STEYR M968 M975 Tractor Service Manual 7-95860 - PDF DOWNLOAD

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CASE STEYR Landmaschinentechnik GmbH Technische Dokumentation A - 4300 St. Valentin, Steyrer Straße 32

Sva 7-69860 GE/EN

0 0 &6 &6

Chapter 2007 WORKSHOP MANUAL CS68 CS75

from DBD0040007 from DBD0040007

M9078 M9086 M9094

CS78 CS86 CS94

from DBD0055001 from DBD0055001 from DBD0055001

9105 9115 9125 9145

CS110 from DBD0075001 CS120 from DBD0075001 CS130 from DBD0075001 CS150 from DBD0075001

2007

M968 M975

CASE-STEYR Landmaschinentechnik GmbH Technical Documentation A - 4300 St. Valentin, Steyrer Straße 32

Sva 7-98510 EN

© 2000 Case Steyr Landmaschinentechnik GmbH May, 2000

2007-2

INDEX INDEX ......................................................................................................................................2 SPECIAL TOOLS .....................................................................................................................5 FOR THE USER ......................................................................................................................7 Engine serial number ............................................................................................................7 SAFETY REGULATIONS ........................................................................................................8 ENGINE DATA .........................................................................................................................9 Lifting the engine ...................................................................................................................9 TECHNICAL DATA ................................................................................................................10 Cylinder block ......................................................................................................................10 Cylinder liners ......................................................................................................................10 Cylinder head ......................................................................................................................10 Valves, rocker arms and push rods .....................................................................................11 Camshaft .............................................................................................................................12 Crankshaft ...........................................................................................................................12 Flywheel ..............................................................................................................................13 crankshaft inertia weight (engine type 420) .........................................................................13 Camshaft drive ....................................................................................................................13 Con-rods ..............................................................................................................................14 Pistons, piston rings and piston pins ...................................................................................14 Lubrication system ..............................................................................................................15 Lubrication oil pump (320, 420) ...........................................................................................15 Lubrication oil pump (620) ...................................................................................................15 Thermostat ..........................................................................................................................15 Coolant temperature switch Coolant temperature transmitter ..........................................................................................15 Cooling water pump (320, 420) ...........................................................................................16 Cooling water pump (620) ...................................................................................................16 Turbo charger ......................................................................................................................16 Tightening torques ...............................................................................................................17 CONSTRUCTION ..................................................................................................................18 General information .............................................................................................................18 Cylinder block ......................................................................................................................18 Flywheel casing ...................................................................................................................18 Cylinder head ......................................................................................................................19 Valve mechanism ................................................................................................................19 Crankshaft drive ..................................................................................................................19 Timing gears ........................................................................................................................20 Lubrication system ..............................................................................................................21 Cooling system ....................................................................................................................22 Intake / exhaust system .......................................................................................................23 Sva Sva 7-98510 EN

Edition 05/00

2007-3

JOB INSTRUCTIONS ............................................................................................................24 1. CYLINDER BLOCK .........................................................................................................24 A. Measuring the cylinder liner wear ..................................................................................24 B. Removing the cylinder liner ...........................................................................................24 C. Checking the cylinder block ...........................................................................................24 D. Replacing the camshaft bush ........................................................................................24 E. Oversize bushes for the camshaft .................................................................................25 F. Fitting the plug at the rear camshaft end .......................................................................27 G. Fitting the plug at the rear camshaft end after inserting an oversize bush ....................27 H. Installing the oil dipstick tube .........................................................................................27 I. Fitting the cylinder liner ...................................................................................................27 2. FLYWHEEL CASING .......................................................................................................29 A. Fitting the flywheel casing .............................................................................................29 B. Replacing the rear crankshaft sealing ring ....................................................................29 3. CYLINDER HEAD ............................................................................................................30 A. Removing the cylinder head ..........................................................................................30 B. Removing the valves .....................................................................................................30 C. Checking the cylinder head ...........................................................................................30 D. Replacing the valve guides ...........................................................................................31 E. Machining the valve seat ...............................................................................................32 F. Replacing the valve seat rings .......................................................................................32 G. Grinding the valves .......................................................................................................32 H. Fitting the valves ...........................................................................................................32 I. Fitting the cylinder head ..................................................................................................33 4. VALVE MECHANISM ......................................................................................................34 A. Maintenance of the rocker arm system .........................................................................34 B. Replacing the camshaft / camshaft gear wheel .............................................................34 C. Checking and adjusting the valve clearance .................................................................35 5. CRANKSHAFT ................................................................................................................36 A. Removing the crankshaft ...............................................................................................36 B. Checking the crankshaft ................................................................................................36 C. Replacing the crankshaft gear wheels ..........................................................................36 D. Replacement of the crankshaft ring gear (engine type 420 only) ..................................37 E. Fitting the crankshaft .....................................................................................................37 F. Crankshaft hub ..............................................................................................................38 G. Replacing the crankshaft belt pulley and vibration damper ...........................................38 H. Checking the rubber element in the vibration damper (620/420) ..................................39 6. CON-RODS AND PISTONS ............................................................................................40 A. Removing the pistons together with the con-rods .........................................................40 B. Checking and replacing the con-rod bearings ...............................................................40 C. Checking the con-rod ....................................................................................................40 D. Con-rod weight groups ..................................................................................................41 E. Checking and replacing the piston rings ........................................................................42 F. Checking the pistons .....................................................................................................43 G. Fitting the piston pin ......................................................................................................43 H. Fitting the pistons and con-rods ....................................................................................43 7. BALANCING UNIT (420) .................................................................................................44 A. Removing and dismantling the balancing unit ...............................................................44 B. Balancing unit maintenance ..........................................................................................44 C. Fitting the balancing unit ...............................................................................................44 Sva Sva 7-98510 EN

Edition 05/00

2007-4

8. FLYWHEEL .....................................................................................................................45 A. Replacing the starter ring gear on the flywheel .............................................................45 B. Fitting the flywheel .........................................................................................................45 9. TIMING MECHANISM .....................................................................................................46 A. Removing the timing gear case .....................................................................................46 B. Replacing the intermediate gear wheel bush ................................................................46 C. Fitting the timing gear case ...........................................................................................47 D. Front power take-off / auxiliary drive .............................................................................48 10. LUBRICATION SYSTEM ..............................................................................................49 A. Checking the oil pressure valve ....................................................................................49 B. Removing and checking the oil pump ...........................................................................49 C. Assembling and fitting the oil pump ..............................................................................50 D. Fitting the sump .............................................................................................................50 E. Oil cooler .......................................................................................................................50 F. Piston cooling nozzles (620) ..........................................................................................51 G. Recommended lubrication oils ......................................................................................51 11. COOLING SYSTEM ......................................................................................................52 A. Thermostat ....................................................................................................................52 B. Repairing the coolant pump ..........................................................................................52 C. Coolant quality requirements ........................................................................................53 12. INTAKE / EXHAUST SYSTEM ......................................................................................54 A. Checking the air filter .....................................................................................................54 B. Checking the intake / exhaust system ...........................................................................54 C. Checking the boost pressure ........................................................................................54 D. Checking the turbo charger ...........................................................................................55 E. Fitting the turbo charger ................................................................................................56

Sva Sva 7-98510 EN

Edition 05/00

2007-5

SPECIAL TOOLS Pressing tool for the front crankshaft dust seal

Assembly pin for the water pump seal

SS00B068 SS00B064

1 off 1TSW 519

1 off 1TSW 523

Universal pin

Pressing tool for the front crankshaft shaft sealing ring

SS00B077

1 off 1TSW 18390

Pressing tool for valve guides SS00B065

1 off 1TSW 520

Pressing tool for the rear crankshaft shaft seal

SS00B069

1 off 1TSW 524

Valve spring tensioning lever SS00B066

1 off 1TSW 521

Pressing tool for cam shaft cover

SS00B071

1 off 1TSW 014 SS00B067

1 off 1TSW 522 Sva 7-98510 EN

Edition 05/00

2007-6

Extractor

Screw-in fitting

SS00B082

1 off 1TSW 663

Mini-measuring connection SS00B070

1 off 1TSW 662

Cylinder liner extractor

SS98J031

1 off 1TSW 640

M10x1

Mini-measuring line

SS98J030

1 off 1TSW 635 SS00B072

1 off 1TSW 510

Pressure gauge and connection Extraction plate

SS00B073

1 off 1TSW 508

SS00B076

1 off 1TSW 645 1 off 1TSW 5002

Connection Pressure gauge

Dial test indicator and holder Open-ended spanner for visco-hub

Not illustrated

SS00B075

1 off 1TSW 5610 1 off 1TSW 17049-6 Sva 7-98510 EN

Holder Dial test indicator

1 off 1TSW 664

Edition 05/00

2007-7

FOR THE USER The purpose of this manual is to provide basic information required to service and repair Steyr – Sisu diesel engines.

Engine types 320, 420 and 620 are of the same design, therefore the same repair instructions can be used for the varying engine types. Any differences affecting repair work are listed in the technical data and repair instructions. All dimensions are specified in millimetres and apply to parts at a temperature of +20 °C, if not specified otherwise.

Before starting repair work, make sure all necessary special tools, spare parts and accessories are available. It is not absolutely necessary to have all the special tools mentioned in this manual. However, having them does make it quicker and easier to carry out any repairs necessary. After a repair, the engine must be run in just like a new engine.

If any questions arise, which cannot be clarified with the aid of this manual, please contact Case Steyr Customer Service in St. Valentin or the respective importer.

When making any queries, please specify the following engine data:

Engine serial number Engine type

Produced for Case Steyr Important Engine Information

Type

STEYR Power PS 68 Serial No. J19111

320.80 2300 rpm

Cust.

Part No. 320.80.00.0001

320.80

M968

CS68

320.81

M975

CS75

420.81

M9078

CS78

420.82

M9086

CS86

420.83

M9094

CS94

420.85

9105

CS110

620.94

9115

CS120

620.92

9125

CS130

620.93

9145

CS150

SS99N123

Engine number (serial number)

Year code H

1998

J

1999

K

2000

L

2001

M

2002

N

2003

This adhesive label is affixed to the right-hand side of the engine.

320

420

620

SS99N014

Sva 7-98510 EN

Edition 05/00

2007-8

SAFETY REGULATIONS The possibility of injury always exists when carrying out maintenance and repair work. Read the following safety regulations and information before starting work.

•) Never start repair work, which you do not fully understand.

•) Make sure that the environment is safe to work in.

•) Make sure the location is clean and in a good state.

•) Never use incorrect or unsuitable tools.

•) Remove all rings, chains and watches before commencing work.

•) Use state of the art safety equipment. For example, wear goggles when using compressed air for cleaning, grinding, hammering or similar work.

•) Use a lifting device for lifting or transporting heavy parts (over 20 kg). Make sure the hooks and chains are in a good condition and sit firmly in place.

•) Never work below an engine hanging from a lifting device or raised by a jack. Always secure with strong support trestles before commencing work.

•) Only use original Case-Steyr spare parts.

•) Only start the engine from the cab, using the ignition key.

•) Never start the engine with the protective covers removed.

WARNING: It is difficult to see the radiator fan when the engine is running! Baggy clothes and long hair can get caught in rotating engine parts!

•) If the engine is started in a confined space, sufficient ventilation must be provided.

•) Naked flames and smoking are not permitted in the vicinity of fuel tanks or batteries. Electric sparks should be avoided. (Particularly when charging the batteries. Explosion hazard!)

•) Disconnect the cable at the negative battery pole before carrying out service or repair work on the electrical system.

•) If the engine gets excessively hot (over 300 °C), for example, if it catches fire, the viton seals (e.g. bottom O-ring on the cylinder liner or the O-ring on the oil pressure valve) release highly caustic HF acid. Never touch viton seals, which have been subjected to unusually high temperatures, with bare hands. Always wear neoprene gloves or thick work gloves and safety goggles when removing these harmful substances. Wash the seals and contaminated surfaces with a 10 % hydroxide solution or another alkaline solution. Collect the material in air-tight sealed plastic bags and bring them to an authorised collecting depot.

IMPORTANT: Viton seals may never be burned!

•) When checking the injection nozzles, never touch the fuel, which is ejected under high pressure. The jet will penetrate the skin and cause serious poisoning. If contact is made with the skin, consult a doctor without delay!

Fuel, lubrication oil and coolant can cause skin irritations, if contact is made over a longer period.

•) Avoid running the engine in idle unnecessarily.

When carrying out service work, take measures to prevent fuel or other fluids from entering the ground or drains.

•) All seals are asbestos-free.

•) Be careful when washing the engine using a washing facility with a high water pressure. Do not wash, for example, the electrical and fuel systems under high pressure as they can easily be damaged.

•) Never use auxiliary starting fuels on an aerosol basis whilst the pre-glow starting facility is in operation (explosion hazard).

•) Ear muffs must be worn when testing the engine or working close to the engine.

•) Always switch the engine OFF before carrying out maintenance or repair work.

•) Avoid touching the exhaust manifold, turbo charger and other hot engine parts.

•) When the engine is hot and the coolant is pressurised, be careful when opening the radiator cap. Coolant and lubrication oil out of the hot engine can cause severe injuries if contact is made with the skin.

Sva 7-98510 EN

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2007-9

ENGINE DATA Engine type

320.80 320.82 420.81 420.82 420.83 420.85 620.94 620.92 620.93

Number of cylinders 3

Capacity (dm )

3

4

6

3,3

4,4

6,6

Bore (mm)

108

Stroke (mm)

120

Delivery start marking of the V-belt pulley (° before UDC) Compression ratio

15

±1

16,5 : 1

18,5 : 1

Method of combustion

14±1

15±1

13±1

16,5:1

18,5 : 1

16,5:1

direct injection

Injection sequence

1-2-3

1-2-4-3

1

Compression pressure (bar) 2

Charge-air pressure (bar) 3

Weight (kg)

1-5-3-6-2-4

24 1,10

1,20

1,10

280

1,20

1,30

1,30

0,70

340

Direction of rotation of the crankshaft

0,78

1,1

510

Clockwise

1

) Minimum value when idling at operating temperature.

Highest permissible difference between the cylinders is 3 bar.

2 ) measured at full load and nominal engine speed 3 ) Without flywheel and electrical equipment.

Lifting the engine The engine is lifted safely by means of a lifting device, on which the lifting power acts vertically on the lifting eyes.

A = Engine lifting eyes

A

A

SS99N013

Sva 7-98510 EN

Edition 05/00

2007-10

TECHNICAL DATA Cylinder block Guide pin bore holes ........................................................................................... 13.250 - 13.320 mm Diameter of the crankshaft bearing base bore hole ............................................. 91.000 - 91.025 mm Diameter of the crankshaft bearing base bore hole (bearing 162000010800) ...... 92.000 - 92.025 mm Bore hole diameter of the cylinder liner: - top ................................................................................................................ 124.514 - 124.554 mm - bottom .......................................................................................................... 123.000 - 123.040 mm Diameter of the camshaft bearing bush (if fitted) ................................................. 50.010 - 50.070 mm Construction height of the cylinder block ......................................................... 428.170 - 428.430 mm

Cylinder liners Liner height above the cylinder block ..................................................................... 0.030 - 0.080 mm Highest permissible height difference between cylinder liners .............................................. 0.02 mm Diameter of the cylinder liner bore holes in the engine block: - top end of liner .............................................................................................. 124.475 - 124.500 mm - bottom end of liner ........................................................................................ 122.961 - 122.986 mm Cylinder liner bore hole ................................................................................... 108.010 - 108.032 mm Height, cylinder liner flange ........................................................................................ 9.03 - 9.05 mm Height, cylinder liner flange, 1st oversize SP NO 162000040713 ............................... 9.08 - 9.10 mm Height, cylinder liner flange, 2nd oversize SP NO 162000040714 .............................. 9.13 - 9.15 mm Height, cylinder liner flange, 3rd oversize SP NO 162000040715 ............................... 9.23 - 9.25 mm Outer diameter of the cylinder liner flange ....................................................... 131.700 - 131.800 mm

Cylinder head Construction height of the cylinder head ......................................................... 104.800 - 105.000 mm Minimum height of the cylinder head after surface grinding ............................................ 104.000 mm Inner diameter of the valve guide (when not fitted) ................................................. 9.000 - 9.015 mm Outer diameter of the valve guide ....................................................................... 16.028 - 16.039 mm Diameter of the bore hole for the valve guide in the cylinder head ...................... 16.000 - 16.018 mm Projection of the valve guide over the cylinder head face ........................................................ 21 mm Depth, valve head below cylinder head surface: - Inlet valve ........................................................................................ 0.7 ± 0.05 mm (max. 1.70 mm) - Outlet valve ..................................................................................... 0.6 ± 0.05 mm (max. 1.60 mm) Valve seat angle: - Inlet valve ............................................................................................................................. 35°+20’ - Outlet valve .......................................................................................................................... 45°+20’ Valve seat width: - Inlet valve .................................................................................................................... 2.9 - 3.7 mm - Outlet valve ................................................................................................................. 1.3 - 2.3 mm Diameter, outlet valve seat insert SP NO 162000040718 .................................... 44.070 - 44.132 mm Bore hole in cylinder head for outlet valve seat insert .......................................... 44.000 - 44.025 mm

Sva 7-98510 EN

Edition 05/00

2007-11

Valves, rocker arms and push rods Valve control times at a valve play of 1.0 mm: - Inlet valve opens ................................................................................................. 0° ±2° before TDC - Inlet valve closes ................................................................................................. 16° ±2° after BDC - Outlet valve opens ........................................................................................... 39° ±2° before BDC - Outlet valve closes ................................................................................................ 1° ±2° after TDC Valve play when engine is cold/hot: - Inlet valve ........................................................................................................................... 0.35 mm - Outlet valve ........................................................................................................................ 0.35 mm Valve head angle: - Inlet valve .............................................................................................................................. 35°-20’ - Outlet valve ........................................................................................................................... 45°-20’ Valve head diameter: - Inlet valve .............................................................................................................................. 48 mm - Outlet valve ........................................................................................................................... 41 mm Maximum opening of the valves: - Inlet valve ........................................................................................................................... 10.9 mm - Outlet valve ........................................................................................................................ 12.1 mm Diameter, inlet valve stem ...................................................................................... 8.960 - 8.975 mm Diameter, outlet valve stem .................................................................................... 8.925 - 8.940 mm Clearance, inlet valve stem (guide fitted in cylinder head) ...................................... 0.025 - 0.055 mm Wear limit (inlet valve stem) .................................................................................................. 0.30 mm Clearance, outlet valve stem (guide fitted in cylinder head) .................................... 0.060 - 0.090 mm Wear limit (outlet valve stem) ............................................................................................... 0.35 mm Inner diameter of the valve guide (when not fitted) ................................................. 9.000 - 9.015 mm Outer diameter of the valve guide ....................................................................... 16.028 - 16.039 mm Diameter of the bore hole for the valve guide in the cylinder head ...................... 16.000 - 16.018 mm Projection of the valve guide over the cylinder head face ........................................................ 21 mm Depth, valve head below cylinder head surface: - Inlet valve .................................................................................................................. 0.7 ± 0.05 mm - Outlet valve ............................................................................................................... 0.6 ± 0.05 mm Length of the valve spring, relaxed ....................................................................................... 69.8 mm Force of the valve spring compressed to a length of: - 48.6 mm ............................................................................................................................ 327±17 N - 37.4 mm ............................................................................................................................ 500±23 N Diameter, rocker arm shaft ................................................................................. 22.970 - 22.990 mm Diameter of rocker arm bore hole ....................................................................... 23.000 - 23.021 mm Permissible deflection of the push rod (free) ........................................................................... 0.4 mm Length of the rocker arm spring, relaxed ................................................................................. 80 mm Force of the valve spring compressed to a length of 58 mm .............................................. 80 - 100 N Outer diameter of the tappet ............................................................................... 29.939 - 29.960 mm Diameter of the tappet bore holes in the cylinder block ....................................... 30.000 - 30.043 mm

Sva 7-98510 EN

Edition 05/00

2007-12

Camshaft Diameter, 1st camshaft bearing journal .................................................................... 49.925 - 49.950 mm Diameter of the other camshaft bearing journals ...................................................... 49.885 - 49.910 mm Diameter, camshaft bearing journals 2, 3 and 4 (engine type 620) ........................... 49.865 - 49.890 mm Diameter of the 1st camshaft bearing bore hole (bushes fitted) ................................ 50.010 - 50.070 mm Diameter of the other camshaft bearing bore holes .................................................. 50.000 - 50.025 mm Play, 1st camshaft bearing .......................................................................................... 0.060 - 0.145 mm Play of the other camshaft bearings ............................................................................ 0.090 - 0.140 mm Play of camshaft bearings 2, 3 and 4 (engine type 620) ............................................... 0.110 - 0.160 mm Bearing tolerances in the cylinder block ...................................................................... 0.025 - 0.080 mm Diameter of the bearing seat bore holes in the cylinder block ................................... 55.620 - 55.650 mm Axial play of the camshaft with a 0.5 mm seal between the cylinder block and timing case and between the timing case and timing case cover ......................................... 0.5 - 1.0 mm Cam height (dimension between cam base circle and cam lobe): - Inlet valve .............................................................................................................. 41.180 - 41.430 mm - Outlet valve ........................................................................................................... 40.080 - 40.330 mm Cam stroke: - Inlet valve ............................................................................................................................... 7.38 mm - Outlet valve ............................................................................................................................ 8.28 mm Max. permissible deviation of the camshaft ............... 0.03 mm (max. deflection of the dial test indicator)

Crankshaft Diameter of the con-rod bearing journals: - Standard dimension ............................................................................................... 67,981 - 68000 mm - 1st repair level 0.25 mm ........................................................................................ 67.731 - 67.750 mm - 2nd repair level 0.50 mm ...................................................................................... 67.481 - 67.500 mm - 3rd repair level 1.00 mm ....................................................................................... 66.981 - 67.000 mm - 4th repair level 1.50 mm ....................................................................................... 66.481 - 66.500 mm Width of the con-rod bearing journal ....................................................................... 40.000 - 40.160 mm Diameter of the crankshaft journals: - Standard dimension .............................................................................................. 84.985 - 85.020 mm - 1st repair level 0.25 mm ........................................................................................ 84.735 - 84.770 mm - 2nd repair level 0.50 mm ...................................................................................... 84.485 - 84.520 mm - 3rd repair level 1.00 mm ....................................................................................... 83.985 - 84.020 mm - 4th repair level 1.50 mm ....................................................................................... 83.485 - 83.520 mm Diameter, crankshaft bearing casing ....................................................................... 91.000 - 91.025 mm Thickness of the main bearing shells - Standard dimension .................................................................................................. 2.955 - 2.965 mm - 1st repair level 0.25 mm ............................................................................................ 3.080 - 3.090 mm - 2nd repair level 0.50 mm .......................................................................................... 3.205 - 3.215 mm - 3rd repair level 1.00 mm ........................................................................................... 3.455 - 3.465 mm - 4th repair level 1.50 mm ........................................................................................... 3.705 - 3.715 mm - Bearing ET NR 162000010800 (see Chapter 5. B) .................................................... 3.705 - 3.715 mm Crankshaft bearing play .............................................................................................. 0.050 - 0.127 mm Width of the journal at the thrust bearing (crankshaft bearing at flywheel): - Standard dimension (2 standard thrust washers) .................................................. 45.000 - 45.080 mm - 1st repair level (one standard thrust washer and one with an oversize of 0.1 mm) 45.100 - 45.180 mm - 2nd repair level (one standard thrust washer and one with an oversize of 0.2 mm) 45.200 - 45.280 mm - 3rd repair level (one 0.1 mm thrust washer and one with an oversize of 0.2 mm) .. 45.300 - 45.380 mm - 4th repair level (two thrust washers with an oversize of 0.2 mm) ........................... 45.400 - 45.480 mm Other crankshaft bearing journals must not be ground wider.

Axial play of the crankshaft ......................................................................................... 0.100 - 0.380 mm Max. permissible out-of-true of the crankshaft or con-rod bearing journals ................................ 0.03 mm Max. permissible imbalance of the crankshaft ................................................................... 1.0 Ncm max.

Diameter of gear wheel collar for the additional crankshaft inertia weight (engine type 420) ......................................................... 150.220 - 150.260 mm Inner diameter of ring gear for the additional crankshaft inertia weight (engine type 420) ......................................................... 150.000 - 150.040 mm Sva 7-98510 EN

Edition 05/00

2007-13

Flywheel Overlap of the starter ring gear on the flywheel ...................................................... 0.425 - 0.600 mm Before pressing the starter ring gear onto the flywheel, the ring gear must be heated up to a temperature of ............................................................ 150 - 200 °C Max. permissible imbalance at the flywheel .................................................................. 1.0 Ncm max.

Max. permissible warpage of the clutch surface measured at the inner edge of the clutch surface .................................................................................................. 0.06:ø200

crankshaft inertia weight (engine type 420) tooth flank play for the wheels: - crankshaft gear wheel and flywheel .............................................................................. 0.1 - 0.3 mm - between the flywheels ............................................................................................ 0.05 - 0.250 mm Axial play of the flywheels .............................................................................................. 0.1 - 0.5 mm Shaft diameter at the bearing points ................................................................... 36.000 - 36.016 mm Inner diameter of the flywheel bush (when fitted) ................................................ 36.050 - 36.075 mm Drilling diameter, rear wall of casing ................................................................... 36.058 - 36.083 mm Drilling diameter, front wall of casing .................................................................. 35.958 - 35.983 mm Thickness of a washer between casing and cylinder block ...................................................... 0.2 mm

Camshaft drive Tooth flank play: Intermediate gear wheel – crankshaft ......................................................................... 0.05 - 0.25 mm Intermediate gear wheel – camshaft ........................................................................... 0.05 - 0.25 mm Intermediate gear wheel – injection pump ................................................................... 0.05 - 0.25 mm Max. permissible lateral runout of the wheels ....................................................................... 0.05 mm Intermediate gear wheel SP NO 162000010708 (with friction bearing): - Inner diameter, intermediate gear wheel shaft bush (when fitted) ..................... 55.000 - 55.030 mm - Diameter of the intermediate gear wheel shaft .................................................. 54.951 - 54.970 mm Inner diameter, camshaft gear wheel .................................................................. 32.000 - 32.025 mm Diameter, end of camshaft shank ........................................................................ 32.043 - 32.059 mm Timing marks: The timing marks located on the gear wheels correspond to the TDC of the piston in the 1st cylinder, between the compression stroke and firing stroke.

On the crankshaft gear wheel ............................................................................... 2 dots on the teeth On the intermediate gear wheel: - opposite the crankshaft gear wheel ................................................................. "0" mark on the tooth - opposite the camshaft gear wheel ........................................................................ 1 dot on the tooth - opposite the injection pump gear wheel .............................................................. 1 dot at the recess On the camshaft gear wheel ................................................................................. 1 dot at the recess On the injection pump gear wheel ........................................................................... 1 dot on the tooth

Sva 7-98510 EN

Edition 05/00

2007-14

Con-rods Inner diameter, small end bearing bush (bush pressed into the con-rod) .......................................................................... 40.025 - 40.040 mm Outer diameter of the small end bearing bush ..................................................... 44.082 - 44.120 mm Bearing bush taper in the con-rod .......................................................................... 0.057 - 0.120 mm Bore hole, upper con-rod bearing ........................................................................ 44.000 - 44.025 mm Bore hole, lower con-rod bearing ........................................................................ 71.730 - 71.749 mm Thickness of the con-rod bearing shells: - Standard .............................................................................................................. 1.835 - 1.842 mm - 1st repair level 0.25 mm ....................................................................................... 1.960 - 1.967 mm - 2nd repair level 0.50 mm ..................................................................................... 2.085 - 2.092 mm - 3rd repair level 1.00 mm ...................................................................................... 2.335 - 2.342 mm - 4th repair level 1.50 mm ...................................................................................... 2.585 - 2.592 mm Con-rod bearing play ............................................................................................. 0.046 - 0.098 mm Con-rod bearing axial play ..................................................................................... 0.200 - 0.410 mm Perpendicular of the con-rod bore holes to the longitudinal axis of the con-rod .................... 0.15:100 Parallelism of the con-rod bearing bore holes ...................................................................... 0.05:100 The weight markings are punched in the bottom end of the con-rod.

Max. permissible weight difference between con-rods in the same engine .................................. 20 g

Pistons, piston rings and piston pins Smallest gap width between the piston and cylinder head measured through the injection nozzle orifice using lead wire ................................................. 0.900 - 1.150 mm Piston diameter: - 17 mm upwards from the base ...................................................................... 107.873 - 107.887 mm Piston pin bore hole in the piston ........................................................................ 40.003 - 40.009 mm Diameter, piston pin ............................................................................................ 39.991 - 40.000 mm Width of the piston ring grooves: - 1st groove (rectangular compression ring) ........................................................... 2.560 - 2.580 mm - 2nd groove ........................................................................................................... 2.520 - 2.540 mm - 3rd groove ........................................................................................................... 4.040 - 4.060 mm Vertical play of the piston rings in their grooves: - 1st groove (rectangular compression ring) ............................................................. 0.07 - 0.102 mm - 2nd groove ............................................................................................................. 0.03 - 0.062 mm - 3rd groove ............................................................................................................. 0.05 - 0.082 mm - Wear limit .......................................................................................................................... 0.15 mm Piston ring height (in direction of cylinder): - 1st groove (rectangular compression ring) ........................................................... 2.478 - 2.490 mm - 2nd groove ........................................................................................................... 2.478 - 2.490 mm - 3rd groove ........................................................................................................... 3.975 - 3.990 mm End play of piston rings (with piston fitted): - 1st groove (wedge-type compression ring) ............................................................... 0.40 - 0.55 mm - 1st groove (rectangular compression ring) ............................................................... 0.30 - 0.45 mm - 2nd groove ............................................................................................................... 0.60 - 0.80 mm - 3rd groove ............................................................................................................... 0.30 - 0.60 mm - Wear limit, rings I and III ...................................................................................................... 1.0 mm - Wear limit, ring II .................................................................................................................. 1.5 mm Max. permissible weight difference between pistons in the same engine ..................................... 25 g NOTE: When fitting the pistons, make sure the piston recess is on the same side as the injection nozzles.

