VALTRA – VALMET
WORKSHOP MANUAL
ServiceManual Tractors Power transmission Brake system SteeringsystemandFront axle Frameand Wheels Tools Caband Shields Hydraulics ValtraInc. 44200Suolahti,Finland Groups10---100 General Engine Electrical system 40 50 60 70 80 100 90 6000,6100,6200 6250,6300,6350 6400,6550,6600 6650,6800,6850 6900,8000,8100 8200,8400,8050 8150,8450,8550 8750,8950 6600E---8750E 10 20 30
10.General 11.Layout 12.Repairs 13.Maintenance
Tothereader
TheServiceManualfortheValmettractorsisintendedtobeapracticalreferencesourcetobeusedinworkshop.Therepairinstructionsinthemanualarebasedonmethodswhichhavebeenworkedoutinpractice duringnormalworkshopconditionsandwhicharebasedontheuseofspecialtoolsfromthemanufacturer whenstatedintheinstructions.Themanualalsocontainsdescriptionsofthedesignandfunctionofthe components.
DetailedmaintenanceinstructionscanbefoundinOperator’sManual.
TheServiceManualwillbecontinuallyupdatedwithnewrevisedpageswhichshouldbeinsertedinthe manual.Alterationsandadditionswillfirstappearasservicebulletins.
OnlygenuineValmetsparepartsshouldbeusedtoensurethebestpossiblefunctionofthemachine.CertainoperationsshouldbecarriedoutwiththeaidofspecialtoolsdesignedbyValmet.
ValmetTractorsInc.
TractorService
3
ThefollowingsupplementshavebeenpublishedfortheValmet6000---8950ServiceManual:
Supplementno.39256211(15.6.1992)
Includes:
---AutocontrolIII
---airconditioning
---tractor8000
---amendments
Supplementno.39256212(1.9.1992)
Includes:
---20---seriesengines
---amendments
Supplementno.39256213(15.5.1993)
Includes:
---DeltaPowershift
---tractor8400
---amendments
---thelatestfittinginstructionsofoptionalequipment
Supplementno.39256214(1.1.1994)
Includes:
---tractors6000and8200
---AutocontrolII
---AutocontrolIV
---Sige---axledifferentiallock
---industrialfrontaxle
---latestairconditioning
---amendments
Supplementno.39256215(1.1.1995)
Includes:
---amendments
---thelatestfittinginstructionsofoptionalequipment
Supplementno.39256216(15.4.1995)
Includes:
---engineintakeairsystemandcoolingsystem,modifications
---Autocontrol2.1
---Agrodata---instrument
---hydraulictypeclutchreleasemechanism
---DPS,modifications
Supplementno.39256217(15.5.1996)
Includes:
---tractor6800
---tractors8050---8750
---amendments
Supplementno.39256218(1.4.1997)
Includes:
---tractors6200and8000R
---frontPTO
---CareTel
---HiShift ---amendments
---thelatestfittinginstructionsofoptionalequipment
Supplementno.39256219(1.8.1998)
Includes:
---FieldMaster
---pressureairbrakesfortrailer(optional)
---latestfittinginstructionsforoptionalequipment
---amendments
---newfolder,newindexleaves(10---30and40---100)andnew spinelabels.
Supplementno.39260211(1.11.1998)
Includes:
---HiTechreverseshuttle
---AutocontrolV
---New50---seriesmodels
---Frontaxleairsuspension
---E---engines
---Amendments
Supplementno.39260212(1.6.1999)
Includes:
---Autocontrol2.2
---amendments(e.g.forACV)
---fittinginstructionsforoptionalequipment
Supplementno.39260213(1.10.1999)
Includes:
---Carraro20.29frontaxle
---amendments(e.g.version42ofACV)
Supplementno.39260214(1.8.2000)
Includes:
---HiTechgen.2,AC---5.2
---frontPTOon6250H---6850Hitractors
---modifiedlubricatingoilpumpfor6---cyl.engines
---newrearaxlehousingfortransmissions650/550
---amendments
---updatedfittinginstructionsforoptionalequipment
Supplementno.39260215(1.9.2002)
Includes:
---transmissionandfinaldrives700
---Agroline---instrument
---technicalmodifications
Model CodePage 11.General 6000--89501100 1.9.2002 1.8.2000
Orderingnumber Date Notes 39256211 39256212 39256213 39256214 39256215 39256216 39256217 39256218 39256219 39260211 39260212 39260213 39260214 39260215 15.6.1992 1.9.1992 15.5.1993 1.1.1994 1.1.1995 15.4.1995 15.5.1996 1.4.1997 1.8.1998 1.11.1998 1.6.1999 1.10.1999 1.8.2000 1.9.2002
1.Divisionintogroups
Themanualisdividedintogroups(10---100)whicharebasedonthemake---upofthetractor.Thegroupsarelistedonthefirstindex leaf.
