PageDate
Removal--Installation--drivegearcasing ..........806--11
25--FRONTAXLEMECHANICAL TRANSMISSION
CHAPTER1--Frontmechanicaltransmission
MainData..............1--206--11
TorqueSpecifications....3--406--11
Tools..................506--11
Sections...............606--11
Removal--Installation-frontaxle...............8--9--1006--11
Frontaxle.Disassembly-Assembly..............11--12--13-14--15--16-17--1806--11
Replacingsteeringknuckle pinsandbearings .......1906--11
Adjustments--steering knucklebearings ........20--2106--11
Adjustments--beveldrive22--23--24-25--26--27-2806--11
Overhaul--frontdifferential2906--11
LIM--SLIPself--lockingdifferential................30--3106--11
Checkingleadingwheel alignment..............3206--11
Disassembly--Assembly-frontepicyclicfinaldrive..33--3406--11
27--REARMECHANICAL TRANSMISSION
MainData..............1--206--11
TorqueSpecifications....3--406--11
Tools..................506--11
Sections...............6--706--11
Descriptionandoperation.806--11
Troubleshooting .........806--11
Disassembly--Assembly-transmission--gearboxcasing...................9--10--11-1206--11
Adjustments--differential lockengagementsleeve position................1306--11
Adjustments--beveldrive14--15--1606--11
Removal--Installation sidegearcasing .........17--18--19-2006--11
Disassembly--Assembly-drivewheelshaft ........21--2206--11
31--POWERTAKE--OFF
CHAPTER1--Mechanicalpowertake--off
MainData..............1--206--11
TorqueSpecifications....3--406--11
Sections...............5--606--11
Descriptionandoperation.7--806--11
Troubleshooting .........806--11
33--BRAKES
MainData..............1--206--11
TorqueSpecifications....206--11
Sections...............306--11
Descriptionandoperation.406--11
Troubleshooting .........5--606--11
Removal--Installation--servicebrake..............706--11
Removal--Installation--servicebrakepump.........8--906--11
Adjustments--servicebrakepedalstravel .........1006--11
Servicebrakecircuitair bleeding ................11--1206--11
35--HYDRAULICSYSTEMS
CHAPTER1--Rearmechanicalhydrauliclift
MainData..............206--11
TorqueSpecifications....2--306--11
Tools..................306--11
Sections...............406--11
Troubleshooting .........506--11
Descriptionandoperation.6--7--8--9-10--1106--11
Liftinternalcontrols.Disassembly--Assembly......12--13--14-1506--11
4 CONTENTS 84419887A --06--2011
PageDate
PageDate
DraftreadingunitDisassembly--Assembly......16--1706--11
Liftarmsshaft.Disassembly--Assembly..........18--1906--11
Removal--Installation--lift controlvalve............2006--11
Adjustingthelift.........21--22--2306--11
CHAPTER2--Opencentresystemauxiliary controlvalves
MainData..............206--11
Tools..................206--11
TorqueSpecifications....206--11
Sections...............3--406--11
Descriptionandoperation.5--6--7--806--11
Auxiliarycontrolvalves.Disassembly--Assembly...9--10--1106--11
CHAPTER3--Trailerbrakesauxiliarycontrol valves
Sections...............106--11
Descriptionandoperation.1--2--3--4--5 --6--706--11
Troubleshooting .........8--9--1006--11
CHAPTER8--FrontLoader
MainData..............106--11
Sections...............206--11
TorqueSpecifications....306--11
Troubleshooting .........4--506--11
Parkingthefrontloader...606--11
FrontloaderarmconnectionbracketRemoval--Installation...............706--11
Replacementofcontrol struts(mod.MSL).......806--11
Replacementoftriangular articulationlevers(mod. MSL)..................906--11
Bucketsupportdeviceremoval--installation.......1006--11
Positionindicatordisassembly--assembly.......1106--11
Bushingreplacement....12--1306--11
Loadercylinderremoval-installation..............1406--11
Bucketcontrolcylinderremoval--installation.......1506--11
Replacementofpins.....1606--11
41--STEERING
CHAPTER1--Steering
MainData..............206--11
TorqueSpecifications....206--11
Tools..................306--11
Descriptionandoperation.4--5--606--11
Viewofhydrostaticsteering controlvalvecomponents.706--11
Troubleshooting .........8--906--11
Replacement--hydrostatic steeringwheel ..........1006--11
Removal--Installation--hydrostaticsteeringcontrol valve.................. 11--1206--11
Disassembly--Assembly-hydrostaticcontrolvalve..13--14--15-16--17--18-19--20--21-22--23--24-25--26--27-2806--11
Hydrostaticsteeringcontrol valvebenchtesting ......29--3006--11