Sva 7-98510 EN

Edition 05/00

2007-15

Lubrication system Oil pressure at normal operating temperature: - idling ........................................................................................................................ at least 1.0 bar - at operational speed ........................................................................................................ 2.5 - 4 bar Length of the spring in the oil pressure valve, relaxed ............................................................. 80 mm Force of the valve spring compressed to a length of ................................................................ 54+5 N Oil pressure valve piston diameter ...................................................................... 19.602 - 19.635 mm Oil pressure valve cylinder diameter ................................................................... 19.700 - 19.752 mm Lubrication oil filter – overflow valve opens at a differential pressure of .......................... 1.5 - 2.5 bar Oil pressure switch opens when ....................................................................................... p > 0.5 bar

Lubrication oil pump (320, 420) Tooth flank play when the crankshaft lies firmly against the under side of the bearing - between the crankshaft and oil pump drive gear wheels ........................................... 0.05 - 0.25 mm - between the oil pump gear wheels ........................................................................... 0.16 - 0.26 mm Diameter of the drive shaft in the housing and cover .......................................... 17.966 - 17.984 mm Diameter of the drive shaft bore hole in the housing and cover ........................... 18.000 - 18.018 mm Bore hole diameter of the gear wheel on the drive shaft ..................................... 18.060 - 18.078 mm Diameter of drive shaft ....................................................................................... 18.028 - 18.039 mm Depth of the drive shaft end below the housing surface .................................................. 0.5 - 1.0 mm Thickness of the housing seal .................................................................................... 0.06 - 0.08 mm Outer diameter of the gear wheels ...................................................................... 43.486 - 43.525 mm Housing diameter ............................................................................................... 43.650 - 43.750 mm Width of the gear wheels .................................................................................... 24.000 - 24.027 mm Axial play of the gear wheels ...................................................................................... 0.03 - 0.11 mm Housing depth .................................................................................................... 24.000 - 24.043 mm Number of teeth on the drive gear wheel (engine type 320) ........................................................... 51 Number of teeth on the drive gear wheel (engine type 420) ........................................................... 46

Lubrication oil pump (620) Tooth flank play when the crankshaft lies firmly against the under side of the bearing - between the crankshaft and oil pump gear wheels ................................................. 0.05 - 0.025 mm - between the oil pump gear wheels ........................................................................... 0.16 - 0.26 mm Diameter of the drive shaft in the housing and cover .......................................... 17.966 - 17.984 mm Diameter of the drive shaft bore hole in the housing and cover ........................... 18.000 - 18.018 mm Bore hole diameter of the gear wheel on the drive shaft ..................................... 18.000 - 18.018 mm Diameter of the drive shaft at the drive ............................................................... 17.966 - 17.984 mm Diameter of the drive shaft in the pump housing ................................................. 20.035 - 20.048 mm Depth of the drive shaft end below the housing surface .................................................. 0.5 - 1.0 mm Thickness of the housing seal .................................................................................... 0.06 - 0.08 mm Outer diameter of the gear wheels ...................................................................... 43.486 - 43.525 mm Housing diameter ............................................................................................... 43.650 - 43.750 mm Width of the gear wheels .................................................................................... 32.000 - 32.027 mm Axial play of the gear wheels ...................................................................................... 0.03 - 0.11 mm Housing depth .................................................................................................... 32.000 - 32.043 mm Number of teeth on the drive gear wheel ....................................................................................... 46

Thermostat Type .................................................................................................................................. ∅67/79 °C Starts opening at ................................................................................................................... 79 °C±2 Fully open at .............................................................................................................................. 94 °C Maximum opening ..................................................................................................................... 8 mm

Coolant temperature switch Coolant temperature transmitter Type of contact ............................................................................................................ Normally open Operating temperature ........................................................................................................ 106 °C±3 Sva 7-98510 EN

Edition 05/00

2007-16

Cooling water pump (320, 420) Bearing outer diameter ............................................................................................................ 52 mm Bearing housing diameter ................................................................................... 51.979 - 52.009 mm Shaft diameter at bearing .................................................................................... 20.002 - 20.015 mm Shaft diameter at impeller ................................................................................... 15.907 - 15.920 mm Diameter of impeller bore hole ............................................................................ 15.881 - 15.899 mm The impeller must be pressed onto the shaft so that the remaining clearance to the back of the housing is .......................................................................... 1.8 - 2.2 mm Diameter of fan hub ............................................................................................... 25.00 - 25.20 mm Permissible imbalance of the fan ..................................................................... 0.3 Ncm max (30 pcm) Permissible eccentricity of fan ............................................................................................. ± 0.3 mm V-belt tension, when pressed on between the two pulleys, amount of give ................................................................................................................. 15 - 20 mm

Cooling water pump (620) Bearing outer diameter ............................................................................................................ 52 mm Bearing housing diameter ................................................................................... 51.979 - 52.009 mm Shaft diameter at bearing .................................................................................... 19.980 - 19.993 mm Shaft diameter at impeller ................................................................................... 15.907 - 15.920 mm Diameter of impeller bore hole ............................................................................ 15.876 - 15.894 mm The impeller must be pressed onto the shaft so that there is the following clearance to the back of the housing ............................................. 0.8 - 1.2 mm Diameter of the fan hub ................................................................................... 0.3 Ncm max (30 pcm) V-belt tension, when pressed on between the two pulleys, amount of give ................................................................................................................. 15 - 20 mm

Turbo charger Schwitzer (320 ) Axial play of the shaft ................................................................................................... max. 0.14 mm Radial play of the shaft1 ............................................................................................... max. 0.61 mm Tightening torque for the turbine housing bolts ......................................................................... 22 Nm Tightening torque for the hexagon nut on the shaft ................................................................. 6.8 Nm

Schwitzer (420 ) Axial play of the shaft ................................................................................................... max. 0.14 mm Radial play of the shaft1 ............................................................................................... max. 0.51 mm Tightening torque for the turbine housing bolts ......................................................................... 22 Nm Tightening torque for the hexagon nut on the shaft ................................................................. 8.1 Nm

Schwitzer (620 ) Axial play of the shaft ................................................................................................... max. 0.14 mm Radial play of the shaft1 ............................................................................................... max. 0.95 mm Tightening torque for the turbine housing bolts ......................................................................... 17 Nm Tightening torque for the hexagon nut on the shaft ............................................................... 15.6 Nm 1

) Measured at the turbine shaft nut.

Sva 7-98510 EN

Edition 05/00

2007-17

Tightening torques Cylinder head nuts and bolts .................... 80 Nm+90°+90° (+60° after 15 - 20 min. warming up time) Cylinder head bolts in the cylinder block .................................................................................. 30 Nm Crankshaft bearing bolts ........................................................................................................ 200 Nm Con-rod nuts .................................................................................................................. 40 Nm + 90° Nut on the crankshaft (face): - 320/420 ............................................................................................................................... 600 Nm - 620 .................................................................................................................................... 1000 Nm Counterweight of the crankshaft (320) ................................................................................... 160 Nm Belt pulley bolts ....................................................................................................................... 30 Nm Securing bolts for flywheel ..................................................................................................... 140 Nm Securing bolts for flywheel casing: - internal M12 bolts ................................................................................................................ 110 Nm - external M10 bolts ................................................................................................................. 60 Nm Retaining screws for intermediate gear wheel (with friction bearing): - M10 ....................................................................................................................................... 60 Nm - M14 ..................................................................................................................................... 200 Nm Bolts for balancing unit (420) ................................................................................................... 60 Nm Piston cooling nozzles (620.93) ............................................................................................... 30 Nm Nut for lubrication oil pump gear wheel .................................................................................... 60 Nm Retaining screws for lubrication oil pump ................................................................................. 60 Nm Connecting pipe for lubrication oil cooler ................................................................................. 60 Nm Nut for belt pulley on coolant pump ....................................................................................... 120 Nm Fan bolts ................................................................................................................................. 30 Nm Nuts/bolts for exhaust manifold ............................................................................................... 50 Nm Bolts for air intake duct ............................................................................................................ 30 Nm Nut for injection pump gear wheel ........................................................................................... 90 Nm Retaining nuts for injection nozzles (for bolts) ......................................................................... 15 Nm Injection nozzle union nut ........................................................................................................ 60 Nm Injection line union nut ............................................................................................................. 25 Nm

NOTE: Use washers for aluminium parts.

If no particular tightening torques are specified, always use the values specified in the table below.

M8

M10

±5

Cast iron

35

Nm

70±5 Nm

Aluminium

25±5 Nm

50±5 Nm

Bolts for the self-supporting oil sump 1

M8

25 Nm

2

M10

90 Nm

3

M14

160 Nm

4

M20

600 Nm

3 4 1

Sva 7-98510 EN

2 SS99N015

Edition 05/00

2007-18

CONSTRUCTION General information The 20 series Steyr-Sisu diesel engines are watercooled, four stroke, in-line engines (with 3, 4 or 6 cylinders) with direct injection. All models are equipped with an exhaust gas turbocharger.

Cylinder block The rib-reinforced cylinder block forms the main engine unit, onto which other engine components are mounted.

The wet, replaceable cylinder liners are supported in the middle, thus reducing vibration and the coolant flow is mainly directed to the upper section of the cylinder liners.

The bottom part of the cylinder liner and the cylinder block are sealed by three O-rings, which are inserted in the grooves in the cylinder liner.

The upper part is sealed by the cylinder head gasket.

The camshaft is located in the cylinder block. The front camshaft bearing seat is fitted with a separate bearing bush. The remaining bearing seats are incorporated into the cylinder block. The exception is the engine type 620 which is fitted with separate bearing bushes in all camshaft bearing seats. The bore hole for the rear end of the camshaft is sealed by means of a plug.

Guide bearings are fitted on both sides of the rear crankshaft bearings (crankshaft – axial bearings).

SS99N016

Flywheel casing The flywheel casing is fitted at the rear end of the cylinder block. The seal for the rear end of the crankshaft is fitted in a bore hole in the casing. The flange for the starter is located in the flywheel casing.

The underside of the flywheel casing is used as a sealing surface for the oil sump seal. This means that the underside of the cylinder block must be flush with the flywheel casing. When the flywheel casing is fitted, its position is determined by sprung dowel pins.

Sva 7-98510 EN

Edition 05/00

2007-19

Crankshaft drive The crankshaft is made from forged chrome alloy special steel and the bearing and sealing surfaces are induction tempered. The bearings can thus be ground four times without further heat treatment being necessary. The gear wheels are located at the front end of the crankshaft. They are force fit and drive the intermediate gear wheel and the oil pump. In addition, the front end of the crankshaft has key-ways for the V-belt pulley hub. An oil scraper ring is used between the hub and gear wheel and a dust seal is fitted on the hub to protect the seal.

The crankshaft is supported in the cylinder block by crankshaft bearings on both sides of each cylinder. Thus, there is one crankshaft bearing more than there are cylinders. The crankshaft axial bearings are located in both sides of the rearmost crankshaft bearing. A flywheel is mounted at the rear end of the crankshaft and carries a strong, force fit crown gear.

SS99N017

Cylinder head Engine types 320 and 420 are equipped with one cylinder head. Engine type 620 is equipped with two cylinder heads which are interchangeable with each other and also with the type 320 cylinder head. Each cylinder has its own intake and outlet ducts in the cylinder head. To compensate for thermal stress, a cold inlet valve is fitted between the hot outlet valves The cylinder head bolts are high-tensile pretensioned bolts, which are tightened to their elongation limit in accordance with the angular tightening principle. Due to the high degree of elongation, the retaining power is kept constant throughout the entire service life, and the bolts do not therefore have to be check tightened.

The injection nozzle seats are integrated into the cylinder head. The inlet and outlet valve guides are identical and can be interchanged. Furthermore, the outlet valves are fitted with replaceable valve seat inserts.

Valve mechanism The valve mechanism is operated by the camshaft in the cylinder block. The drive power is transferred via valve tappets and push rods. The camshaft gear wheel is force fitted and is secured by a feather key. Every bearing is lubricated by the pressure lubrication system via the drilled oil channels.

Sva 7-98510 EN

The forged con-rod has an I-shaped cross-section.

The lower con-rod bearing is split horizontally. The bearing cover is secured by means of two special bolts and nuts. The upper part has a wedgeshaped bearing seat in which the small end bearing bush is force fitted.

The piston is made of an eutectic aluminium alloy.

There is a combustion chamber in the piston head.

The shape of the combustion chamber optimises the carburetion of air and fuel.

The piston is equipped with three rings. The upper, molybdenum-coated piston ring has a rectangular cross-section. Types 420.85 and 620.93 have an upper piston ring with a trapezoidal cross-section.

The middle ring is wedge-shaped and is fitted in its groove. The wedge shape takes up the play.

The oil scraper ring is sprung and has a two-stage, chrome-plated scraping edge.

The pistons are ring carrier pistons (the top piston ring has a cast iron ring carrier, which is cast into the piston). In addition, the piston is graphitecoated to ensure trouble-free running in.

Four-cylinder engines (type 420) are equipped with a balancing unit. The eccentric weights, which rotate at double the engine speed, compensate for the up and down mass forces exerted by the pistons and crankshaft drive.

Edition 05/00

2007-20

SS99N018

Timing gears The timing gears are tempered, helical gear wheels.

The gear wheels are located in the timing gear case, which is fitted at the front of the engine.

The timing gears drive the camshaft, the fuel injection pump and the oil pump.

The hydraulic pump is driven by the timing gears or by a separate drive unit on the gearbox.

The intermediate gear wheel is borne on a friction bearing.

The bearing journal is fixed to the front surface of the cylinder block.

Sva 7-98510 EN

Edition 05/00

2007-21

4

3 7 6

2 5 Lubrication system (engine type 620)

1 SS99N019

1. Lubrication oil pump 2. Oil pressure valve 3. Oil filter 4. Turbocharger 5. Main oil line 6. Piston cooling nozzles 7. Oil pressure switch

Lubrication system The engine is equipped with a pressure lubrication system, in which the oil pump (gear pump) is fixed to the lower part of the cylinder block. The pump sucks the oil in via an intake basket. After the pump, the oil is fed through an oil line to the oil pressure valve and oil filter. The oil is then fed through the main oil line, from which other oil lines branch off.

The oil flows through the oil lines to the crankshaft bearings and through the crankshaft to the con-rod bearings.

The main oil line then feeds the oil to the turbo charger, to the balancing unit (420) and to a pneumatic compressor, if fitted. In addition, the intermediate gear wheel bush, the camshaft bearing points and the valve mechanism are lubricated via the main oil line.

The oil pressure valve is located below the oil filter on the left-hand side of the engine. The valve regulates the lubrication oil pressure so that a constant value is maintained independent of the engine speed. Depending upon the grade of oil, the engine speed and temperature, the oil pressure is aprox. 2.5 - 4 bar.

The oil pressure is at least 1.0 bar at idling speed.

The oil filter is a one-way main stream filter, which is fitted on the left-hand side of the engine. An overflow valve, on the underside of the filter, ensures reliable cold starting and sufficient lubrication in the event of a filter blockage. In addition, there is a non-return valve which prevents the filter being completely drained of oil.

The oil pressure switch opens at a pressure of 0.5 bar.

In the 620,93 engine, the piston heads are sprayed with oil from below and cooled as long as the lubrication oil pressure is higher than 3 bar.

Sva 7-98510 EN

Edition 05/00

2007-22

5

2 7 6 3

1 4 SS99N020

Cooling system 1. Coolant pump 2. Thermostat 3. Bypass channel 4. Radiator

5. Expansion chamber 6. Oil cooler 7. Engine temperature transmitter

Cooling system The belt-driven rotary coolant pump is located at the front end of the cylinder block.

The thermostat housing is situated above the pump.

The system operates with internal coolant circulation through the bypass channel, the circulation being regulated by means of a two-way thermostat.

This function ensures an even temperature-rise under all conditions.

Sva 7-98510 EN

Edition 05/00

2007-23

SS99N022

Intake / exhaust system The filter system for the engine intake air comprises a pre-cyclone filter (integrated into the air filter) and a dry air filter with safety cartridge. The intake air is rotated in the pre-cyclone filter. This removes most of the dirt particles, which are then discharged via the pre-cyclone filter’s dust discharge valve.

The dirt particles in the air are collected in the main cartridge, which can be cleaned as required. The internal safety cartridge stops dirt particles getting into the engine in the event of the main cartridge breaking or being fitted incorrectly.

exhaust turbocharger and between the turbocharger and the inlet manifold.

The exhaust manifold is fixed to the cylinder head by means of anti-fatigue bolts, without a separate seal The manifold bolts do not need to be check tightened.

The turbocharger is small and thus also reacts quickly at low engine speeds. The turbocharger is lubricated and cooled by oil from the engine lubrication system.

An electronic differential pressure transmitter is located in the filter housing. This transmitter causes an indicator lamp to light up on the instrument panel if the air filter is blocked. The intake system also comprises the lines between the air filter and the

Sva 7-98510 EN

Edition 05/00

2007-24

JOB INSTRUCTIONS 1. CYLINDER BLOCK A. Measuring the cylinder liner wear 1. Set the dial test indicator to zero by means of a micrometer screw or using a new cylinder liner (initial dimension 108.00 mm).

1TSW 510

2. Thoroughly clean the inner surface of the cylinder liner before the measurement.

1TSW 508 SS99N037

C. Checking the cylinder block 1. Clean the cylinder block and all oil lines.

2. Check the cooling channels and remove scale and dirt deposits in order to ensure correct engine cooling.

3. Check the tightness of the shell plugs and screw plugs in the cylinder block and make sure the cylinder block and sealing surfaces are in good condition.

SS99N036

3. Measure cross-wise at the top end, bottom end and in the middle of the cylinder liner.

4. Measure the wear on the camshaft bearing points (compare with nominal values).

4. Check the displayed value for max. wear and ovality (compare with nominal values).

NOTE: If the surface of the cylinder block has to be re-ground, the pistons must be shortened by a corresponding amount. Pay attention to the valve head clearances at the top surface of the piston.

B. Removing the cylinder liner

D. Replacing the camshaft bush

1. If the cylinder liners are to be re-used, they must be marked so they can be re-fitted in the same positions.

1. Pull the bush out using an internal extractor.

After removing the rear camshaft end support piece, the bush can be driven out using a long drift.

2. Remove the cylinder liners using the 1TSW 508 and 1TSW 510 extraction tools.

2. Clean the bush seating.

0.1 - 0.4 mm

SS99N038

Sva 7-98510 EN

Edition 05/00

2007-25 3. Press fit a new bush. Pay attention to the position of the oil bore hole. The bush does not have to be reamed as it has the correct inner diameter if it is fitted in the correct place.

NOTE: For the engine type 620 all camshaft bearing points are fitted with a separate bearing bush.

Pay attention to the different outer diameters when removing and fitting the bushes.

4

5

3

2

1

SS99N039

The numbering starts at the front end of the engine.

Spare part number

Bore hole diameter

1.

162000010716

55.62 - 55.65

2.

162000010718

55.42 - 55.45

3.

162000010719

55.22 - 55.25

4.

162000010718

55.42 - 55.45

5.

162000010720

55.64 - 55.67

E. Oversize bushes for the camshaft If the seat of the camshaft bush (front bearing) is damaged, a bush with an oversize outer diameter of 0.4 mm can be fitted. Bushes are also available for the other camshaft bearings which are not normally fitted with bushes. The spare part numbers and machining dimensions for the bush seatings are shown in the figure.

WARNING: Observe the position of the bush oil bore holes.

The bushes do not have to be reamed after being fitted.

134 mm

140 mm 6 -7 mm

4

3

2

1

Oversized bearing bushes for engine type 320 Spare part Bore hole diameter number 1.

162000010776

56.02 - 56.05

2.

162000010718

55.42 - 55.45

3.

162000010718

55.42 - 55.45

4.

162000010720

55.64 - 55.67

SS99N040

The numbering starts at the front end of the engine.

Sva 7-98510 EN

Edition 05/00

2007-26 134 mm

272 mm 6 - 7 mm

4

3

2

1

SS99N040

Oversized camshaft bearing bushes for engine type 420 Spare part number Bore hole diameter 1.

162000010776

56.02 - 56.05

2.

162000010718

55.42 - 55.45

3.

162000010718

55.42 - 55.45

4.

162000010720

55.64 - 55.67

The numbering starts at the front end of the engine.

266 mm 272 mm

134 mm

6 - 7 mm

5

4

3

2

1 SS99N042

Oversized camshaft bearing bushes for engine type 620 Spare part number Bore hole diameter 1.

162000010776

56.02 - 56.05

2.

162000010777

55.62 - 55.65

3.

162000010718

55.42 - 55.45

4.

162000010777

55.62 - 55.65

5.

162000010779

55.84 - 55.87

The numbering starts at the front end of the engine.

Sva 7-98510 EN

Edition 05/00

2007-27

F. Fitting the plug at the rear camshaft end

3. Drive the guide tube into the cylinder block to the dimension shown in the figure.

116 mm = 320 , 420 111 mm = 620

SS99N044

1. Clean the plug seating.

SS99N045

2. Apply sealant (e.g. Loctite 572) to the contact surface of the plug.

3. Force fit the plug using the pressing tool (1TSW 522).

NOTE: Do not drive the plug in too far, as it could impair the axial play of the camshaft.

G. Fitting the plug at the rear camshaft end after inserting an oversize bush O - Ring

NOTE: The position of the tube influences the measured engine oil level.

I. Fitting the cylinder liner 1. Clean the cylinder liner and liner recess in the cylinder block. Without the O-ring, it must be easy to turn the liner to its installation position.

2. Apply a thin coat of marking paint to the underside of the cylinder liner flange. Fit the cylinder liner without O-rings and turn it back and forth. Remove the cylinder liner and check whether there is paint over the entire contact surface.

3. Clean the contact surfaces.

Cover plate 0.03 - 0.08 mm

Plug SS99N043

Upon completion, the rear camshaft end plug is replaced by the plug (spare part number 162000010797) and the O-ring (spare part number 162000010798). In engines where the flywheel casing does not cover the stopper plug, the cover plate (spare part number 162000010799) must be fitted.

H. Installing the oil dipstick tube 1. Clean the tube seating.

SS99N048

4. Fit the cylinder liners and secure each liner using two clamps. Measure the cylinder liner height using a dial test indicator and the holder (1TSW 5610). Set the dial test indicator to zero on a flat surface, e.g. the cylinder block. Measure each cylinder liner at four points. The cylinder liner should protrude from the top of the cylinder block by 0.03 - 0.08 mm.

2. Apply locking fluid (e.g. Loctite 601) to the bottom end of the tube.

Sva 7-98510 EN

Edition 05/00

2007-28 The difference in height between the cylinder liners within one cylinder head must not exceed 0.02 mm. In addition, a middle cylinder liner must not be lower than one of the outer ones.

5. If the cylinder liner height is insufficient, a liner with a higher flange must be fitted.

BLACK GREEN

H

SS99N050

SS99N049

Spare part number

Height (H)

Marking grooves (quantity)

162000040704

9.03+0,02

(standard)

162000040713

9.08+0,02

1

162000040714

9.13+0,02

2

162000040715

9.23+0,02

3

7. Insert the O-rings in the grooves in the lower cylinder section and lubricate them with liquid soap (not with oil).

NOTE: Stretch the O-rings as little as possible when pulling them onto the cylinder liners.

The max. permissible elongation is 6 %.

An oversize of the cylinder liner (higher flange) is marked as follows on the outer circumference by means of one or more marking grooves: 1. oversize, 0.05 mm = 1 marking groove 2. oversize, 0.10 mm = 2 marking grooves 3. oversize, 0.20 mm = 3 marking grooves 6. If the height of a cylinder liner is not the same over the entire circumference, the cylinder liner flange and recess depth must be checked.

Cylinder liners with warped flanges must be replaced. If necessary, ream the liner seating in the cylinder block.

SS99N051

8. Press the cylinder liners into the cylinder block.

It should be easy to press them into their initial position. Make sure the cylinder liners do not move upwards once they have been fitted.

Sva 7-98510 EN

Edition 05/00

2007-29

2. FLYWHEEL CASING Spacer ring

A. Fitting the flywheel casing The flywheel casing is centred on the cylinder block by means of two sprung dowel pins. The flywheel casings, which are also available as a spare part, are supplied with the bore holes for the pins.

1. Clean the sealing surfaces between the cylinder block and flywheel housing.

SS99N054

NOTE: If the crankshaft is worn at the sealing ring seat, a 2 mm spacer ring (spare part number 162000020718 can be fitted behind the crankshaft sealing ring.

5. Carefully press the sealing ring in down to the bottom of the flywheel casing using the 1TSW 521 and 1TSW 662 fitting tools.

1TSW 662 SS99N052

2. Apply sealant (e.g. silicone) to the points shown in the figure.

3. Lift the flywheel casing to the correct position and insert all the bolts.

4. Centre the casing and fit the sprung dowel pins using a mandrel.

5. Tighten the inner ring bolts to a torque of 60 Nm and the outer ring bolts to a torque of 110 Nm.

1TSW 521

SS99N056

NOTE: THE ASSEMBLY PROCEDURE MUST BE CARRIED OUT IN A DRY AND OIL-FREE STATE.

B. Replacing the rear crankshaft sealing ring 1. Separate the tractor between the engine and power unit.

2. Remove the flywheel.

3. Remove the sealing ring without damaging the crankshaft.

4. Clean the sealing ring seat and grind any burr.

Sva 7-98510 EN

Edition 05/00

2007-30

3. CYLINDER HEAD A. Removing the cylinder head 1. Clean the outside of the engine.

Drain plug SS99N057

1. Screw a nut on a grub screw for the rocker arm mechanism. For 3 and 6 cylinder engines no grub screw is provided on the valves for the middle cylinders. A screw of an appropriate length should be used instead.

SS99B056

Drain the coolant at the engine drain plug and the drain cock on the underside of the radiator.

Disconnect the coolant hoses from the cylinder head and the thermostat housing.

2. Remove the intake lines between the exhaust turbo charger and the air filter and between the exhaust turbo charger and the intake manifold.

3. Remove the oil lines from the exhaust turbo charger.

2. Compress the valve springs by means of the 1TSW 014 lever. Remove the valve spring seat retainers, the spring guide and the spring. Remove the valves.

C. Checking the cylinder head 1. Remove carbon deposits from the outlet channels, clean the sealing surfaces and wash the cylinder head.

2. Check the cylinder head for cracks and any other damage.

4. Remove the fuel hose running to the thermostart tank.

5. Remove the injection lines and leakage oil lines.

Remove the injection nozzles. Fit all open connections with sealing caps.

6. Remove the intake and exhaust manifolds as well as the thermostat housing.

NOTE: It is also possible to remove the cylinder head even when these parts are still fitted.

7. Remove the valve cover and bleed hose.

8. Remove the rocker arm mechanism and the push rods.

9. Loosen all cylinder head bolts by a ¼ of a revolution and then unscrew them. Remove the cylinder head.

B. Removing the valves

SS99N058

3. Check the evenness of the cylinder head using a straight edge. An uneven or bent surface must undergo surface grinding. After being ground, the height of the cylinder head may not be less than 104.00 mm. The valve disk depth from the surface of the cylinder head must be 0.60 mm for outlet valves and 0.70 mm for inlet valves.

Make sure that those valves which are to be reused are marked accordingly, so that they can be re-inserted in their original seating.

Sva 7-98510 EN

Edition 05/00

2007-31

D. Replacing the valve guides

SS99N059

4. If necessary, clean the injection nozzle support in the cylinder head using a reamer.

SS99N061

1. Press or drive the old guides out using a mandrel. Clean the valve guide seats.

2. Fit the new guides using the 1TSW 524 pressing-in tool, thus ensuring the correct installation height (21 mm above the end face of the spring).

1TSW 524

SS99N060

5. Measure the clearance between the valve stem and guide by means of a dial test indicator. Lift the valve so that the valve disk juts out of the surface of the cylinder head by 15 mm and measure the clearance. In the case of inlet valves, it may not exceed 0.30 mm and 0.35 mm for outlet valves. To determine whether the valve guide is worn, a new valve must be used for the measurement.

21 mm

SS99N062

3. The same guides are used for inlet and outlet valves. Make sure the steepest chamfer on the guide points towards the valve spring. Also make sure the valves do not stick in the guides.

Sva 7-98510 EN

Edition 05/00

2007-32

E. Machining the valve seat

B A

SS99N065

A

SS99N063

A damaged valve seat must be machined using a milling cutter. If the width of the seat exceeds 2.3 mm in the case of an outlet valve and 3.7 mm in the case of an inlet valve, then it has to be reduced at the outer edge, in particular.

B

INLET VALVE

35°

-20’

35°+20’

OUTLET VALVE

45°-20’

45°+20’

1. Grind the damaged valve disk using a valve grinding tool. Adjust the angle to 45°-20’ for outlet valves and 35°-20’ for inlet valves.

The valve seat angle is 45°+20’ for outlet valves and 35°+20’ for inlet valves.

2. If the edge of the valve disk is less than 1.5 mm after grinding or the valve stem is bent, the valve must be replaced.

F. Replacing the valve seat rings

3. Grind in the valves using grinding paste and check the contact surface with marking dye.

The outlet valves are equipped with separate valve seat rings. If the sealing surface is so badly damaged that it cannot be repaired, then the valve seat rings have to be replaced.

1. Grind the valve disk on a disused valve so that it fits snugly in the valve seat. Fit the valve and weld it to the seat correctly. Cool it with water.

2. Turn the cylinder head round and drive the valve out together with the seat.

3. Clean the valve seat. Cool the new valve seat ring in dry ice or liquid nitrogen.

4. Fit the valve seat ring using a suitable pressing tool. Re-work the seat.

G. Grinding the valves In order to ensure that a sufficient sealing effect is attained around the valves, there are different sealing surface angles. Thus, there is a particularly narrow sealing surface, which ensures an effective sealing effect even after prolonged operation.

Sva 7-98510 EN

4. Clean the grinding paste off the cylinder head and valves.

H. Fitting the valves 1. Use a spring tester to check the straightness, length and tension of the valve springs. Compare these values with the technical data.

2. Lubricate the valve stems and insert the valves in the cylinder in the correct order.

3. Fit the valve springs, valve disks and valve spring seat retainers in the cylinder head with the aid of the 1TSW 014 lever.

4. After inserting the valves, tap the ends of the valve stems, e.g. with a plastic hammer, to make sure the valve spring seat retainers are sitting correctly.

Edition 05/00

2007-33

I. Fitting the cylinder head 1. Measure the length of the cylinder head bolts.

The length should lie within the limit values specified in the figure. If this is not the case, the bolt must be replaced.

420

max. 142 mm

max. 188.5 mm

SS99N068

SS99N066

2. Screw the cylinder head grub screws into the cylinder head and a tighten them to a torque of 30 Nm. Insert the push rods, if they have been removed.

3. Make sure the sealing surfaces are clean and fit the cylinder head gasket. For engine type 620 use a straightedge to make sure the cylinder heads are parallel to each other. Clean, oil and insert the bolts.

320, 620

4. The figures show the bolt tightening sequence.

The correct sequence is also cast into the cylinder heads.

5. Tighten the bolts in phases as follows: 1. Pre-tension of 80 Nm 2. Tighten by 90° 3. Tighten by 90° 4. Adjust the valve clearance (see page 35).

5. Fit the other engine parts, add coolant and engine oil. Let the engine run at low load for approx. 15 - 20 minutes.

6. Tighten by 60°.

7. Adjust the valve clearance NOTE: The cylinder head does not have to be tightened again after this procedure.

SS99N067

Tighten the exhaust manifold securing bolts/nuts to a torque of 50 Nm.

50 Nm

Sva 7-98510 EN

SS99N069

Edition 05/00

2007-34

4. VALVE MECHANISM

B. Replacing the camshaft / camshaft gear wheel

A. Maintenance of the rocker arm system 1. Check the valve tappets, particularly the guide surface on the camshaft. Replace worn and bent valve tappets.

1. Remove the suction pipe between the turbo charger and the intake manifold. Remove the cover for the valve mechanism and the bleed pipe.

Remove the rocker arm mechanism.

2. Remove the radiator, the fan, the alternator and the V-belts.

3. Loosen the crankshaft nut. Remove the V-belt pulley complete with hub (for engine type 620 loosen the belt pulley first).

