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SERVICE MANUAL

SERVICE MANUAL 7630 / 8030 TIER 3 Tractor

7630 8030 Tractor

1/1 Part number 47793462

Part number 47793462 English April 2017

© 2017 CNH Industrial Latin America LTDA. All Rights Reserved.

SERVICE MANUAL 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

47793462 14/03/2017 EN

Link Product / Engine 7630 7630 7630 7630 8030 8030 8030 8030

Product 8x2, Tier 3 16x4, Tier 3 12x3, Tier 3 24x6, Tier 3 8x2, Tier 3 16x4, Tier 3 12x3, Tier 3 24x6, Tier 3

Market Product Latin America Latin America Latin America Latin America Latin America Latin America Latin America Latin America

47793462 14/03/2017

Engine F4CE9484D*J601 F4CE9484D*J601 F4CE9484D*J601 F4CE9484D*J601 F4CE9484E*J601 F4CE9484E*J601 F4CE9484E*J601 F4CE9484E*J601

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

Clutch ....................................................................................... 18 [18.104] Clutch hydraulic release control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 [18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2

Transmission.............................................................................. 21 [21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.130] Mechanical transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 [21.168] Hi-Lo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

Four-Wheel Drive (4WD) system .................................................. 23 [23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 47793462 14/03/2017

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Power Take-Off (PTO) ................................................................. 31 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2

Brakes and controls .................................................................... 33 [33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.116] Three-point hitch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

Hitches, drawbars, and implement couplings.................................. 37 [37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

Frames and ballasting ................................................................. 39 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Electrical systems ....................................................................... 55 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 47793462 14/03/2017

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

Platform, cab, bodywork, and decals ............................................. 90 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

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INTRODUCTION

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Contents INTRODUCTION International symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Foreword - How to use and navigate through this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine cooling system - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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International symbols As a guide to the operation of the machine, various universal symbols have been utilized on the instruments, controls, switches, and fuse box. The symbols are shown below with an indication of their meaning. Heater plug for cold start

Turning signal

Power Take-Off (PTO)

Reaction control

Alternator charging

Activated memory

Transmission in neutral

Accessories socket

Fuel Level

Turn signals

Creeper selection

Implement socket

Automatic fuel shut-off

Turn signals - one trailer

Low speed selection

Percentage slip

Engine speed (rpm x 100)

Turn signals - two trailers

High speed selection

Raising of the hydraulic lift

Hour meter

Wind shield washer

Road speed

Rear hitch lower

Engine Oil Pressure

Windscreen wash wipe

Differential Lock

Hydraulic lift height threshold

Engine Coolant Temperature

Heating temperature control

Rear axle oil temperature

Hydraulic lift disabled

Coolant Level

Cab recirculation fan

Trans Oil Pressure

Transmission filters and hydraulic filters

Machine lights

Air conditioner

Auxiliary Front Wheel Drive (AFWD) operated

Remote control valve extension

Main beam head

Air Filter Restriction

Warning!

Remote control valve command retraction

Dip Beam

Parking brake

Danger warning lights

Remote control valve flotation

Work lamps

Brake fluid level

Variable control

Malfunction! See Operator’s

Stop Lamp

Trailer brake

Pressurized! Open carefully

Malfunction! (alternative symbol)

Horn

Warning! Corrosive substance

Position control

Brake fluid level

Trans Oil Pressure

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Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice. In case of questions, refer to your NEW HOLLAND Sales and Service Networks.

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Foreword - How to use and navigate through this manual This manual has been produced by a new technical information system. This new system is designed to deliver technical information electronically through web delivery (eTIM), DVD, and paper manuals. A coding system called SAP has been developed to link the technical information to other Product Support functions, e.g., Warranty. Technical information is written to support the maintenance and service of the functions or systems on a customer's machine. When a customer has a concern on their machine it is usually because a function or system on their machine is not working at all, is not working efficiently, or is not responding correctly to their commands. When you refer to the technical information in this manual to resolve that customer's concern, you will find all the information classified using the SAP coding, according to the functions or systems on that machine. Once you have located the technical information for that function or system, you will then find all the mechanical, electrical or hydraulic devices, components, assemblies, and sub assemblies for that function or system. You will also find all the types of information that have been written for that function or system: the technical data (specifications), the functional data (how it works), the diagnostic data (fault codes and troubleshooting), and the service data (remove, install adjust, etc.). By integrating SAP coding into technical information, you will be able to search and retrieve just the right piece of technical information you need to resolve that customer's concern on his machine. This is made possible by attaching 3 categories to each piece of technical information during the authoring process. The first category is the Location, the second category is the Information Type and the third category is the Product: • LOCATION - the component or function on the machine, that the piece of technical information is going to describe (e.g., Fuel tank). • INFORMATION TYPE - the piece of technical information that has been written for a particular component or function on the machine (e.g., Capacity would be a type of Technical Data describing the amount of fuel held by the fuel tank). • PRODUCT - the model for which the piece of technical information is written. Every piece of technical information will have those three categories attached to it. You will be able to use any combination of those categories to find the right piece of technical information you need to resolve that customer's concern on their machine. That information could be: • the procedure for how to remove the cylinder head • a table of specifications for a hydraulic pump • a fault code • a troubleshooting table • a special tool

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Manual content This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the end of each Chapter. Page number references are included for every piece of technical information listed in the Chapter Contents or Chapter Index. Each Chapter is divided into four Information types: • Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies. • Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies. • Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies. • Service Data (remove disassemble, assemble, install) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies.

Sections Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a number (00, 35, 55, etc.). The Sections included in the manual will depend on the type and function of the machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This table illustrates which Sections could be included in a manual for a particular product. PRODUCT Tractors Vehicles with working arms: backhoes, excavators, skid steers, …. Combines, forage harvesters, balers, …. Seeding, planting, floating, spraying equipment, …. Mounted equipment and tools, …. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

SECTION 00 - Maintenance 05 - Machine completion and equipment 10 - Engine 14 - Main gearbox and drive 18 - Clutch 21 - Transmission 23 - Four wheel drive (4WD) system 25 - Front axle system 27 - Rear axle system 29 - Hydrostatic drive 31 - Power Take-Off (PTO) 33 - Brakes and controls 35 - Hydraulic systems 36 - Pneumatic system 37 - Hitches, drawbars and implement couplings 39 - Frames and ballasting 41 - Steering 44 - Wheels 46 - Steering clutches 48 - Tracks and track suspension 50 - Cab climate control 55 - Electrical systems 56 - Grape harvester shaking 58 - Attachments/headers 60 - Product feeding

X X X X X X X X X X X X X X

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61 - Metering system 62 - Pressing - Bale formation 63 - Chemical applicators 64 - Chopping 66 - Threshing 68 - Tying/Wrapping/Twisting 69 - Bale wagons 70 - Ejection 71 - Lubrication system 72 - Separation 73 - Residue handling 74 - Cleaning 75 - Soil preparation/Finishing 76 - Secondary cleaning / Destemmer 77 - Seeding 78 - Spraying 79 - Planting 80 - Crop storage / Unloading 82 - Front loader and bucket 83 - Telescopic single arm 84 - Booms, dippers and buckets 86 - Dozer blade and arm 88 - Accessories 89 - Tools 90 - Platform, cab, bodywork and decals

X X X X X X X X X X X X X X X

X X X X X X X X X X

X X X X X X X X X X X X X X X X

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Chapters Each Chapter is identified by a number e.g. Engine - Engine and crankcase - 10.001. The first number is identical to the Section number i.e. Chapter 10.001 is inside Section 10, Engine. The second number is representative of the Chapter contained within the Section. CONTENTS The Chapter Contents lists all the technical data (specifications), functional data (how it works), diagnostic data (fault codes and troubleshooting), and service data (remove, install, adjust, etc.), that have been written in that Chapter for that function or system on the machine. Contents ENGINE ENGINE - Engine and crankcase – 10.001 TECHNICAL DATA ENGINE - Engine and crankcase - General specification (10.001 - D.40.A.10)

4

FUNCTIONAL DATA ENGINE - Engine and crankcase - Dynamic description (10.001 - C.30.A.10)

6

SERVICE ENGINE - Engine and crankcase - Remove (10.001 -F.10.A.10)

8

DIAGNOSTIC ENGINE - Engine and crankcase - Troubleshooting (10.001 - G.40.A.10)

10

INDEX The Chapter Index lists in alphabetical order all the types of information (called information units) that have been written in that Chapter for that function or system on the machine. Index ENGINE - 10 ENGINE ENGINE - Engine and crankcase - Dynamic description (10.001 - C.30.A.10)

6

ENGINE - Engine and crankcase - General specification (10.001 - D.40.A.10)

4

ENGINE - Engine and crankcase - Remove (10.001 -F.10.A.10)

8

ENGINE - Engine and crankcase - Troubleshooting (10.001 - G.40.A.10)

10

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Information units and information search Each chapter is composed of information units. Each information unit has the SAP code shown in parentheses. This indicates the function and type of information in that information unit. Each information unit has a page reference within that Chapter. The information units provide a quick and easy way to find just the right piece of technical information you are looking for. Example information Engine block cover - Front – Remove (10.102.AP.01 - F.10.A.10) unit 10 102 AK 01 F 10.A.10 Information Unit SAP code Pan and covers Engine block Front SAP code classification Engine Service data Remove cover

NHIL12GEN0070A

1

Navigate to the correct information unit you are searching for by identifying the function and information type from the SAP code. • (1) Location and (2) Information type. • (A) corresponds to the sections of the service manual. (B) corresponds to the chapters of the service manual. After (B) there may be some additional information. In this case it shows “.01”, which represents the “Front” block cover. These options may be front/rear, left/right, hydraulic/ mechanical etc. (C) corresponds to the type of information listed in the chapter contents: Technical Data, Functional Data, Diagnostic, or Service. (A) and (B) are also shown in the page numbering on the page footer. THE REST OF THE CODING IS NOT LISTED IN ALPHANUMERIC ORDER IN THIS MANUAL. • You will find a table of contents at the beginning and end of each section and chapter. You will find an alphabetical index at the end of each chapter. • By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly find the information you are looking for.

Page header and footer The page header will contain the following references: • Section and Chapter description The page footer will contain the following references: • Publication number for that Manual. • Version reference for that publication. • Publication date • Section, chapter, and page reference e.g. 10.102 / 9

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Safety rules Standard safety precautions Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for consultation. • Keep working areas as clean as possible. • Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain adequate sanitary equipment. • Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked on a regular basis and personnel must be trained on proper interventions and priorities. • Keep all emergency exits free of obstructions and clearly marked. • Smoking in working areas subject to fire danger must be strictly prohibited.

Prevention of injury • Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to engines and equipment in motion. • Wear safety gloves and goggles when performing the following operations: • Topping off or changing lubrication oils. • Using compressed air or liquids at a pressure greater than 2 bar (29 psi). • Wear a safety helmet when working close to hanging loads or equipment working at head level. • Always wear safety shoes and fitting clothes. • Use protection cream for hands. • Change wet clothes as soon as possible. • In the presence of voltages exceeding 48 – 60 V, verify the efficiency of the ground and mass electrical connections. Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with electricity. • Do not smoke or start an open flame close to batteries and any fuel material. • Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers. • Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may occur. • If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes.

During maintenance • Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F). • Never add coolant to an overheated engine and use only appropriate liquids. • Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be aware of all the risks involved with such an operation. • Always use adequate and safe containers for engine fluids and used oil. • Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents. • Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated. Wear a safety mask if necessary. • Do not leave soiled rags that may contain any flammable substances close to the engine. • Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air in case of engine runaway. • Never disconnect the batteries while the engine is running. • Disconnect the batteries prior to performing any work on the equipment. 47793462 14/03/2017

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• Disconnect the batteries to place a load on them with a load tester. • After any work is performed, verify that the battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. • Before disconnecting any pipelines (pneumatic, hydraulic, fuel pipes, etc.), verify that all pressure has been released. Take all necessary precautions bleeding and draining residual pressure. Always wear the proper safety equipment. • Do not alter the lengths of any wires. • Do not connect any electronic service tool to the engine electrical equipment unless specifically approved by NEW HOLLAND. • Do not modify the fuel system or hydraulic system unless approved by NEW HOLLAND. Any unauthorized modification will compromise warranty assistance and may affect engine operation and life span. For engine equipped with an electronic control unit • Do not weld on any part of the equipment without removing the control unit. • Remove the in case of work requiring heating over 80 °C (176 °F). • Do not paint the components and the electronic connections. • Do not alter any data filed in the electronic control unit driving the engine. Any manipulation or alteration of electronic components will void engine warranty assistance and may affect the correct working order and life span of the engine.

Respect of the Environment • Respect of the environment should be of primary importance. Take all necessary precautions to ensure personnel's safety and health. • Inform the personnel of the laws regarding the dispensing of used engine fluids. • Handle batteries with care, storing them in a well ventilated environment and within anti-acid container.

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Safety rules General safety regulations General Aspects • Strictly follow repair and maintenance procedures. • Do not wear rings, wrist watches, jewelry, accessories, unbuttoned items of clothing, unsecured clothing like ties, torn clothing, scarves, or open jackets or shirts with open zippers that could get caught in moving parts. Use approved safety clothing, such as anti-slip footwear, sleeves, protective goggles, helmets, etc. • Wear safety goggles with side shields when cleaning parts using compressed air. • Worn or damaged cables and chains are not reliable. Do not use these elements in lifting or towing operations. • Use regulation safety equipment, such as approved eye protection, helmets, clothes, sleeves, and special footwear whenever you are welding. All individuals near the welding process must use regulation eye protection. Never look at the welding arc without using suitable eye protection. • Never perform any repairs on the machine if there is someone in the operator seat, except when the person is a qualified operator who is helping with the service to be performed. • Never operate the machine or use accessories from a place other than the operator seat or next to the machine when operating the fender switches. • Never perform any operations on the machine with the engine running, except when specifically instructed to do so. Shut down the engine and release all the pressure from the hydraulic circuits before removing covers, cases, valves, etc. • You must conduct all repair and maintenance operations with the utmost care and attention. • Disconnect the batteries and put warning labels on all of the controls to warn that the machine is being repaired. Lock the machine and all the equipment that you remove. • Never check or fill the fuel tank or batteries or use starting fluid when you are smoking or near a naked flame, because these fluids are flammable. • The fuel filling gun must remain in contact with the filler neck. Maintain the contact until the fuel stops flowing into the tank in order to avoid sparks caused by static electricity build-up. • To transport a faulty machine, use a trailer or a low loader platform trolley, if available. • To load and unload the machine from the mode of transportation, choose a flat area that offers firm support for the wheels of the truck or trailer. Securely fasten the machine to the platform of the trailer or truck, in accordance with the transporter’s requirements. • Always use hoist mechanisms with an appropriate capacity for lifting or moving heavy components. • Chains must always be securely fastened. The fastening device must have sufficient capacity to support the intended load. It is prohibited for bystanders to be near the fastening position. • The work area must always be clean and dry. Clean it immediately if any water or oil is spilled. • Never use gasoline, diesel, or other flammable liquids for cleaning. Use only non-toxic solvents. • Do not allow cloths soaked with oil or grease to accumulate because they can cause a fire risk. Always keep these cloths in a metal container.

Starting • Never start the engine in enclosed spaces that are not equipped with a suitable exhaust system or gas-extraction system. • Never bring your head, body, arms, legs, feet, hands, or fingers close to fans or rotating belts.

Engine • Always loosen the radiator cap slowly before removing it, in order to dissipate the system pressure. You must top up the coolant with the engine stopped. • Do not fill up the fuel tank when the engine is running. • Never adjust the fuel injection pump when the machine is in motion. 47793462 14/03/2017

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• Never lubricate the machine when the engine is running.

Electrical systems • If it is necessary to use auxiliary batteries, you must connect the cables on both sides as follows: (+) to (+) and (-) to (-). Avoid causing the terminals to short circuit. The gas that the batteries release is highly flammable. During charging, leave the battery compartment open to improve ventilation. Avoid sparks and naked flames near the battery. Do not smoke. • Do not charge the batteries in enclosed spaces. • Always disconnect the batteries before carrying out any type of servicing on the electrical system.

Hydraulic system • A little fluid coming out of a small bore could be almost invisible, but strong enough to penetrate the skin. For this reason, never use your hands to check for leaks. Instead, use a piece of cardboard or wood. If any fluid penetrates your skin, seek medical assistance immediately. Failure to seek immediate medical assistance could result in serious infections or dermatitis. • Always read the system pressure using suitable gauges.

Wheels and tires • Make sure that the tires are correctly inflated at the pressure specified by the manufacturer. Inspect the rims and tires regularly for any damage. • Remain next to the tire when filling it with air. • Only check the pressure when the platform is unloaded and the tires are cold, in order to prevent inaccurate readings caused by overpressure. • Never cut or weld a rim with a full tire fitted. • To remove the wheels, lock both the front and rear wheels of the machine. Lift the machine. Install stable and secure supports under the machine, as per the legislation in force. • Deflate the tire before removing any objects that may be caught in the tire tread. • Never inflate tires using flammable gases, as they could cause explosions and injure bystanders.

Remove and install • Lift and handle all heavy components using hoist devices of appropriate capacity. You must suspend the parts using suitable hooks and slings. Use the hoist eyes provided for this purpose. Be careful if there are any bystanders near the hoisted load.

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Safety rules Health and safety precautions Many of the procedures involved in machine maintenance and repair services involve physical hazards and other health risks. This section lists some of these hazardous procedures and the materials and equipment associated with them.

Acids and alkalis Avoid splashing into your eyes and nose, or onto your skin and clothing. Wear suitable sleeves and protective goggles. Irritate and corrode the skin, eyes, nose, and throat. Causes burns. Do not inhale the fumes.

Adhesives and sealants These are highly flammable. You must store them in no smoking areas. Use applicators when possible or secondary containers. The containers must be labeled.

Resin-based adhesives/sealants Skin contact could result in irritation, dermatitis, and the absorption of toxic or harmful chemicals through the skin. Splashes could cause eye injuries. Ensure that there is adequate ventilation and avoid contact with the skin and the eyes. Follow the manufacturer’s instructions. Ensure that there is adequate ventilation as volatile harmful or toxic chemicals may be released.

Anti-freeze These are highly flammable. You must store them in no smoking areas. Anti-freeze can be absorbed through the skin in toxic or harmful quantities. Ingesting anti-freeze can cause death and you must seek medical assistance immediately.

Chemicals – General You must always take care when using and handling chemicals such as solvents, sealants, adhesives, paints, foam resins, battery acids, anti-freeze, brake fluid, oils and greases. They may be harmful, toxic, corrosive, irritant, or highly flammable. They may also emit hazardous fumes or dust.

Do Remove chemicals from skin and clothing as soon as possible after contact. Change very dirty clothes and make provision for cleaning them. Read and strictly adhere to the safety recommendations on the chemical containers. When working with chemicals, wash before breaks, and before eating, smoking, drinking, or using the bathroom. Keep work areas clean, organized, and free of spillages. Store according to local and national legislation. Keep chemicals out of the reach of children.

Do not Do not mix chemicals, except in accordance with the manufacturer's instructions. Some substances could form other chemical substances that are toxic or harmful, emit toxic or harmful fumes, or become explosive after mixing. Do not spray chemicals, especially solvent-based chemicals, in enclosed spaces. Do not apply heat or flames to chemicals, except in accordance with the manufacturer's instructions. Some are highly flammable or could release toxic or harmful fumes. Do not leave containers open. The fumes emitted could accumulate in toxic, harmful, or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, trenches, etc. Do not put chemicals in unmarked containers. 47793462 14/03/2017

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Do not clean your hands or clothes with chemicals. Chemicals, particularly solvents and fuels, dry out the skin and can cause irritation and dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Do not use empty containers to store other chemicals, except when they have been cleaned under supervision. Do not attempt to sniff or inhale chemicals. Rapid exposure to high concentrations of fumes can be toxic or harmful.

Anti-corrosive protective material These materials are varied and you must follow the manufacturers' instructions. They may contain solvents, resins, petroleum derivatives, etc. You must avoid contact with the skin and the eyes. You must carry out spraying with adequate ventilation and never in enclosed spaces.

Post Dust, powders, or clouds may be irritant, harmful, or toxic. Avoid inhaling the chemical powders or dusts that result from dry abrasion services. Use respiratory protection if ventilation is not adequate.

Electric shock Electric shocks result from the use of faulty electrical equipment or from incorrect use. You must keep electrical equipment in good condition and test it frequently. Electrical equipment must be protected by a fuse with an appropriate nominal capacity. Use low-voltage equipment ( 110 volt) for work lights and inspection lights, wherever possible. Use pneumatic equipment instead of electrical equipment wherever possible. In the event of electrocution: • Turn off the electricity before approaching the victim. • If that is not possible, push or pull the victim away from the source of the electricity using a dry, non-conductive material. • If you have been trained, start giving first aid. • Seek medical assistance.

Exhaust fumes These fumes contain asphyxiating, toxic or harmful chemical substances. You must only run engines in adequate extraction or general ventilation conditions, and never in enclosed spaces.

Fiber insulation The fibrous nature of cut surfaces and edges can cause skin irritation. In general, the effect is physical and not chemical. You must take precautions to avoid excessive skin contact. Take care when organizing your work methods. Wear sleeves.

Fire Many materials relating to vehicle repair are highly flammable. Some release toxic or harmful fumes when burned. Scrupulously observe the fire prevention safety recommendations when storing and handling flammable materials or solvents, particularly in the vicinity of electrical equipment or welding processes. Before using any electrical or welding equipment, ensure that there is no risk of fire. Always have an appropriate fire extinguisher nearby when using welding or heating equipment.

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Foams – Polyurethane See fire. Used for soundproofing. Cured foams used in seat cushions and finishes. Follow the manufacturer’s instructions. Components that have not reacted are irritants and could be harmful to the eyes and the skin. Wear sleeves and protective goggles. Individuals with chronic respiratory illnesses, asthma, bronchial problems, or a history of allergic illnesses must not work with or be in proximity to uncured materials. Components, fumes, and aerosol clouds can cause irritation and sensitization reactions, and may be toxic or harmful. You must apply these materials with adequate respiratory protection and adequate ventilation. Do not remove the respirator when you have finished spraying. Keep the respirator on until the fumes and clouds disperse. Burning uncured components and cured foams can generate toxic and harmful fumes. Do not permit smoking, the presence of naked flames, or the use of electrical equipment during the application of foam, and until the fumes/ clouds have dispersed. The hot cutting of cured or partially cured foam must be performed in an environment with a ventilation system with extraction.

Kerosene (Paraffin) Ingesting kerosene can cause irritation to the mouth and throat. The greatest danger from ingesting kerosene is the possibility of breathing it into the lungs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes on the skin and in the eyes cause mild irritation. Avoid contact with the eyes and the skin as far as possible and ensure that there is adequate ventilation.

Fuel oil (diesel fuel) When the quantities are large or the exposure period is long, skin contact with fuel oils with a high boiling point can cause serious skin diseases, including skin cancer.

Gas cylinders See fire. In general, gases, such as oxygen, carbon dioxide, argon, and propane, are stored in cylinders with pressures of up to 140 bar ( 2000 lb/in2). You need to take sufficient care when handling them to prevent physical damage to the cylinders and the valve accessories. The content of each cylinder must be clearly identified with suitable labels. You must store the cylinders in a well-ventilated room, protected from ice, rain, and direct sunlight. You must not store combustible gases near to oxygen cylinders. Be careful to prevent leaks from the cylinders and the gas lines, and to avoid ignition sources. Only qualified personnel may perform services using the cylinders.

General workshop equipment and tools You must keep all equipment and tools in good condition and you must use the correct safety equipment whenever necessary. Never use tools or equipment for any purpose other than that for which they are intended. Never overload equipment such as hoists, jacks, chassis bases and axles, or hoisting slings. The damage caused by overloading does not always appear immediately and could cause a fatal accident the next time that the equipment is used. Do not use faulty or damaged equipment or tools, particularly high-speed equipment, such as emery wheels. A damaged emery wheel can disintegrate suddenly and cause serious injury. Use protective goggles whenever you use equipment for grinding, cutting, polishing, or sandblasting.

Oil test equipment, lubrication test equipment, and high-pressure air test equipment, in accordance with local legislation Always keep high-pressure equipment in good condition and carry out regular maintenance, particularly on connections and fittings. Never point a high-pressure nozzle at the skin as the fluid can cause serious injuries.

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Legal aspects Various laws and regulations lay down the health and safety requirements for working with materials and equipment in workshops. Always observe the regulations and laws in force in the country in which you are working. Workshops must comply with the relevant regulations and laws. Consult the local supervisory authorities or related government bodies if you are in any doubt.

Lubricants and greases Avoid prolonged or recurrent contact with mineral oils, particularly used oils. Thoroughly wash the skin after tasks using oil. Do not use gasoline, paraffin, or other solvents to remove oil from the skin. Lubricants and greases can cause mild eye irritation. You must avoid repeated or prolonged skin contact by wearing protective clothing where necessary. Do not allow your work clothes to become contaminated with oil. Wash or dry clean work clothes regularly. Discard oil-soaked shoes. Do not use used engine oil as a lubricant or for applications where it might come into contact with the skin.

Paints You should preferably perform spraying in a ventilated cab with an exhaust system to remove the fumes and spray from the breathing area. Individuals working in cabs must use respiratory protection. Personnel carrying out smallscale repair work must use respirators with an air supply.

Solvents Contact dries out the skin, and prolonged or recurrent contact can cause irritation and dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Splashes into the eyes can cause serious irritation and even lead to blindness. Wear protective sleeves, protective goggles and protective clothing. Ensure that there is good ventilation during use, avoid inhaling smoke, fumes, and spray clouds, and keep containers securely closed. Do not use in enclosed spaces. Do not apply heat or flame, except in accordance with specific and detailed instructions from the manufacturer.

Arc welding This process emits a high level of ultraviolet radiation that can burn the eyes and skin of the welder and of other people nearby. Gas-protected welding processes are particularly dangerous in this respect. Personal protection is mandatory. Barriers to protect other people are also necessary. You also need to use suitable eye and skin protection because of metal splashes. The heat of arc welding will produce gases and fumes from the metals that are being melted, and from the coatings applied to or contamination on the worked surfaces. These gases and fumes may be toxic and you must avoid inhaling them. You may need to use ventilation with extraction to remove smoke from the work area, particularly in cases where there is not enough general ventilation or in places where a considerable amount of welding is expected to take place. In extreme cases, where adequate ventilation cannot be guaranteed, you may need to use respirators with an air supply.

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Safety rules - Ecology and the environment Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources. • Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly. • The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-conditioning specialist or use a special extractor to recharge the system properly. • Repair any leaks or defects in the engine cooling system or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. NEW HOLLAND strongly recommends that you return all used batteries to a NEW HOLLAND dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil. Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage. Points of sale are obliged to: • Accept the return of your used batteries • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling

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Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine safety signs, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine damage or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine damage or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE

M4 M5 M6 M8

CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr

CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr

2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 lb in)

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft)

2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft)

52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft)

4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 lb ft)

LOCKNUT CL.8 W/CL8.8 BOLT

2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft)

LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft)

NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet.

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METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr

UNPLATED M4 M5 M6 M8

2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in)

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft)

3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft)

4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft)

Metric Hex head and carriage bolts, classes 5.6 and up

1

1. Manufacturer's Identification 2. Property Class

Metric Hex nuts and locknuts, classes 05 and up

20083681

2

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LOCKNUT CL.10 W/CL10.9 BOLT

2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in)

PLATED W/ZnCr

IDENTIFICATION

20083680

LOCKNUT CL.8 W/CL8.8 BOLT

37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft)

226 N·m (167 lb ft) 440 N·m (325 lb ft)

INTRODUCTION

1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60° apart indicate Class 10 properties, and marks 120° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD

12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft)

12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in)

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft)

NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet.

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INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE PLATED UNPLATED PLATED UNPLATED W/ZnCr or PLATED W/ZnCr or PLATED GOLD SILVER GOLD SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

LOCKNUT GrG W/ Gr8 BOLT

LOCKNUT GrF W/ Gr5 BOLT

12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft)

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

IDENTIFICATION Inch Bolts and free-spinning nuts

20083682

3

Grade Marking Examples 1 2 3

Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks

SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120° Apart 6 Grade 8 Nut - Marks 60° Apart

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INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

4

Grade Identification Grade Grade A Grade B Grade C

Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches

Flats Marking Method (2) No Mark Letter B Letter C

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Clock Marking Method (3) No Marks Three Marks Six Marks

INTRODUCTION

Basic instructions - Shop and assembly Shimming For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value shown on each shim.

Rotating shaft seals For correct rotating shaft seal installation, proceed as follows: 1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes. 2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged. 3. Position the sealing lip facing the fluid. NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will move the fluid towards the inner side of the seal. 4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip and the dust lip on double lip seals with grease. 5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a hammer or mallet. 6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that the seal makes contact with the thrust element, if required. 7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.

O-ring seals Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and twisting, which would jeopardize sealing efficiency.

Sealing compounds Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing compound, prepare the surfaces as directed by the product container.

Spare parts Only use CNH Original Parts or NEW HOLLAND Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or NEW HOLLAND Original Parts can offer this guarantee. When ordering spare parts, always provide the following information: • Machine model (commercial name) and Product Identification Number (PIN) • Part number of the ordered part, which can be found in the parts catalog

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INTRODUCTION

Protecting the electronic and/or electrical systems during charging and welding To avoid damage to the electronic and/or electrical systems, always observe the following practices: 1. Never make or break any of the charging circuit connections when the engine is running, including the battery connections. 2. Never short any of the charging components to ground. 3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine attachment. • Position the welder ground clamp as close to the welding area as possible. • If you weld in close proximity to a computer module, then you should remove the module from the machine. • Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you weld. 4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery charger. NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery. The electronic monitoring system and charging system will be damaged if this is not done. 5. Remove the battery ground cable. Reconnect the cable when you complete welding.

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply could result in death or serious injury. W0111A

Special tools The special tools that NEW HOLLAND suggests and illustrate in this manual have been specifically researched and designed for use with NEW HOLLAND machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting operation. By using these tools, repair personnel will benefit from: • Operating in optimal technical conditions • Obtaining the best results • Saving time and effort • Working in safe conditions

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INTRODUCTION

Torque - Standard torque data for hydraulics Installation of adjustable fittings in straight thread O-ring bosses 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove (4). 2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss (5). NOTE: Do not over tighten and distort the metal backup washer.

23085659

1

3. Position the fitting by turning out (counterclockwise) up to a maximum of one turn. Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss (6).

Standard torque data for hydraulic tubes and fittings Tube nuts for 37° flared fittings

Size

Tubing OD

Thread size

Torque

O-ring boss plugs adjustable fitting locknuts, swivel JIC37° seats Torque

4 5 6 8 10 12 14 16 20 24 32

6.4 mm (1/4 in) 7.9 mm (5/16 in) 9.5 mm (3/8 in) 12.7 mm (1/2 in) 15.9 mm (5/8 in) 19.1 mm (3/4 in) 22.2 mm (7/8 in) 25.4 mm (1 in) 31.8 mm (1-1/4 in) 38.1 mm (1-1/2 in) 50.8 mm (2 in)

7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1-1/16-12 1-3/16-12 1-5/16-12 1-5/8-12 1-7/8-12 2-1/2-12

12 – 16 N·m (9 – 12 lb ft) 16 – 20 N·m (12 – 15 lb ft) 29 – 33 N·m (21 – 24 lb ft) 47 – 54 N·m (35 – 40 lb ft) 72 – 79 N·m (53 – 58 lb ft) 104 – 111 N·m (77 – 82 lb ft) 122 – 136 N·m (90 – 100 lb ft) 149 – 163 N·m (110 – 120 lb ft) 190 – 204 N·m (140 – 150 lb ft) 217 – 237 N·m (160 – 175 lb ft) 305 – 325 N·m (225 – 240 lb ft)

8 – 14 N·m (6 – 10 lb ft) 14 – 20 N·m (10 – 15 lb ft) 20 – 27 N·m (15 – 20 lb ft) 34 – 41 N·m (25 – 30 lb ft) 47 – 54 N·m (35 – 40 lb ft) 81 – 95 N·m (60 – 70 lb ft) 95 – 109 N·m (70 – 80 lb ft) 108 – 122 N·m (80 – 90 lb ft) 129 – 158 N·m (95 – 115 lb ft) 163 – 190 N·m (120 – 140 lb ft) 339 – 407 N·m (250 – 300 lb ft)

These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm (0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually. Before installing and torquing 37° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite cleaner and apply hydraulic sealant LOCTITE® 569™ to the 37° flare and the threads. Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

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INTRODUCTION

Pipe thread fitting torque Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant LOCTITE® 567™ PST PIPE SEALANT for all fittings including stainless steel or LOCTITE® 565™ PST for most metal fittings. For high filtration/zero contamination systems use LOCTITE® 545™.

Torque (maximum) 13 N·m (10 lb ft) 16 N·m (12 lb ft) 22 N·m (16 lb ft) 41 N·m (30 lb ft) 54 N·m (40 lb ft)

Thread size 1/8-27 1/4-18 3/8-18 1/2-14 3/4-14

Installation of ORFS (O-Ring Flat Seal fittings) When installing ORFS fittings thoroughly clean both flat surfaces of the fittings (1) and lubricate the O-ring (2) with light oil. Make sure both surfaces are aligned properly. Torque the fitting to specified torque listed throughout the repair manual. NOTICE: If the fitting surfaces are not properly cleaned, the O-ring will not seal properly. If the fitting surfaces are not properly aligned, the fittings may be damaged and will not seal properly. NOTICE: Always use genuine factory replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils. The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.

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50011183

2

INTRODUCTION

Engine cooling system - Basic instructions Definitions Conventional coolant: A coolant that relies on inorganic inhibitors such as silicates, nitrites, and phosphates for corrosion and cavitation protection. Organic Acid Technology (OAT) coolant: A coolant that relies on inhibitors such as organic acid salts for corrosion and cavitation protection.

47757330

1

The decal shown is located near the fill point of the cooling system. Decal code: 47757330. NOTICE: Never mix OAT coolant with conventional coolant. Under no circumstances should you top up the coolant system with only water. You can use a refractometer to check the concentration level. Do not use additional coolant additives when you use NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT. Change the coolant solution at the recommended change interval. If you need to change a machine from conventional coolant to OAT coolant or vice versa, you should follow the “Changing coolant types” procedure below to attain the full benefit of the coolant.

Changing coolant types To change coolant from OAT coolant to conventional coolant or vice versa: 1. Empty the engine cooling system by draining the coolant into a suitable container. 2. Fill the system with clean water. 3. Start the engine. Let the engine run for at least 30 min. NOTE: If the machine is equipped with a warm-up system, make sure that you activate the warm-up system to circulate the fluid through the heater core. 4. Repeat Steps 1 to 3 for a total of two washes. 5. Fill the system with conventional coolant or OAT coolant. 6. Operate the engine until it is warm. Inspect the machine for leaks. 7. If you change to OAT coolant, affix the decal with code 47757330 instead of decal 47488993, to indicate the use of OAT coolant in the cooling system.

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INTRODUCTION

Torque Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads, as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite lubricants, Molydisulfide greases, or other extreme pressure lubricants are used.

Decimal hardware Grade 5 bolts, nuts and studs Nm

Size

12 – 15 Nm 23 – 28 Nm 48 – 57 Nm 73 – 87 Nm 109 – 130 Nm 149 – 179 Nm 203 – 244 Nm 366 – 439 Nm 542 – 651 Nm 787 – 944 Nm 1085 – 1193 Nm 1519 – 1681 Nm 1980 – 2278 Nm 2631 – 2983 Nm Markings for Grade 5 hardware

1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in

lb in/lb ft 108 – 132 lb in 204 – 252 lb in 420 – 504 lb in 54 – 64 lb ft 80 – 96 lb ft 110 – 132 lb ft 150 – 180 lb ft 270 – 324 lb ft 400 – 480 lb ft 580 – 696 lb ft 800 – 880 lb ft 1120 – 1240 lb ft 1460 – 1680 lb ft 1940 – 2200 lb ft

Grade 8 bolts, nuts and studs Size 1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in

Nm 16 – 20 Nm 33 – 39 Nm 61 – 73 Nm 95 – 114 Nm 149 – 179 Nm 217 – 260 Nm 298 – 358 Nm 515 – 618 Nm 814 – 976 Nm 1220 – 1465 Nm 1736 – 1953 Nm 2468 – 2712 Nm 3227 – 3688 Nm 4285 – 4827 Nm Markings for Grade 8 hardware

NOTE: Use thick nuts with Grade 8 bolts.

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lb in/lb ft 144 – 180 lb in 288 – 348 lb in 540 – 648 lb in 70 – 84 lb ft 110 – 132 lb ft 160 – 192 lb ft 220 – 264 lb ft 380 – 456 lb ft 600 – 720 lb ft 900 – 1080 lb ft 1280 – 1440 lb ft 1820 – 2000 lb ft 2380 – 2720 lb ft 3160 – 3560 lb ft

INTRODUCTION

Metric hardware Grade 8.8 Bolts, Nuts and Studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

Nm 3 – 4 Nm 7 – 8 Nm 11 – 12 Nm 26 – 31 Nm 52 – 61 Nm 90 – 107 Nm 144 – 172 Nm 217 – 271 Nm 434 – 515 Nm 675 – 815 Nm 1250 – 1500 Nm 2175 – 2600 Nm Markings for Grade 8.8 hardware

lb in/lb ft 24 – 36 lb in 60 – 72 lb in 96 – 108 lb in 228 – 276 lb in 456 – 540 lb in 66 – 79 lb ft 106 – 127 lb ft 160 – 200 lb ft 320 – 380 lb ft 500 – 600 lb ft 920 – 1100 lb ft 1600 – 1950 lb ft

Nm 4 – 5 Nm 9 – 11 Nm 15 – 18 Nm 37 – 43 Nm 73 – 87 Nm 125 – 150 Nm 200 – 245 Nm 310 – 380 Nm 610 – 730 Nm 1050 – 1275 Nm 2000 – 2400 Nm 3500 – 4200 Nm Markings for Grade 10.9 hardware

lb in/lb ft 36 – 48 lb in 84 – 96 lb in 132 – 156 lb in 324 – 384 lb in 54 – 64 lb ft 93 – 112 lb ft 149 – 179 lb ft 230 – 280 lb ft 450 – 540 lb ft 780 – 940 lb ft 1470 – 1770 lb ft 2580 – 3090 lb ft

Grade 10.9 Bolts, Nuts and Studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

Grade 12.9 bolts, nuts and studs Nm Size lb in/lb ft Typically the torque values specified for grade 10.9 hardware can be used satisfactorily on grade 12.9 hardware. Markings for Grade 12.9 hardware

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INTRODUCTION

Steel hydraulic fittings 37° flare fitting Tube outside diameter/Hose inside diameter mm Inch 6.4 mm 1/4 in 7.9 mm 5/16 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/6 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.4 mm 1 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Nm

Thread Size

lb in/lb ft

8 – 16 Nm 11 – 22 Nm 14 – 34 Nm 20 – 57 Nm 34 – 79 Nm 54 – 108 Nm 81 – 135 Nm 102 – 158 Nm 169 – 223 Nm 285 – 338 Nm

7/16-20 in 1/2-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-3/16-12 in 1-5/16-12 in 1-5/8-12 in 1-7/8-12 in

72 – 144 lb in 96 – 192 lb in 120 – 300 lb in 180 – 504 lb in 300 – 696 lb in 40 – 80 lb ft 60 – 100 lb ft 75 – 117 lb ft 125 – 165 lb ft 210 – 250 lb ft

Straight threads with O-ring Tube outside diameter/Hose inside diameter mm Inch 6.4 mm 1/4 in 7.9 mm 5/16 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/6 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.4 mm 1 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Nm

Thread Size

lb in/lb ft

16 – 26 Nm 22 – 34 Nm 34 – 54 Nm 57 – 91 Nm 79 – 124 Nm 108 – 174 Nm 136 – 216 Nm 159 – 253 Nm 224 – 357 Nm 339 – 542 Nm

7/16-20 in 1/2-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-3/16-12 in 1-5/16-12 in 1-5/8-12 in 1-7/8-12 in

144 – 228 lb in 192 – 300 lb in 300 – 480 lb in 540 – 804 lb in 58 – 92 lb ft 80 – 128 lb ft 100 – 160 lb ft 117 – 187 lb ft 165 – 264 lb ft 250 – 400 lb ft

Split flange mounting bolts Nm

Size 20 – 27 Nm 27 – 34 Nm 47 – 61 Nm 74 – 88 Nm 190 – 203 Nm

5/16-18 in 3/8-16 in 7/16-14 in 1/2-13 in 5/8-11 in

180 – 240 lb 240 – 300 lb 420 – 540 lb 55 – 65 lb ft 140 – 150 lb

lb in/lb ft in in in ft

O-Ring Face Seal End Nominal SAE dash size -4 -6 -8 -10 -12 -14 -16 -20 -24

Tube outside diameter mm Inch 6.4 mm 1/4 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/8 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.41 mm 1.0 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Thread Size 9/16-18 in 11/16-16 in 13/16-16 in 1-14 in 1-3/16-12 in 1-3/16-12 in 1-7/16-12 in 1-11/16-12 in 2-12 in

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Nm 14 – 16 Nm 24 – 27 Nm 43 – 54 Nm 62 – 76 Nm 90 – 110 Nm 90 – 110 Nm 125 – 140 Nm 170 – 190 Nm 200 – 254 Nm

lb in/lb ft 120 – 144 lb in 216 – 240 lb in 384 – 480 lb in 552 – 672 lb in 65 – 80 lb ft 65 – 80 lb ft 92 – 105 lb ft 125 – 140 lb ft 150 – 180 lb ft

INTRODUCTION

Lock nut or O-ring boss end fitting Nominal SAE dash size -4 -6 -8 -10 -12 -14 -16 -20 -24

Tube outside diameter mm Inch 6.4 mm 1/4 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/8 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.41 mm 1.0 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Thread Size 7/16-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-13/16-12 in 1-5/16-12 in 1`-5/6-12 in 1-7/8-12 in

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Nm 23 – 27 Nm 34 – 41 Nm 61 – 68 Nm 81 – 88 Nm 115 – 122 Nm 129 – 136 Nm 156 – 169 Nm 201 – 217 Nm 258 – 271 Nm

lb in/lb ft 204 – 240 lb in 300 – 360 lb in 540 – 600 lb in 60 – 65 lb ft 85 – 90 lb ft 95 – 100 lb ft 115 – 125 lb ft 150 – 160 lb ft 190 – 200 lb ft

INTRODUCTION

Fluids and lubricants System

Quantity

Engine lubrication – with filter

10.0 L (2.6 US gal)

Cooling system

15.0 L (4.0 US gal)

Transmission Front axle – central reservoir Front axle – final drives (hubs)

60.0 L (15.9 US gal) 7.0 L (1.8 US gal) 1.5 L (0.4 US gal)

Fuel tank – main (*)

170.0 L (44.9 US gal)

Grease fittings

Recommended fluid

As required

International specification

NEW HOLLAND AMBRA ACEA E7 API CI-4 MASTERGOLD™ HSP ENGINE CES 20078 OIL SAE 15W-40 50% of water and 50% of ASTM D 6210 NEW HOLLAND AMBRA – Monoethylene ACTIFULL™ OT EXTENDED glycol LIFE COOLANT NEW HOLLAND AMBRA SAE 10W-30, API MULTI G™ HYDRAULIC GL-4 TRANSMISSION OIL Petroleum diesel fuel (B7 Biodiesel) NEW HOLLAND AMBRA GR-9 NLGI 2 MULTI-PURPOSE GREASE

(*) Theoretical fuel tank volume. Use only as a reference for the net volume of the tank. NOTE: To avoid damage to your machine, always use the same type of coolant. When you top up, use pure water. If you change the additive used, clean the cooling system first. For more information, see the procedures in Engine cooling system - Basic instructions (10.400). NOTE: Always check that the implement does not use more oil than is available in the tractor. The transmission should have at least the minimum oil level in order to operate.

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INTRODUCTION

The correct engine oil viscosity grade is dependent upon ambient temperature. See the table below for the recommended viscosity at different ambient air temperature ranges.

SAE 5W30 SAE 10W - 30 SAE 15W-40 -40 °C -40 °F

-30 °C -22 °F

-25 °C (-13 °F)

-15 °C (5 °F)

0 °C 32 °F

10 °C 50 °F

20 °C 68 °F

30 °C 86 °F

40 °C 104 °F

50 °C 122 °F

In environments with extreme air temperatures that require long periods of use of the machine, use SAE 50 oil for extremely high temperatures and SAE 5W30 for extremely low temperatures.

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CONSUMABLES INDEX Consumable Loctite® 569™ Loctite® 567™ PST Pipe Sealant Loctite® 565™ PST Loctite® 545™ NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 15W-40 NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE

Reference

PAGE

Torque - Standard torque data for hydraulics Torque - Standard torque data for hydraulics

27 28

Torque - Standard torque data for hydraulics Torque - Standard torque data for hydraulics Engine cooling system - Basic instructions

28 28 29

Fluids and lubricants

34

Fluids and lubricants

34

Fluids and lubricants

34

Fluids and lubricants

34

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SERVICE MANUAL Engine 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

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CONSUMABLES INDEX Consumable

Reference

Engine coolant NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT

PAGE 10.5 / 6

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Engine - 10 Engine and crankcase - 001

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Engine and crankcase

Engine - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Drive shaft - Remove (23.314).. Prior operation: Exhaust pipes - Remove (10.254).. Prior operation: Radiator - Remove (10.400).. 1. Disconnect the battery negative (-) cable (1). 2. Disconnect the connections of the existing wire harnesses between the cab and the engine. 3. Remove the front ballasts. 4. Remove the engine hood. 5. Remove the engine side shields.

CUIL14TR00227AA

1

CUIL17TR00061AA

2

CUIL14TR00794AA

3

6. Remove the two clips (1) and disconnect the suction line (2). 7. Remove the bolts (3). Disconnect the pressure tube (4). .. NOTE: After disconnecting each of the tubes, protect the disconnected ends with suitable covers.

8. Disconnect the two hoses (1) from the steering cylinder.

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Engine - Engine and crankcase

9. Loosen the throttle cable (1).

CUIL17TR00062AA

4

CUIL17TR00063AA

5

CUIL17TR00064AA

6

CUIL17TR00065AA

7

10. Disconnect the lower radiator hose (1).

11. Disconnect the fuel supply (1) and return line (2).

12. Remove the Intercooler inlet and outlet tubes (1). 13. Remove the air filter intake line (2).

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Engine - Engine and crankcase

14. Remove the transmission cooler (2).

CUIL14TR00545AA

8

CUIL16TR01136AA

9

15. Place the tool (trolley) under the tractor and put two wedges on the front shaft to prevent swaying. 16. Place a wooden shim (1) on the contact points between the trestles and the tractor.

17. Place a fixed trestle (1) under the draw bar support and pull the parking brake.

CUIL16TR01137AA

10

CUIL14TR00803AA

11

18. Remove the fastening bolts (1) between the engine and the transmission. 19. Separate the engine from the transmission, moving the front of the tractor carefully.

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20. Place a fixed trestle (1) under the counterweight cradle and block the front wheels with wooden wedges (2).

CUIL16TR01371AA

12

CUIL16TR01139AA

13

CUIL16TR01140AA

14

CUIL16TR01141AA

15

21. Remove the clutch assembly. Consult the procedures in Clutch - Remove (18.110).

22. Lift the engine slightly and position the mobile trestle (1) under the front axle support.

23. Remove the four bolts (2) securing the engine and remove the engine from the axle support.

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Engine - Engine and crankcase

24. Carefully separate the engine from the front axle and place it on the engine stand.

CUIL16TR01142AA

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16

Engine - Engine and crankcase

Engine - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

WARNING Maintenance hazard! Before performing any maintenance or inspection: -position machine on a firm, level surface -turn off the engine -remove the ignition key -secure the machine (wheels chocked) -disconnect the wiring (unless instructed otherwise) Failure to comply could result in death or serious injury. W1071A

1. Align the front support with the engine. 2. Install the bolts (2) for securing the support to the engine. Torque to 380 – 420 N·m (280 – 310 lb ft).

CUIL16TR01141AA

1

CUIL16TR01139AA

2

3. Install the clutch assembly. Consult the procedures in Clutch - Install (18.110). 4. Bring the front axle support assembly and transmission engine together.

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Engine - Engine and crankcase

5. Install the bolts (1) for securing the engine to the transmission. Torque to 265 – 319 N·m (195 – 235 lb ft).

CUIL14TR00803AA

3

CUIL14TR00545AA

4

CUIL17TR00065AA

5

CUIL17TR00064AA

6

6. Install the transmission cooler (2).

7. Assemble the intercooler inlet and outlet tubes (1). 8. Assemble the air filter intake line (2).

9. Connect the fuel supply (1) and return line (2).

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Engine - Engine and crankcase

10. Connect the radiator hose (1).

CUIL17TR00063AA

7

CUIL17TR00062AA

8

CUIL14TR00794AA

9

11. Install the throttle cable (1).

12. Connect the two steering cylinder hoses (1).

13. Connect the suction hose (2). Install the two clamps (1). 14. Connect the pressure tubes (4). Install the bolts (3). 15. Connect the connections of the existing wire harnesses between the cab and the engine.

CUIL17TR00061AA

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10

Engine - Engine and crankcase

16. Connect the negative battery cable (1).

CUIL14TR00227AA

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11

Index Engine - 10 Engine and crankcase - 001 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Engine - 10 Fuel tanks - 216

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tank Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Fuel tanks

Fuel tank - Drain fluid 1. Park the machine on a level and hard surface. 2. Place a suitably sized container under the component. 3. Remove the plug (1) to drain the fluid. 4. Dispose of the collected fluid appropriately. Adhere to the legislation in effect in your region or country.

CUIL14TR00430AA

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1

Engine - Fuel tanks

Fuel tank - Remove Prior operation: Fuel tank - Drain fluid (10.216). 1. Remove the screws (1) from the platform access ladder. Remove the ladder.

CUIL14TR00429AA

1

CUIL14TR00428AA

2

CUIL13TR00692AA

3

CUIL14TR00427AA

4

2. Loosen nuts (1) and (3). Remove the bolt (4) and the strap (2). 3. Remove the upper platform.

4. Remove the hose (1). 5. Remove the tubes. 6. Remove the rear attachment of the strap.

7. Loosen the nuts (3). Remove the bolt (2) from its housing and remove the strap (1).

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Engine - Fuel tanks

8. Remove the bolts from the fuel tank cradle. 9. Remove the bolts from the fuel tank cradle. Remove the fuel tank cradle.

CUIL13TR00691AA

5

CUIL13TR00690AA

6

10. Remove the fuel tank from its housing.

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Engine - Fuel tanks

Fuel tank - Install Prior operation: Fuel tank - Remove (10.216). 1. Position the fuel tank in its housing. 2. Install the fuel tank cradle. Secure the four bolts. 3. Install the front and rear straps of the fuel tank. 4. Install the plate. Secure the bolts. 5. Install the pipes. 6. Install the hose.

CUIL13TR00692AA

1

CUIL14TR00429AA

2

7. Install the rear wheel. 8. Install the ladder. Secure the bolts (1)

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Index Engine - 10 Fuel tanks - 216 Fuel tank - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Engine - 10 Turbocharger and lines - 250

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Engine - 10 Turbocharger and lines - 250

SERVICE Air-water heat exchanger Air-water heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Turbocharger and lines

Air-water heat exchanger - Remove WARNING Risk of harm during maintenance of the machine! Before you start servicing the machine, always attach a DO NOT OPERATE warning tag to the machine in a visible area. Failure to comply could result in death or serious injury. W1242B

1. Disconnect the negative battery cable. 2. Loosen the clamps (1) and disconnect the intercooler inlet and outlet lines (2).

CUIL17TR00065AA

1

CUIL17TR00060AA

2

3. Remove the four bolts (1). Remove the intercooler (2).

Next operation: Air-water heat exchanger - Install (10.250).

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Engine - Turbocharger and lines

Air-water heat exchanger - Install WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION chapter before you perform any maintenance, service, or repairs. Read and understand the specific service procedures for the components you plan to work with before you start servicing the machine. Failure to comply could result in death or serious injury. W0138B

Prior operation: Air-water heat exchanger - Remove (10.250).. 1. Position the intercooler (2). Torque the four bolts (1) to 43.0 – 56.0 N·m (31.7 – 41.3 lb ft).

CUIL17TR00060AA

1

CUIL17TR00065AA

2

2. Connect the intercooler inlet and outlet lines (2) with the clamps (1). 3. Connect the negative battery cable.

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Index Engine - 10 Turbocharger and lines - 250 Air-water heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Air-water heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Engine - 10 Intake and exhaust manifolds and muffler - 254

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Engine - 10 Intake and exhaust manifolds and muffler - 254

SERVICE Exhaust pipes Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Intake and exhaust manifolds and muffler

Exhaust pipes - Remove CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A

1. Remove the bolts (1). Remove the guard (2).

CUIL17TR00081AA

1

CUIL17TR00082AA

2

2. Remove all of the bolts (1) that secure the exhaust pipe on the turbocharger. 3. Remove the bolts from the support (2) and remove the exhaust assembly.

Next operation: Exhaust pipes - Install (10.254)..

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Engine - Intake and exhaust manifolds and muffler

Exhaust pipes - Install CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Exhaust pipes - Remove (10.254). 1. Place the exhaust assembly onto the support and secure the bolts (2). 2. Install the bolts (1) that secure the turbocharger. Torque to 18 N·m (13 lb ft).

