumen present code number is 155.
--- Tractor max. driving speed is 40 km/h.
Agroline ---instrument shows max. driving speed of 39 km/h
when driving the tractor.
The code number X can be calculated as follows:
155 x 40
X= = 159
39
340
Model Code Page
1. 9. 2001
Wiring diagram
A1: Main current screw, cab supply, under dashboard

H13: PTO ---clutch lever ind. light
H15: Reserve tank warning light
GR2: Starter earth point
H16: Charging warning light
GR3: Earth point, dashboard wire loom, front wall of cab
H20: Diff. lock ind. light
FA1: Infoline and Agroline ---instrument fuse
S1: Ignition switch
FB5: Ignition switch fuse
S14: PTO ---clutch lever ind. light switch
S15: Engine oil pressure sensor
P1: Engine temperature gauge
S17: Diff. lock ind. light switch
P2: Fuel gauge
S20: Engine temperature switch (STOP)
P3: Engine revolution counter
S21: Sensor, air filter vacuum switch
P4: Hour recorder. Lower row of Agroline ---display
S37: Agroline ---instument switch
P5: Agroline ---instrument dsplay upper row
K6: Auxiliary relay, ignition switch
B1: Engine temperature sensor
K9: Auxiliary relay, ignition switch
B2: Fuel lever sensor
B3: Gearbox oil temp. sensor (not Infoline)
B6: Gearbox speed sensor (not Infoline)
Position of connectors:
E8: Thermostart glow plug
X26: Instrument rear face connector, white
E13: Instrument light lamps
X27: Instrument rear face connector, blue
X1: Connector, 37 pins, engine sensors, on the front wall of
G2: Alternator
the cab, RH side
H4: Air filter warning light
Note! Most sensors have an extra connector (not shown in
H5: Engine oil pressure warning light
the wiring diagrams) to connect the sensor
H6: Stop ---warning light
to the main wiring loom. Some switches have internal con-
H11: Parking brake warning light
nectors not shown in the wiring diagram that could cause
H12:Thermostart---ind. light
continuity problems.
341
Model Code Page
1. 9. 2001
3. Sensors and switches B. Gearbox oil temperaure sesnor B3 (Ag-

roline)
A. Gearbox speed sensor B6 (Agroline)
Note! The sensor is placed in the engine compartment on
the LH side in front of the cab.
Note! The sensor is placed under the tractor in the front
end of the 4x4 drive shaft.
IMPORTANT! Agroline ---instrument shows a fault code, if
this sensor is faulty, see page 340/4.
Note! The sensor resistance should be between 1,0 ---1,10
kΩ. It can be measured from pins X26/5 and 22. If the re-
sistance was infinite, it must be measured from sensor
poles, so that possible continunily problems can be identi-
fied.
Note! If the driving speed and distance travelled are inco-

rect in the display, possible fault can also lie in calibration of
instrument, see page 340/4.
Changing speed sensor:
Washer
Note! The gearbox oil temperature must be higher than

+40˚C, before the instrument shows the temperature value.
In lower temperatures LO is visible in the display.
If the display does not show the temperature value, check

the sensor wires and the sensor.
Sensor resistance values:

--- Remove the faulty sensor and clean the threads where --- 34 ---40 Ω (~ +120˚ C)
the sensor fits --- 75 ---90 Ω (~ +90˚ C)
--- Screw in a new sensor until its end touches the measu- --- 200 ---250 Ω (~ +60˚ C).
ring wheel and unscrew then, until the clearance is
0,6 ---0,8 mm (use e.g. 0,7 mm feeler gauge). Resistance can be measured between pins X26/6 and
--- Secure the sensor with a lock nut and connect the wires X27/5. If the resistance value was infinite, measure the re-
--- Carry out a test---drive. sistance on the sensor poles so that possible poor contacts
--- Protect the pins with grease UC1913 (vaseline spray or continuaty problems can be identified.
HHS 2000 (Würth)).
--- Fold the wire onto the sensor and fasten it with a plastic
cable tie.
Note! If the measuring wheel must be removed, it must

be centered with a dial gauge when fitting it. Measure
on every third tooth. The greatest allowable total throw
is 0,2 mm.
342
Model Code Page
1. 9. 2001
C. Engine temperature sensor B1

Note! Sensor is placed on the engine beside the thermos-
tat housing. The gauge pin wire has an resistance of 8
ohms.

this sensor malfunctions, see page 340/4.
STOP---war- Gauge pin

ning light pin
The oil pressure sensor (9) is placed on the RH side of the en-
40
19 mm gine. The pressure relief valve (2) is placed on the LH side.
M14x1,5 E. Fuel level sensor B2

11
this sensor has a fault, see page 340/4. Possible fault can
40
also be seen in the fuel gauge. The warning light comes on,
when the fuel amount is less than 14 litres.
Gauge side resistance values:

60˚C=134± 13,5 Ω
90˚C=51,2± 4,3 Ω
100˚C=38,5± 3,0 Ω
STOP--- warning light flashes, if the engine temperature is

too high (can also be seen in the gauge):
Part no. Alarm temperature

8366 40772 106 ± 3˚C Warning light switch function can be checked by measuring
between pin W and earth (switch function)
The sensor resistance can be measured direct from the

D. Engine oil pressure sensor S15 sensor or between pole G and earth or between pin X27/7
and earth point (GR3). Resistance is about 70 ohms, when
STOP--- warning light flashes, if the engine oil pressure is the tank is empty and about 3 ohms, when it is full.
too low. Also warning light lights up (at the same time also
air filter warning ligh comes on). In this case the engine In case of failure, the sensor is changed. The connector
must be stopped immediately and possible reason must be contact problems can be removed by disconnecting and
found and repaired. reconnecting the connector.
The warning light must be on, when the ignition is switched

on (without starting the engine). The warning light must go F. Engine air filter warning light S21
out, when the engine has started (oil pressure rises in the
engine). The warning light comes on, when the air filter is blocked.
The sensor is placed in the induction pipe of the filter. If the
filter is blocked, a vacuum is created in the pipe. Clean or
change the filter.
Note! The air filter warning light comes on, if the engine oil
pressure warning light comes on while driving, although the
filter is OK.
The function can be tested by blocking the engine intake air
hole with a suitable plate.
343
Model Code Page
1. 9. 2001
4. Other indication lights, rev counter

and hour recorders
Indication lights:
--- the differential lock indication light H20 is on when the

rear axle lock is engaged. The indication light switch is pla-
ced on the LH side of the gearbox at the LH end of the lock
selector fork shaft.
--- the PTO ---clutch lever indication light H13 comes on,
when the lever is pulled to the rear position (can be max. 5
minutes in this position). The light switch is placed at the
lower end of the lever.
--- the parking brake indication light H11 is on, when the
hand brake lever is pulled up. The switch is placed in the
rear end of the lever.
--- the engine glowing indication light H12 is on, when the
ignition switch is turned to the THERM ---position.
--- the charging light H16 is on when the ignition is switched

on but the engine is not running. After the engine is started,
the light must go out. If this light comes on while driving,
the alternator does not charge.
--- In addition, Infoline --- and Agroline ---instruments have

high beam light H14 and direction indicator flasher lights.
Flasher relay K2 is placed on the RH side of the fuse box
(upper relay). The flasher ind. lights do not flash, if one bulb
in the system has blown. Headlights relay K5 is placed abo-
ve the fuse box.
Rev counter and hour recorders:
The engine rev counter gets the signal from alternator (pin
W). The hour recorders also get the signal from alternator
pin W.
344
Model Code Page
1. 9. 2001
345
346
41. Clutch
40. Power Transmission
42. Gearbox
43. Hydraulic power

transmissiom
44. Lowgear
Overdrive
Shuttle
45. Final gears
46. Power take---off
347
348
Model Code Page
1. 12. 1986
41. Clutch 205-- 865 410 1
1. 9. 1992
Contents

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clutch, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reconditioning clutch (Op. no. 411)
1. Changing clutch by splitting tractor:

A. Splitting tractor at clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing/fitting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Assembling tractor at clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Adjusting clutch pedal free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Adjusting PTO clutch lever free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Changing clutch without splitting tractor:

A. Removing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Fitting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. Reconditioning clutch release bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Changing propulsion clutch disc and adjusting clutch:

A. Dismantling clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Assembling and adjusting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HiShift (Op. no. 412)
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Repair instructions:
A. Adjusting instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Hydraulic block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
349
Model Code Page
1. 5. 1996
41. Clutch 205-- 865 410 2
1. 3. 1997
Technical data
The clutch is a mechanically controlled double, dry disc clutch (single ---disc clutch on 205), which is bolted to the flywheel. The
clutch disc closest to the flywheel is for the PTO (not on 205) and the disc inside the clutch is for the propulsion clutch.
Type:
--- 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fichtel & Sach 280
--- 305---455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fichtel & Sach 280/280
--- earlier 465---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LuK 280/280
--- later 365---865 (F14303---) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fichtel & Sach 295/280
Clutch disc:
--- propulsion clutch 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 280 mm, organic linings
--- propulsion clutch/PTO clutch, 305---455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 280/280 mm, organic linings
--- propulsion clutch/PTO clutch, earlier 465---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 280/ 280 ceramic/organic linings
--- propulsion clutch/PTO clutch, later 365---865 (F14303---) . . . . . . . . . . . . . . . . . . . . . . . ø 295/280 mm, organic linings
Thrust spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . disc spring
Thrust of disc spring (F&S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6200---7000 N (not 205)
--- release force, propulsion clutch (F&S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1320 N (not 205)
--- release force, PTO clutch (F&S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 N (not 205)
Thrust of disc spring (LuK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400---7600 N
--- release force, propulsion clutch (LuK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 1740 N
--- release force, PTO clutch (LuK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 2260 N
Required pedal force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 kp (not 205)
Setting values
Clutch pedal free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20---25 mm

PTO clutch lever free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30---40 mm (not 205)
Thickness of spacer blocks (4 pcs) when adjusting clutch
--- F&S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,5 mm (not 205)
--- LuK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,6 mm
Distance between flywheel---propulsion clutch levers:
--- F&S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 ±0,5 mm (not 205)
--- LuK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 ± 0,5
Distance between flywheel---PTO clutch levers
--- F&S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 ±0,5 mm (not 205)
--- LuK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 ±0,5 mm
Tightening torques
Engine ---fuel tank:

--- hexagonal socket head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
--- hexagonal head bolts 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
--- hexagonal head bolts 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Clutch ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Flywheel---engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Pressure oil pipe for hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Pressure oil pipe. steering system ---pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Hose unions, steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Connection sleeve, clutch shaft --- gearbox input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Clutch shaft---low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Release bearing brackets---tractor frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Clutch housing ---tractor frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Top link bracket nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
PTO ---gearbox:
--- 10 pcs (19 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
--- 2 pcs (M16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
--- 2 pcs (M20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm
350
Model Code Page
10. 1. 1992
41. Clutch 205-- 865 410 3
1. 9. 1992
Special tools
Note! Adjusting kit ETV 892 570 below concerns F&S ---clutch. Only some notes are given for LuK ---clutch (on 555---665)
Clutch A
Part no Description
ETV 891 211* Centring drift for PTO clutch disc (not 205)
ETV 892 570 Kit for adjusting clutch (504, 604) containing the following parts:
1. ETV 892 571 Adjusting fixture
2. ETV 892 592 Centring sleeve for propulsion clutch disc
3. ETV 892 575 Press drift D = 150 mm, L = 50 mm
ETV 892 578 Press drift D = 90 mm, L = 40 mm
4. ETV 892 570 Pressure and turning lever, complete
7. ETV 893 710* Spacer block 6,5 mm (4 pcs) (Spacer block 7,6 mm for LuK ---clutch)
8. Std. Bolt M8X60, at least 4 pcs
10. ETV 892 582 Guide pin
12. ETV 893 711* Spacer sleeve 72 mm, propulsion clutch (Spacer sleeve 68 mm for LuK ---clutch)
ETV 893 712* Spacer sleeve 96 mm, PTO clutch (Spacer sleeve 93 mm for LuK ---clutch)
13. ETV 892 584 Indicator sleeve, L = 30 mm
14. ETV 892 585 Long indicator, PTO clutch
ETV 892 586 Short indicator, propulsion clutch
15. ETV 892 58 Indicator nut
(ETV 893 650) Drift for fitting needle bearing and seal inside clutch shaft (see Gearbox)
ET 891 200 Handle for removing centring drift ETV 891 211
ET 893 670* Lifting handle for clutch
(ET 893 760) Support plate, 2 pcs. Prevents front axle oscillation when splitting tractor
ET 893 780* Sleeve for removing clutch release bearing for propulsion clutch
ET 894 130* Centring drift for clutch disc on 205 (see page 102/2)
Note! (*) = entirely new tools for Valmet tractors.
Clutch A
ETV 891 211
ETV 893 650

8
3 4
2 10 12 13 14 15
D
L
ETV 892 570
7
351
Model Code Page
1. 9. 1992
41. Clutch 205-- 865 410 4
1. 9. 2001
ET 891 200
ET 893 780 ET 893 670 ET 893 760
Clutch, description
Both clutch discs are operated separately. The propulsion
The clutch is double, dry disc clutch (on 205 single disc clutch is operated with a pedal and the PTO clutch with a lever
clutch). The disc nearest the flywheel is for the PTO (not 205) (not on 205). The free ---travel of both the pedal and the clutch
and the disc inside the clutch is for the propulsion of the trac- lever (not on 205) can be adjusted with screws on the respect-
tor. The hub of the disc for the propulsion clutch is provided ive controls.
with springs which dampen vibrations. The nominal diameter
of the discs is 280 mm. The discs have organic compound lin- The clutch pedal mechanism includes a starter interlock
ings (on 555---665 the propulsion clutch disc has ceramic lin- switch, which means that the starter motor can only be en-
ings). gaged when the clutch pedal is depressed fully.
The power for the PTO clutch (on 205 only one disc) is trans- At the lower end of the PTO clutch lever (not on 205) there is
mitted via a long shaft which runs inside the main input shaft a switch for a control lamp on the instrument panel which
to the gearbox right through to the back of the tractor. lights when the clutch lever is in the disengaged position
(which should not be used more than necessary and at the
The propulsion clutch transfers the power from the flywheel most for 5 minutes.
via the tubular clutch shaft to the main input shaft of the gear-
box.
Fig. 1. Sectional drawing of clutch mechanism (not 205)

1. EP---grease on splines
2. Universal grease on sliding surfaces
3. The bearings are to be filled with grease
NOTE: With effect from ser. no. 606690 bearing bands are
fitted on the sliding surfaces between the release bearing
sleeves and their supports (points 2 in figure). These bearing
bands must be greased with multi ---purpose grease when re-
pairs are carried out. The clutch cover no longer contains oil
holes and screws.
352
Model Code Page
1. 9. 1992
41. Clutch 255-- 865 410 5
1. 5. 1996
23±1
47±1
Figure 2. Double disc clutch F&S, 305---455, later also on

365---865 tractors when the propulsion clutch disc diameter
has been changed from 280 mm to 295 mm.
2. Grease e.g. Optimol
3. Loctite 270 on threads
4. Adjusting screw, propulsion clutch
5. Adjusting screw, PTO clutch
6. Fill with grease
353
Model Code Page
1. 9. 1992
41. Clutch 465-- 665 410 6
1. 5. 1996
Figure 3. Double disc clutch LuK, earlier 465---665 tractors
2. Adjusting nut, propulsion clutch (secure after adjustment)
3. Adjusting nut, PTO clutch (secure after adjustment)
354
41. Clutch
355
1. 9. 2001
1. 9. 1992
Model
305-- 665
Code
Figure 5. Clutch controls, 305---900
410
1. Set this distance to 17---19 mm after changing propulsion clutch disc
2. Adjusting distance for PTO clutch control lamp switch
Page
3. Adjusting distance for starter interlock switch (pedal fully depressed).
7
4. Power assistance for clutch pedal
5. Universal grease
A. Screw for adjusting PTO clutch free travel
B. Screw for adjusting clutch pedal free travel
Model Code Page
1. 9. 1992
41. Clutch 205-- 900 410 8
1. 1. 1998
Figure 4. Connecting sleeve between clutch shaft and gearbox input shaft, 305---665 (not on tractors with low gear)
1. Universal grease
2. Extra pressure grease on splines
N.B. Bolts to be secured with tab washer at arrows
Figure 4A. Connecting sleeve on 600, 700, 800 and 900 (transmission 270)
5. Gearbox input shaft (45355500). At the front end of the shaft there is a lubricating hole (for new Overdrive and low
gear) . The earlier type shaft 30309820 can be replaced with the new one (the hole must be plugged on tractors without
the Overdrive or low gear. The plug must be removed, if the Overdrive or low gear is fitted).
5a. Plug.
6. Clutch shaft (30598430). The connecting sleeve 3 fixing bolts have been made longer, at which time the splines on
the sleeve have been shortened. The earlier shaft (30598420) can be replaced with the new one, if the sleeve bolts are
changed.
7. Bearing cover. Modified because of the new Overdrive and the low gear.
8. Long PTO clutch shaft. A thinning for lubricating oil has been made on the shaft 8. The earlier shaft can be replaced
with the new one.
356
41. Clutch
357
10. 1. 1992
Model
205
Code
Figure 5. Clutch controls on tractor 205
410
1. Extra pressure grease on splines
2. Universal grease
Page
3. Fill the bearing with grease
9
A. Adjust distance to 14---16 mm after changing clutch disc
B. Adjusting measurement for starter interlock switch (24---26 mm)
358
Model Code Page
10. 1. 1992
41. Clutch 205-- 865 411 1
15. 4. 1994
Reconditioning clutch (Op. no. 411)
1. Changing clutch by parting tractor
Note! On 205---tractor the clutch must be changed according

to this instruction. On models 305---555 the clutch is access-
ible also through the cab floor.
A. Parting tractor at clutch

(see N.B. under point 11 in the following text)
1. Remove the engine hood plates. Remove the battery and
the battery shelf (17 and 19 mm).
2. On the left---hand side of the engine disconnect:
5. Disconnect the heater hoses and disconnect the roller blind

chain.
--- governor and stop controls at the rear ends.
NOTE: (Tractors with a separate stop control knob on the in- 6. Loosen the clamp for the steering system pressure oil pipe
strument panel:) the stop control wire must be disconnected (lower hose) and disconnect the oil lines to the steering cylin-
der (22 mm).
from the injection pump. Later tractors has a throttle control
wire and not a linkage as above. 7. Disconnect the steering system pressure oil pipe and the
suction pipe at the pump.
--- fuel lines (3 pcs)
3. Disconnect the cable harnesses from the front wall of the

cab. 8. Disconnect the hydraulic lift pressure oil pipe (27 and 26
mm). Free the engine breather hose under the front edge of
the cab.
4. Drain the oil from the hydraulic system (approx. 30 litres).
359
Model Code Page
1. 12. 1986
41. Clutch 205-- 865 411 2
10. 1. 1992
N.B. On tractors with powered front axle: disconnect the B. Removing fitting clutch
guard for the propeller shaft (17 and 19 mm) and unscrew the
threaded sleeve on the propeller shaft. N.B. Later tractors
have not the threaded sleeve.
9. Position trestles on castors under the tractor from both sides

of the frame joints.
N.B. Fit support plates ET 893 760 on both sides under the
front end of the tractor to prevent the front axle from oscillat-
ing.
1. Unscrew the clutch attaching bolts evenly and gradually

around the circumference of the clutch.
2. Remove the clutch and the PTO clutch disc (on 205 propul-
sion clutch disc) from the flywheel.
3. Check the contact surface on the flywheel. Also check the

tightness of the flywheel attaching bolts (120 Nm).
N.B. 305 ---555: If the clutch is to be dismantled, use adjusting

10. Unscrew the bolts between the engine and the fuel tank tool ETV 892 570 (see Op. no. 3A and B) or fit an exchange
(17 mm at the top and 10 mm underneath, socket head). unit clutch.
N.B.Before splitting the tractor, engage the PTO, i.e. the clutch 4. Remove the circlip for the ball bearing in the flywheel.
engaging sleeve in the PTO housing should be in the
engaged position (not 205).
5. If necessary, change the bearing in the flywheel and grease

the new bearing with universal grease. Fit the circlip.
11. Push the engine part of the tractor forwards by rolling the
front wheels. Check that the long PTO shaft (not 205) does not
come out forwards with the clutch (the splines at the end of the
shaft should always be level with the front end of the propul-
sion clutch shaft.
Note! 305 ---555: If the shaft has moved forwards more than
20 mm, the small needle bearing and the ball may have disen-
gaged at the rear end of the shaft by the PTO. If the shaft has
moved out too far, the PTO must be removed for checking
(see Op. no. 462 1A)
360
Model Code Page
10. 1. 1992
41. Clutch 205-- 865 411 3
1. 3. 1997
C. Assembling tractor at clutch

Assembling the tractor is made easier by using two bolts
ETV 891211 (M12, l=100) as guide pins.
6. Press in the centring drift ETV 891 211 (205: centring drift
ET 894 130) in the flywheel and fit the clutch disc on the drift
(the longer part of the hub turned towards.
1. Push the frame parts together, while at the same time guid-
ing the propeller shaft for the front axle onto its splines (the uni-
versal joints should lie in the same relative position).
2. Guide the hydraulic system suction pipe into place.
N.B. The clutch shafts are easier to insert in the clutch if the
engine is cranked slightly when fitting.
3. Tighten the bolts in the lower part of the joint to 80 Nm (hex-

agonal socket head 10 mm) and the bolts in the upper part of
the joint to 45 Nm (8.8) or 60 Nm (10.9) apart from the battery
shelf attaching bolts.
4. On four ---wheel drive models tighten the threaded sleeve

7. Fit the clutch and tighten to a torque of 23 Nm. on the propeller shaft. Fit the protecting plate for the propeller
shaft. (N.B. On later models there is no threaded sleeve on the
propeller shaft).
5. Fit the battery shelf. Remove the support plates and trestles.
ETV 891211
8. Remove the centring drift ETV 891 211 with a bolt M12x100.
9. Check the clutch shaft splines and lubricate them with EP

grease.
10. Change the release bearing if necessary (see Op 2 C).
361
Model Code Page
10. 1. 1992
41. Clutch 205-- 865 411 4
15. 4. 1994
12. Adjust the PTO lever free travel (not 205) and the clutch
pedal free travel (see Op. D and E). Test drive the tractor.
D. Adjust clutch pedal free travel
20-- 25 mm
6. Connect the fuel lines (note position of breather and return

hoses) and the rear ends of the accelerator and stop control
(or on the latest models connect the stop control wire to the
injection pump). Later models have a throttle control wire
which should be connected.
A3565--- 104
Adjust the pedal free travel with the adjusting bolt which is lo-
cated in the clutch pedal mechanism on the left side of the
frame. The free travel should be 20 ---25 mm.
C
A
7. Connect the hydraulic system suction pipe, pressure oil
pipe (60 Nm) and hoses to the steering valve (45 Nm).
8. Connect the steering hydraulic pipe to the pump (45 Nm)

and fit the clamp on the pipe.
17-- 19 mm
9. Connect the engine breather pipe. Connect the electrical B
leads at the front wall of the cab.
A3565--- 133
1. Slacken the locking nut A.
2. Turn the adjusting bolt with nut B until the correct free travel
is achieved. Tighten down the locking nut.
N.B. When the locking nut comes up against the adjuster stop
the pedal free travel can not be adjusted any further. This is an
indication that the disc is worn and should be changed. After
changing the disc the distance between the adjuster stop and
the locking nut is set according to the figure to 17 ---19 mm
(305---555) or 14 ---16 mm (205). The tightening torque for the
adjuster stop locking nut is 5 ---6 Nm.
10. Connect the heater hoses. Fit the roller blind. Fit the bat-
tery.
11. Fill with hydraulic oil (approx. 35 litres). Bleed the fuel sys-
tem.
362
Model Code Page
10. 1. 1992
41. Clutch 205-- 865 411 5
1. 3. 1997
3. Also check the function of the starter interlock switch. When

necessary the switch is adjusted according to the figure 5 on
page 410/7 point 3.
E. Adjusting PTO clutch lever free travel

(305---555)
1. Slacken the locking nut B.
2. Turn the adjusting bolt A until the correct free travel is

achieved.
3. Tighten down the locking nut.
A3565--- 105 N.B. Check the function of the control lamp. When necessary
the switch can be adjusted according to item 2 in fig.
2 ---1001A on page 410/7.
The free travel at the top of the lever should be 30 ---40 mm.
363
Model Code Page
1. 12. 1986
41. Clutch 305-- 865 411 6
10. 1. 1992
2. Changing clutch without splitting trac-

tor (305---555)
Note! On 205---tractor the clutch is changed according to
instruction 1 (frame is split at clutch).
A. Removing clutch
4. Remove the floor mat, floor plate and the clutch shaft tunnel
cover.
N.B. The parking brake mechanism should be freed from the

cab wall.
5. Remove the engine hood plates, battery and battery shelf.
1. Remove the accelerator pedal, floor mat strips, pedals and

grommets. Loosen the support rail for the PTO lever from the
front wall of the cab.
6. Free the accelerator linkage at the front of the cab. Free the
fuel pipes on the engine side.
2. Loosen the PTO lever adjusting bolt from the lower end of
the lever and withdraw the lower part from the support shaft.
3. Remove the hydraulic lift lowering speed control knob (not

Autocontrol) and move the lever to the rearward position.
N.B! On machines without low gear: remove the metal plate

which covers the hole.
7. Remove the service hatch from the cab front wall. Free the
clutch cover.
364
Model Code Page
1. 12. 1986
41. Clutch 305-- 865 411 7
10. 1. 1992
8. Lift out the PTO clutch release fork.Turn the propulsion 11. Loosen the bolts for the release bearings.
clutch release forks upwards to one side.
N.B. Before loosening the bearings they should be marked
relative to the frame in order to make fitting and centring
easier.
9. Drain the gearbox oil (23 litres) and remove the PTO (Op.
no. 462 1A). Pull out the long PTO shaft.
12 a) Machines without low gear: unscrew the clutch attach-
10 a) Machines without low gear: loosen the attaching bolts ing bolts evenly. Lift the clutch slightly and remove the clutch
for the connecting sleeve between the clutch shaft and the shaft and release bearing.
gearbox input shaft and move the sleeve onto the clutch shaft.
12 b) Machines with low gear: move the release bearings rear-
wards away from the clutch and unscrew the clutch attaching
bolts.
10 b) Machines with low gear: disconnect the clutch shaft from

the low gear. Pull the shaft forwards and move the O ---ring
onto the shaft neck. Push the rear end of the clutch shaft into
the low gear. 13. Lift out the clutch with ET 893 670. Remove the PTO clutch
disc.
365
Model Code Page
1. 12. 1986
41. Clutch 305-- 865 411 8
10. 1. 1992
14. Machines with low gear: it is easier to lift out the clutch if 3 a) Machines without low gear: push the front end of the
the PTO clutch disc is removed first. After removing the clutch, clutch shaft onto the propulsion clutch disc splines and fit the
the clutch shaft and release bearings can be removed. release bearings on the frame.
15. If the clutch needs to be dismantled, tool ETV 892 570 3 b) Machines with low gear: push the clutch shaft into the
should be used (see Op. 3A and B). clutch once the clutch is attached to the flywheel.
N.B. Lubricate the clutch shaft splines with EP grease.
4. Fit the clutch loosely by its upper part with some bolts, and
B. Fitting clutch mark with chalk the position for the centring drift pin in the
upper part of the clutch.
If the clutch shaft and release bearings have been removed,

on machines with low gear these should be fitted before fitting
the clutch.
Before fitting clutch, see Op. 1B, 3 ---5.
5. Fit the clutch bolts and tighten them evenly to a torque of

23 Nm.
1. Fit the centring drift ETV 891 211 on the flywheel ensuring
that the pin on the drift faces upwards. Fit the PTO clutch disc
on the drift and fit the clutch.
2. Machines without low gear: check the connecting sleeve

O ---rings, change them if necessary. Note that flat areas for the
locking bolts on the splines. Lubricate the splines with EP
grease.
6 a) Machines without low gear: fit the connecting sleeve

between the clutch shaft and the gearbox input shaft. Tighten
the bolts to a torque of 55 Nm and lock with locking washers.
366
Model Code Page
1. 12. 1986
41. Clutch 305-- 865 411 9
10. 1. 1992
it down into the drift threads. Carefully withdraw the drift with-
out rotating the handle.
10. Push in the long PTO shaft. The shaft is fully home when
the distance between its rear end and the contact surface for
the PTO is at least 45 mm.
N.B. If the long PTO shaft does not go fully home against the
flywheel, the fitting may be made easier by disengaging the
PTO clutch slightly.
N.B. Check that the ball and needle bearing are in position at
the rear end of the shaft. Apply locking fluid to the outer bear-
ing race.
6 b) Machines with low gear: push in the clutch shaft onto the
clutch splines and fit the rear end of the clutch shaft in the low
gear and tighten to a torque of 55 Nm.
7. Turn the clutch so that the pin on the centring drift points
upwards (see the marking).
11. Lubricate the release forks with universal grease and fit
them.
8. Fit the release bearings to the tractor frame according to the

guide pins and markings which were made when removing
them. Tighten the nuts to a torque of 45 Nm.
N.B. Assembling must be carefully carried out as any inaccur-

acies may cause the mechanism to bind
12. Fit the clutch cover and tighten down to a torque of 45 Nm.
One of the bolts is used for securing the switch for the PTO
clutch control lamp. Two of the bolts attach the battery shelf.
Fit the cover for the clutch shaft tunnel.
9. Carefully push the handle ET 891 200 from behind the trac-
tor through the tubular shaft to the centring drift and tighten
367
Model Code Page
1. 7. 1989
41. Clutch 305-- 865 411 10
10. 1. 1992
13. Fit the lower part of the PTO clutch lever on its shaft. Con- C. Reconditioning clutch release bearings
nect the accelerator linkage and the fuel hoses. Fit the battery
shelf and battery.
N.B. If the whole release bearing assembly must be removed
on 205---tractor, the frame must be split at clutch and the floor
plate and clutch cover must be removed.
1 a) Machines without low gear: remove the release bearings

according to Op. 2A points 1 ---12.
1 b) Machines with low gear: remove the release bearings ac-

cording to Op. 2A points 1 ---14.
14. Fit the service hatch to the front wall of the cab and fit the
floor plate.
15. Fit the floor mat and strips. Fit the knob on the hydraulic
lift lowering speed control and the plate for the low gear lever
grommet (models without low gear).
16. Fit the grommets for the pedals, the pedals and acceler-
ator pedal. Fit the PTO lever adjusting bolt and the lever sup-
port rail to the front wall of the cab. Fit the switch for the clutch
lever control lamp. 2. Fit a counterhold to the end of the release bearing guide
sleeve and pull out the propulsion clutch bearing from the
17. Fit the PTO (Op. no. 462 1E 1 ---8). Fill the gearbox with guide sleeve. Release the springs and free the support sleeve.
oil.
18. Adjust the clutch pedal and the PTO lever free travel (Op.
1 D and E). Check that the control lamp for the PTO lever func-
tions.
19. Bleed the fuel system and fit the engine hood plates. Test
drive the tractor.
3. Knock the PTO bearing out of the support sleeve and fit a
new bearing.
4. Check the condition of the guide sleeve for wear. Apply

multi ---purpose grease to the sliding surfaces of the sleeves.
With effect from ser. no. 606690 the sliding surfaces are fitted
with bearing bands, which should be changed when necess-
ary. Lubricate the bearing bands with grease.
368
Model Code Page
41. Clutch 305-- 865 411 11
1. 12. 1986
5. Fit the PTO bearing with bearing support on the guide

sleeve. Tap the propulsion clutch bearing into the guide
sleeve end.
6. Fit the release bearings in position (see Op. 2 B)
N.B. Changing the propulsion clutch release bearing is poss-

ible even when the tractor frame is parted at the propulsion
clutch. The bearing is then pulled out with a puller. The puller
is supported on the sleeve (ET 893 780) which is positioned
against the end of the guide sleeve. The puller should not
under any circumstances be supported against the end of the
clutch shaft.
369
Model Code Page
1. 12. 1986
41. Clutch 305-- 865 411 12
10. 1. 1992
3. Changing propulsion clutch disc and

adjusting clutch
Note! This instruction does not concern tractor 205 which has
a single disc clutch. In instruction below is used F&S ---clutch.
For the LuK ---clutch (on 555) there are necessary notes in the
text.
A. Dismantling clutch
3. Slacken the locking nuts (14 mm) for the PTO clutch levers.
ETV 893710 Check the condition of the levers for any damage resulting
from wear.
ETV 892571
1. Position spacers ETV 892 571 (4 pcs), with a thickness of

6,5 mm (For LuK ---clutch 7,6 mm) on the clutch fixture ETV
892 571.
4. Slacken the clutch attaching bolts and carefully lift away the
clutch casing. remove the plastic sleeves and springs which
sit on the attaching bolts. Remove the release pins.
5. Remove the clutch disc, pressure plate and disc spring.

Clean the parts and check their condition.
N.B. Checking the disc spring force is only possible by using

a special method (see Technical Data). Permissible final
machining for the pressure plate is 0,5 mm per friction sur-
face. The clutch surface should be machined by the same
amount so that the disc spring position is constant.
2. Place the clutch on the fixture and bolt it down with the
clutch attaching bolts M8X60.
N.B. Mark the pieces while in place in order to make assem-

bling easier. If the pressure plates need to be changed, the
clutch should be balanced afterwards.
370
Model Code Page
1. 12. 1996
41. Clutch 305-- 865 411 13
10. 1. 1992
B. Assembling and adjusting clutch ETV 892570
1. Screw the guide pin ETV 892 582 into the clutch fixture and
fit the centring sleeve ETV 892 592 on the pin.
2. Position the spacers on the fixture. ETV 892575
3. Place the PTO clutch pressure plate with attaching bolts on

the fixture.
4. Fit the disc spring with the concave side facing upwards.
Lubricate the spring and pressure plate contact surfaces with
grease.
ETV 892582
9. Release the guide stud from the fixture (centring sleeve to

remain in place). Fit pressure drift ETV 892 575 (diam. 150
mm) on the pressure lever ETV 892 570 and bolt down the
lever on the fixture. Press down the PTO clutch levers a couple
of times.
10. Replace the pressure drift with pressure drift ETV 892 578
(diam. 90 mm) and depress the propulsion clutch levers a
couple a time.
Note! The levers are depressed in order that the parts should
become seated.
ETV 892592
11. Remove the pressure lever from the fixture and remove the
5. Fit the propulsion clutch pressure plate and disc (with the propulsion clutch disc centring sleeve.
longer part of the hub facing upwards). Fit springs and plastic
sleeves on the attaching bolts. 12. Fit the guide stud to the fixture. Fit the spacer sleeve ETV
893 712 (l=96 mm) on the stud (the larger diameter hole
6. Fit the clutch casing. Guide the plastic sleeves and fit the turned downwards (for LuK ---clutch the spacer sleeve length
release pins through the openings in the side of the clutch must be 93 mm).
casing.
ETV 892587
N.B. The ends of the release pins should be by the studs
which are there for the pins. Grease the ends of the pins.
ETV 892584
7. Bolt down the clutch to the fixture.
ETV 892585
8. Use new nuts on the PTO clutch levers.
N.B. The nuts should always be changed.
ETV 893 712
13. Bolt the indicator sleeve, indicator and indicator nut onto
the guide studs. Adjust the height of the PTO clutch levers with
the help of the indicator by turning the adjusting bolts.
371
Model Code Page
1. 12. 1992
41. Clutch 305-- 865 411 14
10. 1. 1992
14. Lock the adjusting nuts on the adjusting bolts.
15. Fit a 72 mm spacer sleeve (for LuK ---clutch 68 mm) and

shorter indicator on the guide stud in order to adjust the pro-
pulsion clutch lever. Adjust the height of the propulsion clutch
levers.
16. Lock the adjusting bolt with locking nuts after adjustment.
Apply locking fluid to the threads, for example Loctite 270.
N.B. Check the height of the levers once more after applying
the locking fluid.
17. After adjustment, the clutch is released from the fixture.
372
Model Code Page
1. 6. 1998
41. HiShift 412 1
15. 4. 1999 600-- 900
1. HiShift, description
Picture 1. HiShift, electro---hydraulically controlled clutch

pedal
1. HiShift push buttons in the knobs of the gear levers.

2. Hydraulic pump
3. Clutch fluid reservoir (=brake fluid)
4. HiShift hydraulic block
5. Return oil connection
6. Speed sensor for AD ---instrument
When the push buttons in the gear lever knobs are pus-
hed, the hydraulic pressure pushes the clutch pedal down.
373
41. HiShift 600-- 900 412 2
15. 4. 1999
Repair instructions, see pages, 412/3 ---6
Note! HiShift (option) pushes the clutch pedal electro--- Function of the damping part
hydraulically down when a button in the gear lever knobs is
pressed and it is unnecessary to depress the pedal by foot. The damping cylinder has been connected to the clutch
fluid reservoir (9) by a hose.
Function of the hydraulic part When the working cylinder piston (2) releases the clutch, it
pulls the damping cylinder piston (3) mechanically out by
The working cylinder piston (2) pushes the clutch pedal the pin and the damping cylinder is filled with clutch fluid
down (working pressure from the tractor hydraulics). The via the filling valve.
working pressure is controlled with the solenoid valve (5,
Y14), which in turn is controlled with the push buttons (1) in When the working cylinder solenoid valve is unenergised
the gear lever knobs. (push button is released), the working cylinder piston
(pedal) rises first quickly the extent of the oblong hole in the
When the solenoid valve (5) is energised (one of the but- damping piston and then slower, because the return flow of
tons is depressed), the hydraulic pressure pushes the the clutch fluid into the reservoir is restricted.
pedal down. When the button is released (solenoid unener-
gised), the permanent hydraulic pressure on the piston rod The damping cylinder restriction can be changed by the
side forces the piston to move inwards and the clutch pedal solenoid valve (6, Y15) so that when the driving speed is
returns to the upper position. less than 4 km/h, the solenoid is energised and the clutch
pedal rises up slower. With speeds over 4 km/h the sole-
noid is unenergised and the pedal rises faster.
374
Model Code Page
41. HiShift 600-- 900 412 3
1. 6. 1998
2. HiShift, repair instructions
A. Adjustment
Note! Adjustment has been done in the factory and HiShift

does not normally require any adjustment. In connection
A
with repair works the adjustment can be done according to
this instruction. HiShift hydraulic block is mounted under
the cab on the LH side of the tractor frame.
Pedal travel
C B
7. If necessary, adjust the position of the knee point

(adjusting screw (C) at the end of the damping piston).
Screw outwards=knee point rises and vice versa.
Time
8. When the knee point has been adjusted, close the fore-
1. Pedal up 4. Driving speed < 4 km/h most restriction (B) and then open it 1+1/2 turns. The rear-
2. Pedal down 5. Driving speed > 4 km/h most restriction (A) should be open 2 turns (factory set-
3. Knee point 6. Clutch slips and engages ting). Lock the restriction spindles.
9. In a test---drive with driving speeds under 4 km/h the

1. Check the clutch fluid level. Raise the tractor on axle pedal rises up slower (4) (restriction 1+1/2). With speeds
stands. Start the engine and use the HiShift several times over 4 km/h the pedal rises up faster (restriction
so that air is removed from the system. Let the engine run (1+1/2)+(2)). Here must be observed, immediately the
for a while, so that the hydraulic oil warms up. driving speed exceeds 4 km/h, the pedal rises up faster.
2. Check the HiShift pressure in the test point on the block 10. Turn the steering wheel against the stop at which time
rear end. Correct value is 13 ---15 bar. the pump pressure rises up to 90 bar. Hold the clutch
pedal by hand and press the HiShift button and check, that
3. Close the foremost restriction spindle (B). The other res- the clutch pedal force is not too great (>250 N). In the HiS-
triction spindle (A) should be open 2 turns (factory setting). hift pressure test point, the pressure should be 13 ---15 bar.
4. Press the button in the gear lever knob at which time the 11. Check the function of the clutch. Drive over and under
clutch pedal moves down. Engage gear L1. Adjust the 4 km/h and check that the engagement of the clutch occurs
engine speed to low idling. softly. Check for leaks.
5. Release the button at which time the clutch pedal raises Note! Tractor driver can adjust the Hi Shift between certain
up quickly to the knee point (3), in which the working cylin- limits according to his own choice. However, the foremost
der piston rests against the damping piston. Tractor wheels restriction (B) must always be open at least 1 turn, to pre-
must not rotate. vent excess wear of the clutch disc.
6. Open the restriction spindle (B) a little, at which time the Fault tracing.
pedal starts to rise slowly. The wheels must start to rotate If the clutch pedal in paragraph 5 rises immediately to the
before the pedal has risen 10 mm (ideal value 5 mm) from upper position:
the knee point. --- the foremost restriction spindle leaks.
--- solenoid valve Y15 does not function or leaks.
Note! On account of possible small leakage of the restric- --- damping cylinder filling valve leaks.
tion spindle the pedal can start to rise slowly before the
restriction spindle is opened. The knee point (3) can,
however, be observed from change of rising speed of the
pedal.
375
Model Code Page
41. HiShift 600-- 900 412 4
1. 6. 1998
2 3 7 4
Picture 2. HiShift hydraulic block
Note! The picture above has been changed for visual reasons, so that all galleries can be seen.
In the picture, both solenoids are energised i.e. the button is pressed and the driving speed is
below 4 km/h.
B. HiShift hydraulic block
Note! The tightening torque of the three block fixing bolts is Leaking piston seals can be changed after unscrewing the
23 Nm. Check that the cylinder (1) pushes the pedal fully seal flanges. The filling valve spring and ball can be
home against the stop. In connection with possible fitting removed by unscrewing plug (7) between the restrictions (3
work, all bearing and sliding points must be greased with and 4).
universal grease. Assure, that the working cylinder push
rod functions correctly in the complete stroke of pedal. The restriction spindles have o---rings, which can be
changed. Do not screw in the spindles too hard, otherwise
Note! Impurities in the valve block can cause malfunctions, the spindle tapered surfaces can damage. The restriction
such as jamming of pistons and solenoid valves, blocking spindles have securing nuts.
of oil passages etc., at which time the valve components
can be opened and the valve can be tried to clean. Important! The seal rings of the damping cylinder solenoid
valve Y15 (rearmost) are of different material to the seal
HiShift working cylinder (1) has been connected to the rings of the solenoid valve Y14, and they must not be inter-
tractor working hydraulics. There is a relief valve (5) in the changed. In connection with repair works the solenoid
block (14 bar) and a pressure ---test point (6). The relief valve Y15 seal rings must not be lubricated with oil but, if
valve has been adjusted in the factory and then sealed. needed, with clutch fluid.
The damping part is not connected to the tractor hydraulic

system, but its own circuit uses clutch fluid (=brake fluid).
In case of a malfunction, check the clutch fluid level in the
reservoir, when the pedal is in the upper position.
376
41. HiShift 600-- 900 412 5
1. 9. 2001
C. Electric system of HiShift
When the buttons in the gear lever knobs are pushed, the --- if the solenoid valve is OK, measure whether there is a
foremost solenoid valve Y14 is grounded and it becomes voltage of 12 V in the connector pins of Y14 when the but-
energised and the clutch pedal moves down. tons are depressed. If not, the fault can lie in the valve wires
or in the push buttons.
When the driving speed is under 4 km/h, AD ---instrument
grounds via relay K24 the rearmost valve Y15 (becomes If the pedal rising speed has malfunctions:
energised) and the pedal rises up slower. --- measure whether there is a voltage of 12 V in the con-
nector pins of valve Y15 when the driving speed is under 4
When the engine is running and the hydraulics are OK, but km/h or the tractor is stationary. If not, the fault lies in relay
the pedal does not move down although the button is pres- K24 or in valve wires.
sed: --- when the driving speed is over 4 km/h, the valve Y15
should be unenergised and the pedal rises up faster.
--- check fuse FD3 in the fuse box. If the fuse blows repea-
tedly, the fault can lie in diodes. Valve Y15 has been connected to the speed sensor B6 of
--- if the fuse is OK, check the resistance of the solenoid the AD ---instrument. If the instrument shows correct speed
valves, which should be 11 ---12 ohms. When voltage of 12 and travelling distance, the sensor B6 is OK. Otherwise the
V is fed into solenoid pins, the valve must become magne- sensor should be checked/changed, see page 331/4.
tic and the spindle must move (click).
Note! If the electric system seems to be OK, but malfuncti-
ons still occur, one possible fault can be impurities in the
hydraulic block of the HiShift.
377
Model Code Page
1. 6. 1998
41. HiShift 600-- 900 412 6
1. 9. 2001
HiShift electric components

Position of components:
Note! The push button (S45) wires have been soldered to
the buttons. As a spare part are dispatched wires together Y14: the foremost solenoid on the hydraulic block lower
with the buttons. The wire lower ends have a connector. face under the cab on the LH side of the tractor frame.
Y15: the rearmost solenoid on the hydraulic block lower
The wires of the buttons have been drawn up to the lever face under the cab on the LH side of the tractor frame.
knobs inside a plastic tube round the gear levers. There is a GR3: earthing point on the cab front wall under the dashbo-
protective plate in the lower part of the levers to protect the ard.
connectors. V5: Diode box under the dashboard (the box is changed as
a complete unit)
Note! S45.1 is an optional push button. K24: Relay under the dashboard
Connector X25 under the dashboard
Note! HiShift is connected to the AD ---instrument via white Connector S45 in the lower part of the gear levers.
connector X26/11 on the rear side of the instrument.
378
Model Code Page
42. Gearbox 205-- 865 420 1
1. 12. 1986
Contents
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox 220, 250 and 270, description (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
--- Gearbox lubrication system (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
--- Oil filter (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
--- Gearbox lubrication pump (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gearbox 272, description (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
--- Main shaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C
--- Countershaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11D
--- Bevel pinion shaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11E
--- 4WD shaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11F
--- Gearbox lubrication pump (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11G
--- Gearbox lubrication (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11H
Differential (8+4R) and (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gear levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Selector forks (Op. no. 421)

1. Reconditioning selector forks:
A. Changing selector forks for speed gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Changing selector forks for range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shafts and gear wheels (Op. no. 423)

1. Reconditioning pinion shaft:
A. Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Reconditioning synchromesh unit and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Adjusting pinion shaft position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Fitting pinion shaft and adjusting bearing preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Fitting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Reconditioning layshaft:
A. Removing layshaft and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Fitting layshaft and adjusting bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. Reconditioning input shaft:

A. Removing input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. Changing bearings/synchronizing cones and fitting shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
C. Changing input shaft front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Reconditioning output shaft for powered front axle:

A. Removing shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. Changing selector fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C. Fitting shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
D. Changing shaft front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Differential (Op. no. 424)

1. Changing/reconditioning differential:
A. Removing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing differential side gears and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Fitting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Reconditioning differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
379
Model Code Page
1. 3. 1997
42. Gearbox 205-- 900 420 2
15. 4. 1999
Technical Data
Fully synchronized gearbox with pressure lubrication.
Number of speeds:
(numbers within brackets refer to machines with low gear or overdrive)
--- forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 (12)
--- reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 (8)
Oil
(in common for gearbox and final drives)
Viscosity and quality grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 120/4.
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 l (205---665), 27 l (865,
600---900)
Lubrication of gearbox with gear wheel pump:
--- pump volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 cm3/r
--- pressure limiting valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7 MPa
--- filter, by ---pass valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 MPa
--- filtration capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 μm
Gear ratios:
--- Pinion/crown wheel (30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14 (Z=7/43)
--- Pinion/crown wheel (40 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.67 (Z=9/42)
--- Pinion shaft/output shaft to powered front axle (30 km/h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57 (Z=30/47)
--- Pinion shaft/output shaft to powered front axle (40 km/h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 (Z=32/38)
Total gear ratio (engine/rear wheel hub)
Gear 30 km/h version 40 km/h version

1 (L1) 238,042 180,824
2 (L2) 173,496 131,803
3 (L3) 110,080 83,627
4 (L4) 83,133 63,156
5 (H1) 68,800 52,267
6 (H2) 50,148 38,097
7 (H3) 31,818 24,172
8 (H4) 24,029 18,255
R1 175,543 133,358
R2 127,953 97,205
R3 81,184 61,675
R4 61,311 46,577
Tightening torques
Gearbox ---fuel tank:
--- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
--- M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm
Gearbox ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm
Gearbox ---PTO:
--- 10 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
--- 2 pcs, M16 (earlier models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
--- 2 pcs M20 (latest models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm
Gearbox ---hydraulic lift:
--- ---610311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm
--- 610312--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
Low gear ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Draw bar ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm
Side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
Pinion shaft, round nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Pinion shaft, front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Input shaft, front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Lay shaft, front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Output shaft to powered front axle, round nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Nm
Selector shaft locking nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Selector shaft nut, outgoing shaft to powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Lubricating oil pump:
--- 2 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
--- 3 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Propeller shaft drive flanges:
--- 8.8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
--- 10.9 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
380
Model Code Page
1. 12. 1995
42. Gearbox 205-- 900 420 3
1. 1. 1998
I
Input shaft --- clutch shaft, connecting sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Low gear --- Clutch shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Crown wheel, attaching bolts:
--- earlier M10x60 (8.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
--- later M10x60 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Differential bearing covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
Cab --- rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Rim disc --- hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Nm
Steering system return oil pipe (rear end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Hydraulic system pressure pipe to pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Lower links --- rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm
Settings
Pinion shaft, rolling resistance:

--- measured with torsion meter at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,7---2,3 Nm
Differential, rolling resistance:
30 km ---transmission
--- measured with torsion meter at end of pinion shaft, where the resistance is the rolling
resistance of the pinion shaft bearings + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6---2,0 Nm
40 km ---transmission
--- measured with torsion meter at end of pinion shaft, where the resistance is the rolling
resistance of the pinion shaft bearings+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,8---2,6 Nm
Counter shaft, end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,075---0,150 mm
Imput shaft, end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025---0,075 mm
Tooth backlash, pinion/crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,18---0,33 mm
Required sealing compounds and locking fluids:

Side cover --- gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Silastic 738 RTV
Selector rail locking bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 242
Special tools
Gearbox A
Part no. Description

ETV 893 260 Key for round nut, output shaft front wheel drive (505---905)
ETV 893 630 Plate for fitting seal in bearing cover, input shaft
ETV 893 640 Plate for fitting seal in bearing cover, output shaft front wheel drive
ETV 893 650 Drift for fitting needle bearing/sealing ring in input shaft
Gearbox B
ETV 890 220 Universal handle
ETV 890 830 Sleeve for fitting front bearing on pinion shaft (PTO 505---905)
ETV 891 220 Sleeve for fitting bearing on counter shaft
Sleeve for fitting rear bearing on output shaft, front wheel drive
ETV 891 870 Plate for fitting thrust bearings for differential side gears (Gearbox 505---905)
ETV 891 900 Sleeve for fitting outer bearing race for input shaft front bearing (Gearbox 505---905)
ETV 892 210 Sleeve for fitting bearing race for pinion shaft front bearing (Gearbox 505---905)
ETV 892 230 Key for pinion shaft round nut (Gearbox 702---903)
ETV 892 350 Sleeve for fitting front bearing on output shaft, front wheel drive
Sleeve for fitting rear bearing on input shaft (Gearbox 505---905)
381
Model Code Page
1. 12. 1995
42. Gearbox 205-- 865 420 4
1. 3. 1997
ETV 892 490 Plate for fitting pinion shaft rear bearing bearing race (Final drives 702---903)
ETV 893 660 Key for adjusting differential bearings
ETV 893 610 Tool for removing/fitting input shaft and bearings
--- ETV 893 611 Spindle
--- ETV 893 612 Sleeve for removing shaft
--- ETV 893 613 Sleeve for fitting shaft
--- ETV 893 614 Drift for removing/fitting shaft
--- ETV 893 615 Nut M16, 2 pcs
ET 893 570 Drift for removing/fitting selector shaft

ET 893 620 Sleeve for fitting rear bearing on pinion shaft
Sleeve for fitting counter shaft bearing races
Sleeve for fitting rear bearing on input shaft
(ET 893 760) Support for front frame (2 pcs), prevents front axle oscillation when splitting tractor (see Frame and Wheel)
ETV 893650
ETV 893260 ETV 893630 ETV 893640
ETV 890 220
ETV 890 830 ETV 891 220 ETV 891 900

ETV 891 870
ETV 892 210 ETV 892230
382
Model Code Page
1. 12. 1995
42. Gearbox 205-- 865 420 5
1. 3. 1997
ETV 892 350
ETV 893660
ETV 892 490
ETV 893611
ETV 893612
ETV 893615 ETV 893614
ETV 893613
ETV 893610
ET 893570
ET 893 620 ET 893 760
383
Model Code Page
1. 5. 1996
42. Gearbox 10. 10. 2003 205-- 865 420 6
Gearbox 220, 250 and 270, description

(8+4R)
The speed gearbox has eight forward speeds and four (1---4) is selected with the speed gear lever.
reverse speeds. All speed gears and also the range gears are
synchromesh. Tractors equipped with an extra low gear have On tractors with a powered front axle, there is a shaft in the
twelve forward speeds and eight reverse speeds. lower part of the gearbox which transfers the engine power to
the front axle. The gear on this shaft is in mesh with a gear on
the pinion shaft. The front wheel drive is engaged with a dog
The gearbox is operated with gear levers to the right of the dri-
clutch which is operated with a lever by the driving seat.
ving seat. High/low (H/L) and reverse (R) respectively are
selected with the range lever and the desired speed gear
L R H
4WD
384
Model Code Page
1. 12. 1986
42. Gearbox 205-- 900 420 7
1. 1. 1998
The shafts in the gearbox are supported in taper roller bea-

rings (ball bearings on the output shaft for the front wheel The pinion shaft is fitted with two synchromesh units. The
drive). The gears on the input shaft and on the pinion shaft are front unit is used for selecting the reverse speeds and the
carried in plain bearings apart from the front gear (teeth 29/25) low gear. The rear synchromesh unit engages high gear.
on the input shaft which is carried in needle bearings. The
layshaft has gears formed integral with the shaft. The selector forks are fitted in pairs on the selector shafts
(see Fig. 2). Two tubular pins on the selector shaft pre-
All gears in the gearbox are helical gears, except for the gear vent two speeds from becoming engaged at the same
wheel pair for the front wheel drive. The gears rotate in con- time on the input shaft (or on later models, blocking pins,
stant mesh with the corresponding idler gears. The input shaft see Fig. 2 item A). These are fitted on the selector shaft.
is connected to the clutch shaft with a connecting sleeve (if On the pinion shaft, a blocking plate (see Fig. 2 item B)
the tractor is not equipped with a low gear). is fitted on the selector shaft.
The input shaft is fitted with two synchromesh units. The front The position of the selector forks relative to the synchro-
unit is used for selecting speeds L3, L4, H3, H4 or the reverse
nization rings and synchronization unit can be adjusted
speeds R3 and R4. The rear synchronization unit is used for
with nuts at the front end of the selector shaft.
engaging speeds L1, L2, H1, H2 or the reverse speeds R1 and
R2.
Fig. 2. Selector forks

A. Blocking pins which prevent two speeds from becoming engaged at the same time (input shaft)
B. Blocking plate which prevents two speeds from becoming engaged at the same time (pinion shaft). In gearbox 270 the blocking
plate is different: in the beginning of the series (6) and later (6a) (three parts 6a are different).
The 270 gearbox 270 is fitted on 600, 700, 800 and 900 tractors. The 600---900 tractors’ selector mechanism can be equipped with
Euro blocking device, which prevents engagement of gear H4 (speed limits). On the tractors with the blocking device, the shifter
levers are different.
385
Model Code Page
10. 1. 1992
42. Gearbox 205-- 865 420 8
15. 9. 1995
Figure 3. Position of selector forks and adjustment

1. Selector shaft locking screw. Loctite 242 on the threads
2. The selector levers are lubricated with universal grease
N.B. The shifter levers are attached to the selector lever outer
ends with a larger tension pin (see black arrows) and inside
it must be fitted a smaller tension pin with the split side to the
opposite side as on the larger pin.
386
42. Gearbox 10. 10. 2003 205-- 900 420 9
Gearbox lubrication system (8+4R)

The gearbox is lubricated through splash lubrication and thro- A gear pump fitted to the rear of the input shaft provides the
ugh force ---feed lubrication (of the input and pinion shafts). pressurised oil for lubrication. The lubricating oil is fed via an
The pressurised oil from the lubrication system is ducted to oil filter into a distribution piece and on to the different lubrica-
lubricate the final drives, PTO, brakes and eventually the low tion points.
gear. The oil to the input shaft is fed via the pump housing in
through the space between the input shaft and the long PTO Oil is directed to the oil cooler from the filter bracket (oil cooler
shaft. From there the oil is led through ducts to lubricate the only on 665, 865 and 600---900 tractors).
bearings. The oil to the pinion shaft is ducted in through the-
front end cover and further through ducts to lubricate the
bearings.
Figure 4. Diagram of lubrication system Note! 205---565 tractors have no oil cooler. On
these tractors the filter bracket ports to the cooler
1. Suction pipe are plugged and it has only one outlet connection
2. Pump to the low gear. The filter bracket is fitted with a by ---
3. Pressure oil pipe to filter pass valve. The other lubrication system is similar
4. Filter on 205---665 tractors. The oil cooler on 600---900
5. Distribution piece tractors is the same as on 865 from frame number
6. To input shaft G09303 incl. (the same as on Mezzo 6000---series).
7. To final drives and brakes
8. To pinion shaft
9. To low gear (not this pipe on 600---900)
10. Return oil from low gear
11. To PTO
12. Oil cooler (only 665, 865, 600---900)
387
Model Code Page
1. 9. 1992
42. Gearbox 205-- 865 420 10
10. 10. 2003
Oil filter (8+4R)
In the filter bracket there is a pressure relief valve with an ope-

ning pressure of 0,7 MPa. The filtration capacity of the filter is
0,5 μm (glass fibre filter). The filter is also fitted with a by ---pass
valve with an opening pressure of 0,2 MPa.
Fig. 5 Oil filter (205---565)
1. Pressurised oil from pump

2. Lubricating oil to filter
3. Filter bracket
4. Lubricating oil to gearbox
5. Lubricating oil to low gear
6. To oil sump
Path of oil to the filter (fig. 5).
Oil comes from the pump through the delivery pipe (1) to the If the lubricating oil pressure exceeds 0,7 MPa (102 psi), for
right---hand space of the filter bracket. From there the oil con- some reason, the relief valve in the filter bracket opens and
tinues to the filter inlet (2). The filtered oil is conducted to the ducts (6) oil direct to the gearbox.
left---hand space (3) of the filter bracket and is supplied via a
pipe (4) to the various lubricating points. The by ---pass valve opens at a pressure of 0,2 MPa (29 psi)
if the filter for some reason is blocked, in which case the oil
Oil is supplied to the low gear through the connection (5) (if passes through unfiltered.
there is no low gear, this hole is plugged. The tightening
torque of the plug is 20 Nm (14 lbf ft)). Note! Filter bracket on tractor 665, see previous page.
388
Model Code Page
1. 1. 1998
42. Gearbox 10. 10. 2003 205-- 900 420 11
Gearbox lubrication pump (8+4R)
355---900
Fig. 6. Gearbox lubricating pump
1. Suction pipe from gearbox

2. Delivery pipe to filter
3. Distribution piece
4. Lubricating oil to input shaft
5. Rear end of input shaft with drive lugs
6. Drive lugs
Gerabox 270 is fitted on 600---900 tractors. On these tractors

the gearbox lubricating oil pump is larger since the new
Overdrive and Low gear needs more lubricating oil.
389
Model Code Page
42. Gearbox 10. 10. 2003 600-- 900 420 11A
Gearbox 272, description (12+12R)

The present 8+4R gearbox has got an alternative gearbox This alternative needs always a shuttle unit, because the R
type 12+12R (in some marketing areas limited to 11+11R). (reverse) group has been replaced with LL (creeper) ---
group.
20
24
1) Main shaft
2) Countershaft
3) Bevel pinion shaft
4) 4WD shaft
5) Shuttle unit
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---step, fully synchronized, operated by lever

Speed ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ranges, operated by lever:
H = high range, synchronized
M = medium range, synchronized
LL = creeper range, no synchronized
Forward/reverse gear unit . . . . . . . . . . . . . . . . . . . . . . . . synchronized, operated by lever
No. of speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12+12
390
Model Code Page
42. Gearbox 10. 10. 2003 600-- 900 420 11B
--- Changes: Assembling the transmission 272 in short:

--- Mechanical shuttle unit + control lever 1. Assemble lubrication pipes into the housing.
2. Assemble the parts of the main shaft on the table.
--- The gear ratio difference between 2nd and 3rd gears has
been decreased. The syncro of M ---group has been enlar- 3. The inner races of the countershaft bearings must be
ged (before was 82mm now is 90mm). assembled before setting the countershaft to the gearbox.
4. Install the main and counter axles into the housing and
--- The M ---LL selector fork replaces the L ---R selector fork. fix the bearing covers and check tolerance
The spare part numbers of the selector forks of the main
gears has been changed (space for pump drive shaft). 5. Assemble the bearings, bush and spacer ring to the Z58
gear wheel of the pinion shaft. Glue the bush and the plate
--- There is a new lubricating oil pump for the gearbox and with instant adhesive. Note! Glue should be dropped on
different pipe work. The pump is driven from the shuttle unit the needle bearing. Install the built---up the Z58 gear wheel
by a shaft. The old and new pumps are not interchangea- into the housing.
ble. 6. Install the 4WD fork
--- The PTO clutch shaft has been changed. The shoulder 7. Assemle 4WD axle to the housing. Thread first the gear
has been moved forward (because of the pump gasket). wheels, bearings, spacer rings, circlip and bush. Then as-
The old clutch shaft (45355700) cannot be used in the new semble the bearing of the front end side and the bearing of
gearbox (272) and the new shaft (34806900) can not be the rear end side and the circlip.
used in the old gearbox (270). In the rear end of the new 8. Install M ---LL synchromesh units of the pinion shaft with
shaft there is a machined a shoulder for identification. fork to the housing at the same time.
--- There are few modifications in the gear levers. 9. Install the pinion shaft into the housing and assemle the
gear wheels to the axle. Check the moment of rotation. No-
te! Measure the location of the axle before settings.
10. Install the pump
11. Install the fork of the lock of differential and axle
12. Install the differentiall and check bearing preload and
tooth backlash.
391
Model Code Page
42. Gearbox 10. 10. 2003 600-- 900 420 11C
Main shaft (12+12R)
--- The input shaft is fitted with two synchromesh units. The
front unit is used for selecting gears 1...4. 1) Shims s= 0,10; 0,15; 0,20; 0,50 mm.
The synchromesh units are equal and interchangeable
(with exception of hubs). The mounting direction is free. 2) In connection with repairs, use sliding compound e.g.
Molykote 321 R Spray (UC3957) on sliding surfaces or oil
After fitting new bearings the bearing clearance has to be them. Clean parts well before treatment!
adjusted.
3) Needle bearing is pushed into the shaft until bearing
--- Adjust the bearing end float : front side is at level with shaft end. Bearing number side
--- Fit the spacer ring and select shims so that the bearings forwards.
have a definite clearance in front of the front bearing and fit 4) The bushing pins can be fitted with Loctite 641. Do not
the bearing cover. allow locking fluid to leak on to the bearing!
--- Turn the shaft 20 ---30 revolutions, in order to bed in the 5) Lubricating oil pump
bearings.
6) The new shaft (34806900) has a indication shoulder for
--- Position a dial gauge against the front end of the shaft identification.
and push the shaft forwards and backwards and note the
value of end float on the gauge. The correct value is The clutch shaft of the PTO has been changed. In the new
0,025 ---0,075 mm shaft the (turned) thinning has been moved forward (becau-
se of the new location of the pump gasket). The old clutch
--- Increase or decrease the shim thickness if necessary shaft cannot be fitted into the new gearbox (272) or the new
--- Gearbox type 272: shaft in the old gearbox (270). In the rear end of the new
--- main shaft doesn’t drive the oil pump shaft there is a machined shoulder for recognition.
---The front end and bearing cap of main shaft has been
changed (no oil seal). The corresponding spacing ring to Notice after the installation:
shims (30382900) has been removed --- Install the main and counter axles into the housing and
---The number of teeth for 2nd and 4th gears has been fix the bearing covers and check tolerance
changed (2nd gear; earlier 23 now 24, 4th gear; earlier 32
now 36)
---The bearing for 3rd gear (Z29) has been changed to a
sleeve bearing type.
---The reverse gear Z25 has been removed. In it’s place
there is a spacer sleeve + pin (30187000).
392
Model Code Page
42. Gearbox 600-- 900 420 11D
10. 10. 2003
Countershaft (12+12R)
--- Gearbox type 272: Notice before the installation:

---The number of teeth for 2nd and 4th gears has been --- The inner races of the countershaft bearings must be
changed (2nd gear; earlier 30 now 29, 4th gear; earlier 20 assembled before setting the countershaft to the gearbox.
now 21) Notice after the installation:
--- Axial play has been changed (earlier 0,075---0,150mm --- Install the main and counter axles into the housing and
now 0,025 ---0,075mm). fix the bearing covers and check tolerance
--- The bearing in the Z15 gear side has been changed
--- Foremost bearing cover has been changed
--- After fitting new bearings the bearing clearance has to be

adjusted.
1) Adjusting bearing clearance:
--- place a sufficient number of shims under the end cover
to give the bearings a definite clearance and tighten down
the cover
--- Measure the bearing clearance with a dial gauge. Place
the stylus against the rear end of the shaft.
Reduce the shim thickness until the bearing clearance is
0,025 ---0,075mm.
--- turn the shaft at least 20 ---30 revolutions and check the
clearance again.
2) Bearing cover, see main shaft
393
Model Code Page
42. Gearbox 10. 10. 2003 600-- 900 420 11E
Bevel pinion shaft (12+12R)
--- The output shaft has ball bearings. The gears have pres- 1) Shims (see adjustment of pinion shaft position.
sure lubrication.
2) Spacer rings (see adjustment of bearing preload
--- The pinion shaft is fitted with two synchromesh units. The
front unit is used for selecting the M ---group or LL group. 3) Sliding lac, e.g. Molykote 321 R spray
The rear synchromesh unit engages high gear. 4) Glue the bush and the plate with instant adhesive. Note!
Glue should be dropped on the needle bearing.
--- The other movement direction of the rear synchromesh
unit has been eliminated with a blocking plate (note the
mounting direction). Note! the blocking plate must be mo- Notice before the installation:
unted forward. --- After Installation of the main and counter axles, assemble
the bearings, bush and spacer ring to the Z58 gear wheel
--- Note the mounting direction of the bearing sleeve under of the pinion shaft. Glue the bush and the plate with instant
the gear Z61. adhesive. Note! Glue should be dropped on the needle
--- Gearbox type 272: bearing. Install the built---up the Z58 gear wheel into the
housing.
---The M ---LL ---range replaces the L ---R ---range, with the --- Install the 4WD axle.
twin gear Z58/34 + needle bearings.
--- Install the pinion shaft into the housing and assemle the
---Selection of the range gears has been improved by enlar- gear wheels to the axle. Check the moment of rotation. No-
ging the synchro of the M ---group (82mm ---> 90mm). te! Measure the location of the axle before settings.
NB! The LL group has no synchronizing ring!
394
Model Code Page
42. Gearbox 10. 10. 2003 600-- 900 420 11F
4WD shaft (12+12R)
--- On tractors with a powered front axle, there is a shaft in

the lower part of the gearbox which transfers the engine Notice before the installation:
power to the front axle. --- Install first the 4WD fork.
The output shaft has ball bearings. The gear on this shaft is --- Assemle 4WD axle to the housing. Thread first the gear
in mesh with a gear on the pinion shaft. wheels, bearings, spacer rings, circlip and bush. Then as-
--- The front wheel drive is engaged with a dog clutch which semble the bearing of the front end side and the bearing of
is operated with a lever by the driving seat. the rear end side and the circlip.
Four ---wheel drive can be operated without pressing down

the clutch pedal even when the tractor is running. On the
other hand, engaging must not be done under heavy loa-
ding or if the rear wheels spin.
--- Gearbox type 272 :
For the LL ---range gear there is a twin gear Z51/23, with a
needle bearing
1) To be filled with grease
395
Model Code Page
42. Gearbox 10. 10. 2003 600-- 900 420 11G
Gearbox lubrication pump (12+12R)
--- The lubrication pump has been removed from the center 1) Lubrication oil pump
line of the input shaft. 1a) Drive lug
The pump rotates in one direction (as earlier), but because 2) Suction from the tank (gearbox housing)
of space the pump construction is new. Revolution capacity 3) Pressure oil for filter
is 9,1 cm3 .
4) Distribution piece
The middle gear of the shuttle unit drives the pump. The
pump rotates, although the forward ---reverse shuttle is in 5) Lubricating oil for main shaft
neutral. 6) Driving shaft for pump
The old and the new pump are not interchangeable. Also 7) Seal of the PTO drive shaft (needs the new type of the
the shuttle unit become the lubrication by the lubrication PTO drive shaft)
pump.
--- In connection with repairing, do not block up the tube
which comes to the front part of the pinion shaft with silicon.
--- If the lubrication pump has been opened, secure the
screws with locking fluid Loctite 242 (UK0126).
396
Model Code Page
42. Gearbox 10. 10. 2003 600-- 900 420 11H
Gearbox lubrication (12+12R)
The filter seat (13) has also a by ---pass valve (0,4 MPa),
which protects the system when e.g. oil is stiff in the oil coo-
ler.
Shuttle unit lubrication (272):

The lubrication oil is led through the groove on the joint
surface and with help of the tube X to the bearings of the
shuttle unit clutch shaft. In the shuttle unit housing there is a
throttle (1,0 mm, by which the lubrication oil flow to the
shuttle unit is adjusted).
397
Model Code Page
1. 5. 1996
42. Gearbox
10. 10. 2003 205-- 900 420 12
Differential (8+4R) and (12+12R)

The differential consists of two differential side gears and two
The crown wheel together with the differential casing are differential pinions. The side gears are journalled in plain bea-
mounted in the gearbox housing in taper roller bearings. Bea- rings in the differential casing. The differential pinions are jour-
ring preload and tooth backlash between the pinion and the nalled with locked thrust washers made of bronze. The diffe-
crown wheel are adjusted with adjusting nuts. rential is lubricated with oil from the transmission.
Fig. 7. Section of differential Differential lock

The differential lock is a mechanically engaged pin lock which
1. Crown wheel locks one of the differential side gear against the differential
2. Gearbox 220 differential pinion, 2 pcs. casing with the aid of the engaging sleeve. A lamp lights on
Gearbox 250, 270 and 272 4 pcs. the instrument panel when the lock is engaged.
3. Differential side gear
4. Engaging sleeve for differential lock The differential lock must only be used when travelling on soft
5. Selector fork and/or slippery ground.
6. Adjusting nuts The lock is engaged mechanically with the aid of a spring ---
loaded control located on the RH side of the driving seat.
7. Switch for differential lock control lamp
The lock can be engaged and disengaged when travelling
straight forward if the wheels are turning at the same speed.
398
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 420 13
1. 7. 1989
Function of differential lock ( ---610311)
When the lever (1) is depressed the movement is transferred of the shaft closes the circuit to the control lamp on the instru-
by the rod (2) to the pushrod (3) until this moves against the ment panel.
stop on the link (4). Simultaneously the spring on the pushrod
(3) is compressed. When the lever (1) is lifted, the spring in the rod (2) is ten-
sioned. As soon as the forces between the differential side
When the movement between the differential side gear and gear and housing permit, the spring in rod (2) pulls out the
the casing permits the pins to move, the spring on the push- lock. The control lamp on the instrument panel goes out.
rod (3) pushes in the shaft. The selector fork (5) on the shaft
presses in the coupling device and the differential lock be-
comes engaged. The switch at the end
Figure 8. Differential lock control (---610311) Note! With effect from ser. no. 610312 the differential lock con-
1. Operating lever trol linkage has been changed (new control linkage, see page
2. Damping spring 420/17).
3. Push rod
4. Link
5. Selector fork
6. Adjusting nut
399
Model Code Page
1. 7. 1989
42. Gearbox 205-- 865 420 14
15. 9. 1995
Synchronization Synchromesh unit function (pinion shaft)
All gears (even the reverse) are synchronized. The synchro- Fig. 10. Function of synchromesh unit
mesh units on the input shaft and pinion shaft are of different
design. On the input shaft the synchronizing cones have loc- A
king lugs and wire springs, whilst locking lugs, ball studs and
coil springs are used on the pinion shaft.
The synchromesh unit for high gears (H) is single acting and
is therefore blocked in the opposite direction.
A. Gear in neutral
B. During the initial stage of the engagement, the sliding cou-

pling presses the locking lugs (ball stud and angle piece)
against the synchronizing cone. The cone is pressed against
the cup (taper) on the gear wheel under friction. The diffe-
rence in speed between the synchromesh unit and the gear
wheel begins to even out. The teeth on the synchronizing
cone still prevent the gear from engaging.
C. When the synchromesh unit and gear wheel have the same
speed, the cone is turned out of the locked position exactly
opposite the teeth on the sliding coupling so that it can
engage the teeth on the gear wheel.
Fig. 9. Synchromesh units on input shaft and pinion shaft

1. Synchromesh unit engagement lock:
1. Input shaft
--- gears 1, 2, 3 and 4 (diam. 68 mm, steel) The shape of the teeth inside the sliding coupling and on the
2. Pinion shaft gear, lock the coupling sleeve and prevent it from slipping out
--- reverse/low gear (diam. 82 mm, steel) of engagement when accelerating or engine braking.
--- high gear (diam. 82 mm, steel)
400
Model Code Page
42. Gearbox 205-- 865 420 15
1. 12. 1986
Synchromesh unit function (input shaft)

The function is the same as for the pinion shaft synchromesh
unit. The sliding coupling presses the syncromesh cone loc-
king lug against the synchronizing cone. This is due to the
goove on the inside of the sliding coupling. When the speed
of the synchromesh unit and gear wheel is nearly the same the
sliding coupling engages with the gear wheel.
4
3
5 4
Fig. 11. Synchromesh unit on input shaft
1. When assembling it should be noted that the bent ends of

the springs are not to be fitted in the same locking lug.
2. Sliding coupling
3. Hub
4. Synchronizing cone locking lug
5. Synchronizing cone
6. Gear wheel
401
Model Code Page
42. Gearbox 205-- 865 420 16
1. 12. 1986
Gear levers
The gearbox is operated by two gear levers on the right side The gear levers are mounted in the floor in ball socket joints.
of the driving seat. The range lever is used for selecting low, This design creates exact lever movement. Cup springs are
reverse or high gears. The speed gear lever is used for selec- fitted in the ball joint to eliminate any play in the joint.
ting 1---4.
The engagement of the additional low gear is only possible
The low gear (L) range and reverse (R) of the range lever are when the range lever is in the L or R position. It cannot be
located opposite each other in the gear shifting gate. The engaged in the High position as this is prevented by a mecha-
range lever is used as a direction selector for all speeds. nical lock.
Fig. 12. Gear lever system
1. Range gear lever

2. Speed gear lever
3. Low gear operating lever
4. Ball joints are lubricated with universal grease
5. Lubricate the lower joints on the gear levers with grease
containing molybdenum
6. Differential lock operating lever
7. PTO selector lever
402
Model Code Page
42. Gearbox 205-- 865 420 16A
1. 3. 1997
Gear levers, 610312---
403
Model Code Page
1. 7. 1989
42. Gearbox 205-- 865 420 17
1. 9. 1995
Operation of differential lock (with effect from

ser. no. 610312)
When the movement between the differential side gear and
When the lever (1) is depressed the inner pipe (2) is turned. casing permits the pins of the engaging sleeve to move, the
The inner pipe has two pitched grooves through which there spring (3) pushes the selector fork shaft, the selector fork (5)
is a screw (and bearing bushings).The ends of the screw are and finally the engaging sleeve pins into the differential side
attached to the outer pipe (4).The axial movement of the inner gear holes, thus engaging the differential lock.The switch
pipe loads the spring (3). The ends of the pitched grooves are (S17) at the end the selector fork shaft closes the circuit to the
shaped so that the inner pipe is kept in its extreme position. indicator lamp on the instrument panel.
3 7
6
Fig. 13. New differential lock control (610312---)

(earlier control linkage, see page 420/13)
1. Differential lock lever
2. Inner pipe
3. Spring
4. Outer pipe
5. Selector fork
6. Adjusting nut. When assembling the control linkage the ad-
justing nut is tightened until there is no clearance between the
coils of the spring (spring not loaded. Lock the adjusting nut
with the locking nut.
7. Filled with multi ---purpose grease when assembling.
404
Model Code Page
10. 1. 1992
42. Gearbox 205-- 865 421 1
15. 9. 1995
Figure 13. Position of selector forks and adjustment

1. Selector shaft locking screw. Loctite 242 on the threads
2. The selector levers are lubricated with universal grease
Note! On the selector forks for L ---R and H gears (on the
N.B. The shifter levers are attached to the selector lever outer pinion shaft) there are fitted two plastic sliding pieces
ends with a larger tension pin (see black arrows) and inside from serial no. 659877 incl up to serial no. 663384. With
it must be fitted a smaller tension pin with the split side to the effect from ser. no. 663835 these forks have 4 pcs sliding
opposite side as on the larger pin. pieces. When fitting the forks, the sliding pieces can be
fastened on the forks with a little grease.
405
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 421 2
10. 1. 1992
1. Reconditioning selector forks
A. Changing selector forks for speed

gears
N.B. In these instructions the gearbox has been removed

from the tractor. The selector forks for the speed gears can
also be removed through the side cover of the gearbox, i.e.
without parting the tractor (if the tractor is not equipped with
low gear). In which case the selector shaft is drawn out for-
wards after the floor plate in the cab has been removed.
4. Withdraw the selector shaft carefully while at the same time

ensuring that the ball and spring, located inside the selector
forks, do not fall down into the gearbox.
5. Lift the speed gear selector forks out of the gearbox.
Assembling:
1. Put the gears in neutral and remove the gearbox side cover
(17 mm).
ET 893 570
1. Fit the spring and ball on the front selector fork using ET 893
570. Position the selector fork in the gearbox and push in the
selector shaft through the selector fork.
2. Fit the other selector fork by the same method.

2. Remove the selector shaft locking bolt (13 mm) from the N.B. The ET ---tool is pushed out of the selector fork and can
front end of the shaft. be removed from the space between the selector fork and the
rear wall of the gearbox.
3. Push the selector shaft into position and turn it so that the
grooves in the shaft face the balls.
4. Move the selector forks on the shaft when necessary and

tap in the tubular pins (or on later models the locking pins with
circlips).
3. Move the selector forks on the shaft. Turn the shaft and tap
out the two tubular pins (or on later models two locking pins
with circlips).
406
Model Code Page
15. 9. 1995
42. Gearbox 205-- 900 421 3
1. 1. 1998
N.B. The tubular pins should not be tapped in further than the
same level as the shaft.
B. Changing selector forks for range gears
A visual inspection of the selector forks for the range gears

can be carried out through the access hole. When changing
the selector forks the tractor must be split between the gear-
box and fuel tank in order that the selector shaft can be with-
drawn forwards.
Changing and adjusting selector forks should be carried out

according to instruction A. The only difference is the removal
and fitting of the tubular pin and locking lug.
1. Before tapping out the tubular pin push the selector shaft
towards the rear, until the front end of the shaft is level with the
front face of the gearbox. Put the rear synchromesh unit slide
coupling in the rear position and the front in neutral.
2. The tubular pin can now be tapped out of the shaft between
the selector forks. Turn the shaft slightly if necessary.
5. Adjust the position of the selector forks. Push the shaft axi-
3. Fitting occurs in the same way. The tubular pin is tapped
ally and check the play on the selector forks. Centre the shaft
through the locking lug and shaft at the same time.
with the nut. Check that the sliding coupling and the synchro-
mesh cones move freely, when the selector forks are in the
N.B. On the selector forks there are plastic sliding pieces. Fas-
middle position (neutral). Adjust when necessary the position
ten the sliding pieces on the forks with a little grease when you
of the selector shaft.
fit the forks onto the pinion shaft.
C. Others
An alternative Overdrive can be fitted on 600, 700, 800 and
900 tractors. Since the Overdrive control lever requires more
space, small modifications have been made in the gearbox
selector forks, selector arms and gear levers. These modifica-
tions do not affect the repair instructions, but the spare part
numbers can be different.
6. Tighten the locking bolt on the selector shaft to a torque of

23 Nm (16 lbf ft). Use locking fluis Loctite 242 on the threads.
7. Put the gears in neutral. Clean the side cover sealing surfa-
ces and apply sealing compound (e.g. Silastic 738 RTV black)
on the sealing surfaces. Position the gear shift levers in the
selector fork grooves. Tighten the side cover bolts (17 mm) to
46 Nm (33 lbf ft).
407
408
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 423 1
1. 5. 1996
Shafts and gear wheels (Op. no. 423)
1. Reconditioning pinion shaft
Before removing the pinion shaft, remove:

--- gearbox from tractor (Op. no. 423 1A)
--- differential from the gearbox (Op. no. 424 1A)
Fig. 14. Pinion shaft

1. Shims (adjusting position of shaft). N.B. One shim (0,3 mm
with three lugs) is fitted as standard at the bottom of the bea-
ring location.
2. Spacer rings (adjusting bearing preload)
3. Anti ---friction varnish, Molykote 312 R spary
3. Remove the lower link brackets under the rear axle hou-
sings (30 mm). Remove the extra lifting cylinder (if one is fit-
ted), lower links and lifting links. Disconnect the draw bar from
A. Removing gearbox underneath the gearbox.
4. Slacken and remove the rear wheel nuts (24 mm). Lift the
N.B. The gearbox may be removed by rolling the rear half of rear of the tractor and block it up under the fuel tank.
the tractor away from the middle frame with the gear wheels
still fitted (see Op. no. 441 1A). 5. Remove the rear wheels. Position two axle stands fitted with
castors under the gearbox.
1. Fit support plates ET 893 760 on the front axle in order to
prevent axle oscillation. 6. On tractors with four wheel drive, remove the guard plate
for the propeller shaft and disconnect the propeller shaft at the
2, Drain oil from the transmission (23 liters) and the hydraulic rear drive flange.
system (35 litres).
409
Model Code Page
1. 7. 1989
42. Gearbox 205-- 865 423 2
1. 5. 1996
7. Unscrew the rear mountings for the cab (24 mm). Lift up the
rear of the cab and block it up under both mudguards. NOTE: Later model tractors (610312---): the pressure oil hose
and the auxiliary hydraulic valve lever must be disconnected
from the auxiliary hydraulic valve blocks (on the RH side).
NOTE! 865---tractor: remove the auxiliary hydraulic valve

blocks through the access hole on the RH side rear mudguard
and remove, when necessary, also the valve block stud bolts (
3 pcs). On tractors with Autocontrol, disconect the power lift
sensor wire connectors.
8. Remove the final drives (Op. no. 451 1A).
14. Unscrew the bolted joint between the gearbox and fuel
tank (19 mm).
9. Remove the PTO (Op. no. 462 1A) and the long PTO shaft.
10. Remove the attaching plate for the hydraulic quick ---action
couplings (13 mm) and the oil reservoir (oil reservoir removed
with effect from ser. no. 610312---).
11. Remove the knob on the lowering speed control under the
driving seat (not Autocontrol).
12. Disconnect from the left side of the tractor:

--- leads from the differential lock control lamp
--- front wheel drive control lever from selector lever
--- hydraulic system pressure pipe from pressure filter
15. Pull the gearbox rearwards out of the tractor.
--- control lever joints above valves for auxiliary hydraulics and
the bracket for the levers.
16. Remove the clutch shaft from the gearbox input shaft (or if
the tractor is equipped with low gear, remove the low gear
NOTE: On the latest model tractors (610312---) the pressure
from the front wall of the gearbox).
filter and auxiliary hydraulic valve blocks are located on the
RH side of the hydraulic housing.
17. Remove the hydraulic lift cover and lifting arm shaft and
unscrew the hydraulic lift attaching bolts. Remove the hy-
13. Disconnect from the right side of the tractor:
draulic lift.
--- the lower end of the position control lever from the hydraulic
lift control shaft
N.B. The hydraulic lift is only removed in order to simplify the
--- gear levers from selector levers (range gear lever, speed
reconditioning of the gearbox.
gear lever and low gear lever (if fitted)
--- low gear selector lever (if fitted)
--- differential lock control
--- clamp for hydraulic system suction pipe (rear end)
--- banjo bolt for steering system return oil pipe
--- lifting link gear control from lifting link
410
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 423 3
15. 9. 1995
5. Remove the selector forks (Op. no. 421 1A and B).

B. Removing pinion shaft
Note! Take care of the plastic sliding pieces on the selector
forks.
N.B. In the following figures the gearbox is held in a fixture,
which simplifies the reconditioning work.
6. Remove the bearing cover at the front end of the pinion

shaft (13 mm).
1. Free the circlip from the differential lock selector shaft.
ETV 892 230
7. Undo the shaft nut locking and the nuts using ETV 892 230.
2. Pull out the selector shaft past the lubricating oil pump at the Stop the shaft from rotating by engaging two gears at the
rear of the input shaft. same time with the synchromesh units.
3. Remove the two bolts (13 mm) from the oil pump and 8. Tap the pinion shaft free from the bearings. Pull the shaft out
disconnect the oil pipe from the pump (18 mm). Remove the backwards from the gearbox. At the same time remove the
pump. bearing and the two spacer rings from the front end of the
shaft.
4. Put the gears in neutral. Remove the side cover (17 mm)
together with the selector levers.
411
Model Code Page
42. Gearbox 205-- 865 423 4
1. 12. 1986
9. Lift out the synchromesh units and gears from the gearbox
through the access hole. Remove the rear gear and synchro-
mesh unit first. Pull out the flanged sleeve from the middle
gears. Remove the middle gears and finally the front synchro-
mesh unit and gear.
4. Tap out the outer bearing races from the gearbox housing
with an impact puller.
N.B. The outer bearing race of the front bearing is fitted once
the shaft is in place in the housing. Under the outer bearing
race of the rear bearing there are shims. The outer bearing
10. Remove the intermediate plate from the gearbox and tap race is fitted after adjusting the position of the shaft.
out the plate behind the front bearing with a drift.
D. Adjusting pinion shaft position
N.B. The position of the pinion shaft must be adjusted if the

C. Reconditioning synchromesh unit and
shaft, the gearbox housing or the taper roller bearings have
changing bearings been changed. The purpose of the adjustment is to determine
the number of shims under the rear bearing.
C
1. Check the wear on the synchromesh unit and change any

worn part. When assembling the synchromesh unit, the 1. Measure the thickness of the rear taper roller bearing
synchronizing cone locking lug is pushed into the hub. Push (dimension C) by placing it on two blocks of known thickness
the sliding coupling onto the hub so that the teeth in the sliding and measure the distance from the upper surface of the bea-
coupling are opposite the cut---out in the hub. ring to the surface of the table with a depth micrometer. Sub-
tract the thickness of the blocks from this measurement.
2. Check the wear of the synchronizing cones. Their inner sur-
faces should be clearly fluted. Change worn cones. N.B. The bearing should be rotated at least 20 times under
load, before measuring. Carry out a check measurement,
3. Remove the rear bearing from the shaft with a drift and fit rotate the bearing between measurements
a new one with ET 893 620.
412
Model Code Page
42. Gearbox 205-- 865 423 5
1. 12. 1986
2. Fit the bearing on the pinion shaft using ET 893 620 after
measuring.
3. The required thickness (X) of the shims is obtained as fol-

lows: (note the shim (thickness 0,3 mm) that is fitted as stan-
dard at the bottom of the bearing location).
4. Fix the required number of shims according to the previous

calculation with a little grease at the bottom of the bearing
location (first fit the shim with the three lugs). Available shim
thicknesses are: 0,10 mm, 0,15 mm, 0,30 mm and 0,50 mm.
X = E ---(C+D)
C = the thickness of the bearing
ETV 892 490

151,85
5. Drive in the outer bearing race for the rear bearing against
the shims using ETV 892 490.
D = the measurement stamped into the end surface of the

pinion shaft, gives the distance between the top face of the
bearing and the centre line of the differential bearing location.
13
E. Fitting pinion shaft and adjusting bea-

ring preload
1. Place the pinion shaft gears and synchromesh units in the

correct order and the right way round in the gearbox. The
sleeve located inside the first gear wheel and the end plate is
pushed onto the shaft from the front.
2. Push in the shaft through gear wheels and synchromesh

units.
E = the measurement between the differential center line and

the pinion bearing surface. The nominal measurement is 181
mm. Any differences are marked in decimals on the gearbox
housing. In the case shown the measurement E = 181,13
mm, of which ”13” is marked. If the tolerance is under 181 mm
the whole measurement is marked in the housing
413
Model Code Page
42. Gearbox 205-- 865 423 6
1. 12. 1986
ETV 892 230 270 Nm
3. Push in the bearing sleeve inside the first gearwheel on the --- tighten the round nut to 270 Nm using ETV 892 230.
shaft. Fit the end plate and spacer rings (2 pcs) on the shaft.
Select the spacer rings in order to achieve a combined thick-
ness of for example 11,50 mm.
--- measure the end float of the bearings using a dial gauge.
4. Tap in the disc in the bearing housing drilling using a drift. 5,05 5,14 5,50 5,85 6,12
5,08 5,26 5,62 5,97 6,15
5. Fit the outer bearing race of the front bearing using ETV 892 5,11 5,38 5,73 6,09 6,18
210.
--- add approx. 0,050 mm to the reading on the dial gauge and
reduce the thickness of the spacer rings by the calculated
amount. The spacer rings are found in the following thick-
nesses: 5,05 ---6,18, 15 pcs.
ETV 890 830
--- fit new spacer rings on the shaft. Tap the front bearing onto
the shaft and tighten the shaft nut to 270 Nm.
6. Adjust the pinion shaft bearing preload as follows:
--- fit the front bearing on the shaft using ETV 890 830
414
Model Code Page
1. 7. 1989
42. Gearbox 205-- 865 423 7
15. 9. 1995
F. Fitting gearbox
1. Fit the hydraulic lift on the gearbox housing and place the
gearbox on axle stands with castors.
2. Connect the clutch shaft to the front end of the input shaft
with the connecting sleeve and tighten the locking screws to
55 Nm.
3. If the tractor is fitted with a low gear, connect it to the front

wall of the gearbox, tighten to a torque of 23 Nm.
4. Push the gearbox into position and at the same time guide:
--- the front end of the propeller shaft onto the splines (note the
1,7---2,3 Nm ETV 892 230 positions of the universal joints)
--- hydraulic system suction pipe into position
--- turn the shaft at least 20 revolutions and measure the rolling --- the clutch shaft into the clutch
resistance of the shaft with a torsion meter at the end of the --- hydraulic lift lowering speed control into the cab
shaft. The rolling resistance should be between 1,7 ---2,3 Nm.
If the rolling resistance deviates from the given values, in-
crease or decrease the spacer ring thickness.
N.B. Check that the shaft can rotate freely when measuring
with the torsion meter, i.e. that the synchromesh units are in
neutral and on four ---wheel drive models, that the dog clutch
for the front wheel drive is in neutral.
7. Tighten the round nut to 270 Nm using ETV 892230. Fit the
locking washer on the shaft and tighten the other round nut.
Lock the nuts with the locking washer.
8. Change the o---ring in the front end cover. Fit the cover and
tighten the bolts to 23 Nm.
9. Fit the lubricating oil pump at the rear of the input shaft and
tighten the bolts to 23 Nm. Connect the oil pipe to the pump
(18 mm). N.B. the oil pipe support plate should be placed
under one of the attaching bolts for the pump.
5. Connect the gearbox to the chassis and tighten the bolts to
10. Fit the differential lock selector fork and selector shaft. a correct torque.
Lock the selector fork with the circlip. N.B. The longer half of
the selector fork should face the gearbox wall. 6. Attach the following parts to the right side of the tractor:
--- clamp for the hydraulic system suction pipe
11. Fit the selector forks for the speed and range gears (Op. --- low gear selector lever (if fitted)
no. 421 1A and B). Fasten the plastic sliding pieces onto the --- the lower ends of the gear levers to the selector levers
pinion shaft selector forks with a little grease. --- differential lock control
--- the lower part of the position control lever to the end of the
12. Clean the access (inspection) cover sealing surfaces. control shaft.
Apply sealing compound (e.g. Silastic 738 RTV) to the sealing
surfaces. Fit the cover and tighten to 46 Nm (the gears should On latest model tractors (610312---) connect the pressure oil
be in neutral). hose and the auxiliary hydraulic valve lever to the valve blocks
(on the RH side).
13. Fit the differential (Op. no. 424 1C).
7. Connect the following parts on the left side of the tractor:
--- leads to the differential lock control lamp
--- the four ---wheel drive control lever to the selector lever
--- hydraulic system pressure pipe to the pressure filter (120
Nm)
--- the auxiliary hydraulic control rods to the valves
8. Fit the final drives (Op. no. 451 1E)
On the latest models (610312---) there are no auxiliary hy-

draulic valve blocks and no pressure oil hose on the LH side
of the hydraulic housing.
415
Model Code Page
1. 7. 1989
42. Gearbox 205-- 865 423 8
1. 3. 1997
12. Fit the rear wheels and tighten the bolts to 330 Nm, 865:
550 Nm.
13. Lift the tractor and remove the supports from under the
gearbox and the fuel tank.
14. Fit the draw bar, lower links and extra lifting cylinder (if
fitted) and tighten the bolts to 380 Nm.
15. Fit the rear end of the steering system return oil pipe and
extra lifting cylinder oil hose (where applicable) to the hy-
draulic housing. Tighten the screws to 50 Nm.
16. Connect the propeller shaft rear flange joint (23 Nm (8.8)
or 35 Nm (10.9)). Fit the protecting plate under the tractor.
17. Fill the gearbox (23 l (205---665), 27 l (865)) and the hy-
draulic system (35 l) with oil. Test drive the tractor.
9. Push in the long PTO shaft and fit the PTO (Op. no. 462
1E).
10. Fit the hydraulic system oil reservoir (---610311) and the
support plate for the quick ---action couplings.
11. Lower the cab and fit the rubber dampers at the rear of the
cab (220 Nm). Fit the support for the auxiliary hydraulic control
levers.
2. Reconditioning layshaft
Before removing the counter shaft the following parts should
A. Removing layshaft and changing bear- be removed:
ings --- gearbox from tractor (Op. no. 423 1A)
--- selector forks (Op. no. 421 1A and B)
--- differential and pinion shaft (Op. no. 423 1B)
Fig. 15. Countershaft (4---1044)
416
Model Code Page
42. Gearbox 205-- 865 423 9
1. 12. 1986
1. Remove the input shaft bearing cover (13 mm). Push the
shaft forward slightly until it is free of the rear bearing.
2. Undo the bearing cover from the front end of the counters-
haft (13 mm) and remove the spacer ring and shims that are
located under the cover.
3. Lift the input shaft slightly. Raise the countershaft with one
hand and tap it forward so that the outer bearing race of the
front bearing comes free from the housing. Remove the shaft.
ETV 891 220
6. Fit new bearings on the shaft using ETV 891 220.
7. Remove the outer bearing race of the rear bearing from the
drilling in the housing using a drift or impact puller. Fit the new
bearing race ETV 893 620.
B. Fitting countershaft and checking bea-

4. Remove the countershaft from the gearbox through the
ring clearance
access hole.
1. Lift the rear end of the input shaft and position the counters-
haft in the gearbox front end first. Tap in the outer bearing race
5. Pull the bearings from the shaft with puller.
for the front bearing using ETV 893620.
2. Adjusting bearing clearance:

--- place a sufficient number of shims under the end cover to
give the bearings a definite clearance and tighten down the
cover
417
Model Code Page
10. 1. 1992
42. Gearbox 205-- 900 423 10
1. 1. 1998
--- Increase or decrease the shim thickness as necessary

--- fit a new oil seal under the bearing cover. Fit the cover and
tighten the bolts to 23 Nm.
N.B. The following shims are available; 0,10, 0,15, 0,20, 0,50.
3. Fit the spacer ring and shims under the input shaft bearing
cover and tighten the cover to 23 Nm.
After fitting the countershaft the following parts should be

fitted:
--- pinion shaft (Op 423 1 E)
--- differential (Op 424 1 C).
--- selector forks (Op 421 1 A and B)
0,075---0,150 mm --- gearbox (Op 423 1 F)
--- Measure the bearing clearance with a dial gauge. Place the
stylus against the rear end of the shaft.
--- Reduce the shim thickness until the bearing clearance is
0,075 ---0,150 mm.
--- turn the shaft at least 20 ---30 revolutions and check the
clearance again.
3. Reconditioning input shaft Before removing input shaft, the following parts should be
removed:
--- gearbox from tractor (Op 423 1 A)
A. Removing input shaft --- selector forks (Op 421 1 A,B)
--- pinion shaft (Op 423 1 B)
Note! On 600, 700, 800 and 900 tractors the input shaft is dif-
Figure 16. Input shaft ferent (gearbox 270). This new input shaft can also be fitted
1. Shims into gearbox 250.
2. Anti ---friction varnish e.g. Molykote 321 R spray
3. Needle bearing mounting depth
4. Lubricating oil pump
Note! Locking pins of the middle gear (Z25, Z23) bearing

bushes are fixed with Loctite 641.
418
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 423 11
1. 3. 1997
1. Remove the bearing cover at the front end of the shaft (13
mm) and remove the shims and spacer ring located under the
cover.
1. Remove the outer bearing race for the input shaft rear bea-
ring through the rear wall of the gearbox using an impact pul-
ETV 893 611 ler.
ETV 893 612
ETV 893 614
2. Fit the pulling piece ETV 893 614 to the end of the pulling
rod ETV 893 611 and insert the rod from behind through the
input shaft. Fit the sleeve ETV 893 612 to the front of the pulling
rod and pull the shaft forwards with the nut until it is free from
the bearings.
2. Fit a new outer bearing race (using ET 893 620 when neces-
sary).
3. Withdraw the input shaft from the front of the gearbox and
remove the gear wheels and synchromesh units through the
access hole. N.B. Check that the locking pins in the middle
sleeve remain in place.
B. Changing bearings/synchronizing
cones and fitting input shaft 3. Remove the input shaft front bearing from the shaft using
a puller.
419
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 423 12
1. 3. 1997
9. Fit the outer bearing race of the front bearing for the main
shaft in the housing using ETV 891 900.
N.B. Before the input shaft is fitted in place the counter shaft
should be lifted up onto its bearings.
Adjust the bearing end float as follows:
--- Fit the spacer ring and selected shims so that the bearings
have a definite clearance in front of the front bearing and fit
the bearing cover.
--- Turn the shaft 20---30 revolutions, in order to bed in the bea-
rings.
ETV 892 350
4. Fit the parts to the input shaft according to Fig. 16 and tap
the rear bearing onto the shaft using ETV 892 350.
N.B. The locking pins should be inside the sliding sleeves of
the middle gear wheels.
5. Before fitting the input shaft, remove the counter shaft bea-
ring cover and lower the counter shaft to the bottom of the
gearbox.
6. In the same way, the bearing cover for the four wheel drive
output shaft is removed on four wheel drive models and the
shaft is lifted forwards out of the gearbox, as fas as the gearw-
heel on the shaft permits. 0,025---0,075 mm
--- Position a dial gauge against the front end of the shaft and
push the shaft forwards and backwards and note the value of
the end float on the gauge. The correct value is 0,025 ---0,075
mm
--- Increase or decrease the shim thickness as necessary.
10 When the correct end float is achieved a new shaft seal and
O ---ring is fitted in the bearing cover using ETV 893 630. Apply
universal grease to the seal. Wrap some thin plastic foil round
the splines in order to protect the seal and push the bearing
cover onto the shaft. Tighten the bearing cover bolts to 23 Nm.
11. Tighten down the countershaft bearing cover (13 mm) to

23 Nm. Fit the output shaft and tighten the bearing cover to
23 Nm on four wheel drive models.
7. Insert the complete input shaft in the gearbox. The shaft is
inserted with the rear end first after which the front end is ang-
After fitting the input shaft the following parts should be fitted:
led up in its bearing location and then the shaft is straightened
up. --- pinion shaft (Op. no. 423 1E)
--- selector forks (Op. no. 421 1A and B)
--- fit the gearbox (Op. no. 423 1F)
C. Changing input shaft front oil seal

The input shaft seal can be changed without parting the trac-
tor on machines which are not equipped with the additional
low gear.
ETV 893 613
ETV 893 614
ETV 893 611
8. Fit the pulling piece ETV 893 614 to the pulling rod ETV 894
611 and push in the rod from behind through the input shaft.
Fit the bearing for the front end of the input shaft and push the
bearing into the housing using sleeve ETV 893 613.
420
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 423 13
1. 5. 1996
1. Remove the PTO (Op. no. 462 1A) and the long PTO shaft. 3. Remove the seal cover at the front of the input shaft. Fit the
Remove the cab floor plate (Op. no. 411 2A 1 ---4) and the new seal using ETV 893 630. Wrap e.g. a thin plastic bag
cover for the clutch shaft tunnel. around the splines on the input shaft when the seal cover is
fitted. Remove the protective plastic bag after fitting the seal
2. Unscrew the lock bolts for the connecting sleeve between cover.
the clutch shaft and input shaft, and push the sleeve onto the
clutch shaft. Push the clutch shaft forward, which creates 4. Tighten the seal cover to 23 Nm (17 lbf ft). Fit the connect-
enough space between the clutch shaft and input shaft to be ing sleeve and tighten the bolts to 55 Nm (40 lbf ft). Fit the
able to remove the seal cover. floor plate in the cab. Fit the long PTO shaft and the PTO (Op.
no. 462 1E).
4. Reconditioning output shaft for pow-

ered front axle
A. Removing shaft
Before removing the shaft the following parts should be
removed:
--- gearbox from tractor (Op. no. 423 1A)
--- differential (Op. no. 424 1A)
--- pinion shaft (Op. no. 423 1B)
Fig. 17. Output shaft (4---1043)

1. To be filled with grease
2. Dog clutch
2. Lever the shaft forwards until the bearings come free from
1. Remove the bearing cover from the front of the output shaft the housing. Remove the circlip and spacer ring from the rear
(13 mm). bearing via the access hole.
421
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 423 14
1. 9. 1995
B. Changing selector fork
1. Disconnect the oil pipe from the differential housing in front

of the selector shaft nut. Remove the selector shaft nut (24
mm). Tap the selector fork free once the shaft has been
removed from the gearbox housing.
3. Remove the rear bearing using a puller through the access

hole.
2. Change the shift lever by first removing the selector lever,

circlip, plastic sleeve and O ---ring and then remove the shift
lever from the gearbox. When fitting, change the O ---ring on
the shaft.
4. Remove the shaft dog clutch. Remove the gear wheel cir-
clip and spacer ring and remove the gear wheel from the
shaft.
5. Lift the shaft forwards out of the gearbox.
N.B. When fitting the shift lever, the ball shaped end should
be pointing downwards and the selector lever forwards.
ETV 893 260
6. Secure the shaft in a vice and unscrew the shaft nut using
ETV 893 260. Remove the washer, drive flange and bearing
cover from the shaft.
3. Fit the complete selector shaft with fork to the rear wall of
the gearbox. Position the shift lever in the groove on the fork
7. Remove the O ---ring from the shaft and pull the front bear- and tighten the shaft nut to 120 Nm (88 lbf ft). Connect the
ing off the shaft using a puller. oil pipe.
422
Model Code Page
42. Gearbox 205-- 865 423 15
1. 12. 1986
C. Fitting shaft
D. Changing output shaft front oil seal
The shaft can be changed from below without parting the trac-
tor as follows:
1. Drain the oil from the gearbox. Remove the propeller shaft
protecting plate under the tractor (17 and 19 mm).
2. Disconnect the rear drive flange of the propeller shaft (13

mm).
3. Engage the front wheel drive and apply the parking brake.
ETV 892 350 Unscrew the shaft nut on the output shaft using ETV 893 260.
Remove the washer and the drive flange from the shaft.
4. Remove the seal cover and change the seal using ETV 893
640.
1. Fit the front bearing on the shaft using ETV 892 350. Fit a 5. Tighten the bolts of the seal cover to a torque of 23 Nm. Fit
new O ---ring on the shaft. Change the bearing cover shaft seal the drive flange and washer.
using ETV 893 640 and fill the space between the lips of the
seal with grease. 6. Tighten the shaft nut to 127 Nm. Tighten the bolts of the
flange to 23 Nm. (8.8) or 35 Nm (10.9).
N.B. When necessary, the shaft seal and O ---ring can be
changed without further dismantling the gearbox. 7. Fit the propeller shaft protecting plate and fill the gearbox
with oil.
2. Fit the bearing cover, drive flange and washer on the shaft
and tighten the shaft nut to 127 Nm using ETV 893 260.
3. Insert the shaft from the front of the gearbox and fit the gear
wheel, spacer ring and circlip on the shaft. Position the dog
clutch in the selector fork and push the shaft into position and
tap it into the front bearing.
4. Secure the bearing cover to the front wall of the gearbox to

a torque of 23 Nm.
5. Fit the rear bearing using ETV 891 220 and fit the spacer
ring and circlip on the shaft.
After fitting the shaft the following parts are fitted:
--- pinion shaft (Op. no. 423 1E)

--- differential (Op. no. 424 1C)
--- gearbox (Op. no. 423 1F)
423
424
Model Code Page
42. Gearbox 205-- 865 424 1
1. 12. 1986
1. Changing/reconditioning differential
Fig. 18 Differential
A. Removing differential
First remove the following parts:

--- PTO (Op. no. 462 1A)
--- final drives (Op. no. 451 1A)
--- Gearbox (Op. no. 423 1A)
N.B. The rolling resistance of the differential bearings (in

common with the pinion shaft bearings) is measured at the
front end of the pinion shaft using a torsion meter. Because
of this the tractor should be parted between the gearbox and
fuel tank when adjusting the differential bearing preload.
When only reconditioning the differential or the differential

lock there is no need to split the tractor between the gearbox
and fuel tank, if the positions of the bearing nuts are marked
before the nuts are removed --- 1. Position a wooden wedge under the crown wheel. Unscrew
the bolts for the differential bearing housing (17 mm) on both
sides of the gearbox.
425
Model Code Page
42. Gearbox 205-- 865 424 2
1. 12. 1986
2. Pull out the bearing housings using two pinchbars. 5. Also change the outer bearing races of the differential bea-
rings. The bearing races are removed from the housing by tur-
N.B. Mark up the positions of the bearing nuts in relation to the ning the bearing adjusting nuts.
housing in order to simplify the assembly. Also indicate from
which side they were removed.
B. Changing differential side gears
3. Remove the differential from the gearbox.
1. Unscrew the crown wheel attaching bolts (17 mm). Remove

the differential casing half.
4. Remove the differential bearings by using a puller and a

suitable counterhold.
2. Remove the slide bearing for the differential side gear which
is located in the casing half.
426
Model Code Page
1. 5. 1996
42. Gearbox 205-- 865 424 3
10. 10. 2003
ETV 891 870
ETV 891 870
3. Fit a new bearing using ETV 891 870. 7. Fit a new slide bearing using ETV 891 870.
4. Remove the differential side gear. 8. Lubricate the slide bearing and fit one of the differential side
gears in the casing half. There are drillings in the gear for the
differential lock.
9. Lubricate the sliding surfaces of the differential pinions and

fit them in the housing. Tap in the shaft so that the holes for the
tubular pin in the shaft and casing align.
10. Fit the tubular pin.
11. Position the other differential side gear on the differential

pinions. Fit the crown wheel on the casing so that the attach-
ing bolt holes marry up.
5. Remove the tubular pin for the differential pinion shaft and
tap out the shaft from the drilling. Remove the differential pin-
ions.
NOTE! On transmission 250 (865), there are four differential

pinions.
12. Fit the differential casing half and tighten the bolts (10.9)
evenly to a torque of 60 Nm (43 lbf ft). Check that bolts are
M10x60 (10.9).
6. Remove the slide bearing for the other differential side gear
using a suitable cranked lever.
13. Fit the differential lock coupling sleeve.

427
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 424 4
1. 9. 1995
C. Fitting differential
0,18---0,33 mm
4. Arrange a dial gauge with the stylus at right angles to the

side of a tooth on the crown wheel, and measure the tooth
1. Lift the differential into place in the gearbox housing and backlash between the pinion and the crown wheel. The cor-
position the differential lock coupling sleeve in the selector rect backlash is 0,18 ---0,33 mm.
fork. Block up the differential with a wooden wedge under the
crown wheel. 5. If the recorded backlash deviates from the given value,
adjust the backlash by turning both nuts.
N.B. Ensure that there is no play in the bearings during the

adjustment by turning both nuts equally in the same direction.
Z7 (Z9)
Z43 (Z42)
2. Fit the bearing housing and tighten the nuts.
6. After adjusting the tooth backlash, measure using a torsion

meter the common rolling resistance of the differential and
the pinion shaft at the front end of the pinion shaft.
The value on the torsion meter should be the rolling resistance
of the pinion shaft bearings + rolling resistance of the differen-
tial bearings (see picture above) as follows:
On transmission 30 km/h (number of teeth on pinion/differen-

tial Z7/43):
2,3 ---4,3 Nm (1.6 ---3.1 lbf ft).
On transmission 40 km/h (Z9/42):

2,5 ---4,9 Nm (1.8 ---3.6 lbf ft).
ETV 893 660
Adjust the rolling resistance by turning the differential bearing
adjusting nuts.
3. Tighten the differential bearings using ETV 893 660 until
there is no clearance. Rotate the differential in order to 7. When the bearing preload is correctly adjusted, fit the lock-
”bed ---in” the bearings. ing plates for the adjusting nuts and tighten the bearing hous-
ings to a torque of 46 Nm (33 lbf ft).
8. Check the bearing rolling resistance and the tooth backlash

between pinion and crown wheel.
428
Model Code Page
1. 12. 1986
42. Gearbox 205-- 865 424 5
1. 7. 1989
D. Reconditioning differential lock

2. Withdraw the selector shaft. Remove the selector fork
from the differential housing.
Changing selector fork and selector shaft
3. Fit a new selector fork and push in the selector shaft
1. The selector fork can be removed by first removing the final through the fork. Lock the fork on the selector shaft using
drives (Op. no. 451 1A), the differential (Op. no. 424 1A) and the circlip.
the circlip for the selector fork on the selector shaft.
4. Fit the differential (Op. no. 424 1C) and the final drives
(Op. no. 451 1E).
Adjusting the differential lock operating control ( -- 610311)
NOTE: These instructions concern tractors up to ser. no. 610311. For

instructions regarding the new operating control, see page 420/17.
Fig. 19. Differential lock operating control (---610311) 1. When the differential lock is engaged, the adjusting nut (6)
is turned until there is no play on the pushrod (3). Then the nut
1. Operating lever is tightened 1/3 ---1/2 turns.
2. Damping spring
3. Pushrod N.B. At the end of the selector shaft there is a switch for the
4. Link differential lock control lamp. Adjust the switch as necessary
5. Selector fork when the differential lock is not engaged according to the fig-
6. Adjusting nut ure.
429
430
Model Code Page
1. 1. 1998
44. Low gear and Overdrive 205-- 900 440 1
10. 10. 2003
Contents
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Low gear, description:
--- general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
--- function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
--- lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overdrive, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shuttle (12+12R gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair instructions (Op. no. 441)
Low gear and Overdrive

1. Reconditioning low gear and Overdrive:
A. Changing low gear/Overdrive front oil seal and o---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing low gear/Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Dismantling low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Assembling low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Fitting low gear/Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Dismantling and assembling Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Disassembling/assembling Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technical Data
Gear ratios:
--- Low gear/Overdrive disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=1:1
--- Low gear engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=4.16:1
--- Overdrive engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=0,87:1
Low gear total gear ratios
Number of teeth pinion/crown wheel, Z=7/43
Gear Direct Low gear Gear Direct Low gear

1 (L1) 283.024 990.526 7 (H3) 31.818
2 (L2) 173.496 721.995 8 (H4) 24.029
3 (L3) 110.080 458.093 R1 175.543 730.513
4 (L4) 83.133 345.956 R2 127.953 532.471
5 (H1) 68.800 R3 81.184 337.844
6 (H2) 50.148 R4 61.311 255.142
Tightening torques
Low gear ---gearbox, Overdrive ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Gearbox ---fuel tank:
--- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
--- M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm
Clutch shaft---low gear, clutch shaft---Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Cab ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Lubricating oil pipe ---low gear on 205---865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
Hydraulic system pressure oil pipe:
--- to pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
--- to oil pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Steering system return oil pipe, rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Locking screw for selector fork shaft, low gear on 205---865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Propeller shaft drive flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Setting values
Brake pedal free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 mm
Overdrive/low gear input shaft bearing axial float, tractors 600, 700, 800 and 900 . . . . . . . . . . 0,05---0,15 mm
Adjusting value of Overdrive selector fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70,5---70,7 mm
Clearance between Overdrive/new low gear synchronous couper hub ---input shaft rear end . min 0,15 mm/min 0,10 mm
431
Model Code Page
1. 12. 1986
1. 1. 1998
Special tools
44. Low gear and Overdrive A

ETV 892 440 Plate for fitting front oil seal and removing/fitting input shaft bearings (PT0 702---903)
44. Low gear and Overdrive B
Part. no. Description

(ETV 892 350) Sleeve for fitting rear oil seal (see Gearbox)
(ETV 893 650) Drift for fitting needle bearings/oil seal in main gearbox input shaft (see Gearbox)

ET 893 380 Drift for fitting selector fork rail (Gearbox 505---905)
(ET 893 760) Support (2 pcs) for front end frame, prevents front axle oscillating when parting tractor (see Frame and
Wheels
Low gear and Overdrive A
ETV 892 440
Low gear and Overdrive B
ETV 892 350

ETV 893 650
ET 893 380
ET 893 760
432
Model Code Page
1. 12. 1986
44. Low gear 205-- 865 440 3
1. 1. 1998
Low gear, description
General
The mechanical low gear is located in front of the main gear- high (H) gear range. Machines equipped with a low gear, have
box and it has a gear ratio of 4,16:1. When using the low gear 12 forward gears and 8 reverse. The low gear is engaged and
much lower speeds are obtained in the low (L) and reverse (R) disengaged through a straight toothed unsynchronized
gear ranges. There is a mechanical blocking device to prevent clutch (dog clutch). Because of this engagement and disen-
the low gear from being engaged while the gearbox is in the gagement should take place with a stationary tractor, depres-
sed clutch and a low engine speed.
The low gear may also be fitted at a later date as extra equip-
ment.
20 Nm
20 Nm
Fig 1. Low gear on 255---865 tractors
433
Model Code Page
1. 1. 1998
44. Low gear 205-- 865 440 4
10. 10. 2003
Picture 2. Section of low gear on 255---865
Low gear control lever: 7. Selector fork rail locking screw (Loctite 222 or similar)
--- forward position=directly connected: i=1,00 8. Lubricating oil inlet
--- rearward position=low gear engaged: i=4,16 9. Oil filling level
1. Universal grease (4 g) 10. Attaching bolt for low gear layshaft
2. EP grease (2 g) Note! When tightening the bolt check that the shaft is located
3. Anti ---friction varnish (e.g. Molykote 321 R or similar) in the ”cut---out” on the bearing retainer.
4. Cam on gear for fixing engaging sleeve 11. Tubular shaft
5. Clutch shaft 12. Layshaft
6. Tension pin (prevents ring from rotating) 13. Low gear input shaft
14. Oil flange
434
Model Code Page
1. 12. 1986
44. Low gear 205-- 865 440 5
1. 1. 1998
Construction and function of low gear on

255---865 tractors
(See picture on previous page)
The low gear is attached to the front wall of the gearbox with a
bolted joint (9 bolts). The bolt located at the front of the low
gear passes through the housing.
The low gear input shaft (13) has a machined gear (Z24) and
splines for the dog clutch. The shaft is connected to the clutch
shaft by internal splines and it is carried in two ball bearings in
the low gear housing. The long PTO clutch shaft runs through
the low gear input shaft and the gearbox input shaft.
The hollow low gear layshaft (12) is carried in needle bearings

in the tubular shaft (11). The tubular shaft is attached to the
housing by a long bolt which also acts as one of the low gear
attaching bolts.
The gear (Z47) at the front end of the gearbox input shaft is
carried in needle bearings. The tubular shaft (11) and the gear
teeth 47 are connected by the bearing plate.
When the low gear dog clutch is in the forward position the
power passes directly through the low gear to the gearbox
input shaft (i=1:1).
When the dog clutch is in the rearward position the power

from the low gear input shaft passes to the layshaft (teeth
24/teeth 34) and on to the gear which is carried in bearings on
the front end of the gearbox input shaft (teeth 47). This is in
turn connected to the gearbox input shaft by a dog clutch. The
gear ratio is then i=4,16:1.
Lubrication
(See also picture 4 on page 420/9)
The low gear is lubricated by the oil pump in the gearbox. The
oil is taken from the oil filter bracket to the end of the low gear
selector rail. From there the oil is directed via the drilling
(arrows in fig. 2) into the oil flange (14), the tubular shaft (11)
and the layshaft needle bearings. The needle bearing for the
gear (teeth 47) is splash lubricated.
The oil is returned through the gearbox layshaft front bearing

and on into the gearbox. Following repairs to the low gear the
tractor should be driven in the direct drive position for a while
in order to ensure that the oil level has time to rise sufficiently in
the low gear.
435
Model Code Page
44. Low gear 600-- 900 440 5A
1. 1. 1998
Low gear on 600---900 tractors.
Figure 2A. Low gear on 600---900 tractors.
436
Model Code Page
15. 4. 1999
44. Low gear 600-- 900 440 5B
10. 10. 2003
Low gear on 600---900 tractors.

The build ---up of the low gear on 600---900 tractors has
been changed so, that some points are similar to the
build ---up of the Overdrive, which is shown on the next
page. The gear ratio of the low gear is the same as in the
low gear on 255---865 tractors.
Figure 2A Low gear on 600---900 tractors

The lubrication of this low gear is similar to the lubrication of
1. Universal grease (4g)
the Overdrive. In addition, the tapered roller bearings of the
1a. Grease filling (universal grease)
low gear input shaft are the same as in the Overdrive. Also the
2. Spread high pressure grease (2g) evenly on the splines.
adjustment of the bearing axial float is the same.
3. There is a lubricating oil groove between the gearbox
bevel pinion shaft front end and the low gear upper shaft
There is a thrust bearing between the gearbox input shaft
rear end. The groove has been machined on the front sur-
bearing cover and the low gear rear gearwheel as in Over-
face of the low gear housing.
drive. Also the gear shift mechanism has been made uniform
4. The low gear oil level has been raised by changing bear-
with the Overdrive.
ing cover casting. If no extra gear is fitted, the bearing cover
must be turned 180° (because of the bearing cover at the
front end of the gearbox layshaft).
5. Clutch shaft. Position of the input shaft bearing cover
6. Axial float is adjusted to 0,05... 0,15 mm with shims. --- If the gearbox has an extra gear, then the bearing cover of
7. Selector fork rail. the gearbox input shaft must support the layshaft bearing be-
8. Selector fork locking ball. cause the layshaft bearing cover can not be fitted with extra
9. Oil level (tractor running), see point 4. gear. (See figure 2B. point A).
10. Fixing bolt of the low gear upper shaft. --- If the gearbox has not an extra gear, the bearing cover has
11. Axle tube been turned 180° because of the bearing cover at the gear-
12. Upper shaft box layshaft front end.(See figure 2B. point B).
13. Low gear input shaft
15. Sliding pieces (32888200, 4 off) IMPORTANT! When the repairing the extra gear, the bearing
16. Paper gasket cover 453 556 00 must be replaced with new bearing cover
17. There must be clearance (0,1---0,3) between the coupler 453 556 10.
hub and the toothed shaft Z24.
Figure 2B. Position of the input shaft bearing cover in different cases.
437
Model Code Page
44. Overdrive 365-- 900 440 6
1. 1. 1998
Overdrive on 600---900 tractors.
Figure 3. Overdrive on tractors 600, 700, 800 and 900
438
44. Overdrive 365-- 900 440 7
10. 10. 2003
Figure 3. Overdrive on tractors 600, 700, 800 and 900 Build ---up and function of the Overdrive
1. Universal grease
2. Spread high pressure grease evenly onto the splines. Figure 3 on the previous page.
3. Oil groove on the Overdrive front surface.
4. The Overdrive oil level has been raised by changing bear- The gear ratio of the Overdrive is 0,87, and it can alternatively
ing cover casting. If a tractor has not an extra gear, the bearing be fitted in place of the low gear on tractors 600---900. The
cover has been turned 180° because of the cover at the gear- build ---up of the Overdrive resembles the low gear on
box layshaft front end. 600---900 tractors, see page 440/4 (earlier low gear), 440/5A
5. Clutch shaft (new low gear) and 440/6 (Overdrive).
6. Bearing axial play is adjusted to 0,05 ---0,15 mm with shims
7. Selector fork rail. The Overdrive is synchronized (synchronizing cone ø 68 mm)
8. Selector fork locking pin. and it can be used with all gears and with all range gears. A
9. Oil level (engine running), see point 4. tractor with Overdrive has 16 forward and 8 reverse gears.
10. Fixing bolt of the upper shaft The driving speed rises about 15 % when the Overdrive is
11. Axle tube engaged. Direct ratio, when the synchronous coupler is in the
12. Upper shaft front position and faster ratio when the coupler is in the rear
13. Overdrive input shaft position. The gear lever of the Overdrive does not stay in the
14. Spring mechanism forces the Overdrive either to position neutral position, since it is eliminated with a spring mecha-
I or II nism 14 in the Overdrive housing.
15. Sliding pieces (32888200, 4 pcs)
16. Paper gasket Lubrication
17. There must be clearance between the synchronous On tractors 600---900 with the Overdrive the gearbox input
coupler hub and the toothed shaft Z33 (0,15---0,40 mm). shaft (270) is different to the earlier (220, 250). Also the gear-
box input shaft front bearing cover has been modified.
Notice in the fitting
If the Overdrive is fitted as a retro---fitting, the gearbox layshaft The lubricating oil flows from the gearbox bevel pinion shaft
front end cover and the o---ring must be removed, shims re- front end through the machined groove on the Overdrive front
main stay in place. In the same way the bevel pinion shaft front surface into the Overdrive upper shaft rear end. There is not
end cover must be removed. a separate oil cap at the front end of the bevel pinion shaft on
The oil seal of the long PTO shaft must be removed inside the transmissions with the Overdrive or low gear on 600---900
gearbox input shaft front end and oil plug (mounted with Loc- tractors.
tite) shall be taken out. Otherwise the Overdrive lubricating oil
cannot flow into various lubricating points. The long PTO clutch shaft has a thinning for the lubrication.
The shaft can be fitted on all 65---models.
Position of the input shaft bearing cover
--- If the gearbox has an extra gear, then the bearing cover of Others
the gearbox input shaft must support the layshaft bearing be- Because of the greater travel of the Overdrive control lever,
cause the layshaft bearing cover can not be fitted with extra some small changes have been made in the gearbox selector
gear. (See figure 4. point A). forks, selector arms and gear levers.
--- If the gearbox has not an extra gear, the bearing cover has
been turned 180° because of the bearing cover at the gear- On 600---900 tractors without Overdrive or low gear, the spli-
box layshaft front end.(See figure 4. point B). nes of the hollow clutch shaft have been modified and also the
locking of the clutch shaft.
IMPORTANT! When the repairing the extra gear, the bearing
cover 453 556 00 must be replaced with new bearing cover
453 556 10.
Figure 4. Position of the input shaft bearing cover in different cases.
439
Model Code Page
44. Shuttle 600-- 900 440 8
10. 10. 2003
Shuttle with 600---900 tractor (12+12R)
20
A-- A
24
C -C
440
Model Code Page
44. Shuttle 600-- 900 440 9
10. 10. 2003
--- The present 8+4R gearbox has got an alternative gear-

box type 12+12R.
This alternative needs always a shuttle unit, because the R
(reverse) group has been replaced with LL (creeper) --- gro-
up.
The power shuttle lever in the cabin can be fitted either on
the left or right side of the seat. This selection must be ma-
de when ordering the tractor. The position of the lever can
be changed after production, but this will require splitting
the tractor. You will also need the following parts:
--- To move the lever to the left side: the flange (35137100)
and, only if the tractor is fitted with the HiShift ---function,
the wiring set (34962600).
--- To move the lever to the right side: the flange
(30930700), no need for the wire set.
The reverse speeds are 1 % faster.
The lubrication pump has been removed from the center
line of the input shaft. The pump rotates in one direction (as
earlier), but because of space the pump construction is
new.
The middle gear of the shuttle unit drives the pump. The
pump rotates, although the forward ---reverse shuttle is in
neutral.
--- NOTE! Do not put silicon in to the marked area (see pic-
ture) of the separation wall between gearbox and power
shuttle; the lubrication canal will block up!
1) Multi ---purpose grease

2) High pressure grease (2g Olista long ---time 3EP
(UC3907) or equivalent will be smoothly laid to grooving.
3) Lubrication oil to the gear shaft bearings
4) PTO drive shaft
5) Clutch shaft
6) Gear shaft
7) Selector rail
8) Gear shaft (Z22/20)
9) Gear shaft (Z24)
10) Slide pieces (4 pcs)
11) When fitting the shuttle unit onto the main shaft be ca-
reful not to pre load the thrust bearing.
12) Grease filling (multipurpose grease)
13) Silicon, Loctite 5900 (UK0067). Do not spread silicon
inside the marked lines!
441
Model Code Page
44. Shuttle 600-- 900 440 10
10. 10. 2003
Shuttle unit lubrication
(347 847 00)
(KATSO MODUULI NRO: 34715700)
A-- A
4X
--- Lubrication for power shuttle via lubrication oil pump.
--- In connection with repairing, do not block up the tube

which comes to the front part of the pinion shaft with silicon.
442
Model Code Page
1. 5. 1996
1. 1. 1998
1. Reconditioning low gear and Overd- B. Removing low gear and Overdrive
rive (Op. no. 441)
N.B. Before removing the low gear/Overdrive the tractor
A. Changing low gear/Overdrive front oil frame must be parted between the gearbox and fuel tank.
seal and O---ring
1. Remove the engine hood plates and loosen the top plate
1 a) Without splitting the tractor: remove the clutch (Op. no. from its attaching points. Turn it to one side.
411 2A 1 ---14).
2. Remove the hydraulic lift lowering speed control knob
1 b) By splitting tractor: Split the tractor at the clutch (Op. under the front edge of the driving seat (not Autocontrol).
no. 411 1A) and remove the cab floor (Op no. 411 2A
1 ---4). Remove the long PTO shaft. Remove the clutch shaft N.B. Removing cab floor plate (Op. no. 411 2A 1 ---4)
from the low gear/Overdrive (17 mm). makes the parting and assembling of the tractor frame
easier, but it is not necessary.
2. Remove the circlip from the low gear/Overdrive input
shaft (remove also the shims on the Overdrive/latest low 3. Drain the hydraulic and gearbox oil.
gear). Punch a hole in the front oil seal using a centre
punch. Screw in a self tapping screw in the hole and pull
out the seal.
3. Remove the spacer ring and fit a new greased O ---ring

on the low gear/Overdrive input shaft.
4. Lubricate a new oil seal and fit it by using ETV 892 440.
Fit the spacer ring. Place the circlip on the input shaft (with
the tubular pin on the spacer ring in the hole of the circlip
on the earlier low gear). On the Overdrive and on the new
low gear, fit the same shims in front of the spacer ring
before fitting the circlip.
5a) Without splitting the tractor frame: fit the clutch shafts
and clutch assembly (see Op. 411 2B).
4. Free the rear ends of the brake rods on top of the rear
axle (22 mm).
5. Disconnect on the right---hand side of the tractor under

the cab:
--- Ball joints from the speed gear lever, range gear lever
and low gear/Overdrive lever (13 and 17 mm) (or free the
5 b) Parted tractor frame. Fit the clutch shaft and the long ball joints of the levers from the cab floor and lift up the
PTO shaft and connect the frame joint (Op. no. 411 1C levers in the cab.
1 ---10). Fit the cab floor (Op. no. 411 2B, paragraphs 10 --- Selector lever from the gearbox access hole (lower)
and 14 ---19). --- Engagement blocking device from the end of the low
gear selector shaft.
--- Lower joints for the hydraulic lift position control lever (11
and 13 mm) (not Autocontrol).
443
Model Code Page
1. 5. 1996
1. 1. 1998
--- Differential lock engagement mechanism and spring

(610312---, only lower end of the lever from engagement
mechanism).
--- Hydraulic system suction pipe, rear clamp. Autocontrol:
disconnect sensor wires.
--- 610312---: remove, if necessary, the valve block set.
--- 610312---: hydraulic system pressure pipe from the pres-
sure filter union.
12. Position axle stands with wheels under the fuel tank and
gearbox.
13. Slacken the rear reflector attaching bolts slightly (13 mm)
and turn them to the side.
--- Steering system return oil pipe and (earlier models with an
extra lifting cylinder) extra lifting cylinder oil hose.
--- Lower end of lifting link gear control rod.
7. Disconnect on the left side of the tractor:

--- Leads to the differential lock control lamp
--- ---610311: Control lever joints at top of valves for auxiliary
hydraulics and the bracket for the control levers (not
610312---)
--- ---610311: Hydraulic system pressure oil pipe from pres-
sure filter (not 610312---).
14. Unscrew the bolted joint between the gearbox and fuel
tank (22 mm). Roll the rear part away by turning the wheels.
N.B. On four ---wheel drive models: remove the guard for the Ensure that the cab does not damage the auxiliary hydraulic
propeller shaft. Disconnect the drive flange at the rear of the control valves.
propeller shaft and disconnect the four ---wheel drive control
lever from the selector lever. N.B. If the cab does not clear the control valves, the rear of
the cab should be lowered slightly. On 865, 600---900: remove
the auxiliary hydraulic valve levers, valves and, if needed,
studs.
15. Disconnect the clutch shaft from the low gear (17 mm).
Remove the long PTO clutch shaft.
8. Remove the rear wheel mudguards (13 mm)
9. Remove the rear attaching bolts for the cab.
10. Lift up the rear of the cab slightly and block it up on both
sides in front of the final drives.
11. Support the front of the tractor on the front axle on both 16. Disconnect the oil pipe on the earlier low gear (14 mm) and
sides of the frame using support plates ET 893 760. the low gear/Overdrive from the gearbox (13 mm).
N.B. Do not forget to loosen the attaching bolt which runs

through the low gear housing (see arrow).
444
Model Code Page
1. 12. 1986
44. Low gear 205-- 865 441 3
1. 1. 1998
C. Dismantling low gear on 255---865
6. Tap the selector shaft forwards out of the housing (the selec-
tor fork ball may fall down in the housing). Remove the selec-
tor fork and the oil flange sleeve from the housing.
7. Remove the circlip from the front of the input shaft.

1. Tap out the tubular shaft forwards out of the housing.
2. Remove the bearing plate.

8. Tap the input shaft rearwards out of the housing. Check that
3. Remove the large gear wheel and the needle bearing and the layshaft gear wheel does not interfere. Remove the front
the sleeve which is located inside. oil seal spacer ring from the housing.
4. Move the selector shaft to its rear position and remove the
engaging sleeve and its hub.
9. Remove the layshaft and oil flange from the housing.

Remove the needle bearing and intermediate sleeve from the
layshaft.
5. Unscrew the selector shaft locking screw (5 mm socket 10. Remove the circlip for the input shaft ball bearings.
head).
445
Model Code Page
1. 12. 1986
44. Low gear 205-- 865 441 4
1. 1. 1998
11. Tap out the input shaft front bearing and oil seal forwards
out of the housing using ETV 892 440.
12. Change the selector shaft o---ring.
D. Assembling low gear on 255---865
1. Fit the circlips for the input shaft ball bearings.
ETV 892 440

ETV 892440
5. Tap in the input shaft rear bearing in the housing using ETV
892 440.
6. Apply anti ---friction varnish to the ends of the layshaft (e.g.