4. Remove the gearwheel case cover.

SS99N070

2. Check the straightness of the push rod. Also check the condition of the spherical faces at the ends of the push rod.

3. Dismantle the rocker arm mechanism and clean the components. Check the rocker arm shaft for wear and the condition of the oil lines.

4. If the pressure surface of the rocker arm is worn, grind it until it has the right shape. Do not grind off more than necessary as the pressure surface is hardened.

SS99N075

5. Lock the valve tappets so that they do not fall down on removing the camshaft and impair the installation of the camshaft. Raise two adjacent valve push rods by tilting them towards each other.

Clamp adjacent push rods together to form a pair (e.g. using an O-ring) so they remain in the top position.

WARNING: Excessive tensioning of the push rods causes deformation.

SS99N072

6. Turn the crankshaft, so the positioning marks on the camshaft gear wheel and intermediate gear wheel coincide. Pull the camshaft out.

7. Loosen the camshaft gear wheel using a suitable mandrel.

60°

8. If the used camshaft or camshaft gear wheel is going to be re-fitted, clean them before assembly.

9. Push the feather key into the corresponding groove in the camshaft. Heat the camshaft gear wheel up to 200 °C and fit it in the corresponding position.

SS99N073

5. Fix a flange seal on one end of the rocker arm shaft. Lubricate the shaft and assemble the parts in the correct order. Make sure the shaft and the bearing retainers are in the right position. The split side of the retainers and the oil bore holes in the shaft must be on the valve side, as shown in the figure. Fix the other flange seal

Sva 7-98510 EN

10. Grease the bearing surfaces and press the shaft into the cylinder block, paying attention to the position marks on the camshaft gear wheel.

11. Fit the timing gear case cover and the belt pulley complete with hub.

Edition 05/00

2007-35 12. Release the push rods and fit the rocker arm mechanism. Adjust the valves. Then screw the valve cover and air bleed hose onto the cylinder head. Also fit the suction pipe between the turbo charger and intake manifold.

13. Fit the alternator and V-belts. Tension the V-belts accordingly. Fit the radiator.

C. Checking and adjusting the valve clearance

0.35

Engine type 320 Check the valve play in the injection sequence.

Injection sequence:

123

- check the valves in cylinder 1 when the cylinder 3 outlet valve is fully open (6th valve from the front of the engine).

- check the cylinder 2 valves when the cylinder 1 outlet valve (2nd valve) is fully open.

- check the cylinder 3 valves when the cylinder 2 outlet valve (4th valve) is fully open.

Engine type 420 - turn the crankshaft in the direction of rotation until the valves of cylinder 4 overlap. (Outlet valve closes, inlet valve opens). Check the valves of the first cylinder.

SS99N077

The inlet and outlet valves have a clearance of 0.35 mm. It can be checked when the engine is hot or cold. Check and adjust the valve clearances of a cylinder whilst the piston is at top dead centre of the compression stroke. Proceed according to the injection sequence of the engine.

If the valve clearance deviates from the specified value, loosen the locking nut and adjust it to the correct value via the adjusting screw. A 0.35 mm feeler gauge must fit tightly between the rocker arm and the end of the valve stem.

I = INLET I

O

I

O

I

O

O = OUTLET

O

420

Sva 7-98510 EN

- continue work in the sequence of injection: Injection sequence:

1 2 4 3

Change-over of the valves in the cylinders:

4 3 1 2

Engine type 620 - turn the crankshaft in the direction of rotation until the valves of cylinder 6 overlap. (Outlet valve closes, inlet valve opens). Check the valves of the first cylinder.

- turn the crankshaft 1/3 of a revolution in the direction of rotation so that the valves of the 2nd cylinder overlap. Check the valves of the 5th cylinder.

- continue work in the sequence of injection:

320, 620

I

- turn the crankshaft 1/2 of a revolution in the direction of rotation so that the valves of cylinder 3 change over. Check the valves of cylinder 2.

I

O

I

O

I

O

Injection sequence:

1 5 3 6 2 4

Valve overlap:

6 2 4 1 5 3

SS99N077

Edition 05/00

2007-36

5. CRANKSHAFT A. Removing the crankshaft 1. Unscrew the sump.

2. Separate the balancing unit lubrication oil line from the cylinder block and remove the balancing unit fixing bolts. Remove the balancing unit and the lubrication oil line (only for engine type 420).

3. Unscrew the securing bolts for the lubrication oil pump pressure line in the cylinder block. Remove the oil pump and the intake/pressure lines.

4. Remove the flywheel casing.

5. Remove the belt pulley/hub from the front end of the crankshaft (also refer to the instructions concerning the timing gears page 46).

6. Remove the con-rod bearing covers and push the con-rods up so they are not in the way when removing the crankshaft.

7. Remove the crankshaft bearing covers and lift the crankshaft out.

B. Checking the crankshaft

SS99N079

4. If the bearing play exceeds 0.18 mm for the crankshaft bearings or 0.14 mm for con-rod bearings with new bearing shells, the bearing journals on the crankshaft must be ground. For the correct undersize and corresponding bearings, refer to the technical data. Make sure the radii do not change during the grinding process.

NOTE: In the event of the crankshaft bearing base bore holes being damaged or worn as a result of bearing damage, crankshaft bearings are also available as a spare part with an oversize of 1.0 mm (outside dimension) and an undersize of 0.5 mm (inside dimension). The cylinder block must now 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 groove and a hole is fitted in the cylinder block and the bearing shell without an oil bore hole in the bearing cap.

C. Replacing the crankshaft gear wheels 1TSW 662

SS99N078

1. Clean the crankshaft. Do not forget to clean the oil bore holes.

2. Measure the wear on the crankshaft bearing journals at different points. Ovality, conicity or other wear must not exceed 0.03 mm.

3. Insert the bearing caps with new bearing shells and tighten them to the correct torque. Measure the inner diameter with a dial test indicator, which has been reset to zero according to the dimensions measured under item 2. The indicator thus displays the actual bearing play. If the bearing housing which shows signs of wear is not round, take measurements at several points.

Sva 7-98510 EN

SS99N080

1. Attach an extractor to the crankshaft gear wheels and pull off both gear wheels.

2. Clean the seat on the crankshaft using a wire brush, for example.

3. Heat up the new gear wheels to 200 °C. Drive the gear wheels onto the shaft using a suitable sleeve or soft mandrel. Pay attention to the position of the feather key and make sure the alignment marks on the front gear wheel are visible. Allow the parts to cool down.

Edition 05/00

2007-37

D. Replacement of the crankshaft ring gear (engine type 420 only)

20°

Make sure the bearing shell noses engage in the corresponding notches and that the shells to be fitted in the cylinder block have an oil bore hole which aligns with the oil bore hole in the cylinder block.

3. Lubricate the bearing surfaces and fit the crankshaft. Insert the axial bearings for the crankshaft so that the lubrication grooves point towards the crankshaft.

7

SS99N081

6

7

7

1. Mark the position of the ring gear on the shaft.

2. Heat the ring gear using a welding torch and loosen it using a suitable mandrel.

3. Heat up the new gear wheels to 250 °C. Fit the ring gear such that the contact surface faces the crankshaft flange and the gears are aligned with the marking or in accordance with the above figure. Hammer the ring gear downward and allow it to cool down.

NOTE: The above figure shows the back view of the crankshaft and the con-rod foot bearing for cylinder 2.

6

7

200 Nm

SS99N083

4. Insert the crankshaft bearing covers according to their numbering, with axial bearings at the rear, which have got joggles. Lubricate the bolts and tighten them to a torque of 200 Nm.

E. Fitting the crankshaft 1. Clean the oil lines, bearing shells and seats.

Make sure the crankshaft is clean.

0.10 - 0.35 mm

B A SS99N084

5. Make sure the crankshaft turns freely and without sticking. Check the axial play using a dial test indicator. The correct axial play is approx. 0.10 0.35 mm. If there is excessive axial play, oversized axial bearings must be fitted.

SS99N082

2. Fit a bearing shell (A) with an oil bore hole and oil groove in the cylinder block and a bearing shell (B) without an oil bore hole in the bearing cover.

Sva 7-98510 EN

NOTE: The bearing shells must never be reamed or machined and the sides of the bearing covers must not be filed.

WARNING: For engine type 320 the bolt tightening torque for the crankshaft counterweight is 160 Nm. Apply a locking fluid (e.g. Loctite 271) to the bolt threads.

Edition 05/00

2007-38

F. Crankshaft hub

3. Fix a new vibration damper or belt pulley onto the crankshaft. Drive the dowel pins in and tighten the securing bolts to a torque of 30 Nm. NOTE: Vibration dampers (belt pulleys) supplied as a spare part do not have an injection marking. New vibration dampers must be marked after being fitted.

SS99N085

When fitting the hub at the front end of the crankshaft, make sure it is in the correct position. (engines with injection marking on the vibration damper.) The hub has an installation marking: -- both lines on the hub must lie adjacent to the dot marking • on a crankshaft tooth.

G. Replacing the crankshaft belt pulley and vibration damper

4. Turn the crankshaft until the piston of the first cylinder is at top dead centre (TDC). Let the valve fall against the cylinder head. Mount the dial test indicator at the top of the valve stem and set it to zero when the piston is at top dead centre. Then turn the crankshaft against the direction of rotation until the dial test indicator reads approx. 15 mm below TDC. Then slowly turn the crankshaft in the direction of rotation until the dial test indicator shows the value which corresponds to the injection marking (see table below).

NOTE: Refer to setting data on page 9 5. Inscribe the injection marking by means of an electric engraving pen (do not punch it in).

Piston stroke to top dead centre in comparison to crankshaft angle

320, 420, 620

SS99N086

NOTE: In the case of a second hydraulic circuit the markings on the belt pulley and on the casing are located lower down for reasons of space.

Degrees

mm

Degrees

mm

1°

0.012

16°

2.983

2°

0.047

17°

3.363

3°

0.106

18°

3.765

4°

0.188

19°

4.188

5°

0.294

20°

4.633

6°

0.423

21°

5.100

7°

0.576

22°

5.587

8°

0.752

23°

6.095

9°

0.951

24°

6.624

10°

1.173

25°

7.173

11°

1.418

26°

7.742

12°

1.686

27°

8.331

13°

1.976

28°

8.939

14°

2.289

29°

9.567

15°

2.625

30°

10.213

1. Loosen the alternator securing bolts and remove the V-belt.

2. Unscrew the bolts holding the belt pulley and vibration damper and remove the parts. The belt pulley and vibration damper are pinned together with the crankshaft hub (injection mark on the vibration damper).

Sva 7-98510 EN

Edition 05/00

2007-39

H. Checking the rubber element in the vibration damper (620/420)

OK

A 1.5 mm

OK

SS99N087

1. If the lines (A) are misaligned by more than 1.5 mm, the vibration damper must be replaced.

OK SS99N088

2. Also check the condition of the rubber element. If pieces of rubber are missing or the rubber part is more than 3.5 mm below the surface, or if a forward motion of the inertial component (outer ring) is discernible, the vibration damper must be replaced.

IMPORTANT: The vibration dampers should be replaced every 4000 operating hours!

Sva 7-98510 EN

Edition 05/00

2007-40

6. CON-RODS AND PISTONS A. Removing the pistons together with the con-rods

5 40.025 40.040

1. Unscrew the sump and the lubrication oil pressure and suction lines.

2. Unscrew the cylinder head.

3. Scratch the carbon ridge off the cylinder liner. If necessary, scrape off the sharp abrasion edge at the reversal point of the piston ring.

4. Remove the con-rod bearing covers and bearing shells. If the bearing shells are to be re-used, their order must be marked.

5. Push the piston and con-rod up by using the shaft of a hammer or some similar object.

6. Remove the piston pin circlips. Push the piston pin out.

NOTE: If the piston pin does not move by applying finger pressure, the piston must be gradually heated up to 100 °C.

B. Checking and replacing the con-rod bearings 1. Clean the con-rod and bearing shells. Fit the bearing shells and tighten the bolts to a torque of 40 Nm + 90°.

SS99N091

4. Press the new bush in. The oil channel in the bush must coincide with the corresponding channel in the con-rod. After fitting it, drill a hole with a ∅ of 5 mm. Use a reamer to ream the bush to the correct diameter.

C. Checking the con-rod Check the con-rod by means of a special device.

208.00

40 Nm+90°

SS99N092

1. Fit the con-rod covers and tighten the nuts to a torque of 40 Nm + 90°.

2. Clamp the con-rod in the test device and insert the piston pin into the bush.

SS99N090

2. Measure the inner diameter with a plug gauge, which has been zeroed at the diameter of the applicable bearing journal. If new bearing shells have a clearance of more than 0.14 mm, the conrod bearing journals must be ground and the next bearing shell undersize fitted (repair kit).

3. If the small end bearing bush is worn, it must be driven out using a suitable mandrel.

Sva 7-98510 EN

Edition 05/00

2007-41

SS99N095

SS99N093

3. Place the aligning gauge at the top of the piston pin. Check the con-rods for distortion with the alignment gauge pins in a horizontal position.

5. Also check the con-rod for S-shaped bending.

For this purpose, use a micrometer to measure the distance between the outer face of the small end bearing bush and the measuring surface of the test device. Then turn the con-rod round and carry out the same measurement. The difference between the measured values must not exceed 0.6 mm.

max. 86.50

SS99N096

6. Measure the length of the con-rod bolts. This must not exceed 86.50 mm. If the bolt is longer, it must be replaced by a new one. It is advisable to replace the bolts every time they are loosened.

D. Con-rod weight groups The con-rods are split into weight groups of 20 g.

A letter designates the weight group. It is marked on the side of the con-rod. All con-rods in an engine must belong to the same weight group, which means the permissible weight difference is 20 g.

SS99N097

SS99N094

4. Check the con-rods for bending with the test pins in a vertical position.

Sva 7-98510 EN

Edition 05/00

2007-42 The letter stands for the following weights: Weight:

Spare part number

X

2150 - 2169 g

354139A1

A

2170 - 2189 g

162000030706

B

2190 - 2209 g

162000030707

C

2210 - 2229 g

162000030708

D

2230 - 2249 g

162000030709

I

2250 - 2269 g

162000030710

H

2270 - 2289 g

162000030711

I

2290 - 2309 g

162000030712

J

2310 - 2329 g

162000030713

K

2330 - 2349 g

162000030714

L

2350 - 2369 g

162000030715

M

2370 - 2389 g

162000030716

N

2390 - 2409 g

162000030717

O

2410 - 2429 g

162000030718

P

2430 - 2449 g

162000030719

R

2450 - 2469 g

162000030720

S

2470 - 2489 g

162000030721

T

2490 - 2509 g

132000030703

U

2510 - 2529 g

354140A1

E. Checking and replacing the piston rings 1. Release the piston rings using piston ring pliers.

Do not expand the rings more than necessary. If the same rings are to be re-used, then they should be kept in the correct order.

SS99N099

3. Insert the piston ring in the cylinder and measure the distance between the ring ends. The distance measured for the 1st and 3rd rings may not exceed 1 mm and 1.5 mm for the 2nd ring.

4. Re-insert the piston rings with the aid of the piston ring pliers. Make sure the rings are fitted in the right place and the letters TOP or the manufacturer’s identification mark on the rings point(s) upwards.

TOP only 420.85/620.93

TOP

TOP

SS99N100 SS99N098

2. Carefully clean the piston ring groove and then measure the piston ring play in the groove. The play must not exceed 0.15 mm. Check whether the play is due to wear in the ring groove. The rings and/or the pistons must then be replaced accordingly.

Sva 7-98510 EN

Edition 05/00

2007-43

F. Checking the pistons

H. Fitting the pistons and con-rods

Inspect the pistons and piston pins by performing a visual check. Pay particular attention to possible cracks at the edge of the combustion chamber or at the upper part of the piston pin bore hole.

Measure the diameter of the piston at the point indicated in the figure and compare the result with the specified value. Replace the piston, if necessary.

1. Insert the bearing shells in the con-rods. Make sure the contact surfaces are clean and the bearing shells sit correctly.

2. Lubricate the piston, piston rings and cylinder with engine oil. Turn the piston ring gaps to different sides of the piston.

∅107.873 107.887 17 mm SS99N101

G. Fitting the piston pin 1. Insert the con-rod in the piston and push the piston pin to its position.

SS99N103

3. Use a piston ring clamp or tapered installation tool for fitting. Insert the piston and con-rod so that the weight class mark is on the camshaft side (arrow on the piston points towards the front).

4. Oil the con-rod bearing journals and bearing shells and push the piston down. Mount the bearing cover so that the joggles on the bearing shells are on the same side. Then tighten the nuts to a torque of 40 Nm+90°.

5. Check whether the lower con-rod bearing has sufficient axial play on the crank journal.

SS99N102

WARNING: The combustion chamber in the piston and the letter for marking the weight class of the con-rod come on the opposite side.

2. Then fit the circlips for the piston pin. The ends of the circlips must point upwards.

Sva 7-98510 EN

Edition 05/00

2007-44

7. BALANCING UNIT (420) A. Removing and dismantling the balancing unit 1. Remove the sump.

2. Loosen the lubrication oil line to the balancing unit.

3. Loosen the balancing unit fixing bolts and remove the balancing units including any spacer washers between the balancing unit and the cylinder head.

4. Loosen the balancing shaft clamping bolts. Slide out the shaft in the direction of the clamping bolts.

Remove the counterweights and the thrust washers.

5. Clean all parts thoroughly.

0,1 - 0,5

SS99N105

4. Check whether the counterweight tooth play is according to specifications (0.05 - 0.25 mm) and that the counterweight axial play is correct (0.1 0.5 mm).

B. Balancing unit maintenance Check the shaft wear and the condition of the gear wheels and bearings.

1. If the gear wheels are worn out, the counterweights must also be replaced. The gear wheels are not available as a separate spare part.

C. Fitting the balancing unit 1. Fix the sprung dowel pins into place on the cylinder block.

2. If necessary drive the old bearing bushes out of the counterweights using a suitable mandrel.

Before removing the bushes mark the position of the oil groove in the bearing bush on the counterweight. Press the new bearing bush into the counterweight, keeping the oil groove aligned with its original position. After fitting, machine the bearing bushes down to their final dimension.

2. Fit the balancing unit into place such that the marking point on the gear wheel matches with the marking point on the crankshaft gear wheel.

2

1 1. Marking lines 2. Marking dots

SS99N104

3. Fit the counterweights into the housing. Take care that the counterweights are in the correct position. The gear wheel marked with a dot should be located uppermost in the housing. The marking lines on the gear wheels should be aligned with each other. Slide the shafts into place from the clamping bolt end. When fitting the shaft between the gear wheel and the housing, also fit the thrust washer.

The end of the shaft is flush with the housing.

Apply locking fluid to the clamping bolt threads, (e.g. Loctite 279), and tighten the bolts.

Sva 7-98510 EN

SS99N106

3. Tighten the balancing unit bolts to a torque of 60 Nm. Measure the tooth play between the counterweight and the crankshaft. If the value deviates from that specified (0.1 - 0.3 mm) then the tooth play must be adjusted using 0.2 mm thick spacer washers (spare part number 142080020707) to be fitted between the balancing unit housing and the cylinder block. Insertion or removal of a 0.2 mm ring, alters the tooth play by approx. 0.07 mm.

4. Secure the lubrication oil pipes.

5. Fit the sump.

Edition 05/00

2007-45

8. FLYWHEEL

3. Tighten the flywheel bolts evenly to a torque of 140 Nm.

A. Replacing the starter ring gear on the flywheel

WARNING: Flywheels for "green (low-emission) engines" supplied as a spare part do not have an injection register marking for the "Time Track" check. The new flywheel should be marked when carrying out the assembly process.

The ring gear cannot be re-finished because the teeth on the side of the starter are chamfered and hardened.

1. Free the old ring gear by hitting it with a mandrel. Clean the ring gear seat on the flywheel using a wire brush.

- Turn the crankshaft until the piston of the first cylinder is at top dead centre (TDC). Let the cylinder 1 valve fall against the cylinder head.

Mount the dial test indicator at the top of the valve stem and set it to zero when the piston is at top dead centre. Then slowly turn the crankshaft in the direction of rotation until the dial test indicator reads 4.633 mm after TDC (320 , 420 , 620).

- Drill the hole for the injection register mark in the flywheel using a twist drill (see figure below).

∅ 5 mm twist drill

7 mm

SS99N107

2. Heat up the ring gear to 150 - 200 °C. Mount the ring gear. The chamfered inner edge must point towards the flywheel and the tooth chamfer towards the starter.

∅ 8 mm guide SS99N041

IMPORTANT: Allow the ring gear to cool down.

Do not use coolant.

B. Fitting the flywheel 1. Clean the contact surfaces on the rear crankshaft flange and on the flywheel.

Bolt the flywheel onto the crankshaft. M12 grub screws should be used as guide pins (2), which fit into the in the securing holes in the flywheel. A guide sleeve is used for one flywheel bolt to determine the correct crankshaft position.

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9. TIMING MECHANISM

1

A. Removing the timing gear case

2

The timing gear case acts as a seal to the sump.

The casing cannot be removed without first removing the sump.

1. Remove the sump.

2. Remove the fan, the alternator, the V-belt pulleys and the V-belts. If the tractor is equipped with an air-conditioning system or compressed air system, the compressor must also be removed.

3. Loosen the crankshaft nut and remove the belt pulley.

NOTE: In the case of 620 engines, the belt pulley must be taken off before unscrewing the nut.

4. For engine types 320 and 420 (with the exception of 420.85), remove the hydraulic pump.

5. Remove the timing gear casecover and remove the metal ring from the crankshaft.

SS99N109

1. Lathe chuck 2. Roller ø = 5 mm

After fitting, machine the inner diameter of the intermediate gear wheel bush to the correct size.

Centre the intermediate gear wheel according to the above figure so the tooth play is kept even.

6. Remove the injection pump.

NOTE: If the timing gear case is not going to be replaced, the injection pump can remain in place.

In this case, disconnect all lines and pipes from the pump.

7. Unscrew the intermediate gear wheel bolts.

Remove the flange, gear wheel and bearing journal.

8. Pull out the camshaft.

NOTE: If the cylinder head and valve mechanism are not removed, the valve tappets must be secured against falling down (refer to instructions in page 34).

0.10 - 0.25 55.00 55.03

9. Unscrew the bolts on the timing gear case and remove the timing gear case. If a wedge has to be driven in between the engine block and timing gear case, make sure the sealing surfaces are not damaged.

30

SS99N118

10. Take the front crankshaft sealing ring off the timing gear case and clean all parts which have been removed.

B. Replacing the intermediate gear wheel bush If the intermediate gear wheel bush is to be replaced, press in a new bush so that its rear edge lies within the rear gear wheel edge by 0.1 0.25 mm (see figure).

0.10 - 0.25 55.00 55.03 50

Sva 7-98510 EN

SS99N119

Edition 05/00

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C. Fitting the timing gear case The position of the timing gear case and the cover is determined by two sprung dowel pins. It therefore does not have to be centred for the assembly process. However, the clearance between various gear wheels must be checked.

The timing gear case and cover supplied as spares already have bore holes for the sprung dowel pins.

1. Fit the timing gear case onto the cylinder block using a new seal. Drive the sprung dowel pins in by means of a mandrel. Tighten the nuts and bolts.

2. Install the injection pump together with the gear wheel (if removed).

3. Oil the camshaft bearings and fit the shaft in the cylinder block. Release the push rods and valve tappets, if they have been suspended.

SS99N113

6. Fit the metal ring onto the crankshaft and fit the timing gear case cover, using a new seal. Drive the sprung dowel pins in, by means of a mandrel (mate the hollow pin with the grub screw). Tighten the nuts and bolts.

90Nm

200Nm 60Nm SS99N114 SS99N111

4. Fit the intermediate gear wheel with the shaft grub screw and make sure the marks are aligned correctly. Insert the washer and tighten the bolts to the specified torque.

7. Fit the guard plate in the bearing seat and insert the front crankshaft sealing ring by means of the 1TSW 520 special tool.

SS99N112

5. Check the tooth play.

It should be between 0.05 - 0.25 mm.

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D. Front power take-off / auxiliary drive Engine types 320 and 420 (with the exception of 420.85) are equipped with a timing gearcase with auxiliary drive. The auxiliary drive is driven by the camshaft wheel and drives the hydraulic pump.

SS99N115

8. If it has been removed, re-fit the dust cap on the V-belt pulley hub on the crankshaft. To do so, use the 1TSW 519 pressing tool.

SS99N121

Use ball bearing grease (NLGI 2) for the hydraulic pump shaft grooves and coupling sleeve.

The auxiliary drive is fitted with an external lubrication tube.

600 Nm (320, 420) 1000 Nm (620)

SS99N116

9. Oil both the seal and the sealing surfaces and fit the V-belt pulley together with the hub.

10. Apply a little oil to the thread on crankshaft nut.

Tighten the nuts for engine types 320 and 420 to a torque of 600 Nm and those for engine type 620 to a torque of 1000 Nm. 11. Re-fit the other parts which have been removed.

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10. LUBRICATION SYSTEM

Make sure the wider side of the spring is fitted towards the cover.

A. Checking the oil pressure valve

B. Removing and checking the oil pump

Always check whether the oil pressure valve is functioning if the engine oil pressure does not increase sufficiently or fluctuates noticeably.

However, first check whether there is enough oil in the engine.

1. Drain the engine oil and remove the sump.

2. Disconnect the intake and pressure lines on the oil pump.

3. Remove the oil pump and any adjusting disks between the pump base and the cylinder block.

4. Release the pump cover and the seal. Remove the gear wheel fitted on the axle.

SS99N122

1. Remove the cover on the oil pressure valve and the spring located underneath. Take care to retain the washer between the cover and the spring. Pull the valve insert and cone out of the cylinder block.

Take care that the O-Ring is also removed.

5. Clamp the pump, at the pump gear wheel, in a vice with protected jaws and unscrew the nut on the drive gear wheel. Use a plastic hammer to drive the pump drive shaft off the gear wheel. Pull the drive shaft gear wheel out of the pump body.

6. Wash the parts and check the wear compared with the dimensions specified under "Lubrication oil pump". Replace worn parts and all paper gaskets.

Gear wheel

2. Clean the parts. Check that the valve cone moves freely in the valve insert. If the valve cone sticks, clean out any particles of dirt. If necessary, grind the parts with fine abrasive wool or use new parts. Clean the sealing surfaces between the cylinder block and the cover.

3. Place a new O-Ring in the groove in the valve insert. Fit the cone and the valve insert in the cylinder head. Fit the washer, cover and spring using a new cover seal.

4. Take note of the asymmetrical shape when fitting the valve cover. The side with the greater distance between the cover centreline and the fixing opening should be underneath.

IMPORTANT: From engine number J 7595 onward, a new oil pressure valve should be used.

60Nm +Loctite 243

SS99N124

7. The oil pump bearing points for engine type 620 are fitted with separate bearing bushes. On replacing the bearing bushes, machine them to the dimension 18.000 - 18.018 mm after fitting them.

25 Nm

X SS00B054

The valve seat (X) in this oil pressure valve is glued in using Loctite 638.

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C. Assembling and fitting the oil pump 1. Insert the gear wheels into the recess in the pump body. Fit a new seal between the pump body and cover (as required). Tighten the securing bolts a little. Turn the shaft and tap the cover laterally into the position, in which it rotates most easily.

Tighten the cover securing bolts and check that the shaft still rotates easily.

2. Fit the drive gear wheel onto the shaft, apply locking fluid to the nut threads (e.g. Loctite 243) and tighten the nut to a torque of 60 Nm.

NOTE: When measuring the tooth play, the engine must be in its operating position (upright) as the bearing play has an effect on the tooth play.

5. Fix the pump intake and pressure lines, replace the seals on the mounting flange.

6. Fit the sump and fill it with engine oil.

D. Fitting the sump Fit the sump seal with the silicone strips pointing towards the cylinder block.

SS99N128

E. Oil cooler Engine types 620.92 and 620.93 are equipped with an oil cooler, which is located between the engine oil filter and the cylinder block.

SS99N126

1. The coolant must be drained out of the oil cooler before removing it.

3. Clamp the pump at the mounting base in a vice with protected jaws. Check the axial play of the gear wheel (0.03 - 0.11 mm) with a dial test indicator. Change the number of seals between the cover and pump body as required.

SS99N129

2. Fit new seals. Mount the oil cooler so that the drain connection points downwards. Secure the coolant hoses in a regular manner.

SS99N127

3. Put some screw locking fluid (e.g. Loctite 243) on the thread on the engine end of the mounting pipe and tighten it to a torque of 60 Nm.

4. Secure the pump in its position below the cylinder block and use a dial test indicator to check the tooth play between the crankshaft and pump gear wheels. (0.05 - 0.25mm). Change the number of shim rings between the pump base and the cylinder block (0.2 mm shim ring, order number 162000070716). Inserting/removing a 0.2 mm ring changes the tooth play by approx. 0.07 mm.

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F. Piston cooling nozzles (620) The piston cooling nozzles for engine type 620.93 can be taken out after removing the sump. The nozzle is equipped with a ball valve. It has an opening pressure of 3±0.25 bar.

SS99N131

SS99N130

1. Change the nozzles as required. Unscrew the nozzles from the engine and remove the nozzle pipe. Insert the new nozzles.

2. On assembling the nozzle, fix the nozzle pipe, as shown in the figure, at an angle of 90° to the longitudinal axis of the engine. Tighten the nozzle to a torque of 30 Nm. After assembly, check that the nozzle pipe does not touch the piston or con-rod when the engine is turned over.

G. Recommended lubrication oils - For engines with a turbo charger API

CD/ CE/ CF/ CG-4

ACEA

E2-96/E3-96

Temperature °C

SAE CLASS

-30

-20

-10

0

+10

+30

5W 20 5W 30 5W 40 10W 10W 20 10W 30 10W 40 15W 30 15W 40 20W 20 20W 30 20W 40 30

Sva 7-98510 EN

+20

SS99N132 Edition 05/00

2007-52

11. COOLING SYSTEM

4. Pull the impeller off using the 1TSW 662 extractor.

A. Thermostat

5. Remove the circlip from the pump body. Use a hydraulic press, for example, to press the shaft with the bearing out of the pump body towards the fan. Clamp the pump body so that the shaft bearing can be taken out.

The thermostat is of a two-way design with an opening temperature of 79 °C. If you have doubts about the functionality of the thermostat, check it as follows: - place the thermostat in boiling water without it touching the sides of the vessel.

- the thermostat must start to open within 20 seconds.

- the thermostat must be fully open after no longer than 50 seconds. Compare the measured values with those specified in the technical data.

6. Remove the axial and shaft seals from the pump body by means of a mandrel. Clean the parts and check their condition. Replace worn or faulty parts.

NOTE: If the pump bearings have to be replaced, it is better to fit the pump repair kit, which also comprises all seals required for the repair (refer to spare parts catalogue).