CUIL17TR00082AA

1

CUIL17TR00081AA

2

3. Install the guard (2). Install the bolts (1).

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Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust pipes - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Exhaust pipes - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Engine - 10 Engine cooling system - 400

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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CONSUMABLES INDEX Consumable

Reference

Engine coolant NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT

PAGE 10.5 / 6

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Engine - Engine cooling system

Engine coolant WARNING Burn hazard! Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released. Failure to comply could result in death or serious injury. W0367A

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

WARNING Hazardous chemicals! Chemical agent may be harmful. -Avoid contact with eyes, and prolonged/repeated skin contact. -Wear protective goggles when handling. -Eye contact: Flush with water for 15 minutes. Seek immediate medical assistance. -Wash skin with soap and water after handling. -Keep out of reach of children. Failure to comply could result in death or serious injury. W0370A

To reduce the number of deposits and the level of corrosion, water used in the cooling system must adhere to the following values: Total Hardness 300 parts per million

Chloride 100 parts per million

Use of distilled water If you reside in a country where antifreeze is not available, use clean water premixed with 5% chemical inhibitor. The inhibitor is available from your NEW HOLLAND dealer.

Coolant replacement The coolant has antioxidant properties, anti-corrosive properties, anti-foam properties, and anti-freeze properties. To preserve these properties and, as a result, to increase the service life of your machine's components, replace the coolant in accordance with the procedure below: 1. Park the machine on a level and hard surface. 2. Place a suitably sized container under the components.

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Sulfate 100 parts per million

Engine - Engine cooling system

3. Install the radiator cap and the expansion tank cap (1).

CUIL16TR00393AA

1

CUIL16TR00190AA

2

CUIL16TR00191AA

3

BRIL12AT0041A0A

4

4. Remove the bolts (1), (2), and (3). Remove the radiator guard (4).

5. Disconnect the lower radiator hose (1).

6. Remove the drain plug (1) from the engine block. 7. Completely drain the coolant. NOTE: Dispose of the collected coolant in an appropriate manner. Adhere to the legislation in effect in your region or country. 8. After you drain the coolant, circulate clean water through the cooling system under pressure. NOTE: Repeat this operation until the water runs out completely clean.

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Engine - Engine cooling system

9. Connect the lower radiator hose (1). 10. Install the radiator guard. Tighten the bolts.

CUIL16TR00191AA

5

CUIL16TR00393AA

6

CUIL16TR00393AA

7

11. Slowly fill the system with a ratio of 50% water and 50% NEW HOLLAND AMBRA ACTIFULL™ OT EXTENDED LIFE COOLANT up to the maximum level (1) in the expansion tank (2). NOTE: You must use the expansion tank to fill the system. NOTE: Fill the expansion tank as slowly as possible so that air is not caught in the system. Trapped air may damage the engine.

12. Crank the engine. 13. Continue to run the engine until it reaches working temperature. 14. Check the coolant level. 15. If the level falls below the minimum mark, shut down the engine. Refill the circuit until the level remains stable between the minimum and maximum marks. 16. Install the expansion tank cap (1). NOTE: The use of an approved pressure cap is mandatory. If you lose or damage the cap, purchase an original cap from your NEW HOLLAND dealer.

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Engine - Engine cooling system

Radiator - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

WARNING Hot liquid under pressure! Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual. Failure to comply could result in death or serious injury. W0163A

Prior operation: Engine coolant (10.400). 1. Disconnect the negative cable (1) from the battery.

CUIL14TR00227AA

1

CUIL17TR00065AA

2

2. Remove the intercooler inlet and outlet lines (1) and (3). 3. Remove the air filter intake line (2). 4. Remove the transmission cooler.

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Engine - Engine cooling system

5. Remove the upper radiator hose (1). 6. Remove the expansion tank hose.

CUIL17TR00063AA

3

CUIL17TR00066AA

4

CUIL16TR01192AA

5

7. Remove the lower engine coolant hose (1). 8. Loosen the radiator upper mounting support (3). 9. Remove the deflector mounting bolts (4).

10. Use a suitable lifting device and remove the radiator. NOTE: Do not allow the cooling package to contact the fan blades.

Next operation: Radiator - Install (10.400).

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Engine - Engine cooling system

Radiator - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Radiator - Remove (10.400).. 1. Use a suitable lifting device and position the radiator in its housing. NOTE: Do not let the cooling assembly come into contact with the fan blades. 2. Position the radiator in its housing. 3. Install the deflector mounting bolts (3). 4. Install the radiator upper mounting support (1). 5. Install the lower engine coolant hose (2).

CUIL17TR00066AA

1

CUIL17TR00063AA

2

CUIL17TR00065AA

3

6. Install the expansion tank hose. 7. Install the upper radiator hose (1). 8. Install the transmission cooler.

9. Install the air filter intake line (2). 10. Install the intercooler lines (1) and (3).

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Index Engine - 10 Engine cooling system - 400 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Clutch 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Clutch - 18

[18.104] Clutch hydraulic release control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 [18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2

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18

Clutch - 18 Clutch hydraulic release control - 104

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Clutch - 18 Clutch hydraulic release control - 104

SERVICE Clutch hydraulic release control Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove - Clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Travel adjust - Clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Clutch control cylinder or actuator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Disassemble 1. Lever up the pedal return spring. (1). 2. Remove the snap ring from the clutch pedal shaft . 3. Remove the clutch pedal shaft. 4. Remove the clutch pedal (2).

CUIL17TR00067AA

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1

Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Inspect Prior operation: Clutch hydraulic release control - Disassemble (18.104).. 1. Inspect the clutch pedal. Check for cracks and make sure there is not excessive free play between the bushings and the pedal shaft. Remove and replace damaged parts. 2. Inspect the release clutch cross shaft and bushings inside transmission box. Shaft should rotate smoothly on its bushings without free play between bushings and shaft. If bushings are damaged or worn out, replace the bushings.

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Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Remove - Clutch pedal 1. To disassemble the clutch pedal, disassemble the lefthand side panel of the instrument console. 2. Shut down the master cylinder rod. 3. Lift the return spring of the pedal. Remove the lock ring. Pull the link pin. Remove the tractor’s clutch pedal. Clutch components — hydraulic operation 1.

Oil tank / Brake fluid

2.

Clutch pedal

3.

Lock cable

4.

Slave cylinder air bleeding tube

5.

Slave cylinder set

6.

Slave cylinder oil supply tube

7.

Master cylinder

CUIL17TR00070AA

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1

Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Travel adjust - Clutch pedal 1. The clutch pedal free travel must be from 28 – 41 mm (1.1 – 1.6 in) at the clutch pedal. 2. If adjustment is required, loosen the jam nut (1). Remove the cotter pin (4) and the joint pin (3) . 3. Rotate the joint pin (3) to lengthen or shorten the operating connecting rod as necessary. 4. Install the joint pin (3) with a new cotter pin (4). Tighten the jam nut (1).

CUIL17TR00071AA

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1

Clutch - Clutch hydraulic release control

Clutch control cylinder or actuator - Remove Master cylinder 1. Remove the side cover of the left-hand instrument cluster. 2. Disconnect both reservoir tubes of the fluid and plug them to avoid loosing too much oil. 3. Disconnect the outlet tube to the slave cylinder and cover the tube. 4. Disconnect the driver rod from the clutch pedal. 5. Remove the two bolts that hold the cylinder set to the tractor's bulkhead and remove the cylinder. 6. Assemble the set in the reverse order of disassembly. Clutch components 1.

Clutch pedal pin

2.

Master cylinder safety nut

3.

Adjustment nuts of the rod (version 8x2 and 16x4)

4.

Gear activating rod (only versions 8x2 and 16x4)

5.

Bleed screw

6.

Master cylinder to slave cylinder tube

7.

Master cylinder.

8.

Supply of oil to reservoir CUIL17TR00068AA

Next operation: Clutch control cylinder or actuator - Disassemble (18.104)

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1

Clutch - Clutch hydraulic release control

Clutch control cylinder or actuator - Disassemble Prior operation: Clutch control cylinder or actuator - Remove (18.104).. 1. Turn the driver rod and the cover set backward, remove the set's retaining ring of the driver rod and the coil. 2. Tap the cylinder lightly, from the rods end downward, on a firm surface to disassemble the coil set. 3. Remove the oil inlet adaptors and carefully take out the seals. 4. From the coil and spring set, fold the retaining tab of the retainer backward and remove the spring set. Release the rod and disassemble. Next operation: Clutch control cylinder or actuator - Inspect (18.104)..

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Clutch - Clutch hydraulic release control

Clutch control cylinder or actuator - Inspect Prior operation: Clutch control cylinder or actuator - Disassemble (18.104).. 1. Inspect the diameter of the cylinder for wear, scratch marks and burrs. If the diameter is not in good conditions, replace the cylinder's set. Do not try to repair. 2. There are seals in the available service kit. When you check the main cylinder, purchase a kit and replace all of the seals. 3. Grease all the seals with clean brake fluid before assembly. Next operation: Clutch control cylinder or actuator - Bleed (18.104)..

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Clutch - Clutch hydraulic release control

Clutch control cylinder or actuator - Bleed Prior operation: Clutch control cylinder or actuator - Inspect (18.104).. 1. Make sure that the deposits are full up to the maximum line with brake fluid specified. 2. Assemble an appropriate rubber tube on the bleed screw. Immerse the tube in a jar with clean brake fluid of the right specification. Place the jar on top of the flushing bolt and this will avoid the possible entrance of air in the bleed screw. 3. Open the bleed screw and push the clutch pedal all the way down, close the bleed screw with the pedal on the floor and then release the pedal. Repeat this procedure until oil "without air" enters the jar. NOTE: Regularly check the oil level in the deposit during the bleeding process. Do not allow the deposit to empty.

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Index Clutch - 18 Clutch hydraulic release control - 104 Clutch control cylinder or actuator - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Clutch control cylinder or actuator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Clutch control cylinder or actuator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Clutch control cylinder or actuator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Clutch hydraulic release control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Clutch hydraulic release control - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Clutch hydraulic release control - Remove - Clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Clutch hydraulic release control - Travel adjust - Clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

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Clutch - 18 Clutch and components - 110

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Clutch - 18 Clutch and components - 110

TECHNICAL DATA Clutch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Clutch Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Clutch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove - PTO drive disk bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install - PTO drive disk bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSTIC Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Clutch - Clutch and components

Clutch - General specification 7630

Disk type Material Pressure plate type Thrust bearing type Clutch pedal free play setting

8030 Dry disk – 330 mm Organic, asbestos free Belleville spring (self-adjustment, maintenance free) Mechanical activation. 28 – 41 mm (1.102 – 1.614 in)

Clutch - Torque Component Screws from clutch cover to flywheel Locknut on clutch pedal Bolts of the Power Take-Off (PTO) drive disk Bearing fork setscrew on crosswise shaft

Specification 35 N·m (26 lb ft) 34 N·m (25 lb ft) 129 N·m (95 lb ft) 47 N·m (35 lb ft)

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Clutch - Clutch and components

Clutch - Dynamic description The non-synchronized 8x 2 transmission clutch system is mechanically driven with a 330 mm dry single disc. The pressure plate a self-adjustable spring type and does not require any maintenance. There is a pre-lubricated thrust bearing on the rear end of crankshaft, inside the flywheel. The bearing is located on the drive disk of the Power Take-Off (PTO). With the clutch engaged, the spring loaded pressure plate forces the clutch disc into contact with the engine flywheel. Friction contact between disc material and the surfaces of the flywheel and pressure plate transmits drive from the flywheel shaft to the transmission input shaft via the disc. When placing your foot on the clutch pedal, the thrust bearing moves forward and pushes the pressure plate, separating the clutch disc and disconnecting it from the flywheel. As a result, the friction disc disconnects from the transmission, allowing gear changing to occur. When the clutch pedal is let out, a spring places the pedal back into its free position and the thrust bearing separates from the pressure plate pins. The pressure plate springs exert pressure forward against the disc until it touches the clutch, thus restoring drive between the engine and the gear box.

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Clutch - Clutch and components

Clutch - Remove Prior operation: Engine - Remove (10.001). 1. Remove the bolts that hold the clutch pressure plate and the cover assembly to the flywheel. NOTE: The bolts must be loosened in a criss-cross pattern through the clutch so that the cover assembly is not twisted. 2. Disassemble the pressure plate assembly, along with the clutch disk.

CUIL17TR00072AA

1

CUIL17TR00076AA

2

CUIL17TR00083AA

3

3. At the front of the transmission, disassemble both tubes (2) from the hydraulic disengage bearing (1). 4. Remove the three bolts that attach the disengage bearing set to the transmission front plate and remove the disengage bearing set.

Remove the retaining bolt (2) of the clutch disengage fork. 5. Remove the clutch disengage shaft (3) from the box. 6. Disassemble the clutch disengage fork (1) from the transmission. 7. Slide the clutch disengage bearing and the support hub from the clutch disengage hub.

Next operation: Clutch - Inspect (18.110).

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Clutch - Clutch and components

Clutch - Inspect Prior operation: Clutch - Remove (18.110). 1. Inspect the friction disc. Make sure the linings are not loose, cracked, worn out or dirtied by oil. Check the rivets. If there are signs of overheating due to clutch slippage, replace the disc with a new one. NOTE: Investigate reason for any oil or grease on surfaces. Repair before mounting new disc. 2. Inspect pressure plate. Check that all pins are the same height, that there is no discoloration due to overheating, and that the entire assembly works properly. Check for cracks, scratches or distortion on the surface of the pressure plate. Dispose of pressure plate if any of the above failures are found. NOTE: The diaphragm clutch has no replacement parts. Replace the whole assembly if any problem is found during inspection. 3. Make sure the thrust bearing and hub move freely inside the hub support. Ensure the bearing rotates smoothly and that external side is not damaged or worn out. Look for cracks or distortion on clutch release fork. For example, make sure that all the pins are aligned and not worn out. Remove and replace any broken or defective parts. 4. If needed, check the thrust bearing. Use an extractor (1) with a suitable attachment (3) and a stack plate (4) to separate the thrust bearing (2) from the hub.

CUIL17TR00073AA

Next operation: Clutch - Assemble (18.110).

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1

Clutch - Clutch and components

Clutch - Assemble Prior operation: Clutch - Inspect (18.110). 1. Lubricate the hub housing with grease. Install the thrust bearing and the hub. 2. Reattach the fork and the clutch release shaft. 3. Torque the fork set screw to 47 N·m (35 lb ft). Next operation: Clutch - Install (18.110).

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Clutch - Clutch and components

Clutch - Install Prior operation: Clutch - Assemble (18.110). NOTICE: When installing a new pressure plate, the friction surface must be thoroughly cleaned with alcohol to remove the protective enamel. 1. Lightly lubricate the hub splines of the transmission input shaft with grease. 2. Use the pilot tool to place the clutch disc with the run surface and clutch plates towards flywheel. 3. Place the pressure plate over the flywheel. Torque the bolts to 35 N·m (26 lb ft). 4. Remove the pilot tool from the clutch disk. Next operation: Clutch hydraulic release control - Travel adjust - Clutch pedal (18.104).

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Clutch - Clutch and components

Clutch - Remove - PTO drive disk bearing Prior operation: Clutch - Remove (18.110).. Use a slide hammer (2) and suitable puller attachment (1) to remove the ball bearing (3) from the flywheel adapter.

CUIL17TR00074AA

Next operation: Clutch - Install - PTO drive disk bearing (18.110).

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Clutch - Clutch and components

Clutch - Install - PTO drive disk bearing Prior operation: Clutch - Remove - PTO drive disk bearing (18.110) 1. Place a stack plate (1) so that the flat side faces are on the outside. 2. Use a suitable driver to install the ball bearing (3) in the flywheel adapter (2) for the Power Take-Off (PTO) drive disk.

CUIL17TR00075AA

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Clutch - Clutch and components

Clutch - Troubleshooting Problem No movement when a gear is selected and the clutch pedal is let out.

With foot on the clutch pedal, engine speed raises but drive speed stays the same. It is very difficult to change gears. Cannot engage the machine.

Possible Cause Failure in rear axle or in transmission.

Clutch maladjustment. Thrust bearing is not moving. Chafing of friction disc. Pressure plate failure. Clutch disc slips.

Correction Connect differential lock. If tractor moves, failure is on differential outlet. If machine does not move, possible failure in transmission or in rear axle. Adjust clutch. Check the linkage. Replace the friction disc. Repair or replace pressure plate. • Check clutch adjustment. • Chafing of clutch disc.

• Pressure plate failure. Clutch drag (does not let out completely). • Check clutch adjustment. • Chafing of clutch disc. Clutch does not disengage.

• Pressure plate failure. • Check clutch adjustment. • Chafing of clutch disc. • Jamming of clutch disc over flywheel, pressure plate or input shaft splines.

Noise due to transmission Chafing of thrust bearing. housing. Noise changes when putting foot on clutch pedal and letting it out. Chafing of clutch pilot bearing. Clutch does not engage Faulty clutch disc. gently. Faulty pressure plate. Chafing of clutch pilot bearing. Faulty flywheel.

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• Pressure plate failure. Repair or replace pressure plate. Replace thrust bearing.

Replace clutch pilot bearing. Replace clutch disc. Replace pressure plate. Replace clutch pilot bearing. Check flywheel as detailed in engine section.

Index Clutch - 18 Clutch and components - 110 Clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Clutch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Clutch - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Clutch - Install - PTO drive disk bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Clutch - Remove - PTO drive disk bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Clutch - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Clutch - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

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SERVICE MANUAL Transmission 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Transmission - 21

[21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.130] Mechanical transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 [21.168] Hi-Lo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

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CONSUMABLES INDEX Consumable Loctite® 515™

Reference Mechanical transmission external controls - Assemble - Shift levers and cover

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PAGE 21.2 / 10

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Transmission - 21 Mechanical transmission - 114

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Transmission - 21 Mechanical transmission - 114

TECHNICAL DATA Mechanical transmission General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Mechanical transmission Dynamic description - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exploded view - Shift lever position and circulation of forces - 8x2 mechanical transmission . . . . . . . . . . 9 Dynamic description - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overview - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Functional diagram - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Transmission housing Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SERVICE Mechanical transmission Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DIAGNOSTIC Mechanical transmission Mechanical transmission - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Transmission - Mechanical transmission

Mechanical transmission - General specification Output shaft end play Available shims

7630 8030 0.038 – 0.086 mm (0.0015 – 0.0034 in) 0.076 mm (0.003 in) , 0.127 mm (0.005 in) , 0.305 mm (0.012 in)

Dual power system Planetary gear box end play Available shims Allowed gap between planetary cover and housing

Shims required according to the calculated average clearance

Dual Power system pressure test Lubrication system pressure

7630 8030 0.1 – 0.51 mm (0.004 – 0.020 in) 0.33 mm (0.013 in), 0.81 mm (0.032 in) 1.17 – 1.52 mm (0.046 – 0.060 in) Clearance of 0.025 – 0.33 mm (0.001 – 0.013 in): one 0.33 mm (0.013 in) shim and one 0.81 mm (0.032 in) shim Clearance of 0.34 – 0.66 mm (0.013 – 0.026 in): one 0.81 mm (0.032 in) shim Clearance of 0.67 – 0.81 mm (0.026 – 0.032 in): two 0.33 mm (0.013 in) shims Clearance of 0.82 – 1.14 mm (0.032 – 0.045 in): one 0.33 mm (0.013 in) shim Clearance of 1.15 – 1.52 mm (0.045 – 0.060 in): within specification, no shims needed. 15.2 – 17.9 bar (220.4 – 259.6 psi) 5.0 – 8.5 bar (72.5 – 123.3 psi)

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Transmission - Mechanical transmission

Mechanical transmission - Speeds Range Lever

Dual Power

Main Shift Lever 1

SC

Powe

1

SC

Direct

2

SC

Powe

2

SC

Direct

3

SC

Powe

3

SC

Direct

4

SC

Powe

4

SC

Direct

1

C

Powe

1

C

Direct

2

C

Powe

2

C

Direct

3

C

Powe

3

C

Direct

4

C

Powe

4

C

Direct

1

L

Powe

1

L

Direct

2

L

Powe

2

L

Direct

3

L

Powe

3

L

Direct

4

L

Powe

4

L

Direct

A

SC

Powe

A

SC

Direct

A

C

Powe

Transmis-

Wheel Speed

1500 RPM 1900 RPM 2100 RPM 2200 RPM sion Ratio 0.27 km/h (0.17 mph) 0.34 km/h (0.21 mph) 0.33 km/h (0.21 mph) 0.42 km/h (0.26 mph) 0.58 km/h (0.36 mph) 0.74 km/h (0.46 mph) 0.78 km/h (0.48 mph) 1.01 km/h (0.63 mph) 1.51 km/h (0.94 mph) 1.94 km/h (1.21 mph) 1.88 km/h (1.17 mph) 2.42 km/h (1.50 mph) 3.31 km/h (2.06 mph) 4.25 km/h (2.64 mph) 4.50 km/h (2.80 mph) 5.78 km/h (3.59 mph) 5.39 km/h (3.35 mph) 6.93 km/h (4.31 mph) 6.73 km/h (4.18 mph) 8.65 km/h (5.37 mph) 11.81 km/h (7.34 mph) 15.18 km/h (9.43 mph) 16.07 km/h (9.99 mph) 20.67 km/h (12.84 mph) 0.38 km/h (0.24 mph) 0.49 km/h (0.30 mph) 2.17 km/h (1.35 mph)

0.34 km/h (0.21 mph) 0.47 km/h (0.29 mph) 0.41 km/h (0.25 mph) 0.54 km/h (0.34 mph) 0.73 km/h (0.45 mph) 0.94 km/h (0.58 mph) 0.99 km/h (0.62 mph) 1.28 km/h (0.80 mph) 1.91 km/h (1.19 mph) 2.45 km/h (1.52 mph) 2.38 km/h (1.48 mph) 3.07 km/h (1.91 mph) 4.19 km/h (2.60 mph) 5.38 km/h (3.34 mph) 5.70 km/h (3.54 mph) 7.32 km/h (4.55 mph) 6.83 km/h (4.24 mph) 8.77 km/h (5.45 mph) 8.52 km/h (5.29 mph) 10.96 km/h (6.81 mph) 14.96 km/h (9.30 mph) 19.23 km/h (11.95 mph) 20.36 km/h (12.65 mph) 26.18 km/h (16.27 mph) 0.48 km/h (0.30 mph) 0.62 km/h (0.39 mph) 2.75 km/h (1.71 mph)

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0.37 km/h (0.23 mph) 0.48 km/h (0.30 mph) 0.46 km/h (0.29 mph) 0.59 km/h (0.37 mph) 0.81 km/h (0.50 mph) 1.04 km/h (0.65 mph) 1.10 km/h (0.68 mph) 1.42 km/h (0.88 mph) 2.11 km/h (1.31 mph) 2.72 km/h (1.69 mph) 2.64 km/h (1.64 mph) 3.39 km/h (2.11 mph) 4.63 km/h (2.88 mph) 5.95 km/h (3.70 mph) 6.30 km/h (3.91 mph) 8.10 km/h (5.03 mph) 7.55 km/h (4.69 mph) 9.70 km/h (6.03 mph) 9.42 km/h (5.85 mph) 12.11 km/h (7.52 mph) 16.63 km/h (10.33 mph) 21.25 km/h (13.20 mph) 22.50 km/h (13.98 mph) 28.93 km/h (17.98 mph) 0.53 km/h (0.33 mph) 0.68 km/h (0.42 mph) 3.04 km/h (1.89 mph)

0.39 km/h (0.24 mph) 0.50 km/h (0.31 mph) 0.48 km/h (0.30 mph) 0.62 km/h (0.39 mph) 0.85 km/h (0.53 mph) 1.09 km/h (0.68 mph) 1.15 km/h (0.71 mph) 1.48 km/h (0.92 mph) 2.21 km/h (1.4 mph) 2.84 km/h (1.76 mph) 2.76 km/h (1.71 mph) 3.55 km/h (2.21 mph) 4.85 km/h (3.01 mph) 6.23 km/h (3.87 mph) 6.60 km/h (4.10 mph) 8.48 km/h (5.27 mph) 7.91 km/h (4.92 mph) 10.16 km/h (6.31 mph) 9.87 km/h (6.13 mph) 12.69 km/h (7.89 mph) 17.32 km/h (10.76 mph) 22.27 km/h (13.84 mph) 23.57 km/h (14.65 mph) 30.31 km/h (18.83 mph) 0.56 km/h (0.35 mph) 0.72 km/h (0.45 mph) 3.18 km/h (1.98 mph)

67.08 52.18 53.75 41.81 30.63 23.82 22.50 17.50 11.74 9.13 9.41 7.32 5.36 4.17 3.94 3.06 3.29 2.56 2.63 2.05 1.50 1.17 1.10 0.86 46.47 36.30 8.17

Transmission - Mechanical transmission

Range Lever

Dual Power

Main Shift Lever A

C

Direct

A

L

Powe

A

L

Direct

Wheel Speed

1500 RPM 1900 RPM 2100 RPM 2200 RPM 2.79 km/h (1.73 mph) 7.75 km/h (4.82 mph) 9.96 km/h (6.19 mph)

3.53 km/h (2.19 mph) 9.81 km/h (6.10 mph) 12.62 km/h (7.84 mph)

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3.90 km/h (2.42 mph) 10.85 km/h (6.74 mph) 13.95 km/h (8.67 mph)

4.09 km/h (2.54 mph) 11.63 km/h (7.23 mph) 14.61 km/h (9.08 mph)

Transmission Ratio 6.35 2.29 1.78

Transmission - Mechanical transmission

Mechanical transmission - Torque Component Clutch release bearing hub support bolts Clutch release fork bolt Front support plate bolts Gear shift cover assembly bolts Gear shift fork retaining screws Oil baffle/shift lever stop plates Output shaft retainer bolts Rear support plate retaining bolts Reverse idler shaft retaining bolt Neutral start switch

Specification 67 N·m (49 lb ft) 47 N·m (35 lb ft) 44 N·m (32 lb ft) 56 N·m (41 lb ft) 31 N·m (23 lb ft) 22 N·m (16 lb ft) 44 N·m (32 lb ft) 44 N·m (32 lb ft) 23 N·m (17 lb ft) 40 N·m (30 lb ft)

Dual power system Component Control valve spool cap Control valve body screws Planetary gear box screws Planetary gear cap fastening screws Lubrication tube connection Pressure control tube connection

Specification 38 N·m (28 lb ft) 44 N·m (32.5 lb ft) 105 N·m (77 lb ft) 47 N·m (35 lb ft) 17.5 N·m (12.9 lb ft) 12 N·m (9 lb ft)

Mechanical transmission - Special tools Tool Number 380000541 NHT-0002 NHT-0009 NHT-0011 NHC-00

Description Slide hammer Base plates for extractor Accessory for bearing puller Special tool

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Transmission - Mechanical transmission

LAIL11TS0309F0A

(1) Cradle assembly

1

(2) Work cradle support shaft

The cradle described in the image above can be made to assemble the transmission on the existing work cradles. It is not absolutely necessary to have a mount to assemble the transmission, but the structure makes work swifter and easier to execute. The support shaft (2) allows the cradle to be connected to an existing workbench. If the work bench is not available, an appropriate support shaft can be made. Remove the eight mounting bolts. Remove the gearshift side cover (3) from the transmission. Remove the ten mounting bolts. Take the range shift cover (2) out of the transmission.

CUIL17TR00077AA

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2

Transmission - Mechanical transmission

Mechanical transmission - Dynamic description - 8x2 Mechanical transmission The non-synchronised transmission is a constant gear type that allows eight forward and two reverse speeds, which are selected manually by means of two shift levers. The main lever manually selects among four forward speeds or one reverse speed, while the shorter reduction lever allows the operator to select the long or short connection. The transmission has a built-in safety start switch that only allows the engine to work if the reduction lever is in the neutral position. Shift lever positions (with an optional super reducer) (L) – Low Range (N) – Neutral (C) – Creeper (H) – High Range (R) – Reverse

CUIL17TR00078AA

1

The gears are constantly engaged and the connections are made by sliding couplings. The primary transmission shaft is on the upper shaft and the main counter-axle and the output axle are on the lower shaft. The transmission is equipped with a Power Take-Off (PTO), which is independent of the transmission speeds and has one or two speeds. The transmission has straight cut gears. All bearings are roller bearings except for the output axle which has roller cone bearings. The movement of the output axle is controlled by the thicknesses between the output axle cap and the bearing retainer. Low pressure oil from the hydraulic system is used for pressure lubrication of the gear box. One part of the low pressure hydraulic oil is picked up by external tubes from the oil cooler located at the front of the machine. The cold oil then moves to the gearbox. The main counter-axle and the output axle are hollow and receive oil from the cooler. There are some transversal perforations in the main counter-axle and the output axle that allow the lubrication oil to come out and cool the shift gears. The return hydraulic oil passes through the gear box and goes back to the machine’s hydraulic system and differential box. Therefore, the gear box, differential box and hydraulic system make up a common oil deposit. The dual power option consists of a set of planetary gears directly installed between the clutch and the output axle in the standard transmission. The set of planetary gears allows the operator to directly select drive or reduction for each speed of the standard transmission.

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Transmission - Mechanical transmission

Mechanical transmission - Exploded view - Shift lever position and circulation of forces - 8x2 mechanical transmission

CUIL17TR00213GA

1

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Transmission - Mechanical transmission

Mechanical transmission - Dynamic description - 12x12 Mechanical transmission The 12x12 transmission offers twelve forward speeds and twelve reverse speeds, selected manually using three levers. The basic transmission can be specified using the options below: 1. Auxiliary Front Wheel Drive (AFWD) – consists of an integral gear, clutch and output arrangement that provides coupling between the transmission and the front axle. This AFWD output is available in two ratios to serve different tire combinations. If two wheel drive is specified, without AFWD, this output arrangement is omitted. The AFWD engages automatically when both brake pedals are applied simultaneously to provide braking on all four wheels. 2. For the 40 km/h version, the transmission offers three ranges. Within each range, another four speeds may be selected. In fact, this provides a three times four (3 x 4 = 12) transmission, or 12 speeds. All shifting, except reduction to low range (1st), is synchronized and can be engaged and disengaged while in motion. Speed, ranges and inverter shifting diagram (F) – Forward (L) – Low Range (N) – Neutral (M) – Medium Range (H) – High Range (R) – Reverse CUIL17TR00079AA

1

CUIL17TR00080AA

2

The three levers shown in the figure control the selection of 12 forward speeds and 12 reverse speeds. The figure shows the diagrams of the gear, range, and inverter levers. The main lever (3) functions according to the conventional “H” system. Together with the clutch pedal, the lever is used to select any of the four ratios, with the tractor either stopped or moving. Together with the clutch pedal, the range lever (1) is used to select one of the three ranges.

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Transmission - Mechanical transmission

The inversion lever (2) is used to choose forward or reverse movement when any of the twelve ratios are connected, as long as the clutch pedal is pressed. NOTE: A locking device prevents the movement of the inversion lever unless the clutch pedal is fully depressed. NOTE: A neutral safety switch prevents the starter motor from functioning unless the inverter lever is in neutral. The power is transmitted from the engine to the transmission box through a central dry plate clutch assembly. NOTICE: If the tractor needs to be towed, place the range lever in neutral. Otherwise, damage may occur to the transmission components. The oil supplied by the driven steering motor through the Power Take Off (PTO) and oil radiator ensures lubrication under pressure to the synchronizers, bearings, and output shafts. The transmission shares the common oil reservoir with the rear shaft.

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CUIL17TR00080AA

3

Transmission - Mechanical transmission

Mechanical transmission - Overview - 12x12 Mechanical transmission

CUIL17TR00196FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Component Power Take-Off (PTO) shaft Output shaft Auxiliary Front Wheel Drive (AFWD) shaft 1st range coupling sleeve High and medium ranges synchroniser 1st and 2nd gear synchroniser Reverse gear assembly PTO output shaft PTO clutch Reverse idler gear

1

Reference (11) (12)

Component Input shaft Inverter synchroniser

(13)

Reverse gear (loose on the shaft)

(14)

Engaging 1st gear

(15)

2nd gear (splined to the shaft);

(16) (17) (18) (19)

3rd gear (splined to the shaft); 3rd and 4th gear synchroniser Range gear group Range gear group shaft bearing

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Transmission - Mechanical transmission

Number of teeth 40 km/h 30 km/h 33 33 39 39 31 27 38 34 45 40 52 49 35 33 19 19 60 60 34 34 38 38 44 46 27 31 34 39 41 45 49 52 40 40 37 or 38 37 or 38 26 26 33 33 35 35

Description A B C D AND F G H J K L M N P Q R S T U V W

Reverse actuation gear Reverse driven gear 1st gear 2nd gear 3rd gear High range actuation gear Medium range actuation gear Low range actuation gear Low range driven gear AFWD internal shaft rear gear AFWD gear Medium range driven gear High range driven gear 3rd gear 2nd gear 1st gear Reverse group actuation gear AFWD transfer gear AFWD internal shaft front gear Reverse group gear Reverse idler gear

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Transmission - Mechanical transmission

Mechanical transmission - Functional diagram - 12x12 Mechanical transmission Path of power in the transmission Forward speeds Power passing forward in low

CUIL17TR00189FA

1

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Transmission - Mechanical transmission

CUIL17TR00190FA

2

CUIL17TR00191FA

3

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Transmission - Mechanical transmission

Reverse speeds

CUIL17TR00192FA

4

CUIL17TR00193FA

5

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Transmission - Mechanical transmission

CUIL17TR00194FA

6

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Transmission - Mechanical transmission

Transmission housing - Exploded view Gear shift side cover (forward)

CUIL17TR00198FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component 3rd and 4th fork 1st and 2nd fork Fork fixing bolt Cover gasket Detent plug Detent spring Detent ball 1st and 2nd fork shaft Lock dowel

1

Reference (10) (11) (12) (13) (14) (15) (16) (17)

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Component 3rd and 4th fork shaft 3rd and 4th shaft and lever assembly 1st and 2nd shaft and lever assembly Cover sealants Cover body 3rd and 4th shaft lever 1st and 2nd shaft lever Lock bolt

Transmission - Mechanical transmission

Mechanical transmission - Disassemble Prior operation: Engine - Remove (10.001). 1. Remove the cover from the gear shift levers. Consult the procedures in Mechanical transmission external controls - Disassemble - Shift levers and cover (21.130). 2. Remove the retaining bolt (3) for the clutch release fork (2). 3. Remove the clutch release shaft (4) from the housing. 4. Remove the clutch release fork from the transmission. 5. Slide the clutch bearing (1) and hub from the support. CUIL17TR00083AA

1

CUIL17TR00084AA

2

CUIL17TR00085AA

3

CUIL17TR00086AA

4

6. Disconnect the low pressure lines from the clutch release bearing hub support (1) and the front support plate (2). Remove the hub support.

7. Remove the snap ring (1) that retains the main drive input shaft (2) to the transmission main shaft and remove the input shaft.

8. Remove the retaining bolts (2) for the front support plate (1) and remove the support plate from the housing. 9. If necessary, drive the support plate from the housing using a suitable drift inserted into the main transmission compartment.

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Transmission - Mechanical transmission

10. Use a puller (2) and a shaft protector (3) to remove the front bearing (1) from the idler shaft.

CUIL17TR00087AA

5

CUIL17TR00088AA

6

CUIL17TR00089AA

7

CUIL17TR00090AA

8

11. Remove the snap ring (5), the thrust washer (4) and the hydraulic pump idler gear (3) located on the output shaft retainer. 12. Remove the retaining bolts (1) for the rear support plate (2).

13. Use a rubber or copper mallet to move the front end of the Power Take-Off (PTO) drive shaft back. This will separate the rear support plate from the transmission casing. 14. If necessary, use levers (1) to separate the rear support plate (2) from the casing. Remove the plate with the PTO drive shaft (5). 15. Remove the snap ring (3) that secures the PTO drive shaft bearing (6). Drive the shaft and bearing out of the support plate. 16. Remove the bolts that secure the output shaft retainer to the rear support plate and remove the retainer (4) and shims from the rear support plates. 17. Partially remove the secondary idler shaft assembly (1) until the front bearing is out of the location. 18. Lift the secondary idler shaft to allow the output shaft assembly (2) to be removed from the rear compartment. 19. Remove the idler shaft.

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Transmission - Mechanical transmission

20. Position the high/low sliding coupling on the rear part of the main idler shaft.

CUIL17TR00091AA

9

21. Remove the four detent plungers (1) and springs (2). NOTE: The detent balls (3) are located below the springs and are collected with the shift rail removal.

CUIL17TR00092AA

10

CUIL17TR00093AA

11

CUIL17TR00094AA

12

22. Unscrew the neutral start switch (1) from the housing. 23. Loosen the locknut and remove the bolt locking the high/low range fork (2) to the shaft. 24. Remove the range lever connector (3) from the shaft and slide the rail out from the rear of the gearbox. 25. Place a clean cloth beneath the neutral start switch actuator housing. Take care to ensure the ball, spring and actuating dowel are collected from the housing and rail. 26. Lift the high/low shift fork from the rear compartment.

27. Unscrew the locknut and retaining screw from the 1st - 5th/3rd - 7th shift fork (1) at the front of the shift rail. Drive the rail forward from the transmission casing, pushing the sealing plug out with the end of the rail. 28. Remove the shift connector and fork. 29. Unscrew the locknut and retaining screws from the 4th - 8th shift fork (2) and connector (3) and push the shift rail rearwards from the transmission case. Remove the fork and connector. 30. Unscrew the locknut an retaining screw from the reverse/2nd - 6th shift arm (4) and connector and slide the top rail out rearwards. 31. Lift the shift arm and the connector from the transmission housing.

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Transmission - Mechanical transmission

32. Remove the locknut and screw (1) that retains the reverse/2nd - 6th shift fork to the lower shift rail (4) and push out the rail rearwards. Remove the shift fork from the transmission casing. 33. Remove the lock plungers from the cross bore in the transmission case. If necessary, remove the bore plug situated on the left-hand side to facilitate removal of the plungers. 34. Bend down the lock tab and remove the bolt (3) that secures the reverse idler shaft to the transmission case. 35. Drive the shaft out forwards and lift out the reverse idler gear (2).

CUIL17TR00095AA

13

CUIL17TR00096AA

14

36. Position a step plate in the bore at the rear of the main shaft. 37. Drive the shaft forwards, using a suitable drift, from the transmission case and remove the 4th - 8th coupling gear. 38. Use a puller tool and a step plate to remove the front bearing of the main idler shaft. 39. Remove the snap ring (4) located behind the bearing and remove the thrust washer (2). 40. Move the main idler shaft (3) rearwards. Remove the gears (1), couplings, and thrust washer. Store components in order of removal to aid in reassembly. NOTE: The inner and outer sections of the sliding couplings are matched during manufacture and should not be separated.

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Transmission - Mechanical transmission

Mechanical transmission - Inspect Prior operation: Mechanical transmission - Disassemble (21.114). 1. Inspect the Power Take-Off (PTO) drive shaft and bearing assembly for damage or wear. Replace as required. 2. To remove the bearing, use a puller tool with a suitable attachment and a shaft protector. 3. To install the bearing, use a suitable length sleeve with a 37 mm (1.46 in) internal diameter and 44 mm (1.73 in) external diameter. 4. Inspect the output shaft retainer and rear bearing cup for damage or wear. Replace as required. 5. To remove the bearing cup from the retainer, use a suitable punch. 6. To install the bearing cup, use a step plate and the punch. 7. Inspect the output shaft assembly for damage or wear. Replace as required. 8. To remove the front pilot bearing (3), use a puller tool (1) with a suitable attachment (2) and a shaft protector (4).

CUIL17TR00097AA

1

CUIL17TR00098AA

2

9. To remove the rear bearing, gear, and thrust washer, use a puller tool with a suitable attachment and a shaft protector. 10. To install the rear bearing, align the flats of the thrust washer with the flats of the shaft and position the bearing on the output shaft. Then use a puller tool (1) with a suitable attachment (3), a shaft protector (5) and a sleeve (2) with a 40 mm (1.6 in) internal diameter and 50 mm (2.0 in) external diameter to pull the bearing (4) into position.

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Transmission - Mechanical transmission

11. Inspect the secondary idler shaft assembly for damage or wear. Replace as required. 12. To remove the rear bearing, use a puller tool with a suitable attachment and a step plate. 13. To remove the front bearing (2), place two steel rods (4) that are 4.6 mm (0.18 in) diameter and 51 mm (2 in) long into the holes in the driving gear. Then use the puller tool (1) with a suitable attachment (3) and a step plate (5) to push the bearing from the idler shaft. 14. To install the front and/or the rear bearing, use a puller tool with a suitable attachment and a step plate. CUIL17TR00099AA

3

CUIL17TR00100AA

4

CUIL17TR00101AA

5

15. Inspect the front and rear bearings in the main shaft assembly for damage or wear. Replace as required. 16. To remove the rear bearing (3) for the main shaft, use a puller tool (1) with a suitable attachment (2) and a step plate (4). 17. To remove the front bearing for the main shaft, place two steel rods that are 4.6 mm (0.18 in) diameter and 51 mm (2.01 in) long into the holes in the driving gear. Then use the puller tool with a suitable attachment and the step plate. 18. To install the rear bearing, use a puller tool with a suitable attachment and a step plate. 19. To install the front bearing, use a puller tool with a suitable attachment, a step plate and a suitable length sleeve with 64 mm (2.5 in) internal diameter and 76 mm (3.0 in) external diameter. NOTE: Whenever removing or installing the front bearing for the main shaft, ensure the anti-spin washer is in good condition before assembling. 20. Inspect the oil seal of the PTO drive shaft that is located within the main shaft for damage or wear. Replace as required. 21. To install the oil seal, lightly grease the sealing lip and place the oil seal so that the sealing lip faces rearward. Use a step plate a suitable sleeve to drive the seal into place. 22. Inspect the main idler shaft assembly for damage or wear. Replace as required. 23. To remove the rear bearing (4) from the idler shaft, use a puller tool (1) with legs (6) and a suitable attachment (3), a ratchet (2), and a shaft protector tool (5).

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Transmission - Mechanical transmission

24. Inspect the bearing cup for the output shaft that is located on the end of the main idler shaft for damage, corrosion, or wear. Replace as required. 25. To remove the bearing cup, use a suitable punch (1) inserted through the two holes (2) in the gear . 26. To install the bearing cup, use a puller tool and a step plate.

CUIL17TR00102AA

6

CUIL17TR00103AA

7

CUIL17TR00104AA

8

27. To install the rear bearing (2), use a puller tool (1) with a suitable attachment (3), a step plate (5) and a suitable length sleeve (4) with a 51 mm (2.01 in) internal diameter and 82 mm (3.23 in) external diameter. 28. Inspect all the gears that mount on the main idler shaft for damage or wear. With the gears on the idler shaft, check the bushings for free play. Inspect the reverse idler gear and bushing assembly. Replace as required.

29. Inspect the rear bearing cup for the main idler shaft for damage or wear. The rear bearing cup is situated in the transmission case. Replace as required. 30. To remove the rear bearing cup (1), use a slide hammer (2). 31. To install the rear bearing cup, use a suitable punch. 32. Inspect the front bearing for the main idler shaft for damage or wear. Replace as required. 33. Inspect all of the components with internal splines, external splines or gear teeth for damage or wear. Replace as needed during assembly. 34. Inspect the lubrication drillings for obstruction. 35. Inspect the gear shift forks, rails, arms and connectors for damage or wear. Inspect the detent on the shift rails and replace if worn. 36. Inspect the transmission case. Wash out the transmission case with a suitable solvent to remove all particles of metal and dirt. Dry with a clean, lint free cloth of compressed air. 37. Inspect the case for cracks or other damage. Replace as required. Next operation: Mechanical transmission - Assemble (21.114).

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Transmission - Mechanical transmission

Mechanical transmission - Assemble 1. Install the main counter shaft through the rear compartment and assemble in the following sequence: 2. 2nd – 6th gear (connecting teeth forwards) 3. Reverse/2nd – 6th gear sliding couplings and connector. 4. Bronze thrust washer. 5. Reverse speed gear (connection teeth rearward) 6. Phosphorous bronze washer. 7. 1st – 5th gear (connecting teeth forwards) 8. 3rd – 7th /1st – 5th gear sliding coupling and respective connector 9. 3rd – 7th gear (connecting teeth backwards) 10. Back-up Washer 11. Snap ring 12. Front bearing NOTE: The connectors have a bevel on one side of the inside diameter. This bevel must face the rear part of the transmission to allow the connector to seat correctly on the main idler shaft splines. The sliding coupling and connectors are matched during manufacture and should be installed with the etched marks aligned. 13. Support the main idler shaft during reassembly and ensure the rear bearing seats squarely in the bearing outer track. 14. Position the high/low sliding coupling on the rear of the main idler shaft. 15. Ensure the snap ring is positioned correctly. The snap ring retains the main shaft rear bearing in the transmission case. 16. Install the 4th - 8th coupling gear on the rear of the main shaft with the shift fork groove forwards. 17. Position the main shaft assembly in the transmission casing. 18. Drive the main shaft assembly rearwards to seat the rear bearing in the location within the casing. 19. Place the reserve idler gear (1) between the supporting lugs with the extended hub of the gear towards the front of the transmission. 20. Install the reverse idler shaft from the rear compartment with the retaining bolt hole forwards. Install the retaining bolt (2) and locktab. Tighten the retaining bolt to a torque of 23 N·m (17 lb ft). Bend up the locktab.

CUIL17TR00095AA

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1

Transmission - Mechanical transmission

21. Install the reverse/2nd – 6th (1) gear shift fork onto the appropriate sliding coupling on the main idler shaft. Install the fork retaining screw and the lock nut. Tighten the retaining screw to a torque of 31 N·m (23 lb ft). 22. Install the lower shift rail (2) from the rear compartment with the fork retaining hole to the rear of the shift rail. 23. Install the fork retaining screw and the lock nut. Torque the retaining bolt to 31 N·m (23 lb ft).. 24. Insert the two lock plungers into the bore from the right-hand side of the transmission case. Install the plug. Place each plunger between the three shift rail bores. 25. Place the shift fork (1) for coupling.

4th

–

8th

CUIL17TR00106AA

2

CUIL17TR00106AA

3

CUIL17TR00106AA

4

CUIL17TR00106AA

5

gear on the sliding

NOTE: When you install the remaining top shift rails, make sure that the rails already installed are in the neutral position so the lock plungers do not prevent the rail’s entry into the front support bore. 26. Install the shift rail (2) from the rear, with the oil relief groove rearwards, and pass through the bore in the shift fork. 27. Install the retaining screw and lock nut. Torque to 31 N·m (23 lb ft). 28. Place the lower end of the reverse/2nd – 6th gear shift arm (1) in the location hole on the reverse/2nd – 6th shift fork (4). 29. Slide the reverse/2nd – 6th (2) gear top shift rail in from the rear so that the oil relief groove faces backwards 30. With the shift rail correctly located in the shift arm, install the remaining screw and lock nut. Torque the bolt to 31 N·m (23 lb ft)

31. Fit the 1st – 5th /3rd – 7th gear shift fork (1) in the sliding coupling located at the front of the main counter shaft. Install the 1st – 5th/3rd – 7th gear shift rail (2) in the front of the transmission. 32. Insert the rail in the shift fork and secure with the retaining screw and lock nut. 33. Install the shift connector to the rear of the rail and secure with the retaining screw and lock nut. Tighten each retaining bolt to a torque of 31 N·m (23 lb ft) 34. Install the seal plug at the front end of the rail.

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Transmission - Mechanical transmission

35. Place the high/low shift fork (1) in the groove of the high/low sliding coupling located on the output shaft. 36. Install the high/low shift rail (2) in the shift fork. 37. Secure the shift fork with the retaining screw and lock nut. Torque the retaining bolt to 31 N·m (23 lb ft).. 38. Install the four shift rail detent balls, springs and plungers. Ensure the balls and plungers slide freely in the bores. 39. Ensure the snap ring located immediately in front of the secondary idler shaft front bearing is in position in the transmission casing bore. CUIL17TR00106AA

6

CUIL17TR00107AA

7

40. Hold the secondary idler shaft assembly in position at the top of the rear compartment while you install the output shaft assembly. Align the secondary idler shaft. Drive forward until the front bearing seats against the locating snap ring in the transmission case. 41. Place the rear support plate, without the output shaft retainer assembly, on the transmission rear face. Drive the plate into position on the dowels, then install the retaining bolts. Torque the bolts to 44 N·m (32 lb ft). 42. Install the Power Take-Off (PTO) drive shaft and rear bearing through the rear of the transmission. Use a soft-faced mallet to drive the shaft and bearing into position. Secure the rear bearing with a snap ring. 43. Install shims between the rear support plate and the bearing retainer of the output shaft to obtain the specified end-play in the taper roller bearings of the output shaft. NOTE: Shims are available in thicknesses of 0.076 mm (0.003 in), 0.127 mm (0.005 in) and 0.305 mm (0.012 in). 44. Install shims to obtain a thickness of 1.6 mm (0.06 in) and install the output shaft bearing retainer assembly on the rear support plate. 45. Install the four retaining bolts and tighten to a torque of 44 N·m (32 lb ft). 46. Place the plunger of a dial indicator gauge (3) against the end face of the output shaft (2). Lever the shaft in and out and note the end-play reading. If no end-play is registered, add additional shims to produce a gauge reading. 47. Remove the indicator gauge and the four retainer bolts. Withdraw the retainer (1) and shims. 48. Remove shims to obtain an end float between 0.038 mm (0.0015 in) and 0.086 mm (0.0034 in). 49. After obtaining the correct end-play, install the bearing retainer (with the oil slot to the top), shims, and bolts. Torque the bolts to 43 N·m (32 lb ft). Recheck endplay. 50. Install the hydraulic pump idler gear, thrust washer, and snap ring.

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Transmission - Mechanical transmission

51. Install the front support plate (1) and the retaining bolts (2) in the housing.

CUIL17TR00086AA

8

CUIL17TR00085AA

9

52. Install the main drive input shaft (2) and install the snap ring (1) that retains the main drive input shaft to the transmission main shaft.

53. Install the hub support and connect the low pressure lines from the clutch release bearing hub support (1) and the front support plate (2).

CUIL17TR00084AA

54. For machines with Dual Power transmissions, lift the Dual Power housing. Install the Dual Power housing in the transmission case. Ensure the anti-spin washer is located between the front gear and front bearing in the transmission main shaft. 55. Install the retaining bolts for the dual power housing.

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10

Transmission - Mechanical transmission

56. Place the clutch bearing (1) and hub in the support. 57. Place the clutch release fork in the transmission. 58. Install the clutch release shaft (4) in the casing. 59. Install the retaining bolt (3) on the clutch release fork (2). 60. Install the shift cover. Consult the procedures in Mechanical transmission external controls - Assemble - Shift levers and cover (21.130).

CUIL17TR00083AA

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11

Transmission - Mechanical transmission

Mechanical transmission - Pressure test In the following tests, make sure that the machine’s hydraulic oil is at operating temperature, the transmission and hydraulic system are in neutral, and the Power Take-Off (PTO) is switched off.

Dual Power system pressure test (testing the low pressure hydraulic circuit) 1. Remove the pressure switch (1) from the low pressure hydraulic circuit.

LAIL11TS0014A0A

1

CUIL16TR01252AA

2

CUIL16TR01253AA

3

2. Install a 30 bar capacity pressure gauge (1) in place of the low pressure circuit pressure switch (steering return). 3. (2) – Adapter FT8503-9. 4. (3) – Test tubes. 5. Set the engine speed to 2100 RPM and take a pressure reading. A reading of 18 – 25 bar should be registered.

Transmission lubrication pressure test 1. Start the machine. Set the engine speed to 1000 RPM. Stop the engine, but do not readjust the accelerator. 2. Connect a 30 bar capacity pressure gauge (1) on the oil radiator inlet lines. 3. Start the engine. Take a reading from the pressure gauge. Take the pressure reading quickly then switch off the tractor. The pressure recorded should be 5.0 – 8.0 bar, depending on the engine speed. The minimum operating pressure of the lubrication circuit safety valve, located in the Power Take-Off (PTO) valve and clutch assembly, is 5.0 – 8.0 bar.

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Transmission - Mechanical transmission

Mechanical transmission - Troubleshooting Problem Low pressure only in direct drive

Possible Cause Snap ring for the direct drive clutch is displaced. Gasket for the control valve body is damaged or leaks. Leaks at the sealing rings for the hub of the direct drive clutch or wear is present on the dual power housing. Leaks at interior or exterior seals of piston for the direct drive clutch. Piston or housing for direct drive clutch is broken or cracked. Low pressure only during Gasket for the control valve body is damreduction aged or leaks. Leaks at interior or exterior seals of piston for the reduction clutch . Piston for the reduction clutch is broken or cracked. Low pressure in direct Failure in the low pressure hydraulic circuit. drive and in reduction High pressure in direct Failure in the low pressure hydraulic circuit. drive and in reduction Rear wheels do not move Low pressure in the direct drive clutch circuit. when direct drive is connected (the reduction drive works) Direct drive clutch piston is damaged, scratched or bent. Control valve spool is stuck in reduction position. Direct drive clutch discs are worn out or defective. Pressure plate snap ring of the direct drive clutch is broken or outside its lodging place. Rear wheels do not Low pressure in the reduction clutch circuit. move when reduction is connected (the direct drive works) Reduction clutch piston is damaged, scratched or bent. Control valve spool is stuck in direct drive position. Reduction clutch discs are worn out or defective. Low pressure in the dual power system. Rear wheels do not move in direct drive or in reduction Defects in ring gear of planetary gear set, planetary gear carrier, sun gear, or main shaft splines. Issue in the shift box or differential box. Clutch issue. Engine jams or bounces The piston for the direct drive clutch is when switching from scratched, damaged or bent. direct drive to reduction The piston return springs of the direct drive clutch are broken or defective. Direct drive clutch discs are bent or defective.