Thenumberdesignationforeachgroupisgiveninthetopleftboxoftherespectivepages(andthefirstfigureinthecodedesignation)
2.Divisionintocomponentsorsub---groups
Eachgroupisfurtherdividedintocomponentsorsub---groups.Thenumberandthenameofeachcomponentisgiveninthetop leftboxoneachpage(andcomprisethetwofirstfiguresinthecodedesignation).
7 Model CodePage 11.Layout 8.11.1990 6000--87501101
LayoutofServiceManual
Example.10.General 20.Engine,fuelandcoolingsystems 30.Electricalsystem 40.Powertransmission a.s.o.
4101 50 60 70 80 90 100 Code Page
Example.41.Clutch 42.Gearbox 44.Quick---shiftgear 45.Finaldrivesetc.
3.Codedesignation
Three---digitcodedesignationsareusedtodistinguishthedifferentdocumentgroupsfortherespectivecomponents.Thesame codeisalsousedintheTimeListasareferencetothetextinthisManual.Thecodedesignationnumbersappearbothintheboxat thetopofthepageandalsointheheadings.
Example:Code410:
---Group:Powertransmission(4)
---Component:Clutch(41)
---Documentgroup:General(410)
4.Pagenumbers
Theinstructionsforallcomponentsarenumberedinconsecutiveorderintheright---handboxatthetopofthepage.Thepage numbersbeginwithpage1foreachcomponent.
Atthetopofeachpagetherearetwoboxesfordates.Inthecaseofarevisedissue,thedateoftheearlierissueisprintedinthe crossed---overboxandthedateofthecurrentissueisprintedinthe”real”datebox.
Atthetopofeachpagethetractormodelforwhichthepageisvalidisindicated.
7.Additionsandamendmentsoftheservicemanual
Newandup---datedpageswillbecontinuallyaddedtotheservicemanual.Thenewpagesshouldbeinsertedasindicatedbythe code:thefirstdigit(alsothefirstdigitontheindexleaf)indicatedthegroup:
---thetwofirstdigitsindicatethecomponentorsub---group
---thethirddigitindicatesthedocumentgroupfortherespectivecomponents
---thepagenumberindicatesthedefinitepositionofthepagewithintheservicemanual
Iftherearetwopageswiththesamecodeandpagenumberthepagewiththelaterdateinthedatebox(andtheolddateinthe crossed---overbox)isvalid(orthecurrentpage).
N.B. Fittinginstructionsforextraequipmentareinsertedintotheservicemanualattheendofgroupconcerned(E.g.code39is insertedattheendofgroup30).
8 Model CodePage 11.Layout 8.11.1990 6000--87501102
41.Clutch 15.5.1993 ModelCode Page 6100---8400410 1 8.11.1990
5.Date
6.Model
CodedesignationintheServiceManual
10.General 110Layout
120Repairs
130Maintenance
20Engine
21.Engine
210Technicaldata,tools,description
211Cylinderblockandflywheelhousing
212Cylinderheadandvalvemechanism
213Crankmechanism
214Timinggears
215Lubricationsystemandoilsump
216Inductionandexhaustsystem,turbocharger
219Removingandfittingengine
22.Fuelsystem
220Technicaldata,tools,description
222Fuelfeedpumpandfuelfilters
223Injectionpumpandinjectors
23.Coolingsystem
230Technicaldata,tools,description
231Thermostatandcoolantpump
30.Electricalsystem
310Specifications,wiringdiagrams
311AutocontrolII
312Autocontrol2.1
313Sigma---power
320ACpowerlift
321ACDpowerlift
330Agrodata
331AD---instrument
340Autocontrol---III
350AutocontrolIV
360CareTel
40.Powertransmission
41.Clutch
410Technicaldata,tools,description
411Clutchassemblyandpedalrods
412Hydrauliccoupling
42.Gearbox
420Technicaldata,tools,description
421Selectorforks
422Gearshiftlevers
423Shaftsandgearwheels
424Differential
44.Quick---shiftgear,DPS,reverseshuttle,4WDclutch
440AQuick---shiftgear,technicaldata,tools,description
440BReverseshuttle,technicaldata,tools,description
440C4WDclutch,technicaldata,tools,description
441Quick---shiftgear,repairinstructions
442Reverseshuttle,repairinstructions
4434WDclutch,repairinstructions
444DPS,repairinstructions
45.Finaldrives
450Technicaldata,tools,description