1TSW 18390

1TSW 523

SS99N138 SS99N135

B. Repairing the coolant pump 1. Drain the coolant. Unscrew the thermostat housing, the fan and the V-belt.

2. Remove the coolant pump. Take the back plate off the pump and clean the sealing surfaces.

3. Unscrew the securing nut for the V-belt pulley and remove the belt pulley. Use the 1TSW 662 extractor, if required.

SS99N140

Sva 7-98510 EN

Edition 05/00

2007-53 7. Use the 1TSW 523 mandrel to drive the shaft seal into the pump body. Mount the bearings and intermediate sleeves on the shaft. Grease the bearings with plenty of heat-resistant bearing grease. Fit the shaft and bearings in their place so that the forces produced by pressing do not act on the bearing balls. Fit the bearing circlip in its place.

X SS99N143

10. Fix the back plate using a new seal. To fit the back plate, use guide pins with a diameter of 8.5 mm for the bore holes shown in the figure (engine type 620).

C. Coolant quality requirements -if there are no frost resistance requirements, a mixture ratio of 30 % is enough to ensure sufficient corrosion protection.

SS99N141

8. Fit the impeller whilst supporting the other end of the coolant pump shaft. The play (X) between the pump casing and impeller for engine types 320/420 is 1.8 - 2.2 mm, and for type 620 engines 0.8 1.2 mm. Check that the coolant pump shaft rotates freely.

- check the coolant (anti-freeze) mixture ratio at certain intervals. Replace the coolant every two years.

- the water used must be clean and soft, i.e. it must not contain any metals and their salts.

WARNING: Never use only water as a coolant.

9. Fix the belt pulley on the shaft and tighten the securing nut to a torque of 120 Nm.

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Edition 05/00

2007-54

12. INTAKE / EXHAUST SYSTEM An engine equipped with a turbo charger is far more sensitive to faults and contamination in the intake/exhaust system than conventional engines.

Particular attention must therefore be paid to the intake/exhaust system.

A. Checking the air filter

6. Make sure no loose objects or dirt particles have ingressed into the exhaust pipe or silencer. Such loose objects or dirt particles can increase the back-pressure for the exhaust gases from the turbine wheel.

C. Checking the boost pressure The boost pressure should be checked before removing the turbo charger.

The engine performance and service life are largely dependent on the condition of the air filter.

A faulty air filter lets dirt particles through, which in the long run will cause damage to the turbo charger and engine. A blocked air filter reduces engine performance and also causes oil leakage through the sealing ring on the turbo charger shaft.

WARNING: The safety filter located in the main filter does not have to be cleaned, but must be replaced as required (refer to operating instructions).

A

B. Checking the intake / exhaust system IMPORTANT: Leakages in the intake or exhaust system impair the effect of the turbo charger.

Due to the pressure, even small leaks in the manifold or turbine inlet flange quickly get bigger. Leakages must therefore be eliminated without delay.

1. Check the pipes and sealing surfaces between the air filter and exhaust turbo charger as well as between the exhaust turbo charger and exhaust manifold. If the intake manifold is dusty on the inner side, then there is a leakage in the air filter or in the suction pipes. Eliminate the leakage.

SS00B058

To check the boost pressure, the screw (1TSW 663) is screwed into the intake manifold instead of the thermo-start unit (A). This applies to all engines. In addition, a mini-measuring connector (1TSW 640), mini-measuring line (ITSW 635) and pressure gauge (1TSW 5002) have to be used.

The boost pressures are specified on page 9.

2. Clean the sealing surface of the intake manifold.

Use a straightedge to make sure the sealing surface is level. If the sealing surface is not level or is scratched, machine or replace the intake manifold. For engine type 620 make sure the cylinder heads are parallel to each other.

3. Insert a new seal and secure the intake manifold. Tighten the intake manifold securing bolts to a torque of 30 Nm. Secure the air pipes.

4. Make sure the exhaust manifold is airtight.

Tighten the nuts/bolts to a torque of 50 Nm and check for damage (cracks, deformation, corrosion, etc.). Also check the connection between the turbo charger and exhaust manifold.

5. Remove the manifold, if necessary. Clean the sealing surfaces and remove any carbon deposits.

Make sure the sealing surfaces are level. If the mounting flanges are twisted or the sealing surfaces scratched, machine the flange or replace the exhaust manifold.

Sva 7-98510 EN

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D. Checking the turbo charger If it is assumed that the turbo charger is faulty, the fault can be determined as follows: 1. Carry out a visual check on the turbine and compressor wheels. The blades must not show any signs of damage, deformation or wear caused by foreign objects.

2. Check whether oil leaks through the sealing rings on the shaft in the turbine / compressor housing.

WARNING: A small amount of oil always comes out on the compressor side at low idling speeds.

However, there is no need to worry about this unless a lot of oil is lost.

SS99N145

4. Check the axial play of the shaft. Hold the probe of the dial test indicator against the end of the shaft move the shaft axially. Also refer to the play specified under Technical Data.

If a fault or wear is confirmed, the turbo charger must be overhauled.

If the engine does not run properly even though the turbo charger is not faulty and does not show excessive wear, the fault could have one of the following causes:

SS99N144

3. Check the running play of the turbine shaft. Hold the probe of a dial test indicator against the shaft and move the shaft sideways. Also refer to the play specified under Technical Data.

Sva 7-98510 EN

- a blocked air filter - a leakage in the intake or exhaust system; a leaking flange seal - A faulty or maladjusted injection pump - maladjusted throttle linkage - faulty or maladjusted injection nozzles - insufficient fuel pressure (e.g. caused by a blocked fuel filter) - weak compression, incorrect valve clearance

Edition 05/00

2007-56

6 4 3

7

2 1

5 SS99N146

Schwitzer turbocharger 1. Compressor housing 2. Lock nut 3. Compressor wheel 4. Bearing housing

E. Fitting the turbo charger First, the cause of possible turbo charger damage must be clarified and eliminated before a new turbo charger is fitted.

For perfect operation of the turbo charger, it is important that the engine lubrication oil is changed in accordance with the relevant instructions and that the correct quality class is used. The maintenance specifications for the oil and air filters must also be adhered to.

The injection pump setting, which must correspond with the manufacturer’s specifications, has a major influence on turbo charger operation.

1. Check the fastening and tightness of the exhaust and intake manifolds. Make sure there are no loose carbon particles, rust or other foreign bodies on the exhaust or intake manifolds.

5. Bearing bushes 6. Turbine housing 7. Shaft and turbine wheel

3. Connect the intake / silencer pipe to the turbo charger.

4. Pour clean engine oil into the bearing housing via the oil filler in order to ensure lubrication of the turbo charger bearings after starting the engine.

5. Secure the pressure and oil return pipes. Make sure the turbo charger is held completely by the mounting flange and that the pipes do not put any strain on the turbo charger.

6. Pull out the fuse (for type 320 F15, for types 420 and 620 F29) for the engine cut-out and start the engine several times with the starter. This ensures that there is plenty of oil at all lubrication points before operation. Re-insert the fuse and start the engine. Check the pipe connections for leakage.

2. Fix the turbo charger onto the exhaust manifold by means of the flange. Always use new seals.

Sva 7-98510 EN

Edition 05/00

3

Section 3 HOW IT WORKS INJECTION SYSTEM SISU - WD 320 / WD 420 M968 / M975 and CS68 / CS75 (WD 320) cut in DBD0040007

M9078 - M9094 and CS78 - CS94 (WD 420) cut in DBD0055001

CASE STEYR Landmaschinentechnik GmbH Technical Documentation/Training Center A - 4300 St. Valentin, Steyrer Straße 32

Sva 7-97340 EN

© 1999 Case Steyr Landmaschinentechnik GmbH October, 1999

7DEOH RI FRQWHQV FUEL INJECTION SYSTEM (STANADYNE DISTRIBUTOR PUMP) ........................... 3 General ................................................................................................................. 3 Fuel system with distributor pump ........................................................................ 4 Technical data - Injection pump ........................................................................... 5 Stanadyne distributor pump ................................................................................. 6 Construction ......................................................................................................... 7 Function ................................................................................................................ 8 Adjusting low idle speed ..................................................................................... 10 Removing pump ................................................................................................. 11 Fitting the injection pump and injection timing .................................................... 12 Bleeding the fuel system .................................................................................... 13 Bleeding the Thermostart system ....................................................................... 13 Measuring fuel feed pressure ............................................................................. 14 Injector ................................................................................................................ 15 Fuel quality requirements ................................................................................... 16 Biodiesel fuel ...................................................................................................... 16 Checking injection timing dynamically with TIME TRAC .................................... 17

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4001

Chapter 4001 CIRCUIT DIAGRAM

M948, M948a, M958, M958a M968 / M968a / M975a up to veh. no. 04939 CS48, CS48a, CS58, CS58a CS68, CS68a, CS75a up to DBD 23065

CASE-STEYR Landmaschinentechnik GmbH Technische Dokumentation/Training Center A – 4300 St. Valentin, Steyrer Straße 32

Sva 7-97170 EN

© 1999 Case Steyr Landmaschinentechnik GmbH April 1999

CIRCUIT DIAGRAM

CIRCUIT DIAGRAM INDEX

M948 – M975 CS48 – CS75

Title

Sheet (e.g. 1) Section (e.g. A)

Air conditioning Air-sprung seat Analogue tractor meter Auxiliary control unit, hydraulic motor

12A 7F 5B 14C#

Blower motor for high-top

6F

Brake light Combined instrument Digital clock, high-top Digital instrument Distributor potential 58 Double-action auxiliary control unit multifunction lever Double-action auxiliary control unit multifunction lever/toggle switch Double-action auxiliary control unit toggle switch Electronic Implement Load Relief (EGE) Engine cut-out M948 / M958 Engine cut-out M968 / M975 Front headlamp, high-top Front headlamp, low-top Front wash/wipe, high-top Front wash/wipe, low-top Front wiper Planta Front-end lifting gear external pushbutton, for EGE Front-end lifting gear, external operating pushbutton

Title

Sheet (e.g. 1) Section (e.g. A) 8C# 6C 1E 3G

4D 5A 7A# 5C 3C

Interior light, low-top Italian brake Light switch Number plate lighting, high-top Cold - start accelerator (only for M948/M958) Power socket 40A Power supply M948 / M958 Power supply M968 / M975 Pre-glowing Radio, high-top

9C#

Rear wash/wipe, high-top

7J#

10C#

Rear wash/wipe, low-top

8J#

9E

Rear wiper Planta

13B

11B 1C# 2C# 2G# 1G# 7G# 8G# 13A

Rear, inner roof searchlight Rear, outer roof searchlight Roof supply potential 58 Rotating beacon, high-top Rotating beacon, low-top Safety switch Searchlight switch Searchlight, mudguard

3F 3E 4B 7D# 8D# 9A 3D 3B

11A

Sidelight

4A

9D

Sidelight, high-top

2H#

Front/rear washers Planta

13C

9B#

Front/rear washers, high-top

7H#

Front/rear washers, low-top Heating Indicator lamp block Indicators Interior light, high-top

8H# 6E 6D 4C 7C#

Single-action auxiliary control unit multifunction lever Single-action auxiliary control unit multifunction lever/toggle switch Standard signal socket Starter + Start Inhibitor Steering column switch, horn Supply potential 58 Tank pump

1

6A 7E 1A# 2A# 1D 7B#

10B# 5D 1B 1F 3A 6B

7-97170en

Electrical equipment

Headlight, left Headlight, right Glow plug Fuse, high-beam headlight Fuse, dipped-beam headlight Fuse, engine cut-out Fuse engine cut-out, potential 50 Main fuse Battery 12V/90AH Generator 12V/770W Horn Relay, reserve headlight Relay, reserve headlight Relay, neutral position Starter Switch, pre-glow start Switch, lighting system Switch, reserve headlight Switch, steering column, main/dipped beam S10 Switch, neutral position X1/50 Plug-in connection, instrument – engine X3/6 Distributor, reserve headlight, main beam X3/7 Distributor, reserve headlight, dipped beam X3/13 Plug-in connection, instrument – cut-out X4/51 Plug-in connection, instrument – engine X12/1 Plug-in connection, instrument – engine X15/1 Distributor 55 pole instrument X15/16 Plug-in connection, roof supply X15/50 Plug-in connection, instrument – steering column X16/1 Distributor, potential 30 instrument Y11 Engine cut-out solenoid valve

E1 E2 E10/1 F13 F14 F15 F16 F100 G1 G2/1 H1 K5/5 K5/6 K8/1 M1 S1 S2/1 S2/38 S4/1

3 2

VERSIONS to this Sheet 1 on Sheet/Sheets

Power supply M948/M958 Starter+Start inhibitor Engine cut-out M948/M958 Pre-glowing Light circuit Steering column switch, horn Front headlight, low-top several versions available

A# B C# D E F G# #

Designation of Sections

VDC, stabilised by the 'E' box

S

Black

Ground, directly to a grounding point

Spare

Ground via a box Colourless Spare

Orange

H

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

P

Violet

G

Signal cable

Pink

Green

F

Potential 58 Lighting cable

N

Grey

E

+ Control line (positive) + 15 Si (Potential 15 safety)

Light blue D+

Yellow

D

Brown

White

C

-- Control line (ground)

L

Beige

B

+30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Battery Instrument panel Implement carrier Engine compartment Roof panel Carrier frame Starter

Grounding point

Ident. letter

1 2 3 5 7 13 16

CIRCUIT DIAGRAM

7-97170en

Headlight, left Headlight, right Glow plug Reserve headlight, left Reserve headlight, right Sidelight, roof, left Sidelight, roof, left Fuse, high-beam headlight Fuse, dipped-beam headlight Fuse, engine cut-out Fuse, engine cut-out, pot.50 Main fuse Battery 12V/90AH Generator 12V/770W Horn Relay, reserve headlight Relay, reserve headlight Relay, neutral position Starter Switch, pre-glow start Switch, lighting system Switch, reserve headlight Switch, steering column, main/dipped beam S10 Switch, neutral position X1/50 Plug-in connection, instrument – engine X1/13 Plug-in connection, instrument – cut-out X4/51 Plug-in connection, instrument – engine X5/11 5-pole plug-in connection, roof 56a X5/12 5-pole plug-in connection, roof 56b X12/1 Plug-in connection, instrument – engine X15/1 Distributor 55 pole instrument X15/16 Plug-in connection, roof supply X15/50 Plug-in connection, instrument – steering column X16/1 Distributor, potential 30 instrument Y11 Engine cut-out solenoid valve

E1 E2 E10/1 E21 E2 E31 E32 F13 F14 F15 F16 F100 G1 G2/1 H1 K5/5 K5/6 K8/1 M1 S1 S2/1 S2/38 S4/1

Electrical equipment

5 1

VERSIONS to this Sheet 2 on Sheet/Sheets

Power supply M968/M975 Starter+Start inhibitor Engine cut-out M968/M975 Pre-glowing Light circuit Steering column switch, horn Front headlight, low-top Sidelight, high-top several versions available

A# B C# D E F G# H# #

Designation of Sections

VDC, stabilised by the 'E' Box

S

Black

Ground, directly to a grounding point

Spare

Ground via a box Colourless Spare

Orange

H

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

P

Violet

G

Signal cable

Pink

Green

F

Potential 58 Lighting cable

N

Grey

E

+ Control line (positive) + 15 Si (Potential 15 safety)

Light blue D+

Yellow

D

Brown

White

C

-- Control line (ground)

L

Beige

B

+30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Battery Instrument panel Implement carrier Engine compartment Roof panel Carrier frame Starter Cable support

Ident. letter

1 2 3 5 7 13 16 19

Grounding point

CIRCUIT DIAGRAM

7-97170en

Group, number plate, roof, left Group, number plate, roof, right Searchlight, left-hand mudguard Searchlight, right-hand mudguard Searchlight, roof, rear left inner E23/2 Searchlight, roof, rear left outer E24/1 Searchlight, roof, rear right inner E24/2 Searchlight, roof, rear right outer F1 Fuse, searchlight, mudguard F4 Fuse, searchlight, roof rear K6/10 Relay, supply potential 5 S2/2 Switch, searchlight, mudguard S2/63 Switch, rear searchlight, roof X3/14 3-pole plug-in connection, searchlight, roof X4/14 4-pole plug-in connection, searchlight, rear right X4/15 4-pole plug-in connection, searchlight, rear right X4/16 4-pole plug-in connection, searchlight, rear left X4/17 4-pole plug-in connection, searchlight, rear left X4/18 4-pole plug-in connection, number plate, roof X4/18 4-pole plug-in connection, number plate, roof X5/13 5-pole plug-in connection, roof searchlight X11/50 11-pole plug-in connection, potential 58 X15/1 Distributor 55 pole instrument X15/2 Distributor 55-pole X15/16 Plug-in connection, roof supply

E5/3 E5/4 E8 E9 E23/1

Electrical equipment A B C D E F G

Supply potential 58 Searchlight, mudguard Supply potential 58 Switch, searchlight Roof searchlight, rear inner Roof searchlight, rear outer Number plate lighting, high-top

Designation of Sections

7

Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare Black

E F G

H K L N P S

+ Control line (positive)

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

White Yellow

-- Control line (ground)

D

Beige

B

+30 (potential 30) = Cont. current

Type of use

C

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier Roof panel

Ident. letter

2 3 7

Grounding point

CIRCUIT DIAGRAM

7-97170en

Sidelight, front left Sidelight, rear left Group, number plate, left Sidelight, front right Sidelight, rear right Brake light, left Brake light, right Indicator, front right Indicator, rear right Indicator, rear left Indicator, front left Fuse, sidelight, left Fuse, sidelight, right Fuse, trafficators Indicator relay Switch, hazard warning lights Switch, steering column, indicator Switch, brake light 4-pole plug-in connection, indicator / brake light X4/12 4-pole plug-in connection, trafficator / brake light X5/20 Distributor 58, low-top X10 Plug-in connection 7-pole, trailer X11/10 Distributor, potential 58, high-top X15/1 Distributor 55 pole instrument X15/2 Distributor 55-pole X15/16 Plug-in connection, roof supply X15/50 Plug-in connection, instrument – steering column

E3 E4 E5/1 E6 E7 E12 E13 E14 E15 E16 E17 F2 F3 F6 K2 S2/5 S4/2 S5 X4/11

Electrical equipment A B C D

Sidelight Supply, roof, potential 58 Trafficators Brake light

Designation of Sections

9

White Yellow Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare Black

C D E F G

H K L N P S

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the 'E' Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Beige

B

+30 (potential 30) = Cont. current

Red

Type of use

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier Roof panel Driver's cab frame

Ident. letter

2 3 7 11

Grounding point

CIRCUIT DIAGRAM

7-97170en

A1 B1 B2/1 B3 B6 B7 F5 P1 P3 S2/57 S12 S29 X4/21 X4/23 X5/51 X6/3 X9/1 X9/2 X10 X12/1 X20/30 X20/38 X30

Digital instrument Engine temperature transmitter Fuel tank content transmitter, left Compressed air transmitter Inductive speed transmitter Inductive rear PTO shaft speed transmitter Fuse, instrument, clock Combination unit, square Analogue tractor meter Switch, digital switchover Switch, compressed air indicator Switch, front PTO shaft 4-pole plug-in connection, pin W 4-pole plug-in connection, standard signal 5-pole plug-in connection, potential D+ 6-pole plug-in connection, transmitter line 9-pole plug-in connection, digital 9-pole plug-in connection, digital 15-pole plug-in connection, display Plug-in connection, instrument – engine 2-pole plug-in connection, compressed air 2-pole plug-in connection, tank transmitter 7-pole signal socket

Electrical equipment A B C D

Combination instrument Analogue tractor meter Digital instrument Standard signal socket

Designation of Sections

White Yellow Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare Black

C

11 D E F G

H K L N P S

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the 'E' Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Beige

B

+30 (potential 30) = Cont. current

Red

Type of use

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier

Ident. letter

2 3

Grounding point

CIRCUIT DIAGRAM

7-97170en

/1 /2 /3 /4 /5 /6 /7 /8 /9 /10 /11 /12 /13 F7 F9 F10 H2/ H50/1 H50/2 K5/50 M3 M8/1 M10 S3 S12 S12 S8 S12 S3 S50 S5 S5 X4/50 X4/50 X5/50 X12/1 Y11 Y50

4-wheel drive indicator Tractor trafficator repeater 1st trailer trafficator repeater 2nd trailer trafficator repeater Pre-glowing indicator Main beam indicator Engine oil pressure indicator Compressed air indicator Handbrake indicator Air filter indicator Generator charging indicator Rear differential lock indicator Front differential lock indicator Fuse, brake lights, tank pump Fuse, heating, horn Fuse, roof blower motor Lamp cluster indicator Trailer brake indicator, Italy Trailer brake indicator, Italy Relay, trailer brake valve Heater blower motor Left-hand tank pump motor Roof blower motor Switch, air filter indicator Switch, engine oil pressure indicator Switch, handbrake indicator Switch, rear differential lock indicator Switch, 4-wheel drive indicator Switch, temperature indicator Switch, trailer brake indicator, Italy Switch, heating Switch, roof blower motor 2-pole plug-in connection, trailer brake 5-pole plug-in connection, heating 5-pole plug-in connection, potential 15 Plug-in connection, instrument – engine Cold start booster solenoid valve Trailer brake valve solenoid valve, Italy

Electrical equipment

B C D E F

A

Cold start accelerator only for M948/M958 Fuel tank pump Italian brake Indicator lamp block Heating Blower motor for high-top

Designation of Sections

13

Black

Ground, directly to a grounding point

Spare

Ground via a box

S

VDC, stabilised by the 'E' Box

Colourless Spare

Orange

H

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

P

Violet

G

Signal cable

Pink

Green

F

Potential 58 Lighting cable

N

Grey

E

+ Control line (positive) + 15 Si (Potential 15 safety)

Light blue D+

Yellow

D

Brown

White

C

-- Control line (ground)

L

Beige

B

+30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier Engine compartment Roof panel Carrier frame

Ident. letter

2 3 5 7 13

Grounding point

CIRCUIT DIAGRAM

7-97170en

Rotating beacon unit Radio Right-hand loudspeaker Left-hand loudspeaker Interior lighting Fuse, wiper, auxiliary control unit EGE Fuse, hazard warning lights, clock Fuse, power socket Windscreen washer motor Rear screen washer motor Compressed air seat motor Motor, twin washer pump Digital clock

S2/18/1 Switch, rotating beacon S2/24 Switch, windscreen wiper S2/30 Switch, rear screen wiper S24/1 Left-hand door contact switch S24/2 Right-hand door contact switch W6 Aerial X1/2 1-pole plug-in connection, door contact X1/3 1-pole plug-in connection, door contact X3/15 3-pole plug-in connection, windscreen washer pump X3/16 3-pole plug-in connection, rear screen washer pump X3/17 3-pole plug-in connection, rear screen wiper X3/18 3-pole plug-in connection, windscreen wiper X3/19 3-pole plug-in connection, door contact X3/50 3-pole plug-in connection, washer pump X4/1 4-pole plug-in connection, rear wiper X11/11 Distributor, potential 15, roof X11/12 Distributor, potential 30, roof X12/1 Plug-in connection, instrument – engine X14 3-pole power socket X15/1 Distributor 55-pole, instrument X15/2 Distributor 55-pole X15/16 Plug-in connection, roof supply X14 4-pole rotating beacon socket

F11 F12 M2 M2/2 M7 M9 P7

A5 A6 B14 B15 E19 F8

Electrical equipment

15 8,12,13

VERSIONS to this Sheet 7 on Sheet/Sheets

Digital clock high-top Radio, high-top Interior lighting, high-top Rotating beacon, high-top Power socket 40A Air-sprung seat Windscreen washer-wiper, high-top Front/rear washers, high-top Rear screen washer-wiper, high-top several versions available

A# B# C# D# E F G# H# J# #

Designation of Sections

Brown Pink

Colourless Spare

L N P

Black

Light blue D+

K

S

Orange

H

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the 'E' Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable Green

E

+ 15 Si (Potential 15 safety)

Violet

Grey

D

+ Control line (positive)

-- Control line (ground)

G

Yellow

C

+30 (potential 30) = Cont. current

Type of use

F

Beige White

B

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Implement carrier Roof panel Rear mudguard

Ident. letter

3 7 17

Grounding point

CIRCUIT DIAGRAM

7-97170en

Rotating beacon unit Interior lighting Fuse, wiper, auxiliary control unit EGE F11 Fuse, hazard warning lights, clock F12 Fuse, power socket M2 Windscreen washer motor M2/2 Rear screen washer motor M7 Compressed air seat motor M9 Motor, twin washer pump S2/18/1 Switch, rotating beacon S2/24 Switch, windscreen wiper S2/30 Switch, rear screen wiper S24/1 Left-hand door contact switch S24/2 Right-hand door contact switch X1/2 1-pole plug-in connection, door contact X1/3 1-pole plug-in connection, door contact X3/24 Distributor, rear washer pump X3/50 3-pole plug-in connection, washer pump X3/54 Distributor, door contact X3/55 Distributor, windscreen washer X4/1 4-pole plug-in connection, rear wiper X5/23 Distributor potential 30, low-top X5/24 Distributor, rear wiper X11/11 Distributor, potential 15, roof X12/1 Plug-in connection, instrument – engine X14 3-pole power socket X15/1 Distributor 55-pole, instrument X15/2 Distributor 55-pole X15/16 Plug-in connection, roof supply X14 4-pole rotating beacon socket

A5 E19 F8

Electrical equipment

17 7,12,13

VERSIONS to this Sheet 8 on Sheet/Sheets

A# B# C# D# E F G# H# J# Interior lighting, high-top Rotating beacon, low-top Power socket 40A Air-sprung seat Windscreen washer-wiper, low-top Front/rear washers, low-top Rear screen washer-wiper, low-top #several versions available

Designation of Sections

Brown Pink

Colourless Spare

L N P

Black

Light blue D+

K

S

Orange

H

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the 'E' Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable Green

E

+ 15 Si (Potential 15 safety)

Violet

Grey

D

+ Control line (positive)

-- Control line (ground)

G

Yellow

C

+30 (potential 30) = Cont. current

Type of use

F

Beige White

B

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Implement carrier Roof panel Rear mudguard

Ident. letter

3 7 17

Grounding point

CIRCUIT DIAGRAM

7-97170en

S2/7 Switch, single-action auxiliary control unit S2/9 Switch, dual-action auxiliary control unit S2/13/1 Safety switch S14/3 Front lifting gear external pushbutton "lower" S15/3 Front lifting gear external pushbutton "raise" S16 Switch lever for auxiliary control unit X1/6 1-pole plug-in connection, supply for auxiliary control unit X4/6 4-pole plug-in connection, auxiliary control unit, potential 15 X4/31 4-pole plug-in connection, auxiliary control unit, solenoid valve X4/32 4-pole plug-in connection, auxiliary control unit, parallel X4/33 4-pole plug-in connection, auxiliary control unit, parallel X4/34 4-pole plug-in connection, EGE parallel Y2/1 Solenoid valve control unit Y2/2 Solenoid valve control unit Y2/3 Solenoid valve control unit Y2/4 Solenoid valve interlock block

Electrical equipment

19 10,14

VERSIONS to this Sheet 9 on Sheet/Sheets

#

several versions available

A Safety switch B# Single-action auxiliary control unit Multi-function lever C# Dual-action auxiliary control unit Multi-function lever D Front lifting gear, external operating pushbutton E Dual-action auxiliary control unit Toggle switch

Designation of Sections

Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

E F G

H K L N P

Black

Yellow

D

S

White

C

+30 (potential 30) = Cont. current Beige

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Red

Type of use

B

Colour

A

Ident. letter

Cable colour or coding in accordance with standard 05449

2 Instrument panel 15 Instrument panel socket

Grounding point

CIRCUIT DIAGRAM

7-97170en

S2/7 Switch, single-action auxiliary control unit S2/9 Switch, dual-action auxiliary control unit S2/13/1 Safety switch S16 Switch lever for auxiliary control unit X1/6 1-pole plug-in connection, supply for auxiliary control unit X4/6 4-pole plug-in connection, auxiliary control unit, potential 15 X4/31 4-pole plug-in connection, auxiliary control unit, solenoid valve X4/32 4-pole plug-in connection, auxiliary control unit, parallel X4/33 4-pole plug-in connection, auxiliary control unit, parallel Y2/1 Solenoid valve control unit Y2/2 Solenoid valve control unit Y2/3 Solenoid valve control unit Y2/4 Solenoid valve interlock block

Electrical equipment

21 9,14

VERSIONS to this Sheet 10 on Sheet/Sheets

A Safety switch B# Single-action auxiliary control unit Multi-function lever C# Dual-action auxiliary control unit Multi-function lever # several versions available

Designation of Sections

S

Black

Colourless Spare

P

Ground, directly to a grounding point

Spare

Ground via a box Pink

VDC, stabilised by the ’E’ Box

N

Orange

H

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch Light blue D+

Violet

G

Signal cable

Brown

Green

F

Potential 58 Lighting cable

L

Grey

E

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

+30 (potential 30) = Cont. current

Type of use

K

White Yellow

D

Beige

B C

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Instrument panel socket

Ident. letter

2 15

Grounding point

CIRCUIT DIAGRAM

7-97170en

X4/33 X6/6 X11/9 Y2/1 Y2/2 Y20 Y21

X4/33

X4/32

S16/3 X4/31

S15/3

B20 K6/12 R6 S14/3

A11

’E’ box Electronic Implement Load Relief EGE Pressure sensor for EGE Electronic implement load relief relay Potentiometer for EGE Front lifting gear external pushbutton "lower" Front lifting gear external pushbutton "raise" Switch lever for EGE 4-pole plug-in connection, auxiliary control unit, solenoid valve 4-pole plug-in connection, auxiliary control unit, parallel 4-pole plug-in connection, auxiliary control unit, parallel 4-pole plug-in connection, EGE parallel Plug-in connection for EGE Distributor for EGE Solenoid valve control unit Solenoid valve control unit Solenoid valve EGE Solenoid valve EGE

Electrical equipment

B

A

Front-end lifting gear, external operating pushbutton with EGE Electronic Implement Load Relief (EGE)

Designation of Sections

23

Orange

Light blue D+ Brown Pink

Colourless Spare Black

H K L N P S

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable Green

E

+ 15 Si (Potential 15 safety)

Violet

Grey

D

+ Control line (positive)

-- Control line (ground)

G

Yellow

C

+30 (potential 30) = Cont. current

Type of use

F

Beige White

B

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel socket Rear mudguard

Ident. letter

17

15

Grounding point

CIRCUIT DIAGRAM

7-97170en

25

X6/1 X9/3 Y13

S2/20 X3/40 X3/41 X3/42 X4/25

X1/5

A20 A21 F21 F22 F23 K5/26 K5/27 M12 F13 R9 R10 R11 S30 W2 S15/3

Air conditioning control Blower driver Fuse, air conditioning fan Fuse, roof blower motor Fuse, air conditioning Relay, air conditioning Relay, thermostat Roof blower motor Condensor, air conditioning Temperature sensor Potentiometer ON/OFF, air conditioning Potentiometer ON/OFF, blower Switch, air conditioning pressure Screened cable, air conditioning Front lifting gear external pushbutton "raise" 1-pole plug-in connection, air cond. compressor Plug-in connection, roof blower Plug-in connection, air cond. control Plug-in connection, temperature sensor Plug-in connection, blower potentiometer 4-pole plug-in connection, potentiometer Air conditioning 6-pole plug-in connection, blower Plug-in connection, roof air cond.