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Correction Replace snap ring and any other damaged part. Replace gasket. Replace sealing rings and/or dual power housing. Replace seals. Replace piston or housing. Replace gasket. Replace seals. Replace piston. Troubleshoot the hydraulic system. Troubleshoot the hydraulic system. Troubleshoot low pressure in the direct drive clutch.

Replace piston. Check control valve spool. Replace clutch discs. Install snap ring correctly or replace the snap ring. Troubleshoot low pressure in the reduction clutch.

Replace piston. Check control valve spool. Replace clutch discs. Check the system pressure. Consult the procedures in Mechanical transmission Pressure test (21.114). Check components and replaces as needed. Check and repair as needed. Repair clutch. Replace piston. Replace the springs. Change clutch discs.

Transmission - Mechanical transmission

Problem Engine jams or bounces when switching from reduction to direct drive

Low pressure of lubrication High pressure of lubrication Noisy transmission box

Possible Cause Correction The piston for the reduction clutch is Replace piston. scratched, damaged or bent. The piston return springs of the reduction clutch are broken or defective. Reduction clutch discs are bent or defective. Spring of cooler/lubrication valve is broken or loose or the valve is stuck open. Oil cooler is plugged or covered. Spring of lubrication/cooler valve is stuck open. Low oil level Incorrect oil type

Replace the springs. Change clutch discs. Repair the cooler/lubrication valve. Replace oil cooler. Repair cooler/lubrication valve.

Correct as required Determine the type of oil, drain and top up as needed Worn bearings. Check the transmission lu- Incorrect output shaft longitudinal play. brication pressure. Consult the procedures Check and replace the bearings as needed, in Mechanical transmission - Pressure correct the play test (21.114). Lubricant leak in the lower Leak in the engine sump housing gasket Replace the retainer and gasket on the rear section and rear retainer section. Refer to Engine section Worn or damaged input shaft sealant, Inspect and replace retainers and gaskets power take off shaft sealant, front trans- as needed mission plate gasket; reverse gear idler gear bolt sealant leak Hydraulic bearing sealant leak (the tank re- Replace the bearing assembly retainers quires frequent topping up) Difficult or impossible to Incorrectly adjusted or worn gearshift se- Adjust the gearshift selector rods replacing engage gears lector rods worn parts as needed Damaged connections Inspect, repair or replace as needed Gear forks damaged or worn Inspect the worn or damaged forks and gearshift shafts for wear and warping. Replace if necessary Worn synchroniser assemblies Inspect the synchroniser assembly components. Replace if necessary Excessive output shaft longitudinal play — Inspect the adjustments and replace as necessary. Adjust the longitudinal play worn bearings Air in the hydraulic system, damaged clutch Clutch not working correctly cover Gears jumping out The shift did not fully engage Check the gear lever gearshift selector rod adjustment The gear cover detents are damaged Remove the gear covers and inspect the detent balls and springs Worn synchroniser Inspect the synchroniser assembly teeth. Excessive longitudinal play on the output Check the bearings and adjust the play to shaft (worn bearings) specification The gear will not Worn coupling sleeve or joint Inspect and replace as needed disengage Jammed gearshift selector rods. Adjust the gearshift selector rods and replace worn parts as needed Impossible to shift the Incorrect adjustment of the first clutch lock See the clutch lock assembly cable adjustinverter mechanism or inoperative assembly. ment. Inspect the cable and lever components

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Index Transmission - 21 Mechanical transmission - 114 Mechanical transmission - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Mechanical transmission - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Mechanical transmission - Dynamic description - 12x12 Mechanical transmission . . . . . . . . . . . . . .

10

Mechanical transmission - Dynamic description - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . .

8

Mechanical transmission - Exploded view - Shift lever position and circulation of forces - 8x2 mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Mechanical transmission - Functional diagram - 12x12 Mechanical transmission . . . . . . . . . . . . . . .

14

Mechanical transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Mechanical transmission - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Mechanical transmission - Overview - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . .

12

Mechanical transmission - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Mechanical transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Mechanical transmission - Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Mechanical transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Mechanical transmission - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Transmission housing - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

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Transmission - 21 Mechanical transmission external controls - 130

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Transmission - 21 Mechanical transmission external controls - 130

FUNCTIONAL DATA Mechanical transmission external controls Exploded view - Gearshift lever links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view - Cradle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Transmission housing cover Exploded view - Side cover of the gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exploded view - Top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Mechanical transmission external controls Disassemble - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Transmission housing cover Remove - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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CONSUMABLES INDEX Consumable Loctite® 515™

Reference Mechanical transmission external controls - Assemble - Shift levers and cover

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PAGE 21.2 / 10

Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Exploded view Gearshift lever links

CUIL17TR00201FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Inversion lever Locking ring Nylon Ring Pivot support shaft Bracket assembly Actuation arm Actuation tie rod Actuation arm bushings (4) Nylon Ring

1

Reference (10) (11) (12) (13) (14) (15) (16) (17)

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Component Stand off Top support bushing (4) Reducer lever Lock bolt Lever return spring Main gearshift lever Lock bolt Bottom support bushings (4)

Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Exploded view - Cradle assembly

CUIL17TR00202FA

Reference (1) (2) (3) (4) (5) (6) (7)

Component Nylon Ring External shaft (high and medium ranges) Nylon Ring Internal low range sleeve shaft Central inverter shaft Nylon Ring Bushing

1

Reference (8)

1st

Component and 2nd gear internal shaft

(9)

Nylon Ring

(10) (11) (12) (13) (14)

3rd and 4th gear external shaft Nylon Ring Lock bolt Nylon Ring Lock bolt

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Transmission - Mechanical transmission external controls

Transmission housing cover - Exploded view - Side cover of the gears

CUIL17TR00198FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component 3rd and 4th fork 1st and 2nd fork Fork fixing bolt Cover gasket Detent plug Detent spring Detent ball 1st and 2nd fork shaft Lock dowel

1

Reference (10) (11) (12) (13) (14) (15) (16) (17)

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Component 3rd and 4th fork shaft 3rd and 4th shaft and lever assembly 1st and 2nd shaft and lever assembly Cover sealants Cover body 3rd and 4th shaft lever 1st and 2nd shaft lever Lock bolt

Transmission - Mechanical transmission external controls

Transmission housing cover - Exploded view - Top cover assembly

CUIL17TR00188FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

Component Starter inhibitor switch wire harness Shift cover bolt Washer Cover Gasket Pin Spring Ball Spring Pin Plate retaining bolt Baffle plate

1

Reference (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)

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Component Washer Washer Range lever (high / low) Gear lever Starter inhibitor switch pin Dowel pin Lever fixing pins Retainer Lever spring Seal Brake Gear lever button.

Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Disassemble - Shift levers and cover CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Remove floorplate. 2. Place the shift levers in the neutral position. 3. Disconnect the negative (ground) battery cable. 4. Disconnect the connector for the neutral start switch from the wire harness. 5. Remove the retaining bolts for the shift cover and partially lift the cover from the transmission housing. 6. With the shift cover raised, disconnect the neutral start switch wires from the switch. 7. Remove the shift cover, with the shift lever fasteners, and the gasket from the transmission. 8. Remove the retaining screws for the oil cut-off plate and remove the plate. 9. Remove the washers between the oil cut-off plate and the shift levers. 10. Unscrew and remove the shift cap screws. 11. Carefully cut and remove the snap ring from the shift levers. For example, place the shift lever in a vice before removing the snap ring to prevent the snap ring from dangerously ejecting from the grooves on the shift levers. 12. Remove the retainers and springs from the shift levers. 13. Remove the shift levers. Next operation: Mechanical transmission external controls - Inspect - Shift levers and cover (21.130)..

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Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Inspect - Shift levers and cover WARNING Chemical hazard! Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0180A

CAUTION Eye injury hazard! Wear protective goggles when using compressed air. Failure to comply could result in minor or moderate injury. C0035A

Prior operation: Mechanical transmission external controls - Disassemble - Shift levers and cover (21.130).. 1. Wash the shift levers and cover assemblies in a suitable solvent. Dry with a clean, lint free rag or use compressed air. 2. Inspect the shift cover for cracks or other damage. Replace as required. 3. Inspect the shift lever retainers for damage or wear. Replace as required. 4. Inspect the oil cut-off plate for damage or wear. Replace as required. 5. Inspect the shift levers for damage or wear, including the grooves for the snap rings. Replace as required. 6. Inspect the springs for cracks or distortion. Replace as required. 7. Inspect the shift cap screws for damage or wear. Replace as required. 8. Inspect the wiring harness for the neutral start switch for damage or wear. Replace as required. Next operation: Mechanical transmission external controls - Assemble - Shift levers and cover (21.130)..

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Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Assemble - Shift levers and cover Prior operation: Mechanical transmission external controls - Inspect - Shift levers and cover (21.130). 1. Apply a 2 mm bead of LOCTITE® 515™ to the transmission mating surface of the transmission shift lever cover. 2. Install the shift cover, with the shift lever retainers. 3. Reconnect the neutral start witch wires to the switch. Ensure the neutral start actuator housing aligns with the locating pin in the shift cover. 4. Secure the shift cover with the retaining bolts. Tighten the retaining bolts to a torque of 56 N·m (41 lb ft). 5. Install the oil cut-off plate and secure with the retaining screws. 6. Install the washers on the oil cut-off plate and place the shift levers in the washer. 7. Route the shift levers through the shift lever fasteners on the cover plate. 8. Install the retainers and springs on the shift levers. 9. Install new snap rings on the shift levers. 10. Screw on the shift cap screws. 11. Ensure the shift levers are in the neutral position. 12. Reconnect the negative (ground) battery cable. 13. Install the floor plate.

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Transmission - Mechanical transmission external controls

Transmission housing cover - Remove - 8x2 Mechanical transmission 1. Put the shift levers into neutral. 2. Disconnect the negative battery cable. 3. Disconnect the starter motor inhibitor switch wire from the harness connection. 4. Remove the bolts (1) from the shift lever cover.

CUIL17TR00118AA

1

CUIL17TR00119AA

2

5. Partially lift the transmission box cover (1). 6. Disconnect the wires of the switch for the gear shift lever. Remove the transmission shift assembly.

Next operation: Transmission housing cover - Disassemble - 8x2 Mechanical transmission (21.130).

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Transmission - Mechanical transmission external controls

Transmission housing cover - Disassemble - 8x2 Mechanical transmission Prior operation: Transmission housing cover - Remove - 8x2 Mechanical transmission (21.130).. 1. Remove the oil deflector plate retaining bolts on the lower side of the shift cover and remove the plate and the washers. 2. Remove the lever retaining brakes. If possible, place the gear shift lever on a vise as close as possible to the brake. After, with a punch, split the brakes lastly. During this operation make sure the retaining segments are not hazardously ejected from the lever grooves. Carefully disengage the vise and remove the springs, ball retainers and levers. NOTE: There is no need to remove the lever retaining pins from the cover set due to the levers being grooved. Next operation: Transmission housing cover - Inspect - 8x2 Mechanical transmission (21.130)..

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Transmission - Mechanical transmission external controls

Transmission housing cover - Inspect - 8x2 Mechanical transmission Prior operation: Transmission housing cover - Disassemble - 8x2 Mechanical transmission (21.130).. 1. Wash out the gear cover and gear lever assemblies with a good solvent and dry with either a lint-free cloth or with compressed air. 2. Inspect the gear cover for fractures or other damages, replace the cover when necessary. 3. Inspect the ball seats on the gear lever and the ends for wear and the cover lever fixing pins. Replace worn or damaged pins. The new pins must be placed on the cover with pressure. 4. Inspect the starter switch wire harness for damage. Replace the harness when necessary.

Transmission box Wash the transmission box with an appropriate solvent to remove all the metal particles and impurities. Dry with a clean, lint free cloth of compressed air. Check the box for fractures or other damage, and if it is beyond repair assemble the transmission components in a new box. Next operation: Transmission housing cover - Assemble - 8x2 Mechanical transmission (21.130)..

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Transmission - Mechanical transmission external controls

Transmission housing cover - Assemble - 8x2 Mechanical transmission Prior operation: Transmission housing cover - Inspect - 8x2 Mechanical transmission (21.130).. 1. Lubricate the ball seats with good quality grease and pass the gear shift levers through the cover. 2. Fit the ball retainers and springs, compress the springs and fit the new holding brake. 3. Refit the two baffle washers on the lower side of the gearbox cover, the oil baffle plate and the holding bolts. Next operation: Transmission housing cover - Install - 8x2 Mechanical transmission (21.130)..

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Transmission - Mechanical transmission external controls

Transmission housing cover - Install - 8x2 Mechanical transmission Prior operation: Transmission housing cover - Assemble - 8x2 Mechanical transmission (21.130). 1. Fit the new seal on the gearbox cover and hold it in place with grease to facilitate assembly. 2. Install the cover by following the removal procedure in reverse. Make sure that the immobilizer actuator housing is aligned with the localization pin on the gearbox cover. 3. Torque the cover retaining bolts to 5.6 kgf (12.35 lbf).

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Transmission - Mechanical transmission external controls

Transmission housing cover - Remove - 12x12 Mechanical transmission 1. Remove the tube from the side cover to disconnect the Auxiliary Front Wheel Drive (AFWD) (1). 2. Place all transmission levers in the neutral position.

CUIL17TR00077AA

1

CUIL17TR00121AA

2

CUIL17TR00122AA

3

CUIL17TR00123AA

4

3. Remove the neutral start switch (1) to gain access to one of the top cover bolts. Remove the remaining eight bolts from the top cover. 4. Remove the top cover.

5. Remove the lock ring that holds the Power Take-Off (PTO) axle bearing. Pull out the shaft (1) together with the bearing.

6. Remove the mounting bolts from the rear cover. 7. Remove the rear cover. 8. Remove the four bolts (2) that secure the retainer (3) to the output shaft. 9. Remove the retainer and the respective shims.

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Transmission - Mechanical transmission external controls

Transmission housing cover - Assemble - 12x12 Mechanical transmission Prior operation: Transmission housing cover - Remove - 12x12 Mechanical transmission (21.130). 1. Lubricate the ball seats with good quality grease and pass the gear shift levers through the cover. 2. Fit the ball retainers and springs, compress the springs and fit the new holding brake. 3. Refit the two baffle washers on the lower side of the gearbox cover, the oil baffle plate, and the mounting bolts. Next operation: Transmission housing cover - Install - 12x12 Mechanical transmission (21.130).

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Transmission - Mechanical transmission external controls

Transmission housing cover - Install - 12x12 Mechanical transmission Prior operation: Transmission housing cover - Assemble - 12x12 Mechanical transmission (21.130). 1. Fit the new seal on the gearbox cover and hold it in place with grease to facilitate assembly. 2. Reassemble the cover by following the assembly procedure in reverse. Make sure that the immobilizer actuator housing is aligned with the localization pin on the gearbox cover. 3. Torque the cover retaining bolts to 5.6 kgf (12.35 lbf).

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Index Transmission - 21 Mechanical transmission external controls - 130 Mechanical transmission external controls - Assemble - Shift levers and cover . . . . . . . . . . . . . . . . .

10

Mechanical transmission external controls - Disassemble - Shift levers and cover . . . . . . . . . . . . . .

8

Mechanical transmission external controls - Exploded view - Cradle assembly . . . . . . . . . . . . . . . . .

5

Mechanical transmission external controls - Exploded view - Gearshift lever links . . . . . . . . . . . . . . .

4

Mechanical transmission external controls - Inspect - Shift levers and cover . . . . . . . . . . . . . . . . . . .

9

Transmission housing cover - Assemble - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . .

17

Transmission housing cover - Assemble - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . .

14

Transmission housing cover - Disassemble - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . .

12

Transmission housing cover - Exploded view - Side cover of the gears . . . . . . . . . . . . . . . . . . . . . . . .

6

Transmission housing cover - Exploded view - Top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Transmission housing cover - Inspect - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . .

13

Transmission housing cover - Install - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . .

18

Transmission housing cover - Install - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Transmission housing cover - Remove - 12x12 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . .

16

Transmission housing cover - Remove - 8x2 Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . .

11

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Transmission - 21 Mechanical transmission internal components - 140

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Transmission - 21 Mechanical transmission internal components - 140

FUNCTIONAL DATA Transmission shaft Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Transmission internal parts Exploded view - Synchronizer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description - Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Transmission shaft Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Backlash - Longitudinal of the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . 16 Inspect - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . 19 Install - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Transmission - Mechanical transmission internal components

Transmission shaft - Exploded view – Auxiliary Front Wheel Drive (AFWD)

CUIL17TR00203FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component Oil transfer tube Pilot valve assembly Output shaft Connecting spring assembly Spring guard Front bearing Locking ring Sealant Front Cover Internal sealant External sealant

1

Reference (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

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Component Square section sealant Square section sealant with teeth Clutch half Needle bearing Spacer Needle bearing Clutch half Spacer Rear bearing Locking ring

Transmission - Mechanical transmission internal components

Transmission internal parts - Exploded view - Synchronizer assembly

CUIL17TR00204FA

Reference (1) (2) (3) (4) (5)

Component Clutch body Synchroniser brake Coupling sleeve Synchroniser body Clutch body

1

Reference (6) (7) (8) (9)

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Component Synchroniser brake Spring Guide Data

Transmission - Mechanical transmission internal components

Transmission internal parts - Dynamic description - Synchronizers In the neutral position the data are pushed against the “V” shaped recesses in the coupling sleeve. The gears can turn freely on the shaft. When the coupling sleeve moves from neutral to the gear to be selected the synchroniser brake is forced against the gear body. Any speed difference in the parts to be coupled causes the synchroniser brakes to rotate. This rotation is limited by backstops and forces the synchroniser brake chamfered teeth against the coupling sleeve, preventing sleeve movement. The increase in pressure makes the synchroniser and clutch body eventually rotate at the same speed, synchronised with the shaft and gear speeds. After synchronisation, there is no friction between the clutch body and the synchroniser brake. The power on the chamfered teeth of those components is reduced, allowing the coupling sleeve to go past the synchroniser brake and link up to the gear teeth.

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Transmission - Mechanical transmission internal components

Transmission shaft - Disassemble Prior operation: Mechanical transmission - Disassemble (21.114).. 1. On the front of the transmission, remove the two hydraulic system pipes from the clutch bearing. 2. Remove the bearing hydraulic assembly (2). 3. Remove the front plate assembly (1). To make it easier to disassemble, use an appropriate punch through the top cover opening up to the front cover rear face. Gradually tap the cover near the guide pins until the cover comes loose. NOTE: The reverse idler gear, front cover oil pipe and transmission input shaft are also removed in this operation. CUIL17TR00130AA

1

CUIL17TR00131AA

2

CUIL17TR00132AA

3

CUIL17TR00133AA

4

4. Remove the lock ring from the secondary shaft (top). Move the reverse gear assembly slightly forwards and slide the inverter synchronizer assembly.

5. Slide out the reverse gear.

6. Remove the reverse gear group assembly.

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Transmission - Mechanical transmission internal components

7. Remove the oil distributor. NOTE: Take due care not to damage the guide pins that hold the distributor in position and ensure efficient lubrication of the assembly.

CUIL17TR00134AA

5

CUIL17TR00135AA

6

8. Remove the lock ring (1) from the secondary shaft front bearing.

Next operation: Transmission shaft - Assemble (21.140)..

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble 1. Use a press to install the front bearing (4) and the shim (3) on the upper range gear group (2).

CUIL17TR00142AA

1

CUIL17TR00143AA

2

LAIL11TS0266A0A

3

CUIL17TR00144AA

4

2. Use a hydraulic press to install the bearing (1) on the main shaft assembly (2).

3. Fit the lock ring (6) onto the Auxiliary Front Wheel Drive (AFWD) shaft. 4. Install the rear bearing (9) and the lock ring (7). 5. Install the front bearing (3) in the transmission housing.

6. Install the lock ring (5) on the Power Take-Off (PTO) drive shaft (2). 7. Press on the bearing (4). Secure into position with the lock ring (3). 8. Slide the sealant up to the shaft thrust face.

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Transmission - Mechanical transmission internal components

9. Install the lubrication tube (4) in the reverse gear group (2). NOTE: It is very important that this stud is installed correctly as it allows for the flow of oil to lubricate the front bearing. 10. Use a press and appropriate adaptors to install the bearings (1) and (3) with interference.

CUIL17TR00145AA

5

CUIL17TR00146AA

6

CUIL17TR00147AA

7

LAIL11TS0670A0A

8

11. Assemble the gear (8) and thrust rings on the shaft and fasten with the lock rings (7) and (10). 12. Fasten the gear and the reverse idler shaft assembly onto the front cover with the bolt and washer and a new “O” seal.

13. Install the low range coupling sleeve (5) on the output shaft. 14. Install the low range gear (4) 15. Install the thrust ring (3). 16. Install the spacer (2). 17. Install the bearing (1) and the cup. 18. Check that the coupling sleeve and the gear slide freely.

19. Install the tapered bearing (7) and its cup. 20. Install the bearing (6) on the main idler shaft with a press or an appropriate beater. 21. Install the bearing cup (5).

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Transmission - Mechanical transmission internal components

22. Install the bearing (1) on the input shaft (2). 23. Install the retainer (3) on the rear of the shaft. Lubricate the surfaces before assembly.

CUIL17TR00148AA

Next operation: Transmission shaft - Install (21.140).

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9

Transmission - Mechanical transmission internal components

Transmission shaft - Install Prior operation: Transmission shaft - Assemble (21.140).

Components of the range gear group 1. Make sure that the ring (1) has been fitted on the range assembly. 2. Install the assembly. Secure the shaft needle bearing and engage the 3rd and 4th splines. 3. Assemble the medium gear with the high and medium range synchroniser. 4. Insert the gear and synchroniser assembly through the rear side opening and connect with the idler shaft splines.

CUIL17TR00149AA

1

CUIL17TR00150AA

2

NOTE: You may need to push the Auxiliary Front Wheel Drive (AFWD) gear slightly backwards and remove the external lock ring from the bearing. Make sure that the lock ring is fitted in its place before you install the output shaft. 5. Install the output shaft assembly (2). Connect the assembly to the previously installed assembly (1). 6. Install the rear bearing to the range gear group. Heat up the bearing to a maximum temperature of 125 °C. Push until the bearing is in contact with the lip of the gear. 7. Assemble the rear cover assembly on the transmission housing. 8. Temporarily install the retainer over the output shaft on the rear cover in order to keep the output shaft in position.

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Transmission - Mechanical transmission internal components

Front components 9. Fully install the oil distributor assembly on the secondary shaft, in the housing opening. 10. Align the guide pins with the transmission holes. Check and make sure the lubricating hole is aligned. 11. Install the inverter gear group assembly. NOTE: Do not fully install. 12. Slide the reverse gear and the inversion synchroniser assembly onto the secondary shaft. 13. Once the synchroniser is in contact with the shaft splines, move the synchroniser and the reverse gears group into place.

CUIL17TR00134AA

3

CUIL17TR00152AA

4

CUIL17TR00139AA

5

NOTE: If needed, shift the synchroniser into the forward gear position to allow for assembly. After correctly assembling, put into neutral. 14. Fasten the components with the lock rings. 15. Apply appropriate chemical bond (sealant) between the front cover and the gasket and between the gasket and the transmission casing. Ensure a perfect seal. 16. Install the input shaft assembly and the reverse idler gear in the front cover. Fasten the idler shaft with the retaining bolt and install a new “O” seal. NOTE: Install the cover on the transmission. Make sure that the oil pipe from the front cover to the transmission housing is correctly positioned. Fasten the cover with the fastening bolts. 17. Assemble the clutch hydraulic actuator assembly and fasten with three bolts. 18. Install the hydraulic pipes.

Auxiliary Front Wheel Drive (AFWD) Output Shaft 19. Place the AFWD transfer assembly oil feed pipe in the transmission housing, complete with the sealant. 20. The pipe is installed with interference in the housing. Install carefully using an appropriate punch. 21. Place the AFWD clutch quick action valve with the ball side facing backwards. 22. Use an appropriate punch to firmly tap the rear part of the valve against the oil chamber in the AFWD shaft to ensure a perfect oil seal during operation. Secure the valve. 23. Align the AFWD output assembly gear with the drive gear in the transmission housing and install.

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Transmission - Mechanical transmission internal components

24. Install the AFWD cover. Fasten with the lock ring. A reinforced pair of pliers is recommended.

CUIL17TR00138AA

6

CUIL17TR00153AA

7

Power Take-Off (PTO) shaft 25. Lubricate and slide the Power Take-Off shaft assembly sealant up to the shaft lip. 26. Install the Power Take-Off shaft on the transmission. Fasten with the lock ring.

Next operation: Transmission shaft - Backlash - Longitudinal of the output shaft (21.140).

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Transmission - Mechanical transmission internal components

Transmission shaft - Backlash - Longitudinal of the output shaft Prior operation: Transmission shaft - Install (21.140). The transmission output shaft longitudinal play should be between 0.0254 mm and 0.0762 mm. Perform the procedure below to check the play: 1. Remove the retainer assembly fastened into place with two bolts. 2. Install the shims (1) of known dimensions. Refit the retainer. Tighten the retainer to the specified torque. 3. Rotate the transmission several turns to position the assembly in place.

CUIL17TR00154AA

1

CUIL17TR00155AA

2

4. Install a dial indicator (2) perpendicular to the end of the output shaft. 5. Use a lever (1) to measure the transmission play. To do so, move the transmission components back and forth. 6. The difference between the measured play and the specification is the thickness of the shims required to correctly adjust the transmission longitudinal play. NOTE: Increasing shim thickness increases longitudinal play. Reducing the shims reduces play. 7. Install the output shaft bearing retainer making sure the oil slit is facing upwards (TOP). 8. Check if the input shaft, the Power Take-Off (PTO) shaft, the output shaft, and the Auxiliary Front Wheel Drive (FWD) shaft turn freely. 9. Check for play between the gears and on the synchronisers. 10. Check if all synchronisers are in neutral. 11. Install a new gasket on the top cover and assemble it with the forks in neutral on the transmission assembly. Secure with the eight bolts. Assemble the neutral start switch after tightening the cover. 12. Put the forks in neutral. Fit the (forward) gear cover. Fasten the cover with the ten bolts. Always use a new gasket. 13. Place the range assembly cover (rear) following the same procedure used for the gearshift cover. Apply the specified torque to the eight fixing bolts. 14. Install the AFWD pipe assembly onto the gearshift cover.

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Transmission - Mechanical transmission internal components

Transmission shaft - Remove - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) 1. Remove the lock ring of the Auxiliary Front Wheel Drive (AFWD) outlet assembly.

CUIL17TR00138AA

1

CUIL17TR00139AA

2

CUIL17TR00140AA

3

2. To make removal easier, use an appropriate lever. Support the lever on the points indicated on the cover. Remove the assembly.

3. Remove the lock ring from the front end of the shaft that holds the front gear assembly (3) 4. Remove the external lock ring that holds the rear bearing (2). 5. Remove the lock ring from the recess on the front part of the rear gear (1). Leave the lock ring hanging on the shaft. NOTE: Remove the shaft and the rear bearing as an assembly through the rear of the transmission. 6. To remove the front bearing from the AFWD output shaft, remove the four bolts that attach the shaft bearing support assembly to the housing transmission. Remove both lock rings from the bearing and push it out.

Next operation: Transmission shaft - Disassemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140)..

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Transmission - Mechanical transmission internal components

Transmission shaft - Disassemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) Prior operation: Transmission shaft - Remove - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140). 1. Carefully remove the dust guard cover from the Auxiliary Front Wheel Drive (AFWD) output shaft bearing. 2. Remove the lock ring from the front bearing (7). Use a universal extractor and an appropriate shaft protector (4) to extract the front bearing (3).

CUIL17TR00125AA

1

CUIL17TR00126AA

2

CUIL17TR00127AA

3

3. Raise the spring box assembly (4) and the spring assembly (5) to connect the AFWD. Slide the front half of the clutch (3) out of the shaft (1) and the rear half of the clutch (2).

4. Remove the lock ring from the rear bearing. For removal, use a universal extractor and an appropriate shaft protector (4). Then extract the rear bearing (3). 5. Remove the rear half/gear of the clutch. Take out both bearings with the two spacer rings of the AFWD output shaft.

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Transmission - Mechanical transmission internal components

6. The oil transfer tube supplies oil under pressure to disconnect the AFWD clutch. This transfer tube is installed with interference in the transmission housing. It must be removed and the lock washer must be replaced. 7. Remove the tube (3). To remove the tube, tighten the M10 x 1.5 bolt in the center of the tube. Then use a conventional sliding hammer and an appropriate adaptor to remove the tube.

CUIL17TR00128AA

Next operation: Transmission shaft - Inspect - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140).

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4

Transmission - Mechanical transmission internal components

Transmission shaft - Inspect - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) Prior operation: Transmission shaft - Disassemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140). 1. Inspect all the lock rings and the respective recesses for deformation and damage. 2. Inspect the internal drive shaft gear, the shaft front gear and the clutch half gear and examine the teeth for wear or cuts. 3. Carefully inspect all the bearings for wear or other damage. 4. Install new internal and external sealants on the output shaft. 5. Carefully remove the output shaft sealant from the cover. Install a new sealant with an appropriate sealant installer or an adaptor. Replace the "O" seal. 6. Inspect the clutch spring assembly for split spirals or deformation. See the height of springs with a load of 1540.0 – 1720.0 N (346.2 – 386.7 lb) applied on the spring. Compare with a new part. The specification for deformation with the load applied is 18.8 mm (0.7 in). If in doubt, replace the spring assembly. 7. Inspect the clutch front half internal surfaces for damage, making sure the sealing area is not scratched. 8. Examine the clutch engagement teeth for damage and wear. 9. Inspect the splined areas on the clutch front half, the output shaft and the internal shaft for damage and scratches.

CUIL17TR00129AA

Next operation: Transmission shaft - Assemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140)..

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1

Transmission - Mechanical transmission internal components

Transmission shaft - Assemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) Prior operation: Transmission shaft - Inspect - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140) 1. Follow the disassembly process in reverse order to reinstall the output transfer assembly of the Auxiliary Front Wheel Drive (AFWD). 2. Apply transmission oil to the shaft sealants before proceeding with assembly and allow time for them to expand before assembling the sliding clutch half. 3. Use an appropriate press and a sleeve to install the front and rear bearings, making sure while installing the front one that the sliding clutch half, the spring assembly and its protection plate are not out of alignment, which may damage the sealants. 4. Make sure that the two washers are placed on both sides of the driven half of the clutch. 5. For the clutch teeth to work correctly, it is essential that the pilot valve assembly is fitted so that the ball faces backwards. Next operation: Transmission shaft - Install - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140).

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Transmission - Mechanical transmission internal components

Transmission shaft - Install - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) Prior operation: Transmission shaft - Assemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) (21.140). 1. Install the front shaft bearing on the support assembly and fasten with the lock rings on both sides. 2. Install the support on the transmission housing and fasten with the four bolts. 3. Make sure the lock ring behind the rear bearing is fitted on the transmission housing. 4. Place the Auxiliary Front Wheel Drive (AFWD) gear between the shaft support assembly and the housing. 5. Make sure the rear lock ring is fitted to the shaft. Position and fasten the rear bearing on the shaft. Pass the shaft and the bearing through the rear of the housing, securing it onto the rear gear and its front lock ring, front bearing and front gear. Install the front gear lock ring. NOTE: Take care not to damage the front bearing rollers when installing the shaft. 6. Fasten the rear bearing with the external lock ring (on the housing).

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Index Transmission - 21 Mechanical transmission internal components - 140 Transmission internal parts - Dynamic description - Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Transmission internal parts - Exploded view - Synchronizer assembly . . . . . . . . . . . . . . . . . . . . . . . . .

4

Transmission shaft - Assemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) .

19

Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Transmission shaft - Backlash - Longitudinal of the output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Transmission shaft - Disassemble - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD)

16

Transmission shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Transmission shaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Transmission shaft - Inspect - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . . .

18

Transmission shaft - Install - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . . . . .

20

Transmission shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Transmission shaft - Remove - Transmission shaft for the Auxiliary Front Wheel Drive (AFWD) . .

15

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Transmission - 21 Creeper - 160

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Transmission - 21 Creeper - 160

TECHNICAL DATA Creeper General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Creeper Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Creeper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Transmission - Creeper

Creeper - General specification 7630

Reduction ratio Set of output shafts with reduction gears Preload of output axle with reduction gears (pull necessary to turn the output shaft with a cord wound around the output shaft) Available shims

8030 10.0:1 0.038 – 0.086 mm (0.001 – 0.003 in) 1.0 – 1.8 N (0.2 – 0.4 lb) 0.10 mm (0.0039 in), 0.15 mm (0.0059 in), 0.50 mm (0.0197 in)

Creeper - Torque Torque 47 N·m (35 lb ft) 31 N·m (23 lb ft)

Component Fastening screws of rear support plate Output shaft retainer bolts

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Transmission - Creeper

Creeper - Dynamic description The reduction gear box is optional in the non-synchronized 8x2 transmission with or without dual power. The reduction gear box allows an extra reduction in the ratio under the low standard range. The reduction is obtained through a set of planet gears located in the transmission output axle. Once installed, the reduction gear box allows an additional range of super shorts in four forward and three reverse speeds. This increases the total number of speeds available to 12 forward and three reverse speeds. In transmissions with Dual Power, another eight forward and two reverse speeds are obtained, which increases the total number of speeds available to 24 forward and six reverse speeds. There are alternative gears for reduction, either 5.7:1 or 10.0:1. Basically, all reduction gear boxes have a set of planet gears mounted in place of the transmission output axle of a normal box. The set of planet gears is made up of the following: • One external ring gear related to the shift box. • Planetary gears mounted on the carrier. The teeth on the rear part engage with the external ring gear. • The carrier, which has teeth on the outside diameter, takes the place of the output axle. • The intermediate ring gears engage the teeth on the front part of the planetary gears. • The coupling, which is grooved to and drives the output axle, can connect with the carrier or intermediate gear ring. • The coupling is moved by means of a selector fork in the neutral position. The coupling does not engage any sets of reduction gears. This way, the coupling and the output shaft cannot be driven. The low transmission range is selected by sliding the gear fork rod backward to the detent position adjacent for neutral. The rod movement through the fork makes the coupling engage the reduction gear set conveyor. Now the energy from the secondary counter shaft is transmitted through the conveyor and the coupling to the output shaft. The conveyor has the same number of teeth in the external diameter as the output shaft used in the normal transmission, therefore, the ground speeds obtained in the low range are identical to those of the normal transmission. The reduced range is selected by sliding the gear shift rod and the fork further back to the final detent position. The coupling is moved by the fork inside the conveyor set to engage the idler ring gear. Now the energy is transmitted from the secondary counter shaft to the coupling through the planetary gear set. The planetary gear set was created for the conveyor to be driven and to make the planetary gears turn with the rear teeth engaged in the stopped ring gear. The front teeth of the planetary gears engage and drive the idler ring gear at reduced speed. Therefore, the coupling now engages the idler ring gear and drives the output shaft at a reduced speed to obtain the required reduced range.

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Transmission - Creeper

Creeper - Exploded view

CUIL17TR00206FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Component Roller bearings Back-up Washer Needle bearings Spacer Cone bearings Output axle retainer Roller Socket head bolt Shims Outer ring gear

1

Reference (11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

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Component Support Plate Intermediate ring gear Planetary gears Stand off Coupling Output shaft Bearing Back-up Washer Selector yoke Shift rail

Transmission - Creeper

Creeper - Remove 1. Separate the rear axle from the transmission. 2. Remove the gear shift cover. Consult the procedures in Transmission housing cover - Remove - 8x2 Mechanical transmission (21.130). 3. Remove the snap ring, the thrust washer and that hydraulic pump idler gear located on the output shaft retainer (2). 4. Remove the retaining bolts (3) for the rear support plate (1) and lever the support plate away from the transmission. CUIL17TR00157AA

1

CUIL17TR00158AA

2

CUIL17TR00159AA

3

5. Remove the rear support plate (2) and Power Take-Off (PTO) shaft (1) as an assembly.

6. Extract the secondary idler shaft assembly (1) sufficiently to free the bearing from its housing. 7. Lift up on the secondary idler shaft. Remove the output shaft and reduction gear set assembly (2). 8. Remove the secondary idler shaft. 9. Remove the high/low/creep coupling from the rear of the transmission, or the output shaft, as needed.

Next operation: Creeper - Disassemble (21.160).

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Transmission - Creeper

Creeper - Disassemble Prior operation: Creeper - Remove (21.160). 1. Remove the output shaft retainer (1) from the rear support plate (2). 2. Remove the outer ring gear (3) from the rear support plate.

CUIL17TR00160AA

1

CUIL17TR00161AA

2

CUIL17TR00162AA

3

3. Remove the output shaft (2) from the reduction gear set assembly (1). Use a hammer to drive the output shaft forwards out of the assembly, if needed. Ensure the intermediate ring gear (3) remains inside the reduction gear set. NOTE: Removing the output shaft pushes the bearing off the rear of the output shaft.

4. Remove the thrust washer (3) and the needle roller bearing from the output shaft (or from the intermediate ring (4), if the components remained inside the gear set assembly). 5. Place the planetary gear set on the workbench with the intermediate ring gear upward. Remove the intermediate ring gear. 6. Remove the thrust washer, needle roller bearing, spacer and the second needle roller bearing from the carrier (1). 7. Remove the planetary gears (2) from the carrier. Take care to retain the bearing rollers. Next operation: Creeper - Inspect (21.160).

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Transmission - Creeper

Creeper - Inspect Prior operation: Creeper - Disassemble (21.160). 1. Inspect the output shaft retainer and rear bearing cup for damage or wear. Replace as required. 2. To remove the bearing cup from the retainer, use a puller tool and a hammer. 3. To install the bearing cup, use a plate. 4. Inspect the support plate for damage or wear. Replace as required. 5. Inspect the output shaft and pilot bearing for damage or wear. Replace as required. 6. Inspect the secondary idler shaft and the Power TakeOff (PTO) drive shaft bearings located in the rear support plate. Replace any unserviceable bearing with a suitable step plate. 7. Inspect all needle roller bearings and thrust washers. Replace any unserviceable items. 8. Inspect the planetary gear set carrier, ring gears and planetary gears for damage or wear. Replace as needed during assembly. NOTE: If several components are damaged or worn, replace the complete reduction gear set assembly. 9. Inspect the coupling and gear shift mechanism. Replace any unserviceable components. Next operation: Creeper - Assemble (21.160).

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Transmission - Creeper

Creeper - Assemble Prior operation: Creeper - Inspect (21.160). 1. Install the planetary gears (1) and rollers (4) in the carrier (2). 2. Rest the carrier inside the outer ring gear (3), which acts as an assembly gauge.

CUIL17TR00163AA

1

CUIL17TR00164AA

2

CUIL17TR00166AA

3

CUIL17TR00166AA

4

3. Turn each gear until the master tooth (marked with a pick stroke) points to the center of the support. If the master tooth is not marked, take these actions to identify the master tooth:

4. 5.7:1 reduction – Use a rod (1) between the gears to establish which pair of rear gear teeth align with a pair on the front gear. Looking from the front, there are four pairs of aligned gears. Identify the right teeth of any aligned pair in the 12-tooth gears (2) as the master tooth (3).

5. 10:1 reduction – Use a rod (1) between the gears to establish which pair of rear gear teeth align with a pair on the front gear. Looking from the front, there is only one pair of gears aligned. Identify the tooth opposite the pair that is aligned in the 13-teeth gear (2) as the master tooth (3).

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Transmission - Creeper

6. Place the thrust washer (2) with the smaller diameter, beveled side up, on the support hub. Mount the intermediate ring gear (1) on the support to engage with the planetary gears. 7. Place the coupling, with the slot in front, in the output axle.

CUIL17TR00162AA

5

CUIL17TR00168AA

6

CUIL17TR00165AA

7

8. Place the washer (1) with the bigger diameter on the output axle (2), beveled side facing the coupling (3). 9. Lubricate the needle bearings with high quality grease and install the narrow needle bearings on the intermediate ring gear. Install the wider needle bearings, with a spacer in between, on the support. 10. Keep the previously mounted output axle in a vertical position and place the support on the output axle. NOTE: Once the support has been correctly mounted, the output axle must project over the side of the support.

11. Tighten the rear bearings of the output shaft against the back of the output shaft shoulder (1). 12. Use feeler gauges (2) to check the separation between the bearings (3) and the cradle. The separation must be 0.03 – 0.08 mm (0.0012 – 0.0031 in).

Next operation: Creeper - Install (21.160).

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Transmission - Creeper

Creeper - Install Prior operation: Creeper - Assemble (21.160). 1. Install the mounted support and output axle in the transmission. Make sure that the coupling engages in the selector yoke. 2. Take out the external ring gear from the set of reduction gears. 3. Install the rear plate in the transmission. 4. Secure the rear plate with the screws. Torque the bolts to 47 N·m (35 lb ft). 5. Place the external ring gear on the rear plate. 6. Mount the shims. Use the Allen screws to secure the retainer of the output axle to the support plate and ensure the ring gear is also secured. Tighten the Allen screws to a torque of 31 N·m (23 lb ft). 7. Use a dynamometer and a cord wound around the output shaft to measure the preload, with the transmission in neutral. The dynamometer must record between 1.0 – 1.8 N (0.22 – 0.40 lb). If the result is not within specification, add or remove shims between the output axle retainer to achieve the correct preload. 8. Use a dynamometer and a cord wound around the output axle, with the transmission in neutral. 9. If a dynamometer is not available, add or remove shims until the clearance in the output axle is between 0.03 – 0.086 mm (0.001 – 0.003 in). 10. Install the intermediate gear of the hydraulic pump and the thrust washer. Secure with a snap ring.

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Index Transmission - 21 Creeper - 160 Creeper - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Creeper - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Creeper - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Creeper - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Creeper - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Creeper - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Creeper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Creeper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Creeper - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Transmission - 21 Hi-Lo unit - 168

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Transmission - 21 Hi-Lo unit - 168

TECHNICAL DATA Hi-Lo unit Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hi-Lo unit Dynamic description - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Hi-Lo gears, shafts, and bearings Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hi-Lo gears, shafts, and bearings - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Hi-Lo unit Disassemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Backlash - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Transmission - Hi-Lo unit

Hi-Lo unit - Special tools

CUIL17TR00212FA

Reference (A) (B) (C) (D)

1

Dimension 50 mm (1.97 in) 34.3 mm (1.35 in) 20 mm (0.79 in) 54 mm (2.13 in)

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Reference (E) (F) (G) (H)

Dimension 5 mm (0.20 in) 15 mm (0.59 in) 8 mm (0.31 in) 11 mm (0.43 in)

Transmission - Hi-Lo unit

Hi-Lo unit - Dynamic description - Dual power system The dual power system consists of a planetary gear set installed between the clutch and the input shaft of the transmission. The planetary gear set incorporates two hydraulically operated clutches that secure one or several elements of the planetary gear system to produce either the normal direct drive to the transmission or a reduced power drive (power under-drive). The power under-drive lowers the speed and increases torque.

Direct drive By fixing any two members of the planetary gear system, a direct drive is produced without changing either the speed or the direction of the turn. Upon compressing the direct drive clutch disengagement discs, the sun gear (3) is fixed to the carrier (2) of the planetary gears that operate as a member of the output system. When force is applied, the ring gear (1) turns the normal direct drive.

CUIL17TR00169AA

1

CUIL17TR00170AA

2

When the reduction clutch discs are compressed, the sun gear (4) is fixed to the planetary gear box. When force is passed to the ring gear (1), the planet gears (2) are made to turn on their own axis, so that they will “walk” around the sun gear and drag the planetary gear carrier (3). The planetary gear carrier is part of the output system. The planetary gear turns in the same direction as the ring gear but at a slower speed, which increases the torque. This is how power is produced in a reduction mode. The dual power system is controlled though a two position valve located on one side of the planetary gear box. The valve routes the oil from the low volume side of the hydraulic system’s tandem pump to either the direct drive clutch port or the reduction clutch port. The pressure is regulated by the low pressure control valves. The system is protected against overpressure by the safety valve. Speeds by gear in direct drive are equal to those of an 8 speeds transmission.

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Transmission - Hi-Lo unit

Hi-Lo unit - Hydraulic schema Oil circulation to the direct drive clutch

CUIL17TR00207FA

Pressure oil Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

1

Lubricating oil

Component Pilot valve Control Valve Spool Closing rings Transmission input axle Direct drive clutch piston Transmission counter shaft Direct drive clutch box Hub support plate Direct drive clutch discs Reduction clutch piston return spring

Reservoir and return oil Reference (11) (12) (13) (14) (15) (16) (17) (18) (19)

Component Sun gear Central axle Ring gear and input shaft Planetary gear Planetary carrier Planetary gearbox Reduction clutch disc Reduction clutch piston return springs Reduction clutch piston

The control valve, which has no neutral position, is moved through a solenoid-activated pilot valve. The solenoid is controlled by means of a switch located on the instrument panel. When the dual power control switch is changed to normal position (direct drive), the electric current goes through the solenoid of the control valve and activates the solenoid coil. Activating the solenoid makes the pilot valve close, preventing the oil that enters through the port "A" port from affecting the upper part of the control valve. However, the oil may pass through the center of the control valve and work under the control valve spool. When the oil pressure works under the control valve, it makes the spool go up, routing the oil between the fields to the corridor made in the planetary gear box that connects the direct drive clutch hub with the separation that exists between the second and third closing rings. This hub has a passage that lets the oil pass behind the direct drive 47793462 14/03/2017

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Transmission - Hi-Lo unit

clutch piston. The pressure moves the direct drive clutch piston, compresses the spring and fixes the direct drive clutch discs to connect the direct drive clutch. The hydraulic oil behind the reduction clutch piston comes out and returns through the control valve and the planetary gear box. The control valve oil also returns to the planetary gear box through a passage in the body of the control valve. When the direct drive clutch is connected, the planetary gear carrier is fixed to the sun gear, which is grooved to the direct drive clutch box. When any two members of the planetary gear set are joined, direct drive is produced without any change in the speed or direction of the turn. Therefore, as the planetary carrier and the sun gear remain joined, the force that enters through the ring gear passes directly to the planetary gear carrier, which is stretched by a connection axle to the transmission input.

Oil circulation to the reduction clutch

CUIL17TR00208FA

Pressure oil Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

2

Lubricating oil

Component Pilot valve Control Valve Spool Closing rings Transmission input axle Direct drive clutch piston Transmission counter shaft Direct drive clutch box Hub support plate Direct drive clutch discs Reduction clutch piston return spring

Reservoir and exhaust oil Reference (11) (12) (13) (14) (15) (16) (17) (18) (19)

Component Sun gear Central axle Ring gear and input shaft Planetary gear Planetary carrier Planetary gearbox Reduction clutch disc Reduction clutch piston return springs Reduction clutch piston

When the dual power control switch is moved to the power position (reduction), the electrical connection to the solenoid is cut and deactivated, thus leaving the pilot valve open. 47793462 14/03/2017

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Transmission - Hi-Lo unit

Now the oil from port "A" can work both at the upper surface and the lower surface of the control valve. However, as the upper surface of the control valve is superior to the lower one, the control valve comes down due to the greater force existing above. The oil from port "A" now passes through the control valve spool by means of a perforation in the planetary gear box to the reduction clutch piston. The pressure moves the piston, compressing the return springs and joining the reduction clutch discs; that is, connecting the reduction clutch. The hydraulic oil behind the direct drive piston returns through the control valve and the planetary gear box. The return oil of the control valve also goes to the planetary gear box through a perforation in the control valve box. As the support member in the output, it turns in the same direction but at a slower speed than the ring gear, which produces a reduction. The result has a lower speed and more torque. When the reduction clutch is connected, the direct drive clutch is joined to the planetary gear box. Just as the sun gear is grooved to the direct drive clutch, the planetary gear box is also fixed. When you apply force to the ring gear and sustain the sun clutch, the planet gears of the planetary gear carrier turn on their own axis and “walk” around the sun gear, which drags the carrier with them.

Circulation of lubrication oil The lubrication oil comes from the low pressure hydraulic system. This oil is routed by tubes toward the transmission oil cooler before entering a passage in the body of the control valve. This can be seen at port "B". Refer to the figure for the oil circulation for the direct drive clutch or the reduction clutch shown earlier. The oil circulates through passages in the planetary gear box between the first and second closing rings of the direct drive clutch hub and through a passage in line with the direct drive clutch discs. The oil circulates around the clutch discs and because the set of planetary gears turn, the oil lubricates the bearings and other components of the box. The oil from the bottom of the box goes through a tube that connects it with the bearings of the main counter-axle in the support plate of the tube. Excess oil from the box flows directly to the shift box to lubricate gears and bearings. The oil that enters into the support plate of the hub flows to the central passage of the counter-axle and lubricates the bearings and gears through perforations in the axle. As the components of the output counter-axle and axle turn, the oil passes to the input axle and multiple range gears lubricating the multiple range gears, the upper gears and the shift box bearings. The excess oil from the counter-axle flows directly into the shift box through a slot in the front support plate.

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Transmission - Hi-Lo unit

Hi-Lo gears, shafts, and bearings - Exploded view

CUIL17TR00209FA

Reference (1) (2) (3) (4) (5) (6) (7)

Component Cover Back-up Washer Sun Gear Direct drive clutch Axle Back-up Washer Planetary gearbox

1

Reference (8) (9) (10) (11) (12) (13)

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Component Reduction clutch Planetary carrier Pilot bearing Ring gear and shaft assembly Shim Ring gear bearing

Transmission - Hi-Lo unit

Hi-Lo gears, shafts, and bearings - Exploded view

CUIL17TR00210FA

Reference (1) (2) (3) (4) (5) (6)

1

Component Steel plates Pressure plate Snap ring Friction plates Snap ring Spring retainer

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Reference (7) (8) (9) (10) (11)

Component Piston return spring Sealing rings Direct drive clutch box Piston retainers Piston

Transmission - Hi-Lo unit

Hi-Lo gears, shafts, and bearings - Exploded view

CUIL17TR00211FA

Reference (1) (2) (3) (4) (5) (6)

Component Piston return springs Pressure plate Snap ring Spring retainer Friction plate Back plate

1

Reference (7) (8) (9) (10) (11)

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Component Piston retainers Control valve body Planetary gearbox Piston Dowel pins

Transmission - Hi-Lo unit

Hi-Lo unit - Disassemble - Dual power system Prior operation: Mechanical transmission - Disassemble (21.114).. 1. Drain the oil from the transmission and the rear axle center housings. 2. Disconnect the wiring harness from the wire assembly at the plug connector located above the transmission housing. It is not necessary to take the wire assembly out of the transmission plug. 3. Remove the large rubber plug from the transmission housing. Disconnect the lubrication and pressure control lines from the control valve body. 4. Unplug the cable (2) from the dual power solenoid (3). 5. Remove the bolts that secure the control valve body (4) to the planetary housing and remove the control valve body. 6. Remove the gasket from the control valve body. 7. Remove the pressure line connector (5) and the lubrication line connector (1) from the valve body and remove the o-ring seals from the connectors. 8. Separate the engine from the transmission. 9. Disconnect the rod between the clutch pedal and the clutch release cross-shaft lever by removing the clevis pin at the lever end.

CUIL17TR00171AA

1

CUIL17TR00172AA

2

CUIL17TR00173AA

3

10. Remove the clutch release fork retaining pin (5) that secures the fork (4) and remove the clutch release cross-shaft (6). 11. Remove the fork and the clutch release bearing assembly (3). 12. Remove the bolts (1) that secure the planetary cover (2). 13. Remove the cover from the planetary housing. 14. Remove the gasket from the cover. 15. Remove the ring gear and shaft assembly from the housing. 16. Remove the planetary gear box, shaft, sun gear and direct drive clutch assembly as a complete unit. 17. If necessary, use a slide hammer (3) and a shaft puller (4) to remove the reduction gear set and the direct drive clutch (1) from the ring gear bearing when removing the ring gear. Place the shaft puller over the shaft (2). 18. If necessary, remove the pilot bearing from the shaft using a puller with a suitable attachment and a step plate.

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Transmission - Hi-Lo unit

19. Remove the shaft (2) and separate the planetary gear box (1) from the direct drive clutch (3). 20. Remove the sun gear (4) from the inner splines of the direct drive clutch.

CUIL17TR00174AA

4

CUIL17TR00175AA

5

CUIL17TR00176AA

6

CUIL17TR00177AA

7

21. Remove the bolts (2) that secure the planetary housing (1) to the transmission case. 22. Remove the planetary gear box from the case. Do not discard or lose the anti-spin washer. The anti-spin washer is located between the front gear and front bearing in the transmission main shaft and may come away when the dual power housing is removed. 23. Remove and discard the gasket on the rear hub of the planetary housing. 24. Remove the o-ring between the planetary gear box and the transmission front plate. 25. Remove the direct drive clutch assembly. Remove the sealing rings (1) from the rear hub of the direct drive clutch housing (2).

26. Depress the piston return spring. Use a clutch compressor tool (4) with a puller tool or a press (1) to remove the snap ring (3) from the inner hub. 27. Release the pressure and ensure the spring retainer (2) does not enter the groove for the snap ring. 28. Remove the spring retainer and the piston return spring.

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Transmission - Hi-Lo unit

29. Remove the snap ring (2)for the pressure plate. 30. Remove the pressure plate, the friction plates and steel plates from the clutch housing (1). Note the order of removal to aid in assembly. 31. Remove the piston. Place the direct drive clutch housing face down a bench. 32. Place an air nozzle in the hole between the middle and the rear grooves in the clutch housing hub and carefully blow out the piston. 33. Remove the reduction clutch assembly. Manufacture four restraining clamps as per the instructions on Hi-Lo unit - Special tools (21.168).