451Finaldrives,repairinstructions
46Powertake---off
460Technicaldata,tools,description
461Powertake---off,repairinstructions
463FrontPTO,repairinstructions
9 Model CodePage
6000--87501103 1.4.1997 8.11.1990
11.Layout
50.Brakes
510Technicaldata,description
511.Servicebrakes
520Parkingbrake
60.Steeringsystemandfrontaxle
61.Steeringsystem
610Technicaldata,tools,description
611Steeringvalve
612Priorityvalve
613Steeringcylinder
614Adjustment
64.Poweredfrontaxle
640Technicaldata,tools,description
641Frontaxlehousingandfrontaxlesuspension
643Hubs
644Differential
645Industrialfrontaxle
70Frameandwheels
710Tractorframe
720Tyresandwheeldiscs
80Cabandshields 810Cab
820Shields
830Airconditioner
90Hydraulics
910Technicaldata,tools,description
911Pumpandpipes
912Workinghydraulics
913Three---pointlinkage,towinghook
920ACpowerlift
100.Specialtools
101Specialtools(ETV)
102Locallymanufacturedtools
Note! SeparatefittinginstructionsfortheoptionalequipmentsareinsertedintotheServiceManual.Theseinstructionsarepositionedtotheendofeachmaingroup.E.g.code39areplacedtotheendofgroup30.
10 Model CodePage 11.Layout 6000--87501104 1.4.1997 8.11.1990
Generalinstructionsforrepairs
Outeroilseals
TheServiceManualcontainsinstructionsforchangingallouteroilseals,(e.g.oilsealsonthePTOshaftend,ontheoutputshaft tothefrontwheeldriveandonthepinionshaftonthepoweredfrontaxle,andsoon).
Sealingcompoundandglue
Ifsealingcompoundsorgluearerequiredfortherepairwork,theinstructionswillspecifyasealingcompoundorgluewhichis readilyavailablethroughspecialistdealers.Somesealsshouldbegreasedbeforefittingandthespacebetweenthelipsofthe sealshouldbefilledwithuniversalgrease.Ifthesealistobepushedoversplinesorsharpedgesthesealshouldbeprotected withforexampleathinplasticfoil.
Tighteningtorquesandsettingvalues
Allnecessarytighteningtorquesandsettingvaluesforeachrepairoperationaregivenatthebeginningofeachrepairsection undertheheadingTechnicalData.Themostimportantvaluescanalsobefoundintherepairinstructions.
Table1latergivesthetighteningtorquesinorderofdimension,qualityandsurfacetreatment.Thevaluesgiveninthetableshould beusedifthetighteningtorqueisnotgivenintherepairinstructions.
Safety
Alwaysbearsafetyinmindwhenrepairingorservicingthetractor.Usetoolsandliftingdevicesinthecorrectway.Whenyou areremovingtractorcomponentsorsplittingthetractor,everytractorpartmustbesupportedinsuchaway,thatnoriskofaccident exists.Avoidworkingunderthesupportedtractorpartifitisnotabsolutelynecessary.Whensupportingthetractorthecentreof gravityoftheframepartmustalwaysbechecked.Forinstancethewedgesmustalwaysbefittedbetweenfrontaxleandengine topreventaxleoscillationwhensplittingthefrontframeofthetractor.
Trouble---shooting
Thefollowingprocedure,combinedwiththeinformationcontainedintheworkshopmanualwillbehelpfulintracingfaultsaccurately.Itconsistsoffollowinganumberoflogicalstepstolocateandcorrecttheproblem:
a)Determinetheproblem
b)Listpossiblecauses
c)Differentiatethecauses
d)Conductchecksinlogicalordertodeterminetheexactcause
e)Considerapproximateremainingservicelifeagainstcostofpartsandlabour..
f)Makeanynecessaryrepairs.
g)Recheckthepartsandfunctionsforcorrectoperation
11 Model CodePage 12.Repairs 8.11.1990 6000--87501201
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Handlingofheavycomponents
Unlessotherwisespecified,allremovalsshouldbeaccomplishedusingadjustableliftingequipment.Allsupporting slingsmustbeparalleltoeachotherandasnearverticalas possibleinrelationtotheobjectbeinglifted.However,where slingsareofafargreatercapacitythantheweightoftheload tobefitted,atriangularliftingarrangementmaybeused.