Magnetic coupling, air conditioning

Electrical equipment

7, 8, 13

VERSIONS to this Sheet 12 on Sheet/Sheets

A

Air conditioning, planta

Designation of Sections

Signal cable

Colourless Spare Black

P S

Pink

N

Ground, directly to a grounding point

Spare

Ground via a box

Brown

L

VDC, stabilised by the ’E’ Box

Orange

Light blue D+

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch H

Violet

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

+30 (potential 30) = Cont. current

Type of use

K

Green G

Yellow

D F

White

C

Grey

Beige

B

E

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Roof panel

Ident. letter

7

Grounding point

CIRCUIT DIAGRAM

7-97170en

Fuse, wiper, auxiliary control unit, EGE K3 Wiper interval relay K5/7 Relay, wiper M2 Windscreen washer motor M2/2 Rear screen washer motor M9 Motor, twin washer pump S2/24 Switch, windscreen wiper S2/30 Switch, rear screen wiper S2/31 Switch, wash V1/2 Diode group, wiper X3/17 3-pole plug-in connection, rear screen wiper X3/18 3-pole plug-in connection, windscreen wiper X3/50 3-pole plug-in connection, washer pump X4/24 4-pole plug-in connection, rear wiper X11/11 Distributor, potential 15, roof X12/1 Plug-in connection, instrument – engine X15/16 Plug-in connection, roof supply

F8

Electrical equipment

27 7, 8, 12

VERSIONS to this Sheet 13 on Sheet/Sheets

#

several versions available

A# Windscreen wiper, planta B# Rear screen wiper, planta C# Front/rear screen washer, planta

Designation of Sections

VDC, stabilised by the 'E' Box

S

Black

Ground, directly to a grounding point

Spare

Ground via a box Colourless Spare

Orange

H

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

P

Violet

G

Signal cable

Pink

Green

F

Potential 58 Lighting cable

N

Grey

E

+ Control line (positive) + 15 Si (Potential 15 safety)

Light blue D+

Yellow

D

Brown

White

C

-- Control line (ground)

L

Beige

B

+30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Roof panel

Ident. letter

7

Grounding point

CIRCUIT DIAGRAM

7-97170en

S2/13/1 Safety switch S2/15/2 Switch, dual-action, floating position S2/17 Switch, hydraulic motor S2/26 Switch, floating position V3 Diode 3A interlock X1/6 1-pole plug-in connection, supply for auxiliary control unit X4/6 4-pole plug-in connection, auxiliary control unit, potential 15 X4/31 4-pole plug-in connection, auxiliary control unit, solenoid valve X4/32 4-pole plug-in connection, auxiliary control unit, parallel X4/33 4-pole plug-in connection, auxiliary control unit, parallel Y2/1 Solenoid valve control unit Y2/2 Solenoid valve control unit Y2/3 Solenoid valve control unit Y2/4 Solenoid valve interlock block

Electrical equipment

29 9, 10

VERSIONS to this Sheet 14 on Sheet/Sheets

#

several versions available

A# Safety switch B# Dual-action auxiliary control unit Floating position + Shut-off valve Multi-function lever C# Auxiliary control unit, hydraulic motor

Designation of Sections

Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

E F G

H K L N P

Black

Yellow

D

S

White

C

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) Switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Beige

B

+30 (potential 30) = Cont. current

Red

Type of use

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Instrument panel socket

Ident. letter

2 15

Grounding point

CIRCUIT DIAGRAM

7-97170en

X 4/52

S 12

13 ^

^ 5

16 ^

^ 19

only 68/75

B1 48/58

S24/2

F100

X 16/1 X 12/1 X 4/51 X 4/50 X 1/50

X 19

X 1/3

Viewed from the front right

SS99D043

COMPONENTS and PLUG DESIGNATIONS

31

7-97170en

6

6

6

)

6 6

6

3

)

Only with air-conditioning Plantation tractor

Interior view

3

6

6

33

;

SS99D045

6

6 6

6

6

; 17

6 ;

6 ;

SS97K061

$

; 5

(*(

6

6

; ; ; ; ;

; ; ; ; ;

SS99D048

; ; ; ;

Implement carrier view

SS99D047

6

6

6

2

Instrument panel switch view

COMPONENTS and PLUG DESIGNATIONS

7-97170en

INSTRUMENTS TECHNICAL DATA and TEST VALUES

INSTRUMENTS Fuel gauge Diesel level 0 1/6 1/2 1/6

Resistor Ω 10 33,2 83,3 173,2

display sector red sector start of the yellow/green sector yellow/green sector end of the yellow/green sector

Water temperature gauge Temperature °C 40 75 105 113

Resistor Ω 287,4 80.9 33.6 27.2

120/6

22.7

Display sector 40 °C to 75 °C blue sector start of the yellow/green sector start of the red sector for Engine WD 301 (MWM) start of the red sector for Engine WD 303 (Perkins) end of the red sector

Tractormeter Engine speed RPM 1000 2000

permissive tolerance Analogue Digital +/-100 0 +/-65 0

frequency at generator terminal "W" WD 301 WD 303 254 HZ 269 HZ 508 HZ 538 HZ i = 1:2.54 1:2.69 (6 pole pairs)

Compressed air indicator Pressure in bar 0 5.5 10

Resistor Ω 10 115 184

Display sector red sector start of the yellow/green sector end of the yellow/green sector

35

7-97170en

INSTRUMENTS TECHNICAL DATA and TEST VALUES

SWITCHES, CUT-OUTS and TRANSMITTERS Motor temperature transmitter B1

130300080738

Compressed air indicator switch (breaker) S12 and compressed air transmitter B3 in one

169200710001

Front PTO switch (maker) S29

1-40-171-039

Switching point: Starting torque:

9 bar max. 30 Nm

SS99D051

Cold start facility cut-off switch S32 130300080715 (maker) switching point 40 °C Air filter monitoring switch (maker) S3 161200190040 4-pole switch, combined as a breaker and maker 1 - 40 - 171 - 051 contacts 1-2 maker/contacts 3-4 breaker for handbrake indicator (maker) S7 for 4-wheel drive indicator (maker) S18 for start inhibitor (maker) S10 SS99D053

for brake light indicator (maker) S5 Rear lock indicator switch (maker) S8 133700710023 Trailer brake valve switch, Italy (breaker) S50 Number not allocated Air-conditioning pressure switch Planta (maker) S30 Number not allocated Cut-out solenoid at 48/58 Y11 Number not allocated

37

7-97170en

INSTRUMENTS TECHNICAL DATA and TEST VALUES

LIGHT BULBS AND LIGHTS Type

Part No.

Cab interior lighting

L12V – 10 W

90003452249

Rotating warning lamp

H112V – 55 W

-34-772-051

Rocker switch

W5/1.2 – 12 V – 1.2 W

90003452250

Indicator lamp strip Instrument and indicator lamp

H12 V 2 W

90003452207

lighting

12 V/1.2 W

90003450031

Head lamps, Cab roof head lamps

H4 12 V – 60/50 W

90003450013

Searchlights

H312 V – 55 W

90003452243

Front sidelights, tail lights

G12 V – 5 W

90003452216

Indicators, front and rear, brake light

P25-112 V – 21 W

90003452245

Roof number-plate lamps

L12 V – 10 W

90003452276

Digital tractor meter

12 V/2 W

35700580708

FUSES 3A 5A 7,5 A 10 A 15 A

violet beige brown red light blue

1 - 40 - 258 - 203 1 - 40 - 258 - 105 1 - 40 - 258 - 107 1 - 40 - 258 - 110 1 - 40 - 258 - 115

100 A

20A 25A 30A 40A

yellow white green orange

1 - 40 - 258 - 120 1 - 40 - 258 - 125 1 - 40 - 258 - 130 1 - 40 - 258 - 140

1 - 40 - 277 - 014

39

7-97170en

INSTRUMENTS TECHNICAL DATA and TEST VALUES

Calibrating the speedometer (after replacing tyres or when 3 bars appear on the km/h display) Measure out a distance of exactly 100 m and mark both ends clearly.

– Press the switchover button (engine speed/rear PTO shaft/front PTO shaft/operating hours) for at least 10 seconds, until CAL appears on the km/h display.

– Start to drive and when the tractor’s front axle is in line with the 0 mark, press the pushbutton briefly – the letters COU will then appear on the display.

The impulses will be counted to 9999 on the bottom part of the display, ---- will appear above this, pay no attention to this.

WARNING! Minimum speed within the 100 m markings = 2 km/h – it is possible to drive faster.

– When the front axle is in line with the 100 m mark, press the pushbutton briefly once again – the letters PRO appear on the display.

– Bring the tractor to a halt and if the programming sequence was carried out correctly, press the pushbutton briefly once again – the tractor will then store the new, calibrated count.

If a fault occurs during calibration (delay in pressing the switch etc.) – simply switch the ignition OFF before pressing the switch for the last time, the programming sequence will thus not be accepted and the old values remain in effect.

SS99D060

Repeat the procedure.

41

7-97170en

Chapter

CIRCUIT DIAGRAM

4002

4002

M968, M968a, M975a CS68, CS68a, CS75a post DBD 40001

CASE-STEYR Landmaschinentechnik GmbH Technische Dokumentation/Training Center A - 4300 St. Valentin, Steyrer Straße 32

Sva 7-97000 EN

© 1999 Case Steyr Landmaschinentechnik GmbH October, 1999

4002-2

,1'(; CIRCUIT DIAGRAM INDEX ......................................................................................................................................... 3 Sheet 1 ......................................................................................................................................................................... 4 Sheet 2 ......................................................................................................................................................................... 6 Sheet 3 ......................................................................................................................................................................... 8 Sheet 4 ....................................................................................................................................................................... 10 Sheet 5 ....................................................................................................................................................................... 12 Sheet 6 ....................................................................................................................................................................... 14 Sheet 6a ..................................................................................................................................................................... 16 Sheet 7 ....................................................................................................................................................................... 18 Sheet 8 ....................................................................................................................................................................... 20 Sheet 9 ....................................................................................................................................................................... 22 Sheet 10 ..................................................................................................................................................................... 24 Sheet 11 ..................................................................................................................................................................... 26 Sheet 12 ..................................................................................................................................................................... 28 Sheet 13 ..................................................................................................................................................................... 30 Sheet 14 ..................................................................................................................................................................... 32 List of Plugs................................................................................................................................................................ 34 List of Plugs................................................................................................................................................................ 35 List of Plugs................................................................................................................................................................ 36 List of Plugs................................................................................................................................................................ 37 List of Plugs................................................................................................................................................................ 38 Blower motor – Control A21 ....................................................................................................................................... 39 Air-conditioning – control A20 .................................................................................................................................... 39 EGE control unit A11.................................................................................................................................................. 40 Fuse box..................................................................................................................................................................... 40 Relays ........................................................................................................................................................................ 41 Switches ..................................................................................................................................................................... 42 Potentiometers ........................................................................................................................................................... 44 Sensors ...................................................................................................................................................................... 45 Solenoid Valves.......................................................................................................................................................... 46 Instrument Test Values .............................................................................................................................................. 47 Lamps and Fuses....................................................................................................................................................... 48 Operation and Coding the Digital Instrument with Integrated operating Hours Counter ............................................ 49 Calibrating the speedometer ...................................................................................................................................... 50

Sva 7-97000 EN

Edition 10/99

4002-3

CIRCUIT DIAGRAM INDEX M968-M975 / CS68-CS75

Title Air conditioning Air-sprung seat Analogue tractor meter Auxiliary control unit, hydraulic motor Blower motor for high-top Blower motor, for plantation tractors Brake lights + 4-wheel drive + Opti Stop Combination instrument + Fuel tank pump Continuous power socket+ Power socket 40A Differential lock, rear

Sheet (e.g. 1) Section (e.g. A) 10D 6F 5B 13C# 10B 10C 6B

Light switch Number plate lighting, high-top Power supply Pre-glowing Radio, high-top Rear washer/wiper, high-top Rear washer/wiper, low-top

Sheet (e.g. 1) Section (e.g. A) 1E 3G 1A 1D 7B# 7H# 8H#

5A

Rear wiper, plantation tractor

9B

7E

Rear, inner roof searchlight

3E

6A

3F

7D# 8D#

Title

Digital clock, high-top

7A#

Digital instrument Distributor potential 58 Double action auxiliary control unit, + floating position + shut-off valve, multifunction lever Double-action auxiliary control unit multi-function lever Double-action auxiliary control unit multi-function lever/lever switch Double-action auxiliary control unit toggle switch Electronic implement load relief

5C 3C

Rear, outer roof searchlight Roof supply potential 58, cigarette lighter Rotating beacon, high-top Rotating beacon, low-top

13B#

Safety switch

11A

11C#

Searchlight switch

3D

12C#

Searchlight, mudguard

3B

11E

Sidelight

4A

14B

Sidelight, high-top Single-action auxiliary control unit multi-function lever

2H#

Engine cut-out External operating buttons for front-end lifting gear with electronic implement load relief Filter heating Front headlamp, high-top Front headlamp, low-top Front washer/wiper, high-top Front washer/wiper, low-top Front wiper, plantation tractor Front-end lifting gear, external operating pushbutton Front/rear screenwasher, high-top Front/rear screenwasher, low-top Front/rear screenwasher, plantation tractor Heating Indicator lamp block Interior light, high-top Interior light, low-top Italian brake Sva 7-97000 EN

1C

4B

11B#

14A

Single-action auxiliary control unit multi-function lever/lever switch

12B#

3H 2G# 1G# 7F# 8F# 9A

Standard signal socket Starter, Start inhibit, Front PTO shaft Starter, Start inhibit, Rear PTO shaft Steering column switch, horn Supply potential 58 Trafficator system

5D 1B# 2B# 1F 3A 4C

11D 7G# 8G# 9C 10A 6C 7C# 8C# 6D Edition 10/99

Sheet 1

SS99D124

4002-4

Sva 7-97000 EN

Edition 10/99

Electrical equipment

Headlight, left Headlight, right Glow plug Fuse, high-beam headlight Fuse, dipped-beam headlight Fuse, engine cut-out Main fuse Battery 12V/90AH Generator 12V/770W Horn Changeover relay 56a-56b Relay, reserve headlight Relay, reserve headlight Relay, neutral position Starter motor Switch, pre-glow start Switch, lighting system Switch, reserve headlight Switch, steering column, main/dipped beam S9 Front PTO shaft start inhibit switch S10 Switch, neutral position S11 Front PTO shaft start inhibit switch X3/3 Plug-in connection, roof X3/5 Distributor 56a X3/8 Distributor 56b X3/31 Distributor 56 X4/2 Plug-in connection, start inhibit, chassis, right X4/51 Plug-in connection, instrument - engine X5/10 Distributor, roof changeover switch X5/11 Distributor, roof 56a X5/12 Distributor, roof 56b X9/9 Plug-in connection, instrument - steering column X12/1 Plug-in connection, instrument - engine X15/16 Plug-in connection, roof supply X16/1 Distributor, potential 30 instrument X55 Distributor, instrument Y11 Engine cut-out solenoid valve

E1 E2 E10/1 F13 F14 F15 F100 G1 G2/1 H1 K5/1 K5/5 K5/6 K8/1 M1 S1 S2/1 S2/38 S4/1

Sva 7-97000 EN

2

VERSIONS to this Sheet 1 on Sheet/Sheets

#

several versions available

A# Power supply B# Starter + Start inhibit + Front PTO shaft Switches C# Engine cut-out D Pre-glowing E Light circuit F Steering column switch, horn G# Front headlight, low-top

Designation of Sections

Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

E F G

H K L N P

Black

Yellow

D

S

White

C

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Beige

B

+ 30 (potential 30) = Cont. current

Red

Type of use

A

Colour

Cable colour or coding in accordance with standard 05449 Ident. letter

12 16

Battery Instrument panel Implement carrier Roof panel Starter flange Frame, front of cab Battery rack Starter

Grounding points 1 2 3 7 10 11

4002-5

Edition 10/99

Sheet 2

SS99D125

4002-6

Sva 7-97000 EN

Edition 10/99

Headlight, left Headlight, right Glow plug Reserve headlight, left Reserve headlight, right Sidelight, roof, left Sidelight, roof, left Fuse, high-beam headlight Fuse, dipped-beam headlight Fuse, engine cut-out Main fuse Battery 12V/90AH Generator 12V/770W Horn Changeover relay 56a-56b Relay, reserve headlight Relay, reserve headlight Relay, neutral position Starter motor Switch, pre-glow start Switch, lighting system Switch, reserve headlight Switch, steering column, main/dipped beam S10 Switch, neutral position S11 Front PTO shaft start inhibit switch X3/3 Plug-in connection, roof X3/5 Distributor 56a X3/8 Distributor 56b X3/31 Distributor 56 X4/2 Plug-in connection, start inhibit, chassis, right X4/51 Plug-in connection, instrument - engine X5/10 Distributor, roof changeover switch X5/11 5-pole plug-in connection, roof 56a X5/12 5-pole plug-in connection, roof 56b X9/9 Plug-in connection, instrument - steering column X12/1 Plug-in connection, instrument - engine X15/16 Plug-in connection, roof supply X16/1 Distributor, potential 30 instrument X55 Distributor, instrument Y11 Engine cut-out solenoid valve

E1 E2 E10/1 E21 E22 E31 E32 F13 F14 F15 F100 G1 G2/1 H1 K5/1 K5/5 K5/6 K8/1 M1 S1 S2/1 S2/38 S4/1

Electrical equipment

Sva 7-97000 EN

1

VERSIONS to this Sheet 2 on Sheet/Sheets

#

several versions available

A Power supply B# Starter + Start inhibitor + without Front PTO shaft switch C# Engine cut-out D Pre-glowing E Light circuit F Steering column switch, horn G# Front headlight, high-top H# Sidelight, high-top

Designation of Sections

VDC, stabilised by the ’E’ Box

S

Black

Ground, directly to a grounding point

Spare

Ground via a box Colourless Spare

Orange

H

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

P

Violet

G

Signal cable

Pink

Green

F

Potential 58 Lighting cable

N

Grey

E

+ Control line (positive) + 15 Si (Potential 15 safety)

Light blue D+

Yellow

D

Brown

White

C

-- Control line (ground)

L

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Battery Instrument panel Implement carrier Roof panel Starter flange Frame, front of cab Battery rack Starter

Ident. letter

12 16

1 2 3 7 10 11

Grounding points

4002-7

Edition 10/99

Sheet 3

SS99D126

4002-8

Sva 7-97000 EN

Edition 10/99

Group, number plate, roof, left Group, number plate, roof, right Searchlight, left-hand mudguard Searchlight, right-hand mudguard Fuel filter heating Searchlight, roof, rear left, inner Searchlight, roof, rear left, outer Searchlight, roof, rear right, inner Searchlight, roof, rear right, outer Filter heating element Fuse, searchlight, mudguard Fuse, searchlight, roof, rear Fuse, filter heating Relay, filter heating Relay, supply potential 58 Switch, searchlight, mudguard Switch, rear searchlight, roof Filter thermostat Plug-in connection, roof Distributor, searchlight, roof Searchlight, plug-in connection, mudguard left/right X4/3 Plug-in connection, chassis, right X4/14 Searchlight, plug-in connection, rear left, inner X4/15 Searchlight, plug-in connection, rear left, outer X4/16 Searchlight, plug-in connection, rear right, outer X4/17 Searchlight, plug-in connection, rear right, inner X4/18 Plug-in connection, number plate, roof, left X4/19 Plug-in connection, number plate, roof, right X5/13 Distributor, searchlight, roof X11/50 Distributor potential 58 X15/16 Plug-in connection, roof supply

E5/3 E5/4 E8 E9 E10 E23/1 E23/2 E24/1 E24/2 E32 F1 F4 F43 K5/28 K6/10 S2/2 S2/63 S26 X3/3 X3/14 X2/

Electrical equipment

Sva 7-97000 EN

A B C D E F G H

Power supply potential 58 Searchlight, mudguard Distributor potential 58 Switch, searchlight Roof searchlight, rear inner Roof searchlight, rear outer Number plate lighting, high-top Filter heating

Designation of Sections

Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare Black

E F G

H K L N P S

+ Control line (positive)

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

White Yellow

-- Control line (ground)

D

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

C

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Implement carrier Roof panel

Ident. letter

3 7

Grounding points

4002-9

Edition 10/99

Sheet 4

SS99D127

4002-10

Sva 7-97000 EN

Edition 10/99

Sidelight, front left Sidelight, rear left Group, number plate, left Sidelight, front right Sidelight, rear right Cigarette lighter Indicator, front right Indicator, rear right Trafficator, rear left Indicator, front left Fuse, sidelight, left Fuse, sidelight, right Fuse, trafficator system Blinker relay Switch, hazard warning lights Switch, steering column, indicator Plug-in connection, trafficator/brake light, left X4/12 Plug-in connection, trafficator/brake light, right X5/2 Distributor potential 58 X9/9 Plug-in connection, instrument - steering column X10 Plug-in connection 7-pole, trailer X11/10 Distributor, potential 58, high-top X15/16 Plug-in connection, roof supply X55 Distributor, instrument

E3 E4 E5/1 E6 E7 E11 E14 E15 E16 E17 F2 F3 F6 K2 S2/5 S4/2 X4/11

Electrical equipment

Sva 7-97000 EN

C

A B

Sidelight Supply, roof, potential 58 Cigarette lighter Trafficators

Designation of Sections

Signal cable

Pink

Colourless Spare Black

P S

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

N

Violet

G

Brown

Green

F

Potential 58 Lighting cable

L

Grey

E

+ 15 Si (Potential 15 safety)

Orange

Yellow

D

+ Control line (positive)

-- Control line (ground)

Light blue D+

White

C

H

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier Engine compartment Roof panel

Ident. letter

2 3 5 7

Grounding points

4002-11

Edition 10/99

Sheet 5

SS99D128

4002-12

Sva 7-97000 EN

Edition 10/99

Sva 7-97000 EN

X4/23 X4/52 X5/1 X5/51 X6/3 X9/1 X9/2 X12/1 X30

X4/1

A1 B1 B2/1 B3 B6 B7 F5 M8/1 P1 P3 S2/57 S12 S29 X2/3

Digital instrument Engine temperature transmitter Fuel tank content transmitter, left Compressed air transmitter Inductive speed transmitter Inductive rear PTO shaft speed transmitter Fuse, instrument, clock Left-hand tank pump motor Combination unit, square Analogue tractor meter Switch, digital switchover Switch, compressed air indicator Switch, front PTO shaft Plug-in connection, compressed air system Plug-in connection, instrument cable chassis, left Plug-in connection, standard signal Plug-in connection, digital transmitter Distributor, terminal W Distributor potential D+ Plug-in connection, transmitter cable Plug-in connection, digital Plug-in connection, digital Plug-in connection, instrument - engine 7-pole signal socket

Electrical equipment A B C D

Combination instrument, fuel tank pump Analogue tractor meter Digital instrument Standard signal socket

Designation of Sections

Orange

Light blue D+ Brown Pink

Colourless Spare Black

K L N P S

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

H

Grey

E

+ 15 Si (Potential 15 safety) Green

Yellow

D

+ Control line (positive)

-- Control line (ground)

Violet

White

C

G

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

F

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier

Ident. letter

2 3

Grounding points

4002-13

Edition 10/99

Sheet 6

SS99D129

4002-14

Sva 7-97000 EN

Edition 10/99

Sva 7-97000 EN

X4/3 X10 X11/7 X12/1 X55 Y1 Y10 Y50

/1 /2 /3 /4 /5 /6 /7 /8 /9 /10 /11 /12 /13 F7 H2/ K5/12 K5/50 M7 S2/56 S2/59 S3 S5 S6 S7 S8 S50 X2/10 X2/50 X3/22 X3/23 X4/1

4-wheel drive indicator Tractor trafficator repeater 1st trailer trafficator repeater 2nd trailer trafficator repeater Pre-glowing indicator Main beam indicator Engine oil pressure indicator Compressed air indicator Handbrake indicator Air filter indicator Generator charging indicator Rear differential lock indicator Front differential lock indicator Fuse, brake lights, tank pump Lamp cluster indicator Relay, 4-wheel drive, brake light Relay, trailer brake valve Compressed air seat motor Switch, differential lock Switch, 4-wheel drive Switch, air filter indicator Switch, brake light Switch, engine oil pressure indicator Switch, handbrake indicator Switch, rear differential lock indicator Switch, trailer brake indicator, Italy Plug-in connection, OPTI STOP Plug-in connection, trailer brake Distributor, 4-wheel drive Distributor, 4-wheel drive indicator Plug-in connection, instrument cable chassis, left Plug-in connection, chassis, right Plug-in connection, 7-pole, trailer Distributor, potential 15 instrument Plug-in connection, instrument - engine Distributor, instrument 4-wheel drive solenoid valve Rear differential lock solenoid valve Trailer brake valve solenoid valve, Italy

Electrical equipment

6a

VERSIONS to this Sheet 6 on Sheet/Sheets

A B D D E

Rear differential lock 4-wheel drive with OPTI STOP Indicator lamp block Italian brake Air-sprung seat

Designation of Sections

VDC, stabilised by the ’E’ Box

S

Black

Ground, directly to a grounding point

Spare

Ground via a box Colourless Spare

Orange

H

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

P

Violet

G

Signal cable

Pink

Green

F

Potential 58 Lighting cable

N

Grey

E

+ Control line (positive) + 15 Si (Potential 15 safety)

Light blue D+

Yellow

D

Brown

White

C

-- Control line (ground)

L

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier Driver’s cab frame Carrier frame

Ident. letter

2 3 11 12

Grounding points

4002-15

Edition 10/99

Sheet 6a

SS99J192

4002-16

Sva 7-97000 EN

Edition 10/99

Sva 7-97000 EN

X4/3 X10 X11/7 X12/1 X55 Y1 Y10 Y50

/1 /2 /3 /4 /5 /6 /7 /8 /9 /10 /11 /12 /13 F7 H2/ K5/12 K5/50 M7 S2/56 S2/59 S3 S5 S6 S7 S8 S50 X2/10 X2/50 X3/22 X3/23 X4/1

4-wheel drive indicator Tractor trafficator repeater 1st trailer trafficator repeater 2nd trailer trafficator repeater Pre-glowing indicator Main beam indicator Engine oil pressure indicator Compressed air indicator Handbrake indicator Air filter indicator Generator charging indicator Rear differential lock indicator Front differential lock indicator Fuse, brake lights, tank pump Lamp cluster indicator Relay, 4-wheel drive, brake light Relay, trailer brake valve Compressed air seat motor Switch, differential lock Switch, 4-wheel drive Switch, air filter indicator Switch, brake light Switch, engine oil pressure indicator Switch, handbrake indicator Switch, rear differential lock indicator Switch, trailer brake indicator, Italy Plug-in connection, OPTI STOP Plug-in connection, trailer brake Distributor, 4-wheel drive Distributor, 4-wheel drive indicator Plug-in connection, instrument cable chassis, left Plug-in connection, chassis, right Plug-in connection, 7-pole, trailer Distributor, potential 15 instrument Plug-in connection, instrument - engine Distributor, instrument 4-wheel drive solenoid valve Rear differential lock solenoid valve Trailer brake valve solenoid valve, Italy

Electrical equipment

6

VERSIONS to this Sheet 6a on Sheet/Sheets

D D E

A B

Rear differential lock 4-wheel drive with OPTI STOP M968-75 valid from DBD 40497 CS68-75 valid from DBD 40490 Indicator lamp block Italian brake Air-sprung seat

Designation of Sections

Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

G

H K L N P

Black

Green

F

S

Grey

E

+ Control line (positive)

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

White Yellow

-- Control line (ground)

D

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

C

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Implement carrier Driver’s cab frame Carrier frame

Ident. letter

2 3 11 12

Grounding points

4002-17

Edition 10/99

Sheet 7

SS99D130

4002-18

Sva 7-97000 EN

Edition 10/99

Rotating beacon Radio Right-hand loudspeaker Left-hand loudspeaker Interior lighting Fuse, wiper, auxiliary control unit EGE F11 Fuse, hazard warning lights, clock F12 Fuse, power socket M2 Windscreen washer motor M2/2 Rear screen washer motor M9 Motor, twin washer pump P7 Digital clock S2/18/1 Switch, rotating beacon S2/24 Switch, windscreen wiper S2/30 Switch, rear screen wiper S24/1 Left-hand door contact switch S24/2 Right-hand door contact switch W6 Aerial X1/2 Plug-in connection, door contact X1/3 Plug-in connection, door contact X2/1 Continuous current socket, potential 30/31 X2/4 Plug-in connection, washer pump X3/15 Plug-in connection, washer pump X3/16 Plug-in connection, rear washer pump X3/17 Plug-in connection, rear wiper X3/18 Plug-in connection, front wiper X3/19 Plug-in connection, door contact X4/1 4-pole plug-in connection, rear wiper X11/11 Distributor, potential 15, roof X11/12 Distributor, potential 30, roof X12/1 Plug-in connection, instrument - engine X14 Power socket 40A X15/16 Plug-in connection, roof supply X14 4-pole rotating beacon socket X55 Distributor, instrument

A5 A6 B14 B15 E19 F8

Electrical equipment

Sva 7-97000 EN

8, 9, 10

VERSIONS to this Sheet 7 on Sheet/Sheets

#

several versions available

Digital clock high-top Radio, high-top Interior lighting, high-top Rotating beacon, high-top Continuous current socket Power socket 40A F# Front washer/wiper, high-top G# Front/rear washer, high-top H# Rear washer/wiper, high-top

A# B# C# D# E

Designation of Sections

Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

F G

H K L N P

Black

Grey

E

S

Yellow

D

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Beige White

C

+ 30 (potential 30) = Cont. current

Type of use

B

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Implement carrier Roof panel Rear mudguard

Ident. letter

3 7 17

Grounding points

4002-19

Edition 10/99

Sheet 8

SS99D131

4002-20

Sva 7-97000 EN

Edition 10/99

A5 Rotating beacon E19 Interior lighting F8 Fuse, wiper, auxiliary control unit EGE F11 Fuse, hazard warning lights, clock F12 Fuse, power socket M2 Windscreen washer motor M2/2 Rear screen washer motor M9 Motor, twin washer pump S2/18/1 Switch, rotating beacon S2/24 Switch, windscreen wiper S2/30 Switch, rear screen wiper S24/1 Left-hand door contact switch S24/2 Right-hand door contact switch X1/2 Plug-in connection, door contact X1/3 Plug-in connection, door contact X2/1 Continuous current socket, potential 30/31 X2/4 Plug-in connection, washer pump X3/24 Distributor, for washer pump X3/54 Distributor, door contact X3/55 Distributor, windscreen washer X4/1 4-pole plug-in connection, rear wiper X5/23 Distributor potential 30, low-top X5/24 Distributor, rear wiper X11/11 Distributor, potential 15, roof X12/1 Plug-in connection, instrument - engine X14 3-pole power socket X15/16 Plug-in connection, roof supply X14 4-pole rotating beacon socket X55 Distributor, instrument

Electrical equipment

Sva 7-97000 EN

7, 9, 10

VERSIONS to this Sheet 8 on Sheet/Sheets

A# B# C# D# E F G# H# J# # Interior lighting, low-top Rotating beacon, low-top Power socket 40A Air-sprung seat Front washer/wiper, low-top Front/rear washer, low-top Rear washer/wiper, low-top several versions available

Designation of Sections

Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

F G

H K L N P

Black

Grey

E

S

Yellow

D

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Beige White

C

+ 30 (potential 30) = Cont. current

Type of use

B

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Implement carrier Roof panel Rear mudguard

Ident. letter

3 7 17

Grounding points

4002-21

Edition 10/99

Sheet 9

SS99D132

4002-22

Sva 7-97000 EN

Edition 10/99

Fuse, wiper, auxiliary control unit, electronic implement load relief K3 Wiper interval relay K5/7 Relay, wiper M2 Windscreen washer motor M2/2 Rear screen washer motor M9/1 Motor, single washer pump S2/24 Switch, windscreen wiper S2/30 Switch, rear screen wiper S2/31 Switch, wash V1/2 Diode group, wiper X2/4 Distributor, washer pump X3/17 Distributor, rear wiper X3/18 Distributor, front wiper X4/24 Plug-in connection, rear wiper X11/11 Distributor, potential 15, continuous current X12/1 Plug-in connection, instrument - engine X15/16 Plug-in connection, roof supply X55 Distributor, instrument

F8

Electrical equipment

Sva 7-97000 EN

7, 8, 10

VERSIONS to this Sheet 9 on Sheet/Sheets

A# B# C# #

Windscreen wiper, plantation tractor Rear screen wiper, plantation tractor Front/rear screen washer, plantation tractor several versions available

Designation of Sections

Grey Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

E F G

H K L N P

Black

Yellow

D

S

White

C

+ 30 (potential 30) = Cont. current Beige

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Red

B

Type of use

A

Colour

Cable colour or coding in accordance with standard 05449

Roof panel

Ident. letter

7

Grounding points

4002-23

Edition 10/99

Sheet 10

SS99D133

4002-24

Sva 7-97000 EN

Edition 10/99

Sva 7-97000 EN

X4/50 X6/1 X9/3 Y13

S2/20 X3/2 X3/4 X3/40 X3/41 X3/42 X4/25

A20 A21 F9 F10 F16 K5/26 K5/27 M3 M10 M12 F13 R9 R10 R11 S30 S50/1 S50/2 W2 X1/5

Air-condition control Blower driver Fuse, heating, horn Fuse, roof blower motor Fuse, air conditioning Relay, air conditioning Relay, thermostat Heater blower motor Roof blower motor Roof blower motor Condenser, air conditioning Temperature sensor Air conditioning control potentiometer Roof blower motor potentiometer Switch, air conditioning pressure Switch, heating Switch, roof blower motor Screened cable, air conditioning Plug-in connection, air-conditioning compressor Plug-in connection, roof blower Distributor, blower motor, roof Distributor, potential 15, roof Plug-in connection, air cond. control Plug-in connection, temperature sensor Plug-in connection, blower potentiometer Plug-in connection, potentiometer, air-conditioning Plug-in connection, heating Plug-in connection, blower motor Plug-in connection, roof air cond.