CUIL17TR00178AA

8

CUIL17TR00179AA

9

34. Equally space the restraining clamps (3) around the planetary housing rim and secure the clamps with the planetary housing bolts. 35. Remove the large snap ring (2) from the inner surface of the planetary housing (1). 36. After removing the snap ring, gradually release the pressure as you remove the restraining clamps.

37. Remove the spring retainer (3), the pressure plate (2) and the friction plate (4). Note the order of removal to aid in assembly. 38. Remove the piston return springs (1), the dowel pins (6) and the rear plate (5). 39. Remove the piston. Place the reduction clutch housing face down a bench. 40. Place an air nozzle in the pressure supply port of the control valve housing and carefully blow out the piston. 41. Remove the inner and the outer piston seals. CUIL17TR00180AA

10

CUIL17TR00184AA

11

42. Remove the control valve assembly. Remove the plug (2) from the control valve body (3). 43. Remove the solenoid (1) and pivot valve assembly. 44. Remove the control valve spool (4).

Next operation: Hi-Lo unit - Inspect - Dual power system (21.168)..

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Transmission - Hi-Lo unit

Hi-Lo unit - Inspect - Dual power system WARNING Chemical hazard! Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0180A

Prior operation: Hi-Lo unit - Disassemble - Dual power system (21.168). 1. Clean all parts in a suitable solvent and dry thoroughly with a dry, lint-free cloth or with compressed air. 2. Inspect the lubrication inlet tube, the pressure inlet tube and the lubrication oil tube for damage or distortion. Replace as required. 3. Inspect the control valve solenoid cable for damage or loose connections. 4. Inspect the clutch release hub (2) and bearing (4) for damage or wear. Replace as required. • To remove the bearing, use a puller tool (1) with a suitable attachment (3) and a step plate (5). • When installing the bearing, press the bearing onto the hub so that the thrust face of the bearing faces away from the shoulder on the hub. 5. Pack the recess in the bearing hub bore with a high melting point grease. 6. Inspect the clutch release fork for damage or wear. Replace as required. 7. Inspect the cross-shaft and lever for damage or wear. If damage is present, install a new assembly. Inspect the shaft bushings for wear and replace as needed. When installing a new bushing, drive the bushing into the housing until the bushing is flush with the outside edges of the cross-shaft locating bores. 8. Inspect the planetary cover for damage or wear. Check the face of the cover and the mating surface for nicks or burrs and remove any imperfections with an abrasive stone. 9. Inspect the planetary carrier and gears, planetary shaft, pilot bearing and thrust washer for damage or wear. Replace as required. 10. Inspect the sun gear for excessive wear or damaged teeth.

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CUIL17TR00181AA

1

Transmission - Hi-Lo unit

11. Inspect the sealing rings from the rear hub of the direct drive clutch assembly for damage, distortion or cracks. Replace as required. When installing a new seal: • Insert the seal in a 60 mm (2.36 in) internal diameter test bore for a period of 10 minutes before assembling. This procedure ensures the seals obtain the correct amount of pretension to avoid damage on assembly. • Use suitable grease to hold the seals in position. • Ensure the seal does not protrude above the lands of the direct drive housing. 12. Inspect the bore in the hub of the planetary housing where the direct drive sealing rings locate. Replace the planetary housing if excessive wear or damage is detected. 13. Inspect the direct drive clutch housing both externally for cracks or damage and internally for wear and piston scuffing. Inspect the housing external splines for cracked, broken or missing teeth. 14. Inspect the direct drive clutch piston, friction plates, steel plates, pressure plate and snap ring and install new piston seals. 15. Inspect the direct drive clutch piston return spring, spring retainer and snap ring for damage. 16. Inspect the thrust washer for damage or distortion. 17. Inspect the planetary housing for cracks or damage. Inspect the reduction clutch piston, dowel pins, springs, rear plate, friction plate, pressure plate, spring retainer and snap ring and install new piston seals. Discard and replace any cracked, damaged or badly worn parts. 18. Inspect the front bearing (4) for the transmission input shaft located in the of the planetary housing hub (3). • To remove the bearing, use a puller tool (2) and a slide hammer (1). • Press in a new bearing. 19. Inspect the ring gear and shaft assembly for damage or wear. Inspect the shaft splines for damage. If necessary, install a new ring gear and shaft assembly.

CUIL17TR00182AA

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2

Transmission - Hi-Lo unit

20. Inspect the ring gear bearing (2) for wear or damage. Replace as required. • To remove the bearing, use a puller tool (6) with legs (5) and a suitable attachment (4) and use a step plate (1). Take care not to damage the shim located behind the bearing. • To install the bearing, place the shim against the step on the ring gear shaft (3). Press the bearing onto the shaft using a sleeve of suitable length that has a 82.6 mm (3.25 in) internal diameter and a 95.3 mm (3.75 in) external diameter. CUIL17TR00183AA

3

NOTICE: The shim located behind the ring gear bearing governs the planetary gear set end play. If any of the major components of the planetary gear set are changed, see Hi-Lo unit - Backlash - Dual power system (21.168) for the procedures to determine the correct size shim to be installed. 21. Inspect the valve spool bore in the valve body for damage or wear. 22. Inspect the valve spool lands for scratches, wear or other damage. Remove minor burrs or scratches with a fine abrasive material. Clean and dry prior to reassembly. 23. Inspect the solenoid for cracks or damage. if any doubt exists as to the serviceability of this component, replace with a new solenoid assembly. Next operation: Hi-Lo unit - Assemble - Dual power system (21.168).

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Transmission - Hi-Lo unit

Hi-Lo unit - Assemble - Dual power system Prior operation: Hi-Lo unit - Inspect - Dual power system (21.168).. 1. Assemble and install the control valve assembly. Install the control valve spool (4). 2. Install the solenoid (1) and pivot valve assembly. 3. Insert the plug (2) in the control valve body (3).

CUIL17TR00184AA

1

CUIL17TR00180AA

2

CUIL17TR00179AA

3

CUIL17TR00176AA

4

4. Assemble and install the reduction clutch assembly. Install the piston (7) and the piston inner and outer seals (6). 5. Install the piston return springs (1), the dowel pins (8) and the rear plate (5). 6. Install the spring retainer (3), the pressure plate (2) and the friction plate (4).

7. Install the large snap ring (2) in the inner surface of the planetary housing (1). 8. Equally space the restraining clamps (3) around the planetary housing rim and secure the clamps with the planetary housing bolts. Ensure the snap ring is correctly seated. 9. Gradually release the pressure as you remove the restraining clamps.

10. Assemble and install the direct drive clutch assembly. Install the piston (6) and the piston seals (4) in the clutch housing (5). 11. Install the pressure plate (2), the friction plates (3) and the steel plates (1).

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Transmission - Hi-Lo unit

12. Install the snap ring on the pressure plate.

CUIL17TR00178AA

5

CUIL17TR00176AA

6

CUIL17TR00177AA

7

CUIL17TR00176AA

8

13. Install the spring retainer (2) and the piston return spring (1).

14. Depress the piston return spring and install the snap ring (3) in the inner hub. 15. Release the pressure and ensure the spring retainer (2) and the snap ring are seated correctly.

16. Install the sealing rings (1) in the rear hub of the clutch housing (2). 17. Install the o-ring between the planetary gear box and the transmission front plate. 18. Install a new gasket on the rear hub of the planetary housing.

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Transmission - Hi-Lo unit

19. Install the planetary gear box (1) on the transmission case. Ensure the anti-spin washer is located between the front gear and front bearing in the transmission main shaft. Secure with the bolts (2).

CUIL17TR00175AA

9

20. Install the thrust washer and the shaft (2) in the planetary gear box (1). 21. Install the sun gear (4) in the inner splines of the direct drive clutch (3) and install the direct drive clutch.

CUIL17TR00174AA

10

CUIL17TR00174AA

11

CUIL17TR00172AA

12

22. Install the thrust washer, the planetary carrier (4) and the pilot bearing (5). 23. Install a suitable shim (6) and the ring bearing gear (1) on the ring gear and shaft assembly (3). Install the ring gear and shaft assembly onto the shaft. NOTICE: A new shim is required if you are installing a new cover, bearing, ring gear, planetary carrier, sun gear, direct drive clutch, or planetary gear box. For detailed instructions on how to determine the correct shim, see Hi-Lo unit - Backlash - Dual power system (21.168). 24. Install a new gasket on the cover (2) for the planetary gear box and install the cover. NOTICE: The cover should easily seat in the gear box with all of the components install. Do not force the cover. If the cover does not seat correctly, remove and reassemble the components of the gear box. 25. Secure the cover (2) with the bolts (1). 26. Install the clutch release bearing assembly (3), the clutch release cross-shaft (6), fork (4) and fork retaining pin (5). 27. Install the rod between the clutch pedal and the clutch release cross-shaft lever and secure with the clevis pin at the lever end. 28. Join the engine and the transmission.

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Transmission - Hi-Lo unit

29. Attach the pressure line connector (5) and the lubrication line connector (1) to the control valve body and install new o-ring seals for the connectors. NOTE: Always install new O-rings. Coat all tube joints with a proprietary sealing compound. 30. Install a new gasket on the control valve body (4). 31. Install the control valve body to the planetary housing and secure with the bolts. 32. Attach the cable (2) to the dual power solenoid (3). 33. Connect the lubrication and pressure control lines to transmission bell-housing and install the rubber plug. Ensure the rubber plug fits firmly in place over the solenoid wire. 34. Connect the wiring harness for the wire assembly at the plug connector located above the transmission bell-housing. 35. Add oil to the transmission and the rear axle center housings. Next operation: Hi-Lo unit - Backlash - Dual power system (21.168)..

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CUIL17TR00171AA

13

Transmission - Hi-Lo unit

Hi-Lo unit - Backlash - Dual power system Prior operation: Hi-Lo unit - Assemble - Dual power system (21.168).. The shim located between the bearing and the step on the ring gear shafts determines the end play between the components of the planetary gear box. End play specification is 0.1 – 0.851 mm (0.004 – 0.034 in). NOTICE: The end play needs to be adjusted if you will plan to install a new cover, bearing, ring gear, planetary carrier, sun gear, direct drive clutch, or planetary gear box. 1. Install sun gear in the inside grooves of the direct drive clutch. 2. Place the thrust washer on planetary gear carrier and align the grooves. 3. Install the planetary gear carrier and the thrust washer in the sun gear and ensure the grooves of the planetary gear carrier interlock with the friction discs of the direct drive clutch. 4. Keeping the components together, mount the planetary gear axle from behind. If necessary, tap the axle to ensure full engagement. 5. Place the pilot bearing inside the axle using a sleeve with a 41.2 mm (1.62 in) inside diameter and a 47.8 mm (1.88 in) outside diameter. 6. Place the planetary gear box (with the reduction clutch mounted) on the workbench. NOTE: Place the planetary gear box on blocks so that the rear part of the planetary gear axle does not touch the workbench when the direct drive clutch and planetary gears are installed. 7. Place the thrust washer in the gear box with the tab pointed up and towards the rear part of the transmission. 8. Install the direct drive clutch and the set of planetary gears in the gear box. Check that the assembly is set firmly in the gear box. 9. Install the ring gear and shaft assembly (without ring gear bearing or shim) in the gear box. Place the ring gauge tool on the step of ring gear axle. 10. Place the cover on the planetary gear box without the gasket. NOTICE: Check that all components are set firmly in the gear box. 11. Measure the distance between the face of the cover and the face of the gear box in three equal points and intervals. • If the average of the three measures is between 1.17 – 1.52 mm (0.05 – 0.06 in), a shim is not needed. The measurement is within specification. • If the average measurement is lower than specified above, a different shim is required. Refer to . 47793462 14/03/2017

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Transmission - Hi-Lo unit

12. Remove the cover, the ring gear, and the axle from the planetary gear box. Take out the ring hub. Place the correct shim on the step of the ring gear axle. Put the bearing in the ring gear. Use a sleeve of suitable length that has a 82.6 mm (3.3 in) internal diameter and a 95.3 mm (3.8 in) external diameter to put the bearing in the ring gear. 13. Take out the planetary gear box components and keep them in order for final assembly. See Hi-Lo unit Assemble - Dual power system (21.168).

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Index Transmission - 21 Hi-Lo unit - 168 Hi-Lo gears, shafts, and bearings - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Hi-Lo gears, shafts, and bearings - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Hi-Lo gears, shafts, and bearings - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Hi-Lo unit - Assemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Hi-Lo unit - Backlash - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Hi-Lo unit - Disassemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Hi-Lo unit - Dynamic description - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Hi-Lo unit - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Hi-Lo unit - Inspect - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Hi-Lo unit - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Four-Wheel Drive (4WD) system 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Four-Wheel Drive (4WD) system - 23

[23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3

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CONSUMABLES INDEX Consumable

Reference

Four-Wheel Drive NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL Four-Wheel Drive NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL Four-Wheel Drive Loctite® 518™ Gasket Eliminator®

PAGE 23.2 / 12 23.2 / 15 23.2 / 16

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Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

FUNCTIONAL DATA Front-Wheel Drive (FWD) control valve Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Dynamic description When the dual mobile lead-in valve placed in the central hole moves forward, the pressure oil passes through the valve center and lifts the internal ball from its seat and allows oil to reach the chamber. The camber is closed by two rings. Oil expands inside the chamber and moves the friction gear against the springs arranged in rays, thus removing the gear trigger teeth. Now the gear can turn freely on the front axle because it is disconnected. The solenoid stops working when cutting off the electrical circuit in feed tubes and in chamber. The spring pressure makes the clutch move towards the driven gear. Independent of which way the clutch moves, when discharging the oil the whole lead-in valve moves backwards. This way the first lead-in ball does not allow oil to pass through the valve center any longer, and the whole valve moves backwards. This movement causes a big open escape passage through the radial drill holes on axle and gear, towards the rear axle. A quick disconnection of the clutch is thus achieved. At first, a small quantity of oil comes out from the solenoid so that lead-in valve can move.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Sectional view

CUIL17TR00250FA

1

Reference (1) (2) (3)

Component Driven gear Oil transfer tube (inside) Lead-in valve (ball raised)

Reference (6) (7) (8)

(4)

Chamber

(9)

(5)

Spiral springs

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Component Spring retainer Friction clutch Oil out Lead-in valve (seated ball moved backwards)

Index Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202 Front-Wheel Drive (FWD) control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Front-Wheel Drive (FWD) control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

TECHNICAL DATA Four-Wheel Drive (4WD) gearbox General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Four-Wheel Drive (4WD) gearbox - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Four-Wheel Drive (4WD) gearbox Four-Wheel Drive (4WD) gearbox - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Four-Wheel Drive (4WD) gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Four-Wheel Drive (4WD) gearbox - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Four-Wheel Drive (4WD) gearbox - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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CONSUMABLES INDEX Consumable

Reference

Four-Wheel Drive NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL Four-Wheel Drive NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL Four-Wheel Drive Loctite® 518™ Gasket Eliminator®

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PAGE 23.2 / 12 23.2 / 15 23.2 / 16

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - General specification Type Reduction ratio Number of idler gear teeth Number of driven gear teeth Turning force of the idler gear bearing Shims available for the idler gear Turning force of the output shaft bearing (With adjustment by shims) Shims available for the output shaft bearings Free length of clutch spring

7630 8030 Installation centered on the rear axle with tooth-type, electro-hydraulic, non-sliding clutch action. Electro-hydraulic mechanical engagement and disengagement. 0.930:1 and 0.907:1 44 40 and 39 0.45 – 1 kgf with adjustment by shims 0 mm, 10 mm, 0.25 mm, 0.30 mm, 0.50 mm 1.9 – 4.5 kgf 0 mm, 10 mm, 0.25 mm, 0.30 mm, 0.50 mm 48.0 mm

Four-Wheel Drive (4WD) gearbox - Torque Nm 66.0 N·m (48.7 lb 57.0 N·m (42.0 lb 80.0 N·m (59.0 lb 80.0 N·m (59.0 lb 51.0 N·m (37.6 lb

Components Rear axle transfer case fixing screws Transmission shaft screws Idler gear fixing screws Oil drain plug End cover screws

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ft) ft) ft) ft) ft)

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Dynamic description All of the Auxiliary Four Wheel Drive (AFWD) gear boxes are identical, with the exception of the gear ratios. The different gear ratios are necessary to accommodate different front and rear tire sizes. The gearbox gear ratio is stamped on the front side of the case, under the output shaft. The gear box includes a jaw clutch which connects the driven gear to the output shaft. The clutch is spring applied and hydraulically released. This clutch is activated when the hydraulic pressure of the low pressure circuit is removed and the four springs engage the AFWD clutch. A helical gear installed on the drive pinion shaft of the rear axle transfers drive to an idler gear supported by two taper roller bearings in the gear box. The intermediate gear drives the output shaft gear. The output shaft is supported by two taper roller bearings. The driven gear turns freely on the output shaft. The jaw coupler is splined onto the output shaft and when the clutch is engaged, the jaw coupler and the driven gear are coupled. Gear ratios in the gear box are determined by the number of teeth of the lower, output shaft gear. An electro-hydraulic valve sends hydraulic oil from the DualPower™ and the independent Power Take-Off (PTO) circuits, through an external pipe, to the rear plate of the gear box. When the solenoid is energized, oil passes through the transfer tube to the output shaft bore. The pressurized oil disengages the AFWD clutch.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Sectional view

CUIL16TR01199FA

Reference (1) (2) (3) (4) (5) (6)

Component Jaw clutch Springs Output shaft Solenoid valve Electrical connection Hydraulic oil connection

1

Reference (7) (8) (9) (10) (11) (12)

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Component Sealing rings Outer oil line Check valve Oil transfer pipe Driven gear Idler gear

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Exploded view

CUIL16TR01200FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Component Screw Shim Spacer Idler gear Back plate Oil transfer pipe O-Ring Seal Bearing Back-up Washer Check valve Driven gear Output shaft Sealing rings Jaw gear Spring plate Snap ring

1

Reference (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32)

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Component Shim Front plate Seal O-Ring Seal Bearing Spring Solenoid cover Solenoid valve Housing Oil tube Retainer Shim Bearing Shim Bearing Axle

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Remove WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Proceed as follows: 1. Remove the negative (-) cable (1) from the battery. 2. Remove the Auxiliary Front Wheel Drive (AFWD) drive shaft. Consult the procedures in Drive shaft - Remove (23.314). 3. Remove the fuel tank. Consult the procedures in Fuel tank - Remove (10.216). 4. Drain the oil from the transmission. Consult the procedures in Powered rear axle - Drain fluid (27.100).

CUIL16TR00171AA

1

CUIL16TR01148AA

2

CUIL16TR01149AA

3

5. Remove the solenoid cover (2) on the right-hand side of the gear box.

6. Disconnect the AFWD solenoid wire (1) and the wire protection line (2). 7. Disconnect the hydraulic input line (3) from the case. 8. Support the gear box with a jack and remove the fastening bolts from the case. Lower the gear box and remove it from the machine.

Next operation: Four-Wheel Drive (4WD) gearbox - Disassemble (23.304)..

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Disassemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Four-Wheel Drive (4WD) gearbox - Remove (23.304).. 1. Remove the nut (3) securing the solenoid and remove the coil (4) from the valve body. Remove the valve spool (1) from the shoulder.

CUIL16TR01150AA

1

CUIL16TR01151AA

2

CUIL16TR01152AA

3

2. Loosen the bolt (1) that retains the idler gear (2) and the bearing. If necessary, carefully heat the nut (3) to loosen the factory-applied adhesive used to lock the thread.

3. Mark the front part of intermediate gear (2) for easier mounting later and remove the shaft (1). Remove the gear and bearing (3). NOTE: Keep the bearings, spacers and shims to complete the assembly.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

4. Remove the bolts from the support plate (1) on the output shaft (2) and remove the plate and the o-ring (3). Collect and identify the shims (4) placed between the plate and the outer bearing race.

CUIL16TR01153AA

4

CUIL16TR01154AA

5

CUIL16TR01155AA

6

CUIL16TR01099AA

7

5. Remove the bolts from the rear plate and remove the plate. Remove the short oil transfer tube from shaft, if still connected to the shaft. 6. Carefully move the shaft from the front to the rear and remove the races from the front and rear bearings.

7. With the help of another operator, use prybars (1) and sockets (5) to pry the plate (3) against the clutch springs (4) to release the load on the circlip (2). 8. Remove the circlip and the four clutch springs.

9. Place two support braces (5) between the driven gear (3) and front part of case. Apply pressure to the shaft (4) to push the shaft through the driven gear. Remove the bearing (2). 10. Move the shaft forwards as much as clutch allows and remove the driven gear and the thrust washer. 11. With the shaft toward the front, use the bearing puller NHT-0009 to remove the bearing. 12. Remove the gear circlip by passing it over the smooth part of shaft and over the short section of splines.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

13. Move the shaft (3) rearward and the clutch (2) forward in order to access the rear seal ring (1). Remove the ring.

CUIL16TR01158AA

8

CUIL16TR01100AA

9

14. Move the shaft (3) rearward through the clutch (1) and the rear bearing hole. Remove the clutch and spring plate (2).

15. To remove the check valve (2) from the shaft central bore (1), apply compressed air through the drilled hole between the clutch seal rings.

CUIL16TR01156AA

Next operation: Four-Wheel Drive (4WD) gearbox - Assemble (23.304)..

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10

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Four-Wheel Drive (4WD) gearbox - Disassemble (23.304).. 1. Install new o-rings on both the front and rear plates, and install a new seal ring on the smaller diameter of the shaft. NOTE: Do not install the larger seal ring until the shaft is installed in the gearbox. 2. Lubricate the check valve with grease and install the valve in the shaft. Ensure the valve is placed with the spring pushing the check ball to the rear, as shown.

CUIL16TR01157AA

1

CUIL16TR01158AA

2

CUIL16TR01159AA

3

3. Slide the shaft (4) through the rear bearing hole, the clutch (2), and the spring plate. 4. Install the new, larger diameter seal ring on the shaft. Lubricate the front (3) and the rear (1) seal rings with NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL. 5. Install the clutch on the shaft with the clutch engaged.

6. With the shaft assembly shifted toward the front of the housing, assemble the driven gear (2) and thrust washer. 7. Press the rear bearing (1) onto the shaft while supporting the front of the shaft. 8. Install the circlip on the shaft.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

9. Install all four clutch springs. 10. With the help of another operator, use prybars (1) and sockets (5) to push the plate (3) against the clutch springs (4). Compress the springs so that the circlip (2) can be installed in the groove. Make sure that the circlip is properly seated in its groove. 11. Install the front bearing race and mount the front bearing retainer without the seal and shims.

CUIL16TR01155AA

4

CUIL16TR01161AA

5

CUIL16TR01153AA

6

CUIL16TR01163AA

7

12. Tighten the screws and check the axial play by installing a dial indicator against the clutch and moving the shaft forward and rearward. 13. Select shims that match the dial indicator measurement and then add another 0.1 mm (0.004 in) shim to the result.

14. Remove the front bearing retainer and install the plate (2) and shim (1) assembly. Tighten the plate screws by hand.

15. Use a spring scale (1) and a piece of rope (2) to measure the rolling torque of the shaft. 16. Gradually tighten the screws to their specified torque and compare the rolling torque to the specification. 17. Adjust the thickness of the shim pack to achieve the required rolling torque. 18. Once specified rolling torque is obtained, and the screws are correctly tightened, remove the front bearing plate and install a new seal.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

19. Calculate the preload of the tapered roller bearings. 20. Install the bearing races in the idler gear (1) and install the taper roller bearings with a spacer (3) and with a 0.3 mm (0.012 in) shim (4) between the bearings. 21. Place the assembly in the adjustment tool (2) and tighten the bolt for the tool to a torque of 68 N·m (50 lb ft).

RCPH09TTS386AAD

8

CUIL16TR01193AA

9

22. With the adjustment tool mounted in a bench vise, coil a piece of rope around the gear. Use a spring scale to measure the rolling torque of the bearings. NOTE: Read the spring scale while the gear is turning. Readings should be done when the gear has just begun to turn. 23. To reduce the rolling torque, increase the thickness of the shim pack placed between the bearings. To increase the rolling torque, reduce the thickness of the shim pack. 24. Repeat the adjustment procedure until the required rolling torque is obtained. 25. Use a micrometer (2) to measure the thickness of the bearings (1).

CUIL16TR01164AA

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10

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

26. Use a caliper to measure the distance between the support bracket for the intermediate gear. 27. Subtract the bearing measurement from the support bracket measurement and determine the shim thickness. Divide the measurement by two to distribute in both sides. See the example that follows. Example: Thickness of the bearing cups 3.75 mm Distance between transfer case mounting brackets 3.95 mm 3.95 - 3.75 = 0.2 CUIL16TR01165AA

Two 0.1 mm shims are required. One on each side of the bearing. 28. Remove the intermediate gear from the bench vise and remove the assembly from the adjustment tool. 29. Lubricate the gear bushing with NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL. Install the intermediate gear, the bearing set, and the predetermined shim pack in the gear box. Next operation: Four-Wheel Drive (4WD) gearbox - Install (23.304)..

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11

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Install Prior operation: Four-Wheel Drive (4WD) gearbox - Assemble (23.304).. 1. Clean the mounting surface to remove oil and apply LOCTITE® 518™ GASKET ELIMINATOR ®. 2. Support the gear box with a jack and raise the gear box into position. Make sure that the driven gear mates with the rear axle pinion shaft gear. 3. Install bolts and torque to 80 N·m (59.0 lb ft) 4. Connect the hydraulic input line (6) to the case. 5. Connect the solenoid wire (4) for the Auxiliary Front Wheel Drive (AFWD) and the wire protection line (5). CUIL16TR01149AA

1

CUIL16TR01148AA

2

6. Install the solenoid cover (2) on the right-hand side of the gear box. 7. Install the drain plug (1) in the AFWD gear box. 8. Install the Auxiliary Front Wheel Drive (AFWD) drive shaft. Consult the procedures in Drive shaft - Install (23.314). 9. Refill the rear axle housing with oil. Consult the procedures in Powered rear axle - Filling (27.100).

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Index Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304 Four-Wheel Drive (4WD) gearbox - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Four-Wheel Drive (4WD) gearbox - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Four-Wheel Drive (4WD) gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Four-Wheel Drive (4WD) gearbox - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Four-Wheel Drive (4WD) gearbox - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Four-Wheel Drive (4WD) gearbox - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Four-Wheel Drive (4WD) gearbox - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Four-Wheel Drive (4WD) gearbox - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Four-Wheel Drive (4WD) gearbox - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

TECHNICAL DATA Drive shaft Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Drive shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Torque Torque 34.0 – 41.0 N·m (25.1 – 30.2 lb ft) 75.0 – 98.0 N·m (55.3 – 72.3 lb ft)

Component Clamp mounting bolts Drive shaft mounting bolt

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Remove WARNING Avoid injury! Shut off the engine, remove the key, and make sure all motion is stopped before servicing the machine. Failure to comply could result in death or serious injury. W1128A

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

1. Remove the front, center, and rear fixing bolts from the guard for the Cardan drive of the front axle. Remove the guard.

CUIL14TR00539AA

1

CUIL14TR00540AA

2

2. Remove the upper and lower clamp (1) and remove the cardan shaft (2) from the yoke (3).

Next operation: Drive shaft - Install (23.314)..

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Install WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Drive shaft - Remove (23.314).. 1. Install the cardan shaft (2), securing the upper and lower clamp (1) on the yoke (3) of the front axle.

CUIL14TR00540AA

1

CUIL14TR00539AA

2

2. Install the guard for the Cardan shaft and tighten the front, center and rear bolts.

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Index Four-Wheel Drive (4WD) system - 23 Drive shaft - 314 Drive shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Drive shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Drive shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Front axle system 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL Loctite® 515™ Loctite® 515™

Reference

PAGE

Front bevel gear set and differential - Install

25.2 / 20

Differential - Install Differential - Install

25.2 / 25 25.2 / 25

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Front axle system - 25 Powered front axle - 100

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Powered front axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Powered front axle Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Four-Wheel Drive (4WD) axle Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Powered front axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Powered front axle - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Front axle system - Powered front axle

Powered front axle - General specification Type Pair of bevel gears - differential Pinion crown gear ratio Clearance Between the pair of bevel gears: Thickness of the pinion position adjustment spacer Thickness of pinion bearing adjustment spacer Crown adjustment shim thickness Gap between the satellite teeth and planetary (gear) Thickness of planetary shim Thickness of satellite shim Diameter of the transverse pin to the satellites Diameter of transverse holes from satellite Clearance between transversal pins and holes Diameter of lateral planetary hubs Diameter of hole in differential box lateral planetary hub Clearance between satellites and holes

7630 8030 steering, load support structure, central articulation 10 / 32 = 3.2 : 1 0.15 to 0.20 2.5 – 3.7 mm at 0.1 intervals 2.5 – 4.8 mm in 0.05 steps 0.9 mm - 1 mm - 1.1 mm - 1.2 mm - 1.3 mm - 1.4 mm - 1.5 mm - 1.6 mm - 1.7 mm - 1.8 mm - 1.9 mm - 2 mm 0.15 mm 1.470 – 1.530 mm 1.4 mm - 1.5 mm - 1.6 mm - 1.7 mm - 1.8 mm 21.939 – 21.960 mm 22.040 – 22.061 mm 0.080 – 0.122 mm 43.961 – 44.000 mm 44.080 – 44.119 mm 0.080 – 0.158 mm

Shaft and pivot housings Diameter of the external shafts in relation to the bushings Internal diameter of the installed bushing Clearance between the shafts and bushes Interference between bushes and the respective holes Thickness of the pin adjustment shim

41.975 – 42.000 mm 45.100 – 45.175 mm(1) 0.100 – 0.200 mm 0.064 – 0.129 mm 0.10 mm - 0.15 mm - 0.20 mm - 0.25 mm - 0.30 mm

Final epicyclic transmission Gear ratio: Thickness of the gear shim

6:1 0.77 – 0.83 mm

Axle articulation End clearance between the shaft housing and bearings Maximum admissible clearance Articulated axle front pin diameter Inside diameter of installed front bushings Pin-to-bushing clearance Rear bush external diameter installed in bevel pinion support Rear bush external diameter installed in bevel articulated axle support Clearance between the two bushes and pins Thickness of front and rear reinforcing shim for front shaft

0.3 – 1.1 mm 2 mm 52.652 – 52.671 mm 52.720 – 52.790 mm(1) 0.049 – 0.138 mm 99.020 – 99.050 mm 99.146 – 99.221 mm(1) 0.096 – 0.201 mm 4.90 – 5.00 mm

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Front axle system - Powered front axle

Powered front axle - Special tools Tool Number

380000257 380000268

Description Use a review support appropriate for the weight and size of the front shaft Use a lifting hook appropriate for the weight and size of the differential Bevel Gear Pinion Splined Retainer Deep Socket Bevel Pinion Ring Nut Wrench

Powered front axle - Torque

CUIL17TR00249FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

1

Component Front journal mounting bolt Pinion fastening nut Rear journal mounting bolt Fastening bolt for differential in front axle housing Nut for adjusting differential bearing pre-load Differential cover bolt Crown fixing bolt Fastening nut for wheel hub bearing Fastening bolt for hub cover Steering terminal nuts Axle housing steering assembly fixing nut

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Torque 360.0 N·m (265.5 lb ft) 294.0 N·m (216.8 lb ft) 360.0 N·m (265.5 lb ft) 113.0 N·m (83.3 lb ft) 35.0 – 59.0 N·m (25.8 – 43.5 lb ft) 113.0 N·m (83.3 lb ft) 113.0 N·m (83.3 lb ft) 392.0 N·m (289.1 lb ft) 64.0 N·m (47.2 lb ft) 113.0 N·m (83.3 lb ft) 113.0 N·m (83.3 lb ft)

Front axle system - Powered front axle

Powered front axle - Dynamic description Axles pivot in the center to allow articulation when driving on uneven terrains, and the drive axle or drive pinion passes through the hollow center of the back of connecting point. This layout supports the drive axle by connecting the front axle to the transfer box on a straight plane in any type of articulation. Connection of drive axle is complemented by two universal gaskets and a sliding connection outlet. Final reduction is achieved through three epicyclic gears on a replacement hub fixed to the tube by means of upper and lower coupling links that revolve on cup and cone bearings and that can be lubricated and replaced to increase durability. Each type of axle has a central differential in the axle housing supported by replaceable supports. The differential of each type of axle has a controlled standard sliding system. The action of the sliding control is achieved by means of multidisc gears placed on each side of side differential gears. When one of the two front wheels looses traction, torque response on differential exerts an axial force through the side gears, pressurizing gear discs. External discs are fixed to differential casing and internal discs are fixed to side gears so, when force increases, it is difficult for friction surfaces to move independently. Thus, side gears remain fixed to casing causing a differential lock. As soon as the tendency to slide disappears, the torque response decreases, and the system unlocks automatically. Each axle has a removable drive cylinder fixed to the differential support. A double sided piston controls a rod that extends through each cylinder end. Some braces with ball joint connect drive cylinder to each hub. Except for the differential, the reduction hubs, hub bearings, wheel shafts and drive cylinders can be dismantled without having to remove machine’s shaft.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Sectional view

CUIL17TR00251FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Component Spring guard Output shaft front bearing Locking ring Oil sealant Output shaft Protection Cover Cover retaining lock ring Cover "O" sealant. Internal piston sealant Clutch half/gear Locking ring Actuation gear (from transmission output) Bearing lock washer Locking ring Bearing Assembly

1

Reference (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31)

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Component Shaft (transmission output) Output shaft rear bearing Oil pressure supply tube Transmission Housing Plug (supply under pressure) Oil transfer pipe Oil transfer tube sealant Pilot valve assembly Bearing lock ring Needle bearings Steel washers Transmission drain plug External piston shaft Sliding clutch half Connecting spring assembly

Front axle system - Powered front axle

Powered front axle - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

NOTE: The front axle assembly can be removed from the tractor with or without prior disassembly of the transmission shaft. The description below refers to the removal of the front axle with the transmission shaft installed in the tractor. To disassemble the transmission shaft, see the procedures described in Powered front axle - Disassemble (25.100). Depending on the work to be done on the axle, it could be a help to loosen certain nuts before removing the axle from the tractor. For example: • Wheel hub bearing nuts on the right and left sides. • Pinion safety nut. • Wheel shaft end nuts. Proceed as follows: 1. Disconnect the negative (-) cable (1) from the battery. 2. Drain the front axle oil. Consult the procedures in Powered front axle - Drain fluid (25.100). 3. Drain the oil from the front axle hub. Consult the procedures in Wheel hub - Drain fluid (25.108).

CUIL16TR00171AA

1

CUIL14TR00550AA

2

4. Remove the bolts (1) and remove the front mudguard supports (2). 5. Remove the front ballasts.

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Front axle system - Powered front axle

6. Loosen the nuts (1) from the rigid pipes of the steering cylinder. Loosen the two flexible pipes (2) and (3). 7. Remove the drive shaft. Consult the procedures in Drive shaft - Remove (23.314). 8. Remove the front wheels.

CUIL16TR01103AA

3

CUIL16TR01102AA

4

CUIL16TR01101AA

5

CUIL16TR01105AA

6

9. Loosen the fixing bolts (1) of the rear axle support.

10. Loosen the fixing bolts (1) of the front wheel drive support.

11. Using a lifting hook and two nylon cables (1) (one for each side), separate the front axle from the tractor.

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Front axle system - Powered front axle

12. Remove the bushings and other front axle supporting components, according to the sequence in the figure to the side. 1.

Front support column

2.

"O" segment

3.

Spacer

4.

Sealant

5.

Rear support column

CUIL16TR01107AA

Next operation: Powered front axle - Disassemble (25.100)..

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7

Front axle system - Powered front axle

Powered front axle - Disassemble Prior operation: Powered front axle - Remove (25.100).. 1. Position the front axle on a review support as shown in the figure to the side.

CUIL16TR01104AA

1

CUIL16TR01106AA

2

CUIL16TR01108AA

3

CUIL16TR01109AA

4

2. Remove the front axle rear support (1). 3. Disassemble the front support and remove the ferrule.

4. Loosen the two fastening bolts (1) from the wheel axle.

NOTE: Before removing the wheel axle, make sure that the hubs will not turn on the articulations, causing the axle to fall from the work bench. 5. Using the dismounting tool, remove the pins from their holes in the housing and remove the axle from the wheels.

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Front axle system - Powered front axle

6. Remove the retaining rings (2) from the articulated pins on the cylinder rod, unbolt the cylinder pin (1) fastening bolts, remove the pins and separate the two cylinders. 7. Remove the four pins, rings, spacers and the cylinders complete with tubes. 8. Remove the wheel hub. Consult the procedures in Wheel hub - Disassemble (25.108).

CUIL16TR01110AA

5

CUIL16TR01111AA

6

CUIL16TR01112AA

7

CUIL16TR01114AA

8

9. Remove the bolts (1) from the lower articulation pin. 10. Remove the bottom articulated pin and the corresponding adjusting shims.

11. Remove the fastening bolts (1) from the mudguard cradle (2). Remove the cradle.

12. Remove the three fixation bolts from the top articulated pin. 13. Remove the upper articulation pin (1). 14. Remove the axle housing (2).

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Front axle system - Powered front axle

15. Remove the fixing bolt (2) from the shaft (1).

CUIL16TR01115AA

9

16. Remove the shaft (1) from the box. NOTE: Repeat the previous 8 steps on the other side of the shaft. 17. Remove the front axle differential. Consult the procedures in Front bevel gear set and differential - Remove (25.102).

CUIL16TR01116AA

10

CUIL16TR01117AA

11

CUIL16TR01118AA

12

18. Straighten up the lock tab on the safety nut (1) of the splined shaft.

19. To loosen the pinion nut, it is necessary to use a tool 380000257 that holds the pinion shaft.

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Front axle system - Powered front axle

20. Remove the nut using tool 380000268 (1) while using tool 380000257 to prevent the bevel pinion shaft from turning.

CUIL16TR01119AA

13

CUIL16TR01120AA

14

CUIL16TR01121AA

15

CUIL16TR01122AA

16

21. Remove the retention ball from the sleeve.

22. Remove pinion shaft (1) from the rear part of the box and remove the spacer, adjustment shims and bearing.

23. Remove the dust seal, oil seal (1) and the rear bearing.

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Front axle system - Powered front axle

Powered front axle - Alignment Checking the alignment between the wheels and steering When moved in a straight line, the wheels on machines with Auxiliary Front-Wheel Drive (AFWD) must be parallel to the longitudinal axis of the machine, and/or, as an alternative, a slight convergence of the front wheels is allowed, up to a maximum value of 6 mm measured from the extremities of the wheel rims. To check the exact convergence adjustment value for a front-wheel drive machine, proceed as follows: 1. Calibrate the front tires to recommended pressure. 2. Position the steering wheel so that the front wheels are aligned with the machine. 3. Check if the wheels are parallel with the longitudinal axis of the machine. 4. Measure the distance (1) between the internal front ends of the wheels at the height of the centre of the wheel hubs.

CUIL16TR01123AA

1

CUIL16TR01123AA

2

CUIL16TR01125AA

3

5. Turning the wheels 180° is necessary to eliminate the influence of any wear to the wheels on the measurement. Turn the front wheels 180° and re-measure the distance between (2) the inner ends of the wheel at the height of the center of the wheel hub. 6. The measurement (2) must vary within 6 mm of the measure (1).

7. If it is necessary to correct the wheel alignment, disassemble the nut (2) and remove the wheel shaft stub (1) out of its housing. Loosen the nut (3) and adjust the terminal (1) inward or outward to increase or reduce the distance (2), figure 1. 8. Replace the terminal (1) in its housing and check the alignment again, as described in items 4 and 5. 9. After the alignment has been adjusted within the recommended limits, fasten nut (3) to a torque of 180 N·m (132.8 lb ft) and nut (2) to 100 N·m (73.8 lb ft). NOTE: The auto-lock nut (2) must be replaced every time it is removed or partially loosened.

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Front axle system - Powered front axle

Powered front axle - Drain fluid 1. Park the machine on a level and hard surface. 2. Place a suitably sized container under the component. 3. Remove the plug (1) to drain the fluid. After draining all fluid, re-fit the drain plug. 4. Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country.

CUIL13TRO0223AA

Next operation: Powered front axle - Filling (25.100)..

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1

Front axle system - Powered front axle

Powered front axle - Filling Prior operation: Powered front axle - Disassemble (25.100).. 1. Park the machine on a level and hard surface. 2. Remove the plug (1) and fill with new oil. See the system capacity and the oil quantity on page Fluids and lubricants. 3. Reinstall the plug (1).

CUIL13TRO0223AA

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1

Index Front axle system - 25 Powered front axle - 100 Four-Wheel Drive (4WD) axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Powered front axle - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Powered front axle - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Powered front axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Powered front axle - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Powered front axle - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Front axle system - 25 Front bevel gear set and differential - 102

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Front axle system - 25 Front bevel gear set and differential - 102

TECHNICAL DATA Differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Front bevel gear set and differential Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Differential Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Differential lock Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Front bevel gear set and differential Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjust - Pinion depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjust - Pinion shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Differential Gear tooth contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL Loctite® 515™ Loctite® 515™

Reference

PAGE

Front bevel gear set and differential - Install

25.2 / 20

Differential - Install Differential - Install

25.2 / 25 25.2 / 25

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Front axle system - Front bevel gear set and differential

Differential - General specification 7630

Front convergence Resistance to turning of shaft hub bearing Shaft wheel play Reciprocating bearing preload Drive Pinion Rolling Torque Backlash between ring and pinion Ring and pinion adjustment Differential bearing rolling torque Limits of clutch discs wear/Differential limited slip: Side disc (internal spline) – New Side disc (internal spline) – Minimum shim Side disc (internal spline) – New Side disc (internal spline) – Minimum shim

8030 0 – 6.0 mm (0.00 – 0.24 in) Pre-adjusted Pre-adjusted 0.2 – 0.4 mm (0.008 – 0.016 in), for calipers: 0.10 mm (0.004 in), 0.19 mm (0.007 in), 0.35 mm (0.014 in) 9.3 – 13.9 kgf (20.50 – 30.64 lbf) 0.17 – 0.24 mm (0.007 – 0.009 in) Adjustable by 2.5 – 3.4 mm calipers in intervals of 0.1 mm and 0.100 – 0.136 in in intervals of 0.004 in 3.8 – 4.8 kgf (8.38 – 10.58 lbf)

2.8 mm (0.110 in) 2.7 mm (0.106 in) 1.6 mm (0.063 in) 1.45 mm (0.057 in)

Differential - Special tools Tool Number 380000249 380000248 380000253 380000600 380000257 380000268 380000548 380000252 NHT-0412 75300932

Description Universal Pinion Installation Tool Kit Bevel Pinion Bearings Adjusting Guage Tool to adjust the preload of the front differential bearing (Class II and III) Bevel Pinion Shimming Adjusting Gauge Use a review support appropriate for the weight and sizes of the component Bevel Gear Pinion Splined Retainer Deep Socket Bevel Pinion Ring Nut Wrench Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25) Front Axle Ring Nut Wrench Installation tool for the rear pinion bearings Bearing heater Torque wrench

The tool to be manufactured for adjusting the bevel pinion is used together with tool 380000248. Made using UNI C40.

LAIL11TL0483A0A

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1

Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Dynamic description The machine has a central front wheel drive and a coaxial drive shaft in the longitudinal direction of the tractor. The drive shaft has no universal joints. The differential has two planetaries and movement is transmitted to the lateral epicyclic final units (installed in the wheel hubs) through universal joints that do not require any maintenance.

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Sectional view Front wheel drive cross-section

CUIL16TR01202FA

Reference (1) (2) (3)

Component Tractor axle front support bush Front backing washer Front articulated pin

1

Reference (4) (5) (6)

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Component Rear backing washer Rear axle support bushing Rear axle support bushing (seat)

Front axle system - Front bevel gear set and differential

Differential - Exploded view Differential pinion

CUIL16TR01206FA

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component Shim (pinion depth) Bearing Bearing ring Housing Nut Anti-dust cover Seal Ball

1

Reference (9) (10) (11) (12) (13) (14) (15) (16)

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Component Sleeve Bearing Bearing ring Shim (Pinion bearing pre-load) Shim (Pinion bearing pre-load) Spacer Segment 'O' Pinion

Front axle system - Front bevel gear set and differential

Differential - Exploded view

CUIL17TR00252FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Component Differential housing Shaft lock pin Screw Locking plate Lug nut Bearing Drive disc (external flange) Friction disc (internal flange) Thick pressure disk Side gear Back-up Washer Differential gear Axle Bevel Gear

1

Reference (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)

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Component Pinion Shim Bearing Washer Spacer Washer Bearing Spring washer Ring nut Flange Shaft seal Retaining ring Flange, pinion shaft Retaining ring

Front axle system - Front bevel gear set and differential

Differential - Sectional view Differential Lock

CUIL16TR01204FA

1

Reference (1) (2) (3)

Component Pinion oil seal Pinion nut Pinion

Reference (8) (9) (10)

(4)

Pinion bearing preload shimming

(11)

(5)

Pinion depth shim Nut for adjusting differential bearing pre-load Nut safety lock for adjusting the differential bearing pre-load

(12)

Component Crown wheel Friction Disc Steel separator plate Nut for adjusting differential bearing pre-load Planetaries

(13)

Satellites

(6) (7)

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Front axle system - Front bevel gear set and differential

Differential lock Dog clutch - Dynamic description On tractors with a hydraulic differential lock (optional), the drive is processed through a solenoid valve. When energized, the solenoid valve sends oil from the low pressure system ( 16 – 18 bar) to the lock piston, to engage the gear. When power to the solenoid is cut, the return spring empties the oil from the piston and disengages the toothed gear, thus turning off the differential block.

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Remove Prior operation: Powered front axle - Remove (25.100).. 1. Remove the two fixation bolts from the conic support of the transmission-differential to the shaft box. 2. Bolt the two studs 380000548 (1). 3. Remove the remaining bolts and separate the differential support from the axle housing. 4. Connect a winch (2) to the support and remove the differential support (3) from the axle housing.

CUIL16TR00703AA

1

CUIL16TR00704AA

2

CUIL16TR00692AA

3

CUIL16TR00691AA

4

5. Install two fasteners (1) with appropriate capacity in the workbench vise. 6. Fasten the differential support to the tool and remove the lifting cable. 7. Remove the bolt (2) and remove the protection from the retaining nut (3). 8. Repeat the operation 7 for the other side of the differential.

9. Remove the differential adjustment nut using tool (1) 380000252.

10. Remove the two fastening bolts from the crown covers of the transmission box (1).

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Front axle system - Front bevel gear set and differential

11. Remove the bearing (2) and cover (1) of the differential bearing. 12. Repeat the operation on the opposite side.

CUIL16TR00738AA

5

CUIL16TR00737AA

6

13. Remove the differential from the support.

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Inspect 1. Inspect the differential side bearings. If necessary, remove the internal tracks with a puller and a suitable attachment.

CUIL17TR00233AA

1

CUIL17TR00234AA

2

CUIL17TR00235AA

3

CUIL17TR00236AA

4

2. Inspect the pinion bearings. If necessary, remove the bearing internal track with a puller and a suitable attachment. NOTE: A shim is between the pinion internal bearing and its head. 3. Remove the external tracks from the differential housing support. 4. Inspect the differential gears, thrust washers and shaft for damage or wear. Replace as required. 5. Inspect the side gears and their splines for damage.

6. Inspect the bushings inside the differential housing for wear. If necessary, remove these bushings with a slide hammer and install new bushings.

7. Inspect the clutch groups. 8. Make sure the discs are perfectly flat. 9. Inspect the area of the internal splines and the external pins of the intermediate drive discs 10. Check that the internal discs are not worn more than 0.15 mm (0.006 in). New discs measure 1.6 mm (0.063 in). Compare worn discs with new ones. The thrust washer placed under the head of each side gear shall not be worn more than 0.1 mm (0.004 in). Washers have an original thickness of 2.8 mm (0.11 in).

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Adjust - Pinion depth The aim of this procedure is to determine the adjustment shim (1) thickness of the bevel pinion position.

CUIL16TR00726AA

1

CUIL16TR00721AA

2

CUIL16TR00722AA

3

CUIL16TR00720AA

4

1. Install the pinion bearings in the differential support housing and fasten them in position with the tool 380000248. 1.

Pinion measuring cone - tool number 380000249.

2.

Pinion bearing clamp. Use tool number 380000248 or tool NHT-0412 as shown.

3.

Pinion bearing.

4.

Pinion bearing.

5.

Micrometer (Tool part number 380000249).

NOTE: If tool 380000248 as described in the procedure for adjusting the pinion bearing shims is not available, then use the bearing clamping tool NHT-0412 to tighten the bearings. 2. Install the roller bearings and tighten the fastening nuts to a torque of 113 N·m. 3. Install tool 380000249 (1) in the differential housing.

4. Adjust the cones of tool 380000249 so that the tip of the micrometer touches the internal track of the pinion bearing and measure the size (H3).

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Front axle system - Front bevel gear set and differential

Distance between the centre of the differential and the support base of the bearing in the pinion 1. Determine the corrected distance (H5) between the centre of the differential and the support base of the bearing in the pinion: H5 = H4 + C, where: • (H4) : 115 mm. Nominal distance between the center of the differential and the support base of the bearing in the pinion.

CUIL16TR00720AA

5

LAIL11TL0497A0A

6

2. • (C): Correction value entered in pinion preceded by + or - sign (if different from 0). This value should be added to or subtracted from the nominal distance (H4) according to the sign, as indicated to the side. 3. For the example given, the measurement (H5) will be 115 mm + 0,2 mm = 115,2 mm

Thickness of adjustment shim 1. The shim thickness will be determined by the formula S = H3 - H5, where: • S: shim thickness • H3: distance measured with the micrometer • H5: corrected nominal distance between the centre of the differential and the support base of the bearing in the pinion. 2. For the example already used, the shim thickness will be: • S = 118 mm - 115.2 mm = 2.8 mm

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Adjust - Pinion shim Pinion shim adjustment 1. Install the roller bearings (without the bearing cover) and fasten with a torque of 113 N·m (83.3 lb ft). 2. Measure the internal dimension of the bearing diameter and call this dimension (A). 3. Install the pinion bearings in the differential support housing and fasten them in position with tool 380000600. NOTE: Fasten the clamp so that the bearing cones can be turned by hand.

CUIL16TR00724AA

1

CUIL16TR00725AA

2

CUIL16TR00726AA

3

4. Place the template bar – tool part number 380000600 – through the bearing diameter. Measure dimension (B). 1.

Depth Micrometer

2.

Template bar – Tool part 380000600.

3.

Pinion shaft bearings

4.

Tool 380000600.

5.

Differential; support box

5. Calculate dimension H4 using the formula H4 = B-25*+(A/2) NOTE: *The template bar 380000600 has a diameter of 25 mm 6. Determine the thickness of shims “S2” which will be installed behind the pinion gear as follows: S2 = H4 - H3 Where: H4 = Dimension calculated in step 5 above H3 = 115 mm + correction factor (C) 115 mm is the manufacturer's nominal dimension of the rear face of the pinion gear to the conical tip of the pinion. (Supplied by the manufacturer). C = Manufacturer's correction factor, engraved on the pinion face. Example A = 95 mm B = 95.77 mm H4 = B-25*+(A/2) H4 = 95.77–25*+(95/2) H4 = 118.27 C = 0.1 mm H3 = 115+0.1=115.1 Thickness of shim S2 (1) = 118.27–115.1= 3.17 mm

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Front axle system - Front bevel gear set and differential

Installation of the shim and pinion bearing 7. Install the shim selected in the adjustment procedure of the pinion shim between the pinion head and bearing. NOTE: Make sure that the chamber on the shim is turned facing the pinion head.

CUIL16TR00727AA

4

CUIL16TR00728AA

5

8. Install the bearing onto the pinion. NOTE: Tool 75300932 will help you to install the bearings without the need for a press.

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Preload Adjusting the preload of the pinion shaft bearings CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Proceed as follows: 1. Fix the tool 380000248 (1) in the vice, install the internal races of the bearings (3) and (4) the spacer (2) and fasten the tool nut until the end of run.

CUIL16TR00716AB

1

LAIL11TS0072A0A

2

LAIL11TS0073A0A

3

2. Use a micrometer to measure the distance "H1" between the top surface and the pin of tool 293391 380000248 (1). 3. Disassemble the above parts. Lubricate the bearings with transmission oil. Then reinstall the parts, excluding the bearing spacer (3), figure 1, of the differential shaft housing, complete with the external races of the bearings, held in place with the aid of the review support.

4. Tighten the nut of tool 380000248 (1) to the end, while turning the tool to ensure that the bearings are correctly seated. 5. Use a micrometer to measure distance "H2" considering the tool in this condition.

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Front axle system - Front bevel gear set and differential

6. The thickness required for the adjustment shim is determined by: (1) S = (H2 - H1) + 0.05 mm Example: H2 = 10.5 mm H1 = 8.3 mm S = ( 10.5 mm - 8.3 mm) + 0.05 mm S = ( 2.2 mm) + 0.05 mm S = 2.25 mm 7. Remove tools 380000248 and 380000249 from the bevel pinion housing. 8. Install the complete bevel pinion with internal bearing race, spacer, and adjustment shim with the previously determined thicknesses. Next operation: Front bevel gear set and differential - Install (25.102)..

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CUIL13TR00717AA

4

Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Install Prior operation: Front bevel gear set and differential - Preload (25.102).. 1. Fit the O-ring sealing (1) onto the pinion shaft. 2. Next, insert the retainer race and afterwards the ball, after having carefully lubricated the external surface.