Pressurereliefvalvetesting3106--11
Steeringcontrolcylinder. Removal--Installation....32--3306--11
Steeringcontrolcylinder. Disassembly--Assembly..34--3506--11
50--CABHVACSYSTEM
Safetyregulations .......206--11
MainData..............306--11
Tools..................406--11
Operatingprinciples.....506--11
Conditioningsystemcomponents ................6--7--8--9-1006--11
Cabcontrols............11--12--1306--11
Testingoperationandcooling....................14--1506--11
--06--2011
CONTENTS 5 84419887A
PageDate
PageDate
Airconditioningsystem maintenance ............16--1706--11
Troubleshooting .........18--19--20-2106--11
Refrigerantrecovery--recyclingandevacuation--chargingstations............22--2306--11
Dehydration,recharging andrefrigerationcheck...24--25--26-27--28--29-3006--11
Checkingforandeliminatinganygasleaks.......31--3206--11
Cabheating/air--conditioningsystem.Removal--Installation...............33--3406--11
Cabelectricfanunit.Disassembly--Assembly......3506--11
Air--conditioningsystem condenserremoval--installation..................3606--11
55--ELECTRICALSYSTEM
CHAPTER1--Instruments
Summary...............106--11
Digitalanaloginstrument206--11
Speedometer/tachometer.306--11
LCDpanelsettings ......3÷706--11
Coolanttemperature.....706--11
Fuellevel...............706--11
Indicatorlights..........8÷906--11
Transmitters,sensorsand switches...............10÷18 06--11
Electroniccontrolunitinputs/outputs(ADIC)......19÷2106--11
CHAPTER2--StartingSystem
Summary...............106--11
Technicaldata..........206--11
TorqueSpecifications....206--11
Descriptionandoperation.306--11
Starterandrechargingcircuit.................... 4--506--11
Troubleshooting .........6--706--11
Fuseandrelaylocations..7--806--11
--06--2011
Systemtesting..........8÷1006--11
Startermotorremoval--installation...............11÷1306--11
CHAPTER3--Chargingsystem
Summary...............106--11
Technicaldata..........206--11
TorqueSpecifications....206--11
Tools...................306--11
Descriptionandoperation.3--406--11
Systemtesting..........506--11
BeltTension.............606--11
Alternatormotorremoval andinstallation..........7--806--11
CHAPTER4--Battery
Summary...............106--11
Technicaldata..........206--11
Descriptionandoperation.206--11
Batteryremovalandinstallation.................. 306--11
Batterytestingandchargingprocedure ..........4÷1406--11
CHAPTER5--Electricalcircuits
Summary...............106--11
Maxipowerfuses........2
Powerfuses............4
506--11
1506--11
Batterycut--out..........1506--11 Sockets................1606--11
Gridheater .............1706--11
Electronicmodules ......1706--11
MainConnectors ........18--1906--11
Groundpointsidentification20
Howtousethewiringdiagrams..................22
Componentsindescriptive order..................27
2106--11
2606--11
3106--11
Listoftablesforsystemwithout“standardandfulloptional”cab ..............32--3306--11
Componentswithcodein ascendingorder .........34
3706--11
6 CONTENTS 84419887A
PageDate
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÷
÷
÷
÷
÷
Tables.................38
6606--11
CHAPTER6--WiringHarnessesand
Summary...............106--11
Componentsindescriptive order..................2÷606--11
Componentswithcodein ascendingorder .........7÷1006--11
Harnesses..............13÷2006--11
Connectors .............11
6406--11
90--PLATFORM,CAB,BODYWORK CHAPTER1--Cab Bonnet.Removal--Installation....................206--11
Cabassemblywithplatform.Removal--Installation....................3--4--5--6-7--8--906--11
Cabright--handpillarguard removal--installation.....1006--11
Cabright--handtopguard removal--installation.....1106--11
Cabright--handmudguard guardremoval--installation1206--11
Cableft--handtopguardremoval--installation.......1306--11
Windows.Replace .......14--15--1606--11
--06--2011
CONTENTS 7 84419887A
PageDate
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Connectors
÷
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GENERALINSTRUCTIONS
IMPORTANTNOTICE
AllmaintenanceandrepairworkdescribedinthismanualmustbeperformedexclusivelybySTEYRservice technicians,instrictaccordancewiththeinstructionsgivenandusinganyspecifictoolsnecessary. Anyoneperformingtheoperationsdescribedhereinwithoutstrictlyfollowingtheinstructionsispersonally responsibleforanyeventualinjuryordamagetoproperty.