Cleanliness
Toensurelonglifeofamachine,itisimportanttokeepdirtand foreignmaterialoutofitsvitalworkingcomponents.Precautionsmustbetakentosafeguardagainstthis.Enclosedcompartments,sealsandfiltershavebeenprovidedtokeepthe supplyofair,fuelandlubricantclean.Theseprotectivedevicesmustnotberemoved.
Wheneverhydraulic,fuel,lubricatingoilorlinesaredisconnected,cleanthepointofdisconnectionandthesurrounding area.Assoonasalinehasbeendisconnected,cap,plugor tapethelineoropeningtopreventtheingressofforeignmaterial.
Thesamecleaningandcoveringprecautionsshouldbetaken whenaccesscoversorinspectionplatesareremoved.
Cleanandinspectallparts.Makesurethatallpassagesand holesareclear.Coverallpartstokeepthemclean.Makesure partsarecleanwhentheyarereassembled.Leavenewparts intheirwrappinguntiltheyareactuallyneededforreassembly
Whenremovingacomponentatanangle,rememberthatthe capacityofaneyeboltisreducedwhentheanglebetweenthe supportingmembersandtheobjectbecomeslessthan90
Assembly
Whenreassemblingamachine,completeeachstepinsequence.neverpartiallyassembleonepartthenstarttoassembleanother.Makeallrecommendedadjustments.Alwayscheckthejoboncompletiontoensurethatnothinghas beenoverlooked.Recheckthevariousadjustmentsbefore puttingthemachinebackintoservice.
Note! Beforefittingnewparts,removerustpreventativecompoundfromallmachinedsurfaces(usually”peel---offsubstances).
Lubrication
Whereapplicable,fillthecompartmentsofrepairedorrenewedcomponentswiththequantity,typeandgradeofclean lubricantrecommendedintheroutinemaintenancesectionof theOperator’sManual.
Shims
Whenshimsareremoved,tiethemtogetherandidentifytheir location.Keepshimscleanandtakecarenottobendthem beforerefittingthem.
A.Load B.Liftingshackle
C.Shackleretainingplate(3mmthick)
D.Sleeve
Whennecessarytheforgedeyeboltcanbesupportedinthe wayshowninfigureabove.SleeveDmayormaynotbe weldedtoplate.
Warning! Ifapartresistsremoval,checkthatallnutsandbolts havebeenremovedandthatthereisnointerferencefromadjacentparts.
Gaskets
Makesurethattheholesingasketslineupwithlubricatingoil passagesinthematingparts.Ifgasketshavetobemade,use materialofthecorrecttypeandthickness.Makesurethat holesarepunchedintherightplaces. Incorrectlypunchedgasketscancauseseriousdamage.
Liptyperubberseals
Lubricatethelipsoflip---typerubbersealswithoilbeforefitment.Donotusegreaseonseals,exceptforgreaseseals.
12 Model CodePage 12.Repairs 8.11.1990 6000--87501202
Oikein Rätt Right Richtig Giusto Väärin Fel Wrong Falsch Sbagliato Correct Teisingai Mauvais Neteisingai
˚ B C D A Forgedeyeboltsupport
Thefigureaboveshowstheconstructionofasimplelip---type seal.Thecrosssectionshowstheheel(4)andthetoe(5), usedtoidentifythesidesofasingleelementseal.Withafew exceptions,thetoeofasingle---lipislocatedonthelubricant side.Somesealshaveasecondauxiliarylipwhichhasno spring.
Cablesandwires
Whenremovingordisconnectingagroupofcablesorwires, labeleachonetoensurecorrectrefitment.
Lockingdevices
Correctandincorrectuseofretainers
Correctandincorrectmethodoffittingandbendinglocking tabs.
Slackeningofnutsandboltsispreventedbymechanical meanssuchaslockwashers,tabwashersandcotterpins,or byLoctite---typelockingagents.
Flatretainersmustbeinstalledproperlytobeeffective.Bend oneendoftheretaineragainsttheedgeofthepart.Bendthe otherendagainstoneofthenutorbolthead.Alwaysfitnew retainersincompartmentswhichhousemovingparts.When fittinglockwashersonaluminiumhousings,placeaflat washerbetweenthelockwasherandthehousing.
Note!
1)Neverfitalockwasher(Grower,fan,spring,etc.)underanut orbolttowhichaspecifiedtorquehastobeapplied.
2)Alwaysthoroughlydegreasecomponentsbeforeapplying Loctitetypelockingagents.