Molykote 321 R). Fit the lubricated needle bearings and the
intermediate sleeve in the layshaft.
7. Fit the layshaft and oil flange in the housing.
2. Tap in the front bearing from the front into the bearing hous-
ing using ETV 892 440.
3. Remove the o---ring from the input shaft and loosen the
inner bearing with a puller.
8. Tap in the input shaft from the rear onto the bearings.
ETV 892350
4. Change the oil seal located inside the rear end of the input
shaft using ETV 892 350. The lip is turned towards the gearbox
when fitting.
9. Fit a lubricated o---ring at the front of the input shaft.
10. Fit the spacer ring and circlip on the input shaft so that the
spacer ring tubular pin engages in the hole in the circlip
446
Model Code Page
1. 1. 1998
1. 9. 2001
16. Tighten the locking screw (5 mm socket head 45 Nm (33

lbf ft) using Loctite 601 on the threads). Fit the oil pipe con-
nection to the front of the shaft (12 mm 20 Nm (14 lbf ft)).
ETV 892440
17. Position the engaging sleeve in the selector fork and move
the fork to the forward position. Fit the hub on the engaging
sleeve splines with the toothed side turned forwards.
18. Apply anti ---friction varnish on to the sliding surface of the

large gear wheel (e.g. Molykote 321R) and fit it against the hub
with the engaging teeth (dog clutch) turned towards the selec-
tor fork.
11. Apply grease between the lips of the input shaft front oil
seal and tap in the seal in the housing using ETV 892 440.
12. Change the O ---ring located on the tubular shaft and tap
in the shaft from the front of the housing. Leave approx. 3 cm
of the shaft projecting outside the housing for fitting the bear-
ing plate.
1
19. Fit the sleeve and the lubricated needle bearing inside the
large gear wheel. Fit the bearing plate and push the tubular
shaft fully home.
2 N.B. The chamfer at the end of the shaft should be turned out-
wards in order to enable the end of the shaft to glide through
the bearing plate until it is level with the end face of the hous-
ing.
E. Fitting Low gear/Overdrive
1. 205 ---865: Check the needle bearings and the oil seals
inside the clutch shaft and gearbox input shaft and change
them when necessary (ETV 893 650).
600 ---900: See notes on pages 440/ 7 concerning the retro---
fitting of the Overdrive or the new low gear.
13. Fit the oil sleeve (1) to the end of the oil flange (2).
2. 600 ---900: Before fitting the Overdrive/Low gear, place the
ET 893 380 parts, which are situating on the gearbox input shaft front end,
on the shaft. In connection with retro---fitting, the bearing
cover and o---ring are removed in the gearbox layshaft front
end and the bearing cover of the bevel pinion shaft front end.
14. Fit the selector fork spring and ball using the tool ET 893
380. Fit the fork in the housing.
15. Unscrew the oil pipe connection (12 mm) from the end of
3. Change the gasket between the extra gear and the gear-
the selector fork and change the O ---ring on the shaft. Fit the
box. Fit the gear to the gearbox (13 mm, 23 Nm (17 lbf ft)).
shaft from the front through the oil sleeve and the selector fork.
In this way the tool is forced out of the shaft.
4. 600 ---900: After fastening the Overdrive/low gear, check by
hand , that the extra gear input shaft has an axial float (adjust-
N.B. The selector shaft locking groove should be turned
ment, see page 441/10 instr. C).
towards the locking screw hole.
447
Model Code Page
1. 7. 1989
1. 1. 1998
5. 205 ---865: Before fastening the low gear, check that the
large gear wheel hub is positioned in the hole of the bearing
plate and that the sleeve and needle bearing remain inside the
gear wheel.
6. 205 ---865: Connect the low gear lubricating oil pipe (14
mm; 20 Nm).
7. Fit a new o---ring on the clutch shaft. Apply EP grease ap-

prox. 2 g on the clutch shaft splines. Fit the clutch shaft to the
low gear/Overdrive ( 17 mm; 55 Nm). Lock the attaching bolt.
Fit the long PTO shaft.
14. Connect the following on the right side of the tractor:

--- Steering system return oil pipe (22 mm, 50 Nm). On earlier
tractors equipped with an extra lifting cylinder the hose to the
cylinder is secured under the same bolt.
--- Range gear lever, selector lever to the gearbox service ac-
cess cover.
--- Low gear/Overdrive selector lever to the selector shaft (also
functioning as a blocking device)
--- Differential lock control mechanism and spring (610312---,
only lower joint of lever to the control mechanism)
--- Hydraulic lift position control lever, lower joints (13 and 10
mm) (not Autocontrol).
--- Ball joints at lower ends of the gear levers (13 and 17 mm)
--- Tighten the connection on the hydraulic suction pipe.
8. Push the rear part of the tractor forwards and note the fol- --- Hydraulic system pressure oil pipe (only 610312---)
lowing: --- Lever for auxiliary hydraulics to the valve blocks (only
--- Guide in the pick ---up hitch release lever above the rear 610312---)
axle.
--- Guide in the lifting link gear control rod on the right side of 15. Connect the following on the left---hand side of the tractor:
the hydraulic lift control shaft (not Autocontrol). --- Hydraulic system pressure oil pipe to the pressure filter
--- Guide in the PTO control rod above the rear axle. connection (60 Nm) (not 610312---)
--- Guide in the brake rods above the rear axle. --- Electric leads to the differential lock control lamp
--- Guide in the steering system return oil pipe between the hy- --- Control lever joints at top of valves for auxiliary hydraulics
draulic lift housing and the differential lock control (not and associated bracket on the cab floor (not 610312---)
610312---). --- Autocontrol: reassemble control valve/pipes, if detached.
N.B. The final stages of guiding the tractor parts together is N.B. Four ---wheel drive models: connect the lower part of the
made easier if guide bolts are screwed in on both sides of the control lever to the selector lever and the drive flange at the
frame (M14, length 100---200 mm). rear end of the propeller shaft (35 Nm) and fit the guard plate
for the propeller shaft.
9. Guide the hydraulic lift lowering speed control in through
the hole in the cab floor. Fit the cab rear rubber dampers. 16. Turn the reflectors round to their correct position and
tighten them down (13 mm).
10. Guide in the hydraulic suction pipe towards the end of the
assembling operation.
N.B. If the clutch shaft does not engage its splines, rotate the
shaft slightly.
11. Tighten the bolted joint once the tractor parts have been
brought together (200 Nm (M14), 300 Nm (M16)).
12. Remove the axle stands under the tractor and the support
plates on top of the front axle.
13. Remove the support from under the cab and fit the cab at-
taching bolts (24 mm, 220 Nm).
N.B. Fit the rubber supports under the bolts.
17. Connect the brake rods to the brake levers (22 mm) above
the rear axle. Adjust the brake pedal free travel to 50 mm using
the adjusting nut.
448
Model Code Page
1. 12. 1986
1. 1. 1998
18. Connect the lifting link gear control rod.
19. Fit the mudguards and engine hood plates. Fill the gear-
box and hydraulic system with oil.
N.B. Allow the engine to run for a couple of minutes before

driving in order to lubricate the low gear/Overdrive. Then
test---drive the tractor.
449
Model Code Page
44. Overdrive 600-- 900 441 8
1. 1. 1998
2. Disassembling/assembling Overdrive
Changing Overdrive front oil seal, see page 441/1.
Removing Overdrive, see page 441/1.
Fitting Overdrive, see page 441/5.
A. Disassembling overdrive
1. Remove the rear coupling gear, synchronizing cone,
sleeve and the thrust bearing on the gearbox input shaft (if
not loosened when the overdrive was removed).
2. Move the overdrive selector fork to the rear position and

remove the synchronizing coupler (if not loosened earlier).
Remove the front synchronizing cone.
3. Take care of the selector fork plastic sliding pieces (4 off).

7. Tap the input shaft rearwards out of the housing.
4. Remove the selector fork rail circlip in the rail rear end.
8. Tap the layshaft axle tube forwards and remove it.
Remove the layshaft out of the housing.
9. Unscrew the screw of the spring mechanism support

axle. Pull out the axle and take care of the spacer sleeves.
Remove the selector arm.
5. Tap the rail forwards and remove it. The selector fork
locking ball also releases. Remove the selector fork. Take
care of the spring and the ball.
10. Remove the assembled selector mechanism.
Note! If the round shaped selector lever must be replaced,

the spring mechanism and the connecting plate must also
be changed since they are delivered together.
Important! If the selector fork, or the selector mechanism is

changed, the position of the selector fork must be adjusted,
see instruction B.
6. Remove from the overdrive input shaft front end: circlip,

shims, wear ring and the o---ring under the wear ring.
450
Model Code Page
44. Overdrive 600-- 900 441 9
1. 1. 1998
11. If the input shaft taper roller bearings must be changed, Note! There may be a spacer ring between the housingand
remove the rear bearing on the shaft and fit a new one. the layshaft rear end.
12. Remove the oil seal from the housing front end and 2. Push in the input shaft until the rear bearing is against
remove the front bearing. Remove the bearing outer races the outer race.
in the housing and fit new ones (fitting e.g. ETV 892
440+universal handle). 3. Push the front bearing onto the shaft against its outer
bearing race.
13. If you change the seal in the input shaft rear end, a new
seal can be fitted with sleeve ETV 892 350. 4. Fit an o---ring into its groove on the input shaft front end
and place the wear ring on the o---ring and push it against
Note! The synchronizing coupler has the same build ---up the front bearing.
as the couplers on the gearbox input shaft, see page
420/15. 5. Grease the oil seal lip and knock it into place so that it is
parallel with the housing front edge (the seal can be fitted
with ETV 892 440+universal handle).
B. Assembling overdrive
Note! If you have changed parts of the selector mechan-
ism, the adjustment of the selector fork is carried out as
follows:
--- Refit the selector lever together with the spring assembly
into the housing (if removed) and refit the spring assembly
support axle with its spacer sleeves. Do not fit the layshaft
at this stage.
--- Refit the selector fork together with its rail and locking
mechanism. Refit the circlip at the rear end of the rail.
--- Press the fork to the front position.
6. Fit the circlip in front of the wear ring (do not fit yet the
shims). Measure with a dial gauge stylus against the input
shaft front side the axial play of the taper roller bearings,
which should be 0,05 ---0,15 mm.
7. If necessary, place shims (s=0,1 or 0,3) in front of the

wear ring, until the axial play is correct. After adjustment
ensure that the circlip is placed correctly in its groove.
Note! When necessary, measure the clearance between

the input shaft rear end and the synchro coupler hub, see
instr. C on page 441/10.
8. Position a drift (ø 16 mm, e.g. ET 893 380) inside the

selector fork, so that it keeps the locking ball and spring
down.
--- Press the rail forwards until the circlip rests against its
recess on the housing. Measure with a straight ruler and a
vernier caliper the distance between the housing contact
surface and the bottom of the plastic sliding piece location
on the fork. This distance should be 70,5 ---70,7 mm.
--- Adjust the distance, if needed, by turning the nut at the
end of the spring assembly in the housing (there is enough
space as the layshaft is not fitted).
--- After the adjustment, remove the selector fork so that the
layshaft can be fitted.
9. Position the selector lever round end in the fork hole and
1. Put the layshaft together with its bearings in the housing. push the rail from front through the fork so that the locking
(the greater gearwheel Z27 rearwards). Push the axle tube ball remains under the rail and the drift is pushed out.
with its o---ring through the layshaft.
451
Model Code Page
44. Overdrive 600-- 900 441 10
1. 1. 1998
Paper gasket
Bearing cover
10. Grease the rail o---ring and press the rail into place. Fit
the circlip to the rail. Move the fork to the rear position.
11. Place the synchronizing cone on the gearwheel Z33.

Place the synchronizing unit on the fork (also the sliding
pieces) and push the fork to the front position.
Note! The plastic sliding pieces can be fastened on the fork

with a little grease.
12. Fit the bearing ring, thrust bearing and the sleeve on the
gearbox input shaft. Place the rear coupling gear on the
sleeve. Fit the overdrive and assemble the tractor frame,
see page 441/5 instr. E.
2. Place the Overdrive parts, which are situated on the front

end of the gearbox input shaft, on the Overdrive input shaft
according to the picture above.
C. Checking clearance between input 3. Remove the gearbox input shaft bearing cover and
shaft rear end and synchro coupler hub place it to the top.
4. Fit a paper gasket on the housing contact surface. Place

Note! This checking has to be done, if the parts that affect
a straight ruler against the contact surface and measure
the clearance have been changed (e.g. gear housing, input
shaft and its gearwheels etc). with a feeler gauge clearance (S) between the ruler and the
gearbox bearing cover (cover surface which is against the
gearbox front side).
1. Place the Overdrive housing together with the mounted
input shaft on a table so that the weight of the housing rests 5. The clearance (S) should be at least 0,15 mm.
against the end of the input shaft. Then the bearing clear-
ance comes upwards. 6. When necessary, the clearance can be made larger by
fitting two paper gaskets no. 45355900.
452
Model Code Page
44. Low gear 600-- 900 441 11
1. 1. 1998
3. Reconditioning low gear on

600---900
Changing low gear front oil seal, see page 441/1.

Removing low gear, see page 441/1.
Fitting low gear, see page 441/5.
Note! This instruction includes briefly some important

points concerning the low gear on 600---900 tractors com-
pared with the Overdrive. Picture of the low gear, see page
440/5A.
A. Disassembly/assembly
Disassembling order is the same as for Overdrive:

1. Remove the low gear parts on the gearbox input shaft
2. Remove the low gear toothed coupler
3. Remove the layshaft axle tube
4. Remove the selector fork and its rail
5. Remove the input shaft of the low gear
6. Remove the layshaft
7. Remove the selector arm and the selector lever
Assembly in the reverse order. The same special tools

can be used as for the Overdrive.
B. Adjustments
1. Adjustment of the input shaft bearing clearance is
carried out in the same way as for the overdrive, see
page 441/9.
2. Checking the clearance between the input shaft rear

end and the toothed coupler hub is made in the same
way as for the Overdrive, see instr. C on the previous
page, but the clearance S should be 0,10---0,30 mm.
Note! The selector fork of the low gear has neither an

adjustment nor a spring mechanism to eliminate the
neutral position.
C. Others
The low gear housing is the same as on the Overdrive.

Also the paper gasket is the same.
The low gear layshaft has the thrust bearing plates on

both sides of the shaft. The notches of the plates fits on
the selector fork rail to prevent rotation of the plates.
453
Model Code Page
44. Shuttle 600-- 900 441 12
10. 10. 2003
3. Disassembling/assembling Shuttle
Disassembling shuttle
Tractor split for shuttle disconnected can be done alike as
low gear and overdrive
3. Knock off the forks for gear tension pins and remove the
selector shaft. Remove the shift lever. Open screw with
forks for gear and remove sliding coupling, forks and coun-
tershaft. Take care of the selector fork plastic sliding pieces
(4 off)
1. Unscrew attaching bolts of the shuttle(13mm) and pull of

the shuttle from gearbox.
4. Remove the overdrive input shaft front end: circlip,

shims, wear ring and the o---ring under the wear ring. Tap
the input shaft rearwards out of the housing.
2. Oil pump drive gear and shuttle rear gear remain with in
gearbox. They can be disconnected by pulling.
5. Remove the selector shaft and take care of locking ball.

Open the plug on side and remove circlip.
454
Model Code Page
44. Shuttle 600-- 900 441 13
10. 10. 2003
6. Check the oiltube for bearings. There is a throttle under 4. Put in the spring and ball into the housing of the shuttle.
the oiltube. Check thet the throttle is clear, because the bea- Press the ball with drift (ø 16 mm, obs. ET 893 380) and
rings of input shaft will get their lubrication through this push in the selector shaft. Turn in the plug.
throttle.
min. 1,0 mm min. 1,0 mm
5. Install the o---ring under the wear ring.
7. Check the condition of synchronizing ring and the sliding

coupling. Change the parts thet are wore out if needed
Shuttle assemblying
6. Install the new oil seal into the housing and push in the
wear ring.
1. Check, and if needed, change the bearings of input

shaft. Then advance change also new oil seal with in hou-
sing.
2. Thread the input shaft in, and turn the housing upside
support, the input shaft and press the shaft in the housing,
for example with hydraulic press. 7. Put in the circlip. Notice that the heads of the circlip must
3. If you change the rearside seal of the input shaft, you can be placed on the both sides of the tension pin, that is instal-
install the new one by a socket ET 892 350. Spread some led into the wear ring. By doing this you will make sure that
grease into the lip seal. the wear ring doesn’t left turning on the input shaft.
455
Model Code Page
44. Shuttle 600-- 900 441 14
10. 10. 2003
8. Check, and if needed, change the bearings of both coun-

tershaft. Note! Axles second head bearings are in the gear-
box head. The lower countershaft also lubrication pump by
axle. 11. If you have disconnected rear gear and lower counters-
haft of the shuttle, install them to the front side of the gear-
box
Note! If you have changed the axle of the oil pump make
sure thet the axle has enoungh axial slip. The axial slip can
be checked by taking off the service hatch of the gearbox.
12. Apply sealing compoud to the contact surface between
the housing and the gearbox. Clean coontact surfaces if
needed.Note! Put sealing compound only to the outer ed-
ge of housing of the shuttle.
13. Install the second syncronizing ring for example using
grease and lift the shuttle in its place. By align you can use
M8 bolts.
23Nm
9. Install in the selector shaft and lever on the positioning.

The plastic sliding pieces can be fastened on the fork with a
little grease.
Install in the housing, syncronizing ring, sliding coupling,
fork and upper countershaft.
14. Tighten the housing srews to a torque of 23Nm and

check shuttle float
15. Assemble the tractor frame alike as low gear and overd-
rive
10.Put in the tension pins of the lever of forks. Notice of the

assembly direction, slotted holes must be cross direction of
the selector shaft.
456
Model Code Page
1. 3. 1997
45. Final drives 205-- 900 450 1
15. 4. 1999
Contents
General (Op no 450)
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Final drives, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Repair instructions
Final drives (Op no 451)
1. Reconditioning final drive

A. Removing final drive from tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing roller bearings in planetary pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing bearings and seals on drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Adjusting drive shaft bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Fitting final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Reconditioning final drives on 865 ---tractor (transmission 250) . . . . . . . . . . . . . . . . . . . . 6
Technical Data
Gear ratio, planetary gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=5,6
Rear axle flange distance, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1640 mm
Rear axle flange distance, 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 mm
Tightening torques
Drive axle housing ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm (24 mm)

Wheel nuts, rear wheels:
--- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Nm (24 mm)
--- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm
Oil draining plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm (36 mm)
Centre bolt, outer drive shaft, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (24 mm)
Centre bolt, outer drive shaft, 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---5 Nm (24 mm)
Cab ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm (24 mm)
Check links---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (19 mm)
Lower links---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm (30 mm)
Brake mechanism ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Setting values
End float, outer drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,010---0,075 mm

Distance between drive shaft end ---rear axle housing contact surface, 205---665 . . . . . . . . . . . max 129 mm
Distance between drive shaft end ---rear axle housing contact surface, 865, 600---900 . . . . . . . max 128,7 mm
Brake pedal free travel, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 mm
Oil
(Final drives have oil space in common with gearbox)
Viscosity and quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 120/4.
Total oil volume:
--- 205---665. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 l
--- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 l
457
Model Code Page
45. Final drives 205-- 865 450 2
1. 12. 1986
Special tools
Final drives B
ETV 891 710 Sleeve for fitting bearing race for outer drive shaft (Gearbox Valmet 1102---1203)
(ETV 892 210) Sleeve for fitting oil seal for outer drive shaft (see Gearbox)
ETV 893 320 Plate for fitting outer shaft seal for outer drive shaft (also Final drives 505---905)
ETV 893 690 Plate for fitting bearing race for outer drive shaft
ET 893 410 Support bar for removing bearing race for outer drive shaft (also Final drives 505---905)
Final drive B
ETV 893 320
ETV 893 690
ETV 891 710 ETV 892 210
ET 893 410
458
Model Code Page
1. 5. 1996
45. Final drives 865
450 2A
1. 1. 1998 600-- 900
Special tools, 865 and 600---900

ETV 893 310 Plate for fitting drive shaft inner oil seal (Mezzo)
ETV 893 320 Plate to fit drive shaft bearing outer races (Mezzo)
ETV 894 210 Centring tool foor outer brake application ring when fitting final drives on 865 and 600---900.
ET 893 410 Support to remove drive shaft bearing outer races (Mezzo)
ETV 890220 ETV 893 310
ETV 893 320
Itsetehtävät työvälineet ETV 894 210
ET 893 410
459
460
Model Code Page
1. 12. 1986
45. Final drives 205-- 865 450 3
1. 3. 1997
Final drives, description

drives the planetary pinions and the planetary retainer. The
The final drives are of the planetary gear type with mechani- power is then transferred via the splined joint between the
cally operated multi ---disc brakes which run in oil. The rear planetary retainer and the outer drive shaft and further on to
axle housing is bolted to the gearbox by eight screw studs. the driving wheels.
The brakes are fitted between the gearbox and the planetary
gear in the final drive and the brake control mechanism is The outer drive shaft is carried in taper roller bearings in the
fitted on top of the rear axle housing. The construction of the rear axle housing. The planetary pinions are carried in needle
final drives is identical on tractors 205---665. bearings on the shaft studs which are fixed to the planetary
retainer.
The power is transmitted from the differential via the inner
drive shaft to the planetary gear and on to the outer drive shaft. The final drives are fully encased and run in the same oil as the
The gear ratio in the planetary gear is 5,6:1. gearbox and differential.
The planetary ring gear is fitted in the rear axle housing with There is a grease nipple on top of the axle housing for greas-
a press fit. The planetary sun gear is machined integrally with ing the outer bearing of the drive shaft. The inner bearing is
the inner drive shaft. When the inner drive shaft rotates it lubricated by the gearbox oil.
Picture 2. Final drives 305---405 (up to ser. no. 302139 incl.)
1. Paper gasket (also suitable sealing compound can be

used)
2. Locking fluid Loctite 270 or corresponding
3. Locking fluid Loctite 126 or corresponding
4. Universal grease (20 g).
5. Inner drive shaft
6. Planetary pinion
7. Ring gear
8. Outer drive shaft
9. Rear axle housing
10. Centre bolt. Loctite 2701 onto the threads.
11. Brake discs
12. Pressure plate
461
Model Code Page
1. 7. 1989
45. Final drives 305-- 665 450 4
1. 3. 1997
Fig. 2. Final drive 305---455 (with effect from ser. no. 302140)
1. Paper gasket
2. Extension sleeve
3. Locking fluid (Loctite 242 or similar)
4. Universal grease (20 g)
5. Inner drive shaft
6. Planetary pinion
7. Ring gear
9. Rear axle housing
10. Centre bolt. Loctite 2701 onto the threads.
11. Brake discs
12. Pressure plate
N.B. With effect from ser. no. 610312 the planetary pinions (6)
have been made wider. In connection with this modification
the spacer rings between needle bearing races inside the
planetary pinions have also been made wider.
462
Model Code Page
1. 3. 1997
45. Final drives 865 450 5
1. 9. 2001
Picture 3. Final drive on 865---tractor (Transmission 250)
1. Paper gasket
2. Wear ring
3. Loctite 242 or equivalent to threads of spring pins
4. Universal grease (20 g)
5. Inner drive shaft (with sun gear).
6. Planetary gears (3 pcs).
7. Ring gear
10. Centre bolt for planetary gear unit. Loctite 2701 to threads
of the bolt.
11. Brake discs, 4 pcs, Intermediate discs, 3 pcs (organic
linings)
12. Brake application ring
Note! The final drive outer drive shaft (8) together with the
seals and bearings are the same as on Mezzo---transmission
300. The brake discs are also the same as on Mezzo---tractors.
463
464
Model Code Page
1. 12. 1986
45. Final drives 205-- 865 451 1
1. 7. 1989
1. Reconditioning final drive (Op. no. 451)

N.B. The construction of the final drives is identical in tractors
305---455.
A. Removing final drive
1. Drain the oil (3 drain plugs, max 23 litres). Free the check
link bracket from the rear axle housing.
2. Free the lower link (and extra lifting cylinder if fitted) from un-
derneath the rear axle housing.
3. Slacken the wheel nuts. Block up the tractor under the gear-
box. Remove the wheel.
8. Pull the rear axle housing straight outwards so that it clears
the gearbox.
N.B. Removing the rear axle housing from the gearbox is

made easier by removing the brake mechanism from the rear
axle housing.
B. Changing roller bearings in planetary pin-

ions
1. Remove the final drive (Op. A).
4. Disconnect the rear end of the brake rod from the lever on
the rear axle housing.
NOTE: (Up to ser. no. 610311): RH side final drive: Disconnect

differential lock control mechanism also.
5. Remove the cab rear attaching bolts. Lift the rear of the cab
slightly and block it up with suitable supports or a lifting de-
vice.
6. Position an axle stand on castors under the rear axle hous-

ing. 2. Remove the brake discs and inner drive shaft. Undo the
locking washer on the centre bolt which secures the outer
drive shaft to the planetary retainer and unscrew the bolt. The
attaching plate remains inside the planetary retainer. Pull the
planetary retainer off the drive shaft.
3. Cut the locking wire which is located under the locking

7. Unscrew the rear axle housing nuts (24 mm). spring for the planetary pinion shaft studs. Remove the lock-
ing wire.
465
Model Code Page
45. Final drives 205-- 865 451 2
1. 12. 1986
4. Compress the locking spring with a pair of pliers and pull

the shaft studs out of the planetary retainer.
8. Lower the planetary retainer onto the splines on the drive

shaft and so that the planetary pinions engage the ring gear.
Secure the planetary retainer to the end of the drive shaft by
tightening the centre bolt.
9. Adjust the drive shaft bearing clearance (Op. D) and fit the
final drive on the tractor (Op. E).
C. Changing bearings and seals on drive

shaft
1. Remove the rear axle housing from the chassis (Op. A).
Remove the planetary gear (Op B2).
5. Remove the planetary pinions from the planetary retainer.

Change the bearing rollers. The easiest way of fixing the
rollers in position is by pacing them in a little grease.
Note the spacer ring between the two rows of rollers.
6. Press the bearing wear washers against the sides of the

planetary pinions and press them into the retainer. Compress
the locking spring and push the shaft studs into position and
make sure the locking spring engages the groove in the studs.
Note! Fit the attaching plate for the planetary retainer before 2. Tap the end of the drive shaft so that it slides out of the bear-
fitting the third planetary pinion. ings. Pull the shaft out of the axle housing.
7. Push in a wire diam. 2,0 mm under the locking spring. Wind

the wire ends together one and a half turns and bend them
down.
Note! The ring gear is fitted in the rear axle housing by a press
fit. If the ring gear is damaged the whole rear axle housing
must be changed as well as the ring gear.
3. Remove the drive shaft outer bearing using a puller. Heat

the new bearing and fit it on the shaft.
466
Model Code Page
45. Final drives 205-- 865 451 3
1. 12. 1986
N.B. When necessary the wear ring on the shaft should be

changed. Removing and fitting is carried out by heating the
metal ring.
4. Remove the shaft outer seal using a puller.
ETV 892210
8. Remove the inner seal. Fit a new seal using ETV 892 210.
ET 893 410
5. Position support bar ET 893 410 against the rear axle hous-
ing. Pull out the outer bearing race. Fit a new bearing race
using plate ETV 893 690.
ETV 891710
ETV 893 320 9. Fit a new bearing race using ETV 891 710.
10. Grease the bearings thoroughly before fitting. Carefully

6. Fit a new seal using ETV 893 320. Lubricate the felt seal. insert the drive shaft in the axle housing. Ensure that the seals
are not damaged.
11. Fit the drive shaft inner bearing on the shaft. Fit the plane-
tary retainer on the splines on the drive shaft and press the
planetary retainer home. Secure the planetary retainer to the
end of the drive shaft with the attaching plate and the centre
bolt.
12. Adjust the drive shaft bearing clearance (Op. D). Fit the
final drive (Op. E).
D. Adjusting drive shaft bearing clearance
1. Place the drive shaft with the wheel flange on the floor. Bed
in the bearings by rotating the axle housing approx. 20 turns.
ET 893410
7. Remove the inner bearing race using a puller and support
bar ET 893 410.
467
Model Code Page
1. 7. 1989
45. Final drives 205-- 865 451 4
10. 1. 1992
10 Nm
3. Position an axle stand with castors under the final drive and
move it inwards at right angles so that the inner drive shaft en-
2. Tighten the bolt fixing the planetary retainer to the shaft to gages in the differential.
a torque of 10 Nm. Again rotate the axle housing and check
N.B. Fit the brake mechanism on the rear axle housing if it has
the torque. After some time of operation the correct shaft been removed.
bearing clearance, i.e. 0,010 ---0,075 mm will be established.
3. Lock the planetary retainer attaching bolt (shaft centre bolt)

with the locking washer. The correct position is found by mov-
ing the washer round to different positions.
E. Fitting final drive
4. Tighten the nuts for the rear axle housing to a torque of 230
Nm.
5. Press in approx. 20 g of grease through the lubricating

nipple by the drive shaft outer bearing. Rotate the shaft while
doing this.
N.B. Right rear axle housing up to ser. no. 610311: fit the dif-
ferential lock control and the brake mechanism.
1. Fit the inner drive shaft, brake discs and pressure plate (Op.
no. 511 1A 5 ---7).
N.B. Check that the distance between the end of the inner
drive shaft and the contact surface of the rear axle housing is
max. 129 mm.
2. Clean the contact surfaces between the gearbox housing

and the rear axle housing and fit a new gasket. Also can be
used sealing compound (e.g. Hylosil).
NOTE: (Up to ser. no. 610311) control setting with differential

lock engaged: nut 1 is tightened until there is no spare clear-
ance in pressure rod 2. Then the nut is turned a further
1/3---1/2 of a turn.
NOTE: With effect from ser. no. 610312 the differential lock
control mechanism has been changed. The new mechanism
no longer needs to be removed when the RH side final drive is
removed.
468
Model Code Page
1. 7. 1989
45. Final drives 205-- 865 451 5
10. 1. 1992
6. Connect the brake rod to the brake lever.
7. Secure the check link bracket to the rear axle housing up

to a torque of 80 Nm.
8. Secure the lower link (and extra lifting cylinder) to the under-
side of the rear axle housing, tightening torque is 380 Nm.
9. Lower the cab and tighten the attaching bolts to 220 Nm.
10. Fit the rear wheel and tighten the wheel nuts to 330 Nm.
Fill with oil and adjust the brakes (Op. no. 511 1B). Test---drive
the tractor.
469
Model Code Page
1. 3. 1997
45. Final drives 865
451 6
1. 1. 1998 600-- 900
2. Reconditioning final drives on 865 and B. Reconditioning planetary gear

600---900
1. Before reconditioning, remove the rear axle housing, brake
NOTE! This instruction deals with differences between final application ring, inner drive shaft and brake discs and the
drives on 205---665 and on 865 and 600---900 tractors. brake support behind the discs.
A. Removing/fitting rear axle housing 2. Unscrew the centre bolt and remove the planetary gear.
3. Reconditioning planetary gear, see instruction B on page

Removing: 451/1.
1. Removing occurs as shown in instruction A on page 451/1. Note! In assembly the outer drive shaft bearing clearance is
adjusted by tightening the centre bolt to a certain torque, see
the following instruction.
Note! When the rear axle housing is pulled apart from the
gearbox housing side, brake balls (6 off) release and fall Note! There are four friction discs and three intermediate
down. It is possible that the inner brake ring remains on the discs in the brake disc pack. Fit first the friction disc against
side of the gearbox housing. the brake support and then by turns intermediate disc and
friction disc.
Fitting:
Note! On some planetary gears, there can be two tension pins
1. Fitting is done as shown in instruction E on page 451/4 with to prevent rotation of the planetary gear shaft stud locking
the following differences: ring. Locking ring ends must be fitted between the pins. Later
the rotation of the locking ring is prevented with a modification
of the planetary retainer casting.
C. Changing outer drive shaft seals and

bearings
Note! The drive shaft, bearings and oil seals are the same as
on Mezzo---tractors (transmission 300). Also the special tools
used in this work are the same as on Mezzo---tractors, see
page 450/2A.
The drive shaft bearings and seals are changed in the same
manner as shown in instr. C on page 451/2.
The drive shaft bearing clearance are adjusted in the same

way as described in instr. D on page 451/3, but the centre
bolts is tightened to a torque of 3 ---5 Nm.
ETV 894 210
2. Position the brake discs in place on the inner drive shaft.

Push the inner drive shaft fully home. Compress the outer
brake application ring against the springs (2 pcs) and fit the
centring tool ETV 894 210 into place so that it supports and
centres the application ring.
Note! The plug of the centring tool ET 894 210 is screwed into
the oil draining hole of the rear axle housing and the upper end
of the bolt, which goes through the plug, supports the brake
application plate. Picture of the tool, see page 102/5.
3. Fasten the brake balls (6 pcs) onto the grooves on the inner
brake ring by using thick grease (e.g. Renax). Position the
inner brake ring onto the side of the gearbox in correct posi-
tion.
4. Fit the final drive. Remove the support tool and tighten the
rear axle housing bolts to a torque of 230 Nm.
470
Model Code Page
1. 3. 1997
46. PTO (Power take ---off) 205-- 900 460 1
15. 4. 1999
Contents
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1---speed PTO (Power take ---off), description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2---speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PTO brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front---mounted PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
N.B. Reconditioning PTO clutch, see instruction 41. Clutch.
Repair instructions
PTO (Power take-- off) (Op. no. 462)

1. Reconditioning 1 ---speed PTO:
A. Removing PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing bearings at PTO shaft end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing bearings at upper shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Changing selector fork/selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Fitting PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. Changing oil seal at PTO shaft end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Reconditioning 2 ---speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. PTO unit with brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Technical Data
PTO shaft end (ISO 500---1979 Z6):

--- nominal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 mm
--- number of splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Nominal speed, engine/PTO shaft end 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1890 rpm /540 rpm
Nominal speed, engine/PTO shaft end 540E (=750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1594 rpm/540 rpm
Nominal speed, engine/PTO shaft end 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2074 rpm/1000 rpm
PTO outputs (kW) at a nominal speed of 540 r/min
Tractor 205 255 305 355 365 405 455 465 555 565 665 865
Output 29 32 32 36 37 37 41 42 43,5 45,5 49 52
PTO outputs (kW) at a nominal speed of 1000 r/min
Tractor 365 465 565 665 865 600 700 800 900
Output 38,5 46,5 48,5 51,5 56 37,5 46,5 51,5 58
Oil
Common for gearbox and final drives:
--- Viscosity and quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 120/4.
--- Total oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 litres, 865, 600---900: 27 litres
NOTE: With effect from gearbox no. 406714 a lubricating oil pipe is fitted from the gearbox pressure lubrication system to the
power take ---off unit so that the PTO is lubricated in all conditions.
Tightening torques
PTO housing ---gearbox:

--- 10 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
--- 2 pcs, M16 (earlier tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
--- 2 pcs, M20 (latest tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm
PTO shaft end guard plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
Bolt for top link bracket spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Top link bracket lower attaching point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
471
Model Code Page
15. 4. 1994
46. Power take ---off 205-- 665 460 2
1. 3. 1997
Special tools
Power take ---off A
Part no Description
ETV 893 700* Sleeve for fitting PTO shaft end, bearings or oil seal.
Power take ---off B

(ETV 892 350) Sleeve for fitting upper shaft or bearings, 1---speed PTO (see gearbox)
ETV 894 080 Tool for fitting shifter fork locking ball, 2---speed PTO (also PTO 6000---8400)
Note! Part number marked with asterisk has been made specially for 305---665.
ETV 893 700
ETV 892 350 ETV 894 080

(1 ---speed PTO) (2 ---speed PTO)
PTO, description
Function of 1---speed PTO (see fig. 1)
The PTO operates independently of the gearbox. It is equip-
ped with its own clutch disc in the dual clutch which is bolted When the PTO selector lever (1) is moved forwards, the move-
to the flywheel. The power is transferred from the flywheel to ment is transferred via the control rod (2) to the selector lever
the PTO via a PTO shaft which runs through the gearbox. (3), which moves the selector fork (4). The engaging sleeve (6)
connects the PTO clutch shaft (5) to the shaft (8).
The PTO is selected with the PTO selector lever to the right of
the driving seat and engaged and disengaged with the clutch
lever located to the left of the instrument panel. The PTO shaft end begins to rotate as the clutch shaft (5)
begins to rotate.
Before selecting the PTO, the clutch lever should be moved
to its rearward position, i.e. clutch disengaged, and after
selecting the PTO the clutch lever should be moved to its for-
ward position, i.e. engaged. The clutch lever should only be
used for temporarily disengaging the PTO (for at the most 5
minutes).
472
Model Code Page
1. 12. 1986
46. Power take ---off 205-- 665 460 3
1. 7. 1989
Fig. 1. Principle diagram, PTO
1. Selector lever
2. Control rod
3. Selector lever
4. Selector fork
5. PTO clutch shaft
6. Engaging sleeve
7. Oil dipstick
8. Upper shaft
9. Locking fluid Loctite 222 or similar NOTE: With effect from ser. no. 610312 the PTO engaging
A. Selector lever bearings mechanism has been changed slightly; the position of the
B. Note position of tubular pin lever in the cab is different.
473
Model Code Page
46. Power take ---off 205-- 665 460 4
1. 12. 1986
Fig. 2. Section of PTO
1. Paper gasket
2. Thrust bearing
3. Needle bearing
4. Clutch disc for PTO
5. PTO shaft end
474
Model Code Page
15. 4. 1994
46. PTO 365-- 865 460 5
1. 3. 1997
2---speed PTO
Note In point 10 between the gearwheel Z63 and the ball bea-
ring, there are fitted on latest units (G07101---) a spacer ring
The foremost gear wheels (Z18/Z63) are for PTO 540 r/min. (s=3,0 mm) and possible shims (s=0,1 and 0,3 mm). With
The rearmost gear wheels are either for PTO 540E (Z21/Z62) these shims are adjusted the play of the two gearwheels on
or PTO 1000 r/min (Z27/Z56). the PTO shaft to 0,05---0,1 mm. The gearwheel Z63 has also
been modified. As a spare part only this new gearwheel is deli-
vered , which requires the above mentioned shims.
475
Model Code Page
15. 4. 1994
46. PTO 365-- 865 460 6
15. 9. 1995
2---speed PTO
3
Lubrication
Picture 4. Lubrication of PTO
1. Lubricating oil inlet

2. Oil space at the rear end of the upper shaft
3. Selector arm
Lubricating oil is directed from the gearbox lubricating system The PTO shaft has a lip ---type oil seal. Both shafts are suppor-
distribution piece via pipe 1 to the front end of the selector rail. ted with ball bearings. A paper gasket or a suitable sealing
compound is used between the gearbox and the PTO hou-
Oil flows through the rail to the oil space 2 at the rear end of sing.
the upper shaft and inside the upper shaft via the oil drillings
to the sliding surfaces of the gear wheels. Important! If the selector fork of the 2---speed PTO unit has
been changed due to the excess wear, it is necessary to make
The lower shaft has a splash lubrication. a modification also to the PTO control lever linkage. On the
earlier PTO units the selector fork wear may be caused by a
wrong control lever mounting. This control lever modification
has already been carried out in the tractor works for all new
tractors.
476
Model Code Page
46. PTO 600-- 900 460 6A
1. 9. 2001
477
Model Code Page
46. PTO 600-- 900 460 6B
1. 9. 2001
478
Model Code Page
15. 9. 1995
46. PTO 365-- 865 460 7
1. 3. 1997
PTO brake
With effect from tractor serial number 666440, the 2---speed
PTO unit has a brake which ensures, that the PTO shaft stops
rotating, when the control lever is moved to the neutral posi-
tion.
Picture 5. PTO shaft brake

In the neutral position, spring (4) presses the brake shoe (1) 1. Brake shoe
against the big gearwheel (7) on the PTO shaft and prevents 2. Selector fork
the PTO shaft from rotating. 3. Selector fork rail
When the PTO is engaged, the selector fork moves and ball 4. Brake spring
(6) presses the brake shoe away from the gearwheel. 5. Pivot pin of the brake shoe upper end
6. Ball for releasing the brake
Note It is possible to fit the PTO brake also on the earlier 7. Gearwheel Z63
manufactured tractors, which have the 2---speed PTO unit,
see page 462/9.
479
Model Code Page
15. 9. 1995
46. PTO 365-- 900 460 8
1. 1. 1998
Front PTO
Without priority valve
600-- 900
Fig. 6. Front PTO (option)

On the tractors with the priority valve, the counter pressure
created by the priority valve raises the free flow pressure up
1. Hose union from pump to pressure line.
to about 11 bar.
1a) Valve (7 bar) which increases the free flow pressure on
tractors which do not have the priority valve.
The front PTO is engaged electro---hydraulically by means of
2. Solenoid valve (solenoid/pressure reduction)
the switch (3) in the dash board. The solenoid valve (2) opens
3. Control switch in the dash board (fuse FA4)
allowing oil pressure of max. 11 bar into the cone clutch of the
4. Front PTO
front PTO. The function of the solenoid valve ensures that the
5. Return oil flow to the tank via T ---connector on the pipe for
PTO is engaged progressively i.e. the valve raises the clutch
the auxiliary hydraulic oil.
pressure gradually up to 11 bar.
The PTO shaft rotates 1000 rpm at engine speed of 1950 rpm.
The electronics of the valve has been adjusted in the factory
PTO shaft end (grooves/diam.) 6/35 mm (1 3/8”).
so that the engaging time is modulated. However, if an opera-
Direction of rotation (seen from the front).
tor wants to adjust the engaging time, it can be done by tur-
ning the middle potentiometer screw. The screws are covered
Front PTO + front linkage is an optional equipment. The front
by a detachable cover.
PTO is not fitted without the front three ---point linkage.
NOTE! The longer the engaging time, the greater the cone
In the hydraulic system without the priority valve, the free flow
clutch wear.
pressure is 4---5 bar, which is not high enough to drive the
front PTO (required pressure is 11 bar). In this case, the valve
1a is fitted in the pipe system. The valve causes a pressure
drop, which raises the free flow pressure (between pump and
valve) up to about 11 bar.
480
Model Code Page
46. PTO 365-- 865 460 9
15. 9. 1995
Repairs
Picture 7. Sectional view of front PTO unit
The front PTO clutch is a dry cone clutch, which has six friction
1. Intermediate flange 11. Oil passage pieces (5) pressed by spring (6) against the clutch taper surfa-
2. Universal shaft 12. Support plate ces.
3. Clutch drum 13. Shaft The friction pieces are accessible after unscrewing the univer-
4. Hub 14. Oil gallery ---in cover sal joint (2) attaching flange on the clutch drum (3) and by
5. Friction piece (6 off) 15. PTO shaft releasing the clutch drum bearing circlip through holes in the
6. Spring 16. Oil level checking plug drum. After that the clutch drum/bearings can be pulled out
7. Bolt (3 off) 17. Oil draining plug by using puller screws (M10). When the drum/bearings have
8. Spring (6 off) 18. Solenoid valve been removed, the friction pieces can be changed.
9. Piston 19. Gasket The clutch assembly can be detached from the PTO housing
10. Clutch cylinder after removing the clutch drum by unscrewing bolts inside the
clutch. In this case, rotation of the clutch should be prevented
in a suitable way.
The PTO shaft seal can be changed by removing the seal

cover circlip after which the seal/cover can be detached. In the
Maintenance same way the upper shaft front seal is changed.
a) Retighten all fixing bolts after the first 15 --- 25 running If the PTO shaft or the upper shaft rear seal has to be changed,
hours. the PTO housing should be parted by removing the centring
b) It is not necessary to change the oil in the PTO housing. pins and by unscrewing the housing halves attaching bolts.
Check the oil level at intervals of six months. Top up, if neces- Do not tap a wedge between the housing halves since the
sary, normal SAE 90 EP transmission oil. The oil level should sealing surfaces can damage.
be at a level of the checking plug.
c) Grease the universal joints with grease of a good quality When assembling the PTO unit, the universal joints must be
once a year. alined in a correct way.
481
Model Code Page
46. PTO 365-- 865 460 10
15. 9. 1995
Without priority valve
Attachning plate
Fixing bolts (240 Nm)
Picture 8. Explored view of the front---mounted PTO.
482
Model Code Page
15. 9. 1995
46. PTO 365-- 865 460 11
1. 3. 1997
B
A
To working hydraulics
To priority valve
7 bar
0---11 bar
VA=white
KEVI=yellow green
VI=green
SI=blue
RU=brown
KE=yellow
With priority valve Without priority valve
Picture 9. Front PTO control valve (solenoid+pressure

reduction valve).
The engagement of the front PTO is electronically controlled,

so that the engagement will happen progressively. When the rocker switch is turned on, the solenoid is magnetic.
If the front PTO shaft does not start to rotate, altought the cont-
1. Solenoid valve rol switch is turned to the running position, first check the fuse
1a. Solenoid valve spool FA4 in the fuse box and check whether the current comes to
2. Pressure reduction valve the solenoid. If it is there, but the solenoid is not magnetic, the
2a. Pressure reduction valve spool fault lies in the solenoid.
3. Front PTO unit
4. The electronics have been adjusted to modulate a correct If the electrical system is OK, it is possible, that there there is
engaging time. However, if the operator wants to adjust the dirt in the valve. Dirt prevents movement of the valve spools
engaging time, it can be done by turning the middle potentio- and obstruct oil holes.
meter screw.
A worn ---out cone clutch or too low oil pressure can cause
Important! On the latest tractors the electronic box A3 toge- clutch slip and noice.
ther with its potentiometer screws has been moved from the
valve connector into the steering wheel console, see wiring If the engagement doesn’t happen ”softly”, the control valve
diagram B above. Wiring diagram A shows the earlier version. does not function properly.
483
Model Code Page
46. Power take ---off 600-- 900 460 12
15. 4. 1999
Later front PTO

The front PTO has been renewed in 600---900 tractors. The
construction is shown on pages 460/12 ---14. The elctrical
system is the same as earlier. The mechanical system is
different. I production with effect from ser. no. H47255.
Picture 10. Front PTO of new type (600 ---900).
1. Pressure oil from pump to control valve (2) and into the Note! The control unit A3 has an adjusting screw (middle) ,
PTO clutch. with which the engaging time of the front PTO can be adjus-
2. Control valve (solenoid Y9+pressure reduction). ted. Adjustment has been done in the factory, and readjust-
3. Front PTO rocker switch S38. ment is normally unnecessary.
3a. Front PTO control unit A3. Too long engaging time causes excess wear in the clutch.
4. Front PTO unit
5. Return oil to tank flows via T ---connection in the return oil
connector for the auxiliary hydraulics. Maintenance:
Electrical parts --- Check the bolt thickness after the first 100 running hours.
--- check the condition of the rubber joint at intervals of 500
FA4, fuse for front PTO running hours. Change when necessary.
S38, rocker switch in the dashboard --- change the oil at intervals of 6 months.
X42, connector under the dashboard --- check now and then possible leakages
GR3, earth point, cab wire loom.
A3, electric control unit Oil volume 1,4 litres.
Oil quality: 10W/30, API CE/SF, API GL 5/4, CCMC D4.
484
Model Code Page
46. Power take ---off 600-- 900 460 13
15. 4. 1999
Picture 11. Cross ---section, front PTO Changing fan belts:

--- Unscrew bolts of flange (2)
1. Elastic rubber joint Wiring diagram --- Push the shaft into splined sleeve (3),
2. Flange --- Remove the belts through the opening
3. Tapered joint --- If the opening is too small, unscrew the PTO unit
4. Upper shaft fixing bolts and pull the unit forwards until the
belts can be changed.
5. Clutch drum / gear
--- Fitting in the reverse order: tighten the unit fixing
6. 5 pcs steel discs
bolts (4 pcs) to 200 Nm. Tighten the flange (2)
7. 6 pcs friction discs bolts to 90 Nm (12.9).
8. Cylinder / piston
9. Cylinder flange Elastic joint:
10. Piston return springs Apply grease onto the bolt head lower face. Tighten
11. Seal flange the bolts to 140 Nm, so that rubber does nor bend
12. PTO shaft (three axial and three radial bolts).
13. Oil filling plug
13a. Draining plug
14. Tension pins, housing halves
15. Brake wear plates Fault tracing:
--- If the front PTO does not start with rocker switch
S38, check the fuse FA4.
--- If the fuse is OK, check whether the current is in the
solenoid Y9 connector, when the rocker switch is in
the engaging position.
--- If not, check the switch, connector X42, control unit
A3 and earth point GR3.
--- If there is current in the solenoid, but the PTO does
not start, check the solenoid by measuring its resis-
tance. Change , if damaged.
--- If the solenoid is OK, the fault may lie in the hydrau-
lics. Check the control valve.
--- check that hydraulic pressure affect the PTO clutch.
--- if the pressure is OK, the fault lies in the mechanical
parts of the PTO unit.
485
Model Code Page
15. 4. 1999
46. Front PTO 600-- 900 460 14
10. 10. 2003
3 C
B
A 10
5 8
2
A. Changing external oil seals --- Drain the oil in the housing
--- Unscrew the bolts of the housing halves and remove the
Oil seal A can be changed from the front by prying it out of front part (tension pins in the joint).
the housing (do not damage the shaft surface). Grease lips --- Remove the upper shaft bearing (3).
of a new seal and strike it in with a suitable sleeve. Reduce --- Tap with a soft mallet on the flange (2), at which time the
oil level in the housing before seal removal. Remove the lower shaft is pushed out of its location. Remove flange
shaft protecting guard, if necessary. (2) and the lower shaft rear bearing (10).
--- press with two glue clamps on flange (4) to compress
Oil seal B is changed as follows: springs (5) and remove the snap ring (6).
--- Remove the PTO unit --- Remove the cylinder/piston (7), after which the clutch
--- Unscrew the bolt (M16, 12.9, 360 Nm) of the tapered discs can be changed. Check/change the clutch seal
joint (1) rings.
--- Pry out the seal B and fit a new one with a suitable sleeve --- If the entire PTO shaft must be changed, remove bea-
--- clean the tapered joint. Connect the joint and tighten the rings and disc pack front flange on the shaft.
bolt to 360 Nm. --- Check wear of plates (9). Change when needed.
The rotation of the shaft can be prevented in a vice/ with Note when reassembling:
pliers. Hold on the splined shaft near the welding joint, but
not on the tapered part. --- In connection with repairs the seal A should be changed.
--- Joint C has a paper gasket of 0,4 mm, which should be
The o---ring of the seal flange (2) is accessible after remo- changed during repairs
ving securing ring (8) and by pulling the flange out of the --- It is useful to change the whole disc pack (6 friction and
bore. 5 steel discs)
--- grease all seals during mounting
B. Reconditioning multi-- disc clutch/ --- when the lower shaft with the clutch is in its location, pla-
changing PTO shaft ce the o---ring of flange (2) against bearing (10) and tap
in the flange and fit the snap ring (8).
--- Remove the PTO unit (it is unnecessary to open the tape- --- Oil volume 1, 4 litres.
red joint (1)
486
Model Code Page
46. PTO---HiShift 600-- 900 461 1
1. 9. 2001
1. PTO---HiShift (option)
The PTO ---HiShift hydraulic block (3) pushes electrohydrau-
lically the PTO clutch disc to the disengaged position and
back to the engaged position with the aid of the rocker
switch (1) in the cab. The PTO clutch lever (6), however,
does not move when the switch is used (safety).
a)
b)
c)
d)
Picture 1. PTO ---HiShift in the 600---900 tractors

The slow engagement can be adjusted by means of a res-
1. Positions of PTO ---HiShift rocker switch (S 69): triction screw on the hydraulic block (3). The clutch lever (6)
--- figure a: middle position: PTO ---clutch engaged, the can also be used manually, but the engagement cannot be
clutch lever in the front position in manual use. made faster.
--- figure b: left edge down, PTO ---clutch disengaged, the
clutch lever in the rear position in manual use. Engine can- The rocker switch (1) is placed either in the dashboard or
not be started in this position. on the side console (if ACB power lift).
--- figure c: the switch is pressed from position b to the
middle position, fast engagement (e.g. light implement) Retro fitting: On tractors without the priority valve (and with-
--- figure d: the right edge is held down, slow engagement out the clutch pedal HiShift), a non ---return valve must be
(e. g. heavy implement). The switch must be held in this fitted (33683100, 10 bar) in order to obtain the correct con-
position during the whole engagement. trol pressure for the PTO HiShift.
2. Pump The control pressure in the hydraulic block (3) is limited by

3. PTO ---HiShift hydraulic block a pressure relief valve. Adjusing value is 1,8 Mpa.
4. HiShift (for clutch pedal (option)).
5. Return oil into the hydraulic housing
6. PTO clutch lever
7. PTO ---lever
487
Model Code Page
46. PTO---HiShift 600-- 900 461 2
1. 9. 2001
Picture 2. PTO ---HiShift, mechanical parts
A. Switch (S 69) in the middle position. PTO ---clutch is in

the engaged position (lever is in the front position in manual
use). The piston is inside the hydraulic block.
B. Switch (S 69) front edge depressed, at which time the

piston is pushed out and presses the PTO clutch disc into
the disengaged position (in manual use the clutch lever is
moved to the rear position).
C. Manual control is always possible.
488
Model Code Page
46. PTO---HiShift 600-- 900 461 3
1. 9. 2001
Picture 3. Hydraulic block, disengagement Function when disengaging the PTO---

1. Restriction screw to adjust the slow engagement.
clutch
Basic adjustment: 3,5 turns open (adjusting range ±1
Picture A:
turns).
2. Pressure ---limiting valve. This valve reduces the pump The rocker switch S 69 is in the middle position. Solenoid
valves Y16 and Y17 are unenergised.
pressure to 18 bar (1,8 MPa). The valve is sealed.
Behind piston 7 there is pressure, which holds the piston
3. Valve block.
inside the valve block and the PTO ---clutch disc is in the
4. PTO ---HiShift---pressure test point. The correct value sho- engaged position (in the manual use the PTO clutch lever is
in the front position).
uld be 18 ---22 bar. When measuring the pressure, the oil
must be in the normal operating temperature and the engi-
ne revs about 1500 rpm. Picture B:
5. Pressure from pump. The switch S69 left edge is pressed down, at which time
the solenoid valve Y16 becomes energised and opens an
oil way from the pressure side to the solenoid valve Y17.
6. Return oil to the hydraulic housing.
The valve Y17 is also energised and it allows oil to flow into
7. Piston (the same seals as on the clutch pedal HiShift the valve block cylinder.
piston).
Hydraulic pressure pushes the piston 7 out of the valve
block and by means of the external linkage the PTO ---clutch
disc is moved to the disengaging position. The solenoid
valves are energised as long as the switch S 69 is in this
position (left edge down). In the manual use the PTO clutch
lever is moved to the rear position.
489
Model Code Page
46. PTO---HiShift 600-- 900 461 4
1. 9. 2001
Picture 4. Hydraulic block, engagement
Function when engaging the PTO clutch

By means of the restriction screw (1), the retrun oil flow can
Picture C (fast engagement):
be adjusted and in this way affected the return speed of the
piston (7).
The rocker switch S 69 is pressed to the middle position.
The piston returns slow and the PTO is engaged smoothly.
Both solenoid valves become unenergised. Solenoid valve
Y17 opens an oil way from the cylinder to the tank. Pressu-
re on the piston rod side presses the piston 7 back into the
General about the hydraulic block:
cylinder and the PTO ---clutch disc moves fast to the enga-
ging position.
--- in case of leakage various seals and o---rings are availa-
ble as a spare part. When fitting piston seal KH 3714 speci-
al tool ETV 894 320 can be used.
Picture C1 (slower engagement): --- impurities in oil can block oil ways in the valve and can
cause malfunctions. Large particles can prevent movement
The rocker switch S 69 right edge is held down against a of the solenoid valve spindles or pressure ---limiting valve (2)
spring force. may stick in the open or closed position. The valve can, in
this case, be removed and disassembled and the oil ways
The solenoid valve Y17 becomes energised and it directs can be tried to be cleaned.
oil from the cylinder through valve Y16 (unenergised) and --- external damage can also affect the linkages between
the restriction screw (1) into the tank. the piston and the clutch lever lower end.
490
Model Code Page
46. PTO---HiShift 600-- 900 461 5
1. 9. 2001
Wiring diagram
Picture 5. PTO ---HiShift, electrical connections --- At the same time the control coil of relay K25 is earthed
(via switch S69 pins 8 and 4).
Switch S 69 in the middle position (engagement): --- The relay is functioning and cuts the connection between
the ignition switch pin 4 and the safety switch S12. In this
--- When the ignition is switched on, current is fed into the position, the engine cannot be started.
switch S 69 (pin 3).
--- When the switch is in the middle position, current cannot Note! The PTO clutch lever varning light H13 is earthed
flow forwards from the switch. also via switch S 69, and illuminates when the relay K25 is
--- Solenoid valves Y 16 and Y17 are unenergised and the on. This informs the driver, that the PTO ---clutch disc is re-
PTO ---clutch lever is in the front position (clutch disc enga- leased.
ged).
Switch S69 right edge is held down (slow engagement):

Switch S 69 left edge down (disengagement):
--- Solenoid valve Y17 is energised and steers oil from the
--- Both solenoid valves Y16 and Y17 are energised. The cylinder via the adjustable restriction hole into the tank.
PTO ---clutch disc is released when the clutch lever is pulled
rearwards.
491
Model Code Page
46. PTO---HiShift 600-- 900 461 6
1. 9. 2001
Picture 6. Position of main electrical components
The elctrical system in general:
--- In case of problems, check first fuses FA1, FB5 and --- If the slow engagement has problems, the fault may lie
FD3. In addition, pins inside the rocker switch S 69 can be also in the diodes V6. In case of diode damage, the whole
checked for oxcidation. diode housing is replaced.
--- In case of malfunction, check the solenoid valves Y16 --- Position of various wire connectors and components can
and Y17. The resistance of the valves should be between be found in the picture on page 310/2D. The tractor’s whole
10 ---12 ohms. When the switch S69 left edge is down, both wiring diagram is shown on pages 310/31 ---33.
solenoids must be magnetic and unenergised when the
switch is in the middle position. When the switch right edge
is held down, only valve Y17 is magnetic. IMPORTANT! The engine does not start, if the switch S 69
left edge is down, because the circuit is prevented by relay
K25.
492
Model Code Page
46. PTO (Power take ---off) 205-- 665 462 1
1. 12. 1986
1. Reconditioning PTO (Op. no. 462)
A. Removing PTO (1---speed PTO)
N.B. Once the PTO has been removed the thrust and roller
bearings should be checked. They are located at the end of
the long shaft. The roller bearing should be locked, using Loc-
tite 542, applied only at the outermost edge of the bearing .
Ensure that the locking fluid does not come into contact with
the rollers on the bearing.
Important! On the later tractors the roller bearing has been

locked in the factory. Only check that the bearing is placed
tightly in the boring.
1. Drain the oil from the gearbox. Remove the top link.
6. Remove the PTO shaft end guard plate. Attach a suitable
2. Disconnect the upper ends of the pick ---up hitch lifting links lifting device to the PTO housing and unscrew the attaching
and lower the hitch. bolts.
3. Disconnect the lower end of the pick ---up hitch release cont-
rol. Disconnect the control rod from the selector lever on the
right side of the PTO housing.
7. Pull out the PTO housing straight backwards so that it beco-

mes free from the guide pins.
4. Slacken and remove the nut for the top link bracket (spring). B. Changing bearings at PTO shaft end
Remove the tubular pin from the shaft at the top of the bracket
(impulse transmitter lock) and remove the shaft and its cup
spring. 1. Remove the PTO (Op. A).
N.B. There are shims under the top link bracket spring which
become free when the bracket is removed. When fitting the
bracket the same number of shims must be placed under the
spring.
5. Remove the top link bracket lower shaft in order to free the
top link bracket.
2. Remove the circlip in front of the shaft front bearing.
493
Model Code Page
46. PTO 205-- 665 462 2
1. 12. 1986
7. Position the gear in the PTO housing with the hub facing
rearwards and push the shaft into place through the gear. Tap
the shaft home using sleeve ETV 893 700.
8. Fit the circlip in front of the front bearing. Fit the PTO (Op.
E).
C. Changing bearings at upper shaft
1. Remove the PTO (Op. A) and the PTO shaft end (Op. B,
2 ---4).
3. Tap on the rear end of the shaft using for example a soft
mallet in order to free the shaft from its bearings. The rear bea-
ring remains in the housing.
4. Remove the gear through the opening in the lower part of

the housing.
2. Remove the engaging sleeve (1) and the selector fork (2)
at the front of the shaft. Ensure that the ball (3) and the spring
(4) are not lost.
5. Remove the front bearing using a puller. Fit a new bearing

using sleeve ETV 893 700. Ensure that there is a spacer ring
on the shaft behind the bearing.
3. Remove the circlip from in front of the front bearing.
6. Remove the rear bearing using a puller and fit a new one
using sleeve ETV 893 700. Change the oil seal before fitting
the shaft. Fit a new seal using sleeve ETV 893 700.
494
Model Code Page
46. PTO 205-- 665 462 3
1. 12. 1986
4. Force out the shaft by for example using a 24 mm key. 8. Fit the engaging sleeve at the front end of the shaft with the
hub pointing forwards and at the same time fit the selector fork
on the selector rail. Depress the ball and spring using a screw-
driver.
9. Fit the PTO shaft (Op. B, 7 ---8) and the PTO housing (Op.
E).
D. Changing selector fork/selector shaft
1. Remove the PTO (Op. A).
5. Remove the bearings from the shaft using a puller. 2. Pull the selector fork (2) and the engaging sleeve (1) off the
selector shaft. At the same time ensure that the ball (3) and the
spring (4) are not lost.
N.B. It is easier to free the selector fork if, at the same time, the
selector arm is turned.
6. Fit new bearings using sleeve ETV 892 350.
7. Tap the shaft into the housing using sleeve ETV 892350. Fit
the circlip in front of the front bearing.
3. Unscrew the outer and slacken the inner locking screws for
the selector rail. Pull out the selector rail.
4. Push in the new rail. Fit a new O ---ring on the shaft and lubri-
cate it. Push the shaft into position.
495
Model Code Page
1. 7. 1989
46. Power take ---off 205-- 665 462 4
10. 1. 1992
5. Turn the shaft so that the groove aligns with the inner locking 2. Lift the PTO housing into position and at the same time
screw. Tighten the inner locking screw and lock it with the guide it so that the engaging sleeve engages the PTO clutch
outer locking screw. Apply locking fluid Loctite 222 on the shaft. On the latest models guide the PTO lubricating oil pipe
threads of the outer locking screw. rear end into its hole on the PTO housing.
N.B. If the selector lever is to be changed, the PTO shaft end NOTE: Assembly is made easier by turning the PTO shaft end
must first be removed, before removing the selector lever. or the selector arm (lever).
6. Fit the selector fork and engaging sleeve at the same time. 3. Once the PTO is located on the guide pins, the bolts are
Also check that the inner selector arm (lever) is located in the tightened to 100 Nm (10 pcs, 19 mm) and 195 Nm (M16, 2
hole (socket) in the selector fork. Depress the ball and spring pcs) or 380 Nm (M20, 2 pcs).
using a screwdriver.
4. Connect the lower end of the pick ---up hitch control to the
7. Fit the PTO (Op. E). locking device. Connect the control rod to the selector lever.
5. Fit the top link bracket. Fit the lower shaft first. Fit shims of
the same thickness as before under the top link bracket
spring. Press the top part of the bracket into position and fit the
plate on the bolt.
N.B. The shims are used to adjust the position of the top link
bracket so that the bracket does not move when the impulse
transmitter lock is turned down into its locked position. Shims
are available in the following thickness:
E. Fitting PTO 0,5, 1,0 and 2,0.
1. Clean contact surfaces on the gearbox housing and PTO

housing. Fit a new gasket.
496
Model Code Page
1. 12. 1986
46. Power take ---off 205-- 665 462 5
1. 7. 1989
5. Fit a new seal using sleeve ETV 893 700.
6. Fit the protecting ring in front of the seal. Fit the guard plate
and tighten to a torque of 195 Nm. Fit the PTO cup guard.
7. Fill the gearbox with oil (23 litres).
220 Nm
G. Special instruction
Earlier 305 and 405 models are not equipped with a lubricat-
ing oil pipe for the PTO unit, but this can be fitted if required.
This involves the fitting of a new oil distribution piece in the
6. Fit the upper shaft (impulse transmitted lock) with its cup gearbox and a lubricating oil pipe between the gearbox and
springs in position and fit the tubular pin. Apply locking fluid PTO unit. A hole must be drilled through the PTO housing rear
Loctite 270 to the threads of the screw stud and tighten the nut wall for the rear end of the pipe.
to 220 Nm.
This modification should be carried out if the tractor is often
N.B. Check that the top link bracket cannot move when the
used on sloping ground, with the front end of the tractor lower
impulse transmitter lock is turned downwards into its locked
position. than the rear end.
7. Fit the PTO shaft end guard plate and tighten the bolts to
195 Nm. Fit the PTO cup guard.
8. Lift up the pick ---up hitch and connect the upper ends of the
lifting links.
9. Fill with oil (23 litres). Test---drive the tractor.
F. Changing oil seal at PTO shaft end
1. Drain the oil (23 litres). Remove the PTO shaft end cup
guard and guard plate.
2. Remove the protecting ring in front of the seal. Tap a small

hole in the seal using a centre punch.
3. Carefully screw in a self ---tapping screw or similar in the

hole. Take care not to damage the shaft.
4. Break the seal out of the housing.
497
Model Code Page
15. 9. 1995
46. PTO 365-- 865 462 6
1. 3. 1997
Repair instruction of 2---speed PTO

(without PTO brake)
A. Removing and fitting PTO housing
The 2---speed PTO is removed in the same way as the earlier

unit, see page 462/1 instr. A.
The PTO is fitted as shown in instr. E on page 462/4.
Note! In connection with the 2---speed PTO, there is no ball

and needle bearing inside the PTO clutch shaft rear end. The
clutch shaft rear end guides into the unit upper shaft front end.
B. Changing PTO shaft seal