BATTERY
Beforecarryingoutanykindofserviceoperationdisconnectandisolatethebatterynegativelead,unless otherwiserequestedforspecificoperations(e.g.:operationsrequiringtheenginetoberunning),afterwhichit isnecessarytodisconnecttheabove--mentionedleadtocompletethework.
SHIMMING
Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenadd uptherecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortherated valueindicatedforeachshim.
ROTATINGSHAFTSEALS
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
--beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes;
--thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged;
--positionthesealinglipfacingthefluid;withhydrodynamiclips,takeintoconsiderationtheshaftrotation directionandpositionthegroovessothattheywilldeviatethefluidtowardstheinnersideoftheseal;
--smearthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andfillthegapbetweenthe sealinglipandthedustlipondoublelipsealswithgrease;
--insertthesealinitsseatandpressdownusingaflatpunch,donottapthesealwithahammerormallet;
--whilstinsertingtheseal,checkthattheitisperpendiculartotheseat;oncesettled,makesurethatitmakes contactwiththethrustelement,ifrequired;
--topreventdamagingtheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.
O--RINGSEALS
LubricatetheO--RINGsealsbeforeinsertingthemintheseats,thiswillpreventthemfromoverturningand twisting,whichwouldjeopardisesealingefficiency.
SEALINGCOMPOUNDS
ApplyoneofthefollowingsealingcompoundsonthematingsurfacesmarkedwithanX:LOCTITE518or LOCTITE5205orSUPERBOND559orBETALOKA272M.
Beforeapplyingthesealingcompound,preparethesurfacesasfollows:
--removeanyincrustationsusingawirebrush;
--thoroughlydegreasethesurfacesusingoneofthefollowingcleaningagent:trichlorethylene,petrolorawater andsodasolution.
BEARINGS
Wheninstallingbearingsitisadvisedto:
--heatthebearingsto80 ÷ 90 0Cbeforefittingontheshafts;
--allowthebearingstocoolbeforeinstallingthemfromtheoutside.
SECTION00--GENERAL--CHAPTER1 1 84419887A --06--2011
SPRINGPINS
Whenfittingsplitsocketelasticpins,ensurethatthepinnotchispositionedinthedirectionoftheforcerequired tostressthepin.
Spiralspringpinsdonotrequirespecialpositioning
SPAREPARTS
Usegenuinepartsonly.
Onlygenuinesparepartsguaranteethesamequality,durationandsafetyastheyarethesamepartsthatare assembledduringproduction.
Only genuineparts canofferthisguarantee.
Whenorderingspareparts,alwaysprovidethefollowinginformation:
--tractormodel(commercialname)andframenumber;
--enginetypeandnumber;
--partnumberoftheorderedpart,whichcanbefoundonthe“SparePartsCatalogue”,whichisthebasefor orderprocessing.
NOTESFOREQUIPMENT
ThetoolsthatSTEYRofferandillustrateinthismanualare:
--specificallyresearchedanddesignedforusewithSTEYRvehicles;
--necessarytomakeareliablerepair;
--accuratelybuiltandstrictlytestedtoofferefficientandlong--lastingworkingmeans.
Byusingthesetools,repairpersonnelwillbenefitfrom:
--operatinginoptimaltechnicalconditions;
--obtainingthebestresults;
--savetimeandeffort;
--workinginsafeconditions.
IMPORTANTNOTES
Wearlimitvaluesindicatedforcertainpartsarerecommended,butnotbinding.Theterms“front”,“rear”, “right--hand”and“left--hand”(whenreferredtodifferentparts)areintendedasseenfromthedrivingpositionwith thetractorinthenormaldirectionofmovement.
MOVINGTHETRACTORWITHTHEBATTERYREMOVED
Externalpowersupplycablesshouldonlybeconnectedtotherespectivepositiveandnegativecableterminals, usingefficientclampsthatguaranteeadequateandsecurecontact.
Disconnectallservices(lights,windshieldwipers,etc.)beforestartingthevehicle.
Ifthetractorelectricalsystemrequireschecking,carryoutoperationswiththepowersupplyconnected.Once checkingiscompleted,disconnectallservicesandswitchoffthepowersupplybeforedisconnectingthecables.
2 SECTION00--GENERAL--CHAPTER1 84419887A --06--2011
SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thiswarningsymbolpointsoutimportantmessages concerningyoursafety.