Bushesandpressfits
Donotfitbusheswithahammeralone.Useasuitablefitting toolandahammeror,betterstill,apressifpossible..
Whenusingapress,ensurethatpressureisapplieddirectly inlinewiththebore.Iftheringhasanoilhole,takecaretoalign itwiththeoilholeinthematingpart.Whenpressfittingapart intoanotherpart,lubricatethematingsurfaces.Taperedparts shouldbeassembleddry.Beforeassembly,checkthatthe tapersaredryandfreefromburrs.
Fittingboltsinblindholes
Useboltsofthecorrectlength.Aboltwhichistoolongmay ”bottom”beforetheheadcomesintocontactwiththepartit istohold:thiswillcausedamagetothethreads.Ifaboltistoo short,theremaynotbeenoughthreadsengagedtoholdthe partsecurely.
13 Model CodePage 12.Repairs 8.11.1990 6000--87501203 4 5 3 2 1
Themainpartsoflip---typeseal: 1.Case 2.Sealingelement 3.Ringspring
Table1. Tighteningtorques,metricstandardthread(ISO)
1)1Nm=0,102kpm
2)Zne=zincelectroplating
3)Znk=hotgalvanized
Iftheboltsdiffersfromthestandardrangethevaluesinthe tablemustnotbeused.
14 Model CodePage 12.Repairs 8.11.1990 6000--87501204
Table
TighteningtorquesNm1) Dim. Quality,surfacetreatment,materialandsoon 8.8 lubr. tol.± 8.8 Zne2) tol± 8.8 Znk3) tol.± 10.9 lubr. tol.± 12.9 lubr tol.± M4 M5 6,4 0,6 5,7 0,5 9 1 11 1 M6 11 1 10 1 12 1,2 15 1,5 18 2 M8 25 2 23 2 30 3 35 4 45 5 M10 50 5 45 5 60 5 70 7 90 10 M12 90 10 80 8 100 10 125 10 151 15 M14 140 15 125 10 160 15 200 20 240 20 M16 220 20 195 20 250 25 300 30 370 40 M18 300 30 270 30 350 35 430 40 510 50 M20 430 40 380 40 480 50 600 60 720 70 M22 570 60 500 50 650 65 800 80 970 100 M24 740 70 660 70 830 80 1030 100 1250 120 M27 1100 100 950 100 1200 120 1500 150 1800 180 M30 1500 150 1300 130 1600 160 2040 200 2500 250
Conversiontableforcommonunits
Quantitiesandunits
Conversionfactors
Overallanddetaildimensionsmillimetres(mm)100mm=3,94inches 1inch=25,4mm
Shortdistancese.g.turningcirclesmetres(m)
Traveldistanceskilometres
Tractorweights,axleloadingskilograms(kg)
Travelspeedkilometresperh(km/h)
Drawbarpullkilonewtons(kN) 1kN=224,8lbs 1lb=4,448N
Power(identifiedbysuchtermsascrankshaftpower,1kW=1,34hp ptopower,beltpower,drawbarpower,indicating1hp=0,746kW thepointatwhichthemeasurementwastaken) kilowatts(kW)
Enginetorquenewtonmetres(Nm)
Fuelconsumptionbyweight(kilogramsperhr,kg/h)1kg/h=2,2lb/hr (byvolume)litresperhr(l/h)
Fueleconomy(specificfuelconsumption)
gramsperkilowatthr(g/kWh)
Enginedisplacementlitres(l)
Hydraulicpump
pressure---mecapascal(MPa)
delivery---millimetrespersec(ml/s)
Tyre pressure---kilopascal(kPa)
15 Model CodePage 12.Repairs 8.11.1990 6000--87501205
1m=3,28ft 1ft=0,305m
1km=0,62mile 1mile=1,61km
1kg=2,2lbs
1lb=0,454kg
1km/h=0,62mph 1mph=1,61km/h
1Nm=0,74ftlb 1ftlb=1,356Nm
1lb=0,454kg 1l/h=0,22gal/hr 1gal=4,54l
304g/kWh=0,5lb/hphr
1l=61,02mcuin 100cuin=1,639l
1MPa=145psi
1000psi=6,9MPa
100ml/s=1,32gpm 1gpm=75,77ml/s
100kPa=14,5psi 1psi=6,9kPa Areaacres---hectare Toconvertmultiplyby 0,404686 Volumebushel---litre Toconvertmultiplyby 39,3687 Quantitypoundperacre---kilogramperhectareMultiplyby1,12085 Volume Multiplyby superficialfoot---cubicmetre 0,002360