3. Tap at the PTO shaft rear end until the shaft releases from
See instruction F on page 462/5. its bearings and remove the PTO shaft forwards. The front
bearing remains on the shaft and the rear bearing remains in
its location on the housing.
Note! Take care of the possible spacer ring and shims behind
the PTO shaft front ball bearing, see note on page 460/5.
C. Dismantling PTO
1. Remove the PTO housing, see Op. A.
4. Take the large gear (Z63) out of the housing.
2.Unscrew three ball bearing fixing bolts on the front face of

the PTO unit.
498
Model Code Page
15. 4. 1994
46. PTO 365-- 900 462 7
1. 9. 2001
5. Remove the smaller gear wheel from the housing.
Note! The PTO selector fork and its lever can be removed
without removing the PTO shaft as described above.
6. Unscrew the selector fork rail locking screw on the RH side

of the housing.
7. Push the selector fork rail rearwards and take it out of its
location at which time also the selector fork locking ball and
spring release.
11. Insert an impact puller inside the upper shaft and tap
the shaft forwards until it releases.
Note! The front bearing of the shaft remains on the shaft

and also the front gear wheel (Z18).
12. Take the coupling sleeve and the bigger gear wheel
out of the housing.
13. If the shaft rear bearings have to be changed, remove

them with an impact puller and fit new bearings by using
sleeve ETV 893 700 or use a suitable drift.
8. Turn the selector fork so that the shifter lever ball---shaped Note! The upper shaft rear ball bearing is fitted so that the
end releases from the fork hole. Remove the fork. bearing protective plate is turned forwards (towards the
PTO).
9. Pull the shifter lever outwards and remove it.
14. If you change the shaft front bearings, pull them out
with an extractor and fit new bearings.
Note! Before fitting the upper shaft front bearing, ensure

that the front gear (Z 18) is placed on the shaft.
Important! If the upper shaft must be replaced, always fit a

latest spare shaft, which have three axially machined flat
surfaces for lubrication.
10. Remove the circlip inside the upper shaft front end.
499
Model Code Page
15. 4. 1994
46. PTO 365-- 865 462 8
1. 3. 1997
B. Assembling PTO unit
1. Fit the front gear (Z18) onto the upper shaft and fit the front
bearing fully home, if removed.
2. Push the upper shaft into its location through the front bear-
ing hole and fit inside the housing the coupling sleeve and the
rear gear onto the shaft.
3. Push the shaft in place and tap at its front end until the shaft
rear end is bushed into the rear bearing and the front bearing
into its location.
7. Push in the selector fork rail from the rear so that the rail hole
more chamfered side is turned towards the rail locking screw
hole.
Note! The selector fork rail forces the tool ETV 894 080 out
and the locking ball remains under the selector fork rail.
ETV 894080
4. Fit the circlip inside the shaft.
8. Take the tool ET 894080 out of the housing.
10. Apply locking fluid Loctite 572 to the threads of the rail
locking screw. Ensure that the rail hole is at the locking screw
hole and screw in the screw.
11. Fit the ball bearing onto the front end of the PTO shaft
using sleeve ETV 893 700 (if removed).
5. When the upper shaft is in place, place the selector fork onto Note! Make sure that the PTO shaft rear bearing is in its loca-
the coupling sleeve. Pass the shifter lever into place and fit its
tion fully home. Tap, if necessary, using sleeve ETV 893 700.
round ---shaped end into the hole on the selector fork.
Note! Check/change, if necessary, the shifter lever o---ring

and grease it before fitting the lever.
5. Position the spring into the drilling in the fork.
6. Place the ball onto the spring and push tool ET 894 080 from
the rear into the fork so that the tool chamfered side presses
the ball into place and the tool remains on the ball.
500
Model Code Page
15. 9. 1995
46. PTO 365-- 865 462 9
1. 3. 1997
12. Fit the PTO shaft smaller gear into the housing with the hub 2. Remove spring (4). Unscrew the three fixing bolts for the
longer side turned forwards and then, in front of the smaller bearings. The upper bolt fixes the pivot pin (5) of the brake
gear, the larger gear (Z63) with the longer hub side turned shoe (1). Remove the pin (5).
rearwards.
3. Remove the PTO shaft and its gearwheels, selector fork rail
13. Push the PTO shaft from the front through the gears and and the fork, see instr. C on page 462/6 paragraphs 3---9. Take
tap the shaft into place (ETV 893 700), until it is pushed into care of the steel balls. Remove the upper shaft and the brake
the rear bearing and the front bearing into its location. shoe, see paragraphs 10---14 on page 462/7.
Note! Observe the possible spacer ring and shims behind the B. Assembling
front bearing, see note on page 460/5.
1. Place the foremost gearwheel (Z18) onto the upper shaft
and fit the ball bearing in front of the gear fully home (if remo-
ved).
2. Push the upper shaft into place and place (inside the hou-
sing) the brake shoe, sliding coupler and the rear gearwheel
onto the shaft.
3. Push the upper shaft into place and tap at its front end until
the shaft rear end is pushed through the rear bearing and the
foremost bearing is pushed into its location.
4. Fit the selector fork and its rail, see page 462/8 paragraphs
5---10. Turn the brake shoe into a correct position.
5. Put the PTO shaft gears into the housing. The brake shoe
notch must engage with the big gearwheel. Fit the PTO shaft,
see page 462/8 paragraphs 11---13.
14. Fit the bearing locking bolts and their washers and tighten
the bolts to 80 Nm.
15. Engage the PTO with the selector fork and rotate the PTO
shaft and ensure that the shafts can be rotated easily.
16. Refit the PTO housing according to instruction A.
3. PTO brake 3
Note! Compared with the brakeless PTO unit, the PTO unit
with the brake has a new gearwheel Z63 and a new selector 6. Fit the pin (5) so that it engages with the brake shoe hole.
fork rail. In addition, to the brake. Also the casting of the PTO Fit the bearing fixing bolts (3 off) together with washers. The
housing has been modified.The brake can be retro---fitted washer of the upper bolt must engage with a groove on the pin
onto the earlier tractors, which have a 2---speed PTO unit (fit- (5).
ting kit number is 31972900).
7. Fit the steel ball (3) into the selector fork drilling and fit the
A. Disassembling brake shoe in place so that the shoe notch is engaged with the
big gearwheel and the ball (3) remains under the shoe. Fit the
spring (4) (lower end first). Fit the PTO unit.
1. Remove the PTO unit, see instr. A on page 462/6
501
Model Code Page
46. PTO 205-- 865 462 10
1. 3. 1997
C. Modifikation of PTO brake
With effect from tractor serial number G04305 the function

of the brake has been made more precise by adding an
adjustment for the brake shoe.
Adjust the position of the brake shoe so that the gearwheel

rotates without dragging.
502
51. Service brakes
50. Brake system
52. Parking brake
503
504
Model Code Page
1. 5. 1996
51. Brakes 205-- 900 510 1
1. 1. 1998
Contents

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Brake system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Repair instructions
Service brakes (Op. no. 511)

1. Reconditioning service brakes:
A. Changing brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Changing brake mounting and brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parking brake (Op. no. 512)

A. Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Technical data
Brake type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical control disc brake
running in oil
Number of friction discs per brake:
--- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 pcs
--- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 pcs
Number of intermediate steel discs per brake:
--- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 pcs (660938---; 3 pcs)
--- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 pcs
Friction area, total:
--- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2316 cm2
--- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2950 cm2
Brake disc, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 mm (8.82 in)
Depth of oil grooves in new friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 mm (0.012 in)
Number of balls per brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 pcs
Brake pedal free travel, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 mm (2 in)
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuates the foot brake
mechanically
Note! 205---665: With effect from tractor serial number 660938 the brake discs have been changed to the organic type. At the
same time one steel disc has been added (innermost), since the friction area of the organic discs is greater. The organic discs
require smooth steel discs. The organic brake discs cannot be fitted on the earlier tractors due to lack of space. The application
plate, support plate and the return spring pins have been changed from tractor ser. no. 667467 incl. The new return spring pins
must be fitted in connection with repairs also onto the earlier manufactured tractors (allow greater space for the springs).
Note! The organic brake discs can be fitted in place of the ceramic ones, but the braking surface of the innermost disc is not
entirely in use (if not an additional plate is fitted, which requires machining etc.).
Tightening torques
Gearbox ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm (170 lbf ft)

Cab ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm (162 lbf ft)
Rear wheel nuts, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Nm (243 lbf ft)
Rear wheel nuts, 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm
Check link ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (59 lbf ft)
Lower link bracket---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm (280 lbf ft)
Brake mounting ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (59 lbf ft)
505
Model Code Page
51. Brakes 205-- 865 510 2
1. 12. 1986
Brake system, description
The brakes are multi ---disc brakes running in oil and are fitted
in the final drive housing between the planetary gear and the
differential. The brakes are mechanically controlled by the
brake pedals. The brake pedals can be used latched together
for when transport driving, or individually as steering brakes.
The parking brake actuates the service brakes mechanically.
Fig. 1. Construction of brakes

The brake mechanism consists of six balls which are housed
in the gearbox, application plate, friction discs, intermediate
1. Oil supply for the final drive and the wet---type brakes
discs and support plate nearest to the final drive. There are
2. Ball (6 pcs)
grooves in the application plate for the six balls. When the
3. Application plate
brake is applied, the application plate is turned and the six
4. Friction discs (3 pcs)
balls force the application plate to compress the brake discs.
5. Intermediate discs (2 pcs)
The brake discs are fitted onto splines on the inner drive shaft.
6. Support plate
The intermediate discs are secured to the final drive housing
7. Brake levers
with the aid of the support plate. When the brake is not
8. Transmission housing
applied, the coil springs between the application plate and the
9. Final drive housing
support plate provide a sufficient clearance between the
brake discs.
506
Model Code Page
1. 12. 1986
51. Brakes 205-- 865 510 3
1. 7. 1989
Fig. 2. Brake controls
1. Brake light switch

2. The parking brake switch prevents the connection of the
brake lights when the parking brake is applied
3. Note the position of the pin
4. Adjusting nut for service brakes
5. Adjusting nut for barking brake
NOTE: With effect from ser. no. 610312 a new type RH side
brake rod is fitted. At the same time a new brake mounting has
been fitted onto the RH side rear axle. These modifications
have been made necessary by the new differential lock con-
trol mechanism which has been fitted on the RH side of the
gearbox.
507
Model Code Page
1. 7. 1989
51. Brakes 205-- 865 510 4
15. 9. 1995
Fig 3. Trailer brake valve from ser. no. 610312 incl. (without
priority valve)
1. Brake pedal
2. RH side brake rod
3. Brake cylinder with a bleeding nipple
4. Control pressure to brake valve
5. Brake valve
6. Quick couplings
7. Trailer brake cylinder
8. Hydraulic pump
9. Valve blocks+power lift
10. Hand brake
11. Brake rod
508
Model Code Page
15. 9. 1995
51. Brakes 205-- 865 510 5
1. 9. 2001
Fig. 4. Trailer brake valve (with priority valve)

1. Brake pedal
2. Brake rod
3. Brake cylinder with bleeding nipple
4. Control pressure to brake valve
5. Brake valve
6. Quick couplings
7. Trailer brake cylinder
8. Hydraulic pump
9. Valve blocks+power lift
10. Hand brake
11. Brake rod
12. Priority valve
509
51. Brakes 865, 600-- 900 510 6
1. 9. 2001
Brakes on 865---tractor and 600---900
Picture 5. Brake mechanism on 865. Brake pedals are adjusted in the same way as earlier, see instr.
B on page 511/2.
1. Brake pedals. Can be latched together.
2. Pedal rod Adjusting hand brake, see page 512/2.
3. Brake rods
4. Brake lever Since the brake mechanism on 865---tractor has been
5. Outer brake application ring changed, the rear axle housing should be removed and fitted
6. Inner brake ball ring (new part). according to instruction A on page 451/6 when changing the
7a. Friction disc, 4 pcs brake discs. Otherwise the brake discs are changed in the
7b. Intermediate disc, 3 pcs same manner as shown on page 511/1.
8. Spring support pin
9) Brake support The brake discs on 865---tractors are the same as on Mezzo---
10. Foot brake adjusting screw tractors.
11. Hand brake adjusting screw
510
Model Code Page
51. Brake system 600-- 900 510 7
15. 4. 1999
Pressure air brakes for trailer (option)
Picture 6. Components of pressure air brakes
1. Compressor
2. Deicer
3. Pressure regulator (incl. filter and relief valve).
4. Pressure gauge
5. Pressure air reservoir
6. Drain cock
7. Trailer brake control valve
8. Trailer brake control valve
9. Two ---line system; reservoir line (red)
10. One ---line coupling (black)
11. Two ---line system; brake line (yellow)
Note! Valve (7) controls combined two---line and one ---line

trailer brake system according to the pilot pressure from the
tractor brake pedal.
The valve has additionally a lever, which has been connec-
ted to the hand brake mechanism. When the hand brake
lever is pulled up, the valve lever turns and causes braking
effect in the trailer brakes.
Note! Valve (8) is intended to control the one ---line system.

The valve is controlled by pilot pressure from valve 7.
Valve (8) also limits pressure to the trailer brakes to 5,2 bar.
During braking the valve (8) lowers (in one ---line system)
the trailer brake pressure. When the braking is stopped air
can flow via valve (8) to refill the air reservoir of the trailer
brake.
511
Model Code Page
51. Brake system 600-- 900 510 8
15. 4. 1999
Pressure air brakes for trailer (option)
1: Compressor
3: Pressure regulator
4: Pressure gauge
5: Pressure air reservoir
7: Control valve (one and two line system)
8: Control valve (one line system)
General
The trailer is connected in the two---line system to two cou- If the outdoor temperature is below +5°C, eythol alcohol
plings. The couplings (9, 10, 11) have been marked as fol- or methanol must be used in the deicer (2) . Antifreeze
lows: agent flow valve lever (B) must then be open (position 1).
--- Reservoir line --- red protecting cover Reservoir (5) and lever (B) are placed in front of the cab on
--- Brake line --- yellow protecting cover the LH side.
--- In the one ---line system the trailer is connected to the NOTE! In the system there must be full pressure, about
black (brake line) coupling (in certain marketing areas). 7---8 bar, before driving the tractor. Pressure gauge (4) is
placed in the cab beside the dashboard.
By turning connection (A) on the pressure regulator (3) to When connecting in the two---line system trailer to tractor,
the bottom, compressed air can be taken off for auxiliary connect first the trailer yellow coupling (without pressure).
purposes (pressure about 8 bar, e.g. for tyre inflation). Thro- When disconnecting the trailer, disconnect first the red cou-
ugh this connection the system can also be filled with auxi- pling (reservoir line).
liary compressed air, e.g. if the tractor compressor does not
function. In this case the connection (A) need not be scre-
wed fully into the bottom.
When the trailer brake quick couplings (9, 10, 11) are not in
use, the protective caps must be correctly placed on the
couplings.
512
Model Code Page
1. 12. 1986
51. Brakes 205-- 865 511 1
15. 9. 1995
Repair instructions
Service brakes (Op. no. 511)
1. Reconditioning brakes
There are grooves on the ceramic friction surfaces of the

brake discs. The depth of these grooves is 0,3 mm (0.012 in)
when the ceramic discs are new. When these grooves
become shallow, the oil cannot pass through the friction discs
and this results in impaired brake action. If the brake discs are
worn they should be changed.
A. Changing brakes
3. Pull the friction and intermediate discs off the shaft.
4. Check the surfaces of the support plate and the application

plate and remove dirt and uneven spots using an emery cloth.
5. Fit new friction and intermediate discs alternately (friction

discs first and last).
Important! See note on page 510/1.
6. Fit the springs onto the application plate attaching lugs and
fit the plate onto the springs.
1. Remove the final drive (Op. no. 451 1A).
2. Remove the circlips and washers from the application plate

attaching lugs and pull out the application plate. Remove the
springs from the lugs.
7. Push the application plate against the discs and fit the
washers and circlips on the lugs.
8. Fit the final drive (Op. no. 451 1E) and adjust the brakes
(Op. B).
N.B. The brake application balls, (6 pcs) which are positioned

in both sides of the differential housing, can be removed from
their drillings with the aid of compressed air. Seats are fitted
behind the application balls.
513
Model Code Page
51. Brakes 205-- 865 511 2
1. 12. 1986
B. Adjusting brakes
1. The brake pedal free travel should be 50 mm (2 in) when

the pedals are latched together.
2. Raise the rear end of the tractor off the ground and adjust
both brakes separately by turning the adjustment nut until the
wheel can no longer be rotated (see Fig. 2).
3. Then slacken the nut one turn and check that the wheel
again rotates freely. Check the pedal free travel and if necess-
ary adjust using the nuts.
4. Check for even brake action by driving with the pedals

latched together and then applying the brakes. Again check
the brake pedal free travel and adjust the parking brake (Op.
no. 512 A).
C. Changing brake mounting and brake

lever
1. Change the rubber protections by disconnecting the brake

rods from the levers (19 mm) and the protections from the
retainers (13 mm). Tightening torque 23 Nm (17 lbf ft).
2. When changing the brake mountings, the mounting attach-

ing bolts must be removed. When changing the RH side
mounting, the differential lock control must be disconnected
on the earlier tractors and when assembling the control must
be adjusted (see Op. no. 424 1 D).
N.B. When fitting the brake lever, check that the brake lever
engages the groove of the mounting and that the stud of the
application plate engages the hole on the lever.
3. Adjust the brakes (Op. 1 B).
514
Model Code Page
51. Brake system 600-- 900 511 3
15. 4. 1999
2. Pressure air brakes for trailer (option)
1: Compressor
3: Pressure regulator
4: Pressure gauge
5: Pressure air reservoir
7: Control valve (one and two line system)
8: Control valve (one line system)
A. Maintenance
Weekly maintenance
General Check the mounting of the compressor. Check/adjust the
The pressure reservoir must not be welded or drilled. compressor belt tightness by adjusting the tension pulley.
In the system there is a filter, which is placed in the pres- Maintenance at intervals of 250 running hours
sure regulator. The filter must be cleaned/changed periodi-
cally (depending on use). The filter can be removed by Grease the quick coupling rubber surfaces (9, 10, 11).
removing the tyre filling connection (A) on the pressure Check the tightness of the system. The system must be so
regulator (3). tight that the pressure drop after the engine stop is max.
The pressure regulator has an in ---built relief valve, which 0,15 bar during 10 minutes (2%).
blows off, when the pressure in the reservoir exceeds
12---14 bar. This can be caused by e.g. faulty relief valve, Others
icing or blocking filter.
If the hoses or hose unions have leakages, new parts are
Daily maintenance available as a spare part. Other components of the pres-
sure air system must be changed as a complete unit since
no separate spare parts are available.
Condensed water must be drained from the system daily
by pressing or pulling the pin of the draining tap (6) under
the air reservoir.
515
Model Code Page
51. Brake system 600-- 900 511 4
15. 4. 1999
B. Compressor for pressure air brakes C. Pressure regulator
Air from compressor flows in through port 1. Air flows then

via strainer 2, opens one ---way valve 3, and flows through
port 4 into reservoir.
Picture 1 Compressor
1. Compressor draws air from the engine air intake system

2. Compressor
3. Pressure air into pressure regulator
4. Tension pulley
5. Compressor requires extra belt pulley (+hub piece)
6. Lubricating oil from engine
7. Return oil into engine
8. Preessure plates
9. Suction plate
Compressor . . . . . . . . . . . . . . . . . . . Knorr LK1311

Displacement . . . . . . . . . . . . . . . . . . 110 cm3
Output (2300 1/min, with 7 bar
counter pressure) . . . . . . . . . . . . . . 220 l/min
Power consum. (2300 1/min, 7 bar) 1,8 kW
Lubrication . . . . . . . . . . . . . . . . . . . . Engine lub. circuit
Cooling . . . . . . . . . . . . . . . . . . . . . . . Air cooling
Note! On 3--- and 4---cylinder engines (without air condi-

As soon as pressure in the reservoir is greater than spring
tioning/electric stop) the compressor is fitted on the LH side
force 11 (ca. 8 bar), membrane 5 distorts and piston 6
of the engine. moves upwards. At the same time rubber collar round the
If the tractor is retrofitted with the air conditioning/electric
piston closes port in the piston and opens a passage to the
stop, the compressor is fitted on the RH side of the engine. upper part of piston 7.
If fitted with pressure air brakes+air conditioning the com- Pressure moves piston 7 downwards against spring 9, and
pressor is driven by two belts.
air from compressor to port 1 blows off via port 8 to
atmosphere.
Note! It is possible to adjust the working pressure with the

adjusting screw of spring 11. When the screw is turned
outwards, working pressure lowers and vice versa.
516
Model Code Page
51. Brake system 600-- 900 511 5
15. 4. 1999
D. Control valve of one ---line system E. Control valve for trailer brakes
(One --- and two---line systems)
The valve controls the trailer braking. Depressing the brake
A pedals or using the parking brake causes the valve body to

turn which causes the braking effect in the trailer brakes.
Function:
Fig. A (not braking)
Spring 5 holds membrane+sleeve 6 up. Upper end of

valve spindle 8 has opened passage from inlet port 1 to
trailer brake port 2. Pressure air flows from tractor reservoir
via ports 1 and 2 to the trailer brakes.
Simultaneously in port 2 pressure acts on the underside of
piston 1.
C
Picture A. Neutral position, brakes are not used:
The trailer brake line from port ”A” is connected to atmosp-
here via the internal part of valve 2 and via air exhaust val-
ve 4. Valve 2 prevents pressure air from flowing from reser-
voir ”V” into the trailer brakes.
Function, fig. C (when braking):
When depressing the brake pedal pilot pressure from the

trailer control valve port 4. Pressure affects the upper part
of membrane 7, and moves the membrane and sleeve 6
downwards against spring 5. Passage from port 2 to
sleeve 6 internal hole opens.
Pressure flows from port 2 via sleeve 6 and cover hole 3 to
atmosphere to give quick pressure drop for trailer pre ---bra-
king.
The pressure drop causes an action of trailer brake valve in
one ---line system. Picture B. When depressing the brake pedals, the valve
body is turned anti ---clockwise (lever 5 moves down). Push
NOTE! During braking replacing air does not flow into the rod 6 moves downwards and guide piece 1 closes passa-
trailer brake system. ge through the valve (2) into atmosphere.
When further depressing the brake pedals valve (2) moves
--- The one ---line system working pressure (5,2 bar) is lower downwards and opens passage from port ”V” to port ”A” to
than that in the two---line system. Control valve lowers the
the trailer brakes.
system pressure from 7 bar to 5 bar. Contrary to the two---
line system coupling (yellow), the black coupling of the
one ---line system is under pressure when not braking.
The control valve does not require maintenance.
517
Model Code Page
51. Brake system 600-- 900 511 6
15. 4. 1999
Picture C. Increasing pressure in port ”A” loads piston 7,

which moves downwards against the spring force and clo-
ses port to connection ”V” so that pressure air cannot flow
forwards. The control valve is now in the final position.
When braking force is still increased, the full reservoir pres-
sure flows into the trailer brakes.
--- When the brakes are released, the push rod 6 moves
upwards and opens passage from port ”A” to atmosphere
4.
The pressure drops in the trailer brake line: When pressure
lowers in port ”A” , piston 7 rises up to the starting position.
--- Relative weak force activates the control valve. That is
why the trailer brakes function a little earlier that tractor
brakes.
This function order prevents trailer pushing and turning
during braking.
7a) The spring protects the valve, when it is turning.
Adjusting pre ---braking: spring (7a) in the upper hole

(longer movement) = trailer brakes faster.
Spring in the lowest hole (shorter movement) = the trailer
brakes slower than the tractor.
Checking the pressure air system:
Not braking with pedals or hand brake lever Full braking with pedals or hand
brake lever
Reservoir line (red) 6,0 --- 8,0 bar 6,0 --- 8,0 bar
Brake line (black) 4,8 --- 5,6 bar 0

Brake line (yellow) 0 6,2 --- 7,5 bar
518
51. Brakes 205-- 665 512 1
1. 5. 1996
Parking brake (Op. no. 512)
A. Adjusting parking brake on 205---665
1. Adjusting nut
2. The parking brake switch prevents the connection of the
brake lights when the parking brake is applied
1. When the parking brake is not applied, the clearance

between the lever and the adjusting nut should be 5 ---10 mm.
Adjust the clearance with the adjusting nut.
519
Model Code Page
1. 3. 1997
51. Brakes 865, 600-- 900 512 2
15. 4. 1999
B. Adjusting parking brake on 865 and

600---900 tractors
Picture 6. Brake system on 865 and 600---900 tractors

1. Brake light switch S13
2. Hand brake switch S18
3. Tension pin
4. Brake pedal adjusting nut (on both sides)
5. Hand brake adjusting nut
1. Before adjustment, release the parking brake by pushing

the hand level to the lowest position.
2. Adjust the distance between the support iron and the

adjusting screw (5) to 3---7 mm. Secure the adjusting nut with
the locking nut.
Note! The brake pedal adjustment affect the hand brake

adjustment. Before the hand brake adjustment it is recom-
mended, that the brake pedals are adjusted.
520
60. Front axle and 61. Steering system
steering system
62. Front axle, 2WD
63. Front axles, industrial

tractors
64 Powered front axle ZF
64. Powered front axle Sige
521
522
Model Code Page
1. 5. 1996
61. Steering system 205 -- 900 610 1
1. 9. 2001
Contents
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Equipment for checking oil pressure in steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering system, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering cylinders, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering valve, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair instructions
Steering valve (Op. no. 611)

1. Reconditioning steering valve:
A. Removing steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking pressure ---limiting valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Checking shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Changing/cleaning pressure ---limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F. Adjusting shock valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G. Cleaning/changing shock valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering cylinders (Op. no. 613)

1. Reconditioning steering cylinder, powered front axle:
A. Changing seals in steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Measuring clearance between cylinder barrel and end pieces . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Assembling steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Reconditioning steering cylinder, non ---powered front axle:

A. Dismantling steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Assembling steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical data
Note! From ser. no. K26106 the Sauer pump (13+10) has been changed into Bosch ---pump (11+11) (with priority valve) or
from ser. no. K47331 (without priority valve) Sauer 16+12---pump has been changed to Bosch 16+14 pump.
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic

Steering valve up to cab no 54623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF ---Servostat 2
Steering valve from cab no 54624 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbitrol OSPC---100
Steering cylinder, non ---powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double ---acting special cylinder
Steering cylinder, powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double ---acting plunger piston
type
Steering system oil pump (Sauer or Bosch pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Pump capacity/revolution, ---K47330 without priority valve// with priority valve combined
capacity , ---K26105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 cm3/r // 23 cm3/r
Pump capacity/revolution, K47331--- without priority valve // with priority valve combined
capacity , K26106--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 cm3/r // 22 cm3/r
Pump capacity per minute:
--- without priority valve, ---K47330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 litres / 2350 r/min
--- without priority valve, K47331--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 litres / 2270 r/min
--- with priority valve combined capacity, ---K26105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 litres / 2350 r/min
--- with priority valve combined capacity, K26105--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 litres / 2270 r/min
Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MPa
Pressure ---limiting valve, opening pressure at 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---10 MPa
Shock valve, opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---17 MPa
Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washable metal gauze filter
Suction filter, degree of filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 μm
Number of steering wheel revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,6 revolutions
Oil
(The oil is common to both steering and working hydraulics)
Oil capacity, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 litres
Capacity when changing oil, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 litres
Viscosity and quality, see page 120/4
Tightening torques
Non ---powered front axle:
Clamping bolt, steering arm ---piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Front axle member ---steering cylinder:
--- cone nut M12, 1 pc (---600704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm
523
Model Code Page
1. 9. 1992
61. Steering system 205-- 865 610 2
15. 9. 1995
--- screw M12, 2 pcs (---600704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm

--- screw M16, 3 pcs (600705---) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
Cylinder ends---cylinder frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
Oil hoses to steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Powered front axle ZF:

End piece ---cylinder frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Oil hoses to steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Stop for steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Steering valve ZF (up to cab no 54623):

Steering valve attaching bolts, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
Steering valve bolts, housing halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Nm
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Pressure ---limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Unions on right---hand side of engine for steering hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

Hose union at oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm
Hose union at steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Oil hose at pump for steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Equipment for checking oil pressure in steering system
1. Checking opening pressure of pressure ---limiting valve (9---10 MPa). Pressure test kit 31965000 includes these parts.
2. Checking opening pressure, shock valve (15---17 MPa). Pressure test kit 31965000 includes these parts (not hand pump).
524
Model Code Page
1. 12. 1986
15. 9. 1995
Special tools
Steering cylinder B (non ---powered front axle)

ETV 892 380 Sleeve for removing bearing sleeve and seal from steering cylinder (Gearbox 505---905)
(ETV 893 630) Plate for fitting scraper seal, seal and bearing sleeve in steering cylinder (see Gearbox)
ETV 893 630
ETV 892 380
525
Model Code Page
1. 12. 1986
1. 7. 1989
Steering system, general
The tractor is fitted with a hydrostatic steering system which

means that the steering wheel movements are transmitted to
the front wheels by oil under pressure. This provides a steer-
ing system which is easy to handle.
Should the oil pressure fail for some reason, e.g. when the en-
gine stops, the tractor can still be steered. The steering valve
then acts as a pump, but a considerably greater effort is re-
quired for turning the steering wheel.
Fig. 1. Steering system on the 305---455 tractors (a non ---powered front axle is shown)
1. Gear ---type oil pump

2. Suction pipe from hydraulic housing
3. Steering valve
4. Steering cylinder
5. Steering system return oil pipe to hydraulic housing
6. Suction strainer
526
Model Code Page
1. 12. 1986
1. 7. 1989
The gear ---type pump on the right---hand side of the engine turned, the steering valve allows the oil to circulate back to the
(front pump for working hydraulics, rear pump for steering hy- hydraulic housing. The return oil from the steering cylinder is
draulics) draws oil from the hydraulic housing via the suction conducted through the steering valve (3) and through the re-
strainer (6) through the suction pipes (2). The gear ---type turn pipe back to the hydraulic housing.
pump (1) for the steering hydraulics supplies the oil to the
steering valve (3). If the tractor is provided with an extra lifting cylinder, the hose
from the piston rod end of the lifting cylinder has been con-
The steering valve directs the oil flow to either end of the steer- nected to the rear connection on the return oil pipe. This
ing cylinder (4) depending on the direction in which the steer- means that the return oil flow aids the hydraulic lift when
ing wheel is turned. If the steering wheel is not lowering.
Steering cylinders, description

Non-- powered front axle
The steering cylinder is a double ---acting special cylinder. The
piston rod acts as a piston and there are only seals round the
piston rod. The steering arm is secured to the centre of the pis- The steering cylinder is secured to the front axle member with
ton rod. The track rods, in their turn, are secured to the steer- a tapered nut and two bolts. The front bolts are provided with
ing arm. This design provides for an ample steering force lock washers.
even close to the full steering lock positions.
Fig. 2. Steering cylinder for non ---powered front axle

1. Screw studs secured with Loctite 222
2. The bearing sleeve is provided with a groove which should
be facing upwards.
3. Check that there is a clearance between the bearing sleeve
and the seal
4. Cylinder frame
5. Cylinder ends
6. Piston (=piston rod)
7. Steering arm
527
Model Code Page
1. 12. 1986
15. 9. 1995
Steering cylinder, ZF ---axle
The steering cylinder is fitted at the back of the front axle The distance between the mating surfaces on the cylinder
barrel and the end pieces are adjusted with shims in order to
member where it is protected from external damage.
be able to adjust the clearance to zero. (Shims are available
in thicknesses between 0.9 ---1.8 mm (0,035 ---0.071 in), Fig.
The piston is fitted at the centre of the piston rod which runs
3).
through both ends of the cylinder. There are seals on the pis-
ton against the cylinder barrel and in both end pieces against
the piston rod. The tie ---rods are connected directly to the pis- The steering lock can be adjusted with stops fitted at the pis-
ton rod ends. The steering lock stops, which are fitted as stan-
ton rod ends. In this way steering movements are transmitted
dard, are set to give a steering lock of 50˚. By turning the stops
symmetrically via the tie rods to the steering arms and there
is an ample steering force even close to the full---lock posi- the steering lock can be limited to 45˚, as extra equipment, the
front axle can be fitted with stops which further reduce the
tions.
steering lock to 37˚.
Fig. 3. Steering cylinder on powered front axle ZF
1. The tie rods are secured by upsetting the edge

2. Secured by applying Loctite 242 to the threads
3. End piece
4. Piston
5. Piston rod
6. Cylinder barrel
NOTE! Steering cylinder on Sige ---axle, see page 640A/7

and pages 613/7 ---9.
528
Model Code Page
61. Steering system 205-- 865 610 6A
15. 4. 1994
Hydraulic system with priority valve
Picture 3a. Alternative hydraulic system. Priority valve is the same as on 6000---8400 tractors, Danfoss
OLS 80.
1. Twin pump with combined output.
2. Oil cooler. Tractors, which have a priority valve, the steering valve is diffe-
3. Priority valve. rent. The steering valve has then five hose connectors. The
5th connector is for the LS line (Load Sensing) to the priroty
In this alternative hydraulic system the twin pump outputs valve. The steering valve revolution volume, however, is the
have been combined and the total pump output is then 55 same as earlier.
dm3/min at engine speed of 2350 r/min (pump revolution
volume is 12,8+10,3 cm3/r). The working pressures are the
same as earlier.
The priority valve ensures that there is always enough oil for
the steering system even if the working hydraulics are used
at the same time.
Auxiliary hydraulics must not be connected before the priority
valve, because the steering system does not function when
this auxiliary hydraulics are used.
529
Model Code Page
61. Steering system 205-- 865 610 6B
15. 4. 1994
1
2
6
5
4
3
EF CF
LS
P
EF CF
LS
P
Picture 3b. Priority valve --- The priority valve is located on the RH side of the tractor
1. Plug beside the pressure filter.
2. Sealing ring
3. Connector nut The priority valve directs oil both to the steering system (port
4. Sealing ring CF) and to the working hydraulics (port EF).
5. Spring
6. Valve spool The valve gives a priority to the steering system. This means
that there is always enough oil supply to the steering system
CF=to steering valve regardless of loading of the hydraulic power lift or the auxiliary
EF=to working hydraulics hydraulic. When the steering wheel is not turned, the whole
P=pressure from pump combined pump output is available for the working hydrau-
LS=load sensing line. When the steering wheel is turned, the lics.
LS hose is pressurised and the priority valve spool is moved
so that oil is directed to the steering valve and vice versa.
530
Model Code Page
61. Steering system 600-- 900 610 6C
1. 1. 1998
Picture 3c. Steering system on 600---900 tractors with prio-

rity valve.
On 600---900 tractors the pump pressure pipes have been

connected together on the pump. In addition, the oil cooler
pipes have been bent in a different way (steering valve
OSPC 100LS).
531
Model Code Page
61. Steering system 600-- 700 610 6D
1. 1. 1998
Picture 3d. Alternative steering system on 600---700 trac-

tors without priority valve (steering valve OSPC 100ON).
532
Model Code Page
1. 12. 1986
1. 9. 1992
Steering valve ZF, description

(up to cab no 54623)
7
8
9
10
1
11
2
12
3 13
5
14
6
15
16
17
18
Fig. 4. Section of ZF steering valve

10. Valve housing
1. Pressure ---limiting valve 11. Shut---off valve
2. Metering unit (rotor set) 12. Valve sleeve
3. Rotor 13. Steering wheel column
4. Pivoted shaft 14. Pivoted shaft with centring spring
5. Shock valve 15. Valve for emergency steering
6. anti ---cavitation valve 16. Shock valve
7. Oil reservoir 17. Anti ---cavitation valve
8. Oil pump 18. Steering cylinder
9. Non ---return valve
533
Model Code Page
1. 12. 1986
1. 9. 1992
Construction of steering valve ZF Valves within the steering valve
--- Pressure ---limiting valve (1) limits the working pressure in

The metering unit (or rotor set) is a gear ---type rotor pump. A the steering system.
rotor (3) with six external teeth rotates inside the stator (2)
which has seven internal teeth. A compression space is --- Shock valves (5, 16) takes up any shocks transmitted from
formed between these two sets of teeth profiles. The rotor set the steering cylinder.
requires a flow distributor which rotates synchronously with
the rotor, as the parting line which separates the suction and --- Anti ---cavitation valves (6, 17) are both positioned in separ-
the pressure sides rotates with the planetary movement of the ate passages and they counteract cavitation in the steering
rotor. system.
The flow distribution is achieved with the aid of the turning --- Non ---return valve (9) prevents the return flow of oil when
movement of the sleeve (12) which rotates synchronously the pump is not working.
with the rotor.
--- Shut---off valve (11) prevents the return of the front wheels
The measuring unit supplies an amount of oil, delivered by the when the steering wheel is not actuated.
pump (8), in proportion to the turning of the steering wheel.
--- Valve for emergency steering function (15). Through this
The steering valve consists of a housing (10) with drilled pass- valve the rotor can draw oil without the aid of the pump.
ages. The sleeve (12) inside the valve housing can be turned,
but it is also axially moveable.
Working principal of steering valve
The outside of the valve sleeve has axial and radial grooves.
These correspond to similar grooves on the inside of the valve
When the steering wheel is turned anti ---clockwise the valve
housing.
sleeve (12) moves to the left allowing oil under pressure from
the pump (8) to flow via the flow distributor to the inlet side of
The turning movement of the steering wheel is transmitted
the rotor set (2, 3).
through the steering column, the pivoted shaft (14) with
centering springs and the pivoted shaft (4) to the rotor set (2,
The rotor set directs the oil flow (red), which is proportional to
3).
the movement of the steering wheel, through the outlet pass-
age via the flow distributor to the piston rod side (18) of the
The valve sleeve (12) is on the one hand, connected to the
steering cylinder.
rotor (3) through the upper end of the pivoted shaft (4), and
on the other hand it is connected to the steering column (13)
The piston in the steering cylinder moves towards the left. The
and the pivoted shaft (14) through three internal lugs which
piston side of the steering cylinder is connected to the return
move in a helically cut groove on the pivoted shaft (14). These
line via the grooves on the outside of the valve sleeve.
lugs cause the valve sleeve (12) to move axially.
When the steering wheel is released, the valve sleeve (12) is
The centering springs allow for a small movement between
returned to neutral, thus opening the return passages on
the steering column and the valve slide. This movement dis-
either side of the delivery passage.
places the valve slide axially in the housing. In the figure, the
valve slide has been moved to the left from the neutral posi-
tion.
The axial movement of the valve slide affects the working

pressure. The radial movement, depending on which way the
steering wheel is turned, affects the flow distribution of the
rotor set.
The rotor set and the valve sleeve are within the same space
which is under pump pressure, thus reducing internal leak-
age. Round the steering column there is a slide ring seal
which is under constant pressure. Above this seal there is a
space which is connected to the return line. The upper end
of this space is sealed by a combined lip and dust seal.
534
Model Code Page
1. 9. 1992
Steering valve Orbitrol OSPC---100 (from cab no 54624)
6
2 3
10
1
4
12
11
Figure 5. Steering valve
1. Shock valve (2 pcs, 19,5 MPa) 7. Inner valve spool

2. Non ---return valve 8. Outer valve spool
3. Non ---return valve for emergency steering 9. Rotor shaft
4. Rotor ring 10. Centring springs
5. Rotor 11. Pressure ---limiting valve (14 MPa)
6. Valve housing 12. Anti ---cavitation valves (2 pcs)
535
Model Code Page
61. Steering system 355-- 865 610 10
1. 9. 1992
Steering valve, description (Danfoss valve) A
See figure 5 on previous page.
The steering valve consists of a metering unit (rotor set) and

a valve unit. The rotor set consists of a rotor ring (4) with seven
internal teeth and a rotor (5) with six external teeth. The valve
unit consists of a valve housing (6), outer valve slide (8) and
inner valve slide (7).
The inner slide (7) is directly actuated by the steering wheel.

The outer valve slide (8) is mechanically connected to the
rotor (5) by a cross pin and rotor shaft (9). The cross pin which
runs through both valve slides permits the inner valve slide to
move 8˚ in both directions independent of the outer valve
slide.
When the steering wheel is in the rest position, centring

springs keep the inner and the outer valve slides in neutral (in
relation to each other) and the oil flows freely through the
steering valve. The passages to the steering cylinder are kept
closed and the steering cylinder cannot move.
Figure 6. Steering valve lower face
When the steering wheel is turned, the inner valve slide is A. Anti ---cavitation valves
turned in relation to the outer valve slide. The neutral---position
passages become restricted at the same time the passages
down to the measuring unit and on to the steering cylinder B
gradually open. Simultaneously the return oil from the other
side of the steering cylinder flows back via the steering valve.
The oil flow from the pump through the valve makes the rotor
and the outer valve slide turn in the same direction as the
steering wheel and the inner valve slide.
When the steering wheel is not turned any further and kept
still, the centring springs bring the outer and the inner valve
slide back into the neutral position The passages to the steer-
ing cylinder close and the oil flows freely again through the
steering valve.
When the hydraulic pump does not supply any oil, the meter-
ing unit of the steering valve acts as a manually powered
pump. The oil which is drawn from the steering cylinder and
the return line via the non ---return valve (3) is delivered to the
other side of the steering cylinder when the steering wheel
(and inner valve slide 7) is turned 8˚. The cross pin then also
makes the following parts turn: the outer valve slide (8), rotor
shaft (9) and rotor (5). Shocks and knocks against the steering
wheel are dampened by the two shock valves (1) which are
fitted in the steering valve.
C
The shock valves are combined with anti ---cavitation valves Figure 7. Steering valve upper face
(point A in figure 5) in order to keep the cylinder fully supplied B. Shock valves
with oil at all times. C. Pressure ---limiting valve
536
61. Steering system 205 -- 865 611 1
1. 9. 1992
Steering valve (Op. no. 611)
Note! This instruction concerns both ZF and Danfoss steering

valve. Follow notes in text below.
1. Reconditioning steering valve
A. Removing steering valve
1. Remove the knob from the stop/hand throttle control (13

mm) and the rubber grommet for the control (later type
models have a stop control in the instrumrnt panel).
5. Remove the steering valve.
B. Fitting steering valve
1. Fit the steering valve attaching bolts, rubber damber and

washers (fix the lowermost washers with a quick ---acting
glue).
2. Remove the guard plate under the instrument panel (at the
same time disconnect the heater hoses from the nozzles).
2. Fit the valve and tighten the bolts (13 mm, 20 Nm (15 lbf ft))
and secure with the tab washer.
3. Connect the oil hoses to the steering valve (22 and 24 mm,
45 Nm (33 lbf ft)). secure the flasher relay if it was removed
earlier.
4. Fit the guard plate under the instrument panel and connect
the heater hoses to their respective nozzles.
3. Disconnect the oil hoses from the steering valve (delivery 5. Fit the stop control rubber grommet and the knob (13 mm).
and return hoses (22 mm) and the hoses to the steering cylin-
der (24 mm)). 6. Check the oil level in the hydraulic housing and top up with
hydraulic oil if necessary. Start the engine and check that the
N.B. If the flasher relay is removed it will be easier to remove system works.
the steering valve.
4. Undo the lock washers and remove the steering valve

attaching bolts (13 mm). Take care not to damage the electri-
cal leads.
537
Model Code Page
1. 12. 1986
1. 9. 1992
C. Checking pressure ---limiting valve D. Checking shock valve opening pres-

opening pressure sure
1. Remove the engine hood upper side plate on the right--- 1. Remove the upper, right engine hood side plate.
hand side.
2. Disconnect the union on one of the hoses to the steering
cylinder. connect the pressure gauge and a hand pump to the
hose (measuring equipment, see page 610/2 point 2).
2. Unscrew the hose union (22 mm) on the oil hose to the
steering cylinder.
3. Fit the gauge using the necessary union and adapters 3. Pump up the pressure leading into the steering valve and
(measuring equipment, see page 610/2 point 1). read off the pressure when the shock valve opens. compare
with the opening pressure given in the Technical Data.
If the measuring equipment is not used, use a union with
3/4---16 inch thread and a tapered sealing surface equivalent N.B. The hand pump does not provide an even pressure so
to JIC 37˚. that after each pumping movement, the pressure on the
gauge drops due to internal leakage in the steering valve. It
is better to use a pump that provides a steady pressure.
4. Start the engine and set the hand throttle to approx. 1500
rpm. Turn the steering wheel to full lock and read off the open-
ing pressure. If the reading deviates from the value in the If the measuring equipment is not used, use a union or an
Technical Data, the pressure ---limiting valve must be cleaned adapter which has 3/4---16 inch thread and a tapered sealing
or changed (see under heading E (ZF) or H (Danfoss)). surface corresponding to JIC 37˚. Connect a gauge as close
to the steering valve as possible to prevent the pressure drop
5. Remove the gauge and connect the steering hose (22 mm, in the hoses from affecting the result of the pressure check.
45 Nm (33 lbf ft)). Fit the engine hood plate.
4. Slacken the hose union on the other oil hose and check the
opening pressure of the other shock valve. If the reading devi-
ates from the value given in the Technical Data, the shock
valves should be adjusted (see under heading F (ZF) or H
(Danfoss)).
5. Remove the measuring equipment and connect the oil

hoses (22 mm, 45 Nm (33 lbf ft)). Fit the engine hood plate.
538
Model Code Page
1. 12. 1986
1. 9. 1992
E. Cleaning/changing pressure ---limiting 5. Fit the pressure ---limiting valve (8 mm, socket head, 30 Nm
(22 lbf ft)) and secure the steering valve (13 mm, 20 Nm (15
valve (ZF steering valve) lbf ft)).
1. Loosen the steering valve, but do not disconnect the oil
6. Check the pressure ---limiting valve opening pressure (see
hoses from the valve (see under heading A 1 ---4). Slightly pull under heading C). If the opening pressure deviates from the
the valve out from its place. value given in the Technical Data, the pressure ---limiting valve
must be changed.
7. Fit the steering valve (see under heading B).
F. Adjusting shock valves (ZF steering

valve)
1. Loosen the steering valve, but do not disconnect the oil

hoses from the valve (see under heading A 1 ---4). Slightly pull
the valve out from its place.
2. Unscrew the pressure ---limiting valve (8 mm, socket head).
2. Remove the protective plug by the shock valve adjusting

screw and turn the screw (5 mm, socket head) in the desired
direction.
N.B. A 1/4 of a turn on the screw corresponds to a difference

in the opening pressure of approx. 3 MPa (435 psi).
3. Clean the pressure ---limiting valve, using compressed air.
3. Check the opening pressure (see under heading D) and if
necessary adjust. fit the protective plug on the adjusting
screw.
4. The other shock valve is adjusted in the same way.
G. Cleaning/changing shock valves (ZF

steering valve)
1. Remove the steering valve (see under heading A).
4. Remove the oil filter (14 mm) between the oil hoses at the
side of the valve. Clean the filter, fit it and tighten to 12 Nm (9
lbf ft).
539
Model Code Page
1. 12. 1986
1. 9. 1992
3 b) If a new shock valve is fitted: fit the set of springs, valve

ball and valve cone in the valve bore (check the o---rings on
the valve cone). Screw in the valve until the end of the valve
is flush with the face of the valve housing. Carry out the same
procedure with the other shock valve.
4. fit the steering valve and connect the oil hoses to the valve
(45 Nm (33 lbf ft)). Check the shock valve opening pressure
(see under heading D) and if necessary adjust (see under
heading F 2 ---4).
2. Remove the shock valve screw (5 mm, socket head).

Remove the valve ball and the set of valve springs from the
valve bore.
N.B. If the same shock valve is to be fitted again, the valve

screw and valve housing must be marked and the distance
between the top of the adjusting screw and the top face of the
valve housing must be measured to facilitate assembling.
3 a) If the same shock valve is refitted: clean the valve and fit
the spring set, valve ball and valve cone in the valve bore
(check the o---rings on the valve cone). Screw in the valve to
the same depth as before the valve was removed.
540
Model Code Page
1. 9. 1992
15. 4. 1994
H. Cleaning shock valves and pressure --- 6. Fit the valve ball, washer and the spring.
limiting valve (Danfoss valve) 7. Apply a little locking fluid to the threads on the adjusting
screw. Screw in the screw to the depth as measured in para-
1. Remove the steering valve (see instr D). Secure the valve graph 3.
in a vice with soft jaws.
8. Fit the sealing ring and the valve plug and tighten to a torque
Note! There are two shock valves in the steering unit. Both of 40 ---60 Nm.
valves are similar.
9. Unscrew the pressure ---limiting valve plug (8 mm socket
head). Measure and make a note of the distance between the
adjusting screw and the upper face of the steering valve to
facilitate the setting of the operating pressure of the pres-
sure ---limiting valve.
2. Remove the plug on the shock valve (6 mm socket head)

and remove the sealing ring of the plug.
10. Unscrew the pressure ---limiting valve adjusting screw with

a 6 mm Allen key.
11. Carry out operations shown in paragraphs 4---8.
Note! When assembling the valve, screw the plug to the same
depth as it was before disassembling.
12. Fit the steering valve (see instr. G) and check the steering
system pressures (see instr. A and B).
3. Measure and make a note of the distance between the ad-

justing screw and the upper face of the steering valve to facili-
ate the setting of the opening pressure of the shock valve.
4. Remove the adjusting screw (6 mm socket head). Shake

out a spring, washer and a ball.
5. Clean and check the parts and change faulty ones. Lubri-
cate all parts with oil before assembling. Minor damage to the
seat can be polished with a ball and fine grinding paste.
541
Model Code Page
1. 9. 1992
I. Changing seals in steering valve (Dan-

foss valve)
1. Remove the steering valve (see instr. D).
2. Secure the steering valve in a vice with the cover upwards.

Mark the position of the cover, distributor plate and rotor ring
for easier fitting.
4. Remove the cover, rotor ring and the rotor and the washer
inside the rotor.
3. Unscrew the cover fixing bolts.
5. Remove the rotor shaft and the distributor plate. Check/

change o---rings between the parts.
6. Push up the valve slide and pull them out of the valve hous-
ing. Remove the thrust bearing from the slide bore.
Note! Remember where the bolt with the locating pin was
fitted. If the valve is turned upside down, three valve balls and
two pins will fall out.
542
Model Code Page
15. 9. 1995
1. 1. 1998
Note! If the centring springs are changed, they must be fitted

as shown in figure above.
Note! Before removing the springs, mark position of the valve

spindles in ralation to each others e.g. with tusche. Rinse the
spindles with gas oil (also lubricating properties) so that they
can move easily and the centring springs can center them.
9. Fit the ring over the centring springs. Place the thrust bear-
ing assembly onto the valve slide.
7. Turn the steering valve to a horizontal position and prize out
the seal from the valve housing. Remove the inner oil seal. Fit Note! Thick thrust washer first, then bearing and then the thin
a new outer seal. Apply some grease to the seal and turn the thrust washer. Chamfered side of the thick washer towards the
valve back to the vertical position. slide.
8. Fit the inner seal (and the support ring) using tool ETV 893
100 as follows:
ETV 893 100
10. Push the valve slide into the housing fully home
Note! The valve slide together with the thrust bearing is easier
--- lubricate the o---ring. Fit the support ring on the stud of the to fit into the housing when the steering valve is horizontally.
tool and fit the o---ring on the support ring. Push the stud into Turn the slides until the cross pin is parallel to the flat side of
the guide sleeve. the valve housing.
11. Fit a new o---ring and the distributor plate onto the housing
according to the mark. Fit the rotor shaft so that grooves on
it engage the cross pin.
---push the guide sleeve into the valve housing and push the
seal together with the support ring in place using the stud on
the tool. Remove the tool and check that the seal is property
positioned.
Note! The inner seal has been changed during autumn 96 in

all steering valves (fitting tool ETV 894 330).
543
Model Code Page
1. 9. 1992
1. 1. 1998
Stepped
splines
Note! In the latest steering valves the rotor shaft and the rotor
have stepped splines at which time the mutual position of the
parts is determined automatically.
13. Then fit a new o---ring and the rotor ring according to the
marks. Fit the rotor according to the figure above. Note! The stepped splines also prevents the rotor shaft from
releasing from the cross pin inside the valve. With regard to
Note! Concerning the latest steering valves, see picture in the possible repair works is recommended, that a spacer is fitted
column beside. at the end of the rotor shaft to ensure the position of the shaft.
The spacers are still available as spare parts.
14. Fit the washer inside the rotor.
15. Fit the cover according to the marks and tighten the bolts
to a torque of 30 ---35 Nm.
16. Fit the steering valve (see next instruction).
544
Model Code Page
15. 4. 1994
1
2
6
5
4
3
Priority valve (Op. no. 612)
1. Cleaning priority valve
A. Dismantling B. Assembling
1. Detach the priority valve which is fitted beside the pressure
filter under the cab floor on the RH side. 1. Push the spool (6) into the housing. Fit a new sealing ring
on the plug (1).
2. Open the plug (1) and remove the sealing ring (2).
2. Place the spring (5) into the housing. Fit a new sealing ring
3. Unscrew the connection (3) and remove the sealing ring (4) and the connection (3). Tighten the connection to 40 ---60 Nm.
and the spring (5).
3. Tighten the plug (1) to 40 ---60 Nm.
4. Push out the valve spool (6) by using e.g. a pencil. Do not
damage contact surfaces on the spool and the housing. 4. Fit the priority valve.
5. Check and clean the parts. Replace the sealing rings with
new ones. Lubricate the parts with oil before fitting.
545
546
Model Code Page
1. 12. 1986
15. 9. 1995
Steering cylinders
1. Reconditioning steering cylinder (4WD,

ZF ---axle)
A. Changing seals in steering cylinder
The seals can be changed without removing the front axle.
3. Disconnect the oil hose (22 mm) from the end piece and
remove the end piece (17 mm).
1. Slightly raise the front axle. Remove the steering lock stop
(13 mm). Note the position of the stop so that it can be refitted
in the same way.
4. Pull the piston rod out of the steering cylinder
2. Disconnect the tie rods from the piston rod ends (27 mm
and 46 mm).
5. Pull out the cylinder barrel
6. Push the end piece from the other end of the cylinder into
and through the cylinder housing and take it out.
547
Model Code Page
61. Steering cylinder 205-- 665 613 2
1. 12. 1986
7. Remove the scraper seal, the seal and the o---ring from the 12. Remove the O ---ring (7) which is fitted in the middle, inside
end piece and fit new parts (the lip of the seal should be turned the piston.
inwards and the lip of the scraper seal outwards).
13. Remove the piston (8) and locking ring halves (5) from the
8. In the same way change the seal and the scraper seal in the other side.
other end piece.
14. If necessary, change the locking ring (3), intermediate ring
(4) and spacer ring (6).
15. Fit the locking ring halves (5) in their groove and push the
piston (8) onto the piston rod, with the assembled side against
the locking ring halves.
Steering cylinder piston (powered front axle).
9. Remove the support rings (1) and seal ring (2) from the pis-
ton.
16. Fit the O ---ring (7) and spacer ring (6) in the piston and fit
the locking ring halves (5) for the other side in their groove. Fit
the intermediate ring (4) and locking ring (3).
17. Fit the sealing ring (2) and support rings (1) on the piston.
Turn the support rings so that the places where the rings are
split come on opposite sides of the piston.
18. Fit the piston in the steering cylinder (see under headings
B and C).
10. Remove the locking ring (3) and intermediate ring (4).
11. Remove the locking ring halves (5) and spacer ring (6)
behind them.
548
Model Code Page
1. 12. 1986
B. Measuring clearance between cylinder C. Assembling steering cylinder

barrel and end piece
Measuring should be carried out if the cylinder barrel or the
end piece has been changed.
1. Push the inner end piece into the cylinder housing.
2. Insert the cylinder barrel in the housing with the narrower

end first.
3. Lubricate the seals on the piston and in the end piece with
oil, and carefully push the piston into the cylinder barrel.
End piece of steering cylinder (powered front axle ZF).
1. Measure the distance A on the end piece between the con-

tact faces for the cylinder barrel and for the cylinder housing
4. Fit the other end piece (17 mm, 70 Nm). Connect the oil
(e.g. 27,3 mm). hoses (22 mm) and tighten to 45 Nm.
2. Measure the distance B between the end surface of the cyl-
inder barrel and the end face of the cylinder housing (e.g.
25,80 mm).
3. Shim thickness X =A---B (=1,5 mm, see the table above).
5. Connect the tie rods to the ends of the piston rod (27 and
46 mm) and secure by upsetting the edge. Use for example
Loctite 242 on the threads (see Fig. 3 items 1 and 2).
549
Model Code Page
1. 12. 1986
3. Remove the steering cylinder ends (8 mm, socket head)

6. Fit the steering lock stop (13 mm, 25 Nm). Make sure the
and remove the o---rings. Remove the cover plate from the
stop is fitted in the same way as before it was removed.
steering cylinder frame (10 mm) and move the piston until it
is in the centre.
N.B. If the piston rod has been changed, check the toe ---
inand if necessary adjust (see under heading 641 1D), See
the Technical Data for the toe ---in measurements.
7. Lower the front axle to the ground and check the level in the
hydraulic system. Top up if necessary. Check the function of
the steering system.
2. Reconditioning steering cylinder (non ---

powered front axle)
A. Dismantling steering cylinder
The steering cylinder ends can be changed without removing

the steering cylinder.
1. Disconnect the tie rods from the steering arm (22 mm). Dis- 4. Remove the clamping bolts for the steering arm (use the
connect the hoses (22 mm) from the steering cylinder. screwdriver to stop the bolt from turning), and remove the bolt
together with the bearing.
5. Remove the circlip from the end of the bolt and remove the
bearing using a drift.
6. Drive the piston rod (piston) out of the cylinder frame using
a soft drift. Remove the steering arm together with the tie rods.
2. Remove the steering cylinder (bolts M16, 3 pcs); One

wheel should be turned to full lock.
7. Remove the scraper seals from the cylinder frame.

550
Model Code Page
1. 12. 1986
3. Position the steering arm together with tie rods in the cylin-
der housing
ETV 892 380
90 Nm
8. Drive out the bearing sleeve, the seal and intermediate ring
from either end of the cylinder frame using ETV 892 380.
4. Tap the piston rod (piston) into the cylinder with a soft
B. Assembling steering cylinder hammer (note the groove for the steering arm bolt). Secure
the steering arm to the piston rod (19 and 22 mm, 90 Nm).
5. Fit the bearing to the end of the bolt and secure with the cir-
clip. Fit the cover plate onto the cylinder frame (10 mm).
1. First fit the scraper seal (sealing lip in towards the cylinder
frame) using ETV 893 630. Position the intermediate ring at the
bottom of the seal housing.
6. Fit the O ---ring onto the bearing sleeve and fit the cylinder
ends to the frame (8 mm, socket head 65 Nm). Make sure that
the holes for the hoses face forward and upwards.
7. Fit the steering cylinder to the tractor and tighten the bolts
ETV 893 630 (19 mm, 80 Nm, screw stud 85 Nm, w.e. fr. ser. no. 600705,
24 mm, 195 Nm). Apply Loctite 222 or equivalent to the
threads on the screw studs. Secure the front bolts with the tab
washers (see Fig. 2 on page 610/5).
2. Drive the seal in against the intermediate ring using ETV 893
630. Drive in the bearing sleeve until it bottoms, using ETV 893
630, with the groove in the bearing sleeve upwards. The clear-
ance between the seal and the bearing sleeve will then be
approx. 1 mm. Points 1 and 2 apply to both ends of the cylin-
der frame.
551
Model Code Page
1. 12. 1986
50 Nm
120---150 Nm
8. Connect the oil hoses (22 mm, 50 Nm) and secure the tie
rods to the steering arms (22 mm, 120 ---150 Nm).
9. Start the engine and turn the steering wheel until the steer-
ing cylinder is filled with oil. Check for any leaks.
10. Start the engine and check the oil level in the hydraulic sys-
tem.
552
Model Code Page
15. 9. 1995
Steering cylinder, Sige axle
1. Changing seals in steering cylinder

Note! This instruction concerns earlier steering cylinder
up to axle number 129/92. Later cylinder, see page 613/9.
A. Removal of steering cylinder
N.B. It is not necessary to remove the front axle from tractor

when repairing the steering cylinder. In the figures below the
front axle is detached.
1. Raise the front end of the tractor and place axle stands
behind the front axle. Turn the front wheels to the left against 6. Remove steering cylinder attaching bolts (on LH side).
the limiter screw.
7. Pull out the cylinder to the left from the axle housing.
2. Heat up the RH side piston rod end at the joint between the
piston rod and tie rod until the locking fluid in the threads melts
(apply heat carefully about 30 mm from end, max 200˚ C).
Important!. the metal must not be allowed to become blue

B. Changing seals in RH side end piece
during the heating operation. Do not heat up the ball joint
because this can damage the rubber cover on the joint.
1. Remove steering cylinder (instr. A).
2. Secure the cylinder in a vice. Tap a pin (ø 4 mm) in the RH

side end piece hole. Push the pin as far as possible.
3. Disconnect the tie rod from the piston rod end.
4. Turn the LH wheel to the right against the limiter screw and
disconnect the threaded joint between the LH side piston rod
and tie rod in the same way as described above.
5. Disconnect oil hoses from the steering cylinder. Remove

the connecting fitting from the RH side end piece. Cover all
holes with suitable plugs.
553
Model Code Page
15. 9. 1995
C. Changing seals in LH side end piece

1. Remove steering cylinder (instr. A).
2. Secure steering cylinder in a vice.
3. Turn the end piece with tool ET 894000 until the locking wire
emerges. Remove the end piece from cylinder. Remove the
pin from the end piece.
4. Change the o---ring and support ring which sits against the
cylinder liner. Grease the o---ring with universal grease (sup-
3. Unscrew the locking screw on the LH side end piece.
port ring is fitted outermost).
5. Change scraper seal, support ring and seal which sits

against the piston rod. Grease parts with universal grease.
Change the innermost support ring when necessary.
Note! Scraper seal lip outwards, seal lip inwards.
4. Knock out the end piece using a hammer. Remove the now
loose locking ring segments.
5. Change the o---ring on the cylinder liner outer side. Change

the scraper seal, sealing ring and two support rings which are
fitted on the end piece. Grease parts with universal grease.
Important: The lip of the scraper seal should be inwards.
6. Fit the end piece onto the cylinder liner until it lies against
the segments of the locking ring. Turn the end piece until the
6. Push the end piece carefully into the cylinder, hook the
locking screw can be fitted.
safety wire into the hole and rotate the end piece until the
whole wire has been correctly positioned in the groove (note
N.B.! Apply silicon to the locking screw.
direction of rotation).
7. Fit the steering cylinder into the axle housing (Op. D).
7. Drive the pin into the hole until it is level with the surface of
the end piece.
N.B. Never use a pin that is too long ( max ø4x8 mm), because
it will prevent removal of the end piece in the future..
8. Apply silicon to the pin, to the locking wire groove and to the
joint between cylinder liner and end piece.
9. Fit the steering cylinder into the front axle housing (Op. D).
554
Model Code Page
15. 9. 1995
2. Later steering cylinder

D. Fitting steering cylinder
The steering cylinder on Sige front axles has been changed
from axle number 130/92.
The new cylinder is as a complete unit exchangeable with the

earlier one. Order number of the new steering cylinder is
31955500.
A. Changing seals
1. Removing the cylinder, see instr. 1A on page 613/7.

190 Nm
1 2
1. Push the steering cylinder into the axle housing. Tighten

cylinder attaching screws to 190 Nm.
290 Nm
2. Remove the locking ring (1). Push the end piece a little
inwards and remove the securing ring (2).
3. Pull the piston rod/piston out of the cylinder with a rapid

movement at which time also the end piece releases.
4. Remove all damaged seals and fit new ones.
Note! A seal ring kit no 31797510 is available.