Carefullyreadthefollowingsafetyregulationsand observeadvisedprecautionsinordertoavoid potentialhazardsandsafeguardyourhealthand safety.
Inthismanualthesymbolisaccompaniedbythe followingkey--words:
WARNING --Warningsconcerningunsuitablerepair operationsthatmayjeopardisethesafetyofRepair personnel.
DANGER --Specificwarningsconcerningpotential hazardsforoperatorsafetyorforotherpersons directlyorindirectlyinvolved.
TOPREVENT ACCIDENTS
Mostaccidentsorinjuriesthatoccurinworkshops aretheresultofnon--observanceofsimpleand fundamentalsafetyregulations.Forthisreason,IN MOSTCASESTHESEACCIDENTSCANBE
AVOIDEDbyforeseeingpossiblecausesand consequentlyactingwiththenecessarycautionand care.
Accidentsmayoccurwithalltypesofvehicle, regardlessofhowwellitwasdesignedandbuilt.
Acarefulandjudiciousservicetechnicianisthebest guaranteeagainstaccidents.
Preciseobservanceofthemostbasicsafetyruleis normallysufficienttoavoidmanyseriousaccidents.
DANGER. Nevercarryoutanycleaning,lubrication ormaintenanceoperationswhentheengineis running.
SAFETYRULES
GENERALGUIDELINES
--Carefullyfollowspecifiedrepairand maintenanceprocedures.
--Donotwearrings,wristwatches,jewels, unbuttonedorflappingclothingsuchasties,torn clothes,scarves,openjacketsorshirtswithopen zipswhichcouldgetcaughtonmovingparts. Useapprovedsafetyclothingsuchas anti--slippingfootwear,gloves,safetygoggles, helmets,etc.
1
--Donotcarryoutrepairoperationswithsomeone sittinginthedriver’sseat,unlessthepersonisa trainedtechnicianwhoisassistingwiththe operationinquestion.
--Donotoperatethevehicleoruseanyofthe implementsfromdifferentpositions,otherthan thedriver’sseat.
--Donotcarryoutoperationsonthevehiclewith theenginerunning,unlessspecificallyindicated.
--Stoptheengineandensurethatallpressureis relievedfromhydrauliccircuitsbeforeremoving caps,covers,valves,etc.
--Allrepairandmaintenanceoperationsmustbe carriedoutusingextremecareandattention.
--Servicestepsandplatformsusedinaworkshop orinthefieldshouldbebuiltincompliancewith thesafetyrulesinforce.
--Disconnectthebatteriesandlabelallcontrolsto indicatethatthevehicleisbeingserviced.Block themachineandallequipmentwhichshouldbe raised.
--Donotcheckorfillfueltanks,accumulator batteries,norusestartingliquidwhensmokingor nearnakedflames,asthesefluidsare inflammable.
--Brakesareinoperativewhenmanuallyreleased forrepairormaintenancepurposes.Useblocks orsimilardevicestocontrolthemachineinthese conditions.
--Thefuelnozzleshouldalwaysbeincontactwith thefillingaperture:Maintainthiscontactuntilthe fuelstopsflowingintothetanktoavoidpossible sparksduetostaticelectricitybuildup.
SECTION00--GENERAL--CHAPTER1 3 84419887A --06--2011
--Onlyusespecifiedtowingpointsfortowingthe vehicle.Connectpartscarefully.Makesurethat allpinsand/orlocksaresecuredinposition beforeapplyingtraction.Neverremainnearthe towingbars,cablesorchainsthatareoperating underload.
--Transportvehiclesthatcannotbedrivenusinga traileroralow--loadingplatformtrolley,if available.
--Whenloadingorunloadingthevehiclefromthe trailer(orothermeansoftransport),selectaflat areacapableofsustainingthetrailerortruck wheels.Firmlysecurethevehicletothetruckor trailerandlockthewheelsinthepositionusedby thecarrier.
--Electricheaters,battery--chargersandsimilar equipmentmustonlybepoweredbyauxiliary powersupplieswithefficientgroundinsulationto avoidelectricalshockhazards.
--Alwaysusesuitablehoistingorliftingdevices whenraisingormovingheavyparts.
--Takeextracareifbystandersarepresent.
--Neverpourpetrolordieseloilintoopen,wideor lowcontainers.
--Neverusegasoline,dieseloilorother inflammableliquidsascleaningagents.Use non--inflammable,non--toxiccommercially availablesolvents.
--Wearsafetygoggleswithsideguardswhen cleaningpartswithcompressedair.