Magnetic coupling, air conditioning

Electrical equipment

7, 8, 9

VERSIONS to this Sheet 10 on Sheet/Sheets

A B C D

Heating Blower motor for high-top Blower motor, plantation tractor Air-conditioning, plantation tractor

Designation of Sections

Green Violet

E F G

Black

Colourless Spare

P S

Pink

N

Ground, directly to a grounding point

Spare

Ground via a box

Light blue D+ Brown

L

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

+ 30 (potential 30) = Cont. current

Type of use

K

Orange

Grey

D

H

White Yellow

C

Beige

Red

B

A

Colour

Cable colour or coding in accordance with standard 05449

Implement carrier Roof panel

Ident. letter

3 7

Grounding points

4002-25

Edition 10/99

Sheet 11

SS99D134

4002-26

Sva 7-97000 EN

Edition 10/99

S2/7 Switch, single-action auxiliary control unit S2/9 Switch, dual-action auxiliary control unit S2/13/1 Safety switch S14/3 Front lifting gear external pushbutton LOWER S15/3 Front lifting gear external pushbutton RAISE S16 Switch lever for auxiliary control unit X4/6 Distributor, auxiliary control unit, potential 15 X4/31 Plug-in connection, auxiliary control unit solenoid valve X4/32 Plug-in connection, auxiliary control unit, parallel X4/33 Plug-in connection, auxiliary control unit, parallel X4/34 Plug-in connection, electronic implement load relief, front X55 Distributor, instrument Y2/1 Solenoid valve control unit Y2/2 Solenoid valve control unit Y2/3 Solenoid valve control unit Y2/4 Solenoid valve interlock block

Electrical equipment

Sva 7-97000 EN

12,13

VERSIONS to this Sheet 11 on Sheet/Sheets

#

several versions available

A Safety switch B# Single-action auxiliary control unit Multi-function lever C# Dual-action auxiliary control unit Multi-function lever D Front lifting gear, external operating pushbutton E Dual-action auxiliary control unit Lever switch

Designation of Sections

Green Violet

Orange

Light blue D+ Brown Pink

Colourless Spare

F G

H K L N P

Black

Grey

E

S

Yellow

D

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

Beige White

C

+ 30 (potential 30) = Cont. current

Type of use

B

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Instrument panel socket

Ident. letter

2 15

Grounding points

4002-27

Edition 10/99

Sheet 12

SS99D135

4002-28

Sva 7-97000 EN

Edition 10/99

S2/7 Switch, single-action auxiliary control unit S2/9 Switch, dual-action auxiliary control unit S2/13/1 Safety switch S16 Switch lever for auxiliary control unit X4/6 Distributor, auxiliary control unit, potential 15 X4/31 Plug-in connection, auxiliary control unit solenoid valve X4/32 Plug-in connection, auxiliary control unit, parallel X4/33 Plug-in connection, auxiliary control unit, parallel X55 Distributor, instrument Y2/1 Solenoid valve control unit Y2/2 Solenoid valve control unit Y2/3 Solenoid valve control unit Y2/4 Solenoid valve interlock block

Electrical equipment

Sva 7-97000 EN

11, 13

VERSIONS to this Sheet 12 on Sheet/Sheets

#

several versions available

A Safety switch B# Single-action auxiliary control unit Multi-function lever C# Dual-action auxiliary control unit Multi-function lever

Designation of Sections

Signal cable

Colourless Spare Black

P S

Pink

Ground, directly to a grounding point

Spare

Ground via a box

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

N

Violet

G

Brown

Green

F

Potential 58 Lighting cable

L

Grey

E

+ 15 Si (Potential 15 safety)

Orange

Yellow

D

+ Control line (positive)

-- Control line (ground)

Light blue D+

White

C

H

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Instrument panel socket

Ident. letter

2 15

Grounding points

4002-29

Edition 10/99

Sheet 13

SS99D136

4002-30

Sva 7-97000 EN

Edition 10/99

S2/13/1 Safety switch S2/15/2 Switch, dual-action, floating position S2/17 Switch, hydraulic motor S2/26 Switch, floating position V3 Diode 3A interlock X4/6 Distributor, auxiliary control unit, potential 15 X4/31 Plug-in connection, auxiliary control unit solenoid valve X4/32 Plug-in connection, auxiliary control unit, parallel X4/33 Plug-in connection, auxiliary control unit, parallel X55 Distributor, instrument Y2/1 Solenoid valve control unit Y2/2 Solenoid valve control unit Y2/3 Solenoid valve control unit Y2/4 Solenoid valve interlock block

Electrical equipment

Sva 7-97000 EN

11, 12

VERSIONS to this Sheet 13 on Sheet/Sheets

#

several versions available

A# Safety switch B# Dual-action auxiliary control unit, floating position + (shut-off valve) Multi-function lever C# Auxiliary control unit, hydraulic motor

Designation of Sections

VDC, stabilised by the ’E’ Box

S

Black

Ground, directly to a grounding point

Spare

Ground via a box Colourless Spare

Orange

H

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch

P

Violet

G

Signal cable

Pink

Green

F

Potential 58 Lighting cable

N

Grey

E

+ Control line (positive) + 15 Si (Potential 15 safety)

Light blue D+

Yellow

D

Brown

White

C

-- Control line (ground)

L

Beige

B

+ 30 (potential 30) = Cont. current

Type of use

K

Red

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel Instrument panel socket

Ident. letter

2 15

Grounding points

4002-31

Edition 10/99

Sheet 14

SS99D137

4002-32

Sva 7-97000 EN

Edition 10/99

Sva 7-97000 EN

Y21

Y2/1 Y2/2 Y20

X11/9

X6/6

X4/34

X4/33

X4/32

X4/31

S16/3

S15/3

S14/3

K6/12 R6

A11 B20

’E’ box Electronic Implement Load Relief Pressure sensor for electronic implement load relief Relay, electronic implement load relief Potentiometer for electronic implement load relief Front lifting gear external pushbutton LOWER Front lifting gear external pushbutton RAISE Lever switch for electronic implement load relief Plug-in connection, auxiliary control unit solenoid valve Plug-in connection, auxiliary control unit, parallel Plug-in connection, auxiliary control unit, parallel Plug-in connection, electronic implement load relief, front Plug-in connection, electronic implement load relief Distributor for electronic implement load relief Solenoid valve control unit Solenoid valve control unit Solenoid valve for electronic implement load relief Solenoid valve for electronic implement load relief

Electrical equipment

B

A

Front-end lifting gear, external operating pushbutton, for electronic implement load relief Electronic implement load relief

Designation of Sections

Brown Pink

Colourless Spare Black

L N P S

Ground, directly to a grounding point

Spare

Ground via a box

Light blue D+

K

VDC, stabilised by the ’E’ Box

+ 15 (potential 15.1 or 15.2) switched current after the pre-glow switch Orange

Violet

G

Signal cable

Potential 58 Lighting cable

+ 15 Si (Potential 15 safety)

+ Control line (positive)

-- Control line (ground)

+ 30 (potential 30) = Cont. current

Type of use

H

Green

F

Yellow

D

Grey

White

C E

Beige

Red

B

A

Colour

Cable colour or coding in accordance with standard 05449

Instrument panel socket Rear mudguard, left EGE operating console Rear mudguard – right

Ident. letter

17 18

15

Grounding points

4002-33

Edition 10/99

4002-34

List of Plugs X 1/3 X 19

X 12/1 X 4/51 X 4/50 F 100

S24/2

B1

12

X 4/52

10 11

B 20 Y20 Y21

S6

S 12 B3

S 29 Y1 Y10

S3

16

X 1/2

X 19

E 10/1

S 24/1

S 26

S 15/3 S 14/3

Y 11

1

E10 M 8/1 B 2/1

SS99J202

Sva 7-97000 EN

Edition 10/99

4002-35

List of Plugs X 3/2 X 3/3 X 3/4 X 3/5 X 3/8 X 3/14 X 3/15 X 3/16 X 3/17 X 3/18 X 3/19 X 3/24 X 3/41 X 3/42 X 3/54 X 3/55

7

X 4/11 X 4/12

A6

S 50/2

X 2/1 E 11

X 5/2 X 5/10 X 5/11 X 5/12 X 5/13 X 5/24 1 2 3 4 5 6

X 11/10 X 11/11 X 11/12 X 15/16

S 2/24 S 2/38 S 2/63 S 2/2 S 2/30 S 2/18/1

X 4/16 X 4/17 X 4/18 X 4/24

SS99J205

E 5/3

X 4/14 X 4/15 X 4/19

E 5/4

A5

E 23/2

E 23/1 X 10

E8

E 24/2

E 24/1 Y 2/1 Y2/2 (EGE)

E9

X 30 X 4/31 X 4/32 X 4/33 X 4/34

15 X 14

17 Y 50 S 50 S8

B6

B7

SS99J204

Sva 7-97000 EN

Edition 10/99

4002-36

List of Plugs X 4/11 X 4/12

X 3/2 X 3/3 X 3/4 X 3/5 X 3/8 X 3/14 X 3/15 X 3/16 X 3/17 X 3/18 X 3/19 X 3/24 X 3/41 X 3/42 X 3/54 X 3/55

A6

X 5/2 X 5/10 X 5/11 X 5/12 X 5/13 X 5/24

R 10 1 2 3 4 5 6 7

X 11/10 X 11/11 X 11/12 X 15/16

S 2/24 S 2/31 S 2/38 S 2/63 S 2/2 S 2/30 S 2/18/1

X 1/5

K3 K 5/7 V 1/2 X 2/20 X 3/40 X 4/25 X 6/1 X 9/3

R 11

S 30

SS99J203

Y 13

Condenser

M 13

R9

M 12 Dryer K 5/26

A 21

A 20

K 5/27

SS99D050

Sva 7-97000 EN

Edition 10/99

4002-37

List of Plugs

P1

S 4/1 S 4/2

A1 P3

F 1-16 S5

S 10

S7

K 5/28 F 43

S 2/7 S 2/9 S 2/15

S 2/17

EGE

S 16/3 (X 6)

SS99J199

S 16 (X 6) R6 (X 4/32)

A 11 K 6/12 (Fuse)

17 X 11/9 SS97K061 Sva 7-97000 EN

Edition 10/99

4002-38

List of Plugs X 4/1

X 9/1 X 9/2

X 12/1

S 50/1

S1

2 S2/13/1

S2/57

S2/1

S2/59

S2/5

S2/56 X 11/50 X 5/51

X 5/1

SS99J201

X 5/51

X 11/7

X 3/8

X 3/22

X 3/23

X 3/31

X 3/5

X 16/1 K 5/50 K 5/12

3 K 6/10 K 5/1 K 5/5 K 5/6

Sva 7-97000 EN

K2 K 8/1 X 55 SS99J200

Edition 10/99

4002-39

Blower motor – Control A21

SS99J156

List of plugs, blower motor – control X 3/42

Plug-in connection, blower motor potentiometer (R 11)

Air-conditioning – control A20

SS99J080

List of plugs, air-conditioning – control X 3/40 X 4/25

Plug-in connection, air-conditioning control Plug-in connection, air-conditioning potentiometer (R 10)

Sva 7-97000 EN

Edition 10/99

4002-40

EGE control unit A11

SS99J232

List of plugs, EGE control unit X 6/6

Plug-in connection, electronic implement load relief

R6

Electronic implement load relief potentiometers

Fuse box

SS99J235

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 R

Searchlight mudguard, pot. 58 (switch and instrument lighting) ..................................................................... 15 Ampere Left-hand parking lamp, number plate lighting – mudguard, pot. 58 L .......... 7.5 Ampere Right-hand parking light, pot. 58 R clock and switch lighting, Roof number plate lighting, roof parking light ................................................ 7.5 Ampere Rear roof searchlight ...................................................................................... 20 Ampere Instruments, digital clock ............................................................................... 7,5 Ampere Blinker, standard signal socket ....................................................................... 10 Ampere Brake lights, indicator lamps, compressed air seat, digital tractor meter Cold-start accelerator, 4-wheel drive/diff. lock, trailer brakes ........................... 5 Ampere Fuel tank pump, front and rear wipers, safety switch Washer pump, auxiliary headlight switch, air-cond. compressor .................... 15 Ampere Heater blower motor, horn .............................................................................. 20 Ampere Blower motor, roof.............................................................................................. 20 Amps Hazard warning lights, digital clock, power socket, cigarette lighter, interior lighting, rotating beacon...................................................................... 15 Ampere Power socket ..................................................................................................... 40 Amps Main beam ......................................................................................................... 15 Amps Dipped beam ..................................................................................................... 15 Amps Electrical engine stop..................................................................................... 7.5 Ampere Air-cond. fan ..................................................................................................... 20 Amps Room for spare fuses Glass fuse for EGE (on the printed circuit in the EGE operating console) ....... 4 Ampere

Sva 7-97000 EN

Edition 10/99

4002-41

Relays Miniature relays: Centre zero relay / Normally open

SS99K014

Rated voltage..............................................12 VDC Load............................................................ 20/30 A Suppression.................................................. 390 Ω Continuous duty............................................ 100% Resistance 85 – 86 .............................. 65 Ω ± 10%

Power relays: Rated voltage..............................................12 VDC Load................................................................. 70 A Suppression.................................................. 560 Ω Continuous duty............................................ 100% Resistance 85 – 86 ..........................................80 Ω

SS99G150

Changeover – Micro-relays: Rated voltage..............................................12 VDC Load............................................................ 15/25 A Suppression.................................................. 680 Ω Continuous duty............................................ 100% Resistance 85 – 86 ................ 90 Ω ± 10 % at 23 °C SS99K013

Sva 7-97000 EN

Edition 10/99

4002-42

Switches Safety switch – Air-cond. system (S30): Rated voltage..............................................12 VDC High pressure contact, opens at ..........p > 31.5 bar Low pressure contact, opens at ................p < 2 bar

SS99G174

Engine oil pressure switch (S6): opens at .................................................p > 0.5 bar Type of contact ............................. Normally closed

SS99H186

Optistop – brake light switch (S5) Indicator switch, parking brake (S7) Start safety switch (S10): Type of contact ............................... Normally open SS99D053

Pressure switch, front PTO shaft (S29): Switching point.................................p > 9 ± 0.5 bar Tightening torque .................................max. 30 Nm Type of contact ............................... Normally open

SS99J074

Switch – cooling water temperature, engine temp. transmitter (B1): (one component) SS99J172

Switching temperature ...................... 106 °C ± 3 °C Type of contact ............................... Normally open

Compressed air switch (S12): Switching point.......................................p > 5.5 bar Type of contact ............................. Normally closed

SS99J078

Sva 7-97000 EN

Edition 10/99

4002-43

Shut-down solenoid valve (Y11): Rated voltage..............................................12 VDC Coil resistance ...................... 3.8 Ω ± 10% at 20 °C The solenoid must not be activated for longer than 40 seconds in a dry state. As the cooling effect of the fuel on the coil is missing.

,03257$17 Starter switch S1 must only be switched to position 1 immediately prior to starting.

SS99J069

Thermo-start unit (E10/1): Supply voltage ............................................12 VDC Heating element res............................... 1 Ω ± 10% SS99H188

Thermostatic switch, fuel pre-heating (S26): Switching point ............................................... ϑ > 5 °C Type of contact ............................. Normally closed

ϑ SS99J167

Sva 7-97000 EN

Edition 10/99

4002-44

Potentiometers Air-cond. roof blower motor potentiometer (R11): Res. measured A – C ....................... 15 KΩ ± 20% Res. measured A – B.................. 0 – 15 KΩ ± 20%

SS99G170

Air-cond. potentiometer (R10): Potentiometer with integrated air-cond. – ON/OFF Switches Res. potentiometer ........................... 10 KΩ ± 20% Res. measured A – B.................. 0 – 10 KΩ ± 20% Switch ON/OFF.............................................. C – D SS99G171

Stepping potentiometer EGE (R6): Resistance measurement across X4/..

SS99J070

Pin

Latch 0

Latches 1-24

3–4

3.5 kΩ

3.5 kΩ

2–4

•

3.5 kΩ – 0.2 Ω

2–3

•

0,2 Ω – 3.5 kΩ

1–2

0.2 Ω

•

1–2

Sva 7-97000 EN

Edition 10/99

4002-45

Sensors Pressure sensor EGE M2 (B20): 1 = supply voltage........................................12VDC 2 = ground 3 = signal ..................................................see table RL ...................................................................... ≥ 5 kΩ SS99J072

Signal voltage measured at plug X6/5 (pins 1 and 3) Pressure (bar)

Voltage (V)

Pressure (bar)

Voltage (V)

Pressure (bar)

Voltage (V)

18

0.50

45

1.48

70

2.20

25

0.75

50

1.55

75

2.30

30

0.85

55

1.65

80

2.40

35

1.00

60

1.80

85

2.47

40

1.20

65

1.95

160

5.0

Inductive transmitter, driving speed (B6) Rear PTO shaft speed (B7): Resistance ....................................... 1050 Ω ± 10% SS99D056

Air-conditioning temperature sensor (R9):

SS99J157

Sva 7-97000 EN

Type ................................................................. NTC Resistance A – B ............................. ≈ 11 kΩ at 20 °C

Edition 10/99

4002-46

Solenoid Valves Solenoid valve 4-wheel drive (Y1) Rear axle diff. lock (Y10) Messr’s Hytos: Rated voltage..............................................12 VDC Suppression .................................... double Z diode Resistance ............................... 8 Ω ± 10% at 20 °C Continuous duty ............................................ 100% SS99G166

Solenoid valve, shut-off valve Double-action auxiliary control unit (Y2/4): Double-action auxiliary control unit (Y2/1):

SS99J025

Supply voltage ............................................12 VDC Resistance ............................................. 5 Ω ± 10% Power...........................................................28,8 W Continuous duty ............................................ 100%

Solenoid valve (directional control valve) Double-action auxiliary control unit (Y2/1,Y2/2,Y2/3) Single-action auxiliary control unit (Y2/2):

SS99J017

Supply voltage ............................................12 VDC Resistance .......................................... 4.4 Ω ± 10% Power...........................................................32.7 W Continuous duty ............................................ 100%

Solenoid valve EGE (Y2/1, Y2/2): (Messr’s. Wandfluh) Supply voltage ............................................12 VDC Resistance ............................ 5.4 Ω ± 10% at 20 °C Continuous duty ............................................ 100% SS99J171

Solenoid valve EGE (Y20, Y21): Supply voltage ............................................12 VDC Resistance ............................ 7.5 Ω ± 10% at 20 °C Continuous duty ............................................ 100% SS99J170

Sva 7-97000 EN

Edition 10/99

4002-47

Instrument Test Values

Fuel tank transmitter B2/1

Fuel gauge

Diesel level

Resistance Ω

Display range

0

10

red sector

1/8

31.2

start of green sector

1/2

95

green sector

1

180

end of green sector

Engine temperature transmitter (B1)

Engine temperature gauge

Temperature °C

Resistance Ω

Display range

40

287.4

40 °C to 75 °C blue sector

75

80.9

start of green sector

106

31.8

start of red sector

120

22.7

end of red sector

Compressed air transmitter (B3)

Compressed air indicator

Pressure in bar

Resistance Ω

Display range

0

10

red sector

5.5

115

start of green sector

10

184

end of green sector

Tractormeter Permissible deviation

Pointer angle

Frequency at generator terminal "W"

1000

± 100

67 °

300 Hz

2000

± 65

163 °

600 Hz

Engine speed 1/min

Transmission ratio, engine – generator i = 1: 3 Generator has 6 pairs of poles = 6 pulses per revolution

Sva 7-97000 EN

Edition 10/99

4002-48

Lamps and Fuses Rotating beacon

H1 12V – 55W

1-34-772-051

Searchlight

H3 12 V – 55W

90003452243

Headlight, roof headlight

H4 12V – 60/55W

90003450013

Trafficators, front and rear, brake light

P25-1 12 V – 21W

90003452245

Roof number plate light

L 12 V – 5W

90003452276

Cab interior light

L 12V – 10W

90003452249

Front sidelights, tail light

G 12 V – 5W

90003452216

Row of indicator lamps

H 12V 2W

90003452207

Digital tractor meter

12V/2W

35700580708

Instrument lighting and indicator lamps

12V/1.2W

90003450031

W5/1.2 – 12V – 1.2W

90003452250

Rocker switch

3A

violet

1-40-258-203

20A

yellow

1-40-258-120

5A

beige

1-40-258-105

25A

white

1-40-258-125

7.5A

brown

1-40-258-107

30A

green

1-40-258-130

10A

red

1-40-258-110

40A

orange

1-40-258-140

15A

light blue

1-40-258-115

100A 4A (slow-blow)

Sva 7-97000 EN

1-40-277-014 EGE

∅ 5 x 20

Edition 10/99

4002-49

Operation and Coding the Digital Instrument with Integrated operating Hours Counter General information All functions are called up using the spring-loaded switch (button), marked by the PTO symbol, on the right-hand side of the instrument panel. The switch need only be pressed briefly to call up operating functions. If it is held pressed for longer than 10 sec’s. coding values can be checked and/or corrected.

Operating / function Ignition ON/Starting/Operation

the display shows a small "h" and the cumulative operating hours.

Press the button

again the rear PTO shaft speed will be shown on the display.

Press the button again

the front PTO shaft speed will be shown on the display.

Press the button again

the operating hours will again be shown on the display.

Coding the engine speed (operating hours) of the rear PTO shaft speed indicator of the front PTO shaft speed indicator

General information Each time the button is briefly pressed, the display will be visibly increased by one impulse. If the button is pressed continually for longer than 1.5 sec’s. the impulses will be increased rapidly. When the button is released, "PRO" appears on the display after 8 sec’s. The value set is stored by briefly pressing the button once again and the display will return to the starting position (operating hours).

Coding the engine speed indication (operating hours) Press the button for 20 sec’s.

The combination of numbers 1 – 1 appears in the upper part of the display, the current value or value to be corrected appears in the lower part of the display. The code adjustment range is 15 – 255 impulses. Tractors M968 – M975 or CS68 – 75 have the code number 18.

Coding the rear PTO shaft speed indication Press the button for 22 sec's.

The combination of numbers 2 – 2 appears in the upper part of the display, the current value or value to be corrected appears in the lower part of the display. The code adjustment range is 1 – 100 impulses. The code number 10 must be set and stored for all models (code number 10 = 10 teeth on the measuring wheel).

Coding the rear PTO front speed indication Press the button for 24 sec's.

The combination of numbers 3 – 3 appears in the upper part of the display, the current value or value to be corrected appears in the lower part of the display. The code adjustment range is 1 – 100 impulses. The code number 38 must be set and stored for all models.

Sva 7-97000 EN

Edition 10/99

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Calibrating the speedometer Re-calibration is required after replacing tyres or when 3 bars appear on the km/h display.

Measure out a distance of exactly 100 m and mark both ends clearly.

– Press the pushbutton (Switchover Rear PTO/Front PTO/Operating hours) for at least 10 seconds, until CAL appears on the km/h display.

– Start to drive and when the tractor’s front axle is in line with the 0 mark, press the pushbutton briefly – the letters COU will then appear on the display.

The impulses will be counted to 9999 on the bottom part of the display, ---- will appear above this, pay no attention to this.

:$51,1* Minimum speed within the 100 m markings = 2 km/h – it is possible to drive faster.

– When the front axle is in line with the 100 m mark, press the pushbutton briefly once again – the letters PRO appear on the display.

SS99K002

– Bring the tractor to a halt and if the programming sequence was carried out correctly, press the pushbutton briefly once again – the tractor will then store the new, calibrated count.

If a fault occurs during calibration (delay in pressing the switch etc.) – simply switch the ignition OFF before pressing the switch for the last time, the programming sequence will thus not be accepted and the old values remain in effect.

Repeat the procedure.

Sva 7-97000 EN

Edition 10/99

&KDSWHU

DISASSEMBLY AND ASSEMBLY T537

CASE Steyr Landmaschinentechnik GmbH Technische Dokumentation A - 4300 St. Valentin, Steyrer Straße 32

Sva 7-96440 EN

© 1998 CASE Steyr Landmaschinentechnik GmbH November 1998

TABLE OF CONTEXT *HQHUDO :RUNLQJ 1RWHV 7HFKQLFDO GDWD ,QVWDOODWLRQ 'UDZLQJ 3RZHU 8QLW 6FKHPDWLF 'LDJUDP NP K L 3RZHU 8QLW 6FKHPDWLF 'LDJUDP NP K L 0DLQWHQDQFH DQG ,QVSHFWLRQ ,PSRUWDQW 'DWD DQG 1RWHV 7LJKWHQLQJ 7RUTXHV LQ 1P ,QWHUPHGLDWH +RXVLQJ &OXWFK 'LV HQJDJHU 7 'LV DVVHPEO\ Removing the PTO Shaft: .............................................................................................................................15 Removing the Driving Clutch: ........................................................................................................................15 ,QWHUPHGLDWH +RXVLQJ &OXWFK 'LV HQJDJHU 7 5H DVVHPEO\ Adjusting the drive sleeve shaft axial play: ....................................................................................................20 Re-fitting the driving and PTO shaft clutch: ...................................................................................................21 /DWHUDO 6KLIW 7 'LVDVVHPEO\ Shift stub disassembly: ..................................................................................................................................23 /DWHUDO 6KLIW 7 5H DVVHPEO\ Shift frame pre-assembly: .............................................................................................................................28 Gear shift adjustment: ...................................................................................................................................30 Gear range shift adjustment: .........................................................................................................................31 Shift stub re-assembly: ..................................................................................................................................32 Shift column pre-assembly: ...........................................................................................................................34 Shift cover pre-assembly: ..............................................................................................................................34 (&2 372 6KDIW 7 'LVDVVHPEO\ Gearshift disassembly: ..................................................................................................................................40 (&2 372 6KDIW 7 5H DVVHPEO\ Gearshift pre-assembly: ................................................................................................................................44 *HDUER[ 7 'LV DVVHPEO\ Crawler gear removal ....................................................................................................................................47 Countershaft removal: ...................................................................................................................................51 Main shaft removal: .......................................................................................................................................53 Removing the reverse gearwheel: .................................................................................................................54 Drive shaft removal: ......................................................................................................................................55 PTO shaft 540/1000 removal: .......................................................................................................................55 PTO shaft gearshift removal: .........................................................................................................................56 *HDUER[ 7 5H DVVHPEO\ PTO shaft 540/1000 re-fitting: .......................................................................................................................59 PTO shaft gearshift re-fitting: ........................................................................................................................60 Reverse gearwheel re-fitting: ........................................................................................................................61 Fitting the drive shaft: ....................................................................................................................................61 Main shaft re-fitting: .......................................................................................................................................62 Countershaft re-fitting: ...................................................................................................................................65 PTO shaft re-fitting: .......................................................................................................................................70 Crawler gear re-fitting: ...................................................................................................................................70 Fitting the drive shaft: ....................................................................................................................................73 Fitting the crawler gearshift: ..........................................................................................................................74 Fitting the side cover: ....................................................................................................................................74 $[OH 6WXE 7 'LVDVVHPEO\ $[OH 6WXE 7 5H DVVHPEO\ Adjusting the axle shaft bearings: .................................................................................................................81 %UDNH 7 'LVDVVHPEO\

November 1998

-3-

Sva 7-96440

TABLE OF CONTEXT %UDNH 7 5H DVVHPEO\ Adjusting the brake: ...................................................................................................................................... 88 5HDU $[OH 7 'LVDVVHPEO\ PTO shaft removal: ....................................................................................................................................... 89 Differential gear removal: ............................................................................................................................. 90 Countershaft removal: .................................................................................................................................. 93 Field/Road gearshift removal: ....................................................................................................................... 94 Bevel pinion removal: ................................................................................................................................... 94 Engine/ground speed PTO shaft gearshift removal: ..................................................................................... 96 Sleeve shaft removal: ................................................................................................................................... 96 5HDU $[OH 7 5H DVVHPEO\ Ground speed PTO shaft replacement: ........................................................................................................ 98 Engine/ground speed PTO shaft gearshift re-fitting: .................................................................................... 99 PTO shaft re-fitting: .................................................................................................................................... 101 Bevel pinion re-fitting: ................................................................................................................................. 102 Determining the packing ring thickness for initial bearing tension: ............................................................. 103 Determining the packing ring thickness for correct meshing: ..................................................................... 103 Fitting the Field/Road gearshift: .................................................................................................................. 107 Countershaft re-fitting: ................................................................................................................................ 108 Fitting the differential gear: ......................................................................................................................... 111 Correct meshing check: .............................................................................................................................. 115 Fitting the gearbox to the rear axle: ............................................................................................................ 116 Adjusting the engine/ground speed PTO shaft gearshift: ........................................................................... 117 )URQW D[OH GULYH 7 'LVDVVHPEO\ )URQW $[OH GULYH 372 7 5H $VVHPEO\ Multiple-disk clutch pre-assembly: .............................................................................................................. 123 Adjusting the front axle drive PTO: ............................................................................................................. 124 Determining packing ring size for axial bearing play: ................................................................................. 127 Determining the packing ring size for tooth flank play: ............................................................................... 128

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November 1998

PREFACE This document serves to assist the trained specialist in carrying out repair work on the

POWER Units T537 for Tractors CASE CS68, CS75 and STEYR M968, M975 It is assumed that proprietary tools and other devices are available to service personnel.