2. Connect the piston rod to the tie rods. Tighten the joint to Lubricate all seals with oil before assembling the cylinder.
290 Nm. Apply locking fluid Loctite 586 to the threads.
5. Assemble the cylinder in the reverse order. Fitting the cylin-
3. Connect the oil hoses to the steering cylinder. der into the front axle, see instr. D on this page 613/9.
4. Start the engine and check that the steering system func-
tions properly. Check for possible leaks. Check oil level in
hydraulic oil tank.
555
556
Model Code Page
1. 12. 1986
62. Non ---powered front axle 205-- 865 620 1
10. 1. 1992
Contents
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Non ---powered front axle, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Repair instructions
Front axle with central pivot bearings (Op. no, 621)
1. Reconditioning front axle:
A. Changing wheel bearings and hub seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing steering knuckle bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Adjusting track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Checking and adjusting toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.
2. Front axle central pivot bushing:

A. Changing axle member and central pivot bearing bushings . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical Data
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel member
Toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---6 mm
Axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±13˚
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2˚
KPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8˚
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0˚
Front axle flange distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1390---1490---1590 mm
Tyres and track widths (measurement between centres of tyres):
Tyres Track widths Ground clearance Track widths w. e. fr. ser.

no. 600705
7.50---16/8 1436---1536---1636 mm 460 mm 1336---1436---1536
10.00---16/8 1442---1542---1642 mm 505 mm 1410---1510---1610
Max. permissible axle loads:

(with standard track widths 1436 or 1336)
With tyres 7.5---16/6 max 3000 kg

With tyres 10.00---16/8 max 3000 kg/35 km/h
max 3600 kg/8 km/h
max 4500 kg/8 km/h with front loader use with short distances (<100 m)
Setting values
Steering knuckle bearing end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---0,3 mm
Wheel bearing end float (equals to 1/12 turns of the nut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1---0,2 mm
Tightening torques
Track width adjusting nuts on tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Axle ends --- axle member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Nm (3/4” ---16”)
380 Nm (M20)
Axle member front bearing mounting --- front frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (M12)
195 Nm (M16)
Tie rod, nut for ball/socket end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120---150 Nm
Front wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm (1/2”)_
130 Nm (M14)
Steering arm --- steering knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Steering knuckle attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Wheel bearing hub cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
557
Model Code Page
1. 12. 1986
Special tools
62. Non ---powered front axle B

Ordering no. Description
ETV 890 820 Drift for fitting central pivot bearing bushings (front axle 504---604)
ETV 892 390 Sleeve for fitting wheel hub bearing race (front axle 505---805)
ETV 892 410 Plate for fitting wheel hub bearing race (front axle 505---805)
(ETV 892 210) Sleeve for fitting shaft seal in hub (see Gearbox)
(ETV 892 400) Sleeve for fitting roller bearing in wheel hub (see powered front axle)
ETV 892 370 Sleeve for fitting roller bearing on steering knuckle (front axle 505---805)
(ETV 892 350) Sleeve for fitting needle bearing race on steering knuckle (see Gearbox)
ETV 891 230 Drift for fitting needle bearing in steering knuckle housing (front axle 505---805)
ETV 892 360 Plate for fitting roller bearing in steering knuckle housing (front axle 505---805)
ETV 892390
ETV 892400
ETV 890820 ETV 892410 ETV 892210
ETV 892370 ETV 892350 ETV 891230 ETV 892 360
558
Model Code Page
1. 12. 1986
1. 7. 1989
Non ---powered front axle, description
The main component of the front axle is a box ---type steel

member. The axle is pivoted on a removable bearing mount-
ing. The extendable axle ends are secured in the frame
member with bolts which allow for three different settings of
the track width, in steps of 100 mm. With effect from ser. no.
600705: the width of the front axle is 100 mm narrower than
on earlier type models.
50 Nm
4
380 Nm
2
120---150 Nm
195 Nm
5 6
130 Nm
Fig. 1. Non ---powered front axle 305---455
1. Axle member
2. Front axle outer end
3. Wheel hub
4. Tie rod
5. Steering arm
6. Steering knuckle
559
Model Code Page
1. 12. 1986
1. 3. 1997
Picture 2. Hub and steering knuckle bearings
1. The steering knuckle bearing end float (0 ---0,3 mm) is adjusted before the final tightening of nut 2.
3. The wheel bearing end float 0,1 ---0,2 mm corresponds to 1/12 of a turn of the nut.
4. Grease the bearings thoroughly and fill the outer space of the bearings with universal grease and fill the space between the
bearings to one third full with universal grease.
5. To be filled with universal grease.
560
Model Code Page
1. 12. 1986
Repair instructions
ETV 892410
Non ---powered front axle (Op. no. 621)
1. Reconditioning front axle
A. Changing wheel bearings and hub seal
1. Jack up and support the front axle. Remove the front wheel
(22 mm). Remove the wheel bearing hub cap (13 mm).
5. Fit the outer bearing race of the outer bearing in the hub
using ETV 892 410.
ETV 892210
2. Remove the hub nut cotter pin and unscrew the nut. Pull the 6. Grease and fit the inner bearing and the shaft seal in the hub
hub off the shaft. using ETV 892 210.
3. Secure the hub in a vice and knock out the inner bearing,
the shaft seal and the bearing races.
ETV 892390
ETV 892400
7. Lift the hub onto the shaft. Grease the outer bearing with
universal grease and fit it using ETV 892400. Fit the washer
and tighten the nut.
Note! Fill the space between the bearings to one third of the
space with universal grease. The space in the hub cap should
4. Fit the outer bearing race of the inner bearing in the hub be completely full with universal grease.
using ETV 892 390.
8. Adjust the wheel bearing clearance as follows:
--- Turn the hub at least 20 turns in order to bed in the bearings.
--- Tighten the nut until the hub no longer can be turned by
hand.
--- Slacken the nut 1/12 of a turn (corresponding to a bearing
clearance of 0,1 ---0,2 mm).
--- Secure the nut with the cotter pin.
561
Model Code Page
1. 12. 1986
9. Secure the hub cap (13 mm, 23 Nm). Fit the wheel (22 mm,
1/2” 100 Nm or M14 130 Nm. Lower the tractor from the sup-
ports.
ETV 892370
C. Changing steering knuckle bearings
Note! The hub does not have to be removed in order to

change the steering knuckle bearings.
1. Remove the steering knuckle lock bolt (19 mm) and the
washer. Unscrew the steering arm attaching bolt (24 mm) and
turn the arm to one side.
2. Push the steering knuckle down out of the bearing location 5. Fit the protective plate and a new bearing onto the steering
in the axle. knuckle using sleeve ETV 892 370.
ETV 892350
3. Remove the needle bearing from the upper part of the steer- 6. Fit the needle bearing inner race on the steering knuckle
ing knuckle location in the axle using an internal extractor. using sleeve ETV 892 350.
Remove the lower bearing outer bearing race from the loca-
tion using puller.
ETV 892360
7. Fit the lower bearing outer bearing race from underneath

into the bearing location using ETV 892 360 and fit the needle
4. Remove the inner bearing race for the needle bearing from bearing using ETV 891 230.
the steering knuckle using a puller. Remove the bearing race
for the lower bearing using a puller or a suitable drift. 8. Grease the steering knuckle bearings and the steering
knuckle and push it into the bearing location.
562
Model Code Page
1. 12. 1986
D. Checking and adjusting toe ---in

1. First check that there is no play at the ball---socket joints
between the tie rods and the steering arms. Check that the
front wheels are set for driving straight forwards.
200 Nm A
9. Fit the protective plate and steering arm to the upper end
of the steering knuckle. Secure the steering arm with its bolt
(24 mm, 200 Nm) and at the same time adjust the bearing A+ 2...6 mm
clearance to 0 ---0,3 mm. See Fig. 2 on page 620/4.
10. Fit the washer to the upper end of the steering knuckle and
tighten the bolt (19 mm, 80 Nm).
11.Connect the tie rod to the steering arm (22 mm, 120 ---150 2. Checking:
Nm) and lock the nut. If the steering arm has been changed, --- Make a mark with a piece of chalk or similar on the inside of
the toe ---in must be checked (see Op. D). the tyres in front of the axle at hub height.
--- Measure the distance between the marks.
--- Roll the tractor forwards until the marks are at hub height
behind the axle. Again measure the distance between the
C. Adjusting track width marks.
--- The distance between the inside of the tyres should be 2 ---6
mm greater behind the axle.
(2) 3. Adjusting:
50 Nm
3 2
(50 Nm) 1
380 Nm (1)
7.50--- 16 1336 1436 1536
10.00--- 16 1410 1510 1610
1. Raise the front end with a jack positioned at the centre

under the front axle. Remove bolts 1 (28 mm). Unscrew tie rod
bolts 2 (17 mm) and slacken the tie rod locking nut (30 mm). --- Slacken the clamping bolts (1) and slacken the nut (2)
Pull out the outer shaft ends until the desired track width has --- Turn the tie rod (3) in the desired direction. Tighten the bolts
been obtained.
1 (50 Nm) and the nut 2 (80 Nm).
2. Secure the outer axle ends (3/4, 320 Nm or M20, 380 Nm
and the bolts on the tie rods (17 mm, 50 Nm or 30 mm, 80 Note! Adjust both tie rods to the same length.
Nm). Check the toe ---in (see under heading D).
563
Model Code Page
1. 12. 1986
1. 7. 1989
2. Front axle central pivot bearing
A. Changing front axle member and central

pivot bearing bushings
N.B. When the central pivot bearing bushings have to be

changed there is no need to remove the wheels, the outer
ends of the axle or the steering cylinder.
1. Block up the front end of the tractor and remove the front
wheels (22 mm).
5. Remove the front bearing bushing from the bracket, and the
rear bushing from the bearing location in the front end of the
tractor using an extractor (e.g. Kukko 21/6)
ETV 890820
2. Disconnect the tie rod ends from the steering arms (22 mm).
Remove the outer axle ends from the axle member.
3. Disconnect the oil hoses from the steering cylinder (22

6. Fit the new bearing bushings using ETV 890820 and grease
mm). Remove the steering cylinder (M12 22 mm, M14 24
them.
mm). Also remove the screw stud. Remove the hose bracket
(13 mm) from the axle member.
7. Fit the spacer washers onto the central pivot shaft and fit the
axle member. Secure the front bearing (195 Nm).
8. Fit the bracket (13 mm) for the oil hoses and fit the steering
cylinder (19 mm, 80 Nm, screw stud 85 Nm, or 24 mm, 195
Nm) onto the axle member. Connect the oil hoses to the steer-
ing cylinder and check that the hoses do not touch any parts
of the tractor when the axle oscillates.
380 Nm
4. Place a jack under the axle member or connect a hoist to

both ends of the axle member. Unscrew the bearing bracket
bolts and pull the axle forwards and remove it.
9. Fit the outer axle ends (3/4---16” 320 Nm or M20 380 Nm).
NOTE: During 1988 the front axle central pivot bearings have 10 Secure the tie rods to the steering arms (22 mm, 120 ---150
been fitted with grooves and “O” rings. The smaller “O” rings Nm). Fit the front wheels (22 mm, 1/2”, 100 Nm or M14, 130
Nm).
are fitted into the outer grooves on the shaft. Bigger “O” rings
are fitted onto the spacer washers. These “O” rings can also
11. Lower the tractor to the ground and check the toe ---in (see
be fitted on earlier tractors. under heading 1D)
564
Model Code Page
64. Powered front axle ZF 205-- 665 640 1
1. 12. 1986
Contents

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Repair instructions
Axle housing and central pivot bearing brackets (Op. no. 641)
1. Axle housing and central pivot bearing brackets, repair instructions:
A. Removing front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing front axle central pivot bearing bracket sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Fitting front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Drive shafts (half shafts (Op. no. 642)

1. Reconditioning drive shafts:
A. Changing outer bearing bushing and oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing inner bearing bushing and oil seal, and changing double universal joint . . . . . . . 2
Hub reduction gear (Op. no. 643)

1. Reconditioning planetary hub gear:
A Changing planetary pinion roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting drive shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C Changing hub bearings and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Changing steering knuckle bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Reconditioning differential:
A. Changing pinion shaft seal (without removing the shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing differential bearings, differential side gears and discs . . . . . . . . . . . . . . . . . . . . . . 2
D. Adjusting tooth backlash and differential bearing preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Changing pinion shaft bearings and oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F. Adjusting pinion shaft position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G. Fitting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
565
Model Code Page
1. 12. 1986
1. 7. 1989
Technical Data
Axle type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APL 325 (ZF)

Gear ratios:
--- Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2,16
--- Planetary gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:7,33
--- Total gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:15,82
Steering lock (adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50˚, 45˚, 37˚

Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1˚
King pin inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8˚
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5˚
Toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---5 mm
Front axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±13,5˚
Automatic differential brake:

--- Locking value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 %
--- Number of friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8+8 pcs
--- Number of intermediate discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10+10 pcs
--- Thrust plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 pcs
Oils
Viscosity and quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 80W/90 API GL ---5
--- at temperatures below ---20˚C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 75W API GL ---5
Oil capacities:
--- Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 litres
--- Hub reduction gears, in each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 litre
Tightening torques
Planetary gear housing mounting bolts (socket head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (8 mm)

Ring gear mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm (15 mm)
Crown wheel mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm (17 mm)
Pinion shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . about 180 Nm (30 mm)
Axle housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Nm (22 mm)
Pressure oil pipe to steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (22 mm)
Steering knuckle attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm (19 mm)
Tie rod ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm (27 mm)
Front axle attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm (24 mm)
Wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Nm (24 mm)
Propeller shaft:
--- 8.8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
--- 10.9 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Guard plate for propeller shaft:
--- 17 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
--- 19 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Setting values
Drive shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3---0,6 mm
Clearance between differential brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1---0,15 mm
Tooth backlash, crown wheel---pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1---0,15 mm
Rolling resistance of pinion shaft bearings:
--- measured with a torsion meter at the shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2 Nm
--- measured with a spring balance at drive flange screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4---4.8 kg
Rolling resistance of differential bearings measured with a torsion meter at the
pinion shaft nut:
--- Pinion shaft bearing resistance + 1---2 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---4 Nm
Rolling resistance of differential bearings measured with a spring balance at pinion
shaft drive flange screw:
--- Pinion shaft bearing resistance + 2.4---4.8 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8---9.6 kg
Steering knuckle bearing rolling resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8---11 Nm
566
Model Code Page
1. 12. 1986
Special tools
Powered front axle A

ETV 891 840 Sleeve for fitting oil seal on pinion shaft (Gearbox 505---905)
ETV 892 400 Sleeve for fitting pinion shaft nut locking sleeve (Front axle 505---805)
Powered front axle B

(ETV 890 820) Drift for fitting drive shaft seal and bearing bushings (see Non ---powered front axle)
ETV 891 780 Plate for fitting oil seal in hub (Gearbox 1102, 1203)
(ETV 892 350) Sleeve for fitting steering knuckle bearing races (see Gearbox)
ETV 893 720 Plate for fitting pinion shaft bearing race
ETV 893 730 Plate for fitting pinion shaft bearing race
ETV 893 750 Plate for fitting bearing race in hub
ETV 893 770 Tool for adjusting pinion shaft bearing preload
Tool for adjust tooth backlash pinion / crown wheel
ETV 891 840
ETV 892 400
ETV 891 780
ETV 892 350

ETV 890 820
567
Model Code Page
1. 12. 1986
ETV 893 730

ETV 893 720
ETV 893 750
ETV 8932 770
568
Model Code Page
1. 12. 1986
Powered front axle, description

The drive to the front axle is engaged with a dog clutch on the
The powered front axle is attached to the front end of the trac- output shaft of the gearbox. The control lever for the dog
tor by two bearing brackets. The bearings are positioned con- clutch is positioned to the right of the driving seat.
centrically with the pinion shaft which means that the propeller
shaft is not moved sideways when the front axle oscillates The power is transmitted from the gearbox to the pinion shaft
by the propeller shaft which is protected against external
damage by guards.
From the pinion shaft, power is transmitted through the differ-

ential to the drive shafts and through the double universal
joints to the hub reduction gears and the front wheels
9
10
7
6
5 3
8 4
11
Fig 1. Planetary hub gear The drive shafts on either side of the differential are carried in
bearing bushings in the axle housing and in the steering
1. Shims for adjusting king pin bearings knuckle (swivel housing). The end float of the drive shafts is
2. Shims for adjusting drive shaft end float adjusted by changing shims in the planetary retainer in the
3. Drive shaft (half shaft) respective hubs.
4. Double universal joint
5. Sun gear shaft In each hub gear, the planetary pinions (3 pcs) are carried in
6. Planetary pinions (3 pcs) roller bearings in the retainer. The ring gear is bolted to the
7. Planetary retainer steering knuckle.
8. Ring gear
9. Hub The steering knuckle is attached to the front axle housing by
10. Steering knuckle (swivel housing) the king pins which are carried in taper roller bearings. The
11. King pin bearing clearance of the king pins is adjusted with shims at
12. Front axle housing the upper pin.
The double univerasl joint of the dirve shaft allows for a large
steering lock. The universal joint is connected to the drive
shaft and the sun gear by splines and circlip
569
Model Code Page
1. 12. 1986
Fig. 2. Differential
1. Pinion shaft 7. Differential side gear

2. Compression bushing 8. Friction discs
3. Crown wheel 9. Intermediate discs
4. Differential casing 10. Drive shaft (half shaft)
5. Shaft for diff. pinions 11. Axle housing, longer section
6. Differential pinion 12. Axle housing, shorter section
570
Model Code Page
1. 12. 1986
The crown wheel is bolted to the differential casing and trans- The differential is provided with an automatic differential
mits the power via the differential pinions, pinion shaft and dif- brake. The friction discs are fitted between the differential side
ferential side gears to the respective drive shafts (half shafts). gears and the differential casing.
Compression bushing (item 2 in Fig. 2) is fitted by the pinion The position of the pinion shaft and the tooth backlash are
shaft outer bearing to create a correct preload of the pinion adjusted with shims under the pinion shaft inner bearing and
shaft bearings when the nut is tightened. the bearing preload of the bearings carrying the differential
casing is adjusted with shims between the axle housing and
the RH side differential bearing. The available shim thickness
are shown in Fig. 2.
Automatic differential brake

Fig. A. Power transmission through differential when the
wheels are not slipping and the tractor is driven straight for-
wards:
The entire differential rotates as one unit and the respective

drive shafts rotate at the same speed and transmit the same
torque.
Fig. B. Power transmission through differential when the RH

side wheel is slipping or when driving through a left---hand
bend:
The drive shafts rotate at different speeds because the differ-

ential side gears begin to rotate in relation to each other.
When one wheel is slipping, the torque transmitted by the

drive shafts is reduced, and thereby also the pulling power of
the tractor.
The torque of the crown wheel (differential casing) and the

resistance of the drive shafts create a force between the differ-
ential pinions and the differential side gears. This force pres-
ses the differential side gears outwards, compressing the fric-
tion discs and the steel discs between the side gears and
casing.
When one wheel is slipping, the brake torque created
between the friction discs and the steel discs slows down the
rotation of the slipping wheel and transfers the torque to the
other wheel which is not slipping.
The magnitude of the transferred torque depends on the

torque of the crown wheel which can never be greater than the
torque of the slipping wheel.
This means that the differential brake does not work if the slip-
ping wheel is on a very slippery surface (e.g. ice) or if it has
been lifted off the ground. In this case the differential works as
an ordinary differential without a differential brake, i.e. the
power is transmitted through the slipping wheel.
The differential brake only works when there is a certain differ-

ence in torque between the left--- and right---hand wheel, i.e.
the slipping wheel must have a certain friction. The brake
torque is proportional to the torque of the crown wheel. This
relationship is stated in percentage terms and is called the
locking value (max. 45 %).
571
572
Model Code Page
1. 12. 1986
Axle housing and central pivot bearing

brackets (Op. no. 641)
1. Axle housing and central pivot bearing

brackets, repair instruction
A. Removing front axle
2. Remove the bearing sleeve from the bearing bracket.
1. Drain the oil from the hub and from the differential (if
required because of the repairs to be done).
2. Remove the guard for the propeller shaft (17 and 19 mm)
and slacken the nut for the split joint. N.B. Later type tractors
do not have this ring nut fitted.
3. Disconnect the hoses from the steering cylinder (22 mm).
3. Remove the O ---ring, plastic sleeve and scraper seal from

the metal sleeve.
4. Fit a new O ---ring to the bearing bracket. Grease the metal

sleeve and fit the plastic sleeve and the scraper seal on the
metal sleeve.
5. Push the sleeve into the bearing bracket and check that the
split in the plastic sleeve facing downwards.
6. Fit the front axle (Op. C).
4. Raise the front end of the tractor and support the tractor
frame. Remove the front wheels (24 mm).
5. Connect a hoist to the front axle and remove the attaching C. Fitting axle
bolts (24 mm). Remove the bearing brackets
1. Push the bearing brackets into position on the axle. Make

B. Changing front axle central pivot bear-
sure that the locking lugs of the sleeves engage the grooves
ing bracket sleeves on the axle housing.
The bearing sleeves can be changed without removing the

front wheels.
1. Remove the front axle together with the bearing brackets

(Op. A, 2 ---5)
573
Model Code Page
1. 12. 1986
2. Lift up the front axle so that the attaching bolts for the bear-
ing brackets can be fitted to the front end of the tractor and
tighten to 195 Nm.
N.B. The rear bolts for the front bearing bracket should be
fitted before the bearing brackets fits up against the contact
surface. Make sure that the universal joints on the propeller
shaft align with each other.
3. Connect the hoses to the steering cylinder (22 mm, 45 Nm).

Tighten the ring nut by the propeller shaft slip joint, if such a
nut is fitted to the shaft.
4. Fit the front wheels (24 mm, 330 Nm) and remove the sup-
ports from under the front end of the tractor.
5. Fit the guard for the propeller shaft (19 mm, 80 Nm and 17
mm, 45 Nm).
6. Fill with oil the differential housing (4,5 litres) and both hubs
(0,5 litre), if the oil was drained, and check the level of the
hydraulic oil. Grease the front axle central pivot bearings.
574
Model Code Page
1. 12. 1986
Drive shafts (half shafts) (Op. no. 642)
1. Reconditioning drive shafts
A. Changing outer bearing bushing and oil

seal
1. Drain the oil from the hub, raise the axle off the ground and
remove the front wheels (24 mm).
2. Remove the planetary retainer (8 mm socket head) and

remove the circlip and the washer from the sun gear shaft.
5. Remove the drive shaft bearing bushing using a puller.
3. Disconnect the tie rod from the steering arm (27 mm).
Remove the king pins (19 mm) and lift out the entire hub gear.
6. Drive or press the new bearing bushing into the steering

knuckle using ETV 890 820. Apply grease to the bushing.
4. Remove the drive shaft seal from the steering knuckle

(swivel housing).
7. Coat the lips of the seal with grease and apply sealing com-
pound to the outer side of the seal (e.g. Silastic RTV 738).
Drive or press the seal into the steering knuckle using ETV 890
820.
N.B. Turn the lip of the seal towards the hub.
575
Model Code Page
1. 12. 1986
8. Apply grease to the bearing races of the king pins. Wrap a

thin plastic foil round the end of the sun gear shaft to protect
the seal.
9. Lift the hub reduction gear into position and remove the
plastic foil. Check the position of the king pin O ---rings and
push the pins into position. Any shims should be positioned
under the upper king pin. Tighten the bolts for the pins (19
mm, 120 Nm).
10. Connect tie rod to the steering arm (27 mm, 110 Nm) and
fit the bearing washer and the circlip to the sun gear shaft.
11. Fit the planetary retainer and the wheel (Op. no. 643 1A,
8 ---9).
B. Changing inner bearing bushing and oil 4. Pull the bearing bushing out of the axle housing using a
puller.
seal and changing double universal joints.
1. Drain the oil from the differential. Remove the wheel hub
(see under heading A, 1 ---3).
5. Fit a new bearing bushing using ETV 890 820. Apply grease
to the bushing.
6. Fit a new seal using ETV 890 820. Apply grease to the lips
2. Pull the drive shaft out of the axle housing and disconnect of the seal and apply sealing compound (e.g. Silastic RTV
the double universal joint from the shaft. 738) to the outside of the seal before fitting it.
N.B. Turn the lips of the seal towards the differential.
7. Push the drive shaft into the axle housing and fit the hub
reduction gear (Op. A, 8 ---11).
8. Fill the differential with oil (4,5 litres).
3. Remove the drive shaft seal from the end of the axle hous-
ing.
576
Model Code Page
1. 12. 1986
1. Reconditioning planetary gear
A. Changing planetary pinion roller bear-

ings
1. Drain the oil from the hub. Raise the end of the front axle,
which is to be repaired, off the ground and remove the wheel
(24 mm).
2. Remove the planetary retainer (8 mm socket head).
7. Heat the planetary wheels slightly and push them into posi-
tion in the planetary retainer. Secure with the circlips.
8. Check the O ---ring of the hub and change it if necessary.

Apply grease to the O ---ring. Fit the planetary retainer and
tighten the bolts (8 mm, socket head, 50 Nm).
9. Fit the front wheel (24 mm, 330 Nm) and lower the front axle.
Fill the hub with oil (0,5 litre).
3. Remove the circlip for the planetary wheels. Lift the pinion
slightly upwards using two angular bars and then pull out the
wheel using a puller. B. Adjusting drive shaft end float
The drive shaft end float should be 0,3 ---0,6 mm.
4. Remove the circlip from the planetary wheels. Remove the

bearing rollers.
5. Fit a new bearing rollers and fix them in position with some 1. Measure the distance between the shims in the bottom of
grease and push the bearings into the planetary wheels. the planetary retainer and its upper contact surface
(measurement A).
N.B. Individual rollers may not be changed, but should
instead be changed as one set. The grooves in the planetary
wheels and the rounded inside of the bearings should be
facing in towards the planetary retainer.
6. Secure the bearing rollers with the circlip.
577
10. 1. 1992
2. Push in the drive shaft and measure the distance between 3. Remove the ring gear attaching bolts (15 mm). Pull out the
the shaft end and the contact surface for the planetary carrier ring gear using a puller (e.g. Kukko 20---20) and 4 M10x100
on the hub (measurement B). mm bolts together with a support plate.
3. The end float (X) is the difference between the two values N.B. The end of the shaft must not be used as a support for
X=A ---B. Adjust with shims until the correct end float has been the puller bolt.
obtained. Shims are available in thickness between 1,0 and
2.5 mm.
N.B. The shims can be fixed in position with grease or with a

punch mark.
C. Changing hub bearings and seals
1. Remove the planetary retainer (Op. A; 1 ---2).
4. Remove the hub in the same way as the ring gear using a
puller.
5. Remove the scraper seal and the shaft seal from the hub.
2. Remove the circlip and the washer from the sun gear shaft. Important! The latest front axles have in hub a cassette ---type
seal (order no 31062710). It is exchangeable with the earlier
seal. The wear ring of the earlier seal must be removed before
fitting the new seal.
578
10. 1. 1992
10. Heat the inner bearing of the hub and fit it against the outer
6. Drive out the outer bearing races for the wheel bearings bearing race which is fitted in the hub. Tap or press the
using a drift and fit new ones using ETV 893750. greased seal in against the bearing using ETV 891780. Fit the
scraper seal so that the plane face comes towards the steer-
ing knuckle. Fit the hub on the steering knuckle.
N.B. The fitting has to be carried out quickly before the bear-
ing has time to cool down. Apply sealing compound to the
shaft seal before fitting (e.g. Silastic 738 RTV).
Important! If You fit the cassette ---type seal (order no

31062710), apply sealing compound onto the outer diameter
of the seal. Apply alcohol onto the rubber coated inner diam-
eter. Fit the seal to a depth of 2,0 ---2,2 mm.
11. Heat the outer bearing and push it into position.
12. Pull the ring gear into position using its own bolts. Rotate
the hub at the same time and tighten the bolts to 90 Nm (66
lbf ft). Apply locking fluid to the threads (e.g. Loctite 601).
13. Fit a washer and circlip to the sun gear shaft. Check the
end float of the drive shaft (see under heading B).
7. Split the wear ring for the shaft seal using a chisel and
remove the ring. 14. Fit the planetary retainer (Op. A, 8 ---9).
D. Changing steering knuckle bearings
1. Remove the hub reduction gear (Op. 642 1A; 1 ---3) and pull
the drive shaft out of the housing.
8. Remove the inner wheel bearing. First use a wedge and

then a puller (e.g. Kukko 15---17 no. 3 and bolts).
N.B. If the wear ring is not removed, the bearing should be

removed by attaching the puller behind the bearing rollers.
9. Take a new wear ring, heat it and then fit it.
Important! If You fit a new cassette ---type seal (order no 2. Remove the steering knuckle bearings and drive out the
31062710), the wear ring must not be fitted. outer bearing races and the sealing cups. Fit new cups.
579
Model Code Page
1. 12. 1986
3. Drive in new outer bearing races using ETV 892 350.
4. Fit new steering knuckle bearings. Grease the bearing

races.
5. Push the drive shaft into the axle housing. Lift the hub
reduction gear into position and fit the king pins (19 mm, 120
N m).
N.B. The king pins must be fitted with O ---rings and seal cov-
ers it they were fitted before the parts were dismantled.
6. Measure the rolling resistance of the steering knuckle bear-

ings with a torque wrench applied to the king pin attaching
bolt. The resistance should be 8 ---11 Nm. Adjust the rolling
resistance adding or removing shims from under the upper
king pin.
7. Connect the tie rod to the steering arm (27 mm, 110 N m).
8. Fit the wheel (24 mm, 330 N m) and remove the support
from under the front axle. Fill the axle with oil (4.5 litres in the
differential and 0.5 litre in the hub).
580
Model Code Page
1. 12. 1986
Differential (Op. no. 644) 7. Connect the propeller shaft and tighten the bolts (23 Nm
(8.8) or 35 Nm (10.9) and secure the guard plate. Fill the differ-
ential with oil (4,5 litres).
1. Reconditioning differential
A. Changing pinion shaft seal

(without removing the shaft)
B. Removing differential
1. Drain the oil from the differential housing. Loosen the guard
for the propeller shaft. 1. Remove the front axle (Op. no. 641 A).
2. Disconnect the propeller shaft from the front end flange. 2. Remove the hub reduction gear from the longer axle hous-
ing section (Op. 642 1A, 2 ---3). Remove the drive shaft.
3. Mark the flange, the nut and the shaft so that the parts can
be assembled in the same relative position and also measure 3. Disconnect the tie rod on the opposite side from the steer-
the depth of the nut. This is done in order not to affect the rolling arm (27 mm).
ing resistance of the pinion bearings when assembling.
4. Pull the axle housing sections apart once the bolts have
4. Remove the locking sleeve for the nut, the nut itself, the been unscrewed (22 mm).
washer and drive flange. Change the shaft seal (ETV 891 840).
5. Position the bolts in the drive flange and push it into position
5. Remove the differential unit from the axle housing.
6. Fit the washer and nut on the pinion shaft and tighten the
nut to the same position as was recorded before dismantling.
Drive the locking sleeve into position using ETV 892 400 and
upset the edge of the sleeve at the groove.
581
Model Code Page
1. 12. 1986
6. Disconnect the universal joint from the drive flange. 3. Screw three M10 bolts into the tapped attaching holes of the
crown wheel and position a plate on top of the bolts. Press the
crown wheel away from the differential casing.
C. Changing differential bearings, differ-
N.B. Place something reasonably soft under the crown wheel
ential side gears and friction discs teeth and make sure the load is evenly distributed.
N.B. If the crown wheel has been changed, it is also necess-
ary to change the pinion shaft as they are a matched pair.
4. Remove the friction discs and the differential side gear from
the differential casing.
1. Pull off the differential bearings using puller.
5. Drive out the locking pin from the differential pinion shaft.
Remove the shaft and the differential pinions together with
2. Remove the lock washer for the crown wheel bolts and
bearings.
remove the bolts (17 mm).
582
Model Code Page
1. 12. 1986
6. Remove the other differential side gear and the friction

discs.
7. Fit the thrust plate in the differential side gear with the
ground face towards the differential gears.
13. Measure the clearance between the friction discs on the

other side through the opening in the casing using a feeler
gauge.
--- If the clearance is not between 0,10 ---0,15 mm the thrust

plates should be changed until the correct clearance is
8. Fit the intermediate discs and the friction discs alternately obtained. The thrust plates are available in thicknesses
on the differential side gear. between 2,8 ---3,3 mm, see table in figure 2.
9. Fit the differential side gear in the differential casing. 14. Drive in the locking pin for the differential pinion shaft.
10. Fit the differential pinion bearings, the pinions and the 15. Fit the crown wheel and tighten the attaching bolts cros-
shaft in the casing. swise and evenly (17 mm, 70 Nm) and drive down the lock
washer for the bolts using a sleeve which has a slightly larger
11. Fit the other differential side gear and the trust plate with diameter than the bolt heads.
the grounded face towards the gear and the friction discs in
the casing. 16. Warm up the differential bearings and fit them.
17. Adjust the tooth backlash and the preload of the differen-
tial bearings (Op. D).
12. Compress the friction and intermediate discs, and

measure the clearance between the top intermediate disc and
the face of the casing using a depth micrometer.
583
Model Code Page
1. 12. 1986
D. Adjusting tooth backlash and differen-

tial bearing preload
Fig. 3. Adjusting tooth backlash and differential bearing pre- 3. Lift the differential unit into the housing. Fit the other outer
load.
bearing race in tool ETV 893 770 (item 2 in fig 3) and fit the tool
in the axle housing as shown in the figure below.
1. Remove the outer bearing races for the differential bearings
using an impact puller.
4. Tighten up the bearings using the centre bolt of the tool

(item 3 in Fig. 3) until there is no clearance. At the same time
2. Fit shims to a thickness of 1,2 mm in the bearing housing
rotate the differential to bed in the bearings.
of the differential bearing, and drive the outer bearing race into
the housing using a drift.
584
1. 9. 1995
5. Insert the stylus of the indicator gauge through the oil drain- 9. Remove the adjusting tool and take away the outer ring.
ing hole so that it rests against a tooth on the crown wheel, and Measure the distance between the contact surface of the tool
measure the backlash which should be 0,1 ---0,15 mm and the bottom of the bearing housing (measurement E in
(0.004 ---0.006 in). If the backlash is not correct change the fig. 3.).
thickness of the shims pack. Shims are available in thick-
nesses between 0,5 and 1,8 mm, item 1 Fig. 3.
6. Fit the differential unit into the housing using tool ETV 893
770 and tighten up the bearing until there is no longer a clear-
ance.
N.B. Rotate the differential casing while tightening in order to

bed in the bearings.
10. Measure the corresponding distance on the shorter axle

housing (measurement F in fig. 3).
11. The shim thickness (X) which is required for the correct
bearing preload is obtained as the difference between
measurement E and measurement F (X=E ---F). Set the calcu-
lated shim thickness under the bearing in the shorter axle
housing.
7. Tighten up the differential bearings using the tool and

measure the combined rolling resistance of the differential
unit and the pinion shaft. The resistance should be the rolling
resistance of the pinion shaft + 1 ---2 Nm (0.7 ---1.5 lbf ft).
N.B. Adjust the rolling resistance for the differential to the

lower limit if the corresponding value for the pinion shaft was
close to the lower limit (conversely adjust it to the upper limit).
N.B. If the pinion shaft has not been removed for repair its roll-
ing resistance should be measured before the differential unit
is fitted.
8. When the correct rolling resistance has been obtained lock

the slide of the tool with the locking screw.
585
Model Code Page
1. 12. 1986
E. Changing pinion shaft bearings and oil

seal
N.B. When changing the pinion shaft, the crown wheel has to
be changed too.
1. Remove the differential unit from the axle housing.
5. Pull out the outer bearing outer race using a puller (e.g.
Kukko 22---2 and puller drift 21/7).
2. Remove the locking sleeve and the pinion shaft nut (30
mm).
6. Remove the inner bearing from the shaft using a puller (e.g.
Kukko 15---17 and Kukko 20---20). The compression bushing
comes away at the same time.
7. Then measure the position of the pinion shaft (Op. F.).
3. Tap the pinion shaft out of the bearing.
8. Fit the outer bearing outer race using ETV 893 730.
4. Remove the pinion shaft seal. Drive out the inner bearing
outer race using a drift.
586
Model Code Page
1. 12. 1986
N.B. Rotate the shaft while tightening the nut.
9. Position the shims at the bottom of the bearing location for

the inner bearing. Pull in the outer bearing race of the inner
bearing into the housing using E1V 893 720 by using ETV 893 16. Drive the locking sleeve onto the shaft using ETV 892 400
730 and a bolt (diam. 20 mm, length 160 mm). and upset its edge in the locking groove.
10. Heat the inner bearing and fit it on the shaft.
11. Fit the compression bushing (which always should be

changed when the pinion shaft has been removed) on the pin-
ion and push the pinion into the housing.
12. Heat the outer bearing and push it onto the shaft.
13. Drive on the shaft seal using ETV 891 840. Fit bolts in the
drive flange and push the flange onto the pinion shaft.
14. Fit the washer and the nut on the pinion. Tighten the pinion
by holding the flange at the bolts.
15. Measure the rolling resistance of the shaft and tighten the
nut to approx. 180 Nm until the torque required to turn the
shaft is between 1 and 2 Nm (see Fig. 4 item 1).
587
Model Code Page
1. 12. 1986
F. Adjusting pinion shaft position

N.B. The position of the pinion shaft should be checked when
changing the axle housing, crown wheel/pinion shaft or the
pinion shaft bearings.
Fig. 4. Measuring position of pinion shaft
2. To the obtained measurement G add half the diameter of

1. Measure the distance from the edge of the hole in the differ- the hole in the differential housing (measurement H/2 in Fig.
ential housing to the edge of the rear pivot bearing (measure- 4, e.g. 81,4 mm). In this way measurement A is obtained, i.e.
ment G in Fig. 4, e.g. 150,6 mm). G+H/2, e.g. 232,0 mm.
588
Model Code Page
1. 12. 1986
G. Fitting the differential unit

1. Lift the differential unit into the axle housing. Change the
O ---ring at the end of the axle housing.
3. Measure the distance between the rear edge of the axle

housing and the bottom of the inner bearing housing (mea-
surement B in Fig.4 e.g.121.5 mm. Use a shim or similar as
an aid).
2. Fit the shims and outer race tor the bearing in the axle hous-
ing and assemble the axle housing (22 mm, 90 N m). Connect
the tie rod to the steering arm (27 mm,110 N m) and secure
the nut.
4. Measure the thickness of the inner bearing (measurement

C in Fig.4, e.g.25.4 mm). Rotate the bearing in order to bed
in the rollers.
5. Read off the values stamped into the end of the pinionshaft 3. Push in the drive shaft from the other end of the housing and
(measurement D in Fig.4, e.g.84.0 mm). lf a tolerance is also fit the hub reduction gear (Op.642 1 A, 8—10) .
stamped into the end of the pinion shaft, this tolerance should
be subtracted or added depending on whether there is a 4. Change the hub O ---ring and lubricate it. Push the planetary
minus or plus sign in front of the tolerance. retainer into place and tighten the bolts (8 mm, socket head,
50 N m).
6. Shim thickness:
5. Secure the universal joint to the pinion shaft drive flange
X=A---(B+C+D) (8.8 bolts 23 N m,10.9 bolts 35 N m).
E.g. X = 232.0 mm --- (121.5+25.4+84.0) mm = 1.1 mm 6. Fit the front axle (Op.641 C).
(Shims are available in thicknesses between 0.9 and 1.5

mm).
7. Adjust the tooth backlash and the differential bearing pre-

load (Op. D).
589
590
Model Code Page
64. Powered front axle Sige 355-- 665 640A 1
1. 9. 1992
Contents
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Repair instruction
Axle housing and central pivot bearing brackets (Op. no. 641)
A. Removing front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing front axle central pivot bearing bracket sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Fitting front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Drive shafts (half shafts) (Op. no 642)

1. Reconditioning drive shafts:
A. Changing outer ball bearing and oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing inner bearing bushing and oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Reconditioning double universal joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.
1. Reconditioning planetary hub gear:
A. Changing planetary pinion roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing hub bearings and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Changing steering knuckle bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. Reconditioning differential:
A. Changing pinion shaft seal (without removing the shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing differential brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Changing pinion shaft/crown wheel:

A. Removing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Removing pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Fitting pinion shaft and adjusting position of pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Adjusting differential bearing preload and tooth backlash pinion/crown wheel . . . . . . . . . . . 5
E. Assembling front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjustments (Op no 645)

A. Adjusting toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting front wheel steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
591
Model Code Page
1. 9. 1992
Technical data
Front wheel drive is engaged with a dog clutch in the gearbox.
Axle type designation:
--- on 665 as standard. On 355---555 tractors from tractor ser. no. 658483 . . . . . . . . . . . . . . . . . Sige 020V
Gear ratios:
--- differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,846
--- hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,538
--- total gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,763
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1˚
KPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5˚
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---5 mm
Front axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±13,5˚
Steering lock (adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 55˚
Flange distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1580 mm
Automatic differential brake:
--- number of friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3+3 pcs
--- number of intermediate discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4+4 pcs
--- thrust plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1+1 pcs
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W/90 GL ---5 EP
10W/30 GL ---4
Oil capacities:
--- differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,5 litres
--- hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x0,5 litres
Tightening torques
Front axle attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Front wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Nm
Propeller shaft flange joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Tie ---rod --- steering arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
King pin attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Ring gear attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Crown wheel attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Pinion shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm
Axle housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Nm
Planetary gear housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Setting values
Thickness of diff. brake disc set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,51---14,69 mm
Steering knuckle bearing preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6 mm
Differential bearing preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm
Tooth backlash, crown wheel/pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2---0,25 mm (measured at
pinion shaft drive flange)
Rolling resistance, pinion shaft bearings measured
using spring balance (without seals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---5 kg ø 60 mm (0,9---1,5 Nm )
Axial clearance (between axle housing ---pivot bearing brackets) . . . . . . . . . . . . . . . . . . . . . . . . . 0,1---1,1 mm
Sealing compounds and locking fluids used

Sealing compound Loctite 290
--- on outer sides of oil seals
--- on wear ring inner surfaces
--- on hub seal dust cover
Medium strength locking fluid Loctite 242
--- ring gear attaching bolts
Heavy strength locking fluid Loctite 586
--- tie ---rod --- piston rod
592
Model Code Page
15. 9. 1995
1. 3. 1997
Special tools
ETV 892 290 Sleeve for fitting drive shaft outer oil seal (Sige 6100---8100)
ETV 893 600 Sleeve for fitting pinion shaft oil seals (Sige 6100---8100)
ETV 894 020 Plate for fitting hub oil seal (Sige 6100---8100)
ETV 894 150 Plate for fitting latest hub oil seal of cassette type, 1108/94---.
ET 894 010 Drift for fitting/removing drive shaft bushings (Sige 6100---8100)
ETV 892290 ETV 893600
ET894010
ETV 894020
ETV 894150
Extractor for removing king pins
593
Model Code Page
1. 9. 1995
1. 3. 1997
Powered front axle
Powered front axle Sige on 355---555 and 665 tractors is a In each hub gear the planetary pinions (3 off) are carried
lighter version of the heavier Sige axle which is fitted on Valmet
in roller bearings in the retainer. The ring gear is bolted to
6100---8100 tractors. Below are given constructional differ-
the steering knuckle.
ences compared with the heavier Sige axle:
The steering knuckle is attached to the front axle housing
--- Hub planetary pinions are narrower and they have only one
by the king pins which are carried in taper roller bearings.
bearing roller race. The hub cover (planetary gear carrier) is
The bearing preload of the king pins is adjusted with
narrower.
shims at the upper pin.
--- Drive shafts and double joints are smaller. Drive shaft inner
oil seal is different.
The differential is provided with an automatic differential
--- Axle housing is smaller and it has not openable hatches.
brake. The friction discs are fitted between the differential
--- Pinion shaft and its bearings are smaller.
side gears and the differential casing.
--- Different oil fillings in the hubs and in the axle housing.
Position of pinion shaft, tooth backlash and differential
The drive shafts are carried in bearing bushings in the axle
and pinion bearing preload are adjusted with shims.
housing and in ball bearing in the swivel housings.
Figure 1. Sige front axle

1. Plug for checking oil level in axle housing
2. Oil filling plug for axle housing
3. Plug for draining oil in axle housing
4. Oil filling and draining plug for hub
Note! Oil levels in the axle should be checked every 400 running hours. Oil should be changed yearly/every 800 running hours.
Central pivot bearing bracket nipples (B) must be greased every 50 running hours, other nipples every 200 running hours.
594
Model Code Page
1. 9. 1992
Figure 2. Planetary gear
1. Shims for adjusting steering knuckle bearing preload

2. Locking fluid Loctite 242 on threads
3. Shims for adjusting wheel bearing preload
4.Sealing compound Loctite 290
a) Adjustment of steering knuckle bearings preload
b) Adjustment of steering knuckle bearings preload
595
Model Code Page
1. 9. 1992
Figure 3. Differential, powered front axle
596
Model Code Page
1. 9. 1992
Steering cylinder
2 1
2
4
2
5
Figure 4. Steering cylinder up to axle no. 129/92 6

(same as on 6100 ---8100 tractors)
1. Removal of locking wire

2. Fill with silicon mass when fitting
3. Locking fluid Loctite 586 on the threads
5. Pin to prevent rotation of end piece
6. Fitting of locking wire
Figure 5. Steering cylinder from axle no. 130/92

1. Locking fluid Loctite 586.
597
598
Model Code Page
1. 9. 1992
Axle housing and central pivot bearing

brackets (Op. no. 641)
A. Removing front axle

1. Drain the oil from the hub gears and from the differential (if
necessitated by the repair job in hand).
2. Remove the propeller shaft guard. Disconnect the pro-

peller shaft front flange joint from the pinion shaft.
3. Disconnect oil hoses from the steering cylinder. Raise the

tractor front end and place axle stands under the front frame.
Remove front wheels if needed.
4. Connect the hoist to the front axle and remove axle bearing
brackets from tractor frame. Remove the axle from the tractor.
3. Check condition of v ---rings and intermediate rings. Grease
all parts with universal grease. Also grease the o---ring for the
rear bracket sleeve.
4. Fit bearing brackets onto the axle and fit the axle (Op C).
N.B. Central pivot bearing brackets should have a small axial

B. Changing central pivot bearing clearance (0,1---1,1 mm). Adjust this if necessary using shims.
brackets sleeves
1. Remove front axle (Op. A 2 ---4)
C. Fitting front axle

1. Check that the bearing brackets are in right position on the
axle.
2. Lift up the front axle and tighten the bearing bracket attach-
ing bolts to 200 Nm. Ensure that the guide sleeves are in right
positions.
3. Connect the steering cylinder oil hoses. Connect the pro-

peller shaft flange joint to 35 Nm. Fit the propeller shaft guard.
4. Fit the front wheels if removed (330 Nm). Remove supports

from under the tractor.
5. If the oil was drained refill the differential (6,5 litres) and
2. Remove bearing brackets from axle. Check condition of both hubs (2x0,5 litre).
bearing sleeves.
6. Grease the front axle central pivot bearings.
7. Test run the tractor and check that the steering system func-
tion properly and that the front axle bracket do not have too
much axial play.
599
600
Model Code Page
1. 9. 1992
Drive shafts (Op. no. 642)
1. Reconditioning drive shafts
A. Changing outer oil seal and ball bear-

ing.
1. Raise the tractor front end and place axle stands under the
tractor. Drain the oil from the hub.
4. Unscrew the planetary gear housing screws and pull the

planetary gear unit out from the hub.
2. Disconnect the tie rod from the steering arm.
5. Unscrew the ring gear attaching bolts and pull out the ring
gear using puller screws (M8).
3. Support the hub with a suitable hoist and remove the king
pins. Carefully pull out the hub from the axle housing; the drive
shaft will also be loosened.
Note! Do not damage the drive shaft inner oil seal. King pins
can be removed by using a standard extractor e.g. Kukko
22---1 (see page 640/3)
6. Remove the drive shaft circlip and spacer ring and knock
out the drive shaft from the hub.
7. Pry out the drive shaft outer seal from the hub. Remove the
ball bearing circlip and the bearing. Fit a new bearing; push it
right home against the bottom of the housing and fit the circlip.
601
Model Code Page
1. 9. 1992
1. 9. 1995
ETV 892 290
8. Oil the new seal and fit it into the place against the circlip
(tool ETV 892290 can be used when fitting the seal). 11. Fit the ring gear and tighten bolts evenly to 75 Nm. Apply
locking fluid Loctite 242 to threads.
Note! Apply sealing compound Loctite 290 to the outer side
of the seal. 12. Check the planetary gear housing o---ring and change if
necessary. Apply universal grease to the o---ring. Attach the
9. Fill the space between the seal lips with universal grease. housing to the hub. Tighten the screws to a torque of 70 Nm.
13. Fit the hub on the axle housing and push the drive shaft
carefully into the housing, avoiding damage to the drive shaft
10. Wrap e.g. a small plastic bag round the drive shaft splines inner oil seal. Push the drive shaft until its splines slide into the
(sun gear) and push carefully into the hub. Remove the pro- splines in the differential.
tective plastic bag. Fit the drive shaft spacer ring and circlip.
14. When the drive shaft is fully home the hub is attached to
the axle by means of the king pins. Replace the same shims
under the upper king pin, which were removed. Tighten the
king pins to 120 Nm.
15. Connect the tie rod to the steering arm (160 Nm). Fill the
hub with oil and fit the front wheel (330 Nm). Test run the trac-
tor and check for possible leakages
602
Model Code Page
1. 9. 1992
B. Changing inner bearing bushing and oil 5. Fit the drive shaft and the hub onto the axle housing (see
Op. A; 13 ---15).
seal
C. Reconditioning double universal joint

1. Remove the drive shaft (see Op. 642 1A; 1 ---6).
1. Remove the hub and the drive shaft (see Op A; 1 ---3).
2. Remove the old oil seal from axle housing.
3. Check the bearing bushing behind the seal. If the bush has
to be changed tap it into the axle housing by using the drift ET
894010. Fit the new bush into its place with the same drift. 2. Remove the cross journal snap ---rings (8 pcs).
Grease the bushing with universal grease.
N.B. The old bushing can be removed from the axle housing
by unscrewing the axle housing joint.
3. Secure the joint in a vice and tap either side of the fork
shank to remove the bushings. Remove all the bushings in the
same way; this will also free both cross journals.
4. Apply sealing compound Loctite 290 to the outer side of the
new oil seal. Oil the seal and fit it carefully in place. Fill the N.B. There are bearing needles in the bushing. The needles
space between the seal lips with universal grease. can be kept in position with grease.
603
Model Code Page
1. 9. 1992
4. Fit the bushings as shown in the figure above. When the

bushings are in place the snap ---rings can be fitted.
5. Fit the drive shaft (see Op. 642 1A; 10 ---15).
604
Model Code Page
1. 9. 1992
Hub reduction gears (Op. no 643)
1. Repairing planetary gear
A. Changing planetary pinion roller bear-

ings
1. Raise the front end of the tractor and support the tractor
frame. Remove the front wheel on the side requiring repair.
Drain the oil from the hub.
4. Pull off the shafts using a screw (M8). The fit is not particular-
ly tight.
5. To remove the gears, first move two from the outside, after
which the third one can be removed through the middle. Re-
move all the gears in the same way.
6. Remove the old bearing rollers from the gears.
7. Fit new bearing rollers (rollers are changed as a complete

set) and apply grease to the rollers so that they are held in
place on the gears. Fit the spacer rings onto the gear sides.
8. First fit the two gears carefully through the middle hole of
2. Unscrew the planetary gear housing screws and pull the the retainer and position them against the housing. Then fit
housing off the axle. the third gear into place through the middle hole.
N.B. Check that the rollers and side rings are correctly posi-
tioned before fitting the pins.
9. Push the pins into place and fix them with circlips.
3. Remove the planetary pinion shaft circlips.

10. Check the o---ring on the planetary gear housing and
change if necessary. Fit the planetary gear onto the steering
knuckle and tighten the bolts to 70 Nm.
11. Fit the front wheel (330 Nm). Fill the hub with oil and test
run the tractor.
605
Model Code Page
15. 9. 1995
1. 3. 1997
B. Changing wheel bearing and hub oil

seal
1. Raise the front end of the tractor and support it with sturdy
trestles. Remove the front wheel from the side to be repaired.
Drain the oil from the hub.
6. Remove the inner bearing from the steering knuckle using

an extractor. When the bearing is changed it can be removed
by attaching a puller behind the rollers.
7. Heat the new inner bearing (80˚C) and push it fully home
onto the knuckle. Oil the bearing rollers.
2. Unscrew the planetary gear housing screws and remove

the housing from the axle.
3. Unscrew the ring gear attaching screws; pull off the ring
gear with aid of two screws (M8).
8. Change hub oil seal if necessary (ETV 894 020). It can be

removed by tapping it through the holes in the opposite side.
Fit the dust seal ring. Fill the space between the lips of the seal
with universal grease.
4. Pull off the wheel attaching flange using a puller; this action
releases the outer bearing of the wheel. Note! The latest axles have a new cassette seal in the hub.
This seal is fitted with plate ETV 894 150. The cassette seal is
5. Use a drift to tap out the wheel bearing outer races. Fit new fitted on the axles with effect from axle no. 1108/94.
outer races.
9. Check the wear ring of the hub oil seal and change it if
necessary. The wear ring is easier to remove if it is warmed up.
N.B. Heat the wear ring to 80˚C when fitting. Apply sealing
compound Loctite 290 to the inner surface of the wear ring.
Important: to ensure that the wheel bearing has the correct

preload replace the same shims under the outer race of the
outer wheel bearing.
606
Model Code Page
1. 9. 1992
1. 9. 1995
C. Changing steering knuckle bearings

1. Raise the tractor front end and support it with sturdy trestles.
Remove the front wheel from the side to be repaired.
2. Disconnect the tie rod from the steering arm.
10. If you change the dust---cover apply sealing compound

Loctite 290 to the rear side. Fix the dust---cover with six equi-
distant clips of the drift punch.
11. Fit the wheel attaching flange onto the knuckle. It should
be pushed fully home so that the outer race of the bearing is
against the bearing rollers.
3. Support the hub with a hoist and remove the king pins by
using extractor Kukko 22---1 (see page 640/3).
12. Heat up the outer bearing (80˚C) and push it fully home
against the outer race. Oil the bearing.
4. Pull the hub carefully off the axle housing; this releases the
drive shaft.
Note! Do not damage the drive shaft inner oil seal if it is not
being changed.
13. Fit the ring gear and tighten the screws to 75 Nm. Apply
locking fluid Loctite 242 to the threads.
14. Check the condition of the o---ring on the planetary gear

housing and change it if necessary. Grease the o---ring. Fit the
planetary gear housing and tighten the screws to 70 Nm.
15. Fit the front wheel, tighten to 330 Nm and fill the hub with
oil. Test---run the tractor.
607
Model Code Page
1. 9. 1992
1. 1. 1998
5. Change the outer races of the steering knuckle bearings.

Apply compound Loctite 290 to the outer sides of the races.
Apply grease to the bearing surface and fill the bearing loca-
tion with grease. Fit the spacer rings in front of the races. Apply --- On the knuckle housing measure the distance between the
Loctite 290 to the spacer rings. surfaces as shown in the figure above (measurement M e.g.
256,85)
6. Remove the bearings from the king pins and fit new bear-
ings. Grease bearing rollers. Fit new seals into the king pin --- Calculate the number of shims required (measurement S),
holes inside the knuckle.Grease the seals. taking into account the fact that the bearings are preloaded by
0,6 mm (measurement P).
7. Adjust the steering knuckle bearing preload as follows:
S=N---M ---P (=258,50---256,85---0,6=1,05)
8. Fit the required number of shims under the upper king pin.
9. Fit the steering knuckle onto the axle housing (see Op 642
1A;13 ---15).
D. Knuckle housings
Only one type of knuckle housings are delivered as a spare
part for the powered front axle Sige on 365---900 tractors. It is
fitted without changes with the earlier hub oil seal.
If the knuckle housing is fitted with the cascette seal, the wear
ring must be removed and a protective ring must be added
onto the knuckle housing. The protective ring is always deliv-
ered together with the knuckle housing.
Knuckle housings which are delivered as a spare part include

wear ring 31791120 ø 165/150 and protective ring 31791010 ø
200/178.
--- Press the king pins into place using a screw clamp and
measure the distance between the inner surfaces of the king For earlier (and current) axles, knuckle housings as a spare
pin cover (measurement N e.g. 258,50 mm) part are supplied with wear ring 31791110 ø 165/163 up to
axle number 941107.
608
Model Code Page
1. 9. 1992
1. Reconditioning differential
A. Changing pinion shaft seal (without

removing the front axle)
1. Drain the oil from the differential. Remove the protective
shield and unscrew the propeller shaft front flange joint.
2. Unscrew the pinion shaft nut and remove the spacer ring
and shims which are under the nut. Pull the drive flange off
the shaft.
3. Pry out the oil seals and fit new seals (tool ETV 893600 can
be used to facilitate fitting the seals). Fill the space between
the lips of the seal with universal grease).
4. Check the drive flange o---ring and change if necessary. 3. Pull the axle housing section apart once the bolts have been
Grease the o---ring. unscrewed. Remove the differential unit from the axle hous-
ing.
5. Fit the drive flange, shims (use the same shims) and the
spacer ring onto the shaft. Tighten the nut to 250 Nm. Connect
the propeller shaft flange joint (35 Nm). Fit the protective
shield.
6. Fill the differential with oil and test---run the tractor. Check for
possible leakages.
B. Changing differential friction discs

1. Raise the front end of the tractor and support it with sturdy
trestles. Drain the oil from the differential housing.
4. Unscrew the bolts holding the differential carrier. Knock off

the crown wheel and remove the locking pins.
N.B. Mark the halves of the differential carrier to facilitate reas-

sembling.
2. Disconnect the tie ---rod from the steering arm on the side
with the shorter axle section.
5. Open the carrier and remove the various components.
609
Model Code Page
1. 9. 1992
10. Rotate the differential with the splined end of the drive
shaft. The drive shaft should turn freely, without resistance.
11. Fit the differential unit into the housing and attach the
bolted joint of the axle housing. Check the o---ring on the joint
and apply grease to it. Tighten the screws to 190 Nm.
12. Attach the tie ---rod to the steering arm (160 Nm). Fill the
differential housing with oil. Test---run the tractor.
2. Changing crown wheel/pinion shaft

Note! This operation is easier if the front axle is detached from
the tractor. However this is not essential.
6. Check the friction disc for wear and change if necessary. A. Removing differential
Measure the total thickness of the set of discs. It should be in
the range 14,51 ---14,69 mm. Immerse the discs in oil before
reassembling. 1. Remove the front axle (Op. no. 641 A). Drain the oil from the
differential housing.
N.B. In the event of replacement, renew both the RH and LH
pack. The thickest disc with internal teeth should be fitted with 2. Detach the tie ---rod from the steering arm on the side with
the smooth side against the differential side gear. Next fit fric- the shorter axle section.
tion disc and intermediate disc alternatively. The last disc
should have external teeth.
7. Also check both differential pinions and side gears and

change if necessary. Oil all parts.
N.B. The differential pinion shaft is locked by means of the

locking pin. The diff. pinion thrust---washers are fitted so that
the locking lugs engage in the grooves on the differential
carrier.
8. Reassemble the differential and fit the carrier halves so that

the marks are in the same places as they were before dis-
mantling. Fit the crown wheel and tighten the screws to 70
Nm.
3. Unscrew the bolted joint on the axle housing.
4. Remove the differential unit. Detach the old crown wheel. Fit
a new crown wheel and tighten the screws to 70 Nm.
9. Fit the locking pins. First fit the bigger pin and then the
smaller pin inside with the split pointing towards the heads of
the screws.
610
Model Code Page
1. 9. 1992
1. 1. 1998
4. Tap out the inner bearing race from the housing and remove
B. Removing pinion shaft the shims from under the race. Tap the inner bearing off the
shaft.
5. Check the condition of the bearings and change if necess-

ary.
C. Fitting pinion shaft and adjusting posi-

tion
(98,00
1. Unscrew the pinion shaft nut and remove the spacer ring
and shims from under the nut. Remove the drive flange from
(124,00)
the shaft.
S=0,2
0,3
Figure 5. Adjusting pinion shaft position.

2. Tap the pinion shaft out from the bearing and remove the
outer bearing as it is freed. 1. Read off value E which is stamped on the end of the pinion
shaft (e.g. 98,00 mm).
2. Check the smaller figure marked in the axle housing (in side
for the longer axle section), measurement C (e.g. 124,00
3. Remove the oil seals from the shaft housing and use a mm).
puller to extract the outer bearing race.
Note! If there is not a measurement marked in the axle hou-
sing, see page 644/6A.
611
Model Code Page
1. 9. 1992
s=0,15
0,2
0,5
Figure 6. Adjustment of pinion shaft bearing preload.

3.Measure the thickness of the inner bearing, measurement
H (e.g. 25,4 mm).
4. Calculate the number of shims required for correct pinion

shaft position:
S = C --- (E+H) = 124,00 ---(98,00+25,4) = 0,6 mm.
9. Use a spring balance (see figure above) to measure the

force needed to rotate the pinion shaft. The rolling resistance
should be 3 ---5 kg. If the rolling resistance is not correct the
number of shims under the nut must be adjusted.
N.B. If the rolling resistance is too great more shims are re-
quired and vice versa.
5. Put the shims required under the inner bearing outer race
10. When rolling resistance is correct the seals can be fitted.
and fit the outer race against the shims. Fit the outer bearing
Grease the lips of the seal with universal grease; fit a dust seal
outer race.
in front of the seal.
6. Heat the inner bearing to 80˚C and fit it onto the pinion shaft.
N.B. Tool 893600 can be used when fitting the seals.
Push fully home.
11. Fit shims, spacer ring and drive flange; tighten the nut to
7. Push the pinion shaft into the housing. Heat the outer bear-
250 Nm.
ing to 80˚C and push it onto the shaft against the outer race.
8. Fit the drive flange onto the pinion shaft (do not fit the seals
yet) and fit the shims, spacer ring and the nut. Tighten the nut
to 250 Nm.
N.B. Turn the shaft 20---30 revolutions before measuring the

rolling resistance and lubricate the bearings with oil.
612
Model Code Page
1. 9. 1992
1. 1. 1998
D. Adjusting differential bearing preload

and pinion/crown wheel tooth backlash
(78,20)
(226,50)
(150,20)
S=0,2
0,5
Figure 7. Adjusting differential bearing preload.
1. Remove differential bearing outer races from both axle sec-

tions and remove any shims that may be fitted behind the
races. Remove roller bearings from the differential carrier.
2. Fit new bearings onto the differential carrier. Press outer

races against the bearings and use a vernier caliper to
measure the distance between them as shown in the figure
above, measurement D (e.g. 226,50 mm). N.B. When
measuring the use of measuring pieces is necessary.
4. Read off measurement B marked inside the shorter axle

housing. This is the distance between the bottom of the bear-
ing housing and the axle housing flange surface (e.g. 78,20
mm).

5. The preload (P) of the differential bearings should be 0,05

mm. Calculate the number of shims required as follows:
S = (A+B) ---D+P = (150,20+78,20) ---226,50+0,05; S =

1,95 mm.
3. Read off measurement A (larger figure) marked inside the
longer axle housing. This is the distance between the bottom
of the differential bearing location and the axle housing flange
surface (e.g. 150,20 mm).

613
Model Code Page
1. 9. 1992
6. Fit an equal number of shims under each differential bear-

ing. Fit the differential into the axle housing and connect the
axle sections with several screws (190 Nm).
0,20...0,25 mm
Figure 8. Adjusting tooth backlash between pinion/crown

wheel
8. If the backlash is not correct transfer shims from one bear-

ing race to the other.
7. Measure the pinion/crown wheel tooth backlash using an
indicator gauge stylus against a screw on the drive flange. The N.B. If the backlash is too small transfer shims from the
backlash should be in the range 0,20 ---0,25 mm. shorter axle section side to the longer side and vice versa.
614
Model Code Page
64. Powered front axle Sige 355-- 865 644A 6A
1. 1. 1998
Note! If there are not fitting measurements marked in the axle

housing, the measurements can be measured according to
the pictures below:
B
78,20
A
150,20
B
S2
S1
A
124,00
C
C
D D
2
615
616
Model Code Page
1. 9. 1992
E. Fitting front axle

1. When the backlash is correctly adjusted unscrew the axle
housing joint and check the condition of the o---ring.
2. Change the o---ring if necessary and apply grease to it.
3. Connect the bolted joint of the axle housing. Tighten the at-
taching screws to a torque of 190 Nm.
4. Attach the tie ---rod to the steering arm.
5. Fit the front axle (see Op no 641 C). Fill the differential
housing with oil.
617
618
Code Page
1. 9. 1992
B. Adjusting steering lock

Adjustments (Op. no 645)
A. Adjusting front wheel toe ---in
1 2
When altering the track width or when fitting a front loader, al-
ways make sure that the front wheels have free movement to
A+0 ---5 mm full lock in both directions and that the front axle and the
wheels can oscillate fully. If necessary adjust the steering lock
First check that there is no play on the ball joints of the steering stop screws on the powered front axle.
arms and tie rod. Set the wheels for running straight ahead. To carry out the adjustment slacken the locking nuts (1) and
adjust the adjusting screws (2). After adjusting tighten the
Checking: locking nuts.
Make a vertical mark at the front both tyres on the middle of the N.B.! Adjust the adjusting screws of both sides to the same
tread level with the hubs. Measure the distance between the length, so that the turning angle is same on both sides.
marks. Roll the tractor forwards so that the marks again come
level with the hub, this time at the rear edge. Measure the dis-
tance between the marks again. The measurement should be
0 ---5 mm larger at the rear edge.
1 2
Adjusting:
Slacken the locking screws (1) of the tie rod and turn the ad-
justing screw (2) in the desired direction.
Check the measurements again as above and tighten the
locking screws when the correct measurement has been ob-
tained. Both tie rods must be adjusted so that there is no limi-
tation on the steering lock.
619
620
71. Frame
70. Frame and wheels
72. Wheels
621
622
Model Code Page
15. 4. 1999
71. Frame 205-- 900 710 1
1. 9. 2001
Dimensional drawing, tractor frame
623
Model Code Page
10. 1. 1992
71. Frame 205-- 865 710 2
1. 3. 1997
Tractor frame
4---cyl.
624
Model Code Page
1. 5. 1996
72. Wheels 205-- 865 720 1
1. 3. 1997
Alternative tyre equipmen (in pairs)
Rear Front 205 255 305 355 365 405 455 465
13.6--- 36/8 7.50--- 16/8 x x x x x x x x
13.6R36/8 7.50--- 16/8 x x x x x x x
16.9--- 30/8 10.00--- 16/8 x x x x x x x
16.9R30/8 10.00--- 16/8 x x x x x x x
13.6--- 36/8 10.00--- 16/8 x x x x x x x
13.6R36/8 10.00--- 16/8 x x x x x x x
14.9--- 30/8 7.50--- 16/8 x x x x x x x
16.9R34/82) 10.00--- 16/8 x x
16.9--- 30/8 7.50--- 16/8 x x
13.6--- 38/8 7.50--- 16/8 x x
Rear Front 205---4 255---4 305---4 355---4 405---4 455---4 465---4 555---4 565---4 665---4 865---4
365---4
16.9--- 30/8 11.2--- 24/8 x x x x x x x x x x
16.9R30/8 11.2R24/8 x x x x x x x x x
13.6--- 36/6 11.2--- 24/8 x x x x x x x x x x
13.6R36/8 11.2R24/8 x x x x x x x x x
18.4R30/8 12.4R24/81) x x x x x x
16.9R34/82) 12.4R24/81) x x x x x
16.9--- 34/8 12.4--- 24/81) x x x x x
16.9R30/8 12.4R24/8 x x x x x
13.6R38/8 12.4R24/81) x x x x x x
480/70R34 360/70R241) x x x x x
16.9R34/8 13.6R24/8 x x x x x
16.9--- 34/8 13.6--- 24/8 x x x x x
480/70R34 380/70R24 x x x x x
18.4R34 14.9R24 x
18.4--- 34/8 14.9--- 24/8 x
520/70R34 420/70R24 x
13.6--- 38/8 12.4--- 24/8 x
14.9R38/8 13.6R24/8 x
16.9R38 14.9R24 x
18.4--- 34/14 14.9--- 24/FOR x
18.4--- 34/14 14.9--- 24/14IND x
16.9--- 34/14 13.6--- 24/12IND x
18.4R30/8 12.4R24/8 x x x x
13.6R36/6 12.4R24/8 x x x x
13.6--- 36/6 12.4--- 24/8 x x x x
13.6--- 36/6 12.4R24/6 x x x x
13.6R38/8 12.4R24/83) x x x x
1)The front wheel turning angles must be limited, when necessary

2)On --- 55 models, use of snow chains prohibited.
3) With 12.4--- 24 tyres the front wheel turning angle must be limited
Always contact your dealer for correct ratio when changing tyres on 4WD--- models.
625
Model Code Page
1. 3. 1997
72. Wheels 205-- 900 720 2
1. 1. 1998
Tyre pressures and permissible loadings (at speed of 30 km/h, 0.