--Limittheairpressuretoamaximumof2.1bar, accordingtolocalregulations.
--Donotruntheengineinconfinedspaceswithout suitableventilation.
--Donotsmoke,usenakedflames,orcause sparksintheareawhenfuelfillingorhandling highlyinflammableliquids.
--Neverusenakedflamesforlightingwhen workingonthemachineorcheckingforleaks.
--Allmovementsmustbecarriedoutcarefully whenworkingunder,onornearthevehicle. Wearsuitablesafetyclothing,i.e.,hardhat, safetygogglesandspecialshoes.
--Whencarryingoutcheckswiththeengine running,requesttheassistanceofanoperatorin
thedriver’sseat.Theoperatormustmaintain visualcontactwiththeservicetechnicianatall times.
--Ifoperatingoutsidetheworkshop,positionthe vehicleonaflatsurfaceandlockinposition.If workingonaslope,lockthevehicleinposition. Movetoaflatareaassoonasissafelypossible.
--Damagedorbentchainsorcablesareunreliable. Donotusethemforliftingortowing.Alwaysuse suitableprotectivegloveswhenhandlingchains orcables.
--Chainsshouldalwaysbesafelysecured.Make surethatthehitch--uppointiscapableof sustainingtheloadinquestion.Keepthearea nearthehitch--uppoint,chainsorcablesfreeof allbystanders.
--Maintenanceandrepairoperationsmustbe carriedoutinaCLEANandDRYarea.Eliminate anywateroroilspillageimmediately.
--Donotcreatepilesofoilorgrease--soakedrags astheyrepresentaseriousfirehazard.Always placethemintoametalcontainer. Beforestartingthetractororitsattachments, check,adjustandblocktheoperator’sseat.Also checkthattherearenopersonswithinthe vehicleorimplementrangeofaction.
--Emptypocketsofallobjectsthatmayfall unobservedintothevehicleparts.
--Inthepresenceofprotrudingmetalparts,use protectivegogglesorgoggleswithsideguards, helmets,specialfootwearandgloves.
--Whenwelding,useprotectivesafetydevices: tintedsafetygoggles,helmets,specialoveralls, glovesandfootwear.Allpersonspresentinthe areawhereweldingistakingplacemustwear tintedgoggles.NEVERLOOKDIRECTLYAT THEWELDINGARCWITHOUTSUITABLE EYEPROTECTION.
--Metalcablestendtofraywithrepeateduse. Alwaysusesuitableprotectivedevices(gloves, goggles,etc.)whenhandlingcables.
--Handleallpartswithgreatcare.Donotputyour handsorfingersbetweenmovingparts.Always wearsuitablesafetyclothing--safetygoggles, glovesandshoes.
4 SECTION00--GENERAL--CHAPTER1 84419887A --06--2011
Chapter1--Engine
CONTENTS
SectionDescription
10000 Generalspecifications2
1000110 EngineRemoval--Installation4 1021610 Radiator--Removal--Installation13
NOTE: Forthemaindata,tighteningtorques,tools,diagrams,lubricationandcoolingdiagrams,faultdiagnosis, disassembly--assembly,checksandoverhauling,seetheRepairsManual printno.84346691A--Italian; printno.84346685A--English; printno.84346689A--French; printno.84346702A--Spanish; printno.84347418A--German; printno.84346687A--Dutch; printno.84346699A--Portuguese; printno.84346686A--Danish.
SECTION10--ENGINE--CHAPTER1 1 84419887A --06--2011 SECTION10--ENGINE
Page
.........................................................
Adjustingtheacceleratorcontrolcable16
GENERALSPECIFICATIONS
Engine,technicaltype:
--mod.4055S--typeF5AE9454J*A(BOSCHpump)
--mod.4065S--typeF5AE9454L*A(BOSCHpump)
Cycle................................................. diesel,4--stroke
Fuelinjection..........................................
Numberofcylindersinline
Pistondiameter........................................ 99mm
Totaldisplacement......................................
Compressionratio...................................... 17.5 ± 0.5:1
MaximumPowerOutput:
--mod.4055S--typeF5AE9454J*A 41kW(55Hp)
--mod.4065S--typeF5AE9454L*A 48kW(65Hp)
Maximumpowerspeed 2300rpm
Maximumtorquespeed 1400rpm
TorqueRise........................................... 35(%)
Numberofmainbearings
Sumppan.............................................
Lubrication
Pumpdrive............................................
Oilfiltration............................................
cartridgeondelivery
Normaloilpressurewithmotorwarmed--upatfastidling..... 2.9
3.9bar
Fan,attachedtothepulley.........................