LAIL11TL0071A0A

1

LAIL11TL0072A0A

2

LAIL11TL0073A0A

3

3. Install the pinion lock key 380000257. 4. Install key 380000268 in the pinion nut. 5. Use a key to lock the pinion. Use a torque meter positioned exactly as shown in figure 3 to fasten the nut to a torque of 294 N·m ( 217 lb ft), and simultaneously turn the pinion to ensure that the bearings are correctly seated.

6. Use a torque wrench and pinion lock 380000257 to check the pinion turning torque. If the turning torque is lower than the recommended value, install a thinner adjustment shim; if the torque value is higher, install a thicker adjustment shim in order to adjust it. NOTE: The pinion turning force measured with the balance must be 2,17 kgf.

Adjustment of the preload of the pinion shaft bearings The values described are obtained with a low load torque meter (1), installed on the pinion shaft, with the bearings previously lubricated with transmission oil NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL. Swing torque Pinion 0.5 N·m

Pinion + differential 1.0 – 1.3 N·m

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Front axle system - Front bevel gear set and differential

If no torque meter is available, use a dynamometer and check the values in the table below. The turning force should be applied to a string wound around the pinion, in the grooved area. Turning force Pinion 31.7 N (7.1 lb)

Pinion + differential 63 – 82 N (14 – 18 lb)

7. After obtaining the specified value, unfasten the lock nut and install the retainer and corresponding dust seal ring. Fasten the nut to a torque of 294 N·m (217 lb ft) and simultaneously turn the pinion to ensure that the bearings are correctly seated. 8. Finally, carefully lock the nut (1) and install the lock ring.

LAIL11TL0052A0A

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4

Front axle system - Front bevel gear set and differential

Differential - Gear tooth contact When the differential assembly needs to be serviced, it will be necessary to adjust the gap between the teeth of the planetary gears and satellite gears. Proceed as follows: 1. Clean the differential components very well and carefully, and remove all the vestiges of oil that may prevent the correct measurement of clearance. 2. Install the planetary gears without the friction shims (self-locking system).

CUIL16TR00707AB

1

CUIL16TR00708AB

2

3. Fit in the two satellite gears complete with backing shims and fix the pin with the fixation bolt, turning it to keep the pin in place. 4. Place a calibrator gauge into the differential housing. 5. Move the planetary gear on the left-hand side in order to establish perfect contact with the satellite and then push against the differential housing and take the gap reading on the calibrator gauge “Gs”. 6. Repeat the above operation to measure the gap on the right-hand side in the other planetary gear “Gd”.

The shim to be installed in the differential housing is therefore determined by. Ss = Gs - 0.25 mm for the planetary gear on the LH side. Sd = Gd - 0.25 mm for the planetary gear on the RH side. 7. Install the shims as closely as possible to the calculated values and using the calibration gauge, follow the procedures described above, checking that the gap of the planetaries on the right and left sides is approximately 0.25 mm.

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Front axle system - Front bevel gear set and differential

Differential - Install Differential bearing adjustments and checking clearance between the pinion and crown. Proceed as follows: 1. Install the differential mounted in the housing.

CUIL16TR00737AA

1

CUIL16TR00740AB

2

CUIL16TR00741AB

3

LAIL11TL0075A0A

4

2. Install the roller bearing covers in the housing case, adjust the differential cover support, fasten the bolts with torques corresponding to 59 N·m (44 lb ft) and then loosen and fasten again with a torque of 20 N·m (15 lb ft).

3. With the bearings perfectly lubricated, turn the differential and at the same time fasten the adjustment nut using wrench 380000252 ( (1) to a torque of 39 – 59 N·m (29 – 44 lb ft) to maintain the axial gap between the components.

4. Measure the gap between the pinion and crown using a 1/100 meter perpendicular to the external ridges of a crown tooth (1). 5. Repeat the measurement in different positions and compare the mean of the three values (Gm) with the recommended normal clearance: • 0.15 – 0.20 mm (mean value of 0.18 mm)

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Front axle system - Front bevel gear set and differential

6. When the measured clearance is not within the recommended tolerance thresholds, adjust the nut by tightening one of the nuts inside and the outside to the same amount. This will fix the axial preload and thereby obtain the recommended clearance.

CUIL16TR00741AB

5

LAIL11TL0073A0A

6

CUIL16TR00741AB

7

LAIL11TS0048A0A

8

7. After adjusting the gap between the pinion and crown teeth, check the differential turning resistance, measured at the end of the pinion, with pinion lock key 380000257 (2) and with torque meter (1) . 8. The pinion and differential turning torque is 1.0 – 1.3 N·m. 9. Should no torque meter be available, use a dynamometer. The turning force should be applied to a string wound around the pinion, in the grooved area. 10. Pinion and differential turning force: 63 – 82 N (14.2 – 18.4 lb) 11. If the recommended value is not obtained, adjust the differential adjustment nuts by fastening the nuts equally to obtain the higher turning force. The maximum fastening torque of the adjustment nuts is 6 kgm. NOTE: Fastening must be applied equally on the right and left hand nuts, so as not to alter the clearance between the pinion and crown teeth.

12. Torque the bearing bolts to 113 N·m (83 lb ft).

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Front axle system - Front bevel gear set and differential

13. Install the safety lock (3), fastening the adjusting nut inwards or outwards, up to the closest tooth. 14. Install the shaft housing assembly, after having carefully cleaned it and removed the oil from all of the contact surfaces and applied a coat of LOCTITE® 515™ of approximately 2 mm in thickness along the line shown in the figure below.

CUIL16TR00704AA

9

Diagram for application LOCTITE® 515™ for installing the differential and complete epicyclic unit.

LAIL11TL0937B0A

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10

Index Front axle system - 25 Front bevel gear set and differential - 102 Differential - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Differential - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Differential - Gear tooth contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Differential - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Differential lock Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Front bevel gear set and differential - Adjust - Pinion depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Front bevel gear set and differential - Adjust - Pinion shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Front bevel gear set and differential - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Front bevel gear set and differential - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Front bevel gear set and differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Front bevel gear set and differential - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Front bevel gear set and differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Front bevel gear set and differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

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Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

TECHNICAL DATA Final drive hub, steering knuckles, and shafts Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Wheel hub Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Axle shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Steering knuckle and king pin Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Wheel hub Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Front axle system - Final drive hub, steering knuckles, and shafts

Final drive hub, steering knuckles, and shafts - Special tools Tool Number 380000269 380000469 380000234 380000265 380001143 380000235 380003016 380000548 380000284

Description Wheel Hub Bearing Ring Socket Hub Bearing Ring Nut Socket Swivel Pin Bearing Outer Race Puller Swivel housing pin pivot puller Front Axle Shaft to Swivel Housing Mounting Guide (Class 3) Swivel Housing Torque Check Adapter Installation tool for the front hub retainer Use alignment pins (M12 x 1.25) for the planetary reduction hub of the front axle Wheel Hub Seal Installer

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Sectional view

CUIL16TR01203FA

Reference (1) (2) (3) (4)

Component Driven gear shims of the epicyclic unit (hub) Oil seals (casette) Hub shaft oil seal Shaft fixing bolt

1

Reference

Component

(5)

Axle

(6) (7) (8)

Shaft oil seal Articulation pin adjustment shims Axle bushing

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Front axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Wheel hub - Disassemble (25.108). 1. Remove side gears support, sun gear, spacer and thrust washer. 2. Place a suitable lift device (1) around the hub and the housing (2)

CUIL17TR00246AA

1

CUIL17TR00247AA

2

CUIL17TR00248AA

3

3. Carefully remove the hub. Separate the front axle housing (2) while you simultaneously prevent the wheel shaft from coming out of the axle housing. 4. When removing the hub and the housing from the axle housing, hold the short end of the wheel shaft when passing through the detent.

5. Carefully remove the wheel shaft (1) from the axle housing. Guide the wheel shaft through the external detent.

Next operation: Axle shaft - Inspect (25.108).

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Front axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Inspect Prior operation: Axle shaft - Remove (25.108). 1. Inspect for damage or wear in the bearing and in the area of the retaining cradle. 2. Use a slide hammer (1) to remove the retaining shafts (2) from inside the tube.

CUIL17TR00239AA

1

CUIL17TR00240AA

2

CUIL17TR00241AA

3

3. Remove the housing.

4. Inspect the bushings of the reciprocating housing and the axle housing. If bushings (1) are damaged or worn, remove the bushings with a slide hammer (2) and a suitable attachment (3). NOTE: The wheel shaft bushings inside the reciprocating housing are held in place by an external retaining ring. Be careful not to damage the retaining ring during disassembly.

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Front axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Install DANGER Falling parts! Keep fingers and hands clear of mating surfaces of counterweight and machine upper structure during counterweight removal and installation. Failure to comply will result in death or serious injury. D0005B

Prior operation: Axle shaft - Inspect (25.108). 1. Assemble the new detents (2) into the housing. Use a pilot tool (1) for this assembly.

CUIL17TR00237AA

1

CUIL17TR00238AA

2

2. Install the bushing (2) in the axle housing using a pilot tool (1). 3. Carefully place the shaft through the axle housing and insert it in the differential side gear. Make sure the detent is not damaged. 4. Install the housing on the other side of the shaft. 5. Assemble the bolts and the shims. Make sure the same number of shims that were removed are installed. Shims should be installed at location of removal. Make sure that the detents are properly squared.

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Replace WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Powered front axle - Remove (25.100).. If pins are difficult to remove, proceed as follows: 1. Remove the grease fitting and the fixing screws of the pins. 2. Fit the bolts (1) of tool 380000265. 3. Fit the plate (2) of the tool and attach it to the three bolts with nuts (5). 4. Fit the central lock bolt (4), fastening it completely into the hole in the pin's grease nipple (6). 5. Fit the nut (3) and tighten it to remove the pin. CUIL16TR00784AA

1

CUIL16TR00785AA

2

6. Using the extraction tool 380000234 (1) remove the spherical bushing. 7. Install the spherical bushings using a suitable mandrel.

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Adjust Prior operation: Powered front axle - Remove (25.100)..

Adjusting the steering casing DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Apply grease 380000235 on the outer track of the bushing and fit the upper pin without the adjustment shims using the (2) tool. 2. Tighten the mounting screws to a torque of 113 N·m (83.3 lb ft). NOTE: To make it easier to install the casing, we recommend that guide 380001143 (1) be installed.

CUIL16TR00786AA

1

CUIL16TR00798AA

2

CUIL16TR00799AA

3

3. Fit the lower pin without adjustment shims and lubricate the three mounting bolts with engine oil. 4. Gradually tighten the lower screws in sequence, turning the casing to allow excess grease to drain out.

5. Use a torque wrench and tool 380000235 (1) to check that the torque needed to rotate the casing is 15 – 25 N·m (11.1 – 18.4 lb ft). Do not take the initial peak torque into consideration. 6. If the value is different, make an adjustment using the screws on the pin's lower flange. 7. Measure the distance (H) between the lower flange of the pin and the casing for the three screws.

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Front axle system - Final drive hub, steering knuckles, and shafts

8. Calculate the average of the three values measured. The total thickness of the "S3" adjustment shim to be inserted under the flange of the lower pin must be calculated as follows: S3 = H - 0.20 mm. If necessary, round the values to the nearest 0.05 mm .

CUIL16TR00800AA

4

CUIL16TR00798AA

5

9. Partially loosen the screws on the flange of the lower pin and insert the shims. 10. Tighten the screws to a torque of 113 N·m (83.3 lb ft). 11. After you rotate the casing several times to align the components, check whether the torque needed to rotate the casing is 118 – 147 N·m (87 – 108 lb ft). Do not consider the initial rolling torque. 12. If the value measured for the torque is higher than recommended, increase the thickness of the shims, and if the value measured is less than recommended, reduce the thickness of the shims. 13. Install the grease nipples in the flanges of the top and bottom pins and lubricate the set.

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Drain fluid 1. Park the machine on a level and hard surface. 2. Place a suitably sized container under the component. 3. Place the plug in the lowest position, as per the adjacent figure. 4. Remove the plug (1) to drain the fluid.

CUIL13TR00457AA

Next operation: Wheel hub - Filling (25.108)..

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1

Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Filling Prior operation: Wheel hub - Drain fluid (25.108).. 1. Place the plug (1) in the intermediate position, as shown in the figure to the side. 2. Fill the lubricant oil level up to the lower lip of the plug nozzle. 3. Install plug (1). 4. See the specification and quantity of fluid in Fluids and lubricants.

CUIL13TR00456AA

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1

Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Disassemble DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Powered front axle - Disassemble (25.100).. 1. Remove the cover bolts (1). 2. Install the two studs 380000548 (2). 3. Remove the cover (1) from the housing.

CUIL16TR00803AA

1

CUIL16TR00804AA

2

4. Remove the washer (1) that secures the control gear (2). Remove the gear.

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Remove the inner stop washer (1)

CUIL16TR00805AA

3

CUIL16TR00806AA

4

CUIL16TR00807AA

5

CUIL16TR00808AA

6

6. Remove the ring (1) on the wheel hub jam nut (2). NOTE: If desired, you can remove the hub and the support housing together, without the need to remove the jam nut from the wheel hub bearing.

7. Use the tool 380000469 (1) to remove the jam nut from the wheel hub bearing.

8. Remove the wheel hub (1) with the crown gear (2).

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Front axle system - Final drive hub, steering knuckles, and shafts

9. Use a suitable extraction tool to remove the seal.

CUIL16TR00787AA

7

CUIL16TR00788AA

8

CUIL16TR00790AA

9

10. Remove the three bolts (1) from the bottom pin of the shaft housing. Remove the lower link pin and the adjustment shims. 11. Remove the fender support and remove the support.

12. Remove the three bolts from the top link pin (1). 13. Remove the top link pin (1). Remove the front axle cradle (2). NOTE: Repeat the procedures described above on the opposite side of the front axle.

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Inspect Prior operation: Wheel hub - Disassemble (25.108).. 1. Inspect the main hub bearings. External tracks will still be in the hub box. If worn, remove them from the box with a pilot tool. 2. Mount new external tracks fitting them inside until they are properly seated. 3. Inspect the side gears bearings, the rollers, and the axles. If worn, replace the axle and the bearings. If a roller is worn or damaged, also inspect its gear support and planetary axle for damage. 4. Hold the crown (3), remove the clamping rings (1) for the support (2) and separate the crown from the support. Look for worn crown teeth.

CUIL17TR00221AA

1

CUIL17TR00222AA

2

5. Inspect the crown support stud bushings to the reciprocating housing. 6. In the housing (2), there is a replaceable detent cradle (4). Check if this support is worn. 7. Carefully inspect planetary shaft cover and support at their contact surfaces as well as support contact surfaces from planetary support to hub looking for wear and tear that could be repaired with abrasive stone.

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Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Axle shaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Axle shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Axle shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Final drive hub, steering knuckles, and shafts - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Steering knuckle and king pin - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Steering knuckle and king pin - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Wheel hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Wheel hub - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Wheel hub - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Wheel hub - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Wheel hub - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Rear axle system 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Rear axle system - 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

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Rear axle system - 27 Powered rear axle - 100

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Rear axle system - 27 Powered rear axle - 100

TECHNICAL DATA Powered rear axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Powered rear axle Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Powered rear axle Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Powered rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Rear axle system - Powered rear axle

Powered rear axle - General specification 7630 Side gears Spiral gear ratios Planetaries Total Diameter of bypass, spiral gear Shaft Diameter Differential lock Draft bars Load capacities

8030 3 5.286 4.5 23.786 333.5 mm (13 in) 66.58 mm (2.6 in) Mechanical 4082 kg (8999 lb) 5443 kg (12000 lb)

Powered rear axle - Torque Torque 407 – 475 N·m (300 – 350 lb ft) 310 – 340 N·m (229 – 251 lb ft) 240 – 298 N·m (177 – 220 lb ft) 92 – 125 N·m (68 – 92 lb ft) 136 – 170 N·m (100 – 125 lb ft) 339 – 542 N·m (250 – 400 lb ft) 176 – 258 N·m (130 – 190 lb ft) 339 – 542 N·m (250 – 400 lb ft) 115 N·m (85 lb ft) 57 – 76 N·m (42 – 56 lb ft) 57 – 76 N·m (42 – 56 lb ft) 88 – 121 N·m (65 – 89 lb ft) 37 – 50 N·m (27 – 37 lb ft) 712 N·m (525 lb ft)

Component Rear disc to hub nuts (manual adjust wheels) Rear disc to rim nuts (manual adjust wheels) Buckle-up bolts Differential case retaining bolts Drive pinion bearing retainer bolts Planetary gear retaining bolts Axle shaft housing retaining bolts Axle shaft retaining bolts Retaining bolts for the differential ring gear Differential lock fork pivot shaft retaining bolts Differential lock hanger retaining bolts Inner brake housing retaining bolts Ring gear thrust block Power adjust wheels

Powered rear axle - Special tools Tool Number 380003114

Description Tractor splitting stand

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Rear axle system - Powered rear axle

Powered rear axle - Dynamic description Description and operation There are two rear axles available. The standard rear axle uses three planetary gears in the final drive. The heavyduty rear axle uses four planetary gears. Both rear axles have a differential lock. For the cab version, engagement of the block is electro-hydraulic and in the platform version, engagement is mechanical. The rear axle, mounted on the rear of the transmission, connects the power from the engine and the transmission to the rear wheels. The following components are contained within the rear axle: • Pinion and differential gear • Differential • Differential Lock • Hydraulic brakes • Final reduction gears • Wheel axle shafts • Power Take-Off (PTO) components • Parking Brake • Fixed displacement hydraulic pumps The transmission output shaft drive is transmitted to the helical bevel pinion by the drive coupling. The pinion is situated forward of the rear axle housing and is supported by two pre-loaded conical ball bearings, and is in contact with the differential gears. The differential gear is riveted to the differential box, which is supported between the ball bearings installed in the rear axle housings. The oil supplied to the PTO and the hydraulic systems are also used in the rear axle components. The differential assembly and the differential gear are partially immersed in oil to provide lubrication for the bearings and bushings.

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Rear axle system - Powered rear axle

Powered rear axle - Sectional view

CUIL16TR01195FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

Component Outer brake housing Axle housing external bearing Axle shaft Axle shaft oil seal Side gear carrier Axle housing Brake torque pin Differential assembly PTO drive and driven gears Rear PTO shaft Differential lock assembly Rear wheel brake assembly

1

Reference (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)

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Component Side gears Axle housing internal bearing Sun Gear Differential lock fork Drive Pinion Drive pinion locknut Rear axle center housing Pinion bearing retainer Differential crown gear Thrust box Inner brake housing

Rear axle system - Powered rear axle

Powered rear axle - Drain fluid 1. Park the machine on a flat, level surface. 2. Place a suitably sized container under the component. 3. Leave the engine on for around 5 min and then turn it off. Remove the drain plug (1), which is located in the transfer case. 4. After draining the oil, re-fit the drain plug. NOTE: Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country. CUIL16TR01169AA

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1

Rear axle system - Powered rear axle

Powered rear axle - Filling 1. Remove the cover (1) and refill the system with new oil. See the system capacity and oil specifications on page Fluids and lubricants. 2. After you fill up the entire system, switch on the engine. Extend all the cylinders. Switch off the engine. Check the oil level as per the procedures described in Powered rear axle - Check oil level (27.100). NOTE: When operating with remote cylinders, the oil level at the rear axle is affected.

CUIL14TR00360AA

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1

Rear axle system - Powered rear axle

Powered rear axle - Check oil level 1. Position the machine on a flat, level surface. 2. Check the oil level with all arms of the hydraulic lifter in the lowered position and the engine off for at least 5 min. Remove the dipstick (1). Check whether the oil level reaches the MAX mark on the dipstick.

CUIL14TR00359AA

1

CUIL14TR00360AA

2

3. If the oil level is below the mark MIN, add oil. Remove the cover (2) from the filler neck. Add oil as necessary. See page Fluids and lubricants for the correct oil specification.

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Rear axle system - Powered rear axle

Powered rear axle - Remove Splitting the transmission, engine and front support from the rear axle WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

1. Remove the fuel tank. Consult the procedures in Fuel tank - Remove (10.216). 2. Disconnect the electric harness as necessary to allow splitting the transmission from the rear axle. 3. Use an appropriate cable to connect a block and tackle to the front weights and remove the front weights (if installed). 4. Remove the Auxiliary Front Wheel Drive (AFWD) drive shaft. Consult the procedures in Drive shaft - Remove (23.314).

CUIL13TRO0092AA

1

CUIL16TR01370AA

2

LAIL11TS0202A0A

3

5. Position wooden wedges (1) between the front axle and the front support. This prevents axle articulation.

6. Position the tractor splitting kit 380003114 beneath the tractor. NOTE: Ensure the transmission and rear axle sections are fully supported to prevent any movement when the transmission is removed. 7. Use the cradle in the splitting kit to support the rear axle on the platform for splitting. 8. Use the cradle in the splitting kit to support the rear axle on the cart for splitting.

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Rear axle system - Powered rear axle

9. Check that all the necessary electrical connectors and hoses have been disconnected. You may need to disconnect additional items because of other optional equipment installed on the tractor. 10. Remove the fixing bolts from the transmission to the rear axle. 11. Remove the transmission and engine from the rear axle.

LAIL11TS0203A0A

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4

Rear axle system - Powered rear axle

Powered rear axle - Install NOTE: Ensure the transmission and rear axle sections are fully supported to prevent any movement when the transmission is removed. 1. Thoroughly clean and degrease the entire contact surface. Apply a bead of liquid gasket of approximately 2 mm in diameter. Follow the pattern shown. 2. Align the transmission to the rear axle and install the fixing bolt from the transmission to the rear axle. Torque to the specified value. 3. Install the front wheel drive shaft and the central cradle. Consult the procedures in Drive shaft - Install (23.314). 4. Use an appropriate cable to connect a block and tackle to the front weights. Install the front weights (if installed). 5. Install the electric motor. 6. Install the fuel tank. Consult the procedures in Fuel tank - Install (10.216).

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Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Powered rear axle - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Powered rear axle - Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Powered rear axle - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Powered rear axle - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Powered rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Powered rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Powered rear axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Powered rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Powered rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Rear axle system - 27 Rear bevel gear set and differential - 106

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Rear axle system - 27 Rear bevel gear set and differential - 106

TECHNICAL DATA Rear bevel gear set and differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Bevel gear Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Differential Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Differential lock Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exploded view - Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Bevel gear Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Differential Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Differential lock mechanical control Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - General specification Differential bearing preload Spin torque of the differential bearing with pull torque: 7 – 30 kgf (15.43 – 66.14 lbf)

Resulting number 0.61 0.76 0.91 1.07 1.22 1.37 1.50 1.65

– – – – – – – –

0.74 mm 0.87 mm 1.04 mm 1.19 mm 1.35 mm 1.50 mm 1.63 mm 1.78 mm

(0.024 (0.030 (0.036 (0.042 (0.048 (0.054 (0.059 (0.065

– – – – – – – –

Spacer to be installed

0.029 in) 0.034 in) 0.041 in) 0.047 in) 0.053 in) 0.059 in) 0.064 in) 0.070 in)

0.97 1.12 1.27 1.42 1.58 1.73 1.88 2.03

– – – – – – – –

1.02 mm 1.17 mm 1.32 mm 1.47 mm 1.63 mm 1.78 mm 1.93 mm 2.08 mm

(0.038 (0.044 (0.050 (0.056 (0.062 (0.068 (0.074 (0.080

– – – – – – – –

0.040 in) 0.046 in) 0.052 in) 0.058 in) 0.064 in) 0.070 in) 0.076 in) 0.082 in)

Final drive pinion preload Drive pinion preload tool Pull torque

1.1 – 1.9 N·m (0.8 – 1.4 lb ft) 5.90 – 10.50 kgf (13.01 – 23.15 lbf)

Rear bevel gear set and differential - Special tools Tool Number 380000503 380000549 NHT-0010 380000991

Description Bevel pinion grooved retainer Slide hammer Internal extractor for bearing cap Bearing preload

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Rear axle system - Rear bevel gear set and differential

Bevel gear - Exploded view

CUIL17TR00262FA

Reference (1) (2) (3) (4)

Component Pinion Shaft Bearing, roller Fixing ring Bearing, conical roller

1

Reference (5) (6) (7) (8)

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Component Bearing, conical roller Lock nut Spring washer Retainer bearing

Rear axle system - Rear bevel gear set and differential

Differential - Exploded view

CUIL17TR00264FA

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component Cone and roller assembly Ring gear and housing assembly Side gear Pinion gear assembly Side gear Differential case Cone and roller assembly Coupling

1

Reference (9) (10) (11) (12) (13) (14) (15) (16)

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Component Differential lock ring Stop washer Spring Adaptor Retaining Screw Back-up Washer Back-up Washer Back-up Washer

Rear axle system - Rear bevel gear set and differential

Differential lock - Dynamic description The machines are equipped with a differential lock system to avoid wheel slippage. For example, if working on soft terrain and one of the wheels begins to slide, all of the machine’s force is transferred to that wheel and the machine does not move. The differential lock assembly is installed on the left side of the crown wheel and overcomes machine wheel slippage by connecting one of the side gears to the differential case assembly. This way, the differential is joined and it has direct control over both wheels. The differential lock is made up of • a sliding coupling (3) connected to the spline of the side gear. • An adaptor (2) positioned between the coupling and the left hand differential case (1). • a spring (4) positioned between the coupling and the adapter. The spring ensures the coupling only enters the adaptor when necessary and that the adaptor trigger and the differential casing are not permanently connected. • a fork and lever assembly (not shown). The fork and the lever work by means of a foot activated spring. When the fork moves, it forces the coupling’s trigger teeth into the adaptor, resulting in the joining of the lateral gear to the differential casing. Once the differential lock of the mechanical drive has been connected, the operator may take the foot off the pedal.

CUIL17TR00286AA

1

The mechanical differential lock is automatically disconnected when the pressure from the spring rises above the lateral force from the coupling teeth. This only happens when the torque is equal in both wheels. NOTICE: Avoid using the differential lock at speeds greater than 8 km/h (5 mph) or when the machine is turning. Engaging the lock causes problems in machine's steering. NOTICE: If one of the rear wheels begins to slide, reduce the motor’s speed before connecting the differential block in order to avoid damaging the transmission.

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Rear axle system - Rear bevel gear set and differential

Differential lock - Exploded view - Pedal

CUIL17TR00263FA

Reference (1) (2) (3) (4) (5)

1

Component Pedal Floor panel cover Counter nut Pedal rod Locking ring

Reference (6) (7) (8) (9)

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Component Axle rod Bushings Stand off Support pivot pin

Rear axle system - Rear bevel gear set and differential

Bevel gear - Remove DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Separate the machine between the transmission and the differential housing. 2. Remove the Power Take-Off (PTO) clutch assembly. Consult the procedures in Power Take-Off (PTO) clutch - Remove (31.114). 3. Remove the emergency brake from the transmission. 4. If installed, remove the transmission hand brake shield from the pinion drive gear. 5. Remove the differential and the differential lock assembly. Consult the procedures in Differential - Remove (27.106). 6. Remove the bolts and washers that secure the drive pinion. 7. Remove the drive pinion assembly (1) from the housing (3). To facilitate removal, place jacking bolts (4) in the holes in the bearing retainer (2) 380000503.

CUIL16TR01127AA

Next operation: Bevel gear - Disassemble (27.106)..

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1

Rear axle system - Rear bevel gear set and differential

Bevel gear - Disassemble Prior operation: Bevel gear - Remove (27.106).. 1. Remove the staked nut or the double nut, if installed, from the pinion axle. 2. Remove the spacer, gear, and emergency brake shims from the transmission, if it is assembled, or the washer from the pinion axle. 3. With a hammer, tap the end of the pinion axle by the gear retainer. 4. Remove the block ring from the front part of the pinion and remove the pinion axle gearing using a puller with a suitable attachment. 5. Remove taper and roller from the axle using a puller with a suitable attachment. Next operation: Bevel gear - Inspect (27.106)..

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Rear axle system - Rear bevel gear set and differential

Bevel gear - Inspect Prior operation: Bevel gear - Disassemble (27.106).. 1. Clean and inspect all components for damage or excessive wear. Replace as required. 2. If necessary, remove the gearing cups from the retainer 380000503. Use the slide hammer 380000549 with a suitable attachment to remove the gearing cups. To install the gearing cups, use a step plate and the press. 3. Install the rear taper and roller in the pinion axle using a puller with a suitable attachment and a bushing. Next operation: Bevel gear - Preload (27.106)..

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Rear axle system - Rear bevel gear set and differential

Bevel gear - Preload Prior operation: Bevel gear - Inspect (27.106).. Before installing the final drive pinion and the retainer, check the preload of the pinion bearing: 1. Lubricate the pinion bearing and place the retaining pinion in a bench screw. 2. Install the staked nut or the double nut, the new washer and the locknut.

CUIL16TR01173AA

1

CUIL16TR01174AA

2

3. With the gauge (1) and the adaptor (2) of the drive pin preload tool or with a spring scale, check and adjust the preload. • Drive pin preload tool: 1.1 – 1.9 N·m (0.8 – 1.4 lb ft) • Spring scale: 5.9 – 10.5 kgf (13.01 – 23.15 lbf) 4. Once you have set the correct preload, tighten the locknut and fold the washer's flaps or stake the nut accordingly. 5. Check the preload again. 6. Tighten the bearing retainer cradle bolts to a torque of 136.0 – 170.0 N·m (100.3 – 125.4 lb ft).

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Rear axle system - Rear bevel gear set and differential

Differential - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Chock the front wheels to prevent unexpected movement. 2. Remove the final drive housing. See the sequence of procedures in Final drive housing - Remove (27.120). 3. With the axle housing removed, remove the differential assembly (1).

CUIL16TR01166AA

Next operation: Differential - Disassemble (27.106)..

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1

Rear axle system - Rear bevel gear set and differential

Differential - Disassemble Prior operation: Differential - Remove (27.106).. 1. Remove the differential lock ring (1) from the end of the gear. 2. Remove the thrust washer (5) and the locking sleeve (4). 3. Remove the spring (3) and coupling (2). 4. Mark the two halves of the differential casing in order to facilitate its correct mounting. 5. Remove the cone and roller from the smaller half of the casing using puller with a suitable attachment and a step plate. 6. Remove the set screws from the differential casing. NOTE: If changing the taper and roller in the smaller half of the casing is unnecessary, dismantling of the casing screws can be done by lifting the smaller half of the casing and gradually removing the screws. 7. Separate the differential casing. 8. Remove the thrust washer, bevel gear, crosshead, pinion, lateral gear and washer from the housing. 9. Remove the tapered bearing from the crown gear half of the casing, with the help of the extractor NHT-0009. 10. Separate pinions from crosshead. Next operation: Differential - Inspect (27.106)..

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CUIL16TR01170AA

1

Rear axle system - Rear bevel gear set and differential

Differential - Inspect Prior operation: Differential - Disassemble (27.106).. 1. Clean and inspect all components for damage or excessive wear. Replace as required. 2. To replace the differential crown gear, proceed as follows: A. Drill out the rivets installed during production. B. Install the bolts and nuts . C. Torque the bolts toTorque the bolts to 115 N·m (85 lb ft). D. Install a new, matching drive pinion assembly with the new crown gear. Next operation: Differential - Assemble (27.106)..

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Rear axle system - Rear bevel gear set and differential

Differential - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Differential - Inspect (27.106).. Assemble the differential in the reverse order of disassembly, with these requirements: 1. Coat all bearings with suitable grease before installing. 2. To correctly install the retaining ring after the pilot bearing on the pinion shaft, place the ring into the groove, and use pliers to form the ring into the groove. 3. Tighten the differential case retaining bolts to a torque of 92 – 125 N·m (68 – 92 lb ft). Next operation: Differential - Install (27.106)..

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Rear axle system - Rear bevel gear set and differential

Differential - Install CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Installation of the differential and differential lock is done in the reverse order used for removal, but pay attention to the following points: 2. Check the differential bearing preload. Consult the procedures in Differential - Preload (27.106).

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Rear axle system - Rear bevel gear set and differential

Differential - Preload Prior operation: Differential - Install (27.106).. To adjust the bearing preload, add or remove spacers between the differential bearing cup and the inner brake housing. The bearing preload is adjusted through the right-hand axle shaft housing. 1. Mount the lower brake disk into the axle housing, without the intermediate axle, brake disks or actuator. 2. Remove the differential bearing cap with the help of the extractor NHT-0010 and the slide hammer 380000549. Remove the spacer from the inner brake housing. 3. Place the gauge of the bearing preload tool where the bearing is missing. 4. Fix the bridge of the bearing preload tool from the buckle in the inner brake housing, making sure the spacers stay between the buckle and the implement. 5. With gauges, measure the separation between the front part of the bridge and the top side of the gauge block. CUIL16TR01171AA

6. Determine the size of spacer to use. Refer to the table below.

0.61 0.76 0.91 1.07 1.22 1.37 1.50 1.65

– – – – – – – –

Gap measurement 0.74 mm (0.024 – 0.029 in) 0.87 mm (0.030 – 0.034 in) 1.04 mm (0.036 – 0.041 in) 1.19 mm (0.042 – 0.047 in) 1.35 mm (0.048 – 0.053 in) 1.50 mm (0.054 – 0.059 in) 1.63 mm (0.059 – 0.064 in) 1.78 mm (0.065 – 0.070 in)

0.97 1.12 1.27 1.42 1.58 1.73 1.88 2.03

7. Remove the bearing preload tool. 8. Install the new, selected spacer and reinstall the bearing. 9. Check the spin torque of the differential. NOTE: It is very important to test the spin torque since the bridge of the preload tool only identifies the initial size of the spacer. 10. Remove the left axle housing, if it has not already been removed. 11. Remove the pinion and the bearing retainer.

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Spacer to be installed – 1.02 mm (0.038 – 0.040 in) – 1.17 mm (0.044 – 0.046 in) – 1.32 mm (0.050 – 0.052 in) – 1.47 mm (0.056 – 0.058 in) – 1.63 mm (0.062 – 0.064 in) – 1.78 mm (0.068 – 0.070 in) – 1.93 mm (0.074 – 0.076 in) – 2.08 mm (0.080 – 0.082 in)

1

Rear axle system - Rear bevel gear set and differential

12. Remove the differential lock spring and place the differential lock coupling in the connection position (1). 13. With the differential installed and the buckle from the right inner brake housing screwed into the differential housing, install one of the intermediate control axles (2) in the differential. 14. Install a dynamometer (3) around the idler shaft. Measure spin torque while the shaft is spinning. Do not measure when the shaft first begins to rotate. The rolling spin torque measured by the pull scale must be 7 – 10 kgf (15.43 – 22.05 lbf). 15. If necessary, add or remove spacers to adjust the spin torque.

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CUIL16TR01172AA

2

Rear axle system - Rear bevel gear set and differential

Differential lock mechanical control - Disassemble 1. Refer to the Differential lock - Exploded view - Pedal (27.106) for an overview of the differential lock components. 2. Remove the cotter pin and washer (1) from the pedal assembly (2). Remove the guide bracket (3).

CUIL17TR00289AA

1

CUIL17TR00290AA

2

CUIL17TR00290AA

3

CUIL17TR00291AA

4

3. Remove both bolts (1) from the hanger and lock rod assembly (2).

4. Remove the grooved pin from the rod assembly. Remove and disassemble the hanger and lock rod assembly. 5. Turn the pedal assembly 90° away from the tractor and slide the pedal out of the slot opening on the operator platform. 6. If the differential shifter fork needs to be replaced, remove the left axle housing to obtain access. Consult the procedures in Final drive housing - Remove (27.120).

7. With the axle housing taken out, remove the two bolts (1) that fix the pivot shaft (2) to the differential box. Remove the pivot shaft and shifter fork (3) together, as one piece.

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Rear axle system - Rear bevel gear set and differential

Differential lock mechanical control - Assemble Prior operation: Differential lock mechanical control - Disassemble (27.106). Assemble the differential lock command linkage in the reverse order of disassembly, with the following requirements: 1. Inspect all components and replace warn or damaged parts. 2. Tighten the pivot shaft bolts in the differential lock fork to a torque of 57 – 76 N·m (42 – 56 lb ft). 3. Torque the pedal guide bolt to 57 – 76 N·m (42 – 56 lb ft). 4. If the differential housing was removed, make sure that the bolts are tightened to a torque of 176 – 258 N·m (130 – 190 lb ft). 5. Refill the axle with the correct grade and quantity of oil. Next operation: Differential lock mechanical control - Adjust (27.106).

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Rear axle system - Rear bevel gear set and differential

Differential lock mechanical control - Adjust Prior operation: Differential lock mechanical control - Assemble (27.106).. 1. If the differential lock control linkage has been disassembled for service, connect the lower rod to the upper rod with the threaded coupler (1), simultaneously threading the coupler onto the upper and lower rods. Adjust as necessary.

CUIL17TR00287AA

1

CUIL17TR00287AA

2

CUIL17TR00288AA

3

CUIL17TR00287AA

4

2. If the differential lock has not been disassembled and only requires adjustment, use the threaded coupler to loosen the jam nuts (1) and adjust the pedal free play.

3. Adjust the coupler (as shown) to provide a minimum of 6 mm (0.25 in) free play at the differential lock pedal. NOTE: A minimum of 6 mm (0.25 in) of free play will ensure that the differential lock fully disengages.

4. After you adjust the free play, depress the pedal. Torque the two jam nuts to 87 – 116 N·m (64 – 86 lb ft). NOTE: After tightening the jam nuts, test the differential lock by starting the tractor and engaging and disengaging the differential lock. After testing the differential lock, recheck the differential lock pedal free play. If the specification of a minimum of 6 mm (0.25 in) is not met, repeat the adjustment procedure until the specification is achieved.

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Index Rear axle system - 27 Rear bevel gear set and differential - 106 Bevel gear - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Bevel gear - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Bevel gear - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Bevel gear - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Bevel gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Differential - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Differential - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Differential - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Differential lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Differential lock - Exploded view - Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Differential lock mechanical control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Differential lock mechanical control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Differential lock mechanical control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Rear bevel gear set and differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Rear bevel gear set and differential - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Rear axle system - 27 Planetary and final drives - 120

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Rear axle system - 27 Planetary and final drives - 120

TECHNICAL DATA Planetary and final drives Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Planetary final drive Planetary final drive - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Planetary final drive Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Final drive housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Rear axle system - Planetary and final drives

Planetary and final drives - Special tools Tool Number NHT-0007 380000549 NHT-0409 NHT-0001 NHT-0002 NHT-0009

Description Internal extractor for the bearing Sliding hammer Special tool Universal Extractor Base plates for extractor Bearing Extractor

Manufacture an adapter plate to disassemble the final drive sun gear, according to the figure below.

RCPH09TTS001FAF

Reference (A) (B) (C) (D) (E) (F) (G) (H) (I)

1

Dimension 254.0 mm (10.0 in) 76.2 mm (3.0 in) 45° 60° 63.5 mm (2.5 in) Radius = 127.0 mm (5.0 in) 4 x 12.7 mm (0.5 in) in B.S.W. 101.6 mm (4.0 in) 12.7 mm (0.5 in)

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Rear axle system - Planetary and final drives

Planetary final drive - Overview In order to increase the torque transmitted to the rear wheels, there is a set of epicyclic reduction gears is in each rear axle housing. The end of each intermediate shaft functions as a planetary sun gear around which there are three side gears. The side gears are mounted onto a support that is splined to the rear axle. The side gears mesh with a ring gear that is mounted on the axle housing. When the intermediate shaft turns, the side gears turn around the inside of the fixed ring gear. This action makes the planetary sun gear turn and reduces the speed, which transmits more torque to the rear axle and wheels.

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Rear axle system - Planetary and final drives

Planetary final drive - Disassemble Prior operation: Final drive housing - Disassemble (27.120).. 1. Remove the ring that holds the planetary (side) gear shafts. 2. Place the carrier assembly on a press. NOTE: The cone and bearing assembly is only installed on the carrier of model 8 x 2 tractors. 3. Remove the cone and roller assembly (5) and the planetary gear shafts (3). To remove these parts, use a step plate (1), three sockets (2), a bearing puller attachment (4), an insulated base (6), and a slave ring (7).

CUIL17TR00293AA

1

CUIL17TR00294AA

2

4. Remove the support gears (3), thrust washers (2) and spacers from the carrier (5). Retain the rollers (4) located between the planet gear shafts (1) and the gears for reassembly. 5. Use the sliding hammer and a puller to remove the gear funnel situated inside the axle housing.

Next operation: Planetary final drive - Inspect (27.120)..

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Rear axle system - Planetary and final drives

Planetary final drive - Inspect CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Planetary final drive - Disassemble (27.120).. 1. Clean and inspect all components for damage or excessive wear. Replace as required. 2. If the planetary crown gear (1) requires replacement, proceed as follows: 3. Insert the universal extractor NHT-0001 to remove the planetary crown (2) behind the gear (1). Adjust the movable plates NHT-0002 to the desired location. Tighten jam nuts (3). 4. If needed, manufacture a special plate for use with the planetary crown extractor/inserter as shown in Planetary and final drives - Special tools (27.120). 5. Position the axle housing under a hydraulic press with the ball end of the housing downward. Insert a bar between the planetary crown puller/inserter and the press ram. Press the crown gear out. 6. Install a new crown gear with the bell end of the axle housing up. Press the crown gear in, until the crown gear is completely seated and there is no gap between the bottom of the gear and the housing shoulder. Next operation: Planetary final drive - Assemble (27.120)..

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CUIL16TR01129AA

1

Rear axle system - Planetary and final drives

Planetary final drive - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Planetary final drive - Inspect (27.120).. 1. When assembling the planetary support, install the same number of rollers to both sides of the spacer between the gear housing. 2. Hold rollers with grease while simultaneously installing the side gear axles. Place the shafts, with the flat part at the head isolated in the center of the support, and then install the fastening ring (1). 3. Fold the ends (2) to set the fastening ring in place.

CUIL17TR00292AA

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1

Rear axle system - Planetary and final drives

Final drive housing - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Powered rear axle - Drain fluid (27.100).. 1. Remove rear wheels. 2. Place a fixed trestle under the frame at the rear base (1) of the cab. Perform the procedure on both sides of the machine. 3. Loosen the bolts (2) that fasten the rear of the cab to the rear axle housing. Perform the procedure on both sides of the machine.

CUIL14TR00788AA

1

CUIL14TR00351AA

2

CUIL16TR00240AA

3

4. Disconnect the service brake line (1) from the final drive housing.

5. Remove the nut (2). Remove the pin (1) from the parking brake.

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Rear axle system - Planetary and final drives

6. Support the final drive housing (1) crosswise with a hydraulic jack (2). 7. Remove the fastening bolts and remove the final drive housing.

LAIL11TS0089A0A

Next operation: Final drive housing - Disassemble (27.120)..

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4

Rear axle system - Planetary and final drives

Final drive housing - Disassemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Final drive housing - Remove (27.120).. 1. Remove the O-ring from the inner end of the axle housing. 2. Remove the hydraulic brake assembly from the housing. 3. Remove intermediate shaft . 4. Remove the bolt and retaining lock washer from the half-shaft.

CUIL16TR01166AA

1

CUIL16TR01130AA

2

CUIL16TR01131AA

3

5. Use the special tool NHT-0007 NHC-00 (1) and remove the planetary final drive assembly (2). 6. Remove the shim located below the drive assembly. NOTE: When lifting the final drive assembly, make sure the special tool is positioned correctly. Do not try to remove or change the assembly without using the correct tool. Failure to comply could result in serious injuries.

7. Use a universal extractor NHT-0001. Remove the halfshaft from the housing. 8. Repeat the same procedure for the housing on the opposite side.

Next operation: Final drive housing - Inspect (27.120)..

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Rear axle system - Planetary and final drives

Final drive housing - Inspect CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Final drive housing - Disassemble (27.120).. 1. Inspect all components for damage or wear. Replace as required. 2. If you need to remove the retainer and bearing from the half-shaft, use a suitable extractor NHT-0009 (1).

CUIL17TR00283AA

1

CUIL17TR00284AA

2

3. Install the shaft seal followed by the bearing assembly, using a suitable line and press. 4. If necessary, use the slide hammer 380000549 with the extractor NHT-0010 to remove the bearing cup from the outer end of the axle housing. To replace the bearing cup, use a step plate and a mallet. Seat the bearing cup completely in the axle housing.

Next operation: Final drive housing - Assemble (27.120)..

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Rear axle system - Planetary and final drives

Final drive housing - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Final drive housing - Inspect (27.120).. 1. Make sure that the brake actuators (1) and the hydraulic hoses are properly installed. The left actuator piping goes towards the hub of the wheel. The right actuator hub goes above, towards the filter.

CUIL17TR00285AA

1

CUIL16TR01166AA

2

2. Install the half-shaft and inner bearings in the housing. 3. Install the shim and the lock washer below the gear assembly, and then install the planetary gear assembly in the axle housing. 4. Install the intermediate shaft. 5. Install the hydraulic brake assembly. 6. If the right-hand axle housing was removed, install the differential assembly to prevent damaging any component during the detailing of the axle parts.

Next operation: Final drive housing - Preload (27.120)..

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Rear axle system - Planetary and final drives

Final drive housing - Preload Prior operation: Final drive housing - Assemble (27.120).. 1. Install the axle into the axle housing. 2. Install the inner bearing cone and roller assembly on the axle shaft. Using a suitable sized pipe, tap the bearing into the axle shaft. DO NOT set the bearing completely over its housing. 3. Install the larger 2.16 mm (0.09 in) spacer onto the axle and mount the planetary gear carrier in the axle housing. 4. Install and tighten the support set screws to a torque of 339 – 542 N·m (250 – 400 lb ft).

CUIL16TR01132AA

1

CUIL16TR01133AA

2

5. Position the comparator dial (2) and adjust to zero. 6. Lift the axle housing (1) to measure the play. 7. Subtract the amount of play from the size of the installed spacer to determine the correct size of the spacer to be mounted. Refer to the following example. • Installed spacer: 2.16 mm (0.09 in) • Obtained reading: 0.66 mm (0.03 in) • Resulting number: 1.50 mm (0.06 in)

Resulting number 1.24 1.35 1.45 1.55 1.65 1.75 1.85 1.96 2.06 2.16 2.26

– – – – – – – – – – –

1.32 mm 1.42 mm 1.52 mm 1.63 mm 1.73 mm 1.83 mm 1.93 mm 2.03 mm 2.13 mm 2.24 mm 2.34 mm

(0.049 (0.053 (0.057 (0.061 (0.065 (0.069 (0.073 (0.077 (0.081 (0.085 (0.089

– – – – – – – – – – –

Shim to be installed

0.052 in) 0.056 in) 0.060 in) 0.064 in) 0.068 in) 0.072 in) 0.076 in) 0.080 in) 0.084 in) 0.088 in) 0.092 in)

1.14 mm 1.24 mm 1.35 mm 1.45 mm 1.55 mm 1.65 mm 1.75 mm 1.85 mm 1.96 mm 2.06 mm 2.16 mm

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(0.045 in) (0.049 in) (0.053 in) (0.057 in) (0.061 in) (0.065 in) (0.069 in) (0.073 in) (0.077 in) (0.081 in) (0.085 in)

Rear axle system - Planetary and final drives

8. Remove the set screw from the axle and remove the planetary gear carrier assembly (1), the safety washer and the large spacer. 9. Install the newly selected spacer and then install the safety washer and the planetary gear carrier assembly. 10. Install the set screw and tighten to a torque of 339 – 542 N·m (250 – 400 lb ft).

CUIL16TR01133AA

3

CUIL16TR01134AA

4

CUIL16TR01134AA

5

11. After shimming is complete, measure the axle shaft rolling torque. 12. Fabricate a plate (1), with a bolt head or nut welded in the center, to slide over the wheel studs (2). Plate specifications: • (A) 51 mm (2 in) • (B) 101.6 mm (4 in) • (C) 101.6 mm (4 in) • (D) 22 mm (0.875 in) diameter

13. Use a torque wrench (1) to check the rolling torque. Specification is 11.6 – 28.2 N·m (8.6 – 20.8 lb ft). 14. Add or remove shims as needed. 15. Repeat for opposite-side rear axle shaft.

Next operation: Final drive housing - Install (27.120)..

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Rear axle system - Planetary and final drives

Final drive housing - Install CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Final drive housing - Preload (27.120).. 1. Use the floor jack (2) and position the final drive housing (1) near the central housing 2. Install the attaching bolts.

LAIL11TS0089A0A

1

CUIL16TR00240AA

2

CUIL14TR00351AA

3

3. Install the parking brake drive pin (1). 4. Install the nut (2).

5. Connect the service brake line (1). 6. Fill the powered rear axle with oil. Consult the procedures in Powered rear axle - Filling (27.100). 7. When necessary, adjust the service brake. 8. When necessary, adjust the parking brake.

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Index Rear axle system - 27 Planetary and final drives - 120 Final drive housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Final drive housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Final drive housing - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Final drive housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Final drive housing - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Final drive housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Planetary and final drives - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Planetary final drive - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Planetary final drive - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Planetary final drive - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Planetary final drive - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Power Take-Off (PTO) 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Power Take-Off (PTO) - 31

[31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2

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Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

FUNCTIONAL DATA Power Take-Off (PTO) control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Power Take-Off (PTO) control valve Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Exploded view

CUIL16TR01357FA

1

Reference (1) (2) (3) (4)

Component Lynch pin Spring Control valve spindle Control valve body

Reference (8) (9) (10) (11)

(5)

Brake piston

(12)

(6) (7)

Return spring Locking ring

(13)

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Component Guide Cover (chamfer facing up) Locking ring Lubrication circuit safety valve Low pressure circuit pressure regulator valve Ball and stop spring

Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Pressure setting 1. The low-pressure system for machines with mechanical transmission is adjusted on the Power Take-off (PTO) control valve. 2. To access the control valve, remove the housing of the hydraulic lift. Consult the procedures in Rear threepoint hitch - Remove (37.110). 3. The control valve (1) is located in the rear axle housing.

CUIL17TR00011AA

1

CUIL17TR00010AA

2

4. Use the regulator valve (1) to adjust the pressure. 5. The pressure specification for the low-pressure system is 16.0 – 18.0 bar (232.0 – 261.0 psi).