Special tools are kept to a bare necessity, these are marked with a tool number and are available from Messrs.

CASE-STEYR.

This document describes disassembly and re-assembly of only one version Slight differences in work procedures for other versions can be easily recognised by qualified specialist service personnel. Refer also to the relevant sectional and exploded view drawings.

Due to advances in the technical development of the product, the aggregate to be repaired may require work and adjustment and test data, which deviate from that described herein.

For this reason, we recommend that you always entrust your CASE-STEYR product to the hands of continually trained, specialist personnel.

Damage caused by inexpert workmanship carried out by non-trained personnel and follow-on costs resulting from such damage are not covered by the manufacturer’s guarantee clause.

This is also valid if parts other than original CASE-STEYR spare parts are used

CASE Steyr Landmaschinentechnik GmbH Issued by the CASE Steyr Landmaschinentechnik GmbH customer service, Technical Documentation department.

All rights reserved.

This document must not be reproduced in full or in part without the express written permission of the manufacturer.

Subject to alterations.

November 1998

-5-

Sva 7-96440

GENERAL WORKING NOTES Persons repairing CASE-STEYR aggregates are personally fundamentally responsible for work safety.

All safety regulations and legal requirements must be strictly observed, in order to avoid injury to persons or damage to the product during maintenance and repair work.

The correct repair of this CASE-STEYR product can only be carried out by correspondingly trained specialist personnel.

The obligation for training lies with the repair personnel.

Cleanliness and expertise must be used when carrying out repair work. Power units removed for repair must therefore be cleaned before dismantling.

It is assumed that tools stipulated by CASE-STEYR will be used.

All parts must be cleaned when disassembled.

This applies particularly to corners, pockets and housing brackets and covers.

Old sealing compound must be removed without trace.

Thoroughly clean parts which are to be re-sealed.

Lubrication orifices, channels and pipes must be checked for blockages. They must be free of deposits, foreign objects and conservation agents. The latter is particularly valid for new parts.

Parts to which damage can not be avoided during disassembly must always be replaced by new parts, e.g.: Rotary shaft seals, ‘o’ rings, circlips, cap gaiters, protective caps etc..

Parts like roller bearings, synch. Parts, etc., which are subject to normal wear and tear during operation, must be checked by a specialist. He will make the decision as to whether they can be re-used.

Hot fitted parts must be drifted into position before cooling. This will ensure that they are seated correctly. Before press fitting shafts, bearings etc. both parts must be oiled.

When re-assembling, all adjustment values, test data and torque values must be adhered to.

The CASE-STEYR aggregates must be topped up with oil after repair.

Procedures and recommended types of oil must be taken from the Operating Manual or the Lubrication Specifications. After filling, oil inspection and drainage plugs must be tightened to the prescribed torque.

Only use original CASE-STEYR spare parts!

Sva 7-96440

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November 1998

TECHNICAL DATA

Max. input power

55 kW (75 PS)

Max. input speed

2300 RPM

Max. input torque

267 Nm

Max. 4-wheel drive torque

1230 Nm

Max. vehicle all-up weight

5000 kg

Max. rear axle loading

4000 kg

Max. rear axle type size / index radius

13.6 - 36 / 715 mm

Oil capacity

approx. 30 l

Permissible operating temperature

100° C

Oil quality

STOU/UTTO API GL4

Weight (dry, with lifting gear) + 4-wheel drive

778 kg

Power Unit Description (basic version)

1.1

Optional extras

4-speed variable speed gearbox with reverse group, pre selection and field/road group (claw)

Pre-selection group 30 / 40 km/h Crawler gear

Shift lever, right-hand side 1st - 4th gear, group F/R and pre-selection groups, synchronised

PTO 540 /1100 RPM

Rear axle with bevel gear drive, differential with 4 bevel gearwheels and mechanically operated differential lock (claw)

lateral PTO shaft drive

Ground speed PTO shaft (R-H/L-H rotation)

Sensor for digital display for driving speed and PTO shaft speed

Final drive via planetary gearbox (i=6.6 / 5.8) Working brake, wet multiple disk brake, hydraulically operated Handbrake, mechanically operated PTO shaft drive, can be engaged independent of normal drive, via the PTO shaft clutch (PTO shaft with 4 speeds) Central 4-wheel drive, mechanically operated multiple disk clutch, with power shift

Number of gears Basic version with crawler gear

Forw.

16 32

Rev. 8 16

Speed ranges (with 13.6 - 36 / 715 mm tyres) 30 km/h Crawler gear 0.30-4.4 Field 1.93-8.58 Road 6.46-28.67 Reverse 1.96-29.03 without pre-selector group

40 km/h 0.30-4.4 1.93-8.58 6.46-28.67 1.96-29.03

SUBJECT TO ALTERATION IN CONSTRUCTIONAL AND VERSION! November 1998

-7-

Sva 7-96440

1.1

INSTALLATION DRAWING

SS97G001

Sva 7-96440

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November 1998

POWER UNIT SCHEMATIC DIAGRAM 30 / 40 KM/H

I= 6.6

1.1

SS97G002

November 1998

-9-

Sva 7-96440

1.1

POWER UNIT SCHEMATIC DIAGRAM 30 / 40 KM/H

I= 5.8

SS97G003

Sva 7-96440

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November 1998

MAINTENANCE AND INSPECTION

1.1

SS97G004

1 Filler plugs 2 Oil level sight glass 3 Drainage plugs (clean magnets at every oil change)

1. Oil change: after 50 operating hours 2. Oil change: after 1,000 operating hours or every 2 years Subsequent oil changes: after 1,000 operating hours or every 2 years

Brand

Denomination

Brand

Denomination

AGIP

Rotra MP 85 W 140

INA

Hipenol GIL HD85W/160

ARAL

Getriebeöl HYP 85W140

KROON-OIL

Gearlube GL-5/Agrigear GL 5

AVIA

Hypoid 140EP

MOBIL

Mobilube HD85W/160

BLASER

Blaser 218

MOTOREX

Gear Oil Universal

BP

Energear FE80/140

MOTUL

HD85W140

CALTEX

Thuban GL5EB

ÖMV

Getriebeöl C

CASTROL

Multitrax 80W140

PANOLIN

Super Duty GL 5

CENTURY OIL

Universal 85W/140

SHELL

Spirax HD 85W-140

DEA

Deagear EP-C

ELF

Tranself B

SUNOCO

GL 5

ESSO

Gear Oil GX 85W-140

TOTAL

Transmission TM

EVROL

Hypoid GO

VALVOLINE

HP Gear X-18MD85W-140

EVVA

Getriebeöl Multi GC-85W-140

VEEDOL

Multigear C

FINA

Pontonic MP SAE 85W-140

WINTERSHAL

Wiolin Hypoid Getriebeöl

FUCHS

Renogear Hypoid 85W-140

YACCO

Yahypo C

GENOL

Hypoid 85-140

November 1998

Spirax S 85W-140

- 11 -

Sva 7-96440

1.1

IMPORTANT DATA AND NOTES

Tightening torque for the main shaft castellated nut

150 Nm

Tightening torque for the countershaft hex. nut

150 Nm

Tightening torque for the bevel pinion castellated nut

250 Nm

Drive sleeve shaft axial play

0.2 - 0.4 mm

Front wheel drive bearing axial play

0 - 0,15 mm

Countershaft axial play

0,1 mm

Range and gear spur wheels axial play

0.3 mm

Diff. Bevel wheel / bevel pinion tooth flank play

0.25 - 0.35 mm

Front wheel drive tooth flank play

0.15 - 0.30 mm

Important Fitting Note -

Only use original CASE-STEYR spare parts Oil orifices must not be blocked (blow through) Compression rings must fit easily into the groove Oil all needle bearings and liners prior to fitting Lightly grease shaft sealing rings Castellated nuts and plain nuts, which are secured by impacting, must always be renewed Keep sealing surfaces clean Use sealant sparingly liners with Molicote Paste G Clamping sleeve slit in the direction of force

Securing - Sealing and Lubricating Agents Surface seals Nut locking fluid Lubricants

-

Loctite 518 or DIRKO Loctite 243/Loctite 638/Loctite 270 Stabutherm GH461 - Kluber Loctite anti-seize lubricant Optimol Olista Longtime 2 Molicote Paste G

- - --------------- Aggregate Number - - --------------- Serial No./Year of construction - - --------------- Assembly order No. - - --------------- Sales designation SS97G004

Type Plate Labelling Sva 7-96440

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November 1998

TIGHTENING TORQUES (IN NM)

1.1

Bolts, headed screws, nuts, grub screws and studs SCREWS AND NUTS Surfacecondition µ tot. 1) Property class

galvanized

0,125 µ

6G

0,14 µ

old

6G

8G

10K

8G

10K

12K

neu

6,9

8,8

10,9 12,9 6,9 8,8 Metric ISO-Standard Thread

10,9

12,9

M4

2,7

3,8

4,6

2,9

4,1

4,9

M5

5,5

8

9,5

6

8,5

10

M6

9,5

13

16

10

14

17

M8

23

32

39

25

35

41

M10

46

64

77

49

69

83

M12

80

110

135

86

120

145

M14

125

180

215

135

190

230

M16

195

275

330

210

295

355

M18

270

390

455

290

405

485

M20

385

540

650

410

580

690

M22

510

720

870

550

780

930

M24

660

930

1100

710

1000

1200

M27

980

1400

1650

1050

1500

1800

M30

1350

1850 2250 1450 Metric ISO-Fine Thread

2000

2400

M 8x1

25

35

42

27

38

45

M10x1,25

49

68

82

52

73

88

M12x1,25

88

125

150

95

135

160

M12x1,5

83

115

140

90

125

150

M14x1,5

140

195

235

150

210

250

M16x1,5

210

295

350

225

315

380

M18x1,5

305

425

510

325

460

550

M20x1,5

425

600

720

460

640

770

M22x1,5

570

800

960

610

860

1050

M24x2

720

1000

1200

780

1100

1300

M27x2

1050

1500

1800

1150

1600

1950

M30x2

1450

2050

2500

1600

2250

2700

Dimensions

12K

polished

1) µ tot. is the total pitch of treads, srews head/nut mating surfaces.

ATTENTION!

Cadmium-plated/copper-plated screws and nuts are to be tightened with a torque 25% below the galvanized values.

Studs are screwd into the work piece with half a torque.

November 1998

- 13 -

Sva 7-96440

1.1

Sva 7-96440

- 14 -

November 1998

INTERMEDIATE HOUSING CLUTCH DIS-ENGAGER T537 - DIS-ASSEMBLY

1.1

Drain power unit and hydraulic oil.

The power unit has been removed completely

SP97G001

Removing the PTO Shaft: Press the clutch lever forwards.

Drive out the clamping sleeves. Loosen the screw in the disengager fork.

Remove the dis-engager fork and dis-engager shaft with return spring.

SP97G002

Remove the dis-engager.

SS97G007

Removing the Driving Clutch: Drive out the clamping sleeve.

Remove the dis-engager fork anddis-engager shaft with return spring.

SP97G002

November 1998

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Sva 7-96440

1.1

INTERMEDIATE HOUSING CLUTCH DIS-ENGAGER T537 - DIS-ASSEMBLY Remove the bearing tube with packing rings and cover

SP97G004

Remove the circlip and washer.

SP97G005

Remove the intermediate housing.

1RWH For versions with ECO PTO shaft, remove the gearshift (see Chapter 3.1).

SP97G006

Remove the bearing from the intermediate housing.

SP97G007

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- 16 -

November 1998

INTERMEDIATE HOUSING CLUTCH DIS-ENGAGER T537 - DIS-ASSEMBLY

1.1

SS97G008

November 1998

- 17 -

Sva 7-96440

1.2

INTERMEDIATE HOUSING CLUTCH DIS-ENGAGER T537 - RE-ASSEMBLY

SS97G008

SS97G009

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- 18 -

November 1998

INTERMEDIATE HOUSING CLUTCH DIS-ENGAGERIS-ASSEMBLY - RE-ASSEMBLY 1.2 Re-fit the intermediate housing

Note: Seal the flange surfaces with LOCTITE 518

Tightening torque (M12/8.8)..... 1P

SP97G009

Re-fit the bearing to the intermediate housing and drive into its seating.

1RWH Press the 540/1000 PTO shaft gearshift against it.

SP97G009

Re-fit the washer and circlip.

SP97G010

Seal the cover with LOCTITE 518 and re-fit it.

Tightening torque (M8/8.8).....23Nm Re-fit the ECO PTO shaft gearshift and turn the cover to adjust the same amount of play for both gear speeds.

SP97G011

November 1998

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Sva 7-96440

1.2 INTERMEDIATE HOUSING CLUTCH DIS-ENGAGERIS-ENGAGER - RE-ASSEMBLY Adjusting the drive sleeve shaft axial play: Re-fit the sleeve shaft to the intermediate housing and drive in to the limit.

Measure dimension A in the intermediate housing.

Measure dimension B at the bearing tube.

Dimension A minus dimension B, minus 0.4mm (axial play) gives the thickness of the adjusting washer

Note: Renew the shaft sealing ring.

SS97G10

Seal the bearing tube with LOCTITE 518 and re-fit it Tightening torque (M8(8.8) .....23Nm

SP97G012

Check the drive sleeve shaft’s axial play (0.2-0.4mm)

SP97G013

Sva 7-96440

- 20 -

November 1998

INTERMEDIATE HOUSING CLUTCH DIS-ENGAGER T537 - RE-ASSEMBLY

1.2

Re-assemble the dis-engager and fit it to the sleeve shaft.

SS97G011

Re-fitting the driving and PTO shaft clutch: Press the bearing bushings into the housing.

Re-fit the rear dis-engager shaft and fork with return spring and secure by means of the sprung dowel pin.

Re-fit the dis-engager shaft, fork and return spring for the PTO shaft clutch.

1RWH Part the new dis-engageris-engager fork for the PTO shaft clutch by breaking.

SP97G014

Secure using a sprung dowel pin.

SP97G015

Fit the screws and spring washers to the dis-engager guide.

SP97G016

November 1998

- 21 -

Sva 7-96440

1.2

Sva 7-96440

- 22 -

November 1998

/$7(5$/ 6+,)7 7 ',6$66(0%/<

Remove the cover (1) and the trunnion (2).

Remove the complete shift cover.

SP97G017

Mark the positions of the shift fingers and shift stubs.

SP97G018

Remove the shit stubs.

SP97G019

6KLIW VWXE GLVDVVHPEO\ Remove the countersink screws (1) and washers (2), and subsequently remove the joint (3) and the serrated washers (4).

Remove the circlips (5).

Use a drift to remove the Ultra sleeves (6).

SS97G012

November 1998

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Sva 7-96440

/$7(5$/ 6+,)7 7 ',6$66(0%/< Remove the shift fingers and the shifter shafts.

SP97G020

SP97G020

Remove the shift column.

SP97G021

SP97G021

Remove the sealing rings and friction bearings from the shift column.

Remove and clean the vent.

SP97G022

SP97G022

Remove the needle (3) and friction (4) bearings from the from the shift cover.

SS97G013

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- 24 -

November 1998

/$7(5$/ 6+,)7 7 ',6$66(0%/<

Engage 2nd gear in order to remove the shift frame.

SP97G023

Remove the shift fork VW QG JHDU from the shift rod.

Remove the complete shift frame.

SP97G024

6KLIW IUDPH GLVDVVHPEO\ Remove the cover plate.

1RWH Take care not to lose balls, springs and washers.

SP97G025

Remove the shift forks and shift rods.

1RWH Take care not to lose the balls for the stop.

SP97G026

November 1998

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Sva 7-96440

/$7(5$/ 6+,)7 7 ',6$66(0%/<

SS97G014

Sva 7-96440

- 26 -

November 1998

/$7(5$/ 6+,)7 7 5( $66(0%/<

*($5 6+,)7

*($5 5$1*( 6+,)7

SP97G027

November 1998

- 27 -

Sva 7-96440

/$7(5$/ 6+,)7 7 5( $66(0%/<

_

6KLIW IUDPH SUH DVVHPEO\ Fit the shift rods (SUH VHOHFWRU JURXS and UG WK JHDU) and shift forks.

SP97G027

Replace the balls (Æ12 mm) for the stop.

Fit the shift rods ( VW QG JHDU) with carriers.

SP97G028

Replace the balls (Æ10 mm) for the stop.

Fit the shift rod(9/ 5) and shift fork.

SP97G029

Replace the balls and catch springs.

1RWH 1st/2nd Gear balls are Æ 9.25 mm.

3rd/4th gear, pre-selector group and forward/reverse group balls are Æ 10 mm.

SS97G016

Sva 7-96440

- 28 -

November 1998

/$7(5$/ 6+,)7 7 5( $66(0%/<

Fit washers to the SUH VHOHFWRU and IRUZDUG UHYHUVH JURXS. Fit and secure the cover using the countersink screws.

SP97G030

Engage 2nd gear and pre-assemble the shift fork ( VW QG JHDU).

SP97G031

Fit the pre-assembled shift frame and fit the shift fork ( VW QG JHDU) to the shift rod.

Place the shift fork onto the sliding sleeves.

SP97G032

Tightening torque (M10/8.8) ... 1P

SP97G007 SP97G033

November 1998

- 29 -

Sva 7-96440

/$7(5$/ 6+,)7 7 5( $66(0%/< *HDU VKLIW DGMXVWPHQW $GMXVW VW DQG QG JHDU to the same amount of shift travel.

Tighten the screws.

Tightening torque (M8/8.8) ... 1P

SP97G034

$GMXVW UG DQG WK JHDU to the same amount of shift travel.

Tighten the screws.

Tightening torque (M8/8.8) ... 1P

SP97G035

Place the carrier for the VW DQG QG JHDU with its groove H[DFWO\ opposite the groove in the shift fork UG DQG WK JHDU.

SS97G017

The gap between the groove in the carrier and the shift fork must be 14 mm. Whereby the shift fork ( VW QG JHDU) must be to the left-hand side of the shift sleeve (in the forward driving direction). Subsequently tighten the screws.

1RWH Check the gap using an Allen key (SW14mm).

SP97G036

Sva 7-96440

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November 1998

/$7(5$/ 6+,)7 7 5( $66(0%/<

*HDU UDQJH VKLIW DGMXVWPHQW Shift the SUH VHOHFWRU JURXS to Neutral Place the shift fork (36) in the centre of the synchronisation.

Turn the shit rod so that the carrier is exactly vertical, whereby the shift fork must be to the right-hand side of the shift sleeve (in the forward driving direction). Clamp the shift fork.

Tightening torque (M8/8.8) ... 1P 1RWH Distance between shift rod and carrier groove 3mm SP97G039

Check the play ( PP).

When the group is engaged, the play is PP.

SP97G037

Shift the )RUZDUG 5HYHUVH JURXS to Neutral and adjust to the same shift travel.

SP97G038

The carrier welded onto the shift fork must be at right angles to the housing upper surface.

SP97G007 SS97G018

November 1998

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Sva 7-96440

/$7(5$/ 6+,)7 7 5( $66(0%/< 6KLIW VWXE UH DVVHPEO\

SS97G019

Make an auxiliary tool.

SS97G020

Fit a circlip.

Oil the Ultra sleeve (1), centre it using auxiliary pin (A) And press in using sleeve (B).

1RWH Ultra sleeve bevel to the flexible joint.

SP97G303

Fit the second circlip.

Press the second Ultra sleeve in using auxiliary tool (C) and with the aid of a long screw (M10) .

SP97G304 SP97G007 SP97G304

Sva 7-96440

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November 1998

/$7(5$/ 6+,)7 7 5( $66(0%/<

Remove the circlip once again.

To make assembly of the serrated washer and the flexible joint easier, press the Ultra sleeve down approx. 4mm.

Fit the flexible joint with both serrated washers.

Fit the washer and countersink screw to one side.

SP97G305

Pre-assemble the circlip.

Screw in a countersink screw as a centring aid, press in using the sleeve until the circlip engages.

SP97G306

Fit the washer and countersink screw to the 2nd side.

SP97G007 SP97G307

November 1998

- 33 -

Sva 7-96440

/$7(5$/ 6+,)7 7 5( $66(0%/< 6KLIW FROXPQ SUH DVVHPEO\ Press both friction bearings (1) into the shift column.

1RWH Make a drift.

SP97G040

Press in the sealing rings (2) to the limit Fit the vent (3).

1RWH Make a drift.

SP97G041

Positions of the friction bearings and sealing rings.

SS97G021

6KLIW FRYHU SUH DVVHPEO\ Press both needle bearings in.

1RWH Make a drift.

SP97G042

Sva 7-96440

- 34 -

November 1998

/$7(5$/ 6+,)7 7 5( $66(0%/<

Press the 1st friction bearing in to dimension $ (91mm).

1RWH Make a drift.

SP97G043

Press the 2nd friction bearing in to dimension % (16mm).

1RWH Make a drift.

SP97G044

Fit the shift shafts and shift fingers (teeth to teeth) 1RWH Long shift finger to long shift shaft.

Observe the marking (disassembly).

SP97G045

Pre-tighten the bolts (M10x40) to 1P. Support the bolt head axially and hit the end of the shift shaft with a hammer (1000g).

Subsequently tighten to 1P. 1RWH Lock using /2&7,7(

SS97G022

November 1998

- 35 -

Sva 7-96440

/$7(5$/ 6+,)7 7 5( $66(0%/< Fit the pre-assembled shift column to the shift cover.

1RWH Seal the flange surfaces with /2&7,7( Tightening torque (M10/8.8) ... 1P

SP97G046

Seal the shift cover with /2&7,7(

SP97G047

Align the deflection lever to the shift finger.

1RWH Fix in this position using grease.

SP97G048

Fit the shift cover to the gearbox housing. and secure using two bolts.

SP97G007 SP97G049

Sva 7-96440

- 36 -

November 1998

/$7(5$/ 6+,)7 7 5( $66(0%/<

Screw in the trunnions into the deflection lever to the limit.

1RWH Lock using /2&7,7(

SP97G050

Adjust the deflection lever play to PP. 1RWH Use packing rings to compensate.

Check the shift finger for freedom of movement.

SP97G051

Fit the cover.

1RWH Seal using ',5.2.

Align the shift cover precisely and secure using the remaining bolts.

Tightening torque (M8/8.8) ... 1P 1RWH Check that the shift fingers are correctly engaged and have freedom of movement.

SP97G052

Fit the shift stubs.

1RWH Pay attention to the position of the shift stubs. (marked during disassembly)

SP97G053

November 1998

- 37 -

Sva 7-96440

Sva 7-96440

- 38 -

November 1998

(&2 372 6+$)7 7 ',6$66(0%/<

The power unit is disconnected from the intermediate housing. (see Chapter 1.1)

The gear shift must not be removed.

sp97g054

Remove the compression and thrust washers.

sp97g055

Remove the spur gears with needle bearings and sleeve shaft.

Pull the bearing off the sleeve shaft.

sp97g056

Remove the carrier, shift sleeve, needle bearings, spacer sleeve and washer.

sp97g057

November 1998

- 39 -

Sva 7-96440

(&2 372 6+$)7 7 ',6$66(0%/< *HDUVKLIW GLVDVVHPEO\ Remove the shift fork and the sleeve carrier.

sp97g058

The flange bearing with shift shaft was already removed during intermediate housing disassembly (Chapter 1.1).

sp97g059

Drive out the sprung dowel pin.

1RWH Mark the position of the lever.

sp97g060

Remove the circlip.

sp97g061

Sva 7-96440

- 40 -

November 1998

(&2 372 6+$)7 7 ',6$66(0%/<

Loosen the grub screw.

Remove the spring and ball.

sp97g062

Remove the shift shaft.

Remove the sealing ring.

sp97g063

SS97G023

November 1998

- 41 -

Sva 7-96440

(&2 372 6+$)7 7 5( $66(0%/<

ss97g024

Sva 7-96440

- 42 -

November 1998

(&2 372 6+$)7 7 5( $66(0%/<

Fit the shift fork and the sleeve carrier.

1RWH Tooth relief grinding towards the bearing.

SP97G064

Fit the shift sleeve (1) with the bevel towards the front, washer (2), needle ring (3) and spacer sleeve (4).

SP97G065

Pre-assemble the spur gears with needle bearing and carrier.

sp97g066

Heat the bearing to °& and fit it to the sleeve shaft.

SP97G007

November 1998

- 43 -

Sva 7-96440

(&2 372 6+$)7 7 5( $66(0%/< Fit the sleeve shaft with pre-assembled bevel gears together.

sp97g068

Fit the compression and thrust washers.

1RWH Fix in this position using grease.

sp97g069

*HDUVKLIW SUH DVVHPEO\ Fit a new sealing ring to the shift shaft and fit this to the flange bearing.

1RWH Fit using grease.

sp97g070

Fit the circlip.

sp97g071

Sva 7-96440

- 44 -

November 1998

Fit the ball, spring and grub screw.

1RWH Screw the grub screw to a depth of 0.5mm.

Lock using /2&7,7( .

sp97g072

Fit the lever.

1RWH Pay attention to the position (marking).

sp97g073

Fit the pre-assembled gearshift only after fitting the intermediate housing. (see Chapter 1.2)

sp97g073

November 1998

- 45 -

Sva 7-96440

Sva 7-96440

- 46 -

November 1998

*($5%2; 7 ',6 $66(0%/<

Remove the intermediate housing (Chapter 1.1) and gearshift (Chapter 2.1).

1 Loosen the brake actuator (1) at both sides and remove the differential lock actuator (2).

SP97G074

Separate the power unit from the rear axle.

1RWH For easier dis-assembly, also remove the brake shaft.

SP97G075

For versions fitted with PTO shaft, the conical headed screw in the shift fork must be loosened.

SP97G076

&UDZOHU JHDU UHPRYDO Remove the PTO shaft side cover.

1RWH Pay attention to the packing rings.

SP97G077

November 1998

- 47 -

Sva 7-96440

*($5%2; 7 ',6 $66(0%/< Remove the gearshift and bearing cover.

SP97G078

Gearshift dis-assembly.

SS97G026

Drive the PTO shaft out.

SP97G079

Remove the drive shaft with bearing cover, pushing the shift fork forwards with the sliding gearwheel.

SP97G080

Sva 7-96440

- 48 -

November 1998

*($5%2; 7 ',6 $66(0%/<

Remove the PTO shaft and needle cage.

Pull the cylindrical roller bearing off.

SP97G081

Remove the sliding gearwheel and shift fork with ball and spring.

Remove the needle ring, washer and needle cage.

SP97G082

Bearing cover dis-assembly.

Remove the circlip.

SP97G083

Remove the circlip.

SP97G084

November 1998

- 49 -

Sva 7-96440

*($5%2; 7 ',6 $66(0%/< Drive the shaft out.

Remove both bearings with retaining ring, bevel gear and shaft with circlip.

SP97G085

Remove both bearings and shaft seal.

SP97G086

ss97g027 41

SS97G027

Sva 7-96440

- 50 -

November 1998

*($5%2; 7 ',6 $66(0%/<

&RXQWHUVKDIW UHPRYDO Unlock and remove the hexagonal nut (SW 36).

1RWH Block the countershaft.

SP97G087

Remove the packing washers at the rear bearings.

SP97G088

Drive the countershaft out to the rear.

SP97G089

Pull the countershaft out and remove the bevel gears with synchronous units from the gearbox housing.

SP97G090

November 1998

- 51 -

Sva 7-96440

*($5%2; 7 ',6 $66(0%/<

SS97G028

Sva 7-96440

- 52 -

November 1998

*($5%2; 7 ',6 $66(0%/<

0DLQ VKDIW UHPRYDO Unlock the castellated nut.

Using a wrench ($) and special tool (76 :), remove the main shaft.

SP97G091

Press the main shaft out and remove the bevel gears and synchronous parts from the housing.

SP97G092

SS97G029

November 1998

- 53 -

Sva 7-96440

*($5%2; 7 ',6 $66(0%/< Remove the circlip and bevel gear from the drive shaft.

(Fig. Version with crawler gear)

SP97G093

Remove the retaining ring.

SP97G094

5HPRYLQJ WKH UHYHUVH JHDUZKHHO (Fig. Version with crawler gear)

SP97G095

Reverse gear disassembled.

(Fig. Version without crawler gear)

SS97G030

Sva 7-96440

- 54 -

November 1998

*($5%2; 7 ',6 $66(0%/<

'ULYH VKDIW UHPRYDO (Fig. Version with crawler gear)

SP97G096

without crawler gear

with crawler gear SS97G031

372 VKDIW UHPRYDO For versions with a ground speed PTO shaft, remove the sleeve and shift fork.

SP97G097

Remove the large and small circlips.

SP97G098

November 1998

- 55 -

Sva 7-96440

*($5%2; 7 ',6 $66(0%/< Drive out the intermediate shaft.

SP97G099

Disassemble the intermediate shaft.

SS97G032

372 VKDIW JHDUVKLIW UHPRYDO Remove the tapered bolt andshift finger.

SP97G100

Remove the shift shaft with lever.

SP97G101

Sva 7-96440

- 56 -

November 1998

*($5%2; 7 ',6 $66(0%/<

Remove the locking screw.

SP97G102

Remove the shift rod and shift shaft.

1RWH Do not lose the springs and balls.

SP97G103

Remove the bearings from the gearbox housing.

For versions with JURXQG VSHHG 372 shaft, remove the support ring.

SP97G104

November 1998

- 57 -

Sva 7-96440

Sva 7-96440

6(&7,21$/ 9,(: % %

6(&7,21$/ 9,(: $ $

6(&7,21$/ 9,(: & &

ZLWKRXW JURXQG VSHHG SRZHU WDNH RII VKDIW DQG FUDZOLQJ JURXS

6(&7,21$/ 9,(:

6(&7,21$/ 9,(: ' '

*($5%2; 7 5( $66(0%/<

- 58 -

November 1998

*($5%2; 7 5( $66(0%/<

372 VKDIW UH ILWWLQJ (Fig. Version without a ground speed PTO shaft)

Fit the cyl. Roller bearing without inner ring (1) into the housing.

Fit both circlips (2)

SS97G034

For versions with a JURXQG VSHHG 372 shaft, also fit the support ring (3).

SS97G035

Heat the bearing inner ring to & and fit this to the intermediate shaft.

SP97G106

Fit the intermediate shaft (1) with bearing ring (2), spacer (3), needle cage (4), spacer (5), bevel wheel (6), sleeve carrier (7), sleeve (8), washer (9) and circlip (10) the housing.