2 SECTION10--ENGINE--CHAPTER1 84419887A --06--2011
......
......
Direct
4
Pistonstroke.......................................... 104mm
3200cm3
................................ 5
structural,castiron
.......................................... forced,withlobepump
fromcrankshaft
viameshfilteroninletand
÷
Cooling ........................................ coolantcirculation Radiator............................................... 4linesofverticalpipeswithcopperfins
intake,inplasticwith11blades Coolantpump.......................................... centrifugalvane--type Temperaturecontrol.................................... viathermostatvalve --initialopening 79 ± 2 °C (continued)
GENERALSPECIFICATIONS
Timing overheadvalvesoperatedbytappets,rods androckerarmsviathecamshaftlocated intheengineblock;thecamshaftisdriven bythecrankshaftusingstraight--tooth gears
Intake:
--start:beforeT.D.C................................... 19°± 30’
--end:afterB.D.C. 37°± 30’
Exhaust: --start:beforeB.D.C.................................. 61°± 30’
--end:afterT.D.C. 21°± 30’
Clearancebetweenvalvesandrockerarmswithenginecold:
--intake............................................. 0.25 ± 0.05mm
--exhaust
Airfiltering.............................................
0.50 ± 0.05mm
viadryairfilterwithdoublecartridge, cloggingwarninglightwithcentrifuge prefilterandautomaticexhaustofdust
Fuelpump............................................. withdoublediaphragm
viameshfilterinthefuelpump,a renewablecartridgefilteronthedeliveryto theinjectionpump
viaenginetiming
SECTION10--ENGINE--CHAPTER1 3 84419887A --06--2011 (overleaf)
............................................
Fuelsystem
Fuelfiltration...........................................
Camoperated
BOSCHInjectionpump................................. rotatingdistributortype All--speedgovernor,incorporatedinpump: BOSCH............................................... centrifugalcounterweights Automaticadvanceregulator,incorporatedinpump: BOSCH............................................... hydraulic Turbocharger --type........................................... HOLSET Injectionpump......................................... rotatingdistributorwithspeedgovernor andadvancevariatorincorporated BOSCHpump: --mod.4055S--typeF5AE9454J*A .................... VE4/12F1150--504246316 --mod.4065S--typeF5AE9454L*A VE4/12F1150--504246318 Directionofrotation..................................... clockwise Injectionorder......................................... 1--3--4--2(forallmodels)
DANGER
Liftandhandleallheavypartsusingsuitablelifting equipment.
Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks.Ensurethat no--oneisinthevicinityoftheloadtobelifted.
ATTENTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.
1.Carryoutoperation 9015010 --Cabassembly withplatform(doonlytheremoval--seesect.90, chapter1).
2.Extractthefixingpinandremovetheballast weights;unscrewthefixingscrewsandrecover theballastsupport.
1
3.Positionasuitablecontainerundertherear transmission,unscrewtheplug(1)anddrainoff theoilfromthetransmission.
NOTE: Considerthattheprescribedquantityis: 35litresformechanicaltransmissionsor40litresfor hydraulictransmissions.
4.Disconnectthepipes(2and3)fromthecentral auxiliarycontrolvalves,unscrewthebracket fixingscrews(1)supportingthecontrolvalves andremovetheunit.
4 SECTION10--ENGINE--CHAPTER1 84419887A --06--2011 Op.1000110 ENGINERemoval--Installation
2
3
5.Disconnectthefollowingpipesfromthecentral auxiliarycontrolvalves:delivery(1)totherear auxiliarycontrolvalvesandreturn(2)tothe transmissionbox.
6.Unscrewtherelativeretainingboltsanddetach thecabright--handsupport(1). Dothisonbothsides.
7.Disconnectanddetachthepipes(1and2) connectingthepowershuttlecontrolvalvetothe cooler.
8.Disconnectthecentralauxiliarycontrolvalve connectionline(5).
9.Disconnecttherearauxiliarycontrolvalve connectionline(1).
10.Disconnectthefour--wheeldriveengagement controlline(4).
11.DisconnectthePTOcontrolline(2).
12.Disconnectthereartransmissionlubricationline (3).
SECTION10--ENGINE--CHAPTER1 5 84419887A --06--2011
4
5
6
7
13.Disconnecttheintakepipe(1)fromtherear transmissionboxandfromthefiltersupport, removethispipe.
14.Unscrewthefront,middleandrearfasteners, anddetachthepropellershaftguard(1).