R---tyres 40 km/h).
Fron wheel Pressure Max. load per tyre
7.50--- 16/8 370 kPa 870 kg
10.00--- 16/8 280 kPa 1190 kg
11.00--- 16/8 160 kPa 1320 kg
11.2--- 24/8 240 kPa 1225 kg
11.2R24/8 160 kPa 1180 kg
12.4--- 24/6 170 kPa 1200 kg
12.4--- 24/8 230 kPa 1415 kg
12.4R24/8 160 kPa 1360 kg
12.4R28 160 kPa 1450 kg
13.6R24 160 kPa 1450 kg
13.6--- 24/8 200 kPa 1545 kg
14.9R24 160 kPa 1700 kg
14.9--- 24/8 180 kPa 1760 kg
14.9--- 24/14FOR 300 kPa 1900 kg
14.9--- 24/14 IND 330 kPa 3090 kg
13.6--- 24/12IND 330 kPa 3090 kg
13.6--- 24/10 FOR 250 kPa 1790 kg
60 kPa 845 kg
360/70R24
160 kPa 1500 kg
60 kPa 930 kg
380/70R24
160 kPa 1650 kg
160 kPa 1900 kg
420/70R24
60 kPa 1070 kg
Rear wheel Pressure Max. load per tyre

13.6--- 36/6 160 kPa 1615 kg
13.6R36/8 160 kPa 1750 kg
13.6R38/8 160 kPa 1800 kg
14.9--- 30/8 180 kPa 1940 kg
16.9--- 30/8 170 kPa 2245 kg
16.9R30/8 160 kPa 2300 kg
18.4R30/8 160 kPa 2650 kg
13.6R38/8 160 kPa 1800 kg
13.6--- 38/8 200 kPa 1910 kg
18.4R34 160 kPa 2800 kg
18.4R30/8 160 kPa 2650 kg
18.4--- 34/8 140 kPa 2565 kg
160 kPa 3150 kg
520/70R34
60 kPa 1775 kg
14.9R38/8 160 kPa 2060 kg
16.9R38 160 kPa 2575 kg
18.4--- 34/14FOR 260 kPa 2985 kg
16.9--- 34/8 170 kPa 2380 kg
16.9R34/8 160 kPa 2430 kg
18.4--- 34/14 IND 290 kPa 4850 kg
16.9--- 34/14IND 290 kPa 3935 kg
16.9--- 34/14 FOR 260 kPa 3025 kg
160 kPa 2725 kg
480/70R34
60 kPa 1800 kg
160 kPa 2575 kg
480/70R30
60 kPa 1450 kg
With diagonal tyres at speed of 30 km/h loading is 20 % greater. When using twin--- mounted wheels the loading on these two wheels together
can be multiplied by 1.76 of the permissible loading on one wheel.
626
Model Code Page
1. 3. 1997
72. Wheels 205-- 865 720 3
1. 1. 1998
Tightening torques of wheel nuts

--- front wheels, 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
--- front wheels, 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Nm
--- rear wheels, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Nm
--- rear wheels, 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm
Rim ---wheel disc, 8.8 (earlier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Nm

Rim ---wheel disc, 10.9 (later) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Nm
Track widths (measured between centre of tyres)

Rear axle flange distance, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1640 mm
Front axle flange distance, 4WD Sige, 205---665 . . . . . . . . . . . . . . . . . . . . 1580 mm
Front wheels, 2WD:

7.50---16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1336---1436 ---1536 mm
10.00---16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1410---1510 ---1610 mm
Front wheels 4WD, with ZF front axle
11.2---24, 11.2R24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1624 ---1518---1430 mm
12.4---24, 12.4R24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1624 ---1518---1430 mm
11.2---24 (industrial front axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1744 ---1638---1550 mm
Front wheels 4WD, with Sige front axle
11.2---24, 11.2R24, 12.4---24, 12.4R24, 360/70 R24 . . . . . . . . . . . . . . . . . . 1320---1415---1520---1615 ---1720---1815
Rear wheels
14.9---30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1419---1480---1593 ---1706 mm
16.9---30, 16.9R30, 18.4R30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1409---1490---1603 ---1696 mm
14.9---24/14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 mm
13.6---36, 13.6R36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400---1504---1604 ---1700 mm
16.9---34, 16.9R34, 13.6R38, 480/70R34 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398---1500---1598 ---1700
18.4R30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1490---1603 ---1696 mm
Track widths 865 (measured between centre of tyres)
Rear axle flange distance, 865 . . . . . . . . . . . . . . . . . . . 1750 mm
Rear axle Track width Front axle Track width

1410, 1510, 1615,
13.6---36 1715, 1810, 1910, 7.50---16 1336---1436---1536
2015, 2115
1415, 1530, 1590,
14.9---30 1705, 1815, 1930, 10.00---16 1410---1510---1610
1990, 2105
16.9---30, 16.9R30, 16.9---34,
1410, 1510, 1610, 11.2---24, 12.4---24, 12.4R24, 1320, 1415,
16.9R34, 480/70R34, 18.4---34,
1710, 1810, 1910, 13.6---24, 13.6R24, 14.9---24, 1520---1615,
18.4R34, 520/70R34, 13.6---38,
2010, 2110 14.9R24, 380/70R24, 420/70R24 1720---1815
14.9R38, 13.6R38, 16.9R38
18.4---34/14FOR, 18.4---34/14IND, 13.6---24/12IND, 14.9---24/14FOR,
1650, 1880 1) 1510, 1630 1)
16.9---34/14IND 14.9---24/14IND
1420, 1515, 1620,
12.4R28
1715, 1820, 1915
1) Fixed discs
Standard track widths are underlined.
When track widths are adjusted or larger tyres fitted, the turning angles have to be checked/adjusted with max
oscillation angle of front axle on both sides. Check also when using chains that the distance from the cab to the
tyres does not go below 80 mm. Check further that the distance from parking lights to the outer sides of the tyres
does not exceed 400 mm.
627
Model Code Page
72. Wheels 600-- 900 720 4
1. 1. 1998
Alternative tyre equipment (in pairs), 600---900
4WD models 2WD models

700, 800, 700, 800,
Rear wheel Front wheel 600 Rear wheel Front wheel 600
900 900
16.9---30/8 11.2---24/8 x x 16.9---30/8 10.00---16/8 x x
16.9R30/8 12.4R24/8 x x 16.9---30/8 7.50---16/8 x x
18.4R30/8 13.6R24/8 x x 16.9R30 10.00---16/8 x x
16.9---34/8 13.6---24/8 x x 16.9R34 10.00---16/8 x x
16.9R34/8 13.6R24/8 x x 13.6---38/8 7.50---16/8 x x
480/70R30 360/70R24 x x 18.4R34 11.00---16/8 x
480/70R34 380/70R24 x x
13.6R36 12.4R24 x x
13.6---36/6 12.4---24/8 x x
13.6R38 13.6R24 x x
18.4R34 14.9R24 x
18.4---34/8 14.9---24/8 x 1) Fixed discs
520/70R34 420/70R24 x On 4WD models correct tyres in pairs must be fitted on front
13.6---38/8 12.4---24/8 x x and rear axle to obtain correct ratio.
14.9R38 12.4R28 x
18.4---34/14 14.9---24/14FOR x
18.4---34/14 14.9---24/10IND x 1)
16.9---34/14 13.6---24/12IND x x
16.9---34/14 13.6---24/10FOR x x
Track widths 600---900 (measured between centre of tyres).

Rear axle flange distance, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 mm
Front axle flange distance 4WD, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1580 mm
Rear axle Track widths Front axle Track widths

1410, 1515, 1610,
13.6R36, 13.6---36 1715, 1810, 1915, 7.50---16 1336---1436---15362)
2010, 2115
1410, 1510, 1610,
16.9---30, 16.9R30, 480/70R30,
1710, 1810, 1910, 10.00---16, 11.00---16/8 1410---1510---1610
18.4R30
2010, 2110
16.9---34, 16.9R34, 480/70R34, 1410, 1510, 1610, 1320, 1415,
18.4---34, 18.4R34, 520/70R34, 1710, 1810, 1910, 11.2---24, 12.4---24, 12.4R24 1520---1615,
13.6---38, 14.9R38, 13.6R38 2010, 2110 1720---1815
13.6---24, 13.6R24, 14.9---24, 1320, 1415,
18.4---34/14FOR, 18.4---34/14IND,
1650, 1880 1) 14.9R24, 360/70R24, 380/70R24, 1520---1615,
16.9---34/14IND, 16.9---34/14FOR
420/70R24 1720---1815
13.6---24/12IND, 13.6---24/10FOR,
1510, 1730 1)
14.9---24/14FOR, 14.9---24/14IND
1420, 1515, 1620,
12.4R28
1715, 1820, 1915
1) Fixed discs. 2) Standard track width, if rear wheels 34” or bigger.
Note! Standard track widths are underlined.
When track widths are adjusted or larger tyres fitted, the turning angles have to be checked/adjusted with max
oscillation angle of front axle on both sides. Check also when using chains that the distance from the cab to the
tyres does not go below 80 mm. Check further that the distance from parking lights to the outer sides of the tyres
does not exceed 400 mm.
628
81 Cabin
80. Cab and shields
82. Shields
83. Air conditioning
629
630
Model Code Page
10. 1. 1992
81. Cab 205-- 865 810 1
1. 3. 1997
Cabin heater
631
Model Code Page
81. Cab 205-- 555 810 2
10. 1. 1992
4 4
6
7
5
3
8
2
1 9
12
10
24 11
23
22
16
15 14
21
19
13
18
17
20
3055--- 27
Controls in cab
13.Differential lock
1.Clutch pedal
14.Position control, hydraulic lift
2.Steering wheel 15.Selector lever, power take ---off
3.Clutch lever, power take ---off 16.Auxiliary hydraulic lever
4.Ventilation nozzles
17.Pick ---up hitch release control
5.Hand throttle lever 18.Lifting link gear
6.Heater control
19.Openable side window
7.Radiator blind
20.Toolbox
8.Brake pedals 21.Engaging control, four ---wheel drive
9.Accelerator pedal
22.Parking brake
10.Range gear lever
23.Lowering speed control
11.Speed gear lever 24.Fuse box
12.Low ---gear lever
632
Model Code Page
81. Cab 205-- 555 810 3
10. 1. 1992
33 34 35
37
36
32
30 38
31
29
41
28 40
39
42
27
26 43
25
3055--- 29
Instrument panel
25.Switch, lighting 34.Rotating warning light

26.Switch, working lights, rear
35.Indicator lamp, differential lock
27.Controls for:
36.Indicator lamp, power take ---off
---direction indicator flashers
37.Hazard warning flasher switch
---full/dipped ---beam
38.Revolution counter
---horn
39.Hour recorder
28.Fuel gauge
40.Ignition switch
29.Indicator lamp, charging
41.Stop control
30.Coolant temperature gauge
42.Switch, windscreen washer
31.Warning lamp, engine oil pressure
43.Switch, fan
32.Indicator lamp, direction indicator flashers
33.Indicator lamp, full---beam
633
Model Code Page
81. Cab 205-- 555 810 4
10. 1. 1992
47
44
45
46
3055--- 30
Driver’s seat
44. Forward/backward adjustment
45. Height adjustment
46. Suspension control
47. Lock for turning seat
634
Model Code Page
81. Cab 665 810 5
1. 9. 1992
Instrument panel on 665

1. Light switch
2. Switch, rear working lights
3. Full/dipped beams, direction indicators and horn
4. Fuel gauge
5. Control lamp, charging
6. Engine temperature gauge
7. Warning light, engine oil pressure
8. Direction indicators
9. Indication lamp, main beams
10. Indication lamp, rotating warning light (optional)
11. Indication light, differential lock
12. Indication light, power take ---off
13. Push button, hazard warning flashers
14. Rev counter
15. Hour recorder
16. Ignition switch
17. Stop control
18. Windscreen wiper switch
19. Heater fan switch
635
Model Code Page
1. 5. 1996
81. Cab 865 810 6
1. 3. 1997
Instrument panel, 865---tractor
1. Switch, headlights 22. Switch, front PTO (option)

2. Switch, rear working lights 23. Rotating warning light (option)
3. Combination control 24. Warning light, blocked air cleaner
4. Fuel gauge 25. Low fuel level
5. Warning light, charging 26. Central warning light, STOP
6. Engine temperature gauge 27. Ind. light, parking brake
7. Warning light, engine oil pressure 28. Ind. light, Thermostart (option)
8. Direction indicators 29. Agrodata ---instrument (option)
8a. Direction indicators II 30. Switch, Agrodata ---instrument (option)
8b. Direction indicators III
9. Ind. light, main beams Note! On 865---tractor, the combination instrument is the
10. Upper headlights (option) same as on Mezzo---tractors. When switching on current, war-
11. Ind. light, differential lock ning lights no 24, 7 and 5 are lit and the Stop light is flashing,
12. Warning light, PTO clutch but they must go out when the engine has started. The central
13. Switch, hazard warning flashers warning light (STOP) is actuated by the engine oil pressure
14. Rev counter and engine temperature.
15. Hour recorder/AC (Agrodata ---instrument: driving speed)
15a. Agrodata ---instrument (option) Note! The instruments are accessible after opening the hatch
16. Ignition switch in the steering wheel console rear face. Unscrew via the hatch
17. Control for steering wheel position screws on the upper rear corners of the dashboard and
18. Windscreen wiper/washer unscrew also the dashboard upper front screws on the sides
19. Switch for fan of the dashboard. When necessary, unscrew the lower bolts
20. Front working lights (option) of the console side plates via the hatch, after which the instru-
21. Rear window wiper/washer (option) ments are accessible. The dashboard switches can be pried
upwards.
636
Model Code Page
83. Air conditioning 600-- 900 830 1
1. 6. 1998
Contents
Air conditioning (Op no 830):

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance, fault tracing, repairs (Op no 831):

--- Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
--- Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
--- Drier container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Fault tracing without special equipment:
A. Correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Refrigerant filling and moisture in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Fault tracing with pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Important information on Air conditioning repairs and spare part storage . . . . . . . . . . . . . . . 8
4. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
637
Model Code Page
1. 6. 1998
1. 9. 2001
Technical data
Note! Compressor (+service connectors), evaporator, expansion valve, drier reservoir/pressure switch and ther-
mostatic switch on 600---900 tractors are the same as on Mezzo---series (6000---6800). Also the roof fan and its
switch on 600---900 tractors are the same as on Mezzo---tractors. The condenser is different.
Air conditioning on Valmet 600-- 900 tractors:
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134a (SUVA)

--- refrigerant filling in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,2 kg
Compressor Diesel Kiki DKS 15 CH (earlier):

--- Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 pcs
--- Cyl diam x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 34 mm x 24 mm
--- Max revs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 r/min
--- Lubricating oil when refrigerant R134a (Valtra UC 1300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZXL 100 PG (DH ---PS)
--- Lubricating oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 cm3 (2,0 dl)
Electro---magnetic clutch:
--- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V (DC)
--- starting torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
--- power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 W (max)
--- clutch clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3---0,6 mm
Compressor Seltek (see Diesel Kiki):
Compressor SANDEN SD7H15FZ8062 (later):

--- Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 pcs
--- Cyl diam x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 29,5 mm x 32 mm
--- Max revs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 r/min
--- Lubricating oil when refrigerant R134a (Valtra UC 1300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZXL 100 PG (DH ---PS)
--- Lubricating oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 cm3 (2,07 dl)
Electro---magnetic clutch:
--- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V (DC)
--- starting torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
--- power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 W (max)
--- clutch clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3---0,6 mm
Drier
Pressure switch switches off at max pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,40±0,2 MPa
--- switches on again when pressure drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,57±0,2 MPa
Pressure switch switches off at min pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190±20 kPa
--- switches on again when pressure rises up to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200±30 kPa
Thermostatic switch:
--- switch off when evaporator temperature is below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +2...+3 ˚C
--- switch on when evaporator temperature has risen up to (max cooling effect) . . . . . . . . . . . . +6...+7 ˚C
--- switch on when evaporator temperature has risen up to (min cooling effect) . . . . . . . . . . . . about +19 ˚C
High and low pressures at engine revs 1500 r/min between temperatures +20...+25 ˚C:
--- low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50---300 kPa
--- high pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700---1400 kPa
638
Model Code Page
1. 6. 1998
Operating principle The Air conditioning functions so that the refrigerant is

continuously circulated in the system at which time it
An Air conditioning takes heat from the cab air when outdoor changes from liquid form into gaseous form. This pro-
temperature is high. Refrigerant in the system is exposed cess absorbs heat from the cab when the refrigerant
under different pressures and temperatures and this causes vaporises in the evaporator and emits heat to outdoors
a cooling effect. Refrigerant vaporizes in the evaporator and when refrigerant becomes condensed in the condenser.
evaporation absorbs heat which is taken from the warm cab
air which is blown through the evaporator. Although the process has four parts, it can be divided
into two main parts: high pressure side and low pressure
side according to the figure below.
Low pressure side High pressure side
Expansion valve
Drier
Heat is trans- Heat is trans-

ferred from ferred from
cab to refrige- Evaporator refrigerant to
rant Condenser outdoors
Compressor
Figure 1. Operating principle of Air conditioning
639
Model Code Page
1. 6. 1998
Evaporator
High pressure gas
High pressure liquid
Low pressure liquid
Low pressure gas
Expan-
sion
Compressor valve
Condenser Drier
Circulation of the refrigerant begins from the compressor. The When the Air conditioning is operating the low pressure hoses
compressor sucks low pressure gas from the evaporator and are cold and high pressure hoses are warm.
compresses high pressure gas into the condenser. In the con-
denser gaseous refrigerant becomes condensed and emits Liquid refrigerant from the condenser is filtered and dried in
heat to outdoors. From the condenser high pressure liquid the drier container. The drier also prevents gaseous freon
flows via a drier to the expansion valve in which a part of the from entering into the expansion valve. In the drier container
liquid vaporizes and the refrigerant cools and its pressure there is a pressure switch which switches off current to the
drops. Liquid flows from the expansion valve into the evapor- compressor if pressure in the high pressure circuit rises too
ator where cab heat changes liquid into gas. This low pres- high or becomes too low:
sure gas then flows into the compressor suction side from
where a new circulation begins.
The drier has two inspection glasses through which can be
Max. cooling effect corresponds to the situation when the checked the refrigerant filling and moisture in the system (see
compressor works all the time. In order to achieve a certain page 831/2).
cooling effect, the compressor has to keep a certain pressure
in the evaporator outlet side.
An evaporation temperature of R134 is ---26˚C. When pres-

sure increases the evaporation temperature rises and vice
versa.
640
Model Code Page
1. 6. 1998
Figure 3. Air conditioning on Valmet 600---900 tractors.
1. Condenser
2. Compressor
3. Drier
4. Expansion valve
5. Evaporator
6. Temperature switch sensor
7. Re ---circulation nozzles
8. Air inlet into cab
9. Condension water hoses. Water becomes condensed in
the evaporator housing when the warm cab air flows through
the cold evaporator.
10. Heater radiator
Compressor (2) is driven by an extra belt pulley at the front Temperature switch sensor (6) (capillary tube) is pushed
end of the crankshaft. The compressor belt pulley is fitted with between the evaporator fins and it senses evaporator tem-
an electromagnetic clutch, which switches the compressor off perature in its coldest place. The sensor switches off the com-
and on according to the required cooling effect. The compressor when the evaporator temperature drops below
pressor is shown on page 831/9. +2...+3˚C (prevents icing on the evaporator), and switches
on again when the evaporator temperature has risen over
The expansion valve (4) regulates the amount of refrigerant in +6...+7˚C (or up to +19˚C when the temperature switch is
the evaporator (5) so that the refrigerant vaporizes in the best in min position).
possible way. The expansion valve lets only as much refriger-
ant flow into the evaporator as the evaporator can vaporize.
641
Model Code Page
1. 6. 1998
Picture 4. Air conditioning parts on the roof.
1. Air filter
2. Recirculation of air/adjuster knob
3. Evaporator
4. Space for condensed water
5. Heater radiator
6. Roof fan/switch S2
7. Air conditioning switch S22
These parts are accessible after removing the cover on the

roof. The roof switch panel can be removed from inside of
the cab.
642
Model Code Page
1. 6. 1998
15. 4. 1999
Picture 5. Electric system of Air conditioning on 600---900 Position of components:

tractors.
X7: Air conditioning connector on the RH side rear part of the
Wiring diagram: roof
X2: connector in front of the cab on the RH side
FD2 = Fuse for Air conditioning/roof fan GR5: earth point in the front part of the roof
FA5 = Fuse for roof fan III ---speed Diodes are placed in connection with switch S2.
S2 = Fan switch The diodes cannot be changed separately, but the roof wire
S22 = Temperature switch loom must be replaced. Relay K8 in the roof in connection
S23 = Pressure switch with the roof switch panel.
Y5 = Magnetic clutch of compressor
M5 = Roof fan
K8 = Relay for fan speed III
E22 = Roof panel light
643
Model Code Page
1. 6. 1998
Expansion valve
5
1
Figure 6. Expansion valve
2 1. Expansion valve
2. Hose from condenser
3. Inlet pipe to evaporator
4. Outlet pipe from evaporator
5. Hose to compressor suction side
Temperature sensor
Diaphragm
When the compressor starts pressure drops in the evap-
orator and the diaphragm pushes the pin downwards and
the ball opens. Refrigerant can now flow via the spring
housing into the evaporator
When the temperature in the evaporator outlet pipe

From evaporator lowers, the temperature sensor pulls the diaphragm
upwards and the valve ball closes preventing refrigerant
from flowing into the evaporator.
To compressor
In this way the expansion valve regulates all the time the
amount of refrigerant in the evaporator.
On the later Air conditioning, the expansion valve func-

tions in a similar way.
To evaporator
Note! The expansion valve and the metal pipes have
From condenser been covered with insulating mass 30794000.
644
Model Code Page
1. 6. 1998
Maintenance, fault tracing and repairs Maintenance
--- Before switching on the Air conditioning, ensure that win-

Safety precautions dows and doors are properly closed. If for any reason the cab
cannot be completely closed, the air recycling system must
be switched off. If these recommendations are not observed,
Important! If the Air conditioning system must be opened,
there is a risk of blockage at the evaporator and risk of dam-
this work must be done by an expert who knows refrigerating age to the compressor.
systems.
--- Check externally the drier, condenser and hoses (if the
--- The pressure of the refrigerant is always greater than its nor- evaporator or expansion valve for any reason should be
mal boiling point. If piping is split, the refrigerant will evaporate checked, the evaporator housing cover must be removed).
or boil very rapidly. All impurities (and ice on evaporator) cause malfunctions.
Check also occasionally the tightness of the compressor
---Uncontrolled escape of refrigerant must be avoided. The belts.
refrigerant is non ---flammable, non ---toxic (except when in
contact with a flame) and non ---corrosive (except in contact --- Check regularly through the drier inspection glasses mois-
with water). ture and refrigerant filling in the system (see next page).
--- Never attempt to empty the system by loosening a connec- --- Always when the system has leaked and it has been
tion. Slow emptying without danger can only be carried out opened and specially if brown or yellow colour can be seen
using a manifold gauge set. in the drier inspection glass or if the moisture indicator has
changed its colour, the drier should be changed.
--- You should be very careful when handling refrigerant. It can
freeze the skin or the eyes on direct contact. Never handle --- From the bottom of the evaporator housing there are drawn
refrigerant without wearing safety goggles, as well as gloves. drain hoses through which the condensing water flows away
from the housing. This prevents icing on the evaporator.
--- Do not empty the system in a room where there is a flame.
Refrigerant R134a and open flame form poisonous and stimu- --- In order to keep the system in good condition, we recom-
lating compounds (e.g. hydrofluoric acid) mend to operate the system for several minutes each month
in order to lubricate all the components, since the compressor
--- Never weld or clean with steam near a filled system: excess oil can get mixed with the refrigerant.
pressure may be created with possible leakage.
--- When restarting the compressor, specially if it has not oper-
--- If it is necessary to retighten a connection, use two ated for some time, proceed in the following manner to ensure
spanners for tightening, so as to prevent distortion which may lubrication right from the first rotations of the compressor:
give rise to leakage.
. Switch on the electromagnetic clutch by switching the fan
--- Do not store refrigerant in the sun or close to a source of on and moving the temperature switch to cold.
heat. . Crank over the tractor engine for a few seconds with the fuel
stop button out.
--- Avoid subjecting the bottle to impact. Do not carry the . Then push in the fuel stop button, start the engine and allow
bottle in the passenger compartment of a vehicle. to idle slowly for several minutes.
In the event of an accident, proceed as follows: A simple functional check:

--- If you get refrigerant in your eyes, wash them carefully with a) Start the engine and adjust engine revs to 1500 r/min.
a solution of mineral oil, and continue to wash them carefully, Turn the fan switch to max speed and select the max cooling
with a solution of boric acid and water (1 teaspoonful of acid, effect with the temperature switch (compressor starts).
diluted in a quarter of a cup of water). Contact a doctor
immediately. b) Check temperature of different components:
Important! Never wash you eyes with pure water because --- Low pressure hoses, compressor inlet hose should be cold
refrigerant+water causes corrosive acid. when touched by hand.
--- Freezing caused by liquid refrigerant can be treated by pro- --- Compressor outlet hose, condenser, drier and every high
gressively thawing the injured area with cold water and then pressure hose should be warm when touched by hand
applying a dry skin cream. Contact a doctor immediately.
Note! Expansion valve and evaporator are accessible only
after removing the cover on the cab roof. The thermostatic
temperature switch is accessible after removing the roof panel
in the cab.
645
Model Code Page
1. 6. 1998
Possible faults can be localized easily if pressure gauges are Note! If You have not got enough training for repairing
connected to the compressor service valves. The low pres- refrigerating systems, it is necessary to call an expert if
sure gauge is connected to valve S and the high pressure the system should be opened or if refrigerant must be
gauge to valve D. For instruction on how to carry out these added. The refrigerating system expert has equipment
pressure measurements, see page 831/5. with which repair work can be done in a correct and safe
way.
.
Drier
The drier reservoir (3) is a combined expansion/liquid

reservoir and a drying filter for moisture. The drier
also includes a filter which filters impurities in the
system. There are two inspection glasses on the
drier: A=inspection of refrigerant and its filling,
B=moisture indicator.
The drier reservoir must not be stored with pipe con-

nections open. The drier must be changed if the
system has been opened for maintenance work.
There is a pressure switch S23 which switches off
current to compressor, if the high pressure rises too
much or is too low.
Inspection glass A (1500 r/min and max cooling effect)
Sightglass Description Conclusion and remarks

No bubbles appear at all. POSSIBLE EXCESSIVE REFRIGERANT
(Reduction by bleeding is necessary). The high--- pressure side will be abnormally hot.
(This can also mean that there is no refri- REMEDY: Contact authorized workshop for releasing the excess refrigerant
gerant at all in the system).
The fluid inside is almost transparent. A SUFFICIENT REFRIGERANT.
few bubbles may appear as the engine The high--- pressure side will be hot and the low--- pressure side cold.
speeds up and down.
A few bubbles appear intermittenly, at INSUFFICIENT REFRIGERANT.
intervals of 1 to 2 seconds. The high--- pressure side will be warm, and the low--- pressure side fairly cold.
(Refilling is necessary) REMEDY: Check for refrigerant leakage. Contact authorized workshop.
When bubbles flow continuously, or the VERY LITTLE REFRIGERANT.
flow has changed to a ”mist” flow, the There will be almost no difference in temperature between the high--- pressure
refrigerant is almost exhausted . side and the low--- pressure side.
(Refilling is necessary) REMEDY: Stop the compressor and inspect the entire system. When neces-
sary, contact authorized workshop.
N.B. The refrigerant in the inspection glass should be clear. If it has brown/yellowish colour, the refrigerant and the drier must be
changed.
Inspection glass B
If the moisture indicator colour is blue, the system is in order. If its colour has changed into pink or grey, the drier and the refrigerant
should be changed.
646
Model Code Page
1. 6. 1998
1. Fault tracing without special equipment C. Electric system
Note! This instruction supposes that the outdoor temperature

is high enough so that the temperature switch switches on the
compressor.
A. Correct function
When the Air conditioning is functioning properly the com-

pressor runs and stops at regular intervals and cool air flows
into the cab according to the position of the temperature
switch.
To check for malfunction, carry out the following simple test in

the shade by fitting a thermometer sensor into the ventilation
nozzle on the LH side and by following nozzle temperatures
during 5---10 minutes. During this test the windows, doors
and re ---circulation nozzles should be closed. Select the max
speed for the fan. Adjust the max cooling effect and set the
engine revs to 1500 RPM.
Nozzle temperatures should be according to the curve below

(±1,0˚C):
T ˚C, LH side nozzle
Outdoor temperature, ˚C
Switch on current to the tractor and turn on the fan. If the fan
If measured temperatures agree with the curve above, the Air does not start, check fuses. If the fan started, turn the tempera-
conditioning is in order. ture switch to max cooling effect at which time the click ---
sound must be heard from the compressor magnetic clutch.
If the nozzle temperatures are higher, make sure that the This indicates that the electric system functions.
heater control knob is closed so that the warm engine coolant
does not circulate in the heating element which is placed in If the click ---sound was not heard, disconnect the wires to the
front of the evaporator. If the knob is closed, see the following pressure switch S23 and connect the wire ends (never con-
instruction B. nect the + wire to the frame). If the click can now be heard in
the compressor, the electric system is OK, but the fault lies in
the pressure switch or in the system pressures. Call an expert.
B. Refrigerant filling and moisture If the click ---sound cannot be heard when connecting the
pressure switch wires, check the supply wire for current to the
pressure switch. If it is there, the fault lies in the compressor
--- Check the amount of refrigerant and moisture in the system magnetic clutch or in its wiring.
through the drier inspection glasses (see page 831/2).
Measure the voltage from the pressure switch supply wire
Moisture in the system causes icing in the expansion valve with different fan speeds. If there is no current with some fan
and in the compressor which in turn causes malfunctions. speed, the fault lies in diodes, which should be changed. The
diodes cannot be changed separately but the complete wire
Refrigerant+water causes a corrosive compound.
loom should be changed.
Possible leakages can be found with an electronic leak If there is no current to the pressure switch wire, check con-
detector. If the refrigerant filling is wrong or there is moisture nectors and wires.
in the system, contact an expert who knows refrigerating sys-
tems. If everything is OK, see the following instruction C. If there is further no current to the pressure switch wire, con-
nect the temperature switch wire ends. If now there is current
to the pressure switch supply wire, the fault lies in the tem-
perature switch which should be changed.
647
Model Code Page
1. 6. 1998
D. Compressor
E. Expansion valve
Note! The expansion valve is accessible after removing the

cover on the cab roof. In addition, the expansion valve is cov-
ered by insulating mass.
--- A faulty expansion valve causes a poor cooling effect.
--- If the expansion valve is noisy (continuing whistle), there is

too little refrigerant in the system which causes bubbles to
appear in the inspection glass of the drier.
--- If the expansion valve does not function (stuck fast or frozen
in open or closed position) the cooling effect is insufficient.
--- If the Air conditioning blows first cool air, then warm and
then again cool, there is ice in the expansion valve which pre-
vents refrigerant from flowing into the evaporator.
1. Normal function
--- When the compressor is functioning properly, it starts and

stops regularly. With max cooling effect the compressor runs F. Evaporator
often but not as long as in min cooling. Unusual sound must
not be heard from the compressor. Check the compressor
Note! The evaporator is accessible after removing the cover
belts regularly.
on the cab roof.
2. Continuing running, no cooling
--- If there is icing on the evaporator, the fault lies in the tem-
--- The compressor is faulty and should be changed. Also perature switch or its sensor is wrongly positioned between
icing caused by moisture can cause this kind of malfunction the evaporator fins.
(check the moisture indicator colour). In this case also tem-
perature difference between high and low pressure pipes is Note! Do not use the Air conditioning if the outdoor tempera-
diminutive. ture is below +20 ˚C.
3. Continuing running, max cooling --- Make sure that the drain pipes for the condensing water are
open i.e. water can flow away from the evaporator housing
--- The compressor is in order but a fault lies in the temperature bottom. Otherwise icing can appear on the evaporator. If
switch which does not switch off current to the compressor there is water on the evaporator housing bottom, the drain
when the evaporator temperature is under +2...+3 ˚C. Make pipes should be checked e.g. with compressed air.
sure that the temperature switch sensor is correctly fitted
between the evaporator fins. This malfunction causes icing on
the evaporator which lowers the cooling effect.
G. Condenser
4. Irregular running
--- Check the compressor belt tightness.

--- Change for faulty compressor
5. Unusual sound
Compressor engaged:
--- Check the compressor attachment.
--- Electromagnetic clutch slips, faulty bearings or valves in the
compressor can cause an unusual sound.
--- Wrong refrigerant filling in the system can cause unusual
sound.
--- Change faulty compressor
Compressor disengaged:
--- electromagnetic clutch clearance is wrongly adjusted. --- If malfunctions occur, always check and clean externally
the condenser from impurities. Cleaning can be carried out
Note! If the compressor front end is oily and moist, the com- with compressed air. The condenser can be pulled to one
pressor shaft seal can be leaking. If the compressor does not side for cleaning.
run at all, the fault is in the electrical system.
648
Model Code Page
1. 6. 1998
2. Trouble shooting with pressure gauges

d) An over ---charged system, an expansion valve stuck open
System pressures depend directly on air pressure and tem- or a clogged condenser will cause excessive pressure on the
perature. At outdoor temperature 20˚ ---25˚C and at engine low pressure side.
revs 1500 r/min the low pressure varies between 50 ---300
kPa and the high pressure between 700 ---1400 kPa. The e) A clogged condenser and an over ---charged system will
pressure gauges are connected to the compressor service cause excessive pressure on the high pressure side.
valves: low pressure gauge to (S) and high pressure gauge
to (D).
Overcharge
Fault analysis and symptoms
Note! The correct refrigerant filling is 1,2 kg on Valmet
a) Leaks in the system will lead to inadequate cooling and low 600---900 tractors.
and high gauge readings will be too low.
In a correctly charged system, refrigerant discharged from the
b) If the system is under ---charged, bubbles will be perma- compressor in the form of gas looses its excess heat, resulting
nently visible in the dehydrator sight glass and both gauge from compression in the first coil of the condenser and con-
readings will be low. denses to a liquid in the subsequent coils. Before flowing to
the reservoir, this liquid is held in the last condenser coil. If the
c) If the evaporator is dirty or an expansion valve is blocked system is over ---charged, the liquid level builds up in the con-
or frozen up, there will be a partial vacuum on the low pressure denser, leaving fewer coils available to condense the gas.
side and insufficient pressure on the high pressure side. Both temperature and pressure then build up, causing hoses
to burst in some cases.
Connecting pressure Stop the engine. Remove the service valve protective caps. Connect the low pres-
gauges: sure gauge to valve S and high pressure gauge to valve D.
Disconnecting gauges: Stop the engine. Unscrew rapidly the low pressure gauge. Run the Air conditioning
5---10 min and stop the engine. Unscrew rapidly the high pressure gauge.
Note! Refrigerant in the gauge hoses blows off. Use gloves and goggles when con-
necting and disconnecting gauges. Recap valves.
Low pressure too low High pressure normal
Possible fault Remedy

1. Expansion valve faulty. 1. Change expansion valve.
2. Moisture in system caus- 2. Empty and flush the sys-

ing icing in expansion valve tem. Change the drier and
the expansion valve if
necessary.
3. Expansion valve is
clogged or evaporator dirty, 3. Empty system and
if low pressure gauge change the expansion
shows underpressure. valve and also the evapor-
ator and drier if necessary.
4. Drier blocked (tempera-
ture difference on different 4. Empty system and
sides of blockage causes change the drier.
icing in the drier when Air
conditioning is functioning).
S D
649
Model Code Page
1. 6. 1998
Low pressure high High pressure normal

1. Expansion valve faulty. 1. Empty system and
Valve stuck fast in open change expansion valve.
position.
2. Compressor faulty or its 2. Check compressor belt.

belt slackened. Change damaged com-
pressor.
3. Too little refrigerant in 3. Empty and refill the sys-

system. tem with refrigerant (1,2
kg).
S D
Low pressure high High pressure low

1. Valves or seals in com- 1. Change compressor.
pressor faulty.
2. Too little refrigerant cau- 2. Empty and refill the sys-

ses the high pressure rea- tem with correct amount of
ding to be too low. refrigerant (1,2 kg).
S D
Low pressure normal High pressure high

1. Air in system or too 1. Empty system and refill
much refrigerant in system. with refrigerant (1,2 kg).
2. Condenser dirty (insects 2. Clean the condenser.

etc)
3. If bubbles appear in 3. Empty system and

inspection glass fast filling change hose connections.
is OK, the drier hose con- Change the drier. Refill sys-
nections have been con- tem (1,2 kg).
nected faulty and refrige-
rant flows in reverse direc-
tion.
4. If there is bubbles and 4. Empty system and
S D icing in the drier, there is

restriction in the drier inlet
remove blockage and fit a
new drier. Refill system
side. (1,2 kg).
650
Model Code Page
1. 6. 1998
Low pressure high High pressure high

1. Condenser is dirty 1. Clean condenser
(insects etc.)
2. Too much refrigerant in 2. Empty and refill system

system. with refrigerant (1,2 kg).
S D
Both gauges show same pressure

1. Compressor magnetic 1. Change compressor
clutch does not function.
2. Compressor is faulty 2. Change compressor
3. Electric system faulty 3. Check electrical system

(temperature switch, pres- (see page 831/3 instr. C).
sure switch, fuse etc.)
S D
651
Model Code Page
1. 6. 1998
Important information on Air conditioning

repairs and spare part storage
Note! Moisture is the worst enemy of any Air conditioning.
1. Keep all spare parts sealed and store in a dry place.
2. Immediately make all connections air tight when interrupt-

ing the refrigerant circuit.
3. Before installation purge refrigerant hoses with nitrogen or

refrigerant.
4. When installing parts, do not remove plugs until shortly

before assembly. This is especially important for the drier. A
drier, which is not sealed, quickly becomes saturated and
cannot be used.
5. Do not pump refrigerant from the Air conditioning back into

the cylinder.
6. Always keep empty refrigerant cylinders closed.
7. Only buy refrigerant from specialized dealers.
8. Do not carry out repairs outdoors in damp weather.
9. Always replace drier receiver after interrupting the refriger-

ant circuit.
10. The presence of moisture in the refrigerant circuit does not

only lead to a poor cooling output but also to the decomposi-
tion of the solid ---state drier and the decay of the refrigerant
lines due to acid formation. Expensive repairs and down ---
time are the result.
11. Before starting, check oil level of the compressor and

evacuate refrigeration circuit according to instructions given.
Time of evacuation 1---4 hours. Dry refrigeration circuit at least
once by breaking the vacuum with liquid refrigerant.
652
Model Code Page
1. 6. 1998
1. 9. 2001
Compressor
The service valves (D and S) are fitted on the pipe
connectors on Air conditionings that have refrige-
rant R134a as in figure below.
D = Discharge
S = Suction
Y5 = magnetic clutch
Technical values, see page 830/2.
If the compressor should be changed, contact an expert

who knows refrigerating systems.
A new compressor is filled with 2,0 dl oil in the factory.

Drain the oil in the new compressor. 1,6 dl oil must run
out. Pour the oil back to the compressor and fit the
plug. If the drained oil amount was not 1,6 dl, add or
reduce the oil volume to 1,6 dl (on account of the inter-
nal build ---in, all oil in the compressor does not run out).
Note! If the system is opened and refrigerant changed,

the compressor oil should also be changed. In this
case, fill the compressor with 2,0 dl oil.
Detach the new compressor protective caps very care-

fully so that the threads and connections do not
damage.
Tightening torques:
--- 3/4” connection on pressure side 24,5 ---29,5 Nm.
--- 7/8” connection on suction side 29,5 ---33,5 Nm.
Draining/filling plug for lubricating oil.
Note! Do not open the plug, if the system is filled

with refrigerant. Compressor oil should be stored in a
closed container.
653
654
Working hydraulics
91
90. Hydraulics Hydraulic power lift
92. Autocontrol---power lift
655
656
Model Code Page
1. 5. 1996
91. Working hydraulics 205-- 900 910 1
1. 9. 2001
Contents
Technical Data (not 865 and 600---900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical Data, 610312--- (not 865 and 600---900)
Hydraulic diagram with list of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Construction and function:

A. General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Function of working hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Distribution block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Pressure ---limiting valve and shock valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. Filtration of hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F. Valves for auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
G. Extra lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
H. Automatic pick ---up hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
I. Control valve and control system:
--- control valve, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
--- damping valve, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
--- control levers for hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
--- linkage in hydraulic lift housing, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
--- draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. Fault tracing:
A. Fault tracing, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
--- valves for auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
--- linkage in hydraulic lift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B. Fault---tracing chart for working hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3. Construction and function of hydraulic lift with effect from serial number 610312 . . 23
4. Mechanical hydraulic lift on 865 and 600 ---900 tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Repair instructions
Pump and pipe system (Op. no. 911)

1. Changing hydraulic pump:
A. Removing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reconditioning hydraulic lift (OP. no. 912)

1. Pressure limiting valve:
A. Checking/adjusting opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Reconditioning working hydraulics:

A. Tracing leakage with system in neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing and pressure ---testing damping valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Removing and pressure ---testing control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Reconditioning unloading valve and lowering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Reconditioning pilot valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Checking for leakage in lifting cylinder and shock valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. Fitting control valve and damping valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Changing lifting cylinder piston seal:

A. Removing lifting arm shaft (rocker shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Changing lifting cylinder piston seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
C. Changing seals and inner lever on lifting arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
D. Fitting lifting arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. Connecting pipes and valves for auxiliary hydraulics:

A. Changing connecting pipe seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. Fitting connecting pipes and valve blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Reconditioning lifting cylinder:

A. Removing lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Changing lifting piston stop seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. Fitting lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
657
Model Code Page
1. 5. 1996
1. 9. 2001
6. Changing hydraulic lift housing:

A. Removing hydraulic lift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. Dismantling parts of hydraulic lift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
C. Fitting hydraulic lift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Basic adjustment of hydraulic lift (Code 913)

1. Hydraulic lift:
A. Adjusting hydraulic lift impulse point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting pick ---up hitch lifting links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Basic adjustment of control valve:

A. Adjusting pilot valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Adjusting damping valve slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Instructions for repair of hydraulic lift with effect from serial

number 610312 (Code 914) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mechanical hydraulic lift on 865 and 600 ---900 tractors, repair instructions (Code 915) 1
Repair instructions for auxiliary hydraulic valve blocks (Kontak) (Code 916) . . . . . . . . . . 1
Hydraulics of AC and ACB power lifts (code 920)
Technical data up to ser. no. 610311

(Technical data of tractors 865 and 600---900, see page 910/36)
Working hydraulics
Pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . From engine timing gears
Pump capacity per revolution (theoretical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,5 cm3/r
Oil flow at 2350 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 litres per minute
Pressure ---limiting valve, opening pressure:
--- ---610311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 MPa
--- 610312--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 MPa
Shock valve, opening pressure:
--- ---653958 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 MPa
--- 653959--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 MPa
Pressure at continuous operation (e.g. running an hydraulic motor) . . . . . . . . . . . . . . . . . . . . . . 10 MPa
Max. lifting force at the whole lifting area:
--- links mounted on rear points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 kN
--- links mounted on front points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 kN
Lifting range at end of lower links:
--- links mounted on rear points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675+20 mm
--- links mounted on front points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775+20 mm
Pressure filter:
--- type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper filter element, replaceable
--- by ---pass valve, opening pressure (at oil temperature 45---55˚C) . . . . . . . . . . . . . . . . . . . . . . 220---280 kPa
--- working temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ---40...+100˚C
--- separation of impurities to a degree of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 %
--- degree of filtration down to a particle size of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 μm
--- working pressure, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 MPa
Suction strainer:
--- type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washable metal gauze filter
--- degree of filtration down to particle size of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 μm
Available amount of oil for auxiliary hydraulics at max. level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 litres
Hydraulic oil:
See table on page 120/4.
Tightening torques
Hydraulic lift housing ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm

Hydraulic lift housing ---gearbox (after ser. no. 602930) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
Hydraulic lift housing ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm
Lifting cylinder ---hydraulic lift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Valves for auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Nm
Control shaft frame ---hydraulic lift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Hydraulic lift housing ---hydraulic lift housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Steering system return oil pipe at hydraulic lift housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Service cover ---hydraulic lift housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
658
Model Code Page
1. 12. 1986
91. Hydraulic lift 305-- 455 910 3
1. 7. 1989
Hydraulic diagram with list of components ( -- 610311)
1. Pump and suction strainer complete 16. Lowering speed valve

2. Suction strainer 17. Lowering valve, main valve cone
3. Gear type pump 18. Lowering valve, pilot valve
4. Distribution block 20. Restriction in lowering valve main valve cone
5. Point for checking pressure 21. Pressure filter
6. Pressure ---limiting valve 22. Lifting cylinder
7. Valve for auxiliary hydraulics 23. Shock valve
8. Quick ---action couplings 24. Steering valve, complete
9. Cover on distribution block 25. Steering valve
10. Control valve, complete 26. Steering system pressure ---limiting valve
11. Damping valve, complete 27. Steering system non ---return valve
12. Unloading valve 28. Steering cylinder
13. Restriction in unloading valve main valve cone 29. Oil reservoir
14. Unloading valve pilot valve ball 30. Extra lifting cylinder
15. Plug for changing over auxiliary hydraulic valves
659
Model Code Page
1. 12. 1986
91. Hydraulic lift 205-- 865 910 4
1. 5. 1996
Special tools
ETV 892 660 Device for checking damping valve (Hydraulic lift 504---604)
ETV 892 670 Device for checking tightness of lifting cylinder and shock valve (Hydraulic lift 504---604)
ETV 892 680 Checking device for control valve (Hydraulic lift 504---604)
ETV 892 660
ETV 892 670

ETV 892 680
The above mentioned tools are included in an earlier used pressure ---test kit ETV 892 920.
Equipment for measuring and testing pressures (865, see pages 101/ 17---18)
R1/4
2120---04---02.50
2103---05---01.00
9801---01---04.00
1. Equipment for checking opening pressure of pressure limiting valve. Measuring equipment in kit
31965000, see page 101/17 ---18.
R1/4
ETV 892 921

(Enerpac P---39) *)
TEMA 2500 (R1/4)
9801---01---04.00
3/4--- 16 UNF
ETV 892 922 *)

A
2. Equipment for pressure testing damping valve and control valve

A. This adaptor is fitted in ETV 892 660 and ETV 892 680.
660
Model Code Page
1. 7. 1989
91. Hydraulic lift 205-- 865 910 5
1. 5. 1996
TEMA 2500 (R1/4) 2103---05---01.00

TEMA 2500 (R1/4)
9801---01---04.00
ETV 892 921
(Enerpac P---39) *)
2120---04---02.50
3. Equipment for tracing leakage with system in neutral position

Checking opening pressure of chock valve for working hydraulics
Equipment for pressure ---testing lifting cylinder
x) These tools are not supplied by Valmet (the tools are included in an earlier testing kit ETV 892920)
Part numbers consisting of digits only indicate parts which are generally available.
N.B. The range of the gauge is 0---40 MPa
ETV 893530 Sleeve for fitting lifting arm shaft seals 505---905)
ETV 894030 Sleeve for fitting lifting arm shaft bushings (610312---)
ETV 894 030

ETV 893 530
1. Working hydraulics, description

NOTE: With effect from ser. no. 610312 the construction of the
hydraulic lift has been changed on 305---455 tractors. The
A. General description extra hydraulic oil reservoir and extra lifting cylinder have
been removed. At the same time the volume of the hydraulic
The hydraulic circuit is a so---called open circuit, i.e. the lift housing and the diameter of the lifting cylinder have been
pumps draw oil from the hydraulic lift housing on top of gear- increased.
box and the oil is returned to the same space.
The system consists of two separate circuits with one oil reser- Additionally, the pressure filter and valves for the auxiliary hy-
voir in common. One of the circuits is for the working hydraulics have been relocated to the RH side of the hydraulic lift
draulics and the other for the steering hydraulics. housing. The construction of the position control lever and
linkage inside the hydraulic lift housing have also been
The pump is a double hydraulic pump fitted on the right-hand changed. The pressure ---limiting valve opening pressure has
side of the engine. The pump is driven from the engine timing been lowered from 21 MPa to 18 MPa. The shock valve has
gears. The front pump unit is for the working hydraulics and been re ---positioned inside the hydraulic lift housing at the lift-
the rear for the steering hydraulics.
ing cylinder.
A suction strainer and a pressure filter are used for filtering the
oil. The pressure ---limiting valve limits the working pressure to NOTE! The new hydraulic lift has been described on page
21 MPa. The system for the working hydraulics is also pro- 910/24 onwards. Instructions for repair can be found on
vided with a shock valve which limits the pressure shocks page 914/1 onwards. 865 ---tractor, see pages 910/36 ---41
from the lifting cylinder to 29 MPa. and pages under code 915.
661
Model Code Page
1. 12. 1986
91. Hydraulic lift 205-- 865 910 6
1. 7. 1989
Fig. 1. Principle diagram of hydraulic system (---610311) 9. Valves for auxiliary hydraulics
10. Oil hoses to steering cylinder
1. Oil pump 11. Return pipe for steering system
2. Suction strainer 12. Steering cylinder (non ---powered front axle)
3. Suction pipe 13. Control valve
4. Hydraulic lift housing 14. Pressure filter
5. Delivery pipe for steering system 15. Point for checking pressure
6. Delivery pipe for working hydraulics 16. Lifting cylinder
7. Steering valve 17. Steering system return pipe to hydraulic lift housing
8. Distribution block
N.B. If the tractor is fitted with an extra lifting cylinder, its deliv-
ery pipe should be connected to the pressure checking point
(15) and the return pipe to the steering system return connec-
tion (17).
B. Function of working hydraulics
N.B. The reference numbers in the following text refer to Fig.

When in holding position, the control valve keeps the oil in the
2. lifting cylinders, maintaining their lifting arms in the set posi-
tion.
1. A pump (2) draws the oil from the reservoir (1) through the
suction strainer (3) and delivers the oil through the pressure 5. The control valve is actuated through the linkage inside the
filter to the distribution block (4). hydraulic lift housing by impulses from the position control
lever and from the automatic draft control and from the cam
2. From the distribution block oil flows through the valve (eccentric) on the lifting arm shaft.
blocks (5) to the control valve (6) of the hydraulic lift. The pur-
pose of this control valve is to direct the oil flow in order to ob- 6. When the valves for the auxiliary hydraulics are actuated,
tain the required lifting, lower and holding functions of the lift- oil is directed to the external implements through the quick ---
ing arms. action couplings (12) and flows in return to the valves and
back through the distribution block (4) to the oil reservoir.
3. When in lifting position, the control valve directs oil under
pressure to the lifting cylinder and also through the distribu- 7. If the auxiliary hydraulics are operated simultaneously with
tion block (4) to the extra lifting cylinder (7), if fitted. the hydraulic lift, the lift stops and remains in the obtained
position.
4. When lowering, the oil is returned from the lifting cylinder
through the control valve to the oil reservoir. Fig. 1. Diagram showing operating principle of hydraulic sys-
tem (---610311)
662
Model Code Page
1. 12. 1986
91. Hydraulic lift 305-- 455 910 7
1. 7. 1989
Fig. 2. Diagram showing operating principle of hydraulic lift 7. Extra lifting cylinder
( ---610311) 8. Return oil from steering system
9. Extra lifting cylinder return restriction
1. Oil reservoir 10. Connection pipe for oil reservoir
2. Pump 11. Breather pipe between oil reservoirs
3. Suction strainer 12. Quick ---action couplings
4. Distribution block 13. Return oil connection, auxiliary hydraulics
5. Control valves for auxiliary hydraulics
6. Control valve
C. Distribution block (fig. 3)

(8). In lowering position the oil is returned from the lifting cylin-
1. The oil is supplied from the pump (1) through the pressure
der through the same passage back to the control valve, and
filter (2) and its filter head to the distribution block (3). via the return pipe (10) back to the oil reservoir.
2. From the distribution block, the oil is directed down through 5. When the control valves (4) are used, the oil flows from the
a vertical passage and through the right---hand passage in the valves to the auxiliary hydraulics (11) and is then returned
centre of the valve block (4) to the end cover (5). from the implement to the upper or the lower passage and
further through the drilling (12) in the distribution block to the
3. From the end cover, the oil flows through the larger passage oil reservoir.
and through the control valves, (if the valves are not used), to
the distribution block and further through the pipe (6) to the 6. If the tractor is fitted with an extra lifting cylinder, it is con-
control valve (7). nected through the pressure checking point (13) on the dis-
tribution block which in turn is connected to the lifting cylinder
4. In lifting position the control valve directs oil under pressure (9) of the hydraulic lift. The extra cylinder is also connected to
into the lifting cylinder (9) the through passage the system through the connecting pipe (6).
663
1. 5. 1996
Fig. 3. Distribution block and control valve for auxiliary hy-

draulics (---610311)
1. Oil supply from pump 10. Return oil pipe

2. Oil to distribution block 11. To auxiliary hydraulics
3. Distribution block 12. Return drilling
4. Valve for auxiliary hydraulics 13. Pressure test point
5. End cover 14. Pressure ---limiting valve
6. Connecting pipe 15. Shock valve
7. Control valve 16. Valve spring
8. Passage to lifting cylinder 17. Shims for adjusting pressure
9. Lifting cylinder
D. Pressure ---limiting valve and shock

valve
The shock valve is fitted under the distribution block The valves are of similar design. However, the valve springs
(---610311) or on the lifting cylinder (610312---) or on the Auto- are different and coloured differently depending on the open-
control power lift it is in ---built in the control valve. The pressur- ing pressure:
e ---limiting valve is fitted inside the rear face of the distribution
block on the LH side (---610311) or on the RH side (610312---). Aluminium=pressure ---limiting valve
See pages 910/36 ---41 for 865---tractor. Orange=shock valve
The valves are of the direct---action type. They open quickly The opening pressures can be adjusted by altering the spring
and the pressure is maintained at a constant level regardless tension with shims inside the respective valve plugs.
of the flow.
The pressure ---limiting valve limits the pressure from the

pump to 21 MPa (---610311) or 18 MPa (610312---). At shock
loads the shock valves limit the pressure in the lifting cylinder
to 29 MPa (---653957) or 20 MPa (653958---). The opening
pressures are stamped into the valve plugs.
664
Model Code Page
1. 7. 1989
91. Hydraulic lift 205-- 865 910 9
1. 5. 1996
1 1
200 Nm
Fig. 4. Sectional view of valve (shock and pressure ---limiting Fig. 5. Pressure filter
valve) 1. The by ---pass valve opening pressure at an oil temperature
of 45---55˚C is 220 ---280 kPa.
1. Opening pressure stamped into valve plug 2. The support ring should be fitted outermost
2. The pressure is adjusted with shims behind the spring 3. Disposable filter element
(available shim thickness are 0,2, 0,5, 1,0 and 2,0 mm)
N.B.: On the latest Sisu ---Valmet tractors, the pressure filter
has been changed. The spring under the filter insert has been
E. Filtration of hydraulic oil removed and the sealing of the filter housing has been simpli-
fied and improved. The new parts are not exchangeable with
the earlier parts.
The system contains two separate filters. On the suction side
there is a metal gauze filter and on the pressure side there is
a filter of glass---fibre construction with a built---in by ---pass
valve in the valve head.
F. Control valves for auxiliary hydraulics
Suction strainer The tractor is provided as standard with two control valves for
auxiliary hydraulics. They can both be changed over to work
The suction strainer is the first and coarser filter used for trap- as either single ---acting or double ---acting. A third control
ping impurities which otherwise would cause interruptions. valve can be fitted as an optional extra. The control levers for
The strainer housing is fitted on the suction side of the pump. the valves are fitted to the right of the driving seat. At the back
Inside the housing there is a strainer which can be cleaned. of the tractor, there are four quick ---action couplings and pre-
Magnetic rings are fitted to the screw stud of the cover. These pared positions for two further quick ---action couplings.
rings separate iron particles from the oil. The fineness of the
strainer is 119 μm.
NOTE: With effect from ser. no. 610312 the valves for the aux-
iliary hydraulics have been relocated on the RH side of the hy-
Pressure filter draulic lift housing and are controlled with one lever. In addi-
tion knobs for selecting between single and double action
All oil to the working hydraulics is conducted through the pres- have been fitted on the underside of valves. Two valves for
sure filter. The filter should be changed every 400 running auxiliary hydraulics are fitted as standard. One extra valve and
hours. If the tractor is often used for operating auxiliary hy- a brake valve for trailer brakes are available as options.
draulics the filter should be changed at intervals of 200 hours.
NOTE! Concerning 865---tractor, see pages 910/36 ---41.
--- Temperature range ---40...+100˚C
--- Degree of filtration 98 %
--- Fineness of filter 15 μm
665
Model Code Page
1. 12. 1986
91. Hydraulic lift 205-- 865 910 10
1. 7. 1989
Fig. 6. Control valve (single ---acting, out) Fig. 8. Control valve (single ---acting, in)
Function: Oil supplied by the pump flows in through the pres- Lowering position: The valve slide is in its lower position. The
sure passage of the valve and further through the end plate
to the through ---flow passage running through the control oil from the auxiliary hydraulics is allowed in through the return
valves (the passage at the center of the valve slide). When the passage and the oil flow from the pump is conducted into the
valves are not actuated, the oil is supplied through the pas- return passage.
sage directly to the control valve tor the hydraulic lift.
Pressure position: When the valve slide is pulled upwards it

closes the through ---flow passage. Pressure builds up in the
pressure passage and opens the non ---return valve so that oil
under pressure is directed to the auxiliary hydraulics.
Fig. 9. Control valve (double acting, out)
The control valve has been changed over to become double ---
Fig. 7. Control valve (single ---acting, neutral) acting by closing the passage between the return and delivery
passages. The oil from the upper port is allowed into the return
Holding position: The valve slide is in the central position. passage only when the valve slide is in a certain position (as
The pressure passage to the auxiliary hydraulics is closed.
The non ---return valve is closed and the passages to the shown in the figure).
hydraulic Iift control valve are open . The oil is conducted
through the pressure passage (P) and through the unloading
valve back to the hydraulic lift housing.
666
Model Code Page
1. 7. 1989
91. Hydraulic lift 205-- 865 910 11
1. 5. 1996
Return connection, auxiliary hydraulics In this way the oil from the auxiliary hydraulics is returned
directly to the oil reservoir and not through the control valves.
As an alternative, the return flow for the auxiliary hydraulics This way of arranging the return flow is used when the auxili-
can be connected to the left---hand oil draining plug for the hy- ary hydraulics require a low return pressure.
draulic lift housing. With effect from ser. no. 610312 the return connection for the
auxiliary hydraulics has been fitted on the rear side of the
hydraulic housing cover.
305, 405 VALVES FOR AUXILIARY HYDRAULICS

Valve type Function Use Order no. Option
1---acting. Out--- Cylinder 724700
hold ---in (standard)
2---acting Out--- Cylinder 724710 30781000

hold ---in (standard)
2---acting Out--- Hydraulic 725550 30785600

float---in motor
2---acting Out--- Hydraulic 725560 30785700

float---in, motor
locked
2---acting Out---hold --- Cylinder 725570 30785800

in ---float,
locked
Fig. 10. Valve diagrams
The upper end of the lifting cylinder is connected to the left lift-
G. Extra lifting cylinder (standard on 865) ing arm and the lower end to the rear axle housing. The oil
supply for the cylinder is taken from the pressure test point on
the distribution block. The union for connecting the pressure
For certain markets the extra lifting cylinder is fitted as stan- gauge is moved to the hose for the extra cylinder. The counter
dard. It can also be fitted to the tractors as an optional extra, pressure is connected to the steering system return oil pipe
thus increasing the lifting force of the lower links which is provided with a restriction (see Fig. 2 item 9).
NOTE: With effect from ser. no. 610312 Valmet 305---455 trac-
tors are no longer fitted with an extra lifting cylinder.
667
Model Code Page
1. 12. 1986
91. Hydraulic lift 305-- 455 910 12
1. 7. 1989
Fig. 12. Hydraulic lift and linkage with extra lifting cylinder
fitted.
1. Extra lifting cylinder (---610311)
668
Model Code Page
91. Hydraulic lift 305-- 455 910 13
1. 12. 1986
H. Automatic pick ---up hitch

150 mm rearwards. The point of the hookcan be clearly seen
The pick ---up hitch is lowered and raised through links con- from the cab. The maximum permissible vertical load on the
nected to the hydraulic lift arms. When the pick ---up hitch is hook is 30 kN (3000 kgf). However, attention must be paid to
raised to its top position, it becomes automatically and mech- the permissible tyre and axle loads.
anically locked. Whe the hook is lowered, it is also moved
Fig. 13. Automatic pick ---up hitch
1. Lifting link
2. Mechanical lock for the hitch
669
Fig. 14. Hydraulic lift housing (---610311)
1. Sealing compound Silastic 738 RTV black or similar
2. Sealing compound Silastic 738 RTV Black or similar
91. Hydraulic lift

3. Universal grease. After securing the service cover it
should be possible easily to turn the valve slide by hand
4. Secure with Loctite 270 or similar
5. The control valve attaching bolts should be tightened
to 50 Nm.
6. Maximum amount to be filled 35 litres.
670
1. 7. 1989
1. 12. 1986
Model
305-- 455
Code
910
Page
14
Note! This hydraulic lift is fitted on tractors 305---455 up to ser. no. 610311.
Model Code Page
1. 12. 1986
91. Hydraulic lift 305-- 455 910 15
1. 7. 1989
Fig. 15. Hydraulic lift housing seen from above (---610311) 5. Anti ---friction varnish
1. Punch marks to be next to each other 6. Note the tightening torque
2. Sealing compound Silastic 738 RTV Black or equivalent 7. Note position of bearing sleeves
3. Universal grease 8. Bearing sleeve positions on lifting arm shaft
4. Locking fluid Loctite 270 or equivalent 9. Locking fluid Loctite 237 or equivalent
671
Model Code Page
91. Hydraulic lift 205-- 865 910 16
1. 12. 1986
I. Control valve and control system
Control valve, description

The control valve consists of two valve blocks: basic block (1)
and damping valve (2). The basic block contains the two
working valves: unloading valve (3) and lowering valve (4).
The valve cones of the working valves are mechanically actu-

ated by the pilot valve balls (8 and 9). A hole is drilled in each
valve cone. The hole connects the pressure chamber in the
pump, or in the cylinder, with the spaces behind the valve
cones which in turn are connected to the pilot valve balls (8
and 9).
The pilot valve ball is opened by a mechanical pressure

applied against the ball, thus allowing oil to flow past. As the
hole in each of the valve cones is smaller, the oil pressure in
the space behind the valve cone drops. The pressure in front
of the valve cone is still higher and the consequent pressure
difference forces the valve cone rearwards and the valve
opens.
If the pilot valve ball is allowed down onto its seat, the pressure
difference on either side of the valve cone disappears and the
return spring, together with the oil pressure (the area at the
back of the valve cone being larger), forces the valve cone
against its seat. The valve is now kept pressed against the seat
by the working pressure.
The two pilot valves are adjusted so that the moveable pres-
Fig. 16. Control valve in floating position sure yoke (10) first actuates the pilot valve ball (9) for the
unloading valve. The clearance between the thrust pin of the
1. Control valve, basic block pilot valve (8) for the lowering valve, and the pressure yoke
2. Control valve, damping valve should have a certain value (see the Technical Data). As long
3. Unloading valve as the movement of the pressure yoke is within the given toler-
4. Lowering valve ances, pilot valve (9) will keep the unloading valve open with-
5. Non ---return valve out opening the lowering valve pilot valve.
6. Control valve slide
7. Damping valve piston When in lifting position, the pressure yoke (10) has no contact
8. Lowering valve pilot ball with either of the pilot valves. Therefore, both pilot valves (8
9. Unloading valve pilot ball and 9) as well as the main valves (3 and 4) remain closed and
10. Pressure yoke the flow passes undiminished via the control valve slide and
11. Lowering speed valve the non ---return valve to the lifting cylinders, thus achieving
the maximum lifting speed.
672
Model Code Page
91. Hydraulic lift 205-- 865 910 17
1. 12. 1986
Fig. 17. Control valve, neutral position
The pressure yoke (10) has opened the unloading valve pilot
valve (9). The pressure difference on either side of the unload-
ing valve cone (3) causes the valve to open and the oil flow is
conducted out through port (T) back to the oil reservoir. The
oil in the lifting cylinders is now locked in by the non ---return
valve (5) and the lowering valve (4 and 8) which is closed.
Fig. 18. Control valve, lowering position
The pressure yoke has now opened both pilot valve balls (8
and 9) for the unloading valve and for the lowering valve. The
pressure difference on either side of both the main valve
cones (3 and 4) causes these to open. The oil now flows in
return from the lifting cylinder at (A) out through (T) both the
lowering speed valve and the unloading valve. Also the oil
flow from the pump is returned to the oil reservoir through the
unloading valve.
673
Model Code Page
1. 7. 1989
91. Hydraulic lift 205-- 865 910 18
1. 9. 1995
Damping valve, description 150 Nm