SP97G107

November 1998

- 59 -

Sva 7-96440

*($5%2; 7 5( $66(0%/< 372 VKDIW JHDUVKLIW UH ILWWLQJ Fit the spring (1) and ball (2) into the shift fork (3).

SS97G036

Fit the shift fork and shift rod.

SP97G108

Fit the locking screw using /2&7,7(

SP97G109

Fit the shift shaft (1) and shift finger (2).

Secure using the tapered bolt (3).

1RWH Fit a new sealing ring (4) to the shaft.

SS97G037

Sva 7-96440

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November 1998

*($5%2; 7 5( $66(0%/<

5HYHUVH JHDUZKHHO UH ILWWLQJ The drive shaft must be fitted first, for versions without a crawler gear.

SS97G038

Fit the bearing bolts.

Fit the double bevel gearwheel, needle ring, spacer and both thrust rings.

1RWH The groove in the rear thrust ring must face towards the housing.

SP97G110

)LWWLQJ WKH GULYH VKDIW (Fig. Version with crawler gear) Heat the bearing, without retaining ring, to & and fit it.

SP97G111

Fit the drive shaft Fit the retaining ring and needle ring.

SP97G112

November 1998

- 61 -

Sva 7-96440

*($5%2; 7 5( $66(0%/< Chase the drive shaft in.

SP97G113

Fit the support ring.

1RWH Lock screws/bolts using /2&7,7( .

SP97G114

0DLQ VKDIW UH ILWWLQJ

SS97G039

Sva 7-96440

- 62 -

November 1998

*($5%2; 7 5( $66(0%/<

Main shaft pre-assembly: Heat the bearing to & and fit to the shaft.

SP97G115

Fit the thrust ring and liner.

1RWH The groove in the thrust ring must face the bearing.

Prevents the liner from turning with respect to the synchronous unit.

SP97G116

Fit the bevel gearwheel VW JHDU with synch. ring and coupling body.

SP97G117

Fit the synchronous unit.

SP97G118

November 1998

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Sva 7-96440

*($5%2; 7 5( $66(0%/< Fit the liner and bevel gearwheel QG JHDU with synch. ring and coupling body.

1RWH Prevents the liner from turning with espect to the synchronous unit.

SP97G119

Fit the bevel gearwheels UG and WK JHDUV.

SP97G120

Pull the main shaft out of the pre-assembled bevel gearwheels.

Fit the bevel gearwheels into position in the housing.

Fit the main shaft.

Fit the needle cage to the main shaft.

SP97G121

Fit the castellated nut and tighten using the wrench ($) Tighten the main shaft using the special tool (76 :).

Tightening torque .............. 1P

SP97G007 SP97G122

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November 1998

*($5%2; 7 5( $66(0%/<

Check the axial play of the bevel gearwheels VW and QG JHDUV.

SP97G123

Lock the castellated nut.

SP97G124

&RXQWHUVKDIW UH ILWWLQJ

November 1998

- 65 -

Sva 7-96440

*($5%2; 7 5( $66(0%/< Countershaft pre-assembly: Heat the bearing inner ring to & and fit it.

SP97G125

Fit the bevel gearwheel QG JHDU and bevel gearwheel UG JHDU with synch. ring and coupling body.

1RWH Prevents the liner from turning with respect to the synchronous unit.

SP97G126

Fit the synchronous unit, bevel gearwheel WK JHDU with liner.

1RWH Prevents the liner from turning with respect to the synchronous unit.

SP97G127

Fit the thrust ring, liner, needle cage and bevel gearwheel (UHYHUVH) with synch. ring and coupling body.

1RWH Prevents the liner from turning with respect to the synchronous unit.

SP97G128

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November 1998

*($5%2; 7 5( $66(0%/<

Fit synch. unit, bevel gearwheel (IRUZDUG), needle cage and liner.

1RWH Prevents the liner from turning with respect to the synchronous unit.

SP97G129

Fit the thrust ring and washer.

SP97G130

Fit the liner, needle cage, bevel gearwheel (SUH VHOHFW) with synch. ring and coupling body.

SP97G131

Fit the synch. unit with spacer ring.

SP97G132

November 1998

- 67 -

Sva 7-96440

*($5%2; 7 5( $66(0%/< Fit the cyl. Roller bearing without inner ring.

SP97G133

Fit the pre-assembled countershaft.

SP97G134

For version with FUDZOHU JHDU, fit the bevel gearwheel and circlip.

SP97G135

Fit the pre-select group.

SP97G136

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November 1998

*($5%2; 7 5( $66(0%/<

Fit the rear bearing.

SP97G138

Tighten and lock the hex. nut.

Tightening torque .............. 1P

SP97G137

Check the axial play of the countershaft ( PP).

1RWH Use packing ring ($) to compensate.

SS97G041

Check the axial play of the bevel gearwheels UG, WK JHDUV, IRUZDUG and UHYHUVH.

SP97G139

November 1998

- 69 -

Sva 7-96440

*($5%2; 7 5( $66(0%/< 372 VKDIW UH ILWWLQJ Heat the bearing to & and fit to the shaft.

Fit the circlip.

SP97G140

Insert the PTO shaft with needle cage.

1RWH Do not place it in its final position at this stage.

SP97G141

&UDZOHU JHDU UH ILWWLQJ

SS97G042

Sva 7-96440

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November 1998

*($5%2; 7 5( $66(0%/<

Bearing cover pre-assembly: Fit the rear bearing.

SP97G142

Heat the bearing to & and fit to the shaft.

Fit the circlip.

SP97G143

Fit the pre-assembled shaft with bevel gearwheel and chase it in.

SP97G144

Fit the circlip.

SP97G145

November 1998

- 71 -

Sva 7-96440

*($5%2; 7 5( $66(0%/< Fit the sliding gearwheel.

Fit the shift fork, with spring and ball, to the shaft.

SP97G146

Insert the bearing cover together with the sliding gearwheel and PTO shaft into its final position.

SP97G147

Fit the PTO shaft and chase it in.

1RWH Press the crawler gearshift to the rear.

SP97G148

Secure the bearing cover.

Lock screws/bolts using /2&7,7( .

Tightening torque (M10/8.8)...... 1P

SP97G149

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November 1998

*($5%2; 7 5( $66(0%/<

Fit the needle cage, bearing ring and needle ring.

SP97G150

)LWWLQJ WKH GULYH VKDIW

SP97G151

Fit the cyl. Roller bearing.

SP97G152

Fit a new shaft sealing ring.

1RWH Smaller diameter sealing lips to the rear.

SP97G153

November 1998

- 73 -

Sva 7-96440

*($5%2; 7 5( $66(0%/< Fit the second bearing.

SP97G154

)LWWLQJ WKH FUDZOHU JHDUVKLIW Fit a new sealing ring to the gear lever.

SS97G043

Seal the cover with /2&7,7( and fit it.

SP97G155

)LWWLQJ WKH VLGH FRYHU

SS97G044

Sva 7-96440

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November 1998

*($5%2; 7 5( $66(0%/<

Fit the double bevel gearwheel, needle rings, spacer sleeve, thrust rings and bearing bolts.

1RWH The groove in the thrust ring must face the double bevel gearwheel.

SP97G156

Determine the size of the packing washer: The dimension in 1/100mm is punched into the housing.

Up to 0.02, round down; from 0.03, round up.

Packing ring selection (s=0,1mm or 0,2mm)

SP97G157

Seal the cover with /2&7,7( and fit it with the packing ring.

Tightening torque (M12/8.8).......... 1P

SP97G158

November 1998

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November 1998

$ ;/( 678% 7 ',6$66(0%/<

If only the axle stub is to be removed, the oil level in the rear axle gearbox must be lowered.

Remove the axle stub.

SP97G159

Remove the internally toothed ring.

1RWH Mark the position.

SP97G160

Remove the planet gearwheels, needle ring and thrust rings.

SP97G161

Remove the safety plate.

Loosen the screws and remove the disk with planet carrier.

SP97G162

November 1998

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Sva 7-96440

$ ;/( 678% 7 ',6$66(0%/< Remove the rear axle shaft.

SP97G163

Pull the bearing and shaft sealing ring off the shaft.

Remove the bearing and bearing outer ring from the axle stub.

SP97G164

SS97G045

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November 1998

$ ;/( 678% 7 5( $66(0%/<

ss97g083

SS97G083

Fit a new shaft sealing cartridge using special tool 76: .

1RWH Apply a thin film of /2&7,7( to the shaft sealing ring and sealing ring seating.

SP97G165

Heat the bearing to & and fit to the shaft.

Chase on using special tool 76: .

SP97G166

November 1998

- 79 -

Sva 7-96440

$ ;/( 678% 7 5( $66(0%/< Fit both bearing outer rings into the axle stub.

SP97G167

Fit the axle stub to the rear axle shaft.

1RWH Coat the shaft sealing ring with a mixture of water and methylated spirits.

Fit the axle stub centrally.

SP97G168

Heat the bearing to & and fit it.

SP97G169

Fit the planet carrier disk and bolt.

SP97G170

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November 1998

$ ;/( 678% 7 5( $66(0%/<

$GMXVWLQJ WKH D[OH VKDIW EHDULQJV Tighten the bolt to a torque of 1P. Then loosen it and tighten to a torque of 1P.

Tap the axle stub free.

SP97G171

Screw the bolt out until the next possible position for the safety plate is located.

SP97G172

Fit the planet gearwheels, needle rings, thrust rings and bolts.

1RWH Pay attention to the fact that the thrust rings are positioned correctly.

SP97G173

Lock the bolt with a spring dowel pin.

SP97G174

November 1998

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Sva 7-96440

$ ;/( 678% 7 5( $66(0%/< Seal internal toothed ring and flange surface of the stub axle with /2&7,7( and fit them together.

1RWH Pay attention to the marking.

Tightening torque (M12/10.9)...... 1P

SP97G176

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November 1998

%5$.( 7 ',6$66(0%/<

Remove the splint (1).

Remove the pull rod (2) from the brake lever.

SP97G177

The gearbox and rear axle need not be separated.

Remove the stub axle (Chapter 5.1) Remove the pinion shaft.

SP97G178

Remove the actuating cylinder, spring and bracket.

1RWH 'HIHFWLYH EUDNH F\OLQGHUV PXVW EH UHSODFHG FRPSOHWHO\.

SP97G179

Loosen the nut.

Remove the spherical washer, pressure spring, cover and seal.

SP97G180

November 1998

- 83 -

Sva 7-96440

%5$.( 7 ',6$66(0%/< Remove the cover and remove both disks with intermediate disks.

SP97G181

Remove the actuation disk with pull rod and the remaining disks and intermediate disks.

SP97G182

SS97G046

Sva 7-96440

- 84 -

November 1998

%5$.( 7 5( $66(0%/<

SS97G047

Fit two lining disks and one intermediate disk.

1RWH &KHFN WKH GLVNV IRU ZHDU DQG UHSODFH DV QHFHVVDU\.

SP97G183

Pre-assemble the pull rod with bolt and splint onto the actuating disk.

SP97G184

November 1998

- 85 -

Sva 7-96440

%5$.( 7 5( $66(0%/< Fit the actuating disk into the brake housing.

Fit the seal carefully using ',5.2.

1RWH Protect the seal from damage by the thread.

SP97G185

Fit the cover and the pressure spring.

Secure using the spherical washer and nut.

SP97G186

Fit the remaining disks and intermediate disks.

1RWH ,QVSHFW WKH GLVNV IRU ZHDU 5HSODFH DV QHFHVVDU\

SP97G187

Fit the cover.

Tightening torque (M12/8.8)...... 1P

SP97G188

Sva 7-96440

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November 1998

%5$.( 7 5( $66(0%/<

Fit the actuation cylinder with bracket to the brake housing.

Fit to the brake lever and secure usingthe bolt, washer and splint.

1RWH 'HIHFWLYH EUDNH F\OLQGHUV PXVW EH UHSODFHG FRPSOHWHO\

Tightening torque (M8/8.8)..... 1P SP97G189

Clip the spring (1) into the bracket.

Push the pinion shaft (2) in.

SP97G190

Fit the internal toothed ring and axle stub (Chapter 5.2) 1RWH Seal using /2&7,7( .

SS97G048

November 1998

- 87 -

Sva 7-96440

%5$.( 7 5( $66(0%/<

$GMXVWLQJ WKH EUDNH When a force F of 100-200N is applied to the brake lever, there must be a gap of PP between the brake lever and brake housing.

Fit the pull rod (1) and secure using the bolt and splint.

SP97G190

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November 1998

5($5 $ ;/( 7 ',6$66(0%/<

Gearbox, lifting gear and 4-wheel drive are removed.

Remove the left-hand axle stub (Chapter 5.1).

Remove the pinion shaft.

Remove the brake housing with brake.

SP97G191

Use thrust screws.

1RWH Pay attention to the packing ring.

SP97G192

372 VKDIW UHPRYDO For versions with a ground speed PTO shaft, remove the sleeve carrier and needle cage.

SP97G193

Remove the bearing cover.

SP97G194

November 1998

- 89 -

Sva 7-96440

5($5 $ ;/( 7 ',6$66(0%/< Bearing cover disassembly.

SS97G050

Pull the PTO shaft out.

If the gearbox is flanged on and has a ground speed PTO shaft, this must be switched ON.

SP97G195 SP97G195

PTO shaft disassembly.

(Fig. Version without a ground speed PTO shaft)

SS97G051

'LIIHUHQWLDO JHDU UHPRYDO Drive the shift fork clamping sleeve out.

Remove the circlip from the shift shaft.

SP97G196

Sva 7-96440

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November 1998

5($5 $ ;/( 7 ',6$66(0%/<

Remove the shift shaft and pressure spring.

SP97G197

Remove the differential together with the shift fork and oil channel.

1RWH For versions with a screw at the oil channel, remove this first.

SP97G198

Pull both bearings off.

SP97G199

Remove the washer, shift ring and locking bolt.

SP97G200

November 1998

- 91 -

Sva 7-96440

5($5 $ ;/( 7 ',6$66(0%/< Part the differential housing.

SP97G201

Remove the differential master gear and disassemble the differential.

SP97G202

SS97G052

Sva 7-96440

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November 1998

5($5 $ ;/( 7 ',6$66(0%/<

&RXQWHUVKDIW UHPRYDO In order to remove the countershaft, the right-hand axle stub and brake housing must be removed.

Remove the oil pipe and check it for damage.

SP97G203

Remove the circlip.

Remove the packing rings.

SP97G204

Drive the countershaft out.

SP97G205

Countershaft disassembly.

SS97G053

November 1998

- 93 -

Sva 7-96440

5($5 $ ;/( 7 ',6$66(0%/< )LHOG 5RDG JHDUVKLIW UHPRYDO Loosen the tapered bolt.

Remove the shift lever and shift finger. Push the shift rod forwards and remove the spring washer.

SS97G054

%HYHO SLQLRQ UHPRYDO Remove the needle bearing.

Unlock the castellated nut and loosen it using special tool 76 :.

1RWH Block the bevel gearwheels.

SP97G206

Drive the bevel pinion out.

SP97G207

Remove the bevel gearwheels, washer and shift sleeve.

Pull the bearing off the bevel pinion.

SP97G208

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November 1998

5($5 $ ;/( 7 ',6$66(0%/<

Remove the shift rod and shift fork.

1RWH Do not lose the ball and spring.

SS97G055

Remove the outer bearing ring, packing rings and circlip.

SP97G209

SS97G056

November 1998

- 95 -

Sva 7-96440

5($5 $ ;/( 7 ',6$66(0%/< (QJLQH JURXQG VSHHG 372 VKDIW JHDUVKLIW UHPRYDO Loosen the tapered bolt.

Remove the shift lever and shift finger.

SP97G212

Loosen the screw (or grub screw).

Remove the ball, spring and sealing ring.

SP97G213 SP97G213

Remove the shift rod and carrier.

SP97G214

6OHHYH VKDIW UHPRYDO (Fig. Version with a ground speed PTO shaft) Remove the circlip and washer.

SP97G215

Sva 7-96440

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November 1998

5($5 $ ;/( 7 ',6$66(0%/<

Remove the sleeve shaft.

Remove the bevel gearwheels.

SP97G216

Disassemble the sleeve shaft and pull the bearing off, Remove the outer bearing ring from the housing.

SS97G057

November 1998

- 97 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< *URXQG VSHHG 372 VKDIW UHSODFHPHQW

SS97G058

Fit the outer bearing ring using /2&7,7( .

Installation dimension: PP from the gearbox flange surface.

SP97G217

Sleeve shaft pre-assembly: Fit the bearing, washer and circlip.

SP97G218

Sva 7-96440

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November 1998

5($5 $ ;/( 7 5( $66(0%/<

Fit the washer and needle cage using the spacer ring.

SP97G219

Place the double bevel and bevel gearwheels in position.

Fit the sleeve shaft and chase it in.

SP97G220

Re-fit the washer and inner bearing ring.

Subsequently fit the needle cage and washer.

Fit the circlip.

SP97G221

(QJLQH JURXQG VSHHG 372 VKDIW JHDUVKLIW UH ILWWLQJ

SS97G059

November 1998

- 99 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Fit the shift rod and carrier.

SP97G222

Fit the ball and spring.

Fit the screw and sealing ring.

Tightening torque (M10/8.8)..... 1P

SP97G223

For versions with a grub screw, select the shift rod to neutral (ball not in the groove) Screw the grub screw in to the limit, subsequently screw it out one turn.

1RWH Lock using /2&7,7( .

SS97G060

Fit the lever and shift finger.

Secure using the tapered bolt Ensure that the shift finger is correctly fitted. Fit a new sealing ring to the shaft 1RWH Ensure that the shift finger is correctly fitted. Fit a new sealing ring to the shaft

The gearshift adjustment is made after the gearbox has been fitted. (Chapter 7.2) SP97G224

Sva 7-96440

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November 1998

($5 $ ;/( 7 5( $66(0%/<

372 VKDIW UH ILWWLQJ

SS97G061

Fit circlips, washers and bearing with retaining ring.

Secure the pick-up ring with a grub screw.

1RWH Lock the grub screw using /2&7,7( .

SP97G225

Fit the PTO shaft.

SP97G226

Fit a new shaft sealing ring into the bearing cover.

SP97G227

November 1998

- 101 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Seal the bearing cover with /2&7,7( and re-fit it.

Tightening torque (M10/8.8)..... 1P

Fit the inductive transmitter and sealing ring.

SP97G228

For versions with a JURXQG VSHHG 372 shaft, fit the sleeve carrier and needle cage.

SP97G229

%HYHO SLQLRQ UH ILWWLQJ The deviation (1) can be read off the bevel pinion.

Information in 1/100mm.

Matching number (2) for differential master gear.

SP97G230

The housing dimension deviation can be read off the upper surface of the housing.

Information in 1/100mm.

SP97G231

Sva 7-96440

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November 1998

5($5 $ ;/( 7 5( $66(0%/<

'HWHUPLQLQJ WKH SDFNLQJ ULQJ WKLFNQHVV IRU FRUUHFW PHVKLQJ The deviation of the bearing (nom. dimension PP) must be measured.

If the deviation from the basic dimension of the bevel pinion, bearing and housing is zero, the thickness of the packing ring V PP EDVLF GLPHQVLRQ .

If the width of the bearing is greater than the nominal dimension, the ring must be thinner by this amount.

If the width of the bearing is smaller than the nominal dimension, the ring must be thicker by this amount.

A deviation in the bevel pinion with a " " preceding it must be subtracted from the basic dimension.

A deviation in the bevel pinion with a " " preceding it must be added to the basic dimension.

A deviation in the housing with a " " preceding it must be added to the basic dimension.

A deviation in the housing with a " " preceding it must be subtracted from the basic dimension.

Example:

Basic dimension Bevel pinion deviation Housing deviation

3,5 -10 +2

3.5mm +0.10mm +0.02mm PP SDFNLQJ ULQJ WKLFNQHVV V PP

Up to 0.04, round down; from 0.05, round up.

Packing rings available: 2.8mm;3.0mm;3.2mm;3.3mm;3.4mm;3.5mm((basic packing ring);3.6mm;3.8mm;

SS97G062

SS97G062

'HWHUPLQLQJ WKH SDFNLQJ ULQJ WKLFNQHVV IRU LQLWLDO EHDULQJ WHQVLRQ

SS97G063

November 1998

- 103 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Measure initial bearing tension 1P

Moment = Force x lever arm 0 ) U

Max. 4.7 kg on the spring balance.

SP97G232

Fit the circlip.

SP97G233

Fit both outer bearing rings and the packing ring, which was determined for the correct meshing.

SP97G234

Heat the bearing to & and fit it.

SP97G235

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November 1998

5($5 $ ;/( 7 5( $66(0%/<

Fit the packing ring for initial bearing tension.

SP97G236

Fit the bevel gearwheel, needle ring, cylinder sleeve, shift sleeve, sleeve carrier and washer.

Version with 4-wheel drive

SS97G064

Version without 4-wheel drive

Make an assembly tube (76 :).

SS97G065

Fit the parts to the assembly tube.

Heat the bearing to & and fit it.

SP97G238

November 1998

- 105 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Push the bevel pinion into the assembly tube.

Remove the assembly tube.

1RWH Pay attention to profile.

SP97G239

Fit the castellated nut using special tool (76 :).

Tap free at both ends.

Subsequently tighten to 1P.

SP97G240

SS97G066

Sva 7-96440

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November 1998

5($5 $ ;/( 7 5( $66(0%/<

Check the bearing’s initial loading 1P.

SP97G241

Lock the castellated nut.

SP97G242

)LWWLQJ WKH )LHOG 5RDG JHDUVKLIW

SS97G067

Insert the spring and ball into the shift fork.

Fit this together with the shift rod.

1RWH Ensure that the shift finger is fitted in the correct position.

SP97G243

November 1998

- 107 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Secure the shift rod using a circlip.

SP97G244

Fit a new sealing ring to the shift lever and fit the lever with the shift finger.

Secure using the tapered bolt.

SP97G245

&RXQWHUVKDIW UH ILWWLQJ

SS97G068

Heat the bearing to & and fit it.

SP97G246

Sva 7-96440

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November 1998

5($5 $ ;/( 7 5( $66(0%/<

Mount the distance sleeve.

SP97G247

Fit the countershaft and spur pinion.

SP97G248

Fit the rear outer bearing ring.

Fit the circlip and chase the countershaft in.

SP97G249

Heat the front bearing to 80°C and fit it.

Then fit the outer bearing ring and and chase it in.

SP97G250

November 1998

- 109 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Check the axial play ( PP).

SP97G251

Determine the size of the packing rings.

SS97G069

Remove the circlip.

Then fit it together with the packing rings.

SP97G252

Fit the oil pipe.

Fit the right-hand axle stub and brake housing.

1RWH Seal the flange surface with /2&7,7( .

Then position the oil pipe correctly and seal with /2&7,7( .

SP97G253

Sva 7-96440

- 110 -

November 1998

5($5 $ ;/( 7 5( $66(0%/<

)LWWLQJ WKH GLIIHUHQWLDO JHDU

Mount the differential master gear onto the differential housing.

1RWH Seal the flange surfaces with /2&7,7( .

Lock screws using /2&7,7( .

Tightening torque (M10/10.9)..... 1P

SP97G254

Fit the axle bevel gear with thrust washer.

SP97G255

November 1998

- 111 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Fit the differential spider with bevel gears and thrust washers.

SP97G256

Fit the axle bevel gear with thrust washer.

SP97G257

Assemble both differential housing halves.

1RWH Pay attention to the marking (No.).

Tightening torque (M10/10.9)...... 1P

SP97G258

Fit the shift ring with locking bolts to the correct side.

SS97G071

Sva 7-96440

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November 1998

5($5 $ ;/( 7 5( $66(0%/<

Fit the ring.

SP97G007 SP97G260

Heat both bearings to &.

SP97G261

Fit the differential gear unit together with the shift fork.

Fit the oil channel.

SP97G262

Fit the pressure spring and shift shaft without sealing rings

Push the shaft through and fit a new sealing ring.

SP97G263

November 1998

- 113 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Secure the shift fork using a sprung dowel pin.

SP97G007 SP97G264

Fit the left-hand brake housing with packing rings.

SP97G007 SP97G265

Chase the differential master gear in.

SP97G266

Check the tooth flank play ( PP).

1RWH Use packing rings to compensate.

Seal the brake housing using /2&7,7( . and re-fit it.

Tightening torque (M12/10.9)..... 1P SP97G267

Sva 7-96440

- 114 -

November 1998

5($5 $ ;/( 7 5( $66(0%/<

&RUUHFW PHVKLQJ FKHFN

SS99N032

SS99N033

SS97G074

SP97G007

Ideal meshing (packing ring thickness is correct)

SS99N034

Fit the pinion shaft and axle stub (Chapter 5.2)

SP97G268

November 1998

- 115 -

Sva 7-96440

5($5 $ ;/( 7 5( $66(0%/< Fit the driving speed inductive transmitter at a distance of PP from the sensor wheel.

1RWH Compensate with packing rings and seal using ',5.2.

SP97G269

)LWWLQJ WKH JHDUER[ WR WKH UHDU D[OH For versions with a gURXQG VSHHG 372 shaft, fit the shift fork and sleeve into the housing.

SP97G007 SP97G270

Fit the gearbox.

1RWH Seal the flange surface with /2&7,7( .

Tightening torque (M12/10.9)..... 1P

SP97G271

For versions with a JURXQG VSHHG 372 shaft, fit the shift fork and shift rod.

Secure using the tapered bolt.

SP97G272

Sva 7-96440

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November 1998

5($5 $ ;/( 7 5( $66(0%/<

$GMXVWLQJ WKH HQJLQH JURXQG VSHHG 372 VKDIW JHDUVKLIW Engage the ground speed PTO shaft.

Shift the Field/Road group to Neutral.

The drive pawl (1) must rest on the larger diameter of the field/road shift sleeve (2).

Adjust the shift lever (3) to a distance of PP to the rear axle housing and tighten the clamping bolt (4).

Subsequently check all shift positions.

SS97G077

November 1998

- 117 -

Sva 7-96440

Sva 7-96440

- 118 -

November 1998

)5217 $;/( '5,9( 7 ',6$66(0%/<

Remove the front axle drive from the rear axle housing.

1RWH Pay attention to the gasket.

SP97G273

Remove the rear cover.

SP97G274

Remove the protective cap.

Drive out the sprung dowel pin and remove the sleeve.

SP97G275

Remove the front cover.

1RWH Pay attention to the gasket.

SS97G078

November 1998

- 119 -

Sva 7-96440

)5217 $;/( '5,9( 7 ',6$66(0%/< Pull the rear outer bearing ring off using special tool 6. .

SP97G276

Pull the bearing off using special tool 6. .

SP97G277

Compress the disk springs using special tool 76 : and remove the circlip.

SP97G278

Drive the drive shaft out.

Remove the disk springs, clutch bell housing and bevel gearwheel.

Pull the bearing off the drive shaft.

SP97G279

Sva 7-96440

- 120 -

November 1998

)5217 $;/( '5,9( 7 ',6$66(0%/<

Remove the cover with rotary spring and disengager fork.

Remove the shaft seals from the housing and cover.

SP97G280

SP97G280

November 1998

- 121 -

Sva 7-96440

)5217 $ ;/( '5,9( 372 7 5( $ 66(0%/<

SS97G080

Sva 7-96440

- 122 -

November 1998

)5217 $;/( '5,9( 372 7 5( $ 66(0%/<

Heat the bearing to & and fit to the drive shaft.

SP97G281

0XOWLSOH GLVN FOXWFK SUH DVVHPEO\ Fit a circlip to the clutch bell housing.

Heat the bevel gearwheel to & and fit the second circlip.

SP97G282

Fit the thrust washer with the groove to the bevel gearwheel and the clutch bell housing with bevel gearwheel.

SP97G283

Fit the disk carrier and pressure ring.

SP97G284

November 1998

- 123 -

Sva 7-96440

)5217 $ ;/( '5,9( 372 7 5( $ 66(0%/< Fit the set of disks.

SP97G285

Fit the pressure spring, pressure piece, bearing and disengager.

SP97G286

$GMXVWLQJ WKH IURQW D[OH GULYH 372 Fit the washer (1) and circlip (2).

Compress the set of disks and measure the gap between the circlip and the washer (dimension A).

Measure the thickness of the set of disk springs (dimension B).

Packing ring ; ; GLPHQVLRQ $ GLPHQVLRQ % SP97G287

SS97G081

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November 1998

)5217 $;/( '5,9( 372 7 5( $ 66(0%/<

Fit the needle bearing into the housing.

SP97G288

Fit the disengager fork.

SP97G289

Fit the multiple disk clutch.

SP97G290

Fit the drive shaft with thrust washer.

Fit the washer and disk springs.

SP97G291

November 1998

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Sva 7-96440

)5217 $ ;/( '5,9( 372 7 5( $ 66(0%/< Fit the packing ring (;) and circlip.

Compress the disk springs using special tool 76 : Fit the circlip.

SP97G292

Fit the torsion spring into the hole in the disengager fork.

Fit a new needle bearing and shaft seal into the cover.

SP97G293

Fit the cover without screws and seal using /2&7,7( .

Insert the torsion spring.

1RWH Do not damage to the shaft seal.

SP97G294

Heat the tapered roller bearing to & and fit it.

1RWH Chase the bearing in.

SP97G295

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November 1998

)5217 $;/( '5,9( 372 7 5( $ 66(0%/<

Fit the outer bearing ring.

Seal the cover with /2&7,7( and fit it.

Tightening torque (M8/8.8)..... 1P

SP97G296

'HWHUPLQLQJ SDFNLQJ ULQJ VL]H IRU D[LDO EHDULQJ SOD\ Fit the front outer bearing ring and chase it in.

Measure GLPHQVLRQ $ on the housing.

SP97G297

Measure GLPHQVLRQ % on the bearing.

Packing ring thickness ; ; GLPHQVLRQ $ GLPHQVLRQ % PP

SP97G298

Fit a new shaft sealing ring to the cover.

Seal using /2&7,7( and fit it together with the packing ring.

SP97G299

November 1998

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Sva 7-96440

)5217 $ ;/( '5,9( 372 7 5( $ 66(0%/< Check the axial play ( PP)

Subsequently pre-tension the spring in the side cover and tighten bolts (M8/8.8) to a torque of 1P.

SP97G300

Check the axial play (0-0.15mm)

Subsequently pre-tension the spring in the side cover and tighten bolts (M8/8.8) to a torque of 1P.

SP97G301

'HWHUPLQLQJ WKH SDFNLQJ ULQJ VL]H IRU WRRWK IODQN SOD\ Read the housing deviation off the underside of the rear axle. (given in 1/100 mm) Up to 0.02mm, round down.

From 0.03mm, round up.

Select a packing ring (s=0.2mm or 0.3mm) upon completion.

SP97G301

Fit the front axle drive with packing ring.

Pay attention to the cylindrical pin.

1RWH seal the flange surface with /2&7,7( .

Tightening torque (M12/10.9)..... 1P Check the tooth flank play ( PP).

The number of teeth on the bevel gearwheel (4-wheel drive) is punched into the housing.

SP97G302

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November 1998