15.Removethecirclip(3)andmovethesleeve(2) backtofreeitfromthesplinedoutputshaftofthe frontaxle(1),dothisontherearsleevetoo.
16.Unscrewbolts(2)andremovethepropellershaft (1).
6 SECTION10--ENGINE--CHAPTER1 84419887A --06--2011
8
9
10
11
17.Disconnectthepipes:(1)connectingtothe hydraulicpump,(2)connectingtothecentral auxiliarycontrolvalvesand(4)hydraulicpump inlet.
18.Unscrewtheretainingboltsandremovethefilter (3)andsupport.
19.Setafixedstandundertheclutchbox,connect therearoftheenginetothehoist,unscrewthe fixingscrews(1)anddetachtheenginetogether withthefrontaxlefromtheclutchbox.
20.Disconnectthepipes(1)connectingtothe transmissionoilcooler.
21.Disconnecttheradiatortopsleeve(2).
22.Disconnectthesleeve(1)connectingthe turbochargertotheairfilter.
23.Unscrewtheretainingboltsanddetachthe maxi--fusesupportbracket(3).
SECTION10--ENGINE--CHAPTER1 7 84419887A --06--2011
12
13
14
15
24.Disconnecttheelectricalconnection(1)fromthe filter/dryer(2).
25.Unscrewtheretainingboltsanddetachthe bracket(1)lockingtheradiatortotheengine.
26.Disconnectthefittings(2)toseparatetherigid pipesfromtheflexiblehoses.
27.Detachthebracket(1)fixingthesteeringcylinder controllines.
28.Unscrewtheboltfasteningthebracket(1)tothe engine.
8 SECTION10--ENGINE--CHAPTER1 84419887A --06--2011
16
17
18
19
29.Disconnectthepipes(1and2)fromthecabair conditioningsystemcompressor.
30.Setafixedstandunderthefrontofthefrontaxle supportandoneunderthebackofit.
31.Connecttheenginetoachain(1)andtothe hoist.
32.Unscrewthebolts(1),onbothsides,andremove theengine.
33.Thenresttheengineonanadequatesupport.
34.Tore--fittheengine,proceedasfollows:
ATTENTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.
--Usingachainconnecttheenginetothehoistand reattachittothefrontaxlesupporttighteningthe screwstotheprescribedtorque.
--Connectthepipestothecompressorofthecab airconditioningsystem.
--Usingtheappropriatebracket,securethe maxi--fuseconnectingcable.
--Securethesteeringcylindercontrollinesusing therelevantbracket.
--Connectthesteeringcylindercontrolpiping.
--Positionandsecurethebracketretainingthe radiatortotheengine.
--Connecttheelectricalconnectiontothe filter/dryer.
--Positionandsecurethemaxi--fusesupport bracket.
--Positionandsecurethesleeveconnectingthe turbochargertotheairfilter.
--Positionandsecuretheradiatoruppersleeve.
SECTION10--ENGINE--CHAPTER1 9 84419887A --06--2011
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--Positionandconnectthetransmissionoilcooler connectingpipes.
--Positiontheenginetogetherwiththefrontaxle andsecureittotheclutchboxtighteningthe screwstotheprescribedtorque.
--Positiontheoilfilter,completewithsupport,and secureittotheengine.
--Connectthepipesforthe:hydraulicpumpinlet, centralauxiliarycontrolvalvesconnectionand hydraulicpumpconnection.
--Positionthepropellershaft,securethecentral support,slidethetwofrontandrearsleevesand securethemwiththecirclips.
--Positionthepropellershaftguardandsecureit.
--Positionthepipedrawingoilfromthe transmissionandsecureit.
--Connectthereartransmissionlubricationline.
--ConnectthePTOcontrolline.
--Connectthefour--wheeldriveengagement controlline.
--Connecttherearauxiliarycontrolvalve connectionline.
--Connectthecentralauxiliarycontrolvalve connectionline.
--Connectthepipesconnectingthepowershuttle controlvalvetothecooler.
--Positionandsecuretherightandleftsupportsof thecab.
--Connectthecentralauxiliarycontrolvalve connectionlinetotherearauxiliarycontrol valves.
--Connectthecentralauxiliarycontrolvalvereturn linetothereartransmission.
--Positionandsecuretheballastsupport.
--Positionandsecuretheballast.
--Carryoutoperation 9015010 --Cabwith platformunit(performinstallationonly).
--Screwtheplugintothereartransmissionbox andfillwithoil(seesect.00,page6for prescribedproductandquantity).