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Index Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104 Power Take-Off (PTO) control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Power Take-Off (PTO) control valve - Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

TECHNICAL DATA Two-speed rear Power Take-Off (PTO) General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Two-speed rear Power Take-Off (PTO) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Two-speed rear Power Take-Off (PTO) Two-speed rear Power Take-Off (PTO) - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Two-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Two-speed rear Power Take-Off (PTO) - Mechanical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Two-speed rear Power Take-Off (PTO) - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Front drive shaft Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Driven shaft Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Power Take-Off (PTO) clutch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE Front drive shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Backlash longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Backlash longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power Take-Off (PTO) clutch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - General specification Solenoid operated Power Take-Off (PTO) with fixed displacement hydraulic pump 7630 Pressure regulator valve – Engine at 2100 RPM Pressure regulator valve – Engine at 800 RPM Lubrication circuit regulator valve – Engine at 800 RPM

8030 16 – 18 bar Minimum 13 bar 5.3 – 8.5 bar

Two-speed rear Power Take-Off (PTO) - Torque Torque 65 – 85 N·m 190 – 230 N·m 27 – 35 N·m 1.0 N·m 21 – 27 N·m 1 – 1.2 N·m 19 – 23 N·m 37 – 50 N·m 27 – 34 N·m

Component Rear shaft roller bearing retainer bolts Bearing retainer for the PTO output shaft Valve front pin Tighten rear (clearance 1/4 of a turn) Rear pin pressure nut Adjustment bolt for the PTO brake belt Clutch Support Bolts Deposit cap bolts Fork bolts

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Dynamic description The mechanical operating principle for the electro-hydraulic Power Take-Off (PTO) is basically the same as the principle for the mechanical PTO. We can use the latter as a basis to understand the operation. The path followed by the engine flywheel power to the output shaft is the same, except for the activation mechanism (on and off), which is not mechanical (lever), but electric (switch). The output shaft working speed depends on the engine speed. By design, the shaft with six thick splines is indicated for normal work at 540 RPM. The shaft with 21 thin splines is aimed at more heavy duty work that consequently requires more power. The following types of electro-hydraulic PTO systems are available: • One-speed PTO with one standard output shaft and six splines for work at 540 RPM. • Non-variable two-speed PTO with two output shafts six and 21 variable spline output shafts for work at 540 RPM and 1000 RPM.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Sectional view Components of the variable two-speed Power Take-Off (PTO)

CUIL16TR01330GA

Reference (1) (2) (3) (4) (5) (6) (7)

Component Drive gear assembly Drive gear bearing shims Bearing retainer Driven gear – 540 RPM Driven gear – 1000 RPM Output shaft snap ring Output shaft

1

Reference (8) (9) (10) (11) (12) (13) (14)

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Component Sleeve Trust-washer Lower cover Needle thrust bearing Output shaft front bearing Shaft, upper Snap ring

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Mechanical schema

CUIL16TR01356FA

Reference (1) (2) (3) (4) (5) (6)

Component Cover of the Power Take-Off (PTO) output shaft PTO output shaft 1000 RPM driven gear 540 RPM driven gear Oil supply line PTO valve assembly

1

Reference

Component

(7)

PTO input shaft

(8) (9) (10) (11) (12)

Hydraulic pump drive gear PTO clutch assembly Brake band Rear PTO shaft Dual drive gear

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Hydraulic schema Oil Flow – Clutch disengaged The return oil from the steering circuit goes through the pump and into the Power Take-Off (PTO) control valve. In the PTO clutch assembly, the oil pressure of the low pressure circuit is regulated by the pressure regulator valve in the low pressure circuit. This valve regulates the pressure of the entire low-pressure circuit (steering return oil). The excess pressure is discharged to the lubrication circuit. The low pressure hydraulic circuit drives the PTO and Dual Power clutch (when installed). The steering return hydraulic circuit must have a pressure of 15 – 18 bar. See Hydraulic systems - Dynamic description (35.000) for the description and function of the low pressure hydraulic circuits. The excess oil pressure that passes through the pressure regulator valve provides the PTO and the Dual Power clutches with lubrication. The oil pressure in the lubrication circuit is regulated by a valve located in the PTO control valve body, together with the pressure regulator valve of the low pressure circuit. The pressure in the lubrication circuit must be between 5.0 – 8.0 bar. Under normal working conditions and with hot oil, this valve is normally closed. When the PTO selector lever is in the disengaged position, the control valve spindle directs the oil pressure to the brake piston. This allows the drive oil of the clutch piston to return to the tank by the action of the piston return spring. The hydraulic pressure displaces the brake piston against the return spring resistance, fastens the belt and prevents the clutch housing from continuing to turn by drag. When the tractor engine is switched off, the pressure regulator valve closes and a groove in the valve spindle body allows the oil applied to the brake piston to return to the tank. This helps to couple the implements to the PTO output shaft

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

CUIL17TR00254GA

1

Return (Tank)

Oil pressure Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Clutch Housing Sealing rings Clutch support Orifice Lubrication circuit valve Low-pressure circuit pressure regulation valve Oil outlet for the radiator Restriction Control valve spindle

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Reference (10) (11) (12) (13) (14)

Component Stop and ball spring Brake piston Brake piston return spring Clutch piston return spring Clutch hub

(15)

Clutch discs

(16) (17)

Brake belt Clutch piston

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Oil Flow – Clutch engaged The control valve spool is composed of two parts connected by a connecting rod and a spring, which allows the clutch to engage smoothly. When the PTO selector lever starts to move into the engaged position, the control valve blocks the oil pressure line and allows the oil pressure in the clutch brake to return to the tank (rear axle). This produces a “loose brake” and “loose clutch” situation. As the selector valve is moved into the engaged position, the control valve spindle discovers the opening, and a controlled flow of oil flows to the clutch. At the same time, the oil passes through a perforation and reaches the end of the control valve. In this position, a “loose brake” and “loaded clutch” situation is produced. The increase in pressure in the clutch and in the extremity of the control valve spool displaces the spool against the pressure of the spring that is located between the two halves of the control valve, and which restricts the flow of oil to the clutch. This restriction of oil ensures that the PTO engagement is dampened in relation to the movement of the selector lever. When the selector lever is in the completely engaged position, the spring at the end of the control valve spool is completely compressed and the spool completely releases the passage of oil to the clutch. It is no longer possible to dampen against the compressed spring and maximum pressure is applied to fully engage the clutch. If the selection lever is moved quickly to the engaged position, a restriction at the pressure line input (Item (8)) reduces the oil flow to the clutch and prevents the abrupt engagement.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Oil flow in the mechanical PTO – clutch engaged

CUIL17TR00255GA

Oil pressure Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

2

Return (Tank)

Lubrification Component Clutch Housing Sealing rings Clutch support Orifice Lubrication circuit valve Low-pressure circuit pressure regulation valve Oil outlet for the radiator Restriction Control valve spindle

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Reference (10) (11) (12) (13) (14)

Component Stop and ball spring Brake piston Brake piston return spring Clutch piston return spring Clutch hub

(15)

Clutch discs

(16) (17)

Brake belt Clutch piston

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Exploded view

CUIL16TR01359FA

Reference (1) (2) (3) (4) (5)

Component Cover Shims (driven gear longitudinal clearance) Drive gear set Shims (rear shaft longitudinal clearance) Shaft, upper

1

Reference (6) (7) (8) (9)

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Component Lock Ring Lock Ring Bearing Bearing

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Driven shaft - Exploded view Interchangeable output shaft and driven gears of the two-speed Power Take-Off (PTO)

CUIL16TR01358FA

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component Output shaft lock ring Output shaft guard Output axle retainer Seal Output shaft sleeve retainer Output shaft sleeve Separating rings Moved gear of 540 RPM

1

Reference (9) (10) (11) (12) (13) (14) (15) (16)

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Component Thin separating ring Thick separator ring Output shaft front bearing Needle bearing Moved gear of 1000 RPM Output shaft rear bearing Locking ring PTO output shaft

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Overview

CUIL17TR00265FA

Reference (1) (2) (3) (4)

Component Brake belt Power Take-Off (PTO) clutch housing Clutch support Valve assembly

1

Reference (5) (6) (7)

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Component Pressure regulating valve Control valve stop Lubrication circuit safety valve

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Exploded view Clutch and disk housing

CUIL17TR00266FA

Reference (1) (2) (3)

Component Clutch Housing Sinterized disks with internal splines (5 units) Pressure disk

1

Reference (4)

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(5)

Component Locking ring Steel disks with external splines (5 units)

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Remove 1. Drain the transmission hydraulic oil. Consult the procedures in Powered rear axle - Drain fluid (27.100). 2. Remove the rear axle bearing retainer (4)

CUIL16TR01273AA

1

LAIL11TS0405A0A

2

LAIL11TS0406A0A

3

3. Remove the multiple gear (2).

4. Remove the shims (4) from the rear axle (3). Pull the tractor shaft. 5. Remove the rear shaft set lower cover. 6. Remove the Power Take-Off (PTO) output shaft. 7. Hold the driven gears and remove the output shaft sleeve and bearing set. See the exploded view in Front drive shaft - Exploded view (31.114). Disassemble the driven gears and the thrust rings. 8. Disassemble the output shaft front bearing. 9. Check the components for wear and damage and replace them as necessary. Replace all of the seal rings and the gasket. Next operation: Front drive shaft - Backlash longitudinal (31.114)..

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Backlash longitudinal 1. Place the drive gear set in the central housing. 2. Assemble approximately 2.0 mm from the shims behind the rear bearing cup. DO NOT assemble the "O" segment. 3. Install the cover (1) with the word “TOP” facing upward. Tighten the bolts enough to ensure the bearings are seated. 4. Measure the clearance at several distinct points to determine the average clearance.

CUIL16TR01274AA

Calculate the required shim thicknesses: Shim thicknesses Average gap (subtract) Longitudinal clearance

2.03 mm 0.36 mm 1.67 mm 0.10 mm 1.57 mm

Correct shim thicknesses: 1.57 mm. 5. Assemble the shims behind the bearing cup. 6. Assemble the rear shaft shim(s) that was removed during disassembly. 7. Assemble the bearing retainer using the new "O" segment.

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1

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Backlash longitudinal CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. With a feeler gauge (1), check the longitudinal clearance between the clutch hub and the lock ring (2). 2. Remove or add shims between the lock ring and the bearing. 3. The correct clearance is 0.46 – 1.0 mm.

CUIL16TR01275AA

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1

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Remove WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Drain the oil from the transmission. Consult the procedures in Powered rear axle - Drain fluid (27.100). 2. Remove the hydraulic lift cover. Consult the procedures in Rear three-point hitch - Remove (37.110).

CUIL16TR01255AA

1

CUIL16TR01256AA

2

CUIL16TR01259AA

3

3. Loosen the fitting (1) and disconnect the line (2). 4. Remove the retaining lock ring (3) from the rear upper shaft.

5. Remove the fastening bolts (1) and (2) from the clutch assembly.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

6. Remove the cover (1) . 7. Slide the shaft (2) outward.

CUIL16TR01260AA

4

CUIL16TR01256AA

5

8. Remove the clutch (1) and the valve (2) from the Power Take-Off (PTO).

Next operation: Power Take-Off (PTO) clutch - Disassemble (31.114)..

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Disassemble WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Power Take-Off (PTO) clutch - Remove (31.114).. 1. Remove the hub (2) and the thrust washer (3) from clutch housing (1).

CUIL16TR01261AA

1

CUIL16TR01262AA

2

2. Remove the snap ring (4) and disassemble the clutch assembly.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

3. Remove the piston (1) and return spring (2). 4. Apply compressed air between the grooves of the front and center seal ring to expel the piston from the housing. 5. Remove the O-ring and seal (3) from the piston.

CUIL16TR01264AA

3

CUIL16TR01265AA

4

6. Disassemble the clutch brake band assembly (1). 7. Separate the support (2) from the valve body (3). NOTE: If the Power Take-Off (PTO) slips due to reduced pressure, NEW HOLLAND recommends that you disassemble and inspect the PTO clutch assembly to check for damage that may have been caused by the slipping.

Next operation: Power Take-Off (PTO) clutch - Inspect (31.114)..

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Inspect WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

Prior operation: Power Take-Off (PTO) clutch - Disassemble (31.114).. 1. Clean all components with a suitable solvent. Allow the parts to dry. 2. Inspect the seal rings (1), (2), and (3) on the clutch housing. Replace if worn or damaged. 3. Inspect the clutch housing externally for cracks or damage, and internally for wear and piston scuffing. 4. Inspect the clutch piston for scoring or burrs and install a new O-ring and seal. 5. Inspect the clutch hub spline and gear for wear and damage.

CUIL16TR01268AA

Next operation: Power Take-Off (PTO) clutch - Assemble (31.114)..

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1

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Assemble Prior operation: Power Take-Off (PTO) clutch - Inspect (31.114).. For assembly of the Power Take-Off (PTO) clutch. 1.

Use new O-rings and seals. Install the seals. Use tools NHT-0712 and 380200170 to install the seals.

2.

Install the pressure regulating valve with the  V groove fitting away from the valve spring.

NOTE: If the brake band requires replacement, soak the band in the oil of the rear axle for at least 3 minutes before installation.

Adjustment of the Power Take-Off (PTO) brake strap 1.

Loosen the lock nut (1).

2.

Tighten the regulator (2) to a torque of 1.0 – 1.2 N·m (0.7 – 0.9 lb ft).

3.

Loosen the regulator screw by 2 1/2 turns and tighten the lock nut.

4.

To check the concentricity of the brake band after adjustment, proceed as follows:

5.

Position the valve housing at the 3 o'clock position.

6.

The valve housing should fall to the 6 o'clock position due to its own weight.

7.

If required, fold the band slightly to give it the required shape and repeat the adjustment.

Next operation: Power Take-Off (PTO) clutch - Install (31.114)..

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CUIL16TR01269AA

1

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Install WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Power Take-Off (PTO) clutch - Assemble (31.114).. 1. Position the clutch assembly (1) in the rear axle housing.

CUIL16TR01256AA

1

CUIL16TR01260AA

2

2. Insert the shaft (2) in the interior of the housing. 3. Rotate the shaft (2) until it fits with the clutch assembly. 4. Install the cap (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

5. Install the bolt (1) with a torque of 27.0 – 35.0 N·m (19.9 – 25.8 lb ft). 6. Install the bolt (2) with a torque of 1.0 N·m (0.7 lb ft). Loosen the bolt (2) 1/4 turn and tighten the jam nut to a torque of 21.0 – 27.0 N·m (15.5 – 19.9 lb ft).

CUIL16TR01259AA

3

CUIL16TR01256AA

4

CUIL16TR01255AA

5

7. Ensure clutch is free to rotate. 8. Connect the line (2) and tighten the fitting (1). 9. Install the lock ring (3).

10. Tighten the hydraulic lift cover. Consult the procedures in Rear three-point hitch - Install (37.110).

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Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Driven shaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Front drive shaft - Backlash longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Front drive shaft - Backlash longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Front drive shaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Front drive shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Power Take-Off (PTO) clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Power Take-Off (PTO) clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Power Take-Off (PTO) clutch - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Power Take-Off (PTO) clutch - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Power Take-Off (PTO) clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Power Take-Off (PTO) clutch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Power Take-Off (PTO) clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Two-speed rear Power Take-Off (PTO) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Two-speed rear Power Take-Off (PTO) - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Two-speed rear Power Take-Off (PTO) - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Two-speed rear Power Take-Off (PTO) - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Two-speed rear Power Take-Off (PTO) - Mechanical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Two-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Brakes and controls 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Brakes and controls - 33

[33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

Reference Brake drums - Inspect

PAGE 33.1 / 12

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Brakes and controls - 33 Mechanical service brakes - 120

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Brakes and controls - 33 Mechanical service brakes - 120

TECHNICAL DATA Mechanical service brakes General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Mechanical service brakes Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Mechanical service brakes Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake control pedals and shafts Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Brake drums Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

Reference Brake drums - Inspect

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PAGE 33.1 / 12

Brakes and controls - Mechanical service brakes

Mechanical service brakes - General specification 7630 Type of brake Brake operation Brake discs (per side) Total friction brake discs surface Brake pedal clearance

8030

In oil bath Mechanical with sphere in ramp 4 2452.8 cm² (380.2 in²) 38 mm (right and left)

Mechanical service brakes - Torque Torque

Component Mounting bolts for the brake mechanism in the transmission Brake pedal bolts Turn buckle counter nut

66 N·m (49 lb ft) 66 N·m (49 lb ft) 25 N·m (18 lb ft)

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Dynamic description Brakes discs in oil bath are located in each axle housing. There are usually four friction discs per side. Brake actuation is mechanical by means of rod and linkage. The brake is comprised of discs with inner grooves in each axle housing, which have an actuator (1) and an intermediate friction disc (2). The actuator is comprised of two discs with internal cams and steel balls (4). Discs are assembled by means of springs (3) and connected to the actuated lever by two coupling links. The actuated lever is operated by means of the linkage connected to the brake pedals. When depressing the brake pedals, the actuators move in sync with each other, making the balls go up the cam and cause the discs to become separated. When discs are separated , they compress the surfaces against the brake metallic case, stopping the intermediate axle.

Brake lock The brake lock joins both service brake pedals for uniform stopping ability. The brake lock is comprised of a rack on the left brake pedal and a brace located on the right brake pedal. In order to close the latch, both brake pedals must be joined. To release, turn the latch one fourth of a turn and release it to then depress the pedals to release them from the rack.

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CUIL17TR00298AA

1

Brakes and controls - Mechanical service brakes

Mechanical service brakes - Exploded view

CUIL17TR00267FA

Reference (1) (2) (3) (4)

Component Housing inside the brake system Sintered brake discs Actuator disks with internal balls Separator disc

1

Reference (5) (6) (7) (8)

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Component Housing outside the brake system Final reducer Rear axle housing Axle

Brakes and controls - Mechanical service brakes

Mechanical service brakes - Disassemble 1. Remove the brake switches (1) on the pedal shaft assembly. 2. Unhook the springs (2) that secure the pedal shaft assembly to the mounting bracket. 3. Disassemble the pedal shaft assembly. 4. Remove the brake pedals (3). 5. Disassemble the brake support shaft assembly. 6. Remove the brake control tie rods (4). 7. Disassemble the thrust bearing assembly. 8. Remove the tie rods (5).

CUIL17TR00299AA

9. Remove the control rods (6) from the brake levers (7). Next operation: Mechanical service brakes - Inspect (33.120)..

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1

Brakes and controls - Mechanical service brakes

Mechanical service brakes - Inspect Prior operation: Mechanical service brakes - Disassemble (33.120).. 1. Clean all components and inspect for damage or wear. Replace as required. 2. Inspect the adjustment of the bolt, the nut and the road threads for damage, rust or wear. Replace as required. Ensure connections are tight. NOTE: Do not attempt to repair and reuse damaged components. Next operation: Mechanical service brakes - Assemble (33.120)..

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Assemble Prior operation: Mechanical service brakes - Inspect (33.120).. 1. Install the control rods (6) in the brake levers (7). 2. Assemble the thrust bearing assembly between the control rods (6) and the tie rods (5) . 3. Assemble the brake support shaft assembly between the tie rods (5) and the brake control tie rods (4). 4. Assemble the pedal shaft assembly with the brake control tie rods (4) and the brake pedals (3). 5. Use the springs (2) to secure the pedal shaft assembly to the mounting bracket. 6. Install the brake switches (1) on the pedal shaft assembly.

CUIL17TR00299AA

1

CUIL17TR00300AA

2

7. The brake switches can now be adjusted as needed by loosening the switch bolts (1).

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Disassemble 1. Block the back wheels and release the parking brake. 2. Disconnect the two return springs (2) of the pedal assemblies (1) situated under the floor. 3. Dismount the cotter pin and the union pin that fix the right brake pedal to the union pin of the brake connecting rod. 4. Dismount the retainer ring and the fixing washer of the right pedal to the brake transversal shaft (3) and remove the pedal on the right side. 5. Remove the left brake pedal lock screw to the transversal shaft. Slide the pedal from the transversal shaft, removing the woodruff key if it is loose in the recess as well as the washer. 6. If necessary, the transversal shaft of the brake can be dismounted according to the following procedure: Remove the retention ring and the union pin that hold the left operating lever to the control fork of the brake connecting rod. Drain the rear axle oil. Pull the differential box shaft using the left brake operating lever.

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CUIL17TR00301AA

1

Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Backlash WARNING Maintenance hazard! Before performing maintenance on the brake system, chock the traction and steering wheels to prevent machine movement. Failure to comply could result in death or serious injury. W0064A

The brake pedal free play must be 38 mm (1.50 in) with the pedals latched. The tractor must stop in a straight line when both pedals are depressed. If not, adjust as follows: 1. Adjustment is done using the brake rods located under the platform. Chock both rear tires, release the pedals and the parking brake. 2. Release the locking nut from the left side brake (1). Turn the adjusting nut (2) until the freeplay is 38 mm (1.50 in), then tighten the locking nut. 3. Repeat the same operation for the opposite brake. 73118477

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1

Brakes and controls - Mechanical service brakes

Brake drums - Inspect 1. Check the condition of the brake disks (sinterized) with regard to wear and possible distortion. If the lubrication channels in the sintered material of the disks no longer exist, or the existing groove is too small, replace the set of disks. 2. Check the wear of the separator disk (steel), if there are scratches or buckling, effectuate replacement. NOTE: Before installing new brake disks (sintered material), the disks must be lubricated, kept in a receptacle with the specified oil NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL, so that there is a uniform lubricant film all over the disk when performing the first braking tests of the tractor. 3. Assemble the components. To assemble the components, use the reverse of the order used in the removal and disassembly. .. 4. Check that lubricating oil does not leak between the transmission and the rear half shaft. Adjust the foot brakes and the parking brake 5. Test the tractor's brakes, applying equal pressure to the two brake pedals. The tractor should stop in a straight line, without changing direction.

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Index Brakes and controls - 33 Mechanical service brakes - 120 Brake control pedals and shafts - Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Brake control pedals and shafts - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Brake drums - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Mechanical service brakes - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Mechanical service brakes - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Mechanical service brakes - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Mechanical service brakes - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Mechanical service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Mechanical service brakes - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Mechanical service brakes - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Brakes and controls - 33 Parking brake or parking lock - 110

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

FUNCTIONAL DATA Parking brake or parking lock Parking brake or parking lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Parking brake or parking lock Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Dynamic description The parking brake is mechanically activated. Operates inside each shaft housing by means of linkage connected to the lever through a cable. When the handle is lifted, the cable pulls on the linkage, which causes the actuator to expand and apply the brakes. The parking brake can also be used to stop the movement of the machine.

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Overview

CUIL16TR01360FA

Reference (1) (2) (3) (4) (5)

Component Cover Lever assembly mounting bolt Adjustment nuts Left-hand cable Right-hand cable

1

Reference (6) (7) (8) (9) (10)

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Component Adjust nut Pin Yoke Stand off Upper adjustment nuts

Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Adjust CAUTION Unexpected machine movement! When the machine is parked and the engine is switched off, the parking brake must be applied. Use wheel chocks if parking on a steep slope. Failure to comply could result in minor or moderate injury. C0014A

The stroke of the control lever of the parking brake cable must be adjusted whenever a parking brake is serviced or is repaired. The main brakes are serviced or are repaired when the stroke of the lever to the idle position is excessive. Proceed as follows: 1.

Park the tractor on a flat surface and shut down the engine.

2.

Chock the front wheels using a suitable means.

3.

Raise all four wheels off of the ground and support the tractor with jack stands.

4.

Disconnect the brake pedal connections (1).

5.

Raise the parking brake control lever 3 notches on the quadrant.

6.

Loosen the jam nut (2).

7.

Turn the adjustment nut (1) until wheels lock.

8.

Lower the parking brake control lever and ensure that the wheels can rotate freely.

9.

Apply the parking brake several times to check that the assembly does not get hung up or operate abnormally.

10. Tighten the jam nut and lower the tractor.

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CUIL17TR00302AA

1

Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake or parking lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Parking brake or parking lock - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Parking brake or parking lock - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Hydraulic systems 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.116] Three-point hitch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

Reference

PAGE

Pump - Assemble - Tandem

35.2 / 27

Pump - Install - Tandem

35.2 / 30

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Hydraulic systems - 35 Hydraulic systems - 000

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Hydraulic symbol - Schematic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic symbol - Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic symbol - Directional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic symbol - Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic symbol - Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic symbol - Table of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SERVICE Hydraulic systems Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Schematic components Accurate diagrams of hydraulic circuits are essential to the technician who must repair them. The diagram shows how the components interact. The diagram shows how the system works, what each component should be doing and where the oil should be going so the technician can diagnose and repair the system. There are two types of circuit diagrams: • Cutaway circuit diagrams show the internal construction of the components as well as the flow paths. Using colors, shades or various patterns in the lines and passages, they show many different conditions of flow and pressure. Cutaway diagrams take considerably longer to produce because of their complexity. • Schematic circuit diagrams, the “shorthand” system of the industry, are usually preferred for troubleshooting. A schematic diagram is made up of simple geometric symbols for the components and their controls and connections. There are several systems of symbols used when making schematic diagrams: • ISO – International Standards Organization • ANSI – American National Standards Institute • ASA – American Standards Association • JIC – Joint Industry Conference A combination of symbols from these systems are shown. There are differences between the symbol systems. There is enough similarity, however, so if you understand the symbols shown, you will be able to interpret other symbols as well.

Reservoirs A rectangle with the top removed represents a vented reservoir (A). A rectangle with the top in place represents a pressurized reservoir (B).

RCIL07CCH025AAA

1

RCIL07CCH027AAA

2

RCIL07CCH030AAA

3

RCIL07CCH032AAA

4

There are other schematic diagrams that show a slightly different version of a pressurized reservoir, but the symbols are similar and easily recognized. An oval with a short line on top or a rectangle with curved sides represents a reservoir that is pressurized.

Lines connected to the reservoir usually are drawn from the top, regardless of where the actual connection is. This symbol shows a line which returns fluid above the level in the reservoir.

If the hydraulic line returns fluid below the level in the reservoir, it is drawn all the way to the bottom of the symbol.

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Hydraulic systems - Hydraulic systems

A hydraulic line connected to the bottom of the reservoir may be drawn from the bottom of the symbol if the bottom connection is essential to the systems operation.

RCIL07CCH033AAA

5

RCIL07CCH124AAA

6

RCIL07CCH034AAA

7

RCIL07CCH035AAA

8

RCIL07CCH036AAA

9

If the pump inlet (B) must be charged or flooded with fluid above the inlet port, the reservoir symbol (A) appears above the pump symbol, and the suction line is drawn out of the bottom of the reservoir symbol. Every system reservoir has at least two hydraulic lines connected to it, and some may have many more. Often the components that are connected to the reservoir are spread all over the schematic. Rather than multiplying lines all over the schematic, individual reservoir symbols are drawn close to the components. The reservoir is usually the only component symbol pictured more than once on a diagram.

Lines, tubes and hoses A hydraulic line, tube, hose or any conductor that carries the fluid between components is shown as a line. A working line, such as an inlet pressure or return, is shown as a solid line.

Working lines with arrows show direction of flow. In the first example (A), fluid flows in one direction only; in the second example (B), fluid can flow in both directions.

Pilot or control lines (A) are broken into long dashes. Drain lines (B) for leakage oil are broken into short dashes.

A flexible line is shown as an arc between two dots and is always represented by a solid line.

RCIL07CCH026AAA

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10

Hydraulic systems - Hydraulic systems

An enclosure outline indicates that there are several symbols that make up a component assembly such as a valve or a valve stack. The enclosure outline is rectangular and is broken with dashes on all sides.

RCIL07CCH028AAA

11

RCIL07CCH038AAA

12

RCIL07CCH047AAA

13

RCIL07CCH048AAA

14

RCIL07CCH040AAA

15

RCIL07CCH041AAA

16

Lines between components are drawn differently when they are crossing or connected. There are lines that cross other lines but are not connected. There are several ways to show crossing lines which are not connected.

Lines that are connected are shown with a dot that represents the connection or shown as a tee connection. The dot connection is the most commonly used when drawing schematic diagrams.

Pumps There are many basic pump designs. A simple fixed displacement pump (A) is shown as a circle with a solid arrow that pointing outward. The arrow points in the direction that the fluid flows. If the pump is reversible (B) or designed to pump in either direction, the symbol has two arrows which point in opposite directions. The pump normally has a pressure port and line (1) from which pressurized fluid is discharged and a suction port and line (2) into which fluid is drawn from the reservoir.

A variable displacement pump (A) is shown by an arrow drawn through the pump symbol at a 45 degree angle. A variable displacement, pressure compensated pump (B) is shown by a small box with an arrow, added to the side of the pump symbol.

If the pump is controlled by a lever (A) or a pedal (B), the appropriate symbol is added to the side of the pump.

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A drive shaft is shown as two short parallel lines extending from the side of the pump. A curved arrow, if present, on the drive shaft indicates the direction of rotation.

RCIL07CCH049AAA

17

RCIL07CCH051AAA

18

RCIL07CCH046AAA

19

RCIL07CCH055AAA

20

Motors Motor symbols are circles with solid black arrows, which point in the opposite direction of a pump’s arrow, to show the motor as a receiver of fluid. One arrow is used for non-reversible motors (A); and two arrows are used for reversible motors (B).

A simple schematic diagram is shown of a hydraulic motor (A) connected to a hydraulic pump (B).

Cylinders A cylinder is a simple rectangle (A) representing the barrel. The piston and rod are represented by a tee (B), inserted into the rectangle. The symbol can be drawn in any position.

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If the cylinder is single-acting (A), there is only one port shown on the end of the cylinder that receives pressurized fluid. The opposite end of the cylinder is left open. Both ends are closed on a double-acting cylinder (B), and two ports are shown.

RCIL07CCH054AAA

21

RCIL07CCH057AAA

22

RCIL07CCH126AAA

23

RCIL07CCH080AAA

24

A double rod end cylinder has a rod extending from each end of the rectangle.

Some cylinders have cushions built into them. The cushion slows the movement of the piston as it nears the end of its stroke. Cylinder cushions are shown as a smaller rectangle (A) on the piston. If the cushion has an adjustable orifice, a slanted arrow is drawn at 45 degrees (B) across the symbol.

Accessories Filters, strainers and heat exchangers are represented as squares that are turned 45 degrees and have the port connections at the corners. A dotted line perpendicular to the flow line represent a filter, strainer or screen.

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A solid line perpendicular to the flow with solid arrows pointing outward represents a cooler.

RCIL07CCH081AAA

25

RCIL07CCH118AAA

26

RCIL07CCH119AAA

27

RCIL07CCH130AAA

28

The symbol for a heater is like the symbol for a cooler, except the solid arrows point inward.

Two sets of arrows pointing inward and outward represents a temperature control unit The solid arrows point in the direction that heat is dissipated. Or in the case of the control unit, they show that heat can be regulated.

An oval with details inside represents an accumulator. The details explain what type of accumulator it is: spring loaded (A), gas charged (B), or other features. The divider line indicates there is a separator between the charge and the fluid. A hollow arrow indicates gas. A spring indicates that the accumulator is spring-loaded.

Reference:

Hydraulic systems - Hydraulic symbol - Pressure control (35.000) Hydraulic systems - Hydraulic symbol - Directional control (35.000) Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Pressure control The basic valve symbol is a square (which is called an envelope) with external port connections and an arrow inside to show the fluid passage and direction of flow. The valve usually operates by balancing fluid pressure against a spring, so a spring is shown on one side of the symbol and a pilot pressure line on the other side.

Normally closed valve A normally closed valve, such as a relief or sequence valve, is shown with an arrow offset from the ports [inlet (A), outlet (B)] toward the pilot pressure line (C) side of the square. The spring (D) holds the valve closed until the pilot line pressure is greater than the spring pressure. Mentally visualize a build up of pressure in the pilot line and the envelope moving over, compressing the spring. Fluid can now flow through the valve. RCIL07CCH059AAA

1

RCIL07CCH060AAA

2

RCIL07CCH061AAA

3

Normally open valve A normally open valve is shown with the arrow connecting the inlet and outlet ports. It closes when pressure overcomes spring force. Mentally visualize a build up of pressure in the pilot line and the envelope moving over, compressing the spring. Fluid flow through the valve is now blocked.

Relief valve A relief valve is shown as a normally closed symbol connected between the pressure line (A) and the reservoir (B). The flow direction arrow points away from the pressure line port and toward the reservoir. This graphically represents how a relief valve operates. When pressure in the system overcomes the valve spring (C), flow is from the pressure line through the relief valve to the reservoir.

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Pressure reducing valve A pressure reducing valve is shown as a normally open symbol in a pressure line. This valve works opposite of a relief valve, since it senses outlet pressure (A) versus inlet pressure (B). As the outlet pressure builds, it works against a predetermined spring force. As the spring force is overcome, flow through the valve is reduced or shut off.

RCIL07CCH063AAA

4

RCIL07CCH062AAA

5

Sequence valve The normally closed symbol is also used for a sequence valve (A). The inlet port is connected to a primary cylinder (B) and the outlet port to the secondary cylinder line (C). When the piston in the primary cylinder reaches the end of its stroke, the pressure in the supply line increases. The sequence valve is also connected to the supply line and also feels the increase in pressure. As pressure increases, the envelope and directional flow arrow move over, connecting the inlet and outlet ports allowing fluid to flow to the secondary cylinder.

Reference:

Hydraulic systems - Hydraulic symbol - Directional control (35.000) Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Directional control One way valve A simple ball check valve is shown. When fluid pressure is exerted on the left side of the ball, the ball is forced into the “V” and no fluid can flow though the valve. When fluid pressure is applied to the right side of the ball, the ball moves away from the “V” and fluid can flow through the valve.

RCIL07CCH066AAA

1

RCIL07CCH067AAA

2

Bypass valve A bypass valve is shown as a one-way valve with a spring on the ball end of the symbol. Pressurized flow is necessary to overcome the spring force and allow flow around the ball.

Reference:

Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Composite One way valve A more complex one-way valve is shown. This directional control symbol uses multiple envelopes with a separate envelope for each valve position. Within each envelope, arrows show the flow paths when the valve is shifted to that position. NOTE: All port connections are made to the envelope which shows the neutral condition of the valve. The left symbol (A) a one-way valve in the closed position. Mentally visualize a build up of pressure on the right side of the valve symbol (B) to enable free flow through the valve. RCIL07CCH072AAA

1

RCIL07CCH073AAA

2

RCIL07CCH074AAA

3

Two position valve Two envelopes (representing the spool) indicate a two position valve. Each envelopes shows the flow conditions for its position. This simple schematic shows fluid supplied to the rod end of the cylinder (A) from the control valve (B). Return flow is from the piston end of the cylinder through the control valve to tank.

Mentally visualize the directional control valve shifted to the other position. Pressurized fluid is supplied to the piston end of the cylinder (A) from the control valve (B), and return fluid flows from the rod end of the cylinder through the control valve to tank.

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Three position valve Three position valves have a centered (neutral) position. The centered position can be either open or closed to flow. The open center (A) is usually used with a fixed displacement pump, while the closed center (B) is usually used with a variable displacement pump.

RCIL07CCH068AAA

4

RCIL07CCH069AAA

5

RCIL07CCH017BAA

6

Actuating controls Valve spools are controlled by pedals (A), levers (B), pilot fluid (C), electric solenoids (D), etc., which are called actuating controls. These actuating controls are shown by symbols placed on the ends of the envelopes. This symbol (E) is used when a solenoid is controlled with internal pilot assist pressure.

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Hydraulic systems - Hydraulic systems

To show that a valve is spring-centered, a spring symbol is placed at each end of the envelope. This symbol shows that a solenoid and pilot pressure assist are required to overcome spring force to move the valve spool.

RCIL07CCH070AAA

Reference:

Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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7

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Flow control Restrictors The basic flow control symbol is a restrictor. If the restrictor is adjustable, a slanted arrow is drawn across the symbol. The restrictor could be a special fitting with a small hole in it or a small drilled passageway within a valve. An adjustable restrictor acts like a faucet: adjusting the restriction regulates flow. Restrictors are used to meter and bleed circuits.

RCIL07CCH075AAA

1

RCIL07CCH078AAA

2

Adjustable restrictors can be pressure-compensated: the size of the opening in the restrictor changes with increases and decreases in pressure. A perpendicular arrow indicates pressure compensation. If the restrictor has both pressure and temperature compensation, the symbol for a thermometer is added.

Reference:

Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Table of symbols Line and line functions Solid line - main line

Dotted line - exhaust or drain line

Dashed line - pilot line

Enclosure outline

Lines crossing

Lines joining

Lines crossing

Liquid direction of flow

Gaseous direction of flow

Flexible line

Mechanical devices Connections (two parallel lines) for shafts, levers, etc.

Variable component (arrow intersects symbol at 45°)

Spring

Pumps and motors Pump, fixed displacement

Pump, variable displacement

Pressure compensated, variable displacement pump

Fixed displacement pump (bidirectional flow)

Motor, fixed displacement

Motor, variable displacement

Oscillator

Reservoirs

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Hydraulic systems - Hydraulic systems

Reservoir, open to atmosphere

Pressurized reservoir

Return line to reservoir below fluid level

Return line to reservoir above fluid level

Cylinders Single acting

Double acting, single rod end

Double acting. double rod end

Single rod end, fixed cushion both ends

Single rod end, adjustable cushion, rod end only

Differential cylinder

Valves Check valve

Pilot-operated check valve

On/Off manual shut off valve

Regulating or selector valves

2 position, 2 way valve

2 position, 3 way valve

2 position, 4 way valve

3 position, 4 way valve

2 position, 4 way open center, crossover valve

Valve capable of infinite positioning (indicated by horizontal lines parallel to the envelope)

Pressure relief valve

Pressure reducing valve

Non-adjustable restrictor valve

Adjustable restrictor valve

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Hydraulic systems - Hydraulic systems

Adjustable restrictor, pressure compensated

Adjustable restrictor, temperature and pressure compensated

Valve actuators Solenoid

Detent

Spring

Manual

Push button

Lever

Pedal

Mechanical

Pressure compensated

Pilot pressure, remote supply

Liquid supply

Accessories Filter

Cooler

Heater

Temperature controller

Accumulator (hydropneumatic

Reversing motor

Station or test point

Pressure indicator

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Hydraulic systems - Hydraulic systems

Temperature indicator

Pressure switch

Quick disconnect (disconnected)

Quick disconnect (connected)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Dynamic description The hydraulic system provides oil flow at regulated pressures for the operation and lubrication of various circuits within the tractor, as well as providing accurate and sensitivity control of implements over a wide range of operating conditions. The standard hydraulic system consists of a top link sensing and three-point linkage system, a fixed displacement tandem (gear type) main pump, an engine mounted auxiliary pump (optional), lift cylinder assembly, and remote control valve(s). The rear axle centre casing functions as the hydraulic system reservoir. A lift control valve, and priority valve pack containing several valves, function together to direct the hydraulic oil as needed. A pressure regulator, and various relief and check valves protect the circuits and components from overload conditions, encountered during normal and arduous operation. The configuration and combination of valves prevents oil back flow. The hydraulic system consists of two major circuits: • High Pressure Circuit (includes optional engine mounted auxiliary pump if equipped) • Low Pressure, Steering and Lubrication Circuit

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Identification Description/location

Identification

Safety Valve

Hydraulic pump.

Control Valve Spindle and sleeve Exhaust Valve Safety Valve Hydraulic lift cylinder assembly Auxiliary services control valve (ASV)

Outflow valve

Flow control valve

Sequence valve Priority valve assembly

Check valve

Auxiliary pump retention valve

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Function Limits the maximum pressure in the high pressure circuit Pressure of 190 bar. Provides four control positions: neutral, lowering, slow rise and fast rise. Maintains constant controlled lowering Protects the lift circuit against overload when the system is in neutral. Opening pressure: 210 bar. The valve has two positions: when it is pulled out, it stops oil entering and exiting the lift cylinder and when it is pushed in (internal), it releases the flow of oil. Used as a safety device when transporting equipment on the hydraulic lift. Controlled by the pressure of the oil that passes through the control valve. Pressure of 4.2 – 21 bar. 48 mm spring. Controls the oil flow to the hydraulic lift by restricting the oil flow to the sequence valve. 73 mm spring. Regulates the oil flow to the remote control valves and diverts the excess pressure to the tank. Controls the maximum hydraulic pressure to the control. Controls the oil flow into the lift cylinder; functions with the hydraulic lift control valve ( 5 – 6 bar). Allows the oil pressure from the auxiliary pump to pass through the high pressure circuit (remote control) and prevents the hydraulic pump pressure from returning to the auxiliary pump (when installed).

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema Hydraulic tandem pump, steering motor valve, and Dual Command valve (optional) assemblies

RCIL10TTS002GAD

– Maximum 49 l/min (13 US gpm) pump supply

1

– Return to tank/sump

Reference

Component

Reference

(A)

Dual Command valve assembly

(C1)

(A1)

Under drive (tortoise gear)

(C2)

(A2)

Direct drive (rabbit gear) Tandem pump (fixed displacement) – 49 l/min (13 US gpm) and 26 l/min (7 US gpm). Pressure relief valve – 176 – 182 bar (2552 – 2639 psi)

(C3)

Steering motor valve assembly

(F)

(B) (B1) (C)

(D) (E)

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– Maximum 26 l/min (7 US gpm) pump supply Component Two-Wheel Drive (2WD) steering cylinder Four-Wheel Drive (4WD) steering cylinder (optional) Regulator differential pressures Tandem gear filter with bypass valve – 0.48 bar (7 psi) Flow to priority valve and three point hitch lifting valve assemblies Flow to Power Take-Off (PTO) clutch valve and Four-Wheel Drive (4WD) valve assemblies

Hydraulic systems - Hydraulic systems

Hydraulic priority valve, three point hitch lifting valve, and remote valve assemblies

RCIL10TTS001GAD

2

– * Maximum 49 l/min (13 US – Return to tank/sump – Maximum 35 l/min (9.2 US gpm) pump supply gpm) pump supply * tractors equipped with an auxiliary pump have a maximum flow of 83 l/min (22 US gpm) between the priority valve assembly and the remote valves. Reference (A)

Component Three point hitch lifting valve assembly

Reference (C)

(A1)

Lift cylinder

(C1)

(A2)

Three point hitch lifting valve

(C2)

(A3) (B) (B1) (B2)

Pressure relief valve – 176 – 182 bar (2552 – 2639 psi) Priority valve assembly Priority Valve Combined valve

Component Remote valve assembly Remote valve – maximum flow capacity 49 l/min (13 US gpm) ** Remote valve – maximum flow capacity 49 l/min (13 US gpm) **

(D)

Flow from tandem pump

(E) (F) (G)

Ram cylinders Auxiliary pump (optional) Hydraulic flow test port

** Maximum flow capacity 57.0 L/min (15.1 US gpm) with auxiliary pump.

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Hydraulic systems - Hydraulic systems

Hydraulic PTO clutch valve and Four-Wheel Drive (4WD) valve assemblies

RCIL10TTS003GAD

– Maximum 26 l/min (7 US gpm) pump supply Reference (A) (A1) (A2) (A3) (A4) (A5)

3

– Return to tank/sump

Component Power Take-Off (PTO) clutch valve assembly Power Take-Off (PTO) control valve Pressure regulator valve – 12 – 15 bar (174 – 218 psi) Safety valve – 5.3 – 8.5 bar (77 – 123 psi) PTO Clutch PTO Brake

Reference

– Lubrication oil supply

(C)

Component Four-Wheel Drive (4WD) valve assembly (optional) Oil cooler

(D)

Transmission

(B)

(E) (F)

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Flow from tandem pump – 26 l/min (7 US gpm) pump supply PTO lubrication

Hydraulic systems - Hydraulic systems

Hydraulic systems - Pressure test The hydraulic pressure of the automatic disarm activator must be regulated when the valve set is serviced or when the control levers and rod prematurely return to neutral. Perform the test in accordance with the following procedure. 1. Install the inlet tube of a flowmeter (4) in the top coupler of the set to be tested. 2. Set the flow control lever (5) to maximum flow. 3. Install the flowmeter return tube (2) on the top coupler of the other group of remote control valves. 4. Completely open the flow meter load valve (3). 5. Run engine at 1700 RPM . 6. Put the lever of the valve assembly to which the flowmeter return is coupled in the float position 7. Put the lever of the valve assembly to which the flowmeter inlet is coupled in the lift position. 8. Adjust the flowmeter load valve to a pressure of 140 bar and keep the engine running until a temperature of 75 °C is attained. 9. Gradually close the load valve and record the disarm pressure of the remote control lever. The disarm pressure should be between 148 – 162 bar. 10. To adjust the pressure: 11. Turn off the engine of the machine. • To increase the pressure, tighten the retainer screw (1). • To reduce the disarm pressure, loosen the screw (1). Turn the screw counter-clockwise to loosen. Each half a turn of the screw is equivalent to approximately 32 bar. NOTICE: Never adjust the retainer screw with the machine running.

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CUIL17TR00305AA

1

Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Hydraulic systems - Hydraulic symbol - Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Hydraulic systems - Hydraulic symbol - Directional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Hydraulic systems - Hydraulic symbol - Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Hydraulic systems - Hydraulic symbol - Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Hydraulic systems - Hydraulic symbol - Schematic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Hydraulic systems - Hydraulic symbol - Table of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Hydraulic systems - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Hydraulic systems - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

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Hydraulic systems - 35 Fixed displacement pump - 104

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Fixed displacement pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General specification - Auxiliary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pump General specification - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Fixed displacement pump Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pump - Sectional view - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dynamic description - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Exploded view - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Overview - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Fixed displacement pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pump Remove - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassemble - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Inspect - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assemble - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Pressure test - Flow - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Pressure test - Main hydraulic pump flow - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Pressure test - Hydraulic steering pump flow - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Pressure test - Low pressure circuit - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Pressure test - Lubrication circuit - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pressure test alternative of the main hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

Reference

PAGE

Pump - Assemble - Tandem

35.2 / 27

Pump - Install - Tandem

35.2 / 30

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - General specification Table 01: Main hydraulic lift pump 7630

8030 Gear pump Engine 56 l/min to 2374 RPM. Engine 35.2 l/min to 2374 RPM. 176 – 183 bar

Type High flow hydraulic pump Low flow hydraulic pump Safety valve adjustment pressure Table 02: Steering pump

7630 Type Flow Pressure of safety valve on orbitrol

8030 Gear pump 35 l/min 166 – 172 bar

Fixed displacement pump - Torque Torques Pump body mounting bolts Bolts to secure the pump to the engine Bolts to secure the tubes onto the pump

Torque value 61 – 68 N·m (45 – 50 lb ft) 57 – 76 N·m (42 – 56 lb ft) 10.0 – 14.0 N·m (7.4 – 10.3 lb ft)

Fixed displacement pump - General specification - Auxiliary pump Maximum flow at engine rpm of 2200 RPM – New pump Maximum flow at engine rpm of 2200 RPM – Used pump

7630 8030 35 l/min (9.2 US gpm) 26 l/min (6.9 US gpm)

The auxiliary pump increases the hydraulic pump oil flow to the remote valves from 49 l/min (13 US gpm) to 83 l/min (22 US gpm).

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Hydraulic systems - Fixed displacement pump

Pump - General specification - Tandem Table 01: Main hydraulic pump 7630 Maximum flow at 2200 RPM of engine – New pump Maximum flow at 2200 RPM of engine – Used pump Relief valve

8030 49 l/min (13 US gpm) 44 l/min (12 US gpm) 176 – 182 bar (2552 – 2639 psi)

Table 02: Steering pump 7630 Maximum flow at 2200 RPM of engine – New pump Maximum flow at 2200 RPM of engine – Used pump

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8030 27 l/min (7 US gpm) 24 l/min (6 US gpm)

Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Hydraulic schema High pressure hydraulic pump circuit Operating with a maximum pressure of 182 bar (2639 psi), the high-pressure circuit supplies oil for control of the hydraulic lift assembly, remote control valve(s), and auxiliary equipment (where installed). With more than two remote valves installed on the tractor, it is necessary to supplement the tandem (gear type) transmission mounted pump with an engine mounted auxiliary pump. The front pump within the tandem pump assembly circulates pressurized hydraulic oil to the priority valve group. A relief valve installed in the pump protects the circuit from overload, with an operating pressure of 176 – 182 bar (2552 – 2639 psi). The oil supply from the tandem pump flows to the priority valve group through internal galleries within the hydraulic top cover, while the supply from the optional auxiliary pump flows to the priority valve group through external tubing. – Pump pressurized oil

– Suction oil / return to deposit

CUIL17TR00270FA

– Trapped oil

1

Reference (1) (2) (3)

Component Position control arm Selector arm Draft control spring

Reference (13) (14) (15)

(4)

Yoke

(16)

(5) (6) (7) (8) (9) (10) (11)

Selector rod and roller assembly Actuator link Safety Valve Low pressure steering pump circuit High pressure hydraulic pump circuit Pump intake filter Lifting piston

(17) (18) (19) (20) (21) (22) (23)

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Component Exhaust Valve Lifting cylinder safety valve Auxiliary pump intake filter (optional) Engine-mounted auxiliary hydraulic pump (optional) Check valve Combined valve (sequential) Flow control valve Priority valve group Relief valve Check valve Booms

Hydraulic systems - Fixed displacement pump

Reference (12)

Component Control valve

Reference

Component

Low pressure hydraulic pump circuits The low pressure circuits perform two major functions. The low pressure circuits supply pressurized hydraulic oil for the operation of the steering system, the Four-Wheel Drive (4WD) clutch, the hydraulic Power Take-Off (PTO) clutch, the PTO brake, and the Dual Command assembly. They supply lubricating oil to the hydraulic PTO clutch, the dual command assembly and the transmission. Before entering the transmission, lubricating oil passes through an oil cooler mounted in front of the radiator. This is an open center system. The low pressure and lubrication circuits provide a continuous flow of hydraulic oil throughout the system. The rear pump within the tandem gear pump assembly circulates pressurized hydraulic oil through the lines to the steering motor, hydraulic PTO clutch control valve, and to the dual command clutch control valve within the transmission housing. A pressure regulating valve in the hydraulic PTO clutch assembly controls the flow of oil to the lubrication and cooling circuit. In addition, excessive oil in the lubrication circuit discharges to sump through an adjacent relief valve. The relief valve protects the circuit from overloading with a maximum operating pressure of 5.3 bar (76.9 psi). – Pump pressurized oil

– Low pressure oil circuit

CUIL17TR00271FA

Reference (1) (2) (3) (4) (5) (6)

Component Transmission oil cooler Dual stack valve Auxiliary Front Wheel Drive (AFWD) solenoid valve Tandem pump PTO supply line PTO Clutch

– Lubrication circuit oil

2

Reference (9) (10)

Component Dual Command assembly Steering Motor

(11)

Steering motor safety valve

(A) (B) (C)

Supply line to steering motor Steering motor return line Supply line to the 4WD valve

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Hydraulic systems - Fixed displacement pump

Reference

Component

Reference

(7)

Low pressure regulating valve

(D)

(8)

Lubrication circuit oil

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Component Supply line to the Dual Command control valve

Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Exploded view

CUIL16TR01342GA

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component O-Ring Locking ring Retainer Ring Front Cover Seal Seal Seal

1

Reference (9) (10) (11) (12) (13) (14) (15)

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Component Journal Driven Gear Drive gear Pump body Rear cover Plain washer Screw

Hydraulic systems - Fixed displacement pump

Pump - Sectional view - Tandem

CUIL16TR01363FA

Reference (1) (2) (3) (4) (5)

Component Output to the hydraulic lift Steering pump drive gear Steering pump driven gear Power Take-Off (PTO) outlet orifice Main pump driven gear

1

Reference (6) (7) (8) (9) (10)

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Component Hydraulic lift pump output Pump Drive Gear Main pump drive gear Connection shaft Suction for both pumps

Hydraulic systems - Fixed displacement pump

Pump - Dynamic description - Tandem The movement to the hydraulic lift pump (front pump) is transmitted by a gear located in the transmission rear cover assembly. A connection shaft between the two pumps transmits the movement to the steering pump (rear pump). The gears inside both pumps move at the same speed and are driven while the engine is running. The constant flow gear pumps are fed with oil from the reservoir in the center of the rear differential, through an intake tube installed in the pump intake orifice. When the engine is running, the gear in the transmission rear cover assembly moves the pump and the oil is driven through the intake orifice, passing through the filter, to the spaces between the gear teeth inside each pumping unit. The oil is compressed between the gear teeth and the pump body is driven to the output orifices where it is unloaded in the hydraulic circuits. The hydraulic lift pump is protected from excessive pressure by a safety valve that operates at 190 bar. The valve allows the excess oil to return directly to the sump whenever there is any overload. This valve may be replaced without disassembling the tractor pump. The lubrication oil circulates directly from the Power Take-Off (PTO) valve to the oil radiator, before the oil supplies lubrication pressure to the transmission.

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Hydraulic systems - Fixed displacement pump

Pump - Exploded view - Tandem Front pump – Hydraulic lift, remote valves, and high pressure

CUIL16TR01361FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Component Pump body Relief valve rear plug Filter support Relief valve spring Relief valve lower piston Relief valve O-ring Relief valve body Relief valve O-ring Backup ring (relief valve) Driven gear Transfer tube O-ring Backup spiral seal Long connector transfer tube Woodruff cotter pin

1

Reference (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)

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Component Screw Screw Grower washer Nut Spring washer Crank gear Oil seal Front pump cover plate Hoop O-ring seal Backup O-ring seal Double bearing block Drive gear shaft Plug with O-ring Snap pin

Hydraulic systems - Fixed displacement pump

Rear pump – Steering, lubrication, and low pressure

CUIL16TR01362FA

Reference (1) (2) (3) (4) (5) (6)

Component Pump body Transfer tube backup spiral seal Transfer tube O-ring Transfer tube O-Ring Crank gear

2

Reference (7) (8) (9) (10) (11) (12)

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Component Rear pump cover plate Hoop O-ring seal Backup O-ring seal Double bearing block Driven gear Spacer plate

Hydraulic systems - Fixed displacement pump

Pump - Overview - Tandem The fixed flow rate gear pump is installed on the right-hand side of the rear of the transmission. The pump body contains two gear pumps, assembled in series.

CUIL16TR01214AA

1

CUIL16TR01221AA

2

The front pump (1) supplies oil at high pressure to the three-point hydraulic lift and to the remote control valves, and is referred to as the hydraulic pump. The rear pump (2), called the steering pump, supplies oil to the hydrostatic steering system. The low-pressure circuits operate the Power Take-Off (PTO) and disconnect the Auxiliary Front Wheel Drive (AFWD). These circuits also supply lubrication to the Power TakeOff (PTO), the bearings, and the output shafts. The valves in the PTO control valve housing regulate the pressure in the low pressure system and secure the lubrication circuit. Both pumps share the same oil filter.

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Remove DANGER Pressurized system! Always remove all pressure before working on the hydraulic system. Follow the pressure BLEED program in the Configuration Mode to remove the pressure in the entire hydraulic system. Failure to comply will result in death or serious injury. D0035A

1. Remove the two clips (1) and disconnect the suction line (2). 2. Remove the bolts (3) and disconnect the pressure tubes (4) and (5). NOTE: After disconnecting each of the tubes, protect the disconnected ends with suitable covers.

CUIL14TR00109AA

1

CUIL14TR00776AA

2

3. Remove the four bolts (1) and remove the hydraulic pump.

Next operation: Fixed displacement pump - Disassemble (35.104)..

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Disassemble Prior operation: Fixed displacement pump - Remove (35.104).. 1. Loosen the bolts (1) and remove the rear cover (9). 2. Remove the lock ring (4), the retainer (6) and remove the front cover (7). 3. Remove the gaskets (8).

CUIL16TR01236AA

1

CUIL16TR01237AA

2

4. Remove the journals (1) and gears (2). 5. Remove the seals (3) and (4).

Next operation: Fixed displacement pump - Inspect (35.104)..

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Inspect Prior operation: Fixed displacement pump - Disassemble (35.104).. 1. Check that the gear contact surfaces are flat and perpendicular to the supports. Insert a thin carbon paper sheet. Use very fine sandpaper that is properly lubricated to remove the small rough spots. 2. Check that the axial clearance of the gear support on the pump housing is between 0.100 – 0.180 mm. The distance (2) must be 0.100 – 0.180 mm less than the width of the body (1). NOTE: Perform maintenance on gears and journals as a set only. Replacing individual pump components may have an adverse affect on the tractor's hydraulic operations. 3. Clean all the parts thoroughly.

CUIL16TR01238AA

1

CUIL16TR01236AA

2

4. Replace the retainer (6), the ring (5), the gaskets (8), and the seals. 5. Lubricate the parts with hydraulic oil.

Next operation: Fixed displacement pump - Assemble (35.104)..

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Assemble Prior operation: Fixed displacement pump - Inspect (35.104).. 1. Assemble the gears (2) and the journals (1). Install the new seals (3) and (4).