The purpose of the damping valve is to slow down the starting
and finishing phases of the lifting movement. In figure 19 the
pressure yoke has just closed the unloading valve and the lift-
ing movement is about to begin (the oil flow is determined by
the control valve slide). Because of the pressure difference
which the control valve slide causes, the damping valve
admits part of the oil flow back to the hydraulic tank.
Since the damping valve is actuated immediately at the start

of the pressure yoke movement, maximum flow to the lifting
cylinder is obtained owing to an increased movement of the
pressure yoke (operated by the position control lever). At nor-
mal lifting, when one wishes to lift the implement quickly to the
transporting position, the hydraulic lift operates at maximum
speed except immediately at the start and finish of the move- 50 Nm
ment.
15 Nm
T
Fig. 19 Damping valve
A P
The oil flow to the lifting cylinder is also reduced when the
pressure yoke is close to the desired position and slowly The damping valve also contains a non ---return valve, the pur-
moves towards the unloading position. In this way the oil flow pose of which is to prevent oil flow from the lifting cylinder from
is gradually reduced from a particular position until the passing via the damping valve.
unloading valve opens. When a lifting impulse reaches the
control valve, via the impulse sender mechanism, the unload-
ing valve closes. The oil pressure is conducted to the damping
valve and temporarily opens the return passage.
The control valve slide takes up a position of equilibrium

where the force acting on the valve piston due to the pressure
difference over the control valve slide is equal to the force
exerted by the return spring.
The impulse transmitter rod is connected to the pressure yoke

via a linkage. When the pressure yoke is actuated the control
valve slide moves so that the flow of the pressurised oil is
directly proportional to the draft resistance. In this way a con-
tinuous transmission of weight to the rear wheels of the tractor
is obtained which is proportional to the draft resistance.
674
91. Hydraulic lift
675
1. 7. 1989
1. 9. 1995
Model
305-- 665
1. Position control lever 12. Lifting arm shaft (rocker shaft)
2. Control shaft 13. Top link
3. Link 15. Top link bracket
Code
910
4. Lifting shaft 16. Adjusting screw
5. Control arm (cam follower) 17. Impulse transmitting rod
6. Lever 18. Pressure yoke return spring
7. Connecting rod 19. Shims
Page
8. Pressure yoke 20. Limiter
19
9. Pilot valve A, B and D are pivoting points
10. Pilot valve
11. Cam (eccentric)
Model Code Page
1. 12. 1986
91. Hydraulic lift 305-- 455 910 20
1. 7. 1989
Control levers for hydraulic lift ( -- 610311) The connecting rod (7) is now displaced to the right (rear-
wards) and the pressure yoke (8) opens the pilot valves and
the lifting arms begin to lower. As the lifting arms lower the
The position control lever is fitted to the right of the driving
cam (11) on the lifting arm shaft (12) moves downwards so
seat. When the lever is moved rearwards the lifting arms are that the upper end of the control arm (5) moves to the left (for-
raised and when the lever is moved forwards the arms are low- wards) and its lower end to the right (rearwards) pivoting
ered. When the lever is left in any intermediate positions the round point (B).
lifting arms will take up a corresponding position within its
range. The link (3) remains in the set position and the lever (6) pivots
round point (C) displacing the connecting rod (7) to the left
The position control lever movements are transferred to the (forwards) which allows the pilot valves to close and the sys-
hydraulic lift through a mechanical linkage. tem takes up a neutral position. The pressure yoke (8) is
spring ---loaded so that the control arm (cam follower) (5) all
In addition, the two control levers for auxiliary hydraulics are the time strives to follow the profile of the cam (11).
fitted to the right of the seat. The lowering speed control is
positioned under the seat. When the lever is pushed in, the lift-
Draft control
ing arms move at the highest speed.
(Top link bracket is not locked)
The impulse transmitter lock for the draft control is fitted at the
back of the tractor. When the lever is in the downward position, On valmet 305 and 405 tractors the top link is used for trans-
the draft control is disconnected. The top link bracket can then mitting the varying pulling force to the hydraulic lift. The draft
not move and thus will not transmit varying draft resistance or control is used when working with fully or partially mounted
variations in the pulling resistance, leaving the hydraulic lift soil penetrating implements (ploughs, cultivators). Draft con-
control mechanism unaffected. trol is in operation when the impulse transmitter lock is in its
upper position. Impulses caused by the varying soil resis-
tance are transmitted through the top link, which through the
Linkage in hydraulic lift housing, description
top link bracket, actuates the control linkage so that an auto-
matic, but varying weight transference from the implement to
Lifting position (fig. 20, black arrows) the rear wheels of the tractor is obtained.
When the position control lever is moved rearwards (to the
right in the figure) in order to initiate a lifting movement, the The position control lever is used for setting a suitable working
control shaft (2) turns and moves the link (3) rearwards caus- depth for the implement. If the draft resistance increases to a
ing the link shaft (4) to turn round pivot point (A). certain value, the draft control in the hydraulic lift raises the im-
plement slightly, thus reducing the required pulling force
The upper end of the control arm (5) is pressed against the which in this way is kept nearly constant. The lifting movement
cam (11), but its lower end, and the lower end of the lever (6), causes weight to be transferred from the implement to the rear
move to the right, forcing the lever (6) to pivot round point (C) wheels of the tractor, thus increasing the pulling power. The
so that its upper end and the connecting rod (7) are moved to sensitivity can be adjusted by connecting the top link in differ-
the left, (in the figure or forwards in the machine), which in turn ent holes in the bracket (15).
causes the pressure yoke (8) to close the pilot valves (9) and
(10). There are shims (19 mm) between the hydraulic lift housing
and the top link bracket spring. The shims are used for adjust-
Oil under pressure flows into the lifting cylinder raising the lifting the position of the top link bracket so that it cannot move
ing arms. when the impulse transmitter lock is moved downwards into
the locked position.
Neutral position (fig. 20)
If the position control lever is not moved when the lifting se- A limiter (20), (fitted on the inner lever of the lifting arm shaft),
quence begins, the link (3) will remain in the set position, while limits the top position of the lifting arms. A cam (11) is also
the cam (11) forces the upper end of the control arm (5) to fitted onto the inner lever of the lifting arm shaft.
move to the right (rearwards) round pivot point B.
The upper end of the lever (6) also moves to the right (rear- Draft control, function (fig. 20)
wards) round pivot point (C) bringing with it the connecting
rod (7). The pressure yoke (8) is moved to the right (rear-
wards) and the pilot valve (9) opens the unloading valve and At an increased pulling resistance, an impulse is transmitted
the lifting arms stop in a position corresponding to the position through the top link, top link bracket, adjusting screw (16) and
set with the position control lever (1). impulse rod (17). The rod is displaced forwards and moves
the upper end of the lever (6) forwards, pivoting around point
Lowering position (fig. 20., white arrows) D. This causes the connecting rod (7) to move forwards clos-
When the position control lever (1) is moved to the left (for- ing the pilot valve (9) for the unloading valve.
wards), the lowering sequence begins. The link (3) is dis-
placed to the left (forwards) and brings the lower end of the This results in a lifting movement of the lifting arms. The draft
control arm (5) to the left (forwards) round pivot point (A) caus- resistance is reduced and the system takes up a neutral posi-
ing the upper end of the lever (6) to move to the right (rear- tion.
wards) round pivot point C.
676
Model Code Page
91. Hydraulic lift 305-- 455 910 21
1. 12. 1986
2. Fault tracing Valves tor auxiliary hydraulics
Possible faults in the valves are leaking seals or the binding

A. General about fault tracing in the of valve slides which is often caused by too hard tightening of
hydraulic system attaching nuts or by impurities. The correct tightening torques
for the nuts are 25 ---28 N m.
When a fault is discovered. it is important to trace the fault and
systematically work out the cause before starting any repair Linkage In hydraulic lift housing
work. The instructions about tracing leaks, which are given in
the repair instructions, facilitate a quick tracing of faults, par- Faults in the linkage often show up as an incorrect function of
ticularly in parts which are actuated when the system is in neu- the hydraulic system. On new tractors such faults may be
tral. caused by binding in the linkage and this can be checked as
follows:
Parts which cause problems in the unloading or lifting posi-
tions cannot usually be traced by pressure testing. In these 1. Drain the hydraulic oil and remove the service cover.
cases, lifting times and measuring of flow may be used for
tracing any faults. 2. Move the position control lever to the lifting position and
push the pressure yoke rearwards. The linkage should auto-
matically be returned to the previous position.
677
Model Code Page
1. 12. 1986
B. Fault ---tracing chart for working

hydraulics
1. Lifting arms do not lift

--- Too big load connected to the lift
--- Impurities in unloading valve restricting hole
--- Damping valve control slide stuck in the open position
--- Unloading valve main valve cone stuck in the open position
--- Unloading valve pilot valve does not close
--- Faulty hydraulic pump
2. Lifting arms do not remain stationary when the system is in

neutral. The arms lower or shake
--- Components which are actuated when the system is in neu-
tral are leaking.
3. Hydraulic lift does not lift normally

--- Pressure limiting valve set too low
4. The oil becomes hot

--- Automatic pick ---up hitch lifting links incorrectly adjusted.
--- Worn hydraulic pump
--- Hydraulic lift overloaded
--- Parts which are exposed to the oil pressure are leaking or
incorrect oil grade is used
5. Lifting arms lift when the position control lever is in its fore-
most position
--- Position control incorrectly adjusted
6. Oil is foaming
--- Leaking suction pipe
--- Too low oil level
7. Noisy pump
--- Blocked suction strainer or suction pipe
8. Too low lifting speed

--- Blocked suction strainer
--- Too thick oil
--- Incorrectly adjusted damping valve control slide
9. Low lifting speed when lifting big loads only

--- Leaks in the pressure side of the system
10. Lifting arms move jerkly at a low lifting speed

--- The oil is too thick (too cold)
--- Air in system
11. The hydraulic oil looks greyish, and is not transparent

--- Water has become mixed into the oil
12. The oil looks milky and is not transparent

--- Air has become mixed into the oil
13. The oil looks very dark but is transparent

--- The oil has become overheated
678
91. Hydraulic lift (610312---) 205-- 665 910 23
1. 9. 1992
Hydraulic diagram (610312---)
1) Pump and suction strainer assy 20) Restriction, low. valve main valve cone 34) Shock valve (20 MPa)
2) Suction strainer 21) Pressure filter 35) Lowering valve pilot piston
3) Double gear pump --- by ---pass valve 0,2 MPa 36) Lowering valve
4) End plate --- pressure ---limiting valve 0,7 MPa 37) Lubricating oil pump
5) Pressure ---test point 22) Lifting cylinder 38) Oil filter
6) Pressure ---limiting valve (18 MPa) 23) Shock valve (29 MPa; 20 MPa from 39) By ---pass valve 0,4 MPa (665)
7) Valves for auxiliary hydraulics tractor no 653958---). Not Autocontrol 40) Oil cooler (665)
8) Quick ---action couplings 24) Steering valve assy
9) Intermediate plate 25) Steering valve
10) Control valve assembly. 26) Pressure ---limiting valve
11) Damping valve 27) Steering system non ---return valve
12) Unloading valve 28) Steering cylinder
13) Restriction, unld. valve main valve cone 29) Tank
14) Unloading valve pilot valve ball 30) Control valve (BOSCH)
15) Change ---over knob (1/2---action) 31) 3---way oil flow regulating valve
16) Lowering speed valve 32) Main valve spool
17) Lowering valve main valve cone 33) Pilot pressure limiting valve
18) Lowering valve pilot valve ball
679
Model Code Page
91. Hydraulic lift (610312---) 205-- 665 910 24
1. 7. 1989
Fig. 21. Diagram showing hydraulic system operating principles (610312---)

1. Pump
2. Suction strainer
3. Suction pipe
4. Hydraulic lift housing
5. Delivery pipe for steering system
6. Delivery pipe for hydraulic lift
7. Steering valve
8. Intermediate plate
9. Valves for auxiliary hydraulics
10. Oil hoses to steering cylinder
11. Return oil pipe for steering system
13. Control valve
14. Pressure filter
15. Pressure ---test point
16. Lifting cylinder
17. Steering system return pipe to hydraulic lift housing
680
Model Code Page
91. Hydraulic lift (610312---) 205-- 665 910 25
1. 7. 1989
Fig. 22. Diagram showing hydraulic lift operating principles (610312---)

2. Gear type pump (front block for hydraulic lift)
3. Suction strainer (+ magnet pieces).
4. End plate
6. Control valve
8. Steering system return oil pipe to hydraulic lift housing
12. Quick ---action couplings for auxiliary hydraulics
13. Return oil connection for auxiliary hydraulics
681
Model Code Page
91. Hydraulic lift (610312---) 205-- 665 910 26
1. 7. 1989
Fig. 23. End plate, intermediate plate and valves for auxiliary 9. Lifting cylinder
hydraulics (610312---) 10. Return oil from control valve to tank
11. To auxiliary hydraulics
12. Return oil from auxiliary hydraulics to oil tank
1. Oil supply from pump 13. Pressure ---test point (connection to lifting cylinder)
2. Pressure filter (on intermediate frame, RH side) 14. Pressure limiting valve (18 MPa)
3. End plate of auxiliary hydraulic valves (new part) 15. Shock valve (29 MPa)
4. Valves for auxiliary hydraulics (on RH side) 16. Pressure ---limiting valve and shock valve have different
5. Intermediate plate springs. The springs are coloured differently.
6. Connecting pipe (pressure oil passage ---control valve) 17. Opening pressure is adjusted by changing spring tension
(lower pipe connects lifting cylinder to pressure ---test point). with shims (thickness shown in figure above)
7. Control valve 18. Return oil connection from auxiliary hydraulics
8. Pressurized oil from control valve to lifting cylinder (lifting).
Return oil to control valve (lowering)
682
Model Code Page
1. 7. 1989
91. Hydraulic lift (610312---) 205-- 665 910 27
10. 1. 1992
Fig. 24. Sectional view of hydraulic lift housing (610312---)
1. Sealing compound UK 0067 between cover and housing

2. Guide pins (2 pcs) are provided with M10 threaded holes for
puller
3. Dipstick:
--- upper mark (35 l)
--- lower mark (25 l)
--- volume of oil available for auxiliary hydraulics is 24 l or 14 l
depending on filling quantity.
--- Upper end of dipstick has inbuilt breather filter
4. Sealing compound Hylosil (UK 0067) around screw holes
in order to prevent oil leakages.
683
Model Code Page
91. Hydraulic lift (610312---) 205-- 665 910 28
1. 7. 1989
Fig. 25. Hydraulic lift housing seen from above (610312---)
1. To position control lever

2. Lowering speed control rod
3. Return oil from steering system
4. Pressure ---test point. Connecting pipe (lower pipe) con-
nects pressure ---test point to lifting cylinder. Test point allows
checking of working pressure in lifting cylinder (18 MPa) and
shock valve opening pressure (29 MPa)
5. Universal grease UC 1811
6. Punch marks on lifting arms and inner lever must align with
punch mark on lifting shaft
7. Sealing compound Hylosil (UK 0067) on contact surface
between housing and intermediate plate.
NOTE: Sealing compound should also be applied to the
lower fixing bolt cavity so that oil cannot leak from the housing
along the bolt to the contact surfaces between valve blocks.
8. Loctite 222 (UK 0094) locking fluid applied to threads. Bolts
should be tightened to a torque of 17 ---23 Nm (3 pcs).
684
Model Code Page
91. Hydraulic lift (610312---) 205-- 665 910 29
1. 7. 1989
Fig. 26. Control linkage in hydraulic lift housing (610312--- ) --- Lowering position (white arrows):
When the position control lever (1) is moved forwards the control
--- The control linkage has been altered with effect from ser. no. shaft (3) turns clockwise and the eccentric pin on control shaft moves
610312. The linkage in the hydraulic lift housing has been simplified the lower end of lever (4) rearwards and also moves the connecting
with a consequent improvement in accuracy. The position of the rod (5) rearwards. The pilot valve ball (8) of the lowering valve opens
position control lever has been made more precise. and the lifting arms begin to lower.
--- The hydraulic lift impulse point is adjusted by altering the length of
the position control lever rod (2) (188 mm). There are no other adjust- While the lifting arms are lowering the cam (10) on the lifting arm shaft
ments or settings on the new hydraulic lift. turns and allows the lower end of control arm (9) to move rearwards
and the lower end of lever (4) to move forwards. The lowering valve
--- Operation when top link bracket (11) is locked pilot valve ball (8) closes and the control valve remains in the unload-
(unlocked in figure above) ing mode.
--- Lifting position (black arrows).

When the position control lever (1) is pulled back, the control shaft (3) --- Draft control
turns anti--- clockwise. The eccentric pin on the control shaft also Draft control is on when the top link bracket is not locked (impulse
turns and moves the lower end of lever (4) forwards.Connecting rod sender lever in vertical position).
(5) pushes the pressure yoke (6) forwards and the pilot valve ball (7) --- Operation:
of the unloading valve closes. Oil starts to flow to the lifting cylinder When pulling resistance increases an impulse is transmitted through
and the lifting arms rise. the top link and top link bracket (11) to the rear end of the impulse rod
--- Neutral position (12). The rod is pushed forwards and moves the control arm (9) so
When the lifting arms rise and lever (1) is not moved, the control shaft that its lower end moves back. At the same time lever (4) moves the
(3) is stationary and the cam (10) on the lifting shaft pushes the lower pressure yoke (6) forwards. This lifts the lifting arms. The draft resis-
end of control arm (9) forwards and at the same time the pressure tance is reduced and the system is again in equilibrium.
yoke is pulled back with aid of the lever (4) and connecting rod (5).
--- The position of the top link bracket is adjusted with shims (13).
Pilot valve (7) opens the unloading valve and the lifting arms stop in a --- Pin (14) limits the max. upper position of the lifting arms when the
position corresponding to that set with the position control lever (1). piston in the lifting cylinder is in its extreme position.
685
Model Code Page
91. Hydraulic lift (610312---) 205-- 665 910 30
1. 7. 1989
Fig. 27. Lifting range and lifting force (610312---)
--- A new type hydraulic lift is fitted with effect from ser. no.
610312.
Max. lifting force at end of lower links:

--- lifting links mounted on rear points . . . . 24 kN (2500 kp)
--- lifting links mounted on front points . . . . 21 kN (2200 kp)
Lifting range at end of lower links:

--- lifting links mounted on rear points . . . . 675 --- 695 mm.
--- lifting links mounted on front points . . . . 775 --- 795 mm.
686
Model Code Page
15. 4. 1994
91. Hydraulic lift 255-- 900 910 31
1. 1. 1998
Alternative hydraulic system
Fig. 28. Hydraulic system in which the twin pump outputs In this system the priority valve gives priority to the steering cir-
have been connected together and the steering system has cuit i.e. if the steering and working hydraulics are used simul-
a priority valve. taneously, the pump output is directed principally to the stee-
ring system and rest of the pump output is available for the
1. Twin pump (12,8+10,3 cm3/r) working hydraulics. When the steering wheel is not turned, the
2. Oil cooler total pump output can be used for the working hydraulics.
3. Priority valve
Auxiliary hydraulics (e.g. front loader) must never be connec-
In this system the twin pump revolution volume is different ted before the priority valve but the oil must be taken either
compared with the system which has separate circuits for the from the quick ---action couplings or after the priority valve
working hydraulics and steering hydraulics. The hydraulic before the pressure ---limiting valve and the valve blocks.
power lift and the working hydraulics are the same as earlier.
The twin pump combined output is 55 dm3/min at engine revs

of 2350 r/min.
687
Model Code Page
1. 6. 1998
91. Hydraulic lift (610312---) 355-- 900 910 32
1. 9. 2001
Front ---mounted three ---point linkage unit

(option)
G06100 ---H21522
H21523 ---
Fig. 29. Front lift At the same time the fastening points of the lower link sup-
ports to the support frames (1) have been modified (ball
1. Support frame bearings+grease nipples+locking flanges).
2. Lower links can be turned and removed
3. Lifting cylinders, 2 pcs (ø 70, 25 kN) Maintenance
4. Control valve
a) Retighten all front lift bolts after the first 15 --- 25 running
5. Pin prevents shaft from rotating in relation to arm
hours.
The front---mounted hydraulic power lift is an option. The b) Grease the lifting cylinder attaching pins and the front lift
mounting kit includes the front lift and the control valve with main shaft at intervals of 250 running hours, depending on
necessary mounting details. The front lift is delivered also the use. Grease also the lower link support ball bearings
with the front PTO (see pages 460/8 ---11). All movable on the latest front lift/linkage (H21523---).
parts of the front linkage are supported with bearings.
The control valve is the outermost valve on the valve block

set (in 100---series the valve is always third valve). The cont- Tightening torques
rol valve is standard valve 32086000 which has been chan-
M20x50 8.8 400 Nm
ged into a single ---acting (---F20200).
On the latest 65---tractors and on 600---900 the control valve M16x50 8.8 240 Nm
number is 33188310 (F20201---). The diameter of a hole at
M14x60 8.8 120 Nm (socket head)
the upper end of the valve spool has been changed.
M14x25 8.8 120 Nm
Note! From ser. no. H21523 incl. small bends have been
made in the front parts of the support frames (1), at which
time the distance between the front ends of the frames has
been changed from 540 mm to 500 mm so that the top link
bracket and the lower links can be the same as on Mezzo---
tractors.
688
Model Code Page
1. 6. 1998
91. Hydraulic lift (610312---) 355-- 900 910 33
1. 9. 2001
H47255---
(latest front PTO)
Fig 30. Dimensions of the front linkage (also the front PTO in
the picture above)
--- Max. lifting force . . . . . . . . . . . . . 25 kN

--- Lifting range . . . . . . . . . . . . . . . . . 620 mm
--- Lower links . . . . . . . . . . . . . . . . . . Ball---Hitch, kat.
--- Front towing point as standard
Loctite 270
Fig. 30A. Front lift lifting ram, ø 70 mm
689
Model Code Page
91. Hydraulic lift (610312---) 255-- 865 910 34
15. 9. 1995
Fig 31. Control valve of the front lift C: When the spool 1 is moved downwards from the neutral
position, return oil flows from the front lift into the tank via
Valve (32086000+plugging): 1---action, 4 positions (out--- port B. Passages N is closed and hydraulic oil from the
hold ---in ---float). Float---position can be locked. pump flows into the upper tank passage.
The upper port A is plugged and the front lift pressure D: Floating position: The spool 1 is moved further down-
hose is connected to the lower port B. wards. Locking piece 3 and locking balls lock the spool.
The middle passages N open and oil flows through the
Function passages into the other valve blocks and onto the power
lift.
A: Neutral position. Hydraulic oil flows via the end plate of The pressure passage P to the port B is shut. The port B is
valve blocks through the passages N and further to the connected to the tank passage.
other valve blocks and the power lift
Port B to the front lift and the non ---return valve 2 is closed. 1) Spool
B: Pressure position: When the spool 1 moves upwards, 2) Non ---return valve
the spool middle part closes the passages N and the spool
lower part opens the passage to port B. Pressure in the 3) Locking piece
passage N increases and also in the passage P (these
passages are connected together in the outermost end 4) Centring springs
plate).
The non ---return valve 2 opens and oil flows via port B into
the front lift cylinders.
690
Model Code Page
15. 4. 1999
91. Working hydraulics 865
910 35
1. 9. 2001 600-- 900
Working hydraulics on 865 and 600---900 tractors

865, 800 and 900 tractors have a priority valve as standard, see page 910/32. On 600 and 700 tractors the priority valve is an
alternative equipment. The hydraulic power lift is available either with a mechanical control or with Autocontrol system.
Due to the new cab, the hydraulic power lift housing casting has been changed a little. The lifting power is higher and the lift
has one auxiliary lifting cylinder on 865, 800 and 900 tractors.
Note! From ser. no. K26106 the Sauer pump (13+10) has been replaced with Bosch ---pump (11+11) (with priority valve) or
from ser. no. K47331 (without priority valve) Sauer 16+12---pump has been replaced with Bosch 16+14 pump.
Technical data
Category II three ---point linkage.
Pump type (Sauer or Bosch pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . double gear pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine timing gears
Pump capacity per revolution (theoretical), without priority valve, 600 and 700 (Sauer) . . . . . . 16 cm3/r (---K47330)
Pump capacity per revolution (theoretical), without priority valve, 600 and 700 (Bosch) . . . . . . 16 cm3/r (K47331---))
Pump capacity per revolution (theoretical), with priority valve (Sauer pump) . . . . . . . . . . . . . . . 13 cm3+10 cm3=
23 cm3/r (---K26105)
Pump capacity per revolution (theoretical), with priority valve (Bosch pump) . . . . . . . . . . . . . . 11 cm3+11 cm3=
22 cm3/r (K26106---)
Combined pump output with priority valve, 865 (Sauer pump) . . . . . . . . . . . . . . . . . . . . . . . . . . 55 l/min/2350 r/min
Combined pump output with priority valve, 600, 700, 800, 900 (Sauer+Bosch) . . . . . . . . . . . . 52 l/min/2270 r/min (max. 55 l)
Pump output without priority valve, 600, 700 (Sauer+Bosch) . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 l/min/2270 r/min (max. 40 l)
Working hydraulic max. pressure:
--- 865, 600---900 (with pump output of 36 l/min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 MPa
--- 600---900 (with pump output of 52 l/min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MPa
Shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 MPa
Hydraulic system capability, measured at quick ---couplings:
--- effect, 90 % of max. pressure (OECD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 kW
--- oil flow, 90 % of max. pressure (OECD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 l/min
Max. lifting force at lower link ends:
--- lifting links in rear holes, 600, 700/800, 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28/33 kN
--- lifting links in front holes, 600, 700/800, 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25/29 kN
Lifting range at lower link ends:
--- lifting links in rear holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
--- lifting links in front holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
Pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replaceable filter insert
Suction strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . washable metal gauze filter
Oil available for auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 or 14 l depending on filling
Continuous pressure (e.g. hydraulic motor use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MPa
Oil volume (max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 l
Valves for auxiliary hydraulics

One 2/1---action 3---position valve and one 2---action 4---position valve, floating position can be locked. As an extra equipment
two extra valves and a trailer brake valve can be fitted.
Towing hook
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically controlled
Max. allowable vertical loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 kN (3000 kp)
Vertical distance between lowered towing hook and rear wheel centre . . . . . . . . . . . . . . . . . . . 650 mm
Towing hook height from the ground when lowered (with tyres 18.9R34) . . . . . . . . . . . . . . . . . . 223 mm
Agricultural drawbar
Distance between PTO shaft --- drawing point and corresponding permissible vertical load:
--- 210 mm/25000 N (2500 kp)
--- 250 mm/15000 N (1500 kp)
--- 355 mm/10000 N (1000 kp)
--- 400 mm/8500 kN (850 kp)
---In two outer positions the drawbar can be turned to two positions also in the lateral direction (¦12,5_ and ¦25_).
Tightening torques
Hydraulic lift housing ---gearbox, 8 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
Lifting cylinder --- hydraulic lift housing, 4 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
Hydraulic lift housing cover ---housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Nuts for studs for auxiliary hydraulic valves (Kontak ---valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26---28 Nm
691
Model Code PAge
15. 4. 1999
600-- 900 910 36
1. 9. 2001
Hydraulic lift on 865 and 600---900 tractors
Picture 32. Mechanical hydraulic lift on 865 and 600 ---900. Compared with the hydraulic lift on 255---665, the control
(Side view of AC and ACB power lifts, see page 920/13). valve, lifting cylinder/piston, lifting arm shaft and control
levers are the same as earlier. Also the hydraulic oil volume
1. Hylosil sealing compound between cover ---housing and oil quality are the same as earlier (see hydraulic lift,
2. Dowels (2 pcs) have M10 thread for extractor. 610312---).
3. Dipstick:
--- upper mark, 35 l Note! The lifting cylinder spare part number is different,
--- lower mark, 25 l since it has an extra connection for an extra lifting cylinder.
--- 24 litres oil available for auxiliary hydraulics when max
filling. Differences:
--- the dipstick end has an in ---built breather. --- Hydraulic lift housing casting has been changed
4. Hylosil sealing compound round the housing bolt holes --- The housing cover (1) has been changed.
on the gearbox. --- The attaching flange between the housing and the auxili-
5. Loctite 270 to the threads ary hydraulic valves has been casted directly to the hous-
6. When moving the top link bracket detent lever (without ing. In the flange there is a pressure limiting valve (8).
loading) the top link bracket must not move. The position of --- Inner lever (9) has different spare part number.
the top link bracket can be adjusted with shims between
the housing and the top link bracket spring (available
shims 0,5 /1,0 /2,0 mm).
7. Shock valve, opening pressure 20 MPa
8. Pressure ---limiting valve, opening pressure 18 MPa.
9. Adjusting dimension of bolt at the rear end of feeler rod.
10. Return oil connection for auxiliary hydraulics
11. A connection pipe has been added for the breather
(H39101 ---). The pipe raises the breather up and to the hori-
zontal position (in the pipe there is a restriction of 3 mm).
692
Model Code Page
1. 5. 1996
910 37
1. 1. 1998 600-- 900
Picture 33. Mechanical hydraulic lift on 865 and 600 ---900.
1. Linkage to the position control lever

2. Lowering speed control lever
3. Return oil connection from steering hydraulics
4. Extra lifting cylinder connection on 865, 800 and 900.
5. Universal grease.
6. Punch marks on the shaft and on the inner lever/lifting arms
must align.
7. Control lever for standard valves
8. Tightening torque 26 ---28 Nm.
9. Dipstick
10. Return oil connection from auxiliary hydraulics
11. Cup plugs on the rear attaching bolts
693
Model Code Page
1. 5. 1996
600-- 900 910 38
1. 1. 1998
Picture 34. Auxiliary hydraulic valve blocks on 865 and Four valve blocks can be fitted (earlier 3 pcs).
600---900 tractors
The two standard valves (inner) have a single lever control.
1. Pressure oil from pump Two extra valves (outer) have separate levers.
2. Pressure filter (on the RH side).
3. End plate (new part). On 865, 800 and 900 tractors there is an extra lifting cylinder
4. Valve blocks (max. 4 pcs). as standard. The extra cylinder raises lifting power up to 33
5. Valve block attaching surface is cast into the housing kN.
6. Connecting tube (pressure passage ---control valve).
7. Control valve The extra lifting cylinder pressure hose is connected to the
8. Pressure oil from control valve to lifting cylinder (lifting). shock valve connecting passage (on the LH side of the lifting
Return oil to control valve (lowering). cylinder). Return oil hose is connected to the LH side of the
9. Lifting cylinder (ø 100 mm) hydraulic lift housing.
10. Return oil from control valve
11. To the auxiliary hydraulics
12. Return oil from valve blocks
14. Pressure ---limiting valve limits pump pressure to 18,0---
18,8 MPa
15. Shock valve limits the lifting cylinder pressure to 20 MPa
(protects against pressure shocks)
16. The pressure ---limiting valve and shock valve have diffe-
rent springs (marked with colour):
--- shock valve has an orange spring
--- pressure ---limiting valve has a red spring
17. Opening pressures can be adjusted with shims
18. Return oil connection from auxiliary hydraulics (1/2”).
694
Model Code Page
1. 5. 1996
910 39
1. 1. 1998 600-- 900
(mm)
1100
1000
900
584 800
PTO 540/1000 700
675 (2.)
750 (1.)
600
500
400
1. 300
2. 900 200 (2.) 1. 2.
200
(kN)
1200
1600
2000
2400
2800
3200
3600
without extra lifting cylinder
Picture 35. Lifting range and lifting power of the hydraulic lift
on 865 and 600---900 tractors
Note! The standard extra lifting cylinder is shown on page

910/12.
695
Model Code Page
91. Hydraulic system 865, 600-- 900 910 40
1. 1. 1998
Hydraulic diagram 865, 600---900
1) Pump and suction strainer, compl. 18) Pilot valve of lowering valve 32) Control spool
2) Suction strainer 20) Restriction hole for lowering valve 33) Control valve for pilot pressure of lowering valve
3) Double gear pump 12,8 cm3/r + 21) Pressure filter 34) Lifting cylinder schock valve (20 MPa)
10,3 cm3/r = 23,1 cm3/r --- by--- pass valve, 0,4 MPa 35) Lowering valve pilot piston
4) End flange 22) Lifting cylinder 36) Lowering valve
5) Test point (not standard) 23) Shock valve (20 MPa). Not AC 37) Lubricating oil pump
6) Pressure limiting valve (18 MPa) 24) Steering valve OSPC 100ON (100 38) Lubricating oil filter
7) Valve blocks cm3/r ) 39) By--- pass valve 0,4 MPa (on 665, 865, 600--- 900)
8) Quick couplings Steering valve with priority valve OSPC 40) Gearbox oil cooler (665, 865, 600--- 900)
9) Extra lifting cylinder (standard on 865, 100LS (100 cm3/r ) 41) Priority valve (OLS 80)
800, 900) 26) Shock valve (16MPa) 42) Brake valve (option)
10) Control valve (mechanical) 27) Steering system pressure limiting 43) Oil cooler
11) Damping valve valve (9MPa) 44) Breather--- dipstick
12) Unloading valve 28) Steering cylinder 45) Free return oil connection (1/2” quick coupling)
13) Restriction hole for unloading valve 29) Tank (hydraulic oil): 35 litres 46) Transmission oil reservoir (23 L)
14) Pilot valve for unloading valve 30) Control valve (BOSCH)
15) Selector plug (1/2--- action) 31) 3---way oil flow control spool
16) Lowering speed control
17) Lowering valve
696
Model Code Page
1. 12. 1986
1. 9. 2001
Repair instructions
Pump and pipe system (Op. no. 911)
1. Changing hydraulic pump
N.B. A faulty hydraulic pump should always be changed as

a complete unit. 600---900 tractors’ Sauer pump has been
replaced with Bosch ---pump from ser. no. K26106 incl.
(with priority valve) or from K47331 (without priority valve).
At the same time curved suction pipe and seal repair kit has
been modified.
A. Removing pump 4. Remove the attaching bolts (6 mm socket head) for the
pump and remove the pump.
1. Drain the hydraulic oil until the oil level lies below the
level of the pump. Remove the engine hood plates on the
right---hand side. B. Fitting pump
1. Position the pump and fit and tighten the bolts (6 mm socket
head) to 23 Nm.
2. Disconnect the delivery pipe unions for both the working
hydraulics (26 and 27) and for the steering hydraulics at the
pump.
2. Connect the suction pipe hose connections and connect

the hose for the working hydraulics (26 and 27 mm, 60 Nm)
and the hose for the steering system (45 Nm).
3. Remove the clamps for the suction pipe and push the
hose against the pipe.
3. Fill with hydraulic oil and fit the engine hood plates. Start the
engine and check the function of the hydraulics and that all
unions are tight.
697
698
Model Code Page
1. 12. 1986
91. Hydraulic lift 205-- 865 912 1
1. 7. 1989
3. Start the engine and try to raise the lifting arms.

Reconditioning hydraulic lift
4. Increase the engine speed to 1500 rpm and read off the
(Op. no. 912) opening pressure of the pressure limiting valve (see the
Technical Data).
1. Pressure ---limiting valve
A. Checking/adjusting opening pressure
N.B. When checking the opening pressure, the oil should

have reached working temperature (approx. 50˚C)
5. If the pressure reading deviates from the given value, adjust

the pressure by changing the number of shims (see the arrow)
behind the spring for the pressure ---limiting valve. The valve
is fitted at the back of the distribution block (or 610312---: see
page 910/27)
N.B. The pressure can also be measured by connecting the

1. Connect the gauge to the test point on the distribution gauge to the quick ---action coupling for auxiliary hydraulics,
block. On tractors fitted with an extra lifting cylinder the point and by moving the control lever for the auxiliary hydraulics
for connecting the gauge has been moved to the hose for the rearwards when the engine is running.
cylinder.
NOTE: From ser. no. 610312 the pressure ---test point is fitted
on the LH side of the hydraulic lift housing.
N.B. See the tool list on page 910/5 for the equipment re-
quired for checking the pressure.
2. Reconditioning working hydraulics
N.B. If the hydraulic lift does not work correctly, trace the fault
step by step. Exercise the greatest cleanliness when working
with the hydraulic system. Tools for testing are given in the tool
list.
A. Tracing leakage with system in neutral posi-

tion
1. Lower the lifting arms and drain the oil from the hydraulic
lift.
2. Lower the pick ---up hitch and the lifting arms to the bottom
position. Block the hitch in the lowered position by placing a
piece of wood or something similar between the drawbar of
the hitch and the PTO housing.
699
Model Code Page
91. Hydraulic lift 205-- 865 912 2
1. 12. 1986
pump connected to the lifting cylinder and check through the

service cover for leaks on the connecting pipes or at the seals
of the control valve.
7. If the seals for the connecting pipes leak they should be

changed (see under heading 4A and B).
8. If no external leakage is visible though the pressure drops,

remove the damping valve and pressure ---test it (see under
heading B).
9. If there is no leakage in the damping valve, remove the con-

trol valve for pressure ---testing (see under heading C).
10. If the control valve is not leaking. Check for leaks in the
lifting cylinder and in the shock valve (see under heading F).
2. Remove the control levers for the auxiliary hydraulics from

the bracket on the left of the driving seat. Remove the seat (13
mm), fold the floor mat to one side and remove the floor plate. B. Removing and pressure ---testing damp-
ing valve
3. Remove the lowering speed control and the breather pipe

(19 mm) for the oil reservoir from the service cover. Remove
the service cover (17 mm).
4. Connect the gauge (range 0---40 MPa) and a hose to the

hand pump. Connect the other end of the hose to the pressure 1. Unscrew the damping valve attaching bolts through the ser-
checking point on the distribution block or on the hose to the vice opening (8 mm socket head, 2 pcs)
extra lifting cylinder.
5. Lower the pick ---up hitch and place a piece of wood or simi-
lar between the drawbar and the PTO housing to prevent the
lift from raising the lifting arms.
2. Remove the damping valve and the guide sleeve together

with the attaching bolts. Also remove the O ---rings for the
valve. N.B. The control valve slide for the damping valve is
attached to the pressure yoke.
6. Pump up a pressure of 21 MPa (15 Ibf ft) with the hand
700
Model Code Page
91. Hydraulic lift 205-- 865 912 3
1. 12. 1986
3. Connect tool ETV 892 660 to the damping valve using two 3. Remove the lowering speed valve from the top of the control
M10x35 bolts. Fit an O ---ring as a seal between the tool and valve and the unloading pipe fitted on the unloading valve.
the valve.
4. Position the control valve on tool ETV 892 680.

4. Connect the hose form the hand pump to the connection
on the tool and connect the gauge to the pump (see Fig. 2 on
page 910/5).
5. Pump up a pressure of 19 MPa in the valve. During a period

of at least 15 seconds there should be no noticeable leakage.
6. If the valve leaks, it should be reconditioned or changed.
7. If there is no leakage, remove the control valve for pressure

testing.
C. Removing and pressure ---testing con-

trol valve
1. Remove the circuit and disconnect the connecting rod from

the pressure yoke. Remove the spring between the presssure
yoke and the control valve. 5. Push the control valve slide into the damping valve and
secure the valve in position. Make sure that the guide sleeves
and the O ---rings remain correctly positioned.
6. Connect the hose from the hand pump to the union on the
tool and pump up a pressure of 6 MPa in the control valve. The
2. Unscrew the attaching bolts (8 mm, hexagon socket, 1 pc) pressure must not drop faster than 1 MPa per miniute.
and lift away the control valve. Also remove the O ---rings.
701
Model Code Page
1. 12. 1986
91. Hydraulic lift 205-- 865 912 4
1. 7. 1989
7. Then pump up the pressure to 17 MPa. The maximum per-

missible pressure drop is 1 MPa per minute.
8. If there is a leak in the control valve, it must be repaired (See

under headings D and E).
D. Reconditioning unloading valve and lower-

ing valve.
5. Pull the plug for the lowering valve out of the housing using
for instance an M10 bolt. Remove the main valve cone from
the housing.
6. Check the sealing surface on the valve cone and inside the
valve housing, using a magnifying glass.
7. If the valve cone is damaged it should be changed. If the

sealing surface in the housing is damaged the entire valve
housing must be changed.
8. Change the o---ring on the plug. Lubricate and push the

main valve cone together with spring and plug into the hous-
ing.
1. Push the main valve cone of the unloading valve together

with the spring and plug out of the housing.
2. Check the valve cone and the surface of the seat in the
housing using a magnifying glass, as an ordinary visual check
is not sufficient in order to detect damage. If the sealing sur-
face in the housing is damaged the whole valve housing must
be changed.
3. Change the o---ring on the plug. Lubricate and push in the

main valve cone together with the spring in the housing and
fit the plug.
9. Knock in the tubular pins in front of the valve, turning the slot
on the larger pin away from the valve and knock the smaller
pin inside the larger, with the slot facing the valve.
NOTE: on the latest models these tubular pins have been dis-
continued. Instead a metal pin is fitted.
4. Knock out the tubular pins which are fitted above the lower-
ing valve main valve cone.
NOTE: on the latest models these tubular pins have been dis-
continued. Instead a metal pin is fitted.
702
Model Code Page
91. Hydraulic lift 205-- 865 912 5
1. 12. 1986
E. Reconditioning pilot valves N.B. The narrower spring end should be turned towards the
valve ball. Apply locking fluid, e.g. Loctite 542, to the threads
of the seat.
N.B. Both valves are reconditioned in the same way.
7. Tighten the valve seat screw to 35 N m.
8. Fit the thrust pins in the correct place, so that the longer pin
is fitted by the unloading valve. The round end of the pin
should be outwards.
1. Remove all circlips from the shaft of the pressure yoke.

Remove the shaft.
2. Remove the pilot valve thrust pins. Do not mix up the pins.
The unloading valve pin is slightly longer in order to create the
necessary clearance.
9. Measure the height of the unloading valve thrust pin from
the underside of the valve housing. using sliding calipers. The
height should be 48.1 ---48.3 mm. The pin for the lowering
valve should be 0.40 ---0.50 mm lower.
10. Any adjustment is done by changing pins. Forthelowering

valve there are seven different pin lengthsavailable between
(18.2 and 18.8 mm), and for the unloading valve there are two
different pin lengths (18.9 and 19.0 mm).
N.B. The pins must never be shortened by machining.
3. Remove the pilot valve seats (14 mm).
11. Fit the pressure yoke. Push in its shaft (the circlip grooves
which are closer together should be towards the lowering
valve) and secure the shaft with the circlip.
4. Remove the seat, ball, spring and spring guide.
5. Check the surface of the seat with a magnifying glass. If the

seat is damaged, the valve ball and the seat should be
changed.
6. Assemble the valve as follows: fit the spring guide, spring,

valve ball and valve seat.
703
10. 1. 1992
12. Check the clearance between the lowering valve pin and 4. Pump up the pressure in the lifting cylinder. The shock valve
the pressure yoke. The clearance must be 0,40 ---0,50 mm should open at a pressure of 29 ---29,7 MPa:n ( ---653957) or
when the pressure yoke just touches the pin of the unloading at 20 ---21 MPa:n (653958 ---). Check the function of the shock
valve. valve three times.
5. Check the tightness of the valve which should hold a pres-

sure of 24 ---24,7 MPa:n ( ---653957) or 15 ---16 MPa
(653958 ---) for at least 30 seconds.
F. Checking for leakage in lifting cylinder 6. If the shock valve is leaking, release the pressure and
and shock valve remove the shock valve plug from the underside of the dis-
tribution block ( ---610311) or on the lifting cylinder inside the
Note! Up to ser. no. 610311 the shock valve is fitted under the power lift housing (610312 ---) or on the Autocontrol---power
distribution block on the LH side. With effect from ser. no. lift in the control valve on the LH side of the hydraulic housing.
610312 the shock valve is placed on the lifting cylinder inside The following parts come out with the plug: shims, spring and
the power lift housing. On the Autocontrol---power lift the valve slide.
shock valve is inbuilt in the control valve of the hydraulic lift.
7. Check the contact surfaces of the valve slide. If they are
faulty the slide should be changed. If the opening pressure is
not correct, adjust by changing the thickness of the shims
between the plug and the spring.
8. If the shock valve is not leaking, keep up the pressure in the

cylinder and check if the cylinder leaks through the piston
stop. If the cylinder leaks, change the seal for the stop (see
under heading 5B).
9. If neither the shock valve nor the piston stop are leaking,
and the pressure still drops, there is a leak at the piston seal
which then should be changed (see under heading 3B).
G. Fitting control valve and damping valve
1. Fit the two o---rings in the grooves at the end of the cylinder.
1. Secure tool ETV 892 670 to the end of the lifting cylinder
(bolts M10x35 mm) 2. Fit the control valve against the end of the lifting cylinder
and fit the lower attaching bolt. Tighten the bolt slightly so that
2. Fit the pressure gauge to the hand pump and connect the the valve is kept in position.
hose from the pump to the pressure checking point.
3. Lock the movement of the lifting arms by putting a piece of

wood between the lowered pick ---up hitch and the underside
of the PTO housing.
704
Model Code Page
1. 12. 1986
3. Push the control valve slide into the damping valve and fit 8. Fit the breather pipe for the extra oil reservoir to the service
the valve in the housing. Check that the O ---rings and the cover and connect the lowering speed control to the slide.
guide sleeves are correctly positioned. Tighten the attaching
bolts for the valve evenly up to a torque of 50 Nm (8 mm, hexa-
gon socket, 3 pcs).
N.B. Do not tighten the bolts too hard as this may cause the
valve slide to bind.
4. Fit the spring between the pressure yoke and the control
valve, and connect the valve slide for the damping valve to the
pressure yoke.
5. Connect the connecting rod to the pressure yoke and

secure with a circlip.
N.B. There should be a spacer ring between the connecting

rod and the pressure yoke.
6. Fit the pipe to the unloading valve. Change the O ---rings for
the lowering speed valve. Push the valve into the housing.
Coat the valve with grease where it goes through the service 9. Fit the floor plate and the mat. Fit the driving seat and the
cover. control levers for auxiliary hydraulics
10. Fill the hydraulic system with oil and check the function of
the hydraulic lift.
7. Tighten the bolts for the service cover to 50 Nm (apply seal-

ing compound Hylosil Grade 102 black or equivalent.
N.B. Check that the lowering speed valve can move freely
after the cover has been tightened down.
705
Model Code Page
1. 12. 1986
3. Changing lifting cylinder piston seal
A. Removing lifting arm shaft (rocker

shaft)
1. Remove the driving seat and the service cover (see under
heading 2A, points 1 ---3).
4. Disconnect the upper ends of the lifting links for the lift and
the lifting links for the pick ---up hitch from the lifting arms.
Remove the oil reservoir (19 mm).
2. Remove the bracket for the quick couplings (13 mm).
3. Disconnect the top link and loosen the upper end of the top
link bracket from the cover on the hydraulic lift housing as fol-
lows:
5. Remove the attaching bolts for the hydraulic lift housing.
N.B. The bracket for the auxiliary hydraulic control levers is

secured by the bolts on the left---hand side. On the right---
hand side the bracket for the differential lock control spring is
secured by one of the bolts and the stop for the control lever
is secured at the font corner.
--- Remove the nut for the top link bracket spring.
6. Turn the lifting arms to the top position and lift away the shaft
--- Remove the impulse transmitter lock together with inner lever and piston rod.
--- Pull the upper end of the bracket away from the cover and
remove the shims under the spring and the washer for the nut
from the screw.
706
Model Code Page
1. 12. 1986
B. Changing lifting cylinder piston seal
3. Mark the lifting arm shaft and the arm with punch marks to
allow for assembling in the same position.
1. Push the piston out of the cylinder with the aid of com-
pressed air through the pressure test point. If necessary the 4. Pull off the lifting arm, seals and bearing sleeve from the
slide in the pressure test point should be pushed inwards to shaft.
allow air to be blown in behind the piston.
N.B. If the control valve has been removed, air can be blown
in through the opening at the end of the cylinder.
5. Remove the circlip for the inner lever and pull the lever off
the shaft.
6. Fit a new inner lever, checking that the punch marks on the
2. Remove the old piston seal. Also check the support ring shaft and the lever align. Secure the inner lever with a circlip.
and change it if required.
3. Lubricate and push the new seal onto the piston by hand.
4. Carefully push the piston into the cylinder.
C. Changing seals and inner lever on lift-

ing arm shaft
1. Disconnect the piston rod from the inner lever by knocking
out the tubular pin.
7. Lubricate the bearing sleeve and fit it. Fit the smaller felt
ring, the new shaft seal and the thicker felt ring. Lubricate the
2. Remove the circlip for the left lifting arm.
felt rings with oil.
707
Model Code Page
1. 12. 1986
8. Fit the lifting arm to the shaft making sure the punch marks
align, and secure it to the shaft with the circlip.
3. Lubricate the felt seals and apply grease between the seals.
Apply sealing compound Loctite 549 or equivalent to the
sides of the shaft seals facing the contact surfaces.
9. Connect the piston rod to the inner lever securing it with the
tubular pin. 4. Clean the contact surfaces on the hydraulic lift housing and
on the cover, and apply sealing compound to the contact sur-
face using e.g. Hylosil Grade 102 black.
D. Fitting lifting arm shaft
1. Lifting the lifting arm shaft into the hydraulic housing and
guide the piston rod into the cylinder.
5. Fit the cover and check that the seals for the lifting arm shaft
are correctly positioned. Tighten the cover attaching bolts to
90 Nm. At this stage do not fit the four bolts for the extra oil res-
ervoir.
N.B. The bracket for the auxiliary hydraulic control levers

should be fitted under the two bolts on the LH side. The
bracket for the differential lock spring should be fitted under
one of the bolts on the RH side. The stop for the differential
control should be fitted under the bolt at the front right corner.
6. Connect the differential control spring to the bracket.

2. The slot of the bearing sleeve should be turned forwards 7. If necessary change the O ---ring for the oil reservoir. Lubri-
and upwards at an angle of 45˚. The sleeve should be posi- cate the O_rings and lift the reservoir into position. Tighten the
tioned at a distance of 10 mm from the edge of the shaft seal bolts to 90 Nm.
groove in order to create a free oil space between the seals
and the sleeve.
708
Model Code Page
1. 12. 1986
8. Fit the bracket for the quick ---action couplings to the oil res- 4. Remove the control valve nuts (14 mm, 3 pcs).
ervoir.
9. Secure the top link bracket:

--- push in the upper end of the bracket and fit the shims under
the spring
--- fit the washer on the screw and tighten the nut to a torque
of 220 N m. Apply locking fluid, e.g. Loctite 270 to the threads
--- fit the impulse transmitter lock.
10. Connect the lifting links to the lifting arms and connect the
top link.
11. Fit the hydraulic lift housing service cover and the driving
seat (see under heading 2G point 7 ---10).
12. Fill the hydraulic system with oil (max. 35 litres) and test
the function of the hydraulic lift.
5. Remove the end plate outside the control valve. Pull the
control valves and the distribution block away from the
hydraulic housing sufficiently far for the connecting pipe to be
removed.
4. Connecting pipes and valve blocks for N.B. If the distribution block catches on the guard plate for the
brake, slacken the nuts for the guard plate so that the distribu-
auxiliary hydraulics tion block can be pulled sufficiently far out.
N.B. During this operation, the hydraulic lift housing cover is

removed. The seals for the connecting pipes can also be
changed without removing the cover. To do this only the
valves for the auxiliary hydraulics and the distribution block
need to be removed after which it is possible to pull the pipes
out of the housing.
A. Changing connecting pipe seals
1. Drain the hydraulic oil. 2. Unscrew the union on the pipe to

the pressure filter. This union is easily accessible through the
cab floor, once the cover has been removed. 3. Disconnect
the control lever rods at the top of the valves for the auxiliary
hydraulics.
6. Pull out the connecting pipes carefully so as not to damage

them.
709
Model Code Page
1. 12. 1986
B. Fitting connecting pipes and valve 2. Remove the connecting pipes (see under heading 4A)
blocks 3. Disconnect the front end of the connecting rod (7) from the
pressure yoke and remove the circiip on the control shaft end
1. Change the O ---rings on the connecting pipes. Also check
(2) for link (3) (see Fig. 20 on page 910/20).
the support rings and change them when necessary. The sup-
port rings should always be fitted furthest in.
2. Push in the pipe ends as far as possible into the holes in the
lifting cylinder.
3. Carefully clean the contact surface between the hydraulic

lift housing and the distribution block, and apply sealing com-
pound (e.g. Hylosil Grade 102 black). Push the distribution
block in against the housing guided by the screw studs.
4. Push in the control valve blocks and fit the end plate onto
the screw studs. Check that the O ---rings between the valve
blocks remain in position.
17 Nm
4. From the outer end of the control shaft remove: the spring
washer (13 mm), the position control lever and the support
washer.
5. Fit the spacer sleeves on the screw studs and tighten the
nuts to 17 Nm.
N.B. Do not tighten the nuts too hard as this can cause bind-
ing of the control valve slides.
6. Connect the control lever rods to the top of the control

valves.
5. Unscrew the attaching bolts for the control shaft frame (8
7. Secure the guard plate for the brakes if it was loosened. mm socket head) and pull out the control shaft together with
its frame.
8. Connect the pressure pipe to the union on the filter tighten-
ing to a torque of 60 Nm.
9. Fill the reservoir with hydraulic oil (35 litres).
5. Reconditioning lifting cylinder
A. Removing lifting cylinder

1. Remove the hydraulic lift housing cover and lifting arm shaft
(see under heading 3A).
6. Remove the lifting cylinder attaching bolts (14 mm socket

head). Remove the support for the control shaft, lift out the cyl-
inder together with the control valve from the hydraulic lift
housing.
710
Model Code Page
1. 12. 1986
B. Changing lifting piston stop seal C. Fitting lifting cylinder
N.B. In this operation the lifting cylinder has been removed 1. Check that the piston is correctly positioned in the lifting cyl-
from the housing. The seal on the piston stop can also be inder. Lift the cylinder together with the control valve into the
changed without removing the lifting cylinder. The parts which hydraulic lift housing. Check that guide pins locate correctly.
have to be removed then are the hydraulic lift housing cover,
control valve, lifting arm shaft and piston.
1. Remove the control valve from the cylinder end as follows:
--- disconnect the damping valve control valve slide from the
pressure yoke.
--- remove the pressure yoke spring
--- remove the damping valve
2. Fit the support for the control shaft and tighten the cylinder
attaching bolts (14 mm socked head) to 220 Nm.
--- remove the control valve attaching bolt (8 mm) and remove
the valve.
3. Change the O ---ring on the control shaft when necessary.

The shaft can be removed from its frame once the circlip has
been removed.
2. Knock out the lifting piston stop from the end of the cylinder.
3. Remove the old O ---ring and fit a new one after it has been
lubricated.
4. Apply locking fluid, e.g. Loctite 542 or equivalent, to the

contact surface of the lifting piston stop and drive the stop
carefully into the end of the cylinder.
5. Secure the control valve to the end of the cylinder checking

that the O ---rings are correctly positioned. The tightening
torque for the control valve bolts is 50 Nm.
4. Clean the sealing surfaces between the hydraulic lift hous-

ing and the control shaft frame and apply sealing compound
to the sealing surface. Fit the control shaft together with frame.
711
Model Code Page
1. 12. 1986
10. Fit the lifting arm shaft and the cover for the hydraulic
housing (see under heading 3D).
6. Changing hydraulic lift housing
N.B. During this operation the lifting cylinder has been

removed as described under heading 5 A before removing
the housing. The hydraulic housing can also be removed with
the cylinder still in place.
A. Removing hydraulic lift housing
5. Tighten the bolts (8 mm socket head) for the control shaft

frame to 50 Nm.
6. Connect the link to the end of the control shaft and secure
with a circlip.
1. Remove the lower shaft for the top link bracket and remove
the top link bracket. Remove the hydraulic oil pressure filter.
7. Fit the position control lever to the outer end of the control
shaft.
8. Attach the connecting rod to the control valve pressure

yoke, securing it with a circlip.
N.B. There should be a washer on the stud of the pressure

yoke under the link.
2. Remove the bolt (22 mm) for the steering system return oil
pipe from the RH side of the housing. If the tractor is fitted with
an extra lifting cylinder, its oil pipe is also secured by this bolt.
3. Remove the differential lock control from the RH side of the

hydraulic lift housing and remove the clamp from the
hydraulic suction pipe.
4. Unscrew the connection of the pipe at the pressure filter.
9. Fit the connecting pipes and the control valves (see under
heading 4 B).
712
Model Code Page
1. 12. 1986
5. Unscrew the front attaching bolts (19 mm) for the housing B. Dismantling parts of hydraulic lift hous-
through the service access opening.
ing
6. Unscrew the bolts (15 mm) inside the housing. The bolt in
1. Remove the adjusting screw for the impulse rod at the back
the rear right corner should preferably be unscrewed using a
15 mm socket and a universal joint. of the housing and remove the spring plate and the springs.
2. Push the impulse rod into the housing and remove its seal
from the bore in the housing. Drive a new seal into the hous-
ing.
N.B. This seal can be changed without having to remove the

hydraulic lift housing . In this case only the top link bracket
upper end needs to be disconnected and the adjusting screw
for the impulse rod and the spring plate should be removed.
7. Attach lifting eyelets in the holes for the cover bolts and lift
off the hydraulic lift housing using a hoist.
3. Remove the circlip on the intermediate shaft of the linkage

and remove the links. Change the O ---ring on the shaft when
necessary.
4. If the nut for where the shaft goes through the wall of the
housing has to be removed, apply Loctite 270 or similar to the
threads when fitting
5. Fit the links. Put the intermediate shaft into the hole and
secure with a circlip (washer under the circlip) . Push the
impulse transmitter into its hole.
713
Model Code Page
1. 12. 1986
125 Nm
6. Fit a plastic sleeve on the slide. Fit the springs and the 3. Tighten the attaching bolts for the housing to 125 Nm (on
spring plate, and screw the adjusting screw into the slide end. the inside 15 mm and at the front 19 mm). Use a socket and
a universal joint on the bolt in the rear right corner.
7. If the screw studs for the auxiliary hydraulic valve blocks
have been changed, the new screw studs should be tigh- 4. Fit the clamp for the suction pipe. Fit the differential lock
tened to 50 Nm. The tightening torque for the suction pipe control to the side of the housing.
bracket attaching bolts is 23 Nm.
5. Secure the steering system hydraulic pipe to the hydraulic
C. Fitting hydraulic lift housing housing, tightening to a torque of 50 Nm. On tractors which
are provided with an extra lifting cylinder, the connection for
its pipe is secured under this bolt too.
6. Fit the working hydraulic pressure filter and the top link
bracket.
7. Fit the lifting cylinder if it was removed (see under heading

5 C) and fit the lifting arm shaft and the cover to the hydraulic
lift housing (see under heading 3 D).
1. Clean the contact surfaces on both the gearbox and the

hydraulic lift housing and apply sealing compound (e.g. Hylo-
sil Grade 102 black or equivalent) round the holes for the
attaching bolts.
2. Lift the hydraulic lift housing into position making sure that
the suction pipe locates correctly. Check that the guide
sleeves of the housing remain in their correct positions.
714
Model Code Page
1. 12. 1986
91. Hydraulic lift 205-- 455 913 1
1. 7. 1989
Basic adjustment of hydraulic lift (Op. no. 913)
1. Hydraulic lift
A. Adjusting hydraulic lift impulse point

NOTE: These instructions cover tractors up to ser. no. 610311.
1. First check that the basic adjustment of the impulse rod is NOTE: with effect from ser. no. 610312 only one adjust-
correct. The distance between the adjusting screw (4) and the ment is required on the hydraulic lift i.e. length of the posi-
rear face of the hydraulic lift housing should be 44 mm. tion control lever rod (188 mm, see figure 26 on page
910/30). By altering the length of the rod the impulse
2. Start the engine and move the position control lever until it point can be adjusted.
is 10 ---30 mm from its foremost position measured on the
quadrant (2). With the position control lever in this position, the
lifting arms should be in their lowest position.
3. Check that the impulse transmitter lock (1) is in the locked

position (moved downwards).
4. Slacken the lock nut (3) at the end of the impulse rod and
turn the adjusting screw (4) until the lifting arms make a lifting
movement.
5. Lock the adjusting screw in this position with the lock nut.
N.B. This adjustment must be correct to make sure that the

flow from the pump does not have to go through the pressur-
e ---limiting valve, i.e. it gives the pump free flow. The measure-
ment of the position control lever rod should be as shown in
the figure (178 ---180).
715
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 913 2
1. 12. 1989
B. Adjusting pick ---up hitch lifting links
3. If necessary adjust the lifting links of the pick ---up hitch by

disconnecting the links at the top and then turning them in the
desired direction. After the adjustment check that both links
are equally long.
1. Adjust the length of 1he pick ---up hitch lifting links (1 ) so 4. Correctly adjusted lifting links are necessary to make sure
that there is a noticeable play in the lifting arms when both the that the hydraulic lift can be raised to its top position while at
hydraulic lift and the pick ---up hitch have been raised to their the same time the oil can flow freely through the control valve.
uppermost position. On the other hand the lifting links must This is necessary to protect the hydraulic pump and to prevent
be sufficiently short to make sure that the mechanical lock to overheating of the oil.
the pick ---up hitch engages when the hitch is raised to its top
position. 5. Make sure that the spring for the pick ---up hitch lock returns
the locking bar (2) all the way in. When the locking bar is
2. Raise the hydraulic lift to its top position. Check the adjust- turned back to the vertical position, this should cause the tow-
ment by lifting at the lifting links (1 ) by hand. Both links should ing hook of the pick ---up hitch to move upwards by 10---14
have a clearly noticeable play. mm.
716
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 913 3
1. 12. 1989
2. Basic adjustments of control valve

2. Adjust this clearance by selecting thrust pins which are of
A. Adjust pilot valves the correct length. Pin length and order numbers are listed in
the table below
1. When the pressure yoke just touches (item 1 in the figure)
the thrust pin of the unloading valve (A), the clearance A = unloading valve
between the thrust pin for the lowering valve (B) and the pres- B = lowering valve pilot valve
sure yoke should correspond with the Technical Data (item 2
in the figure below)
B/lowering valve A/unloading valve

Pin length Part no. Pin length Part no.
l=18,2 mm 878050 l=18,9 mm 824340
l=18,3 mm 866460 l=19,0 mm 866540
l=18,4 mm 866470
l=18,5 mm 866480
l=18,6 mm 878060
l=18,7 mm 878070
l=18,8 mm 878080
B. Adjusting damping valve valve slide
1. Adjust the position of the valve slide to a distance of 13,5

mm according to item 3 in the figure above.
N.B. The valve slide should be turned half a revolution at a
time. When turning, the slide shaft must not be angled in rela-
2. While adjusting, the pressure yoke should fit up against the
tion to the valve slide.
thrust pin for the unloading valve according to item 1 in the fig-
ure above.
4. Apply Loctite 542 at item 4 in the figure.
3. After the adjustment has been completed, the groove at the
5. Note the position of the pins. The slot in the pins should be
end of the valve slide should be positioned as shown in the
turned to an angle of 180˚ relative to each other.
figure.
717
718
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 914 1
1. 7. 1989
Instructions for repair (with effect from ser. no.

610312)
1. Repair instructions (Op. no. 914)

NOTE: From ser. no. 610312 the construction of the hydraulic
lift has been altered on 305---455 tractors. The extra oil reser-
voir and extra lifting cylinder have been removed. The volume
of the hydraulic housing and the diameter of the lifting cylinder
have been increased correspondingly. The working pressure
has been reduced from 21 MPa to 18 MPa. The instructions
below only cover those points which differ from the corre-
sponding points in instructions relating to the earlier type hy-
draulic lift.
4. Remove the driver’s seat, fold the floor mat to one side and
remove the floorplate.
5. Unscrew the hydraulic lift housing cover screws. Move the

cover a little to the rear and remove the dipstick, return oil con-
nection and the pipe from the hole for return oil connection.
A. Removing hydraulic lift housing cover
1. Lower the lower links to their bottom position. Detach the

lifting links from the lifting arms. Remove the top link.
2. Drain the oil from the hydraulic system (max. 35 l).
6. Lift the cover and pull it back to remove it.
NOTE: Take care to ensure no foreign materials are allowed to

drop into the hydraulic housing.
3. Unbolt the quick ---action couplings from the support plate.

Unscrew the two screws to detach the support plate. B. Fitting hydraulic lift housing cover
1. Clean contact surfaces between cover and housing. Apply

sealing compound (e.g. Hylosil Grade 102 black) on the
housing surface. Fit the cover.
NOTE: Before attaching the cover fit the pipe into the hole for
the return connection and fit the connection.
719
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 914 2
1. 7. 1989
C. Repair of control valve
NOTE: The control valve is basically the same as before. Thus

the earlier instructions are still valid for the new hydraulic lift
(see Op. 2 A on page 912/1). On the new valve the shape of
the pressure yoke has been changed, as has the shape of the
unloading pipe on the unloading valve. In addition the attach-
ment of the lowering speed control rod to the control valve and
the attachment of the damping valve slide to the pressure
yoke have been altered. Set---up values, however, are the
same as before.
1. Remove the hydraulic lift housing cover (see Op. A).
2. Tighten the cover fixing screws to a torque of 45 Nm.
NOTE: Quick ---action coupling support plate is fixed with two

cover screws on RH rear corner of the housing.
2. Detach the lowering speed control rod from the control

valve through the service opening in the cab floor.
3. Detach the front end of the control linkage connecting rod

from the pressure yoke.
3. Bolt the quick ---action couplings to their support plate.
4. Fit the cabin floor plate, floor mat and the seat.
5. Fill the hydraulic system with oil. Fit the breather/dipstick.