10 SECTION10--ENGINE--CHAPTER1 84419887A --06--2011
ATTENTION
Handleallpartswithcare.Donotputyourhandsor fingersbetweenparts.Weartheprescribedsafety clothing,includinggoggles,glovesandsafety footwear.
Proceedasfollows.
1.Blockthefrontaxlewithwoodenchocks(1).Do thisonbothsides.
2.Raisetherearofthetractor,positionafixed standunderthereartransmissionbox,unscrew therelevantfixingscrewsanddetachtheleftrear wheel(1).
3.Unscrewtheplug(1)anddrainoffthefuelfrom themaintank.
Considerthatthetotalcapacityis90litres.
SECTION10--ENGINE--CHAPTER1 11 84419887A --06--2011 Op.1021640 FUELTANKRemoval--Installation
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4.Unscrewtherelevantretainingboltsandremove theleftsteps(1).
5.Unscrewthetwofueltankfixingclamps(3).
6.Unscrewthescrewsfixingthebottomguard(2) anddetachit.
7.Unscrewtheclamps(1and3)anddetachthe fuelreturnandinletlines.
8.Disconnecttheelectricalconnection(2)ofthe fuelgauge.
9.Unscrewthetwobrackets(1and2)fixingthefuel returnandinletpipes,finallyremovethefuel tank.
10.Torefitthefueltank,proceedasfollows.
ATTENTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.
--Positionandsecurethetankfuelreturnandfuel inletlines.
--Securethetankfuelreturnandfuelinletlines usingtheappropriatebrackets.
--Connecttheelectricalconnectionofthefuel gauge.
--Positionthefueltankandsecureitwiththe clamps
--Positionandsecurethebottomguardofthefuel tank.
--Positionandsecuretheleftsteps.
--Positionandsecuretheleftrearwheel.
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Removal--Installation ATTENTION
Handleallpartswithcare.Donotputyourhandsor fingersbetweenparts.Weartheprescribedsafety clothing,includinggoggles,glovesandsafety footwear.
Proceedasfollows.
1.Carryoutoperation 9010022 --Bonnet(perform removalonly).
2.Carryoutoperation 5020072 --Air--conditioning systemcondenser(performremovalonly).
3.Carryoutoperation 2110940 --Transmissionoil cooler(performremovalonly).
4.Loosentheclamp,detachthesleeve(1)fromthe radiatoranddrainoffthecoolant 29
5.Disconnecttheairintakesleeve(1). 30
6.Disconnectthesleeve(1)fromtheairfilterand fromtheturbocharger.
7.Disconnectthesleeve(2)fromtheradiator. 31
SECTION10--ENGINE--CHAPTER1 13 84419887A --06--2011 Op.1021610 ENGINECOOLANTRADIATOR
8.Disconnect:thepipes(1)andtheelectrical connection(2)fromthefilter/dryer.
9.Detachtheenginecoolantexpansiontank(1).
10.Unscrewthetopandbottomscrewsfixingthe bracket(1)supportingtheairfilterandrecover theunittogetherwiththefilter/dryer.
11.Disconnectthebracket(1)anddisconnectthe pipe(2)fromthecabairconditioningsystem compressor.
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12.Unscrewtherelatedboltsandremovethe bracket(1)fixingtheradiatortotheengine.
13.Ontherightside,detachthebracketsfixingthe pipesoftheair--conditioningsystemtothe engine.
14.Detachthemaxi--fusesupportbracket(2)and unscrewtherelevantscrewstofreetheshroud (1)fromtheenginecoolantradiator.
15.Unscrewthetwobolts(1)andremovetheengine coolantradiator.
16.Installtheenginecoolantradiatorconsidering thefollowingwarnings.
ATTENTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.
--Positionandsecuretheradiatoronthefrontaxle support.
--Secure:theshroud,maxi--fusesupportbracket andthebracketsfixingtheair--conditioning pipes.
--Positionandsecuretheradiatorretaining brackettotheengine.
--Connectandsecurethepipingtothe compressor.
--Positionandsecuretheairfilterunitand filter/dryer.
--Positiontheexpansiontank.
--Connect:thepipesandtheelectricalconnection tothefilter/dryer.
--Connecttheairfiltersleeves.
--Connectthesleevestotheradiator.
--Connecttheairintakesleeve.
--Carryoutoperation 2110940 Transmissionoil cooler(performinstallationonly).
--Carryoutoperation 5020072 Air--conditioning systemcondenser(performinstallationonly).
--Carryoutoperation 9010022 --Bonnet(perform installationonly).
--Filluptheenginecoolingsystem(seepage6, sect.0forprescribedproductandquantity).
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