CUIL16TR01237AA

1

CUIL16TR01236AA

2

CUIL16TR01239AA

3

2. Slide the gear assembly (1) into the pump body (2). Place new gaskets (3) on the pump body. 3. Install the covers (4) and (5) on the pump body with the bolts (6) and washers. Torque to 61 – 68 N·m (45 – 50 lb ft).

4. Mount the guide ring (4) and the retainer (5). 5. Fit the lock ring (2). Install the new O-ring (1) into the front cover.

Next operation: Fixed displacement pump - Install (35.104)..

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Install WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

Prior operation: Fixed displacement pump - Assemble (35.104).. 1. Install the pump. Secure the pump with the bolts (1). Torque to 57 – 76 N·m (42 – 56 lb ft). 2. Replace all O-rings and seals.

CUIL14TR00776AA

1

CUIL14TR00109AA

2

3. Connect the pressure tubes (4) and (5) and secure them using the bolts (3). 4. Connect the suction line (2) and secure it using the two clamps (1). 5. Attach a new pump filter.

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Hydraulic systems - Fixed displacement pump

Pump - Remove - Tandem DANGER Pressurized system! Always remove all pressure before working on the hydraulic system. Follow the pressure BLEED program in the Configuration Mode to remove the pressure in the entire hydraulic system. Failure to comply will result in death or serious injury. D0035A

Prior operation: Powered rear axle - Drain fluid (27.100). 1. Remove the pump filter (1). 2. Disconnect the transmission oil supply tubes (2). 3. Disconnect the steering oil return tube (3) and the steering oil supply tube (4). NOTE: After disconnecting each of the tubes, protect the disconnected ends with suitable covers.

CUIL16TR01214AA

1

CUIL16TR01240AA

2

4. Remove the six fastening bolts and remove the pump (1) from the rear axle housing. 5. Remove and discard the pump gasket (3).

Next operation: Pump - Disassemble - Tandem (35.104).

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Hydraulic systems - Fixed displacement pump

Pump - Disassemble - Tandem WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

Prior operation: Pump - Remove - Tandem (35.104). 1. Remove the pressure relief valve assembly, and discard O-rings and backup rings.

CUIL16TR01241AA

1

CUIL16TR01242AA

2

CUIL16TR01243AA

3

NOTE: This valve is not adjustable and must be replaced.

2. Remove the nut (1), the lock washer (2), the drive gear (3), and the keyway (4) from the drive gear shaft (5).

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Hydraulic systems - Fixed displacement pump

3. Remove the six bolts (1) and washers from the front pump.

CUIL16TR01244AA

4

CUIL16TR01245AA

5

CUIL16TR01246AA

6

CUIL16TR01247AA

7

4. Ease the cover plate (1) forward to clear the locating dowels (2). Tilt the cover to clear the transfer tube (3) and slide the cover plate off the pump housing.

5. Slide the shaft assembly (1) of the front pump gear out of the housing. NOTE: Take note of the bearing block identification markings while the pump gear is still assembled.

6. Disassemble the front gear pump assembly. Discard the ring, the thrust ring, and the seals.

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Hydraulic systems - Fixed displacement pump

7. Disassemble the rear gear pump assembly. Discard the ring, the thrust ring, and the seals.

CUIL16TR01248AA

Next operation: Pump - Inspect - Tandem (35.104).

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8

Hydraulic systems - Fixed displacement pump

Pump - Inspect - Tandem WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

NOTICE: Do not service gears, bearing blocks, or bushings as individual components but as matched sets. Replacing individual pump components may have an adverse affect on the tractor's hydraulic operations. Prior operation: Pump - Disassemble - Tandem (35.104). 1. Clean all components in a suitable solvent. Allow the parts to dry. 2. Inspect bushings and bearing blocks for wear or damage. Check for blocked lubrication grooves in the bushings. Replace the gears and bearing blocks as a matched set if required. 3. Inspect pump gears for wear or damage, particularly the bearing journals, gear teeth and side facings. 4. To ensure maximum pump efficiency, the width of each pair of pump gears must be within 0.005 mm (0.0002 in) of one another, and the journals within 0.013 mm (0.0005 in). 5. Remove light scoring marks on the gear facing areas using a sheet of "O" grade wet or dry abrasive paper and lubrication on a true flat surface. Polish the area repaired using light pressure in a rotating motion. Polished journals will achieve free movement in the body. 6. Inspect the gear track, embedded during the manufacturing process for the gear teeth, on the suction side of the pump. The track depth must not exceed 0.10 mm (0.004 in), or continue beyond the suction half of the gear aperture. Replace the pump when gear tracks do not fall within specification. 7. Burrs found at the edge of the gear track should be removed with "O" grade emery paper. 8. Inspect the pump cover for damage or cracks, particularly adjacent to the inlet and outlet ports, filter connection and pump face. Check internal passages for blockage.

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Hydraulic systems - Fixed displacement pump

9. Any component found unserviceable should necessitate replacing the pump assembly. If an emergency repair is required and worn components are replaced individually, note the following points: • The installation of new bearings will re-center the gears and prevent the tips of the gear teeth from bottoming, if continuing to use a pump body where the track is out of specifications. Pump inefficiencies will occur. • Under working conditions, hydraulic pressure within the pump loads the gears towards the inlet side of the pump body. Continued use of worn bearing and gear journals causes the gears to shift, thus further damaging the gear track in the pump body. Next operation: Pump - Assemble - Tandem (35.104).

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Hydraulic systems - Fixed displacement pump

Pump - Assemble - Tandem CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Pump - Inspect - Tandem (35.104). NOTICE: Perform maintenance on gears and journals as a set only. Replacing individual pump components may have an adverse affect on the tractor's hydraulic operations. 1. When replacing locating dowels, allow 2.54 mm (0.10 in) of the dowel to protrude from the pump housing (1).

RCPH10TTS019AAD

1

RCPH10TTS065BAD

2

RCPH10TTS066BAD

3

2. Assemble the transfer tube (1), seal (2) and o-ring (3). Insert them into the pump housing. • Install the longer transfer tube assembly on the front pump side of the housing. • Install the shorter transfer tube assembly on the rear pump side of the housing. 3. Lubricate all the components with clean NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL hydraulic oil.

4. Assemble the rear pump's original gears with original bearings. Do not switch components from their original orientation in the pump. If replacing components replace them in pairs not individually. • Place a new O-ring (1) and backup ring (2) on the rear pump's finished off edge bearing block (4). Only one of the two bearing blocks has a finished off edge. • Place the finished off edge of the bearing block into the rear pump housing (3) first. • Place the rear pump assembly over the transfer tube.

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Hydraulic systems - Fixed displacement pump

5. With new O-rings, back up rings, and seals; assemble the front pump gears and bearings.

CUIL16TR01246AA

4

CUIL16TR01245AA

5

CUIL16TR01241AA

6

CUIL16TR01242AA

7

6. Slide the cover plate (1) over the drive gear axle (2). Rotate the cover plate over the transfer tube (4) and push the plate engaging both locating dowels (3).

7. Secure the cover plate to the pump with bolts and washers. Use the following bolt placement information as a guide: • (1) – M10 x 110 mm dark black bolt • (2) – M10 x 110 mm knurled bolt • (3) – M10 x 115 mm knurled bolt • (4) – M10 x 115 mm dark black bolt • Torque the bolts toTorque the bolts to 50 – 62 N·m (37 – 46 lb ft).

8. Install a new pressure relief valve.

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9. Secure the pressure relief valve assembly to the pump housing. Torque to 60 – 68 N·m (44 – 50 lb ft).

RCPH10TTS067BAD

8

CUIL16TR01243AA

9

10. Insert the keyway (4) into the slot on the drive axle gear (5). Secure the assembly with the lock washer (2) and the nut (1). Torque nuts to 50 – 55 N·m (37 – 41 lb ft). 11. Torque the nuts to 50 – 55 N·m (37 – 41 lb ft)

Next operation: Pump - Install - Tandem (35.104).

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Hydraulic systems - Fixed displacement pump

Pump - Install - Tandem WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

Prior operation: Pump - Assemble - Tandem (35.104). 1. Align the new gasket (1) on the opening in the rear axle housing (2).

CUIL16TR01240AA

1

RCPH10TTS061BAD

2

CUIL16TR01214AA

3

2. Fill the pump suction port (1) with clean NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL hydraulic oil and manually rotate the drive gear (2). 3. Align the pump on the transmission over the mounting pin and the hydraulic inlet tube. 4. Confirm the pump drive gear correctly engages with the transmission idler gear. 5. Secure the pump to the transmission with six retaining bolts and washers. Torque to 57 – 76 N·m (42 – 56 lb ft).

6. Connect the oil supply line (2). 7. Connect the return line (3). 8. Connect the steering oil supply line (4). 9. Attach a new pump filter (1).

Next operation: Pump - Pressure test - Flow - Tandem (35.104). 47793462 14/03/2017

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Hydraulic systems - Fixed displacement pump

Pump - Pressure test - Flow - Tandem WARNING Uncontrolled equipment movement! Before disconnecting the hydraulic hoses from the tractor: -Lower the implement to the ground; OR, -Install the transport stops and place the hydraulic remote lever in the float position. Failure to comply could result in death or serious injury. W0907A

Prior operation: Pump - Install - Tandem (35.104). 1. Perform the following pressure and flow tests: • If a suitable flowmeter is not available for the recommended pressure and flow tests, use a pressure gauge with a pressure of 206 bar (3000 psi). • Hydraulic main pump high pressure and flow test • Low pressure circuit pressure test • Lubrication circuit pressure test NOTE: It is important that the flow of oil returning from the steering motor to the tandem pump for redistribution to the low pressure and lubrication circuits is regulated to the correct specification by the pressure regulating valve and lubrication circuit relief valve in the Power Take-Off (PTO) assembly. It is, therefore, recommended that when pressure testing the pump the lubrication and low pressure circuit pressure tests are also performed.

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Hydraulic systems - Fixed displacement pump

Pump - Pressure test - Main hydraulic pump flow - Tandem 1. Remove plug (1) from the pump outlet port.

CUIL16TR01249AA

1

CUIL16TR01250AA

2

2. Install a suitable adapter (5) into the pump outlet port (6). 3. Attach a test hose (3) to an appropriate flow meter and the pump outlet adapter (4). 4. Connect a test hose from the flow meter's return port to the remote valve's upper port (1). 5. Move the corresponding remote valve control lever to the float position. 6. Open the load valve (2) on the flow meter completely. 7. Start engine and set speed to 2100 RPM. 8. Gradually close the load valve until a pressure reading of 137 bar (1987 psi) on the flow meter gauge is obtained. 9. Allow the engine to run until the hydraulic oil reaches a normal operating temperature not to exceed 75 °C (167 °F). 10. Continue to close the load valve on the flow meter until the relief valve begins to react and pressure no longer increases, as observed on the flow meter gauge. The pressure reading must be between 176 – 182 bar (2552 – 2639 psi), and remain constant within 10% of the specified pressure until the relief fully opens, and pressure reduces to zero. NOTICE: Do not allow oil to exceed the maximum pressure of 182 bar (2639 psi) otherwise damage to the pump may occur. Remove and replace the pump's pressure relief valve if not within specifications and repeat the procedure. 11. If the relief valve operated correctly, open the load valve on the flow meter until a pressure reading of 166 bar (2407 psi), at 2100 RPM is obtained. Record the pump flow. 12. The minimum flow rate must be 49 l/min (13 US gpm) for a new pump. Overhaul the pump if not within specifications and repeat the procedure. 13. Turn engine off, release pressure in the hydraulic lines, disconnect the flow meter, and install the pump outlet port plug.

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Hydraulic systems - Fixed displacement pump

Next operation: Pump - Pressure test - Hydraulic steering pump flow - Tandem (35.104).

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Hydraulic systems - Fixed displacement pump

Pump - Pressure test - Hydraulic steering pump flow - Tandem Prior operation: Pump - Pressure test - Main hydraulic pump flow - Tandem (35.104). NOTE: The flow meter for this test must be capable of withstanding back pressure of 21 bar (305 psi). 1. Disconnect the steering pump supply (1) and return (2) tubes. Cap or plug tubes.

CUIL16TR01214AA

1

CUIL16TR01251AA

2

CUIL16TR01214AA

3

2. Install suitable test hose adapters (3) and (4) on the supply hose port (5) and the return hose port (2). Connect test hoses to the inlet and outlet ports on the flow meter. NOTICE: If the flow meter's load valve is closed, damage to the steering pump may occur. 3. Open the flow meter load valve (1). 4. Start the engine and adjust engine speed to 2100 RPM. 5. Slowly close the flow meter load valve until the pressure in the flow meter gauge reaches 137 bar (1987 psi). Do not allow pump pressure to exceed this value. 6. The minimum flow rate must be 34.0 L/min (9.0 US gpm) for a new pump or 30.0 L/min (7.9 US gpm) for a used pump. Overhaul the pump if not within specifications and repeat the procedure. 7. Turn engine off, release pressure in the hydraulic lines, disconnect the flow meter, and connect the steering pump supply (1) and return (2) hoses.

Next operation: Pump - Pressure test - Low pressure circuit - Tandem (35.104).

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Hydraulic systems - Fixed displacement pump

Pump - Pressure test - Low pressure circuit - Tandem Prior operation: Pump - Pressure test - Hydraulic steering pump flow - Tandem (35.104). 1. Disconnect the low pressure circuit fitting (1).

CUIL17TR00307AA

1

CUIL16TR01252AA

2

2. Connect a suitable adapter (1), the test hose (2), and a 21 bar (305 psi) pressure gauge (1) to the open circuit port. 3. Start the tractor and adjust the engine speed to 2100 RPM. Confirm the pressure gauge reading is between 13.8 – 17.9 bar (200 – 260 psi). Overhaul the pump if not within specifications and recheck. 4. Turn engine off, release pressure in the hydraulic lines, and remove pressure gauge assembly. Install the previously removed low pressure circuit fitting.

Next operation: Pump - Pressure test - Lubrication circuit - Tandem (35.104)..

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Hydraulic systems - Fixed displacement pump

Pump - Pressure test - Lubrication circuit - Tandem Prior operation: Pump - Pressure test - Low pressure circuit - Tandem (35.104). 1. Start the tractor and set the engine speed to 1000 RPM. 2. Turn off the engine, do not adjust the throttle, and release pressure in the hydraulic lines. 3. Raise the engine hood and disconnect the oil cooler inlet hose (1). 4. Connect a suitable adapter (3), the test hose (4), and a 21 bar (305 psi) (5) pressure gauge to the flange (1) and (2) of the oil cooler inlet hose. NOTE: The connection between the oil cooler inlet house and the pressure test assembly must be tight for a safe and accurate pressure test. NOTICE: Allow the engine to run just long enough to take an accurate pressure reading, otherwise damage to hydraulic components may occur. It is recommended two people perform the next step to reduce the engine run time during the procedure. 5. Start the engine. Check the pressure reading is between 5.3 – 5.8 bar (77 – 84 psi). Shut down the engine. 77 psi is the minimum operating pressure of the lubricating circuit relief valve. 6. Release the pressure in the hydraulic lines. Remove the pressure gauge assembly and connect the previously removed oil cooler inlet hose. Next operation: Pump - Pressure test alternative of the main hydraulic pump (35.104).

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CUIL16TR01253AA

1

Hydraulic systems - Fixed displacement pump

Pump - Pressure test alternative of the main hydraulic pump Prior operation: Pump - Pressure test - Lubrication circuit - Tandem (35.104).. NOTE: Alternatively, if the tractor is not equipped with an engine mounted auxiliary pump attach the pressure gauge assembly directly to one of the remote valve's upper ports. 1. Remove plug (1) from the pump outlet port.

CUIL16TR01249AA

1

CUIL16TR01254AA

2

2. Attach the 207 bar (3002 psi) pressure gauge assembly (1), (2), (3), (4), and (5) to the pump output port. 3. Start the engine. Set the speed to 2100 RPM. Take note of the pressure indicated on the gauge. 4. Reduce the engine speed to 1200 RPM. Check the pressure reading on the gauge. 5. The pressure readings must be between 176 – 182 bar (2552 – 2639 psi). 6. Turn engine off, release pressure in the hydraulic lines, disconnect the gauge assembly, and install the pump outlet port plug.

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Index Hydraulic systems - 35 Fixed displacement pump - 104 Fixed displacement pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Fixed displacement pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Fixed displacement pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Fixed displacement pump - General specification - Auxiliary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Fixed displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Fixed displacement pump - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Fixed displacement pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Fixed displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Fixed displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Fixed displacement pump - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Pump - Sectional view - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Pump - Assemble - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Pump - Disassemble - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Pump - Dynamic description - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Pump - Exploded view - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Pump - General specification - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Pump - Inspect - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Pump - Install - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

Pump - Overview - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Pump - Pressure test - Main hydraulic pump flow - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Pump - Pressure test - Flow - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Pump - Pressure test - Hydraulic steering pump flow - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

Pump - Pressure test - Low pressure circuit - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

Pump - Pressure test - Lubrication circuit - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

Pump - Pressure test alternative of the main hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

Pump - Remove - Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

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Hydraulic systems - 35 Pump control valves - 102

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hydraulic systems - 35 Pump control valves - 102

FUNCTIONAL DATA Pump control valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Pump control valve Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Priority/Regulator valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Priority/Regulator valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Hydraulic systems - Pump control valves

Pump control valve - Overview Priority valve assembly When the tractor is equipped with a hydraulic gear pump, it needs a priority valve assembly. This set, which is found under the hydraulic lift cover, has a set of valves that establishes the priorities of the pump and controls the flow of oil to the lift cylinder and remote control valves. The function of each of these valves is indicated below.

CUIL17TR00308AA

1

CUIL17TR00306AA

2

Flow control valve (4) This valve, which is in the priority valve set, controls the oil flow to the hydraulic lift cylinder, closing the passage of oil to the remote control. The flow control valve, assures that priority is given to feeding the hydraulic lift and sends the excess oil to the sequence valve.

Outflow valve (3) The outflow valve is controlled by the pressure of the oil sent by the control valve and has two positions. In the raise position the valve allows the pumped oil to pass to the lift cylinder, while in the neutral position or lowering position, the oil goes to the deposit.

Sequencing valve (2) This valve, which is only installed if the tractor is equipped with remote control valves, regulates the oil flow in the remote control circuit, and combines the oil flow coming from the main pump with that from the auxiliary pump (optional). The functions of the sequence valve are: • Return the oil flows from the main pump and the auxiliary pump to the sump when there is no request from the remote valve. • To direct the oil to the remote control valves when there is a request. • Direct part of the flow from the pump to the remote control valves and return the excess oil to the rear axle if the pump output exceeds the flow required. • Protect the Control circuit of the auxiliary pump from excess pressure.

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Hydraulic systems - Pump control valves

Check valve (1) There are two retention valves incorporated into the priority valve set as follows:The first retention valve that is situated in the auxiliary pump feed orifice in the priority valve set, prevents the flow from the main pump from meeting that of the auxiliary pump. The second retention valve that is situated at the base of the priority valve set, avoids the flow of oil from the Lift cylinder to the flow control valve during Lift cylinder lowering, neutral in case of shock, due to the load conditions.

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CUIL17TR00306AA

3

Hydraulic systems - Pump control valves

Pump control valve - Dynamic description Control valve oil flow – Neutral

CUIL17TR00040GA

Reference

(1) (2) (3) (4) (5) (6)

Component Pump Pressure Oil Suction oil/return to deposit To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

1

Reference

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(7) (8) (9) (10) (11) (12)

Component Trapped oil Oil for auxiliary pump (if equipped) Exhaust Valve To lift cylinder Check valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

Hydraulic systems - Pump control valves

With the control valve in the neutral position, the following functions occurs: • The trapped hydraulic oil within the lift cylinder holds the cylinder in the desired position. • Pressurized oil enters the combining valve, located in the priority valve pack on top of the hydraulic lift cover. The combining valve either returns the oil to the reservoir, or directs it to the remote valve(s), depending on demand. • Hydraulic circuits without remote valves installed, do not require a combining valve. With the control valve in the neutral position, the following oil flow occurs: • Pump pressure enters the lift cover at Gallery E, where the control valve prevents the oil from entering Galleries C and D. • Pressurized oil flows up Gallery E to the flow control valve and unload valve. • The unload valve opens to return at the left side via Gallery C, and the control valve center. • Oil pressure applied to the center face of the spool in the unload valve holds the spool to the left. • With the unload valve held to the left, oil in Gallery D, and in the spring-loaded end of the flow control valve, returns to sump through Gallery G, by way of a small internal drilling in the unload valve. • Oil pressure in Gallery E now acts on the right-hand face of the flow control valve via an internal drilling, and moves the valve full left, which allows the oil to flow from Gallery E to Gallery F. • With the remote valve(s) in neutral, the load sensing, line pressure vents to sump through the remote valve(s). Pressurized oil in Gallery F acts on the right-hand side of the combining valve, and moves the valve to the left, which ports oil from Gallery F to return through Gallery G. • The oil in the lift cylinder remains trapped in Galleries A and B by the control valve land, and the check valve.

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Hydraulic systems - Pump control valves

Control valve oil flow – Lowered position

CUIL17TR00041GA

Reference

(1) (2) (3) (4) (5) (6)

Component Pump Pressure Oil Suction oil/return to deposit To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

2

Reference

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(7) (8) (9) (10) (11) (12)

Trapped oil Oil for auxiliary pump (if equipped) Exhaust Valve To lift cylinder Check valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

Hydraulic systems - Pump control valves

With the control valve in the lowering position, the following functions occurs: • Pressurized oil enters the combining valve, located in the priority valve pack on top of the hydraulic lift cover. The combining valve either returns the oil to the reservoir, or directs it to the remote valve(s), depending on demand. • Hydraulic oil within the lift cylinder returns to sump through the control valve and exhaust valve. With the control valve in the lowering position, the following oil flow occurs: • Pump pressure enters the lift cover at Gallery E, where the control valve prevents the oil from entering Galleries C and D. • Pressurized oil flows up Gallery E to the flow control valve and unload valve. • The unload valve opens to sump on the left side via Gallery C, and the control valve center. • Oil pressure applied to the center face of the spool forces the spool to the left. • With the unload valve held to the left, oil in Gallery D, and in the spring-loaded end of the flow control valve, returns to sump through Gallery G, by way of a small internal drilling. • Oil pressure in Gallery E acts on the right-hand face of the flow control valve via an internal drilling, which moves the valve full left, allowing the oil to flow from Gallery E to Gallery F. • In both the neutral and lowering positions, a lack of demand from the remote valve(s) will cause the combining valve to discharge hydraulic oil back to sump. • As the control valve moves to the right from neutral to the lowering position, lift cylinder oil flows out of Galleries A and B, through the control valve, and on to sump through the exhaust valve. • Excess oil flow from the lift cylinder through the exhaust valve forces the valve down against the spring, which reduces the exhaust port aperture.The reduced exhaust port aperture consequently controls the lowering of the lift arms irrespective of the loading on the lift linkage.

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Hydraulic systems - Pump control valves

Control valve oil flow – Raised position (slow)

CUIL17TR00043GA

Reference

(1) (2) (3) (4) (5) (6)

Component Pump Pressure Oil Suction oil/return to deposit To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

3

Reference

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(7) (8) (9) (10) (11) (12)

Trapped oil Oil for auxiliary pump (if equipped) Exhaust Valve To lift cylinder Check valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

Hydraulic systems - Pump control valves

When raising the hydraulic lift, two conditions occur, referenced as slow and fast raises. The number of open ports in the control valve that direct pressurized oil to the lift cylinder determines the speed of the lift. Moving the lift control lever to the point where the hydraulic lift begins to raise, engages the slow lift and the following functions occur: • Pressurized oil flows to the lift cylinder or combining valve. • The position of the control valve determines the position of the flow control valve, giving priority to lift cylinder demand, and diverting the surplus oil to the combining valve. • The combining valve either returns the surplus oil to the reservoir, or directs it to the remote valve(s), depending on demand. With the control valve in the slow raise position, the following oil flow occurs: • The initial movement of the lift control lever shifts the control valve from the neutral to the slow raise position. This allows pressurized oil from Gallery E to flow to Gallery C through a drilled passage in the control valve, and the left-hand end of the unload valve. • The combination of spring pressure in the unload valve, and oil pressure in Gallery C, shifts the unload valve spool full right, connecting Galleries E and D through a large cross drilling. • The channel drilled in the unload valve restricts the hydraulic oil flow to 7.6 l/min (2.0 US gpm), which induces a smooth initial lift. The reduced pressure acts on the left-hand face of the flow control valve spool, and moves it to the right. The initial oil flow from the flow control valve enters Galleries A and B through a check valve. • Further movement of the control valve to the left, uncovers a series of ports connecting Gallery E with Gallery D. Oil flow increases into Gallery D, which speeds up the lift cylinder movement. The flow control valve moves further to the right, reducing oil flow from Gallery E to Gallery F.

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Hydraulic systems - Pump control valves

Control valve oil flow – Raised position (fast)

CUIL17TR00044GA

Reference

(1) (2) (3) (4) (5) (6)

Component – Pump pressurized oil – Suction oil / return to deposit To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

4

Reference

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– Auxiliary pump oil (if equipped) (7) (8) (9) (10) (11) (12)

Exhaust Valve To lift cylinder Check valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

Hydraulic systems - Pump control valves

When raising the hydraulic lift, two conditions occur, referenced as slow and fast raises. The number of open ports in the control valve that direct pressurized oil to the lift cylinder determines the speed of the lift. Moving the lift control lever fully backward engages the fast lift position bypassing the slow lift, and the following functions occur: • The flow control valve gives full priority to the lift cylinder. • At this point, operation of the remote valve(s) would only be possible with an additional auxiliary engine mounted pump installed. With the control valve in the fast raise position, the following oil flow occurs: • The full rear movement of the lift control lever shifts the control valve pass the slow raise position to the fast raise position. All the ports in the control valve bushing uncover, allowing increased pump oil flow from Gallery E to Gallery D. • The combination of spring pressure in the unload valve, and oil pressure in Gallery C, shifts the unload valve spool full right, connecting Galleries E and D through a large cross drilling. • Oil flows from Gallery E to Gallery D with less restriction and the pressure on both sides of the flow control valve equalizes. The flow control vale spring moves the spool to the full right position, closing off Gallery E from Gallery F. • All pressurized oil from the pump diverts to the lift cylinder through Gallery A, giving the lift cylinder priority over the remote valve(s). • The size of the ports in the flow control valve bushing limit the oil flow to the lift cylinder to a maximum of 31.0 l/min (8.2 US gpm). • The completely closed off Gallery F allows the combining valve to move to the right, preventing oil flow to sump through Gallery G, unless there is an auxiliary engine mounted pump installed.

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Hydraulic systems - Pump control valves

Control valve oil flow with auxiliary engine mounted pump (if equipped)

CUIL17TR00044GA

Reference

(1) (2) (3) (4) (5) (6)

Component – Pump pressurized oil – Suction oil / return to deposit To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

5

Reference

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– Auxiliary pump oil (if equipped) (7) (8) (9) (10) (11) (12)

Exhaust Valve To lift cylinder Check valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

Hydraulic systems - Pump control valves

The optional auxiliary engine mounted pump supplements pressurized oil to the remote valve(s) circuit. • A pilot (load sensing) signal applied to the left end of the combining valve moves the valve to the right. This blocks the connections of Gallery F to G and Gallery H to G progressively, depending on the hydraulic requirements of the remote valve(s). • Pressurized oil from the auxiliary pump enters the priority valve pack and forces open the remote valve feed check-valve open to combine with oil flow from the main pump in Gallery F. • With the remote valve(s) circuit in neutral, the load sensing line vents, and pump oil pressure in Gallery F moves the combining valve to the left, opening pump oil flow to return through Gallery G. • The relief valve within the combining valve vents oil to return through Gallery G, if pressure exceeds 182 bar (2639 psi) in the load sensing line, or if there is an overload in the remote circuit. The change in pressure across the combining valve moves the spool to the left, allowing excess oil flow from both pumps in Galleries F and H to be exhausted to return through Gallery G.

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Hydraulic systems - Pump control valves

Pump control valve - Exploded view

CUIL16TR01364FA

1

Reference (1) (2)

Component Priority valve group Spool of the flow control valve

Reference (13) (14)

(3)

Flow control valve plug

(15)

(4) (5)

Check valve plug Check valve spring stop

(16) (17)

(6)

Check valve spring

(18)

(7) (8) (9)

Retention valve ball Priority valve group limiter Priority valve group O-ring and limiter plug Seat/groove of the check valve and O-ring of the lift circuit Lift circuit check valve spring Spacer of the lift circuit check valve with plug

(19) (20) (21)

Component Lift circuit check valve case Lift circuit check valve ball Combined valve spool with internal relief valve Combine valve spring Combined valve plug and O-ring Check valve plug for auxiliary pump circuit with O-ring Relief valve plug with O-ring Spring for lift circuit check valve Relief valve spool with O-ring

(22)

Flow control valve plug with O-ring

(23)

Flow control valve spring

(10) (11) (12)

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Hydraulic systems - Pump control valves

Pump control valve - Pressure test Testing the steering safety valve pressure NOTE: There is no safety valve in the steering pump and the following pressure test can only be performed as set out below. Failure to comply with these precautions could result in serious damage to the hydraulic pump. 1. Turn steering completely to the left. 2. Install a suitable pressure gauge on the flexible feed hose from the steering piston (left-hand side) using the connections. 1.

Pressure gauge of 413.8 bar (6000 psi)

2.

FT8503-8 adapter

3.

Male 7/16 JIC x Male 9/16 JIC

CUIL16TR01321AA

3. Start the engine. Set the rpm to 1500 RPM. Turn the steering wheel to the left and hold it with a force of 2.25 kgf. Take the manometer pressure readout. NOTE: Using a force of more than 2.25 kgf on the steering wheel rim can lead to slightly incorrect readings due to pumping by the hydrostatic steering motor. If the steering test is satisfactory, but the pressure readouts are different from those specified, the steering motor safety valve must be adjusted. The pressure readout should be: • Tractors with Auxiliary Front Wheel Drive (AFWD): 180 – 191 bar. 4. If the system pressure is not in accordance with the specifications, adjust it at the safety valve location on the steering motor. Use a hexagonal 8 mm spanner. Each half a turn of the screw is equivalent to approximately 14 bar. NOTE: To have access to the screw to adjust the pressure on the steering circuit it is necessary to remove the steering motor from the fixation support.

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1

Hydraulic systems - Pump control valves

Pump control valve Priority/Regulator valve - Remove DANGER Pressurized system! Always remove all pressure before working on the hydraulic system. Follow the pressure BLEED program in the Configuration Mode to remove the pressure in the entire hydraulic system. Failure to comply will result in death or serious injury. D0035A

1. Park the machine on a level and hard surface. 2. Lock the front wheels using chocks. 3. Fully lower the lift arms. 4. Remove the operator seat. 5. Disconnect the tube (1). 6. Disconnect the load sensor (2). 7. Disconnect the tube (3). 8. Remove the bolts (4) and remove the control valve. NOTE: After disconnecting each of the tubes, protect the disconnected ends with suitable covers. Next operation: Pump control valve - Inspect (35.102)..

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CUIL16TR01212AA

1

Hydraulic systems - Pump control valves

Pump control valve - Inspect WARNING Improper operation or service of this machine can result in an accident. Make sure you perform the required service and adjustments correctly to avoid injury and machine damage. Failure to comply could result in death or serious injury. W0352A

Prior operation: Pump control valve Priority/Regulator valve - Remove (35.102).. 1. Wash all components with a suitable solvent. 2. Inspect the orifices, plugs and valve seats for damage. Burrs or scratches can be removed with a extremely fine sandpaper. 3. Any heavy scoring of the bores necessitates replacement of the priority valve pack. 4. Check whether the valve of the springs show signs of damage. If necessary, replace the blade springs. 5. Install new seal rings. Lubricate all valves with hydraulic oil before assembly. Next operation: Pump control valve Priority/Regulator valve - Install (35.102)..

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Hydraulic systems - Pump control valves

Pump control valve Priority/Regulator valve - Install WARNING Fall hazard! Keep work areas organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off the floor. Failure to comply could result in death or serious injury. W0175A

Prior operation: Pump control valve - Inspect (35.102).. 1. Position the control valve on top of the hydraulic lift cover. 2. Install the four (4) bolts. Tighten to a torque of 57 – 76 N·m (42 – 56 lb ft). 3. Connect the tube (1). 4. Reconnect the load sensor line (2). 5. Connect the tube (3). 6. Install the operator seat.

CUIL16TR01212AA

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1

Index Hydraulic systems - 35 Pump control valves - 102 Pump control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Pump control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Pump control valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Pump control valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Pump control valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Pump control valve Priority/Regulator valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Pump control valve Priority/Regulator valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

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Hydraulic systems - 35 Remote control valves - 204

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hydraulic systems - 35 Remote control valves - 204

TECHNICAL DATA Remote control valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 s - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Remote control valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Couplers Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Remote control valves Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Hydraulic systems - Remote control valves

Remote control valve - General specification 7630 8030 148.0 – 162.0 bar (2146.0 – 2349.0 psi)

Pressure regulating valve of the retainer

Remote control valve - Torque Component Flow control valve fixing thread Retainer valve rotary vane coupling Retainer valve casing fixing bolts Priority check valve Fixing studs between the valve housing and the coupler Fixation studs between the valve and assembling supports From the remote control valve coupler to the housing

Torque 27.0 N·m (19.9 lb ft) 7.0 N·m (5.2 lb ft) 7.0 N·m (5.2 lb ft) 7.0 N·m (5.2 lb ft) 15.0 N·m (11.1 lb ft) 27.0 N·m (19.9 lb ft) 82.0 N·m (60.5 lb ft)

Remote control valves - Special tools Tool Number 380001740

Description Flowmeter Fitting Kit Flow meter Remote valve coupling

380000554

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Hydraulic systems - Remote control valves

Remote control valve - Overview The adjacent figure shows the installation of a dual remote control housing in a tractor equipped with gear pumps. If necessary, up to four sets of remote control valves can be installed. When a tractor is equipped with gear hydraulic pumps, the set of priority valves that includes a sequence valve is also installed. The hydraulic elevator has priority over the oil flow pumped by the Hydraulic pump. Only the excess flow from the Hydraulic pump is diverted to the remote control through the sequence valve. When installed the auxiliary pump flow is let by external piping up to the priority valve set. The hydraulic pump oil flow is led by means of internal chambers up to the priority valve set.

CUIL17TR00308AA

1

Component Reference (1) Remote Control Valve Body (2) Signal line Of the auxiliary pump, installed on the (3) motor Priority valve set (contains the sequence (4) valve)

To guarantee that the pump flow is controlled by the remote control valve at the highest pressure of the circuit, priority retention valves are installed in the load sensor lines existent between each of the individual remote control valves. Where two, there or four individual sets of valves are installed, a retention valve will be installed at the T joint between the signal line of each valve. If there is a dual set of remote control valves installed, a retention valve will also be installed between the two valve items. The main components of the dual set of remote control valves are shown and should help to identify the parts and understand the oil flow diagrams. The individual parts of the simple set of remote control valves are identical to those that are shown for the dual valve. Pressure Regulating Valve of the Retainer 148 – 162 bar (2146.0 – 2349.0 psi).

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Hydraulic systems - Remote control valves

Remote control valve - Dynamic description Single remote valve operation – Neutral Position

CUIL17TR00045GA

Reference

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Pump Pressure Oil Suction oil/return to deposit Flow control restrictor Charge Check Valve Check valve spring Flow control knob Detent regulating valve Detent spool Detent plunger and spring Detent Balls Centering Spring

1

Reference

Component Trapped oil

(12) (13) (14) (15) (16) (17) (18) (19) (20)

Control Valve Spool Shuttle check valve Load sense line (pilot line) Flow control spring Flow control spool Return to deposit From auxiliary pump (if equipped) Priority valve group Supply to remote valve

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Hydraulic systems - Remote control valves

Reference (10) (11)

Component External cylinder Valve body

Reference (21) (22)

Component Combining valve Main pump supply

A centering spring holds the control valve spool in neutral, blocking pump supply Gallery B. The control valve spool also isolates Galleries G and H from pump supply Gallery B, and oil return Galleries E and F. This traps the hydraulic oil in both ends of the lift cylinder. Galleries C and D connect with the return oil Galleries E and F, allowing pressure in the load sensing lines to return to sump. The combining valve moves to the left, compressing the spring, and diverts oil flow from the pumps, back to the reservoir through the priority valve pack.

Operation of the Single Remote Control Valve – Raise Position

CUIL17TR00046GA

2

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Hydraulic systems - Remote control valves

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component Pump Pressure Oil Flow control restrictor Charge Check Valve Check valve spring Flow control knob Detent regulating valve Detent spool Detent plunger and spring Detent Balls Centering Spring External cylinder Valve body

Reference (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Component Suction oil/return to deposit Control Valve Spool Shuttle check valve Load sense line (pilot line) Flow control spring Flow control spool Return to deposit From auxiliary pump (if equipped) Priority valve group Supply to remote valve Combining valve Main pump supply

With the remote control valve lever in the raise position, the control valve spool moves forward and the spring-loaded detent balls engage the rear grooves of the detent plunger. Pump supply Gallery B connects to Galleries G and D while Galleries H and C connect to return through Gallery E. When initially moving the remote control valve lever, the pressure in Gallery D equalizes with the cylinder pressure, or the hydraulic back-pressure, whichever is greater. The pressurized oil in Gallery D flows to the shuttle check valve and through an internal drilling to the detent regulating valve, flow control valve spool, and the pilot line (load sensing). The pilot line (load sensing) pressure from Gallery D acts on the end of the combining valve spool, moving the spool to the right. The return Gallery in the priority valve pack closes and the main hydraulic and auxiliary pump (if equipped) oil pressure flows to the remote valve inlet port. Pump pressurized oil flows from Gallery A to Gallery B through the flow control valve spool, flow control restrictor, and the load check valve. The flow control restrictor setting (manually set with the flow control knob) determines the volume of oil entering Gallery B and flowing to Gallery G. Exhaust oil from the cylinder Gallery H returns to the reservoir through Gallery E. When the cylinder fully extends, pump supply pressure increases until the detent regulating valve opens. Pump pressurized oil moves the detent spool against the detent spring and releases the clamping effort on the detent balls at the end of the control valve spool. The centering spring now moves the spool back to the neutral position. With the remote control valve lever in the raise position, the control valve spool moves forward and the spring-loaded detent balls engage the rear grooves in the detent plunger.

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Hydraulic systems - Remote control valves

Single remote valve operation – Lowering with slow flow control setting

CUIL17TR00047GA

Reference

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component Pump Pressure Oil Suction oil/return to deposit Flow control restrictor Charge Check Valve Check valve spring Flow control knob Detent regulating valve Detent spool Detent plunger and spring Detent Balls Centering Spring External cylinder Valve body

3

Reference

Component Reduced oil flow

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Control Valve Spool Shuttle check valve Load sense line (pilot line) Flow control spring Flow control spool Return to deposit From auxiliary pump (if equipped) Priority valve group Supply to remote valve Combining valve Main pump supply

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Hydraulic systems - Remote control valves

Moving the remote control valve lever to the lowering position forces the control valve spool rearwards, allowing the spring loaded detent balls to engage the front groove on the detent plunger. Gallery B connects to Galleries H and C, and Gallery G connects to Galleries D and F. This action reverses the connection to-and-from the cylinder. Pressurized oil retracts the remote cylinder in the same manner as described in the raising sequence. The shuttle check valve enables the pilot line to sense pressure in Gallery C, and directs the flow of oil to operate the detent regulating valve and flow control valve spool. The flow control restrictor rotates, reducing the slotted area in which oil flows into Gallery B and to the control valve, restricting oil flow to Gallery B. The degree of restriction, causes supply pressure to increase compared to pilot line pressure. Pressure from the pump supply line, acts on the right hand end of the combining valve, and the spool moves against the spring, diverting surplus oil to sump.

Double remote valve operation

CUIL16TR01339GA

4

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Hydraulic systems - Remote control valves

Reference

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component Pump Pressure Oil Suction oil/return to deposit Flow control restrictor Charge Check Valve Check valve spring Flow control knob Detent regulating valve Detent spool Detent plunger and spring Detent Balls Centering Spring External cylinder Valve body

Reference

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Component Reduced oil flow Controlled oil flow Control Valve Spool Shuttle check valve Load sense line (pilot line) Flow control spring Flow control spool Return to deposit From auxiliary pump (if equipped) Priority valve group Supply to remote valve Combining valve Main pump supply

Operation of two or more remote valves simultaneously, is possible irrespective of cylinder load. When two spools simultaneously operate a light load and heavy load circuit, the oil flowing from the control valve attempts to flow to the light load circuit. The flow control spool maintains the set flow to the light load circuit. The shuttle ball in the load sense line pushes firmly toward the low pressure circuit, isolating the line from the remote valve operating under the lighter load condition. Hydraulic oil from pump supply Gallery B flows to the left side of the flow control valve spool through the shuttle check valve. Oil flows through radial holes in the spool at Gallery A to Gallery B. When pressure differs greatly between two operating remote circuits, an excessive amount of oil flows from the pump supply Gallery B through the flow control valve, via the restrictor, to the remote circuit operating at the lower pressure. This additional flow results in increased pressure generated on the right-hand end of the flow control spool. The flow control spool moves to the left and compresses the spring, progressively covering the radial holes in the spool. This restricts oil from Gallery A to the load check valve, and eliminates excessive oil flow to the light load circuit, while maintaining supply line pressure from the heavy load circuit.

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Hydraulic systems - Remote control valves

Single remote valve operation – Float Position

CUIL17TR00049GA

Reference

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component Pump Pressure Oil Suction oil/return to deposit Flow control restrictor Charge Check Valve Check valve spring Flow control knob Detent regulating valve Detent spool Detent plunger and spring Detent Balls Centering Spring External cylinder Valve body

5

Reference

Component Trapped oil

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Control Valve Spool Shuttle check valve Load sense line (pilot line) Flow control spring Flow control spool Return to deposit From auxiliary pump (if equipped) Priority valve group Supply to remote valve Combining valve Main pump supply

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Hydraulic systems - Remote control valves

The float position allows operation of single acting cylinders when lowering under light load conditions. With the remote control lever full forward in the float position, the control valve spool moves rearward past the lowering position to allow engagement of the detent balls with the grooves on the float detent plunger. The control valve spool requires manual movement to neutral by the operator, as the shuttle check valve generates no pressure to release the detent mechanism. Galleries E, F, G, and H connect to return, allowing the cylinder to float and assume any position. Galleries C and D also connect to Galleries E and F, allowing only low back pressure on either side of the shuttle check valve. There is no pressure in the pilot line, and the pump output returns to the reservoir through the combining valve.

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Hydraulic systems - Remote control valves

Remote control valve - Exploded view Dual remote control valve

CUIL17TR00257GA

1

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Component Valve body Remote control valve rods Flow limiter Charge Check Valve Flow limiter tip cover Flow limiter control shaft Flow limiter control button Retainer rod Centring spring of the control valve spool Fixing nut

Reference (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

(11)

Retainer piston spring

(22)

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Component Retainer piston Detent valve spring adjuster Nine retainer balls Retainer regulator valve spring Spacer Automatic disarm valve spool Retainer body Hydraulic cylinder retainer valve Flow control spring Flow control rod Priority retention valve ball (only with dual escape)

Hydraulic systems - Remote control valves

Remote control valve - Exploded view

CUIL17TR00258GA

Reference (1) (2) (3) (4) (5) (6)

Component Hydraulic remote control levers Control lever linkage Hydraulic hose brackets Remote valve support bracket Hydraulic hose Remote coupler assembly

1

Reference (7) (8) (9) (10) (11) (12)

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Component Remote valve assembly Hydraulic oil fill tube assembly Remote valve oil return tube Remote valve oil pressure tube Hydraulic tube sensor assembly Priority control valve assembly

Hydraulic systems - Remote control valves

Couplers - Exploded view

CUIL17TR00259GA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Component Dust cover assembly Left-hand coupler assembly Right-hand coupler assembly Retaining ring Seal Seal Locking sleeve Spring Seal Backup ring Detent ball Locking body Retaining ring

1

Reference (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29)

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Component Adaptor Seal Seal Spring Valve Spring Probe O-Ring Detent ball Sleeve O-Ring Front sealing ring Retaining ring

Hydraulic systems - Remote control valves

Reference (14) (15) (16)

Component Spring Washer Backup ring

Reference (30) (31)

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Component Spring Body

Hydraulic systems - Remote control valves

Remote control valves - Remove WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

WARNING Uncontrolled equipment movement! Before disconnecting the hydraulic hoses from the tractor: -Lower the implement to the ground; OR, -Install the transport stops and place the hydraulic remote lever in the float position. Failure to comply could result in death or serious injury. W0907A

1. Remove the remote valve (1) as follows: 2. Disconnect the hydraulic hoses (2) from the top and rear of the remote valve. 3. Cap or plug the hydraulic hoses or connectors. 4. Disconnect the lever control linkage (3) from the back of the valve.

CUIL17TR00309AA

1

CUIL17TR00309AA

2

5. Remove the five bolts (1) located underneath and on both sides of the remote valve. 6. Lift the valve off the remote coupler (2). 7. Plug or cap any open ports on the remote coupler.

Next operation: Remote control valves - Disassemble (35.204)..

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Hydraulic systems - Remote control valves

Remote control valves - Disassemble WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

WARNING Uncontrolled equipment movement! Before disconnecting the hydraulic hoses from the tractor: -Lower the implement to the ground; OR, -Install the transport stops and place the hydraulic remote lever in the float position. Failure to comply could result in death or serious injury. W0907A

Prior operation: Remote control valves - Remove (35.204).. NOTICE: Perform the following procedure on a clean smooth surface. 1. From the side of the valve housing, remove the priority check valve (1) and detent ball (3). Discard O-rings (2).

CUIL17TR00310AA

1

CUIL17TR00311AA

2

2. From the back of the valve remove the flow control end cap (1) and discard the O-ring (2). Disassemble the spring (3) and flow control spool (4) from the rear of the valve.

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Hydraulic systems - Remote control valves

3. Remove the shuttle check valve (1). Discard O-rings (2) and (3), and backup ring (4). NOTE: In the following step the bushing can only be pushed into the housing approximately 1 mm (0.04 in), which is sufficient to allow removal of the retaining ring. 4. Remove the remaining flow control components from the front of the valve housing. Proceed as follows:

CUIL17TR00312AA

3

CUIL17TR00313AA

4

CUIL17TR00314AA

5

CUIL17TR00313AA

6

5. Remove the flow control knob (1).

6. Push the flow control bushing (2) into the valve housing and with a suitable tool remove the retaining ring (1).

7. Remove the internal components (1), (2), (3), (4), and (5).

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Hydraulic systems - Remote control valves

8. Discard O-rings, (1) and (3), and backup rings (2) and (4).

CUIL17TR00313AA

7

CUIL17TR00323AA

8

CUIL17TR00322AA

9

9. Remove the three Allen bolts (1) and the detent housing (2) from the end of the flow control spool (3). Discard the O-ring (18).

10. Disassemble detent assembly and detent regulating valve components. Proceed as follows: 11. Using a suitable press, push in the end-cap (1) sufficiently into the detent housing (5) and remove the retaining ring (2). 12. Release the pressure from the end-cap, allowing the spring (3) within the detent housing to eject the endcap. 13. Remove the internal components (5). Confirm all nine detent balls (15) are collected.

14. Disassemble the detent regulating assembly (3). 15. Discard the O-rings (1) and (5) and the backup rings (2) and (4).

CUIL17TR00322AA

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10

Hydraulic systems - Remote control valves

16. Compress the centering spring (3) and remove the detent plunger (6) from the shaft (5). 17. To prevent damage to the housing from the exposed end of the main spool (1), remove the spool from the opposite end of the housing. Remove and retain the washer (4) and both center spring retainers (2). 18. Repeat the procedure on the remaining valve assembly. 19. Clean all components in a suitable solvent and allow to dry before assembly. 20. Inspect all components for obvious damage, excessive wear or distorted spools and valves. Replace faulty components. NOTE: The main spool, flow control spool and restrictor match the valve housing and are not available separately. Next operation: Remote control valves - Assemble (35.204)..

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CUIL17TR00320AA

11

Hydraulic systems - Remote control valves

Remote control valves - Assemble Prior operation: Remote control valves - Disassemble (35.204).. 1. Install a new O-ring into the detent valve channel in the valve housing as shown.

CUIL17TR00318AA

1

CUIL17TR00319AA

2

CUIL17TR00317AA

3

CUIL17TR00321AA

4

2. Place a new O-ring (1) on the main spool. Insert the main spool through the back side of the valve as shown. 3. Secure the back side of the main spool in place with a washer, retaining plate, and screws.

4. Assemble the remaining main spool components as follows: 5. Install new O-rings and backup rings over the main spool (1). 6. Assemble the centering spring retainers (2), spring (3) and washer (4) over the main spool. 7. Apply thread lock to the threads of the detent screw shaft (5). 8. Compress the centering spring assembly and secure it in place with the screw shaft. Torque to 7 N·m (62 lb in). 9. Attach the detent plunger (1) to the head of the screw shaft, as shown.

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Hydraulic systems - Remote control valves

10. Assemble detent assembly and detent regulating valve components as follows: 11. Install new O-rings and back-up ring. 12. Assemble the detent regulating assembly. 13. Install the internal components. 14. Using a suitable press, push in end-cap sufficiently into the detent housing and install the retaining ring.

CUIL17TR00322AA

5

CUIL17TR00323AA

6

CUIL17TR00310AA

7

CUIL17TR00311AA

8

15. Place a new O-ring (1) between the detent housing and the valve housing, as shown. Secure the assembly to the valve with three Allen bolts. Torque to 15 – 20 N·m (133 – 177 lb in).

16. On the side of the valve housing, install a check valve ball (3), new O-rings (2), and the priority check valve (1). Torque to 7 N·m (62 lb in).

17. On the back side of the valve housing, assemble the spring, spool (1) and flow control end cap (2) along with a new O-ring (3).

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Hydraulic systems - Remote control valves

18. Install the remaining flow control components from the front of the valve housing as follows: A. Install new O-rings and backup rings on the flow control bushing. B. Assemble the internal components. C. Push the flow control bushing into the valve housing and install the retaining ring. D. Attach the flow control knob (1). Secure the knob with the set screw.

CUIL17TR00313AA

9

19. Install the shuttle check valve (1) with new O-rings (2) and (3) backup rings. 20. Repeat the steps for the remaining remote valve.

CUIL17TR00312AA

Next operation: Remote control valves - Install (35.204)..

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10

Hydraulic systems - Remote control valves

Remote control valves - Install WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

WARNING Uncontrolled equipment movement! Before disconnecting the hydraulic hoses from the tractor: -Lower the implement to the ground; OR, -Install the transport stops and place the hydraulic remote lever in the float position. Failure to comply could result in death or serious injury. W0907A

Prior operation: Remote control valves - Assemble (35.204).. 1. Remove plugs or caps installed on the coupler during the removal procedure. 2. Replace the O-rings between the valve and coupler (1). 3. Position the remote valve on top of the coupler. Ensure the valve is seated properly. Secure the remote valve to the couplers with five Allen bolts. Torque to 15 – 20 N·m (133 – 177 lb in). 4. Remove caps or plugs from hydraulic hoses or connectors and replace worn O-rings, as needed. 5. Secure the control linkage, the hydraulic hoses/tubes, and the hose cradle (5) to the remote valve. 6. Check the hydraulic oil level and refill as necessary. Next operation: Remote control valves - Pressure test (35.204)..

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Hydraulic systems - Remote control valves

Remote control valves - Pressure test WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

Prior operation: Remote control valves - Install (35.204).. 1. Install the inlet hose of a suitable flowmeter into the upper port of a remote coupler (1). 2. Set the corresponding flow control knob (3) to maximum flow. 3. Install the flowmeter return hose into the lower port of the same remote coupler (2) on the tractor. 4. Fully open the load valve on the flowmeter. 5. Ensure all connections are secure. Start tractor and set engine speed to 2100 RPM. CUIL17TR00309AA

6. Position the remote control lever of the same color as the valve in float position, fully forward 7. Position the remote control lever of the valve slice to be tested rearwards, to the extend position. 8. Gradually close the flowmeter load valve until a pressure of 137 bar (1987 psi) is obtained. Allow the tractor to run until the hydraulic oil reaches an operating temperature near 75 °C (167 °F). 9. Continue to close the flowmeter load valve. Note a steady rise in pressure, until the detent regulating valve opens. At this point the needle on the flowmeter gauge fluctuates, and the remote control lever returns to neutral. 10. The gauge reading immediately preceding needle fluctuation must be within 176 – 182 bar (2552 – 2639 psi) which is the pressure when the detent regulating valve must open. NOTE: The maximum flow capacity for a remote valve is 13.0 l/min (3.4 US gpm). If the tractor is equipped with an auxiliary engine mounted pump the maximum flow capacity is 15.0 l/min (4.0 US gpm).

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1

Hydraulic systems - Remote control valves

11. For readings not within specifications, adjust the pressure as follows: 12. Loosen the detent regulating valve locknut (1). 13. Turn the adjustment screw (inside the valve locknut (1)) to change the pressure. One-half turn (clockwise or counter-clockwise) of the adjustment screw changes the pressure approximately 31 bar (450 psi). 14. Tighten the detent regulating valve locknut. Repeat the pressure test. NOTICE: In the event the remote valve flow capacity is below specifications during maximum output, test the tandem gear pump pressure and if applicable the auxiliary pump pressure. The pumps may require repair.