The lower mark on the dipstick corresponds to 25 l and the
upper mark to 35 l of oil in the hydraulic system.
6. Attach the lifting links to the lifting arms. Fit the top link.
4. Unscrew the damping valve screws (8 mm, 2 pcs) with an

allen key and remove the valve. In the same way remove the
main valve block from the lifting cylinder end.
5. When fitting the control valve check the “O” rings at the end
of the lifting cylinder and change if necessary. Fit the lower
mounting bolt and tighten it a little so that main valve block is
kept in position.
720
Model Code Page
1. 7. 1989
91. Hydraulic lift (610312---) 205-- 865 914 3
10. 1. 1992
6. Push the damping valve slide into its hole. Check that the E. Removing lift cylinder/changing piston seal
“O” rings and the guide sleeves are correctly positioned be-
tween the valve blocks. Tighten the control valve mounting 1. Remove the hydraulic lift housing cover (see Op. A).
bolts (3 pcs) evenly to a torque of 50 Nm.
2. Detach the connecting rod front end from the control valve
7. Connect the connecting rod to the pressure yoke and the pressure yoke. Detach the lowering speed control rod from
lowering speed control rod to the valve. Fit the return spring the control valve.
under the pressure yoke.
8. Fit the hydraulic housing cover (see Op. B).
D. Checking pressure limiting valve/shock

valve
3. Unbolt the lifting cylinder mounting bolts (4 pcs).
4. Pull out the lifting cylinder guide pins using an extractor. The
pins are provided with M10---threaded holes.
NOTE: On the new hydraulic system the shock valve is fitted

inside the hydraulic lift housing at the lifting cylinder. Before
removing the shock valve the hydraulic lift housing cover
must be removed according to instruction A.
The shock valve opening pressure and tightness of the lifting

cylinder can be checked according to instr. F on page 912/6.
Shock valve opening pressure is 29 ---29.7 MPa (---653957) or
20 ---21 MPa (653958---). The pressure ---test point is on the RH
side of the hydraulic lift housing.
5. Move the lifting cylinder to the left until the connecting pipes
are released from the cylinder boring. Remove the lifting cylin-
der from the housing.
NOTE: When the lift piston seal or piston stop seal is changed,
remove the control valve from the cylinder head and the pis-
ton from the cylinder by means of compressed air (see Op. B
on page 912/9 and Op. B on page 912/13).
The pressure ---limiting valve is fitted under the end plate on

RH side of hydraulic lift housing. Opening pressure is 18 MPa,
which can be checked according to instr. A on page 912/1.
The pressure ---test point is on the RH side of the hydraulic lift
housing.
721
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 914 4
1. 7. 1989
F. Fitting lifting cylinder G. Changing hydraulic lift housing
1. Ensure that the piston is in the cylinder. Also secure the con- 1. Remove the hydraulic lift housing cover (Op. A)
trol valve to the lifting cylinder head.
NOTE: Before fitting the cylinder, check the “O” rings on the
connecting pipe and change if necessary.
2. Fit the cylinder; guide the piston rod into the cylinder and
the connecting pipes into the cylinder borings. Fit the guide
pins.
195 Nm
2. Remove the rubber gaiters on the auxiliary hydraulics con-

trol lever and detach the lever from the valve spindles by un-
screwing the three fixing screws.
3. Tighten the cylinder bolts to a torque of 195 Nm.
3. The lowering speed control rod is disconnected at the nut in

front of the hydraulic lift housing.
4. Detach following parts on the RH side of the hydraulic hous-

ing:
--- Hydraulic system pressure oil pipe from the valve blocks
--- Slacken the suction pipe clamp
4. Fasten the connecting rod to the pressure yoke and the --- Unscrew the steering system return oil pipe from the hy-
lowering speed control rod to the control valve spindle. draulic housing
--- Disconnect the position control lever rod from the control
5. Fit the hydraulic lift housing cover (see Op. B). mechanism on the hydraulic lift housing.
NOTE: If the tractor has more than two auxiliary hydraulic

valves the whole valve block set must be detached from the
hydraulic lift housing before the housing is removed.
722
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 914 5
1. 7. 1989
8. Position a suitable hoist and attach a rope to the housing as

5. Remove the top link bracket from the rear of the tractor. shown in the figure above. Lift the housing carefully off until it
is free of the guide sleeves. Guide the housing away from its
NOTE: Save the shims from under the bracket and fit the place.
same shims when re ---installing the top link bracket.
6. Release the lower end of the towing hook release control

rod from the pawl. Release the lower end of the PTO engaging
control rod from the selector lever.
NOTE: The above steps must be taken to ensure that there is

enough space for the valve block set to be removed together
with the hydraulic lift housing. If the tractor has extra valve
blocks the whole valve set must be detached before the hous-
ing is removed.
H. Fitting hydraulic lift housing
NOTE: If the whole hydraulic lift housing has been changed

the following parts can be attached before the housing is
fitted: lifting shaft, control linkage, lifting cylinder, control valve
and valves for auxiliary hydraulics.
NOTE: If the tractor has extra valve blocks for auxiliary hy-
draulics the valve set is fitted in place after the housing has
been fitted on to the tractor.
7. Unbolt the hydraulic lift housing (8 bolts).
723
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 914 6
1. 7. 1989
1. Clean contact surfaces between housing and gearbox. 5. Fit the top link bracket. Refit the same shims under the
Apply sealing compound (e.g. Hylosil Grade 102 black) bracket as were fitted before the bracket was removed.
around the screw holes on the gearbox. Tighten the nut to 220 Nm.
2. Make sure that the guide sleeves are in their borings on the
gearbox. Lift the hydraulic lift housing into position and guide
it under the cab. On the RH side the suction pipe and steering
return pipe rear ends must be guided into place.
195 Nm
6. In the cab connect the auxiliary hydraulic valve lever to the

valve spindles and fit the rubber gaiters on the lever.
7. Working through the service opening in the cab connect the

lowering speed control rod.
3. Tighten the housing bolts (8 pcs) to a torque of 195 Nm.
8. Fasten the lower end of the PTO control rod to the selector
4. On the RH side fit: lever. Attach the towing hook release control rod to the pawl.
--- Steering system return oil pipe to connector
--- Suction pipe clamp 9. Fit the hydraulic lift housing cover (Op B).
--- Position control lever rod to the mechanism on the RH side
of the housing.
--- Pressure oil pipe to the end of the valve block set.
NOTE: (Machines with extra valve blocks) Clean contact sur-

faces between the valve block set and the housing and apply
sealing compound. Tighten the three fixing screws to a torque
of 45 Nm.
724
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 914 7
1. 7. 1989
I. Changing connecting pipe “O” rings 4. Grease new “O” rings. Push the connecting pipes into the
lifting cylinder borings fully home. Clean valve set contact sur-
faces. Apply sealing compound (e.g. Hylosil Grade 102
black) and fasten valve set against the housing to a torque of
45 Nm.
5. Fit the auxiliary hydraulic valve lever and the rubber gaiters.
6. Fit the hydraulic lift housing cover (Op. B).
NOTE: The seals on the connecting pipes can also be

changed, so that the lifting cylinder is first removed and then
the pipes can be pulled into the housing (see Op. E). Then it is
not necessary to remove the auxiliary hydraulic valves.
1. Remove the hydraulic lift housing cover (Op. A)
K. Changing lifting arm shaft seals
1. Detach the lifting links from the lifting arm.
2. Drain the oil from the hydraulic lift housing (max. 35 l).
3. Remove the lifting arm circlip and pull off the arms from the
shaft.
NOTE: Make punch marks on the lifting arm shaft and the arm
so that they can be assembled in the same position.
4. Break the damaged seal out of the housing. Do not damage

the seal housing surface. Grease a new seal and fill the space
between seal lips with grease.
NOTE: Open clamps on the connecting pipes inside the
housing. The clamps prevent the connecting pipe ends from
loosening from the lifting cylinder borings if the auxiliary hy-
draulic valve blocks are removed without removing the hy-
draulic housing cover.
ETV 893 530
5. Fit the new seal using sleeve ETV 893 530.
6. Fit the lifting arm and circlip. Fill the hydraulic housing with
oil. Attach the lifting links to the lifting arms.
2. Remove rubber gaiters of the auxiliary hydraulic valve lever
and unscrew three screws, whereat the lever loosens from NOTE: Apply grease to the lifting arm shaft splines before the
valve spindles. arms are fitted.
3. Detach pressure oil hose from the auxiliary hydraulic valve

block set. Unscrew three fixing screws of the set and pull out
the set until the connecting pipe “O” rings can be replaced.
725
Model Code Page
15. 9. 1995
91. Hydraulic lift (610312---) 205-- 865 914 8
1. 5. 1996
L. Changing lifting arm shaft bushings/ NOTE: There are punch marks on the inner lever and the
shaft.
inner lever
8. Fit new bushings using special tool ETV 894030. Grease
both bushings before fitting. Grease new seals and fit them
1. Remove the hydraulic lift housing according to instruction
with sleeve ETV 893 530.
G.
2. Remove the lifting arms from the shaft. Make punch marks
on the shaft and the arms so that they can be assembled in the
same position.
3. Detach the inner control linkage spring, so the linkage is

freed and no longer presses against the inner lever.
9. Fit the inner lever circlips on the shaft. Fit the control linkage
and the spring. Attach the lifting arms to the shaft according to
the punch marks.
10. Fit the hydraulic lift housing according to instruction H.
N. Valves for auxiliary hydraulics
4. Remove the circlip on the LH side of the inner lever. Move

the lever on the shaft to the left and remove RH side circlip.
On the new hydraulic housing the valves are fitted on the RH

side of the housing. The valves are not fitted on stud bolts as
before but they have been assembled as a valve set on the
valve plate, which is mounted with three bolts on the hydraulic
5. Knock the shaft sharply to the right so the sharp edge of the lift housing.
shaft splines forces the RH side bearing bushing out of its lo-
cation. Note! On the latest 65---models, the valve blocks are fitted on
the stud bolts to make fitting and repair works easier. The
6. When the right bushing has been loosened use the shaft to valve stud nuts tightening torque is 26 ---28 Nm.
force out the LH side bushing.
Two standard valves are of the change ---over type and a con-
7. Push the lifting arm shaft into place through the LH side hole trolled by a single. One extra valve and one valve for trailer
and further through the inner lever and the LH side hole. brakes can be fitted as optional equipment.
When fitting extra valve blocks on the tractor the valve set
mounting screws must be changed for longer ones.
726
Model Code Page
91. Hydraulic lift (610312---) 205-- 865 914 9
1. 7. 1989
O. Changing seals on lowering speed control

rod and impulse transmitting rod.
The impulse transmitting rod lead ---in seal can be changed

after the top link bracket has been removed.
The lowering speed control rod lead ---in seal can be changed
through the service opening in the cab after the driver’s seat is
removed.Before removing the seal, the control rod must be
disconnected at the nut in front of the hydraulic lift housing.
727
728
Model Code Page
1. 5. 1996
91. Hydraulic power lift 865
1. 1. 1998 600-- 900 915 1
Repair instruction of mechanical

hydraulic lift on 865 and 600---900 C. Removing/reconditioning control valve
Note! This instruction shows differences between earlier Note! The control valve is the same as earlier (610312---)
(610312---) and the modified hydraulic lift on 865, and
600---900 tractors. 1. Remove the hydraulic housing cover (instr. B).
2. Remove the damping valve (see page 912/2 instr. B) and

A. Pressure tests the control valve (see page 912/3 instr. C).
Pressure test equipment, see page 101/18. 3. Reconditioning of the control valve is made as earlier, see
pages 912/2 ---6.
Pressure ---limiting valve opening pressure is 18 MPa (=work-
ing pressure) is measured as shown on page 912/1 instr. A. Note! The lowering valve restriction hole diameter has been
The valve is fitted on the auxiliary hydraulic valve block attach- decreased (was/is ø1,8/ø1,6 mm). On these valves, there is
ing flange, which is cast into the hydraulic lift housing. The a marking groove to indicate this modification. As a spare part
valve is accessible through the cab floor hole, through the the new lowering valve with the marking groove must be
access hole on the RH side rear mudguard or from under the used. This applies also to the earlier hydraulic lift.
cab on the RH side.
4. Fastening the control valve to the end of the lifting cylinder,
The shock valve opening pressure (20 MPa) is measured see instr. G on page 912/6.
according to instr F on page 912/6. The control valve and the
hydraulic housing cover can remain in place, but one condi- Note! Control valve adjustments, see under code 913.
tion is that there are not leaks in the control valve (see use of
ETV 892 670). The shock valve is placed in the same place
as earlier. D. Removing hydraulic lift housing
If the inner lever or the lifting arm shaft bearing bushes should
B. Removing/fitting hydraulic housing be changed, the lifting arm shaft must be removed and this
cover requires removing of the cab.
Note! If it is difficult to remove the cab, the hydraulic housing

Removing cover: can be removed also so that the cab rear end is only lifted up
a little as follows:
1. Drain hydraulic oil
--- drain hydraulic oil. Remove the hydraulic housing cover
2. Remove the driver’s seat and the floor plate under the seat and the lowering speed control lever and raise the cab rear
after which the cover is accessible. end and support it.
--- release all links which are attached to the lifting arms
3. Unscrew the cover bolts through the floor opening and --- disconnect the extra lifting cylinder hoses.
remove the cover. --- detach the auxiliary hydraulic valve levers, position control
linkage and disconnect the suction pipe and the steering sys-
Note! After removing the cover, the control valve, shock valve, tem return oil pipe.
lifting cylinder/piston, connecting tube and the inner linkage --- remove the RH side rear wheel and remove the valve blocks
are accessible and can be detached. through the hole in the rear mudguard. Remove, if necessary,
the valve block studs.
Fitting cover:. --- unscrew the hydraulic housing attaching bolts. Knock in
cup plugs which are fitted on the rearmost bolts and unscrew
1. Clean the contact surfaces between the cover and the the rearmost bolts through the cup plug holes
hydraulic housing. --- release the top link bracket and remove the hydraulic hous-
ing, compare instr. G on page 914/4.
2. Apply sealing compound (e.g. Hylosil) to the housing con- --- fitting the housing, compare instr. H on 914/5.
tact surface. Place the cover onto its place and tighten the
bolts to a torque of 45 Nm. Fit all detached parts and fill the Note! When fitting the housing, mount new cup plugs (GR
hydraulic housing with oil. 5026, 2 pcs) on the rearmost bolts. Apply a suitable sealing
compound to the plug sides before fitting.
729
Model Code Page
1. 5. 1996
91. Hydraulic power lift 865
915 2
1. 1. 1998 600-- 900
E. Changing inner lever 7. Fit the lifting cylinder together with the control valve and
connect the inner control linkage, see instr. F paragraphs 1 ---4
1. Remove the cab or remove the hydraulic housing on the on page 914/4.
gearbox, see previous instruction D.
8. Fasten the hydraulic housing on the gearbox, or fit the cab.
2. Remove the lifting cylinder together with the control valve,
see instr. E on page 914/3.
F. Changing lifting arm shaft oil seals
3. Release the hydraulic housing inner control linkage and
place the linkage onto the bottom of the hydraulic housing. Note! The seals can be changed after removing only the lifting
arms, see instr. K on page 914/7.
4. Mark the position of the inner lever (if necessary) in relation
to the lifting arm shaft (the shaft and the inner lever have also Note! The lifting arms must be fitted to the ends of the shaft
punch marks). Release the inner lever snap rings and knock according to the markings. The arms and shaft ends have
the lifting arm shaft out, see instr. L paragraphs 1 ---6 on page punch marks. If necessary, the position of parts can be
914/8 . marked in a suitable way.
Note! The hydraulic housing casting on 865 and 600---900

tractors is a little different and for this reason it is more difficult
to release the snap rings of the inner lever.
G. Valves for auxiliary hydraulics
5. Before fitting a new inner lever, check that the impulse trans- To 865 and 600---900 tractors can be fitted max. four valve
blocks, which are fitted on the stud bolts. There is an access
mitter is correctly in place. Place the inner control linkage to
the bottom of the housing. hole in the RH side rear mudguard through which the valves
can be serviced/changed.
6. Fit the lifting arm shaft and push it through the new inner
lever according to the marks. Fit the inner lever snap rings, The stud nut tightening torque is 26 ---28 mm. Maintenance
see instr. L paragraphs 7 ---9 on page 914/8. Fit the bearing instructions for Kontak ---valves, see under code 916. See also
picture on page 910/39.
bushes with ETV 894030 and oil seals with ETV 893530.
Note! The plastic shim no 33183000 must be fitted between
Important! On 865 and 600---900 the inner lever has been
valves on the stud which is alone on one side. The shim thick-
rotated 2 degrees on the shaft. For this reason the inner lever
order number is different as on other models. In addition, the ness corresponds thickness of o---rings on the other side and
this ensures that the valves are in the correct position in rela-
inner lever has a stopper which limits the movement of the
lever in the upper position. This modification also means that tion to each others.
the Autocontrol hydraulic lift does not need any more the limit
Note! One extra valve can be fitted without changing the stud
switch. This changes also the adjustment of the position sen-
sor, see page 320/10A. bolts into longer ones. If two extra valves are fitted (four val-
ves), the stud bolts should be changed into longer ones.
730
Model Code Page
91. Auxiliary hydraulic valve blocks 205-- 865 916 1
1. 5. 1996
1. Kontak ---valve blocks, maintenance

(Code no 915)
Note ! Remember always cleanliness when servicing

hydraulic components. The valve spool and the block are
matched together. If the spool or the block has been dam-
aged, in this case change the hole unit. Sealing kits are
available for valves, see spare part catalogue.
A. Servicing spool seals
4. Clean and lubricate spool (1). Insert spool into the housing
(2) and set spool in its approximate neutral position.
1. Loosen and remove screws and washers (1 and 3).

Remove seal retainer (2) and end cap (4).
5. From the service kit fit new O ---ring (3) and wiper seal (4).
Punch radius
2. Prevent spool rotating. Remove shoulder screw (5). Disas-

semble spring seats (6), spacer (7), spring (8), and seal
retainer (9).
6. Refit seal retainer (5) with punch radius innermost to hous-

ing. Refit screws and washers (6) and torque tighten to 5 ---8
Nm.
3. Remove spool (10). Remove and discard o---rings (11) and

wiper seals (12).
731
Model Code Page
1. 5. 1996
7. From the service kit fit new O ---ring (7) and wiper seal (8). 2. Position the valve assembly upright on its outlet cover.
Assemble (9) with punch radius innermost to housing. Remove tie rod nuts and washers (2). Remove inlet cover (3).
Assemble (10), (11) and (12). Prevent the spool rotating and Identify each section to note the order of assembly.
refit shoulder screw (13) and tighten to 5 ---8 Nm torque .
Note! On tractor, the valves are fitted on studs and they can
be removed after removing the inlet cover.
8. Refit end cap (14). Refit screws and washers (15) and
tighten to 5 ---8 Nm torque.
B. Intersection seal servicing

3. Remove all the sections (4) from the tie rods (5). Discard all
intersection seals (6) and shims (7). Inspect all seal grooves
and faces for deterioration or damage and ensure all are
clean.
1. Operate each spool in turn to release any trapped pressure.

Loosen tie rod nuts (1) at the inlet cover end of the valve
assembly.
4. Assemble tie rods (1), nuts and washers (2) and refit to the
outlet cover (3).
732
Model Code Page
1. 5. 1996
5. Position the assembly upright on its outlet cover (3). Ensure

all parts are clean. From the service kit fit new intersection 8. Assemble the inlet cover (11).
seals (4) and shims (5).
C
B
9. Evenly torque the tie rod nuts (14) to 26 ---28 Nm, using the
6. Assemble in the correct order the next section (6) over the following sequence, A, B, C and A again.
tie rods (7). Ensure all parts are clean. From the service kit, fit
new intersection seals (8) and shims (9). Repeat until all the
sections have been assembled.
7. Ensure all seal grooves and connections areas are clean.

From the service kit fit new intersection seals (8) and shim (9)
to the final assembled section (10).
733
Model Code Page
1. 5. 1996
D. Spring centre servicing

C. Servicing load check valve
Note! Separate spare parts are not available for this function.
Note! Separate spare parts are not available for this valve. In In case of damage, the complete valve block should be
case of damage, the complete valve block should be changed.
changed.
1. Remove the damaged valve block.
2. Remove check valve guide (3), spring (4) and poppet (5),
from the housing (6) 1. Loosen and remove screws and washers (1). Remove end
cap (2).
3. Inspect all parts for deterioration or damage. Replace
unserviceable items with new parts from the service kit.
4. Assemble the load check valve. Place the valve block onto
the studs and tighten stud nuts to 26 ---28 Nm in correct order.
Important! One stud goes through the valve poppet hole.
2. Prevent spool rotating. Remove shoulder screw (3). Disas-

semble spring seats (4), spacer (5), spring (6), and seal
retainer (7). Remove and discard O ---ring (8) and wiper seal
(9).
3. Inspect all parts for deterioration or damage. Replace

unserviceable items with new parts from the service kit.
734
Model Code Page
1. 5. 1996
E. 3 Position detent
Note! Spare parts are available for this function, see spare
part catalogue.
4. Ensure all parts are clean. From the service kit fit new
O ---ring (1), and wiper seal (2). Refit seal retainer (3) with
punch radius innermost to housing. Refit spring seats (4),
spring (5) and spacer (6). 1. Loosen and remove screws and washers (1). Remove end
cap (2).
5. Ensure shoulder screw (7) threads are clean and undam-

aged. Apply Loctite Hydraulic seal and refit shoulder screw.
Prevent the spool rotating and tighten to 5 ---8 Nm torque. 2. Prevent spool rotating. With a large flat blade/screwdriver
remove detent assembly (3), and seal retainer (4). Remove
and discard O ---ring (5) and wipe seal (6). If the detent assem-
bly is to be reused it is recommended that further disassembly
is avoided.
6. Refit end cap (8). Refit screws and washers (9) and tighten
to 5 ---8 Nm.
3. If the detent assembly is to be disassembled, remove

carrier screw (7) from cage (10), taking care to catch balls (8)
and spring (9). Inspect all parts for deterioration or damage.
Replace unserviceable items with new parts from the service
kit.
735
Model Code Page
1. 5. 1996
F. 4 Position float out
4. Assemble detent components taking care that the cage is 1. Loosen and remove screws and washers (1). Remove end
square to the spool axis when engaging the balls. cap (2).
5. From the service kit fit new O ---ring, and wiper seal (2). Refit
seal retainer (3) with punch radius innermost to housing. Pre- 2. Loosen and remove screws and washers (3). Remove seal
vent the spool rotating, fit detent assembly (4), tighten to 5 ---8 retainer (4). Remove and discard O ---rings (5) and wiper seals
Nm torque . (6).
6. Refit end cap (5). Refit screws and washers (6) and tighten 3. Remove the complete mechanism and spool (7) from the
to 5 ---8 Nm torque. valve body (8). Remove spool seal O ---ring (9), and discard.
Remove face seal O ---ring (10), and discard. Remove rear
seal plate (11). Remove rear seal O ---ring (12), and discard.
DO NOT dismantle the assembly.
Inspect all parts for deterioration or damage. Replace unser-
viceable items with new parts from the service kit.
736
Model Code Page
91. Auxiliary hydraulic valve levers 205-- 865 916 7
1. 5. 1996
4. Clean spool (1) and lubricate with oil. Fit a new O ---ring (2).
Fit a new O ---ring (3). Refit rear face seal plate (4). Fit a new
O ---ring (5). Insert complete spool and mechanism (6) into the
housing (7)
5. Refit end cap (8). Refit screws and washers (9) and tighten
to 5 ---8 Nm torque.
6. From the service kit fit new O ---ring (10), and wiper seal (11).
Refit seal retainer (12). Refit screws and washers (13) and
tighten to 5 ---8 Nm torque .
737
738
Model Code Page
10. 1. 1992
92. Autocontrol ---hydraulic power lift 355-- 900 920 1
15. 4. 1999
4
865, 600 -- 900
P
2
355 -- 665 4
3
5
P
9 6
2
1
8
7
Figure 1. Autocontrol---hydraulic power lift
1. Control valve Bosch (EHR4)

3. Lifting cylinder
5. Pressure oil from pump to control valve
6. Pressure oil to control valve
7. Lifting/holding/lowering to/from lifting cylinder
8. Pressure oil channel from cylinder to pressure test point
9. Return oil from auxiliary hydraulic
A. General
The pressure limiting valve (18 MPa) is placed on the The control valve is attached with three bolts (25 Nm) to
underside of the end plate of the valve blocks (2) the hydraulic lift housing on the LH side of the tractor. Oil
(355---665). On the 865 and 600---900 tractors the pres- holes between the housing and the control valve are sealed
sure ---limiting valve is placed in the cast base for the valve with o---rings.
blocks on the RH side of the hydraulic housing. The earlier
control valve (1) of 355---900 tractors has an in ---built shock Important! On the latest 600---900 tractors there is a control
valve (20 MPa). The latest control valve (see pages valve of a new type, see pages 920/8 ---11.
920/8---11) has not an in ---built shock valve.
The control valve produces the lifting, holding and lowering

functions for the three ---point linkage unit.
739
Model Code Page
10. 1. 1992
15. 4. 1999
Hydraulic diagram, 355---665
740
Model Code Page
10. 1. 1992
15. 4. 1999
Hydraulic diagram, 355-- 665

1. Pump and suction strainer compl.
2. Suction strainer
3. Twin gear pump
4. End plate
5. Pressure test point
6. Pressure limiting valve (18 MPa)
7. Valve for auxiliary hydraulics
8. Quick ---action couplings
9. Intermediate plate
15. Selector knob (1/2---action)
21. Pressure filter
22. Lifting cylinder
23. Shock valve (29 MPa; 20 MPa with effect from ser. no.
653958---). Not on Autocontrol.
24. Steering valve compl.

25. Steering valve
26. Pressure limiting valve, steering system
27. Non ---return valve, steering system
29. Oil tank

30. Control valve (BOSCH EHR ---4)
31. 3---way oil flow regulator valve
32. Main spool
33. Pilot pressure limiting valve
34. Shock valve (20 MPa)
35. Lowering valve pilot piston
36. Lowering valve
37. Lubricating oil pipe

38. Lubricating oil filter
NOTE! Concerning hydraulic diagram of tractors 865 and

600---900, see page 910/41. Concerning the latest control
valve EHR5, see pages 920/8 ---11.
741
Model Code Page
10. 1. 1992
15. 4. 1999
B. Control valve Bosch (EHR4)

Solenoid (lifting)
Lowering valve
Note! Concerning the latest control valve, see pages
920/8 ---11)
The valve is the same as on Valmet ---05 tractors. The valve

is fitted on the LH side of the hydraulic lift housing. The valve
regulates oil flow regardless of loading in the three ---point link-
age.
There are push buttons on the ends of the both solenoid

valves. Thus it is possible to move the control valve main spool
manually if, for instance, there is a malfunction of the control
valve or if it is suspected that the hydraulic system is not func-
tioning properly. (see warning on page 320/8).
Note! Solenoid valves must not be connected direct to the

tractor battery terminals (e.g. for testing purposes) for long
periods (max. 10 seconds) since the solenoids cannot with-
stand strong current and will be damaged. Solenoids can be
Solenoid (lowering) Shock valve (20 MPa)
changed separately. In addition, the shock valve and lowering
valve can be cleaned and checked and valve springs can be
changed Figure 8. Control valve
Function (neutral position)
When the tractor is started oil flows from the pump (port ”P”)
to the left end of the slide (1) through a drilling in the middle
of the slide. The slide is then pushed to the right against a
spring and opens the unloading circuit between ports P and
T (pump ---tank).
Oil also flows through a passage to the right end of the slide
(1). The constant oil flow (Qs) via the main spool (2) causes
pressure loss on the spring side end of the slide (1). This pres-
sure loss keeps the slide (1) open. The pump is now in free
circulation.
The main spool (2) is held in the middle position by the action
of the centring springs. The loading (+ spring) keeps the
lowering valve (6) closed.
1) 3---way oil flow regulating slide

2) Main spool
3) Pilot pressure limiting valve
4) Shock valve
5) Lowering valve pilot piston
6) Lowering valve
7) Plugged (port N)
Figure 9. Control valve in neutral position
742
Model Code Page
10. 1. 1992
Function (lifting position):
In the lifting position the RH solenoid is energized. The

magnet presses the main spool (2) to the left against the cen-
tring spring. Then it opens the passage from the slide (1) to the
lifting cylinders by an amount proportional to the strength of
the current supplied to the RH solenoid.
The right end of the slide (1) is under lifting cylinder pressure.
Pump pressure becomes equal in value to lifting cylinder
pressure + pilot pressure (=spring). The pressure difference
through the restriction of the main spool (2) is always equal to
pilot pressure so the oil flow depends only on the position of
the main spool (2) (and oil viscosity).
The oil flow required for lifting the lower links is proportional
to the current supplied to the RH solenoid. Excess oil from the
pump flows via slide (1) to the tank passage (P and T).

2) Main spool
4) Shock valve
6) Lowering valve
7) Plugged (port N)
Function (lowering position): Figure 10. Control valve in lifting position
In the lowering position the LH side solenoid is energized.

The magnet presses the main spool (2) to the right against the
inner spring. The spool opens the passage between the
lowering valve (6) and tank (T).
At the same time the spool (2) also allows oil (Qs) to flow be-
hind the pilot piston (5). The piston moves to the left and
opens the lowering valve pilot ball. The pressure behind the
lowering valve decreases (compared with the pressure in the
working line) and the lowering valve opens and allows oil to
flow from the lifting cylinders to the tank.
The return oil flow pressure also acts on the front side of the
piston (5). If this pressure reached a sufficient level (greater
than the force of spring+pressure Qs), the lowering valve
stops the flow.
Therefore the return flow does not depend on the pressure

caused by the load on the three point linkage. The rate (lower-
ing speed) of the return flow is proportional to the current
supplied to the solenoid for lowering. The pilot pressure limit-
ing valve (3) sets a pressure difference which acts over the
main spool (2) when the load is being lowered.
The free circulation circuit from the pump (P) to the tank (T)
functions as in the neutral position.

2) Main spool
4) Shock valve
6) Lowering valve
7) Plugged (port N) Figure 11. Control valve in lowering position
743
Model Code Page
1. 5. 1996
15. 4. 1999
C. Reconditioning control valve EHR4
Note! Concering the latest valve, see pages 920/8 ---11.

Lowering valve
pilot piston
Main spool
Lowering
valve
3---way oil flow regula- Shock valve

ting slide
Pilot pressure limiting valve (lowering)

Lowering valve Note! In the picture above there is the earlier construction.
The new pilot valve has neither a ball nor a spring but only a
If the hydraulic power lift makes many lifting corrections (reac- tapered valve pin and a locking nut.
tions) per minute when a weight is attached to the three ---point
linkage, a possible fault can be faulty lowering valve (or its The valve must not be screwed fully home, it must be opened
pilot piston). 1/2---1 turn.
In this case, the lowering valve can be disassembled and The tighter the valve is, the greater is the lowering speed (if the
cleaned as well as the pilot piston. A leaking lowering valve valve is too tight, the free flow pressure rises too much in the
must be changed. In addition, the valve spring must be lowering movement). If the valve is too loose, the lower links
checked and changed. Note! If the lift does not hold the load, do not lower at all (lowering valve does not open).
when the engine is not running, a possible fault can also be
leaky lifting cylinder piston seal.
Solenoids
Shock valve (20 MPa)
Solenoid valves are available as a spare part. When fitting a
If the lift does not hold the load, the possible fault can also be new solenoid, fit the same shims onto the end of the main
leaking shock valve. When the control valve is in neutral posi- spool spring. Do not tighten the solenoid screws too tight.
tion, the pressure caused by the load rests on the shock valve.
Tightening torques
In this case, open and clean the shock valve and, if necessary,
change the valve spring or adjust it with shims. Shock valve plug . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
Lowering valve plug . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Pilot piston plug . . . . . . . . . . . . . . . . . . . . . . . . . 103 Nm
3---way oil flow regulating valve
Note! When reconditioning the control valve, always fit new
This valve can be opened and cleaned. The valve slide must sealing rings. When opening the valve plugs, use good tight
move easily in its bore.
fitting Allen keys because the plugs can be very tight. When
slackening the plugs, knock at the Allen keys with a hammer.
744
Model Code Page
10. 1. 1992
15. 4. 1999
D. Checking opening pressure of pres-

sure ---limiting valve and shock valve
Pressure ---limiting valve opening pressure is 18 MPa. It is

measured by connecting a pressure gauge to the pressure
test point on the RH side of the hydraulic housing. Detailed
instructions can be found in instr. 912 1A on page 912/1.
The control valve has an in ---built shock valve. It opens at 20

MPa. Opening pressure can be checked by pumping oil
through the pressure test point into the control valve. The lift-
ing arms must be prevented mechanically from rising when
pumping pressure. (see instr. F on page 912/6).
E. Adjusting pick ---up hitch lifting links

Note! Concerning the adjustment of position sensor (trans-
port height), see pages 320/10 ---10A (AC) or 321/15 (ACB).
The lifting links should always have a certain amount of clear-

ance when the hydraulic lift is in its upper position. However,
they must be adjusted in such a way that the pick ---up hitch
is securely locked by the pawl.
Before adjusting, raise the hydraulic lift to its upper position

with a position control knob or with a lift/lower switch (max.
transport height). Pick ---up hitch must be unloaded. Check
the adjustment by moving the lifting link by hand. Adjustment
is correct when the link moves loosely but the pick ---up hitch
is locked when the lift is lowered so that the hitch rests on the
pawl, thereby preventing unnecessary loading on the hy-
draulic pump and overheating of the oil.
Adjust if necessary by removing the cotter at the upper end

of the links and turning until a suitable length is obtained.
Check that both lifting links are the same length after adjust- 3055--- 133
ment. It is permissible that the lifting links tighten a little when
the lifting arms are raised to their max. upper position with
push buttons.
Correctly adjusted lifting links ensure that the hydraulic lift can
be raised to its uppermost position.
10-- 14
mm
F. Checking locking of pick-- up hitch
Make sure that the spring returns the pawl fully home.When
the pawl is turned upwards the pick ---up hitch should move up
10 ---14 mm.
3055--- 134
745
Model Code Page
92. Autocontrol ---Power lift 600-- 900 920 8
15. 4. 1999
2. Control valve Bosch, EHR5

(J35101---)
Three fixing bolts,

25 ---31 Nm.
P=Pressure port
A= Cylinder port
R1=Return oil from cylinder
R2=Return oil
Picture 9. Latest Bosch control valve EHR5
746
Model Code Page
92. Autocontrol ---Power Lift 600-- 900 920 9
15. 4. 1999
Picture 10. Hydraulic system with Bosch Control Valve EHR5
30. Bosch Control Valve EHR5
19. Connecting point for front loader.

In the modified construction, where the pressure line (control valve blocks ---> ACB control valve) has been drawn from out of
the hydraulic housing, has been observed the connection of the front loader.
If the front loader is connected before the valve blocks (earlier system) , pressure in the front end of the line rises too much so that
the front loader safety valve opens before the hydraulic lift own valve (18 MPa).
Note! In this construction the opening pressure of the front loader safety valve must not changed (over 18 MPa).
In the new construction tractor’s own safety valve determines the max pressure of the pump.
747
Model Code Seite
92. Autocontrol Power lift 600-- 900 920 10
15. 4. 1999
A. Control valve
Note! The valve allows lowering function also when the
tractor engine is stopped. The lowering function has
See picture 9.
not a pressure compensation, but the lowering speed
varies according to the load. The pressure compensa-
The valve is fitted on the LH side of the hydraulic housing
tion has been replaced with electronics. If the lowering
as the earlier valve with three fixing bolts (25 ---31 Nm). The
speed increases too much, the electronics decreases
valve has pump pressure port P, port A to the lifting cylin-
the lowering speed.
der and return oil ports R1 and R2 (between valve and
housing) which have been sealed with o---rings.
The valve has not an in ---built shock valve, but the
shock valve is located at the lifting cylinder as in the
The valve has lifting and lowering module. Both modules
mechanical power lift.
have proportional magnets. The function of the pressure
balance is cushioned by a restriction. The non ---return valve
The upper solenoid if for lifting and the lower for lowe-
has a lightening function for oil to/from the cylinder. The
ring (I max=3,35 A). The solenoid coils can be chan-
pressure balance and the lifting spool are fitted in the same
ged separately. There are push buttons at the ends of
axle. This causes the lifting magnet to open at pump pres-
both solenoids.
sure. Oil flow to cylinders is limited to 60 l/min.
1,2. Passages (lifting module)

3. Spool (lifting module)
5. Spring (lifting module)
9. Spool (pressure balance, lifting module)
Picture 10. Control valve in neutral position The standard pressure difference is always in passages 1 and
Oil flows from port P via pressure balance 9 to port R2 and 2, and it is the same in all functions. In passage 1 there is al-
back to the tank. The spring side of the pressure balance is ways higher pressure.
connected to port R1, in the other side there is the free --- Passage 2 has been connected to port R1. In order to create
flow pressure. the standard pressure difference, the pressure balance
moves to the position, where oil flow from P to R2 is restricted
Forces against the face of the pressure balance 9 deter- with this pressure difference.
mine its position in relation to body. The sums of forces of
both faces are always equal. Then the pressure in the Lowering and lifting functions are closed in the neutral func-
spring side of the pressure balance is always smaller than tion and both solenoids are unenergised.
the spring force in the opposite side. This pressure differ-
ence is called a standard pressure difference.
748
Model Code Page
15. 4. 1999

Picture 11. Control valve in lifting position
Spool 3 has moved to the left, and has connected pas-

sages 1 and 2. The springs of the pressure balance push it
to the right and restricts oil from port P to port R2.
Passage 2 has not connected to the separate return oil port
R1.
Pressure increases, until the non ---return valve 4 opens.

The spring side of the pressure balance is now connected
to the load pressure (cylinder pressure). Pressure in pas-
sage 1 is standard pressure difference higher. Load pres-
sure+standard pressure difference adjust the pressure
balance 9 between P and R2. Oil flows under standard
pressure difference to cylinder A. Opening cross---section
determines the oil flow.
Stroke of spool 3 is determined by magnetic force of the

solenoid, against which the spring 5 pushes. Then the oil
flow is proportional to the current in solenoid coil.
Since the load pressure affects the pressure balance 9, this
oil flow does not depend on the load (load sensing). The
lowering function is closed.
749
Model Code Page
15. 4. 1999

6. Spring (lowering module)
7. Pre ---steering spool and its bore (lowering module)
7a. Pre ---steering seat surface
7b. Pre ---steering groove
8. Main spool
8a. Restriction
10. RH side of the main spool (lowering module)
Picture 12. Control valve in lowering position Lowering function (only lowering passage open), the lowering
solenoid is energised:
The most important parts of the lowering function are pre --- Pressure balance 9 functions as in the neutral position.
steering spool 7 with bores and main spool 8. When the lowering solenoid pushes the pre ---steering spool
The pre ---steering spool is locating in the middle of the main to the left, first opens the pre ---steering seat surface 7a and
spool. after that the pre ---steering groove 7b.
Oil flows from space 10 to tank. Then the pressure drops be-
Spring 6 pulls the pre ---steering spool 7 to the right against the low the load pressure. Oil flows via restriction 8a back to this
seat 7a. Since the pre ---steering seat is integrate machined in space.
the main spool, also it is pulled to the right against the main
seat. Intermediate pressure in space 10 depends on the opening
The pre ---steering spool is in the balance via passage 7. surface of the pre ---steering grooves. If the force against sur-
This situation is not on in the main spool 8. The load pressure face AS is equal to force of the load pressure against ring sur-
affect the radial surface AR and in the closed situation against face AR, the main spool follows in this position the pre ---steer-
the face AS on the LH side. Since the surface AS is bigger ing spool.
than AR, pressure forces the main spool into this position.
This construction creates a large positioning force. Hydraulic
load sensing is not arranged as in the lifting position. The load
sensing in the lowering position is created electronically.
750
Model Code Page
15. 4. 1999
92. AC and ACB power lifts 600-- 900 920 13
1. 9. 2001
Picture 14. Side view of AC and ACB power lifts
1. Sealing compound Hylosil (UK 0067) between hydraulic housing ---cover plate.
2. Dowels (2 pcs) has M10 thread for puller.
3. Dipstick:
--- upper mark (35 L)
--- lower mark (25 L)
--- with max. filling the available oil volume for the auxiliary hydraulics is 24 litres
4. Sealing compound Hylosil (UK 0067)
5. Limiter bolt limits the max. lifting heigth when using the mudguard push buttons. The limiter bolt is adjusted so that the lifting
arms does not touch the cabin. Loctite 270 (UK0085) on the limiter bolt threads.
The earlier limit switch (S17E) is not needed any more.
Note! When using the position potentiometer, the system must stop the lifting movement before the inner lever touch the limiter
bolt (adjustment of the position sensor, see pages 320/10A and 321/15).
6. Top link locking bolt does not free the top link (the locking bolt has not the level machining).
7. EHR5: The shock valve limits the cylinder shock pressure to 20 MPa
8. Pressure ---limiting valve limits the working hydraulic pressure to 18 MPa:iin.
EHR 5: Boring for control valve pressure oil.
9. Position sensor (B1E)
10. Connecting pipe + breather filter
11. Draft sensor (B2E). EP grease on the sensor.
751
752
101. Special tools (ETV)
100. Special tools
102. Locally prepared tools (ET)
753
754
Model Code Page
1. 12. 1986
100. Special tools 205-- 900 100 1
1. 9. 2001
Contents
1. Special tools (Op. no. 101):
21. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22. Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
23. Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
32. Autocontrol hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
42. Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
44. Low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
45. Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46. PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
61. Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
62. Non powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
64. Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
71. Frame and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
91. Hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2. Locally prepared tools (Op. no. 102):

21. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
41. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
42. Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
44. Low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
45. Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
61. Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
71. Frame and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
91. Hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special tools (ETV)

The special tools for the tractors are divided into two series: A and B.
The A---series: Comprises all tools required for service, minor repairs, repair of clutch and changing external oil seals.
The B ---series: Comprises special tools required for more comprehensive repairs.
Locally prepared tools (ET)

(N.B. These tools are not made by the tractor manufacturer).
These ET ---tools should be made locally (in your own workshop) according to the drawings shown in Code 102.
General
In the following lists the ETV --- and ET ---tools are divided according to the tractor components. As most of the tools are not new,
but already in use for earlier tractor models, the type designation of the earlier tractor model is given at the end of the description
of the respective tool.
If a tool is used for tractors 205---665 only, there is an asterisk after the tool number. If there are brackets around a particular tool
number, this indicates that this tool is also used for repairing another component of the 205---665.
755
756
Model Code Page
1. 12. 1986
101. Special tools (ETV) 305-- 555 101 1
1. 7. 1989
21. Engine A (11 -- series)

1. 8360 97532 Lever for compressing valve spring (505---905)
2. 8360 97336 Counterhold nut for above (505---905)
3. 8361 97470 Milling tool for injector seat (505---905)
4. 8360 97463 Drift for fitting injector sleeve (505---905)
5. 8360 86085 Extractor for injector sleeve (505---905)
6. 8360 97315 Drift for fitting crankshaft rear seal (505---905)
7. 9030 15200 Drift for fitting crankshaft front seal (505---905)
8. 8360 85499 Puller for coolant pump impeller (505---905)
9. 8360 13091 Puller for coolant pump hub (505---905)
10. 9025 58000 Cylinder head spanner (505---905): earlier number 8360 97328
21. Engine B (11 -- series)

11. 8360 97337 Drift for removing valve guide (505---905)
12. 8360 97457 Drift for fitting valve guide (505---905)
13. 8360 97434 T ---handle for valve seat milling cutter (505---905)
14. 8360 97435 Milling cutter for facing exhaust and inlet valve seat(505---905)
15. 8360 97436 Milling cutter for exhaust and inlet valve seat (505---905)
16. 8360 97437 Inner milling cutter for exhaust and inlet valve seat (505---905)
19. 8360 97327 Puller for crankshaft gear (505---905)
20. 9025 79200 Holder for dial gauge (505---905)
21. 9025 78100 Press tool for cylinder liner (505---905)
22. 9025 98900 Drift for fitting dust cover, crankshaft front seal (505---905)
23. 9051 40200 Drift for fitting coolant pump seal (505---905)
26. 9051 73100* Puller for cylinder liner26A. 8365 39293 Puller flange, 305, 405
26B. 8353 39292 Puller flange, 455
27. 9051 72900* Milling cutter for fitting cylinder liner, 305---405
27A. 9051 72800 Milling cutter for fitting cylinder liner, 455
28. 9051 71300* Puller for injector

29. 9051 64900 Drift for fitting coolant pump shaft (505---905)
30. ET(893 760) Support between front end and front axle to prevent oscillation
2
3
4
5
757
Model Code Page
1. 12. 1986
7
11
8
9 10
12
17
14
15
16
18
13
20
19
758
Model Code Page
1. 12. 1989
21
25
22 23 24
26
26A
27 28
759
Model Code Page
1. 12. 1989
22. Fuel system A (11---series)

(8360 13091) Puller for injection pump drive gear (see Engine A)
8360 97339 Control (calibrating) pipe for injection timing (505---905)
9025 99000 Sleeve for limiting control rod travel (505---905)
22. Fuel system B (11---series)

6541 30600 Pressure gauge for checking delivery valve (505---905)
8360 83288 Cleaning tools for injectors (505---905)
9025 99000
8360 13091 8360 97339
6541 30600 8360 83288
760
Model Code Page
1. 9. 1992
355-- 900 101 4A
1. 9. 2001
21A. Engine (20-- series, 656316-- )

1 9051 73100 Puller for cylinder liner
2 9101 65600 *) Milling cutter for cylinder liner seat
3 9052 46400 Centring tool for flywheel housing
4 9052 46300 Drift for fitting rear crankshaft seal
5 9030 15200 Drift for fitting front crankshaft seal

8 9025 87400 Drift for fitting camshaft cup plug
9 9101 66300 *) Press tool for cylinder liner
10 9025 79200 Holder for dial gauge
11 9101 66100 *) T ---handle for valve seat milling cutter

12 9101 71100 *) Milling cutter for facing exhaust valve seat
13 9101 65502 *) Milling cutter for exhaust valve seat
14 9101 65503 *) Inner milling cutter for exhaust valve seat
15. 9101 75800 *) Milling cutter for facing inlet valve seat
16 9101 65505 *) Milling cutter for inlet valve seat

17 9101 65506 *) Inner milling cutter for inlet valve seat
18 9101 66200 *) Lever for compressing valve spring
19 9052 47200 Counter nut for lever above
20 9101 66000 *) Milling tool for injector seat
21 7314 03506 Drift for 36 mm cup plug
22 9101 65800 *) Drift for removing valve guide
23 9101 65900 *) Drift for fitting valve guide
25 9101 65700 *) Spanner for crankshaft nut
26 9052 48800 Puller for crankshaft gears

27 9020 01100 Conical sleeve for fitting pistons
28 9025 98900 Drift for fitting dust cover, crankshaft front seal
29 9025 98800 Drift for fitting tension pin in timing gear casing
30 9025 98700 Drift for fitting tension pins in timing gear casing and flywheel housing
*) New tools for 20---series engines. Other tools are the same as for engines on 305---405 tractors.
3 4
1 2
6 7 8 9 10
761
Model Code Page
1. 9. 1992
101 Special tools (ETV)
355-- 900 101 4B
1. 9. 2001
11
18
12 15 19
13
16
14 17
21 22
20
26
23 25
27 28 29 30
762
Model Code Page
1. 3. 1997
355-- 900 101 4C
1. 9. 2001
22A. Fuel system (20-- series, 656316-- )

9052 47800 *) Pressure gauge for checking delivery valve
9052 48900 *) Puller for injection pump drive gear
9052 47600 *) Control pipe for injection timing
9052 99000 *) Sleeve for limiting control rod travel
9051 71300 *) Extractor for injectors
8366 62022 Tester (TimeTrac) to check dynamic injection advance, E ---engines:
1. 836662121 Magnetic detector
2. 836662122 Cable
3. 836662123 Fastening part
4. 836662120 Timing light (not illustrated)
5. 836859466 TimeTrac in ---line sensor (not illustrated)
6. 836662124 Clamp ---on Transducer 4,5 mm (not ill.)
7. 836662125 ---” ---, 5,0 mm (not ill.)
8. 836662126 ---” --- ,6,0 mm (not ill.)
9. 836662127 ---” --- ,8,0 mm (not ill.)
10. 836662128 ---” --- ,1/4 inches (not ill.)
*) Same tool as for fuel system on 305---405 tractors.
15±1
9025 99000
905248900 9051 71300

3
2
9052 47800
902547600
8366 62022
A B 1
A
B
33346600
A
33370300
30068700 33370100
33346700
(0---1 bar)
Measuring equipment for fuel feed
31965400 pressure:
A
If the pressure is too low in point A, check the
pressure in point B. If further too low, the fault
lies in the fuel feed pump. Otherwise the filter
is blocked.
763
Model Code Page
1. 9. 1992
355-- 900 101 4D
1. 9. 2001
23A. Cooling system (20-- series, 656316-- )

9022 03500 *) Puller for coolant pump impeller, 320--- and 420---engines (earlier no 8360 85499)
9104 27700 Puller for coolant pump impeller, latest coolant pump, see page 231/4.
9051 64900 *) Drift for fitting coolant pump shaft, 320--- and 420---engines
9052 48900 *) Puller for fan hub (see Fuel System)
*) Same tool as for engines on 305---405 tractors.
905140200 905179300
9022 03500
905164900
9052 48900
764
Model Code Page
1. 3. 1997
1. 9. 2001 355-- 900 101 4E
32. Autocontrol hydraulic power lift

ETV 894 100 Cable to check voltages of draft sensor and position sensor
Blue
Yellow ---green
Brown
View A
1 3
Black (1) 2
1 3
2
Blue (2)
A
Red (3)
765
Model Code Page
101. Special tools (ETV) 355-- 900 101 4F
1. 3. 1997

ETV 894 220 Cable to check the control valve solenoids (Y1E, Y2E) on AC power lift (also 6000---8750).
Y1E,
Y2E
ETV 894 220
766
Model Code Page
1. 9. 1992
1. 9. 2001
41. Clutch A
Note! Adjusting kit ETV 892 570 below concerns F&S ---clutch. Only some notes are given for LuK ---clutch (on 555---665)
Clutch A
Part no Description
ETV 891 211* Centring drift for PTO clutch disc (not 205)
ETV 892 570 Kit for adjusting clutch (504, 604) containing the following parts:
1. ETV 892 571 Adjusting fixture
2. ETV 892 592 Centring sleeve for propulsion clutch disc
3. ETV 892 575 Press drift D = 150 mm, L = 50 mm
ETV 892 578 Press drift D = 90 mm, L = 40 mm
4. ETV 892 570 Pressure and turning lever, complete
7. ETV 893 710* Spacer block 6,5 mm (4 pcs) (Spacer block 7,6 mm for LuK ---clutch)
8. Std. Bolt M8X60, at least 4 pcs
10. ETV 892 582 Guide pin
12. ETV 893 711* Spacer sleeve 72 mm, propulsion clutch (Spacer sleeve 68 mm for LuK ---clutch)
ETV 893 712* Spacer sleeve 96 mm, PTO clutch (Spacer sleeve 93 mm for LuK ---clutch)
13. ETV 892 584 Indicator sleeve, L = 30 mm
14. ETV 892 585 Long indicator, PTO clutch
ETV 892 586 Short indicator, propulsion clutch
15. ETV 892 58 Indicator nut
(ETV 893 650) Drift for fitting needle bearing and seal inside clutch shaft (see Gearbox)
ETV 894 320 Fitting tool for HiShift hydraulic block piston seal KH 3714 (not illustrated)
ET 891 200 Handle for removing centring drift ETV 891 211
(ET 893 760) Support plate, 2 pcs. Prevents front axle oscillation when splitting tractor
ET 894 130 Centring drift for clutch disc on 205---tractor
Note! (*) = entirely new tools for Valmet tractors.
Clutch A
ETV 891 211
ETV 893 650

8
3 4
2 10 12 13 14 15
D
L
ETV 892 570
7
767
Model Code Page
1. 12. 1986
10. 1. 1992
ET 891200
ET 893670
ET 893760
ET 893780
ET 894 130
768
Model Code Page
1. 12. 1986
1. 3. 1997
Gearbox A

ETV 893 260 Key for round nut, output shaft front wheel drive (505---905)
ETV 893 630 Plate for fitting seal in bearing cover, input shaft
ETV 893 640 Plate for fitting seal in bearing cover, output shaft front wheel drive
ETV 893 650 Drift for fitting needle bearing/sealing ring in input shaft
Gearbox B
ETV 890 830 Sleeve for fitting front bearing on pinion shaft (PTO 505---905)
ETV 891 220 Sleeve for fitting bearing on counter shaft
Sleeve for fitting rear bearing on output shaft, front wheel drive
ETV 891 870 Plate for fitting thrust bearings for differential side gears (Gearbox 505---905)
ETV 891 900 Sleeve for fitting outer bearing race for input shaft front bearing (Gearbox 505---905)
ETV 892 210 Sleeve for fitting bearing race for pinion shaft front bearing (Gearbox 505---905)
ETV 892 230 Key for pinion shaft round nut (Gearbox 702---903)
ETV 892 350 Sleeve for fitting front bearing on output shaft, front wheel drive
Sleeve for fitting rear bearing on input shaft (Gearbox 505---905)
ETV 892 490 Plate for fitting pinion shaft rear bearing bearing race (Final drives 702---903)
ETV 893 660 Key for adjusting differential bearings
ETV 893 610 Tool for removing/fitting input shaft and bearings
--- ETV 893 611 Spindle
--- ETV 893 612 Sleeve for removing shaft
--- ETV 893 613 Sleeve for fitting shaft
--- ETV 893 614 Drift for removing/fitting shaft
--- ETV 893 615 Nut M16

ETV 893650
ETV 893260 ETV 893630 ETV 893640
769
Model Code Page
1. 12. 1986
ETV 890 220
ETV 890 830 ETV 891 220 ETV 891 900

ETV 891 870
ETV 892 210 ETV 892230
ETV 892 350
ETV 893660
ETV 892 490
770
Model Code Page
1. 12. 1986
1. 3. 1997
ETV 893611
ETV 893612
ETV 893615 ETV 893614
ETV 893613
ETV 893 610
ET 893570
ET 893 620 ET 893 760
771
Model Code Page
1. 12. 1986
1. 1. 1998
44. Low gear/Overdrive A

ETV 892 440 Plate for fitting front oil seal and removing/fitting all bearings (PT0 702---903)
44. Low gear/Overdrive B
Part. no. Description

(ETV 892 350) Sleeve for fitting rear oil seal (see Gearbox)
(ETV 893 650) Drift for fitting needle bearings/oil seal in main gearbox input shaft (see Gearbox)

ET 893 380 Drift for fitting selector shaft (Gearbox 505---905)
(ET 893 760) Support (2 pcs) for front end frame, prevents front axle oscillating when parting tractor (see Frame and
Wheels
ETV 892 440
ETV 892 350

ETV 893 650
ET 893 380
ET 893 760
772
Model Code Page
1. 12. 1986
101. Special tools (ETV) 1. 1. 1998 205-- 900 101 11
45. Final drives B, 205---665

ETV 891 710 Sleeve for fitting bearing race för outer drive shaft (Gearbox Valmet 1102---1203)
(ETV 892 210) Sleeve for fitting oil seal for outer drive shaft (see Gearbox)
ETV 893 320 Plate for fitting outer shaft seal for outer drive shaft (Final drives 505---905)
ETV 893 690* Plate for fitting bearing race for outer drive shaft

ET 893 410 Support bar for removing bearing race, outer drive shaft (Final drives 505---905)
ETV 893 320

ET 893 410
ETV 893 690
ETV 891 710 ETV 892 210
45. Final drives B, 865 and 600---900

ETV 893 310 Plate for fitting drive shaft inner oil seal (Mezzo)
ETV 893 320 Plate to fit drive shaft bearing outer races (Mezzo)
ETV 894 210 Centring tool foor outer brake application ring when fitting final drives on 865 and 600---900.

ET 893 410 Support to remove drive shaft bearing outer races (Mezzo)
ETV 890220 ETV 893 310

ET 893 410
ETV 893 320
ETV 894 210
773
Model Code Page
15. 4. 1994
46. PTO A
ETV 893 700* Sleeve for fitting PTO shaft end, bearings or oil seal
46. PTO B
(ETV 892 350) Sleeve for fitting upper shaft or bearings (see Gearbox)
ETV 894 080 Tool for fitting selector fork locking ball (also PTO 6000---8400)
ETV 893 700 ETV 892 350

(1 ---speed PTO)
ETV 894 080

(2 ---speed PTO)
61. Steering system

ETV 893 100 Tool for fitting seal in steering valve (from cab no 54624) (see also 505---8100)
ETV 893100
61. Steering cylinder B (2WD)
ETV 892 380 Sleeve for removing bearing sleeve and seal from steering cylinder (see Gearbox 505---905)
(ETV 893 630) Plate for fitting scraper seal, seal and bearing sleeve in steering cylinder (see Gearbox)
ETV 893 630

ETV 892 380
774
Model Code Page
Special tools (ETV) 205-- 865 101 12A
15. 9. 1995
Equipment to measure steering system pressures
Equipment to measure steering system working pressure (9 ---10 MPa). Measuring kit no. 31965000 includes these parts. The
parts can also be ordered separately.
Equipment to measure shock valve opening pressure (16 MPa). T ---connector GS 9276 has thread 3/4---16 for the hand pump.
Measuring kit no. 31965000 does not include the hand pump.
775
776
Model Code Page
62. Non ---powered front axle B

ETV 890 820 Drift for fitting central pivot bearing bushings
(front axle Valmet 504---604)
ETV 892 390 Sleeve for fitting wheel hub bearing race
(front axle 505---805)
ETV 892 410 Plate for fitting wheel hub bearing race
(ETV 892 210) Sleeve for fitting shaft seal in hub (see Gearbox)
(ETV 892 400) Sleeve for fitting roller bearing in wheel hub
(see Powered front axle ZF)
ETV 892 370 Sleeve for fitting roller bearing on steering knuckle
(ETV 892 350) Sleeve for fitting needle bearing race on steering knuckle
(see Gearbox)
ETV 891 230 Drift for fitting needle bearing in steering knuckle housing
(front axle Valmet 504---604)
ETV 892 360 Plate for fitting roller bearing in steering knuckle housing
ETV 892390
ETV 892400
ETV 890820 ETV 892410 ETV 892210
ETV 892370 ETV 892350 ETV 891230 ETV 892 360
777
Model Code Page
1. 12. 1986
64. Powered front axle A (ZF axle)
ETV 891 840 Sleeve for fitting oil seal on pinion shaft
(see Gearbox 505---905)
ETV 892 400 Sleeve for fitting pinion shaft nut locking sleeve
(see Front axle 505---805)
64. Powered front axle B (ZF axle)
(ETV 890 820 Drift for fitting drive shaft seal and bearing bushings
(see Non ---powered front axle)
ETV 891 780 Plate for fitting oil seal in hub
(Gearbox 1102---1203)
(ETV 892 350) Sleeve for fitting steering knuckle bearing races
(see Gearbox)
ETV 893 720* Plate for fitting pinion shaft bearing race
ETV 893 730* Plate for fitting pinion shaft bearing race
ETV 893 750* Plate for fitting bearing races in hub
ETV 893 770* Tool for adjusting pinion shaft bearing preload
Tool for adjusting tooth backlash pinion/crown wheel
ETV 891 840
ETV 892 400
ETV 891 780
ETV 892 350

ETV 890 820
778
Model Code Page
15. 9. 1995
ETV 893 730

ETV 893 720
ETV 893 750
ETV 8932 770

ETV 892 290 Tool for fitting drive shaft outer oil seal (Sige 6100---8100)
ETV 893 600 Tool for fitting pinion shaft seals (Sige 6100---8100)
ETV 894 020 Plate for fitting hub seal (Sige 6100---8100)
ETV 894 150 Plate for fitting new hub seal (cassette type), 1108/94---
ET 894 010 Drift to remove/fit drive shaft bearing bushings (Sige 6100---8100)
ETV 892290 ETV 893600
ET894010
ETV 894 020 ETV 894 150
Puller for king pins
779
Model Code Page
1. 12. 1986
91. Hydraulic lift B
ETV 892 660 Device for checking damping valve
(Hydraulic lift 504---604)
ETV 892 670 Device for checking tightness of lifting cylinder and shock valve
ETV 892 680 Checking device for control valve
ETV 892 660
ETV 892 680
ETV 892 670
The above mentioned tools are included in an earlier used pressure ---testing kit ETV 892 920.
Equipment for measuring and testing pressures, see ”Locally prepared tools”, code 102.
ETV 893 530 Sleeve for fitting lifting arm shaft seals (Hydr. 505---905)
ETV 894 030* Sleeve for fitting lifting arm shaft bushings (610312---)
ETV 894 030

ETV 893 530
780
Model Code Page
15. 9. 1995
1. 5. 1996
Measuring equipment, 205---665
Measuring pressure in working hydraulics (18 MPa). Test kit no. 31965000 includes these parts. The parts can also be ordered
separately.
Measuring equipment, 865 with extra lifting cylinder
Measuring working pressure in working hydraulics (18 MPa). T ---connector GS 9276 is connected to the lower hose of the extra
lifting cylinder. Test kit no. 31965000 includes these parts. The parts can also be ordered separately.
781
Model Code Page
1. 3. 1997
Special tools (ETV) 1. 9. 2001 205-- 900 101 18
Hand pump
Measuring opening pressure of shock valve (20 MPa) on 865---tractor. The pressure gauge and hand pump are connected to the
extra lifting cylinder lower hose. Pressure test kit no. 31965000 does not include the hand pump.
A B C
Measuring working hydraulics working pressure on the latest 65---models and on 600---900.
A. Pressure test point on the extra lifting cylinder hose on the LH side.
B. Pressure test point beside the AC power lift control valve.
C. On tractors without the test point, the pressure can also be measured from the quick couplings of the auxiliary hydraulics.
782
Model Code Page
10. 1. 1992
102. Locally prepared tools (ET) 205-- 865 102 1
1. 9. 1995
21. Engine
9051 64900 Drift for fitting coolant pump shaft (505---905)
(ET 893 760) Support plate, 2 pcs. Prevents front axle oscillation when splitting tractor (see Frame and Wheels)
3x45˚
ø 30
120
75
3,2
5
25
R2
ø 16+0,1
R1
ø 22,5+0,5
ø 29,8 --- 0,1
905164900
41. Clutch

Part no Description
ET 891 200 Handle for removing centring drift ETV 891 211 (Clutch 504---604)
(ET 893 760) Support plate, 2 pcs. Prevents front axle oscillation when parting tractor (see Frame and Wheels)
ET 894 130 Centring drift for clutch disc on tractor 205
2000
M12
25
ø 12
120
ET 891 200
783
Model Code Page
1. 12. 1986
10. 1. 1992
85
R10
110
17
R10
ø8
72
35
ET 893 670
184
4
ø 48,5
ø 49±0,5
ø 54 ±0,5
10
190
ET 893 780
ø 40,5
ø 25
ø 19,9
30˚
16
57
103
183
ET 894 130
784
Model Code Page
1. 12. 1986
1. 3. 1997
42. Gearbox

ø 15,9 (---0,1)
20˚
5
23
ET 893 570
400
390
ø 53,7
ø 61,8
ø 60
ET 893 620 20
785
Model Code Page
1. 12. 1986
1. 3. 1997
786
Model Code Page
15. 9. 1995
Locally prepared tools (ET) 205-- 865 102 5
1. 5. 1996

ET 893 380 Drift for fitting selector shaft (Gearbox 505---905)
(ET 893 760) Support (2 pcs) for front end frame, prevents front axle oscillation when
splitting tractor (see Frame and Wheels)
ø 16 h11
120
ET 893 380
45. Final drives

ET 893 410 Support bar for removing bearing race, outer drive shaft (Final drives 505---905)
ET 894 210 Support/centring tool for brake application plate when fitting rear axle housing on 865 tractor
195
30
30
45˚
155
ET 893 410
~2
~6
~6
Ø6
~ 99
~ 75
Oil plug
GR0225
Ø6,3 Standard bolt M6x100

ET 894 210
Plug is fitted on bolt before shaping
the bolt end.
787
Model Code Page
1. 5. 1996
Locally prepared tools (ET) 205-- 865 102 6
1. 3. 1997
788
Model Code Page
15. 9. 1995
102. Locally prepared tools (ET) 205-- 865 102 6A
1. 3. 1997
ET 894 010 Drift for removing/fitting drive shaft bearing bushings (also Sige 505---8100)
165±1
15+0,5
1,5 Stamp ET 894 010

ø39,9 ---0,1
30˚ SR 50
ø 35---0,3
30˚
ø43,5 ---0,2
130±1
789
790
Model Code Page
1. 12. 1989
71. Frame and wheels

ET 893 760 Support plate to prevent front axle oscillation (2 pcs)
100 8
ø 18
20
40
32
40
260
20
90
ET 893 760
25
791
Model Code Page
1. 12. 1989
15. 9. 1995
91. Hydraulic power lift
R1/4
ETV 892 921

(Enerpac P---39) *)
TEMA 2500 (R1/4)
9801---01---04.00
3/4--- 16 UNF
ETV 892 922 *)

ETV 892 660
ETV 892 680
1. Equipment for pressure testing damping valve and control valve
TEMA 2500 (R1/4) 2103---05---01.00

TEMA 2500 (R1/4)
9801---01---04.00
ETV 892 921
(Enerpac P---39) *)
2120---04---02.50
2. Equipment for tracing leakage in neutral position.

Checking opening pressure of working hydraulic shock valve.
Equipment for pressure ---testing lifting cylinder
x) These tools are not supplied by Sisu ---tractors (the tools are included in an earlier pressure ---testing kit ETV 892 920.
Part numbers consisting of digits only indicate parts which are generally available on the market.
N.B. The measuring range of the pressure gauge is 0---40 MPa (0---5800 psi).
792

Service Manual: General

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10 General

205, 255, 305

455, 465, 555

600, 700, 800

A75, A85, A95

Detailed maintenance instructions can be found in Operator’s Manual.

Ordering number Date Content

Ordering number Date Content

Layout of Service Manual

Example. 10. General

2. Division into components or sub ---groups

Example. 41. Clutch

Example: Code 410

8. 11. 1990 Model Code Page

7. Additions and amendments of the service manual

Code designations in the Service Manual

10. General 61. Steering system

21. Engine 62. Non ---powered front axle

43. Torque converter and shuttle on 415 M

44. Low gear

46. Power take off

General instructions for repairs

Outer oil seals

Sealing compound and glue

Tightening torques and setting values

a) Determine the problem

b) List possible causes

c) Differentiate the causes

d) Conduct checks in logical order to determine the exact cause

f) Make any necessary repairs.

g) Recheck the parts and functions for correct operation

Table 1. Tightening torques, metric standard thread (ISO)

Tightening torques Nm1)

Conversion table for common units

Short distances e.g. turning circles metres (m) 1 m=3,28 ft

Travel distances kilometres 1 km=0,62 mile

Tractor weights, axle loadings kilograms (kg) 1 kg=2,2 lbs

Travel speed kilometres per h (km/h) 1 km/h=0,62 mph

Drawbar pull kilonewtons (kN) 1 kN=224,8 lbs

Power (identified by such terms as crankshaft power, 1 kW=1,34 hp

Engine torque newton metres (Nm) 1 Nm=0,74 ft lb

Fuel consumption by weight (kilograms per hr, kg/h) 1 kg/h=2,2 lb/hr

Fuel economy (specific fuel consumption) 304 g/kWh=0,5 lb/hp hr

Engine displacement litres (l) 1 l=61,02 m cu in

Hydraulic pump 1 MPa=145 psi

Area acres---hectare To convert multiply by

Volume bushel---litre To convert multiply by

Quantity pound per acre ---kilogram per hectare Multiply by 1,12085

Maintenance daily/weekly Weekly/every 50 hours

Every 250 hours Every 1000 hours/yearly

Recommended fuel and lubricants

Part of machine SAE class API grade Volume (litres)

Working hydraulics HT60: ---30˚C...+30˚

Cooling system with expansion tank:

Note! The following Valtra oils are recommended:

Note! Recommended oil in front PTO, see code 460.

Oil specification in torque converter/reverse shuttle:

22. Fuel system

23. Cooling system

22A. Fuel system

23A. Cooling system

General (Op. no. 210):

Cylinder block and flywheel housing (Op. no. 211):