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CUIL17TR00309AA

2

Hydraulic systems - Remote control valves

Remote control valves - Pressure setting Prior operation: Remote control valves - Install (35.204).. 1. The hydraulic drive pressure of the automatic disarm must be adjusted when the valve assembly is serviced or when the control levers and rod prematurely return to neutral. Perform the test according to the following procedure. Use kit 380001740. 2. Connect the inlet hose of a flowmeter (4) to the upper hitch of the valve assembly to be tested. 3. Set the flow control lever (5) to maximum flow. 4. Install the flowmeter return hose (2) on the top hitch of the other group of remote control valves. 5. Completely open the flow meter load valve (3). CUIL16TR01263AA

6. Run the engine at 1700 RPM. 7. Put the lever of the valve to which the flowmeter return is connected in the float position. 8. Put the lever of the valve assembly to which the flowmeter inlet is connected in the lift position. 9. Adjust the flowmeter load valve (3) to a pressure of 140.0 bar (2030.0 psi) and keep the engine running until it reaches a temperature of 75 °C. 10. Gradually close the load valve (3) and record the disarm pressure of the remote control lever. 11. The disarm pressure should be between 148.0 – 162.0 bar (2146.0 – 2349.0 psi). 12. To adjust the pressure: 13. Turn off the engine of the machine. 14. Turn the screw (1) clockwise to increase the pressure or counter-clockwise to decrease the disarm pressure. A half a turn of the screw changes the pressure approximately 32.0 bar (464.0 psi). NOTE: Never adjust the retainer screw with the machine running.

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1

Index Hydraulic systems - 35 Remote control valves - 204 Couplers - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Remote control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Remote control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Remote control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Remote control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Remote control valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Remote control valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Remote control valves - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Remote control valves - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Remote control valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Remote control valves - Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

Remote control valves - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Remote control valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Remote control valves - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Hydraulic systems - 35 Three-point hitch cylinder - 116

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hydraulic systems - 35 Three-point hitch cylinder - 116

FUNCTIONAL DATA Three-point hitch cylinder Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Three-point hitch cylinder Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Exploded view

CUIL17TR00268FA

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component Lifting piston O-Ring Stud bolts Ball Spring Detent plug O-Ring Cylinder safety valve

1

Reference (9) (10) (11) (12) (13) (14) (15)

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Component Sealing Ring Control valve sleeve Deflector (diffuser) O-Ring Exhaust Valve ASC (Auxiliary service control) valve Lifting control valve

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Overview The hydraulic top cover (1) provides a base for mounting the priority valve pack, brackets for the hydraulic lift control lever, draft control lever, and quadrant. In addition, the cover houses the top link sensing and draft control linkage system, hydraulic lift control linkage, lifting cylinder and arms, internal galleries, and covers the rear axle center casing hydraulic reservoir (2). The lift cylinder operates the lift arms to raise, lower and transport an implement. The lift cylinder assembly consists of a control valve, piston, exhaust valve, and a safety valve.

Lift cylinder exhaust valve

CUIL16TR01255AA

The spring-loaded exhaust valve, located in the lift cylinder, restricts the flow of exhaust oil from the lift cylinder, thereby maintaining the rate of drop for controlled lowering.

Lifting cylinder safety valve The spring-loaded lift cylinder safety valve, located in the lift cylinder wall, protects the lift cylinder circuit from overloading, such as, when transporting implements over rough ground. The safety valve requires no servicing.

Hydraulic top cover

CUIL17TR00269FA

2

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1

Hydraulic systems - Three-point hitch cylinder

Reference

Component

Reference

(1)

Selector brace

(4)

(2) (3)

Selector arm Control valve tensor

(5) (6)

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Component Control valve with brace and control roller. Lift cylinder Position control brace

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Disassemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

NOTE: When disassembling the cylinder, lay components out in the order of removal to facilitate a quick and easy reassembly. Perform the following procedure on a clean smooth surface. 1. Disassemble the lift cylinder. 2. Insert a suitable tool (soft metal rod) through the safety valve bore to eject the lift cylinder piston. NOTE: The lift cylinder safety valve is not serviceable. 3. Disassemble the control valve. Next operation: Three-point hitch cylinder - Inspect (35.116)..

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Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Inspect 1. Wash all of the parts. Check if the galleries are blocked. 2. Examine all of the valves for wear, scratches, and burrs. Use sandpaper to remove the any small scratches. 3. If you need to replace the stack valve sleeve, use tools NHT-0506 (1) and NHT-0507 (3) to remove and install the sleeve in the housing.

CUIL17TR00001AA

1

CUIL17TR00002AA

2

CUIL17TR00003AA

3

4. Lubricate the valve sleeve. Install tool NHT-0506 (1). The sleeve must protrude 2,52 mm (A) in relation to the machined face, turned toward the cylinder side. Use the special nut of tool NHT-0507 to achieve this measurement. NOTE: The stack valve sleeve has colors that represent the adjustment measurements on the machined side of the housing. When the sleeve is replaced, always install another sleeve with the same color code. 5. Make sure that the valves are thoroughly washed before you assemble them. Make sure that the valves are not locked in the sleeve. 6. If the arm (2), the piston rod (3), or retaining pins (1) and (4) are worn, separate the rod and arm assembly. 7. To disassemble the pins, use an appropriate lever between the rod and the face of the pin.

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Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Assemble 1. Replace all of the seal rings and retainers. 2. Install the ring (1) and the seal ring (2).

CUIL17TR00004AA

1

CUIL17TR00005AA

2

3. To facilitate the installation of the piston in the lift cylinder and to prevent damage to the piston repairs you can manufacture a guide, as per the adjacent image. A. 105 mm B. 134 mm C. 3 mm D. 40 mm E. 155 mm 4. Put the piston (1) in the cylinder (3) with the guide (2). If the guide is not available, use a press. 5. Lubricate the transverse axle and the retainers. 6. Assemble the lift arms. Torque to 27.0 – 40.0 N·m (19.9 – 29.5 lb ft). 7. Raise the lift arms. Tighten the bolt of the right-hand lift arm so that the arms lower by their own weight.

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Index Hydraulic systems - 35 Three-point hitch cylinder - 116 Three-point hitch cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Three-point hitch cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Three-point hitch cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Three-point hitch cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Three-point hitch cylinder - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

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SERVICE MANUAL Hitches, drawbars, and implement couplings 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hitches, drawbars, and implement couplings - 37

[37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

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CONSUMABLES INDEX Consumable Loctite® 518™ Gasket Eliminator®

Reference Rear three-point hitch - Install

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PAGE 37.1 / 24

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Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

TECHNICAL DATA Rear three-point hitch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear three-point hitch Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Rear three-point hitch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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CONSUMABLES INDEX Consumable Loctite® 518™ Gasket Eliminator®

Reference Rear three-point hitch - Install

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PAGE 37.1 / 24

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - General specification Table 01: Cylinder safety valve 7630 Cylinder safety valve opening pressure

8030 197 – 210 bar

Table 02: Lift stack valve spindle and sleeve measurements Color Orange Green Yellow Blue White Green/White Blue/White

15.057 15.052 15.044 15.039 15.034

Spool – 15.055 mm – 15.050 mm – 15.039 mm – 15.034 mm – 15.029 mm -

25.430 25.425 25.420 25.415 25.410 25.436 25.405

Liner – 25.425 mm – 25.420 mm – 25.415 mm – 25.410 mm – 25.405 mm – 25.430 mm – 25.400 mm

Rear three-point hitch - Torque Component Hydraulic lift cylinder to lift cover retaining bolts Hydraulic lift cylinder safety valve Hydraulic lift cover – Assembly to rear axle casing Hydraulic lift arm retaining nuts Hydraulic lift filler plug Control valve turnbuckle locknut Quadrant assembly to lift cover bolts Selector lever adjuster rod locknut Lift lever adjuster rod locknut Draft control nut set screw Position control adjusting screw locknut Yoke retaining nut set screw Priority valve pack to lift cover retaining bolts Detent shaft pivot coupling

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Torque 224 – 271 N·m (165 – 200 lb ft) 102 – 122 N·m (75 – 90 lb ft) 136 – 170 N·m (100 – 125 lb ft) 27 – 41 N·m (239 – 363 lb in) 50 N·m (37 lb ft) 14 N·m (124 lb in) 68 N·m (50 lb ft) 12 N·m (106 lb in) 12 N·m (106 lb in) 30 N·m (266 lb in) 24 N·m (212 lb in) 27 – 34 N·m (239 – 301 lb in) 57 – 76 N·m (42 – 56 lb ft) 7 N·m (62 lb in)

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Dynamic description The three-point hitch can operate in either draft control or position control. The control system selected depends on the type of implement in use and the operating conditions. A draft control lever and a position control lever, located on the right-hand side of the operator's seat, provide control of the hydraulic lift system.

Draft control lever The draft control lever operates in a slotted cradle with formed notches to prevent accidental movement of the lever. To move the lever out of the notch, slide the lever to the right to clear the notches and move it to the desired position. A decal adjacent to the draft control lever clearly identifies the draft and position control settings. With the draft control lever in the forward notch, the three-point hitch is in the most sensitive setting and variations in soil density cause the hydraulic system to respond to small changes in soil condition. Move the draft control lever progressively rearward to decrease draft control sensitivity. The rearmost notch positions the system in position control. NOTICE: Always set the draft control lever to position control in the rearmost notch when automatic correction of the three-point hitch is not desired, such as when attaching equipment, transporting equipment, or with no equipment attached.

Position control lever The position control lever raises or lowers the three-point hitch linkage and implement to the required height or working depth. Pushing the position control lever forward lowers the implement. Pulling the position control lever to the rear raises the implement. An adjustable stop provides a means of returning the position control lever to the selected setting during use. To adjust the location of the stop, turn the knob counter-clockwise to loosen it and slide it to the desired position. Tighten the knob. The stop can be bypassed by easing the lever to the right to clear the stop.

Principles of draft control The draft control system manages the tillage depth engaging implements to maintain an even pull on the tractor and reduce wheel slippage. When lowering a soil-engaging implement, e.g. a plow into the ground, the draft forces (A) applied to the implement tend to make the plow pivot at the point where it attaches to the lower links (B). Without the top link, the plow would tip up (C). Due to the top link resistance, the plow stays level in the ground. This creates a compressive force (1) acting on the top link against the tractor. The draft force will vary according to the depth of work and soil type. When draft forces increase beyond selection, the compressive force on the top link (1) pushes the yoke (3) further into the hydraulic lift cover and the three-point hitch raises the implement until the preset draft load is restored. When

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Hitches, drawbars, and implement couplings - Rear three-point hitch

draft forces decrease below selection, the compressive force on the top link reduces, the yoke moves out from the top cover, and the three-point hitch responds by lowering the implement until the preset draft load is restored.

CUIL16TR01349FA

Reference (1) (2) (3)

Component Top link (compression) Lower link Draft control yoke

1

Reference (A) (B) (C)

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Component Draft forces Pivot point of lower arm Rotational force

Hitches, drawbars, and implement couplings - Rear three-point hitch

Top link sensing and three-point linkage Draft forces applied to an implement, transmit mechanically from a rocker (1) and control yoke (2), to the draft control mechanism, via the top link (3) of the three-point linkage. The hydraulic system responds by raising or lowering the implement, to restore and maintain uniform draft loading.

CUIL16TR01194AA

2

Draft control – Lower position The draft control lever (11) connects to the control arm (9) by a clevis link. As the control lever moves downward, the arm rises and aligns the control rod and roller assembly (5). The control rod and roller assembly attaches to the far end of the lever arm. The top pivot point of the control link (4) connects to the draft control main spring plunger (1). Downward movement of the lift control lever (10) moves the actuating lever (14) forward. The actuating lever pivots about the control rod connector (8) and allows the control valve spring (7) to move the control valve spool rearward into the lowering position. The lowering action stops, when the implement draft compresses the draft control main spring (2) in a forward direction enough to cause the main spring plunger to move the control link forward. This action causes the control rod to pivot the actuating lever about the top attaching point. The actuating lever overcomes the rearward pressure of the control valve spring and moves the control valve spool forward into the neutral position.

CUIL17TR00274FA

3

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Draft control – Raise position An increase in draft to the implement transmits through the yoke (3) to compress the draft control main spring (2), moving the draft control main spring plunger (1) in a forward direction. The control rod and roller assembly (5) connected to the plunger by the control link (4), pivots about the actuating lever (6). The actuating lever overcomes the pressure of the control valve spring (7), and moves the control valve spool forward, into the raise position. As the implement lifts, the draft forces acting on the yoke reduce, and the compression of the draft control main spring eases. The control valve spring moves the control valve spool rearward, back into the neutral position. A further decrease in draft reduces the draft control main spring compression and the pressure on the actuating lever. The control valve spring extends and moves the control valve spool, rearward into the lowering position. As the implement runs deeper, the draft increases and the control valve spool returns to the neutral position.

CUIL16TR01350FA

4

Draft control – Transport position Pulling the draft control lever (10) to the top of the quadrant selects the transport position. The top of the actuating lever (12) pivots rearwards about the control rod connector, which allows the control valve spring (7) to move the control valve spool forward, into the raise position. To limit the height of the implement, the piston skirt contacts a stop pin attached to the actuating lever, when reaching the full raised position. The control valve spool moves rearward into the neutral position, stopping further movement of the lift piston. The stop pin functions in both draft and position control.

Principles of position control The system of position control enables the working depth or height of an implement, relative to the tractor, to be preset and maintained. During position control, the control rod and roller assembly (5) align with the lower end of the control link (4). With the control rod and roller in this position, any variations in draft loading applied to the yoke (3) through the top link and three-point linkage system will not alter the control rod and roller. Consequently, the actuating lever (12) and control valve (7) remain unchanged unless movement of the draft control lever (10) occurs.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Moving of the lift control lever (11) pivots the control rod and repositions the control valve spool, to raise and lower the implement as required. As the lift arms move, the position control link (14) rides the position control cam (13), moving the control rod and actuating lever. With the lift arms in the desired position, the actuating lever returns the control valve to neutral, which stops further movement of the lift arms. Therefore, a direct relationship exists between the height of the lift arms and the position of the draft control lever.

CUIL16TR01350FA

5

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Remove ATTENTION: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your dealer or the Service manual. Failure to comply with these procedures can result in death or serious injury. ATTENTION: When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT handle engine coolant , engine oil or hydraulic oil at temperatures that exceed 49° C (120° F). Failure to comply will result death or serious injury. 1. Disconnect the control lever linkage (2) and (3) from the hydraulic cover lever mechanism (1). 2. Remove the remote valve from the hydraulic cover. 3. Disassemble the operator seat, the Power Take-Off (PTO) (lever, switch, and mechanism), and the parking brake. A. Under the tractor operator platform disconnect the rear electrical harness connection to the seat connection. Remove the bolts securing the seat base to the platform. B. Disconnect the parking brake. C. Disconnect the PTO lever, the switch, the mechanism, and the spring cradle.

CUIL16TR01226AA

1

CUIL16TR01255AA

2

NOTE: Tractor's equipped with an engine mounted auxiliary hydraulic pump and/or hydraulic ram cylinder(s), disconnect the metallic pipe on the priority control valve front port and the ram cylinder rod connection to the lifting arms. 4. Remove the seat, base plate, and bracket from the operator platform. 5. When you repair the lift cylinder, loosen but do not remove the lift cylinder bolt hardware before you lift the hydraulic cover off of the rear axle housing. 6. If necessary remove the control valve (priority control valve) from the hydraulic cover. 7. Remove the bolt hardware from around the perimeter of the hydraulic cover. With a suitable lifting device, lift the hydraulic cover (1) and slide it rearward exposing the rear axle housing (2). NOTICE: Do not let the hydraulic cover assembly rest on any of the internal components or controls.

Next operation: Rear three-point hitch - Disassemble (37.110)..

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Disassemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

Prior operation: Rear three-point hitch - Remove (37.110).. 1. To disassemble the lifting control valve tensioner, proceed as follows: 2. Remove the pin (1). 3. Remove the tensioner (2). 4. Remove the control valve (3). 5. Remove the lever (4). 6. Rotate the top cover so that it is upside down. 7. Remove the four bolts that secure the lift cylinder assembly to the lift cover. 8. Move lift arms to a raised position and carefully remove the lift cylinder from locating dowels.

CUIL16TR01276AA

1

CUIL16TR01277AA

2

Disassemble the hydraulic control linkage support. 1. Loosen the lock nut (4) and remove the Belleville washers (3). 2. Remove the body (2) and the friction disc (1). 3. Remove bolt (5). 4. Remove the pivot pin of the housing (8) and remove the plate (7). 5. Remove the bolts and remove the support (7).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Disassemble the control arm, roller, and lever components as follows: 1. Disassemble the components of the control arm (1).

CUIL16TR01278AA

3

CUIL16TR01279AA

4

CUIL16TR01280AA

5

CUIL16TR01281AA

6

Disassemble the selector arm and eccentric shaft components as follows: 1. Remove the nut (2), washer (11), and bushing (1). 2. Remove the eccentric shaft (10) from the arm (4) and remove the spacer (8). 3. Remove the other end of the arm (3) from the cam (9) by removing the snap ring. 4. Remove the snap ring (5) and remove arm (3) from arm (4). 5. Remove the snap ring (6) and remove the cam roller (7) from the arm (4). Disassemble the main draft control spring and plunger as follows: 1. Remove the yoke (8) and the seal (7). 2. Remove the selector arm (5) and the bracket (4). 3. Remove the retaining nut (2) and the plunger rod (1). 4. Remove the washers (8) and (9). Remove the spring (3). 5. Remove the plunger rod from the cover. 6. Remove the snap ring (6) and remove the selector arm (5) from the plunger rod. NOTE: The spring tension dissipates after the first couple of turns of the retaining nut (2). Disassemble the lift arms as follows: 1. Remove the bolt (3) and washer (4). 2. Use a suitable puller and remove the lifting arms (1) from both sides.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Disassemble the rockshaft as follows: 1. Remove the rockshaft (4). 2. Remove the retaining seals (3) and (8). 3. Remove the bushings (1), (2), (6), and (7)

CUIL16TR01282AA

Next operation: Rear three-point hitch - Assemble (37.110)..

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7

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Assemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Rear three-point hitch - Disassemble (37.110).. 1. Before you assemble the hitch mount components, replace any worn or damaged components. 2. Rotate the top cover to the inverted horizontal position. 3. Before installation of the rockshaft, coat the shaft and lip seals with grease. 4. The following torque procedure must be observed when tightening the lift arm retaining bolts. 5. Assemble the bushings (1), (2) (6) and (7). 6. Assemble the retaining seals (3) and (8). 7. Install the rockshaft (4).

CUIL16TR01282AA

1

CUIL16TR01281AA

2

Assemble the lift arms as follows: 1. Tighten the left-hand arm bolt (3) to a torque of 27 – 40 N·m (20 – 30 lb ft). 2. Lock the bolt in position with the tab washer. 3. Raise both lift arms and tighten the right hand arm retaining bolt sufficiently to allow the arms to lower under their own weight. Lock the bolt in position with the tab washer.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Assemble the main draft control spring and plunger as follows: 1. Prepare the plunger rod (7) sub assembly. 2. Install the selector brace (5) with the washer onto the plunger rod (7) and secure with the retaining ring (6). 3. Coat the plunger rod with grease and Install the rod assembly into the hydraulic top cover. 4. Install the washer (8), the spring (3), and the washer (9) into the draft control spring bore. 5. Thread the retaining nut (2) into the housing. 6. Install the support (4) with bolt and washer. Torque the bolt to 40.7 – 54.2 N·m (30.0 – 40.0 lb ft). Be sure to align the bolt with the machined area on the plunger rod.

CUIL16TR01280AA

3

CUIL16TR01279AA

4

CUIL16TR01278AA

5

7. Install the seal (10) and the yoke (1). Assemble the selector arm and eccentric shaft components as follows: 1. Install the cam roller (7) on the arm (4) with the spacer. Attach retaining ring (6). 2. Assemble the arm (3) onto the arm (4) and secure with retaining ring (5). 3. Attach the other end of arm (3) to the selector (9) and secure with the retaining ring . 4. Install the eccentric shaft (10) through the arm (4) and install the spacer (8). 5. Install the washer (11), the bushing (1), and the nut (2). 6. Rotate the eccentric shaft (10) to position the cam roller (7) in the highest position. Assemble the control arm, roller and lever components as follows: 1. Insert the eccentric shaft (1) in the lever (2) and secure with a snap ring. 2. Install the washer (5) and the detent (6) on the shaft.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Assemble the hydraulic control linkage support. 1. Assemble the link pin (8). Install the plate (7). 2. Assemble the friction disc (1) and the body (2). 3. Assemble the washers (3). Secure the lock nut (3).

CUIL16TR01277AA

6

CUIL16TR01276AA

7

Installation of the hydraulic lift cylinder. 1. Lower the lift arms and carefully install the lift cylinder on the dowel pins. 2. From the top of the hydraulic cover, install the lift cylinder bolts. 3. Install and connect the hydraulic lift control valve. 4. Instal the pin (1). 5. Install the tensioner (2). 6. Install the control valve (3). 7. Install the lever (4). Next operation: Rear three-point hitch - Adjust (37.110)..

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Rear three-point hitch - Assemble (37.110)..

Adjustment and inspection setup 1. Position the hydraulic lift cover assembly on a support with the internal linkage facing upwards (as long as the priority valve pack is removed from the top of the cover), or vertically in a vice with the main draft spring end upward. 2. Ensure the assembly is not resting on the external control selector levers and the lift arms must move freely.

Internal control linkage inspection 1. Move the draft/position control lever (2) and the lift control lever (1) into random positions.

CUIL16TR01283AA

1

CUIL16TR01284AA

2

2. At each setting manually move the lift arms (1) upward (lower position) and downward (raised position). 3. When moving the lift arm, check the internal linkage (cam roller (1), overtravel spring (2), pivot block (3) and control valve spool (4)) for seizure or other defects. Replace worn or damaged components.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

4. Place the lift arms (1) in the raised position (perpendicular with the top cover on the support). Rotate the lift control lever (2) counterclockwise to the fully raised position (lever at top of quadrant). This moves the control valve (3) spool inwards.

CUIL16TR01283AA

3

CUIL16TR01286AA

4

CUIL16TR01287AA

5

CUIL16TR01288AA

6

5. Rotate the draft/position control lever back and forth while observing the stroke of the roller (1) across the cam (2). 6. The roller must move square and parallel (2) with the cam and not at an angle (1) across the cam. 7. Replace any worn components, and proceed with the hydraulic lift internal control linkage adjustments. NOTICE: To ensure the proper operation of the hydraulic lift perform the following adjustment procedures (Main Draft Spring, Draft Control Linkage, Position Control Linkage) in sequence.

Main draft spring adjustment 1. Move the hydraulic lift arms (3) to the fully raised position (perpendicular to the top cover on the support). 2. Rotate the lift control lever (4) and the draft/position control lever (5) until the rod and roller (2) do not touch the cam (1). Ensure there is no tension on the control valve spool and spring (6). Check that the linkage is free to move. • Move the draft/position selector lever in the full position setting. • Move the lift/lower control lever in the full lowered setting.

3. Unscrew the yoke (6) from the plunger (2) and the top cover (1) to remove any previous preload. 4. Loosen the retainer nut adjustment screw (8). Turn the retainer nut (9) counter-clockwise to create play in the main traction spring (4). 5. Turn the retainer nut clockwise until free-play is eliminated (evident by feeling spring resistance).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

6. Assemble the yoke (1) onto the plunger (you should feel the resistance of the spring). Turn the yoke the least amount necessary to position the hole in the yoke so it will be vertical when the hydraulic cover is reinstalled.

CUIL16TR01289AA

7

CUIL16TR01290AA

8

7. Verify the elimination of the play. To verify, pry on the main draft spring through the access hole (2). 8. Tighten the retainer nut setscrew (1) to a torque of 27 – 34 N·m (20 – 25 lb ft).

Draft control linkage adjustment NOTE: Ensure the correct adjustment of the main draft spring is achieved before adjusting the draft control internal linkage. 1. Move the lift arms (2) to the fully lowered position (parallel with the top cover on the support). 2. At the control lever side, check that the eccentric pin (1) rotated so lobe on inside of assembly points into the top of the assembly. If necessary, loosen the nuts on (1) and adjust the pin to obtain this position. NOTE: To ensure the hydraulic lift cylinder piston reaches the fully lowered position, remove the cylinder safety valve. Replace the safety valve after obtaining the fully lowered position.

CUIL16TR01291AA

9

3. Place the position of the draft/position control adjustment plate (3) in draft control and move the lift lever until the notch on the body (2) is 1 mm (0.04 in) before the draft control notch (5) on the support. 4. Check for over-compression of the rod and roller overtravel spring (1), which is evident when a gap exists between the rod and roller pivot block and the washer. If the rod and roller spring is over-compressed, adjust the control valve spool turnbuckle (4).

CUIL16TR01292AA

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10

Hitches, drawbars, and implement couplings - Rear three-point hitch

5. Gradually move the draft/position control lever (1), observing the control valve spool moves approximately 2 mm (0.079 in) into the control valve body (2). 6. Tighten the bolt by hand (3) on the adjustment plate to temporarily secure this position.

CUIL16TR01292AA

11

CUIL16TR01283AA

12

CUIL16TR01295AA

13

CUIL16TR01296AA

14

7. Move the lift arms (1) between the raised position (perpendicular with the top cover) and the lowered position (parallel with the top cover) while observing for movement of the control valve spool (2), as it enters the valve body when raising and exits the valve body when lowering. • If the spool does not move, torque the nut (previously hand-tightened) to a torque of 20 – 29 N·m (15 – 21 lb ft). • If the spool moves, gradually continue the process of resetting the draft/position adjustment plate until no further movement of the spool exists. 8. Place the lift arms in the lowered position (parallel with the top cover). 9. Check that the rod (4) and the roller (2) are adjusted to 48.5 – 50.5 mm (1.91 – 1.99 in) deep on the top cover with the control linkage rod and roller adjustment measurement tool (3). NOTE: If the rod and roller is not within specification, repeat the Draft Control Linkage Adjustment from the beginning. 10. Place the edge of the handle flush with the machined surface of the top cover, measure down to the diagonal leg of the gauge tool dimension H 0.76 mm (0.03 in).

11. With a scribe or similar tool, make a notch (1) in line with the draft control mark and the adjustment plate (2).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

12. Remove the control valve faceplate on the opposite end of the control valve spool. 13. Place the control valve depth gauge (1) into the end of the control valve bushing (2).

CUIL16TR01297AA

15

CUIL16TR01298AA

16

14. Check that the control valve spool (1) just touches the depth gauge – measured 11.7 mm (0.46 in) from the edge of the bushing (2) – dimension (A). If necessary, adjust the control valve spool turnbuckle until the end barely touches the gauge. 15. Apply thread sealant to the turnbuckle threads and tighten lock nut to a torque of 163 N·m (120.2 lb ft).

Position control linkage adjustment NOTE: Ensure the correct adjustment of the main draft spring and the draft control linkage is achieved before adjusting the position control internal linkage. 1. Move the lift arms (2) to the fully lowered position (parallel with the top cover on the support).

CUIL16TR01291AA

17

CUIL16TR01299AA

18

2. Move the lift control lever until the body notch (2) is 1 mm (0.039 in) left of the notch (1) on the position control support.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

3. Loosen the bolt (3). Move the draft/position control adjustment plate (2) until the notch aligns with the mark (1) that was made during the draft control linkage adjustment. 4. Tighten the bolt (3).

CUIL16TR01296AA

19

CUIL16TR01301AA

20

CUIL16TR01297AA

21

CUIL16TR01298AA

22

5. Use the tool FT8527 to set the control rod according to the roller clearance. Place the edge of the tool flush with the machined surface of the top cover (3) and measure down to the diagonal leg of the gauge tool. Check that the rod (4) and roller (1) have a clearance of 0.76 mm (0.03 in) above the upper surface of the tool. NOTE: If the gap is not within specification, repeat the draft control linkage adjustment and the position control linkage adjustment from the beginning. If the measurement is correct, proceed with the adjustment procedure.

6. Remove the control valve faceplate on the opposite end of the control valve spool. 7. Place the control valve depth gauge (1) into the end of the control valve bushing (2).

8. Check that the control valve spool (1) just touches the depth gauge – measured 11.7 mm (0.46 in) from the edge of the bushing (2) – dimension (A). If necessary, adjust the control valve spool turnbuckle until the end barely touches the gauge. 9. Apply thread sealant to the turnbuckle threads and tighten lock nut to a torque of 163 N·m (120.2 lb ft).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

10. If necessary, adjust the control valve spool. To adjust the spool, loosen the lock nut (1) and rotate the eccentric shaft until the end barely touches the gauge. 11. Tighten the lock nut to a torque of 20 – 27 N·m (15 – 20 lb ft).

CUIL16TR01291AA

Next operation: Rear three-point hitch - Install (37.110)..

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23

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Install WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Rear three-point hitch - Adjust (37.110).. Before installation, note the following: • Replace any worn or damaged components. • Before you install the top hydraulic cover, apply a thin layer of LOCTITE® 518™ GASKET ELIMINATOR ® to both sides of the new gasket. The layer must be over the entire face of the gasket at a thickness of 1 mm (0.04 in). 1. With a suitable lifting device, lift the hydraulic cover (1) into place, covering the rear axle housing (2). Secure the bolts around the hydraulic lift cover. Torque to 136 – 170 N·m (100 – 125 lb ft). NOTICE: Do not let the hydraulic cover assembly rest on any of the internal components or controls. 2. If necessary, install the control valve (priority control valve) of the hydraulic cover. Consult the procedures in Pump control valve Priority/Regulator valve - Install (35.102).

CUIL16TR01255AA

1

CUIL16TR01305AA

2

3. Connect the Power Take-Off (PTO) lever, the switch, the mechanism, and the spring cradle. 4. Install the remote valve (1). Consult the procedures in Remote control valves - Install (35.204). 5. Fill the hydraulic oil system. Consult the procedures in Powered rear axle - Filling (27.100). 6. Assemble the control lever linkage of the hydraulic lift.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

7. Install the arms (1), the stabilizers (2), and the auxiliary cylinders (3) (when available).

CUIL14TR00355AA

3

CUIL16TR01218AA

4

8. Install the 3-point arm (1) and the rocker arm (2).

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Index Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110 Rear three-point hitch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Rear three-point hitch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Rear three-point hitch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Rear three-point hitch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Rear three-point hitch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Rear three-point hitch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Rear three-point hitch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Rear three-point hitch - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Frames and ballasting 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Frames and ballasting - 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

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Frames and ballasting - 39 Ballasts and supports - 140

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Frames and ballasting - 39 Ballasts and supports - 140

SERVICE Front ballast Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Frames and ballasting - Ballasts and supports

Front ballast - Remove WARNING Crushing hazard! Counterweights are very heavy. Always use certified lifting equipment to remove and install the counterweights. Make sure the hardware securing the counterweight(s) to the machine is installed correctly and the clamp bolts are tightened fully before operating the machine. Failure to comply could result in death or serious injury. W0402A

WARNING Heavy object! Clear the area around and under the counterweight removal and installation system before installing or removing counterweights. Keep all unauthorized personnel clear of the area. Make sure all lifting devices are in good condition and capable of handling the counterweight mass. Failure to comply could result in death or serious injury. W0037A

1. Loosen the mounting bolts located behind the plates. 2. Use a bar that goes through the central hole to lift all of the plates with the aid of a lifting device. NOTE: Alternatively, you can remove the weights individually. You must remove the mounting bolts and the long bolt (1) beforehand.

CUIL13TRO0091AA

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1

Index Frames and ballasting - 39 Ballasts and supports - 140 Front ballast - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Steering 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

Reference Power steering control valve - Assemble

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PAGE 41.2 / 18

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Steering - 41 Steering control - 101

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Steering - 41 Steering control - 101

FUNCTIONAL DATA Steering column Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - Steering control

Steering column - Exploded view

CUIL17TR00260GA

Reference (1) (2) (3) (4) (5) (6)

Component Steering column assembly Steering wheel column Steering cap Lock nut Lug bolt Pin

1

Reference (7) (8) (9) (10) (11) (12)

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Component Collar Clamp Rubber insulator cushion Screw Washer Cover Steering Motor

Index Steering - 41 Steering control - 101 Steering column - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

Steering - 41 Hydraulic control components - 200

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Steering - 41 Hydraulic control components - 200

TECHNICAL DATA Hydraulic control components General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Hydraulic control components Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power steering control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Power steering control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

Reference Power steering control valve - Assemble

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Steering - Hydraulic control components

Hydraulic control components - General specification 7630 Minimum pump flow Maximum pressure of steering circuit safety valve: Absolute pressure on manometer

8030 31 l/min 170 bar 180 – 190 bar (2610 – 2755 psi)

Hydraulic control components - Special tools Tool Number 380000618 380000281 380000836 380000307

Description Steering Adapter Fitting Steering seal installer RotoGlyd Variable Power Steering Seal Installation Tool (Danfoss) Power Steering Rotor Locker Lever

Hydraulic control components - Torque Component Steering wheel fixing nut Front wheel nuts Engine End Cover Outer hinge of cylinder to extension Outer hinge of cylinder to axle Cylinder ball joint clamps Cylinder ball joint nuts Extension tube from cylinder to cylinder Slope bolt from the column to the frame bolt Cylinder, tube end pin fixation bolt (with 4WD) 24.0

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Torque 23.0 N·m (17.0 lb ft) 475.0 N·m (350.3 lb ft) 23.0 N·m (17.0 lb ft) 43.0 N·m (31.7 lb ft) 176.0 N·m (129.8 lb ft) 43.0 N·m (31.7 lb ft) 176.0 N·m (129.8 lb ft) 271.0 N·m (199.9 lb ft) 23.0 N·m (17.0 lb ft) 23.0 N·m (17.0 lb ft)

Steering - Hydraulic control components

Hydraulic control components - Dynamic description Description and operation The hydrostatic steering system is activated by the oil pressure from the steering pump, which is one of the pumping units of the main hydraulic pump installed on the rear axle of the tractor. The steering pump is responsible for forming the Steering, Low Pressure (Steering return) and Lubrication circuits. The main hydraulic pump receives the force from the idler gear of the Power Take-Off (PTO) and transmits it to the Hydraulic Pump gears. The Hydraulic Pump transmits the force to the group of steering pump gears by means of a power shaft. There is a common filter for the two pumps, responsible for retaining contaminants and particles present in the lubricant oil. The steering pump pumps oil to the hydrostatic steering motor (orbitrol) which is activated by the steering column when the operator moves the tractor steering wheel. The pressurized oil from the steering motor (orbitrol) activates two double-acting pistons. The steering motor (orbitrol) is bolted to the steering column and connected to the steering column by a splined shaft and a lock pin. The tractors have two steering cylinders, one for each wheel. The cylinders are fixed to the axle housing and on the trunnion eyelets. The system pressure safety valve is inside the steering motor (orbitrol).

Operation The system is fully hydrostatic so there is no mechanical link between the steering column and the wheels. The oil is sucked up from the rear axle into the pump through a filter, pressurized by the rotation of the steering pump gears and expelled through the pump outlet orifice to the steering motor. The oil received in the steering motor is sent to the actuation cylinder when the tractor steering wheel is moved. The steering motor includes a measuring unit which adjusts the volume of oil supplied to the cylinder so that it is proportional to the angular movement of the steering wheel. The measuring unit in combination with the test valve allows you to drive the tractor even when there is no oil pressurized by the pump – manual steering.

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Steering - Hydraulic control components

Schematic diagram of steering operation – Dead center position

CUIL16TR01460FA

1

Suction oil Return oil Reference (1) (2) (3) (4) (5) (6)

Pressurised oil (up to 170 bar) Measured oil to the steering piston Component Metering Valve Test valve Check valve Pump Filter Return via cooling and lubrication

Reference (7) (8) (9) (10) (11) (12)

Component Pressure retention valve Control valve liner Control valve coil Not available Not available Steering Cylinders

Position centred With the steering wheel immobile, the centring springs align the spool and sleeve at neutral. In these conditions, no oil is sent to the steering cylinders. However, the retained oil is transferred between the sides of the left and right curves of the cylinders, letting the wheels react to the terrain to provide feedback to the driver.

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Steering - Hydraulic control components

Schematic diagram of the steering operation - Steering activated:

CUIL16TR01459FA

2

Suction oil Supplying the steering motor Return oil

Pressurised oil (up to 170 bar) Measured oil to the steering piston

Turning to the right Reference (1) (2) (3) (4) (5) (6)

Component Metering Valve Test valve Check valve Pump Filter Return via cooling and lubrication

Reference (7) (8) (9) (10) (11) (12)

Component Pressure retention valve Control valve liner Control valve coil Not available Not available Steering Cylinders

By turning the wheel to the right, the movement of the control valve spool aligns a series of grooves in the sleeve. While turning to the right, the oil flows through the liner along a groove in the valve spool and into a passage in the steering motor housing and led to a measuring unit, as shown in the figure above. The measuring unit is activated by the rotor drive shaft and sends the oil along another series of passages in the spool and the liner, and into the steering cylinder. The return oil from the other end of the cylinder is sent through the spool and the valve sleeve to a return passage in the housing. When turning the steering wheel to the left, the oil flows along the sleeve in a manner similar to that described when turning to the right.

Manual Operation In the event of a failure in the steering pump, or loss of oil pressure, the steering system can be put to work manually. Turning the tractor steering wheel activates the measuring unit which forces the oil into the steering cylinder.

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Steering - Hydraulic control components

On the suction end of the measuring unit, the return oil flows from the cylinder and is aspirated through the safety valve to feed the measuring unit. When an extra oil supply is needed, such as when turning left, the additional oil is aspirated from the power steering reservoir through the safety valve to the measuring unit.

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Steering - Hydraulic control components

Hydraulic control components - Hydraulic schema Hydrostatic steering, low pressure and lubrication circuit – models 8x2

CUIL17TR00349FA

1

The figure above shows the hydraulic schematic and the main components of the hydrostatic steering, low pressure, and lubrication circuit. This configuration integrates in the same circuit the three circuits mentioned above and uses the same hydraulic gear pump. The operating principle is similar to the hydraulic schematic with independent steering. The circuit comprises one tandem pump pumping unit mounted on the rear tractor shaft. The rear pump (1) suctions the oil from the reservoir, passing through the filter (2) and pressurises it to the steering motor (10). The steering motor oil return (10) follows on to the pump flow divider. The flow divider (3) directs the oil to the Power Take Off (PTO) (4) and Auxiliary Front Wheel Drive (AFWD) clutch assembly (5). The PTO clutch assembly adjusts the maximum pressure of the low pressure circuit (6) between 16.0 bar and 18.0 bar. The other valve (7) limits the maximum pressure of the lubrication circuit to between 6.0 bar and 8.0 bar. The lubrication circuit is formed by the excess pressure and flow rate from the low pressure circuit. The lubrication circuit is represented by green lines in the lubrication diagram in figure 1. The lubricating oil goes from the PTO (4) to the oil radiator (8) and to the transmission components (9).

Low pressure and lubrication circuit – 8 x 2 Models Figure 2 shows the hydraulic schematic and the main components of the low pressure and lubrication circuit on machines with independent hydrostatic steering circuit. The circuit comprises one tandem pump pumping unit mounted on the rear tractor shaft. The rear pump (1) suctions the oil from the reservoir, passing through the filter (2) and pressurises it to a flow divider in the pump itself. The flow divider (3) directs the oil to the Power Take Off – PTO (4) and Auxiliary Front Wheel Drive (AFWD) clutch assembly (5). The PTO clutch assembly has a valve to regulate the maximum pressure of the low pressure circuit (6) between 16.0 – 18.0 bar and another valve (7) to regulate the maximum pressure of the lubrication circuit between 6.0 – 8.0 bar.

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Steering - Hydraulic control components

The lubrication circuit is formed by the excess pressure and flow rate from the low pressure circuit. The lubrication circuit is represented by green lines in the lubrication diagram in figure 1. The start circuit for the PTO clutch (4) passes the oil radiator (8) and then lubricates the transmission components (9). Maximum circuit pressure is regulated by valves (6) and (7) that release the excess pressure formed by the pump (1) to the reservoir. Pressure adjustment is to be done by adding shim washers to increase valve spring pressure.

CUIL17TR00350FA

2

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Steering - Hydraulic control components

Hydraulic control components - Hydraulic schema Independent hydrostatic steering circuit The figure below shows the hydraulic schematic and the main components of the independent hydrostatic steering circuit. The circuit comprises a single gear pump (8) that supplies flow rate to the orbitrol (10). When the tractor steering wheel (1) is activated the orbitrol conducts (7) the oil to the steering cylinders (6). The hydraulic pressure in the circuit increases as the steering wheel gets closer to the end of travel. In normal operation the circuit will have high pressure peaks 172 bar (2500 psi) during manoeuvres. While the tractor is driven on a straight line, the steering motor (10) sends oil at low pressure to the radiator (5) to be cooled down. The oil at approximately 60 °C is taken to the reservoir (3) from where it is sucked in (4) by the pump (8). NOTE: The radiator must not be eliminated from the circuit as it ensures adequate working temperature.

CUIL17TR00351FA

1

Oil pressure to the power cylinder Oil pressure to the rotor Reference (1) (2) (3) (4) (5)

Component Driving wheel Return line Steering oil reservoir Intake line Steering oil radiator

Inlet, low pressure, or return oil Trapped oil Reference (6) (7) (8) (9) (10)

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Component Steering cylinders Pressure lines Hydraulic gear pump Pressure line Orbitrol or steering motor

Steering - Hydraulic control components

Power steering control valve - Exploded view

CUIL16TR01353FA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Retaining ring Reflow valve balls Reflow valve pins Bearing Retaining ring Retaining ring Relief valeve Rotary valve Springs to return the sleeve to the neutral position

1

Reference (10) (11) (12) (13) (14) (15) (16) (17)

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Component Valve spool lock pin Valve sleeve Rotor drive shaft Sealing Ring Sealing Ring Rotor and fixed ring for the rotor Rear cover Fixing bolt

Steering - Hydraulic control components

Power steering control valve - Remove 1. Position the tractor on a level surface and apply the parking brake. 2. To have access to the steering motor, remove the right side protection cover from the motor. 3. Disconnect the four the steering motor supply/oil return tubes. Cover the ends of the tubes. 4. Remove the flexible fixation pin (4) and the four bolts (1), (2), (3), and (5) that secure the steering motor to the steering column (Orbitrol and oil line fixing bolts). 5. Remove the steering motor from the steering column. CUIL17TR00329AA

Next operation: Power steering control valve - Disassemble (41.200)..

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1

Steering - Hydraulic control components

Power steering control valve - Disassemble Prior operation: Power steering control valve - Remove (41.200).. To disassemble the hydrostatic steering control valve, proceed as follows: 1. Secure the steering motor housing in a vise using a tube coupling. NOTE: When assembling, the guide pin must be in the same position as it was before. 2. Remove the rear cover bolts (2), the rear cover (1), and the seal rings.

CUIL16TR01311AA

1

CUIL16TR01312AA

2

CUIL16TR01313AA

3

CUIL16TR01314AA

4

3. Remove the measuring unit, the valve plate (1), and the seal rings. NOTE: Mark the components to facilitate assembly.

4. Remove the rotor drive shaft (1).

5. Unscrew the retainer from the test valve. Remove the reflow valve assembly (1) and (2).

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Steering - Hydraulic control components

6. Remove the relief valve assembly (1).

CUIL16TR01315AA

5

CUIL16TR01316AA

6

CUIL16TR01317AA

7

CUIL16TR01318AA

8

7. Remove the sleeve (1) and the valve spool, rings, and needle bearing. NOTE: To prevent the spool lock pin from falling into a gallery of the assembly, assemble and disassemble the assembly with the valve body in the upright position. This will prevent the lock pin from entering one of the galleries and locking the spool on the liner.

8. Remove the sealing ring (1).

9. Remove the control valve spool (1) from the sleeve.

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Steering - Hydraulic control components

10. Remove the centering springs (1) and (2). NOTE: The arrangement of the leaves must remain the same after reassembly. 11. Remove the lock pin from the valve spool. 12. Separate the spool from the control valve sleeve. 13. Remove the seal rings and the support segment.

CUIL16TR01319AA

Next operation: Power steering control valve - Inspect (41.200)..

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9

Steering - Hydraulic control components

Power steering control valve - Inspect Prior operation: Power steering control valve - Disassemble (41.200).. 1. Wash all the parts in a suitable solvent to remove all the foreign particles and dry with compressed air. 2. Inspect the valve sleeve and spool for damage or wear. Burrs or scratches can be removed with extremely fine sandpaper. Make sure all the parts are thoroughly clean before they are assembled.

CUIL16TR01319AA

1

CUIL16TR01320AA

2

3. Check whether the centralising springs show signs of damage. If necessary, replace them. 4. Install new seal rings during assembly.

Next operation: Power steering control valve - Assemble (41.200)..

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Steering - Hydraulic control components

Power steering control valve - Assemble Prior operation: Power steering control valve - Inspect (41.200).. 1. Install the spool (internal) and the sleeve (external). Align the grooves to install the centralizer springs (1) and (2). Install the lock pin of the valve spool.

CUIL16TR01319AA

1

CUIL16TR01320AA

2

CUIL16TR01318AA

3

CUIL17TR00021AA

4

2. Install the centralizer springs (1) as shown in the adjacent figure.

3. Install the centralizing spring retainer and the needle bearing. NOTE: The internal needle bearing race must be positioned with the chamfer facing the spool. NOTE: During assembly, make sure you have installed the ring (1) with the chamfer to the front of the valve liner.

4. Lubricate the control valve spool and sleeve before installing the assembly in the steering motor body. 5. Using the special tool 380000281, install the RotoGlyd type seal ring. Before installation, lubricate the tool guide (sealing ring installer) with NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL oil.

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Steering - Hydraulic control components

6. Place the tool 380000281 (seal guide) on the valve body and push down with a twisting action. 7. After seating the sealing ring, remove the tool segment from the other end of the valve housing.

CUIL17TR00022AA

5

CUIL17TR00023AA

6

CUIL16TR01314AA

7

CUIL17TR00024AA

8

8. With the sealing ring installed in the motor body, replace the control valve. NOTE: Make sure the drive is in the horizontal position to help assembly.

9. When the control valve is correctly seated, re-install the reflux valves and the test valve holder. Screw the test valve retainer until it is aligned with the housing surface.

10. Reassemble the sealing ring and put on the rear cover.

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Steering - Hydraulic control components

11. Make a reference mark on the top of the tooth (1), near the seat (2), to indicate the exact position of the sleeve pin.

CUIL16TR01313AA

9

12. Fit the rotor camshaft into the valve body. 13. Insert the tool 380000307 (2) to retain and center the rotor transmission shaft between the rotor and the thrust pad. Rotate the shaft to help to couple the seat and the lock pin installed on the sleeve.

CUIL17TR00025AA

10

CUIL17TR00026AA

11

CUIL17TR00027AA

12

14. Proceed by installing the rotor, taking care to ensure the following: A. Every time the hydrostatic steering is disassembled, invert the rotor to reduce wear on the splined coupling. B. In the figure to the side, the rotor ring (stator) has been removed to show the synchronization between the rotor, rotor control shaft, and lock pin. C. Fit the rotor on the transmission shaft. Keep in mind that synchronization is achieved from the alignment on the axis plane of the lock pin of the teeth (1) and (2) with the center line of one of the rotor compartments. 15. Lubricate the two rings (1) with hydraulic oil. Install the rings in the fixed ring seat of the rotor. Install them so as the fixing holes (2) coincide with the holes on the thrust plate.

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Steering - Hydraulic control components

16. Install the cover so that the fixing holes match the rotor fixed ring holes.

CUIL17TR00028AA

13

CUIL17TR00029AA

14

CUIL17TR00030AA

15

CUIL16TR01315AA

16

17. Remove the retention tool 380000307 and fit the special bolt and washer in the retention valve seat.

18. The bolt with lock pin (1) must be mounted in the position (7). Tighten the bolts in two stages. First to a torque of 17.6 N·m and then to a torque of 34.3 N·m, following the crosswise tightening sequence indicated in the figure to the side.

19. Install the safety valve assembly, leaving the cover (4) off until the safety valve has been adjusted. 20. Make sure the motor turns freely without any difficulty. NOTICE: Install the orbitrol in a vise. Fill it with oil. With the aid of a rod, rotate the spool to one side and the other. The oil should be expelled through the outlets to the cylinders on the left and right.

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Steering - Hydraulic control components

21. Insert a 6 mm Allen key in the bolt to adjust the relief valve pressure. NOTE: The adjustment will be made later on the workbench or on the tractor. Consult the procedures in Power steering control valve - Pressure test (41.200).

CUIL17TR00031AA

17

CUIL17TR00032AA

18

CUIL17TR00033AA

19

22. Tighten the plug (1) with the corresponding sealant, using an 8 mm Allen key to perform the adjustment on the bench or tractor, tightening them to 40 – 60 N·m (29.5 – 44.3 lb ft).

23. Once the unit is assembled, insert the dust guard ring on the control valve body. 24. After fully adjusting the safety valve, re-install the steering motor in the tractor using the four fixing bolts and torque to 12.8 – 19.6 N·m. 25. Reconnect the four oil pipes, steering motor intake and return, and outlet to the right and left cylinders. Torque to 12.8 – 19.6 N·m. 26. Eliminate the air from the system by moving the steering wheel from stop to stop until the system functions correctly.

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Steering - Hydraulic control components

Power steering control valve - Pressure test WARNING Pressurized system! Never disconnect or tighten a hose or tube that is under pressure. If in doubt, engage the controls several times with the engine switched off prior to disconnecting or tightening the hose or tube. Failure to comply could result in death or serious injury. W0998A

Since valves are integrated, it is not possible to test steering once it is installed. Adjustment of pressure limiting valve and safety valves is only possible when steering unit is dismantled and always on the test bench. Use BOSCH injectors checker to verify valves operation. Connect checker to steering unit with a seeder steering hose with adapter KDJ10113. Connect return to injectors checker reservoir with a plastic tube. Fill checker with clean hydraulic oil. Prior operation: Power steering control valve - Assemble (41.200).. 1. Connect hose (6) to pressure connection (5) and return tube (7) to connection (8). 2. Block both connections to the steering cylinder (to turn to the right and left) with suitable stoppers. 3. Turn steering to its full capacity to the right or left using a 5/8” duct adaptor and keep it in this position. Pump lever (3) for pressure to rise. If adjustment of safety valves is appropriate, pressure should not exceed 105 bar (1523 psi), nor be lower than 100 bar (1450 psi).

CUIL17TR00330AA

1

CUIL17TR00331AA

2

Pressure limiting valve adjustment 1. Pressure in the pump (1) is regulated with a valve screw (2). 2. Remove stopper and adjust the valve screw. Turn counterclockwise to increase pressure and clockwise to reduce pressure. Once valve is adjusted, check working pressure with the injectors checker. When pressure is correct, place plug and apply 40 – 60 N·m (30 – 44 lb ft).

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Steering - Hydraulic control components

Relief valve test 1. Safety valves must be checked first. Connect hose (7) to connection (3) of steering cylinder (clockwise turn). Connect plastic tube (8) to return connection (4). 2. Pump lever (5) to increase the pressure. The pressure should increase to 150 – 165 bar (2175 – 2393 psi) Repeat the operation to check the counter-clockwise rotation of the safety valve connection hose (7) to the steering cylinder connection (2). Rotate counter-clockwise.

CUIL17TR00332AA

3

CUIL17TR00333AA

4

Relief Valve Setting 1. Adjust safety valve pressure by turning screws (B) and (C). Remove plugs first. Turn screw clockwise with a 6 mm Allen wrench to increase pressure, or counterclockwise to reduce it. Once adjustment has been made, check valve working pressure again. 2. When pressure is correct, place plug and tighten to a torque of 30 – 40 N·m (22 – 30 lb ft).

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Power steering control valve - Flow test Steering circuit pressure test When the hydrostatic steering system is working, the oil pressure (1) supplied by the steering pump to the steering motor may rise to the maximum pressure of the steering motor safety valve, which is 70 bar. The return from the steering motor (2) goes through the external lines to the main hydraulic pump.

CUIL17TR00334AA

1

CUIL17TR00335AA

2

The oil flow that leaves the steering motor returns to the pump body to be distributed by the low pressure and lubrication circuits. The pressure of the oil returning from the steering motor is regulated to a pressure of 16 – 18 bar by the low pressure regulating valve in the clutch assembly of the Power Take-Off (PTO) at 2100 RPM. As the pressure is regulated, the excess oil in the low pressure circuit flows through the regulating valve to the lubrication circuit that limits the oil pressure in the lubrication circuit to 5.0 – 8.0 bar to 4.5 l/min

Steering pump There is no safety valve in the steering pump. The following practical test will determine whether the pressure generated by the pump is sufficient to adequately run the steering system.

Steering Test 1. Engine speed adjusted to 1000 RPM. 2. Turn the steering wheel rapidly from stop to stop. Evaluate whether the steering is functioning correctly, and that there is no delay between turning the steering wheel and the movement of the wheels. When the steering is at the end of run, you should hear the safety valve in the steering motor relieve the excess pressure to the tank and the speed of the motor should slow down to approximately 970 RPM.

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Index Steering - 41 Hydraulic control components - 200 Hydraulic control components - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Hydraulic control components - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Hydraulic control components - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Hydraulic control components - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Hydraulic control components - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Hydraulic control components - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Power steering control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Power steering control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Power steering control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Power steering control valve - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Power steering control valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Power steering control valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Power steering control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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Steering - 41 Cylinders - 216

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Cylinders Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Steering cylinder Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Steering cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Steering - Cylinders

Cylinders - Exploded view

CUIL17TR00278FA

1

Reference (1) (2) (3) (4)

Component Steering cylinder main assembly Articulating ball joint Ball end Nut

Reference (7) (8) (9) (10)

(5)

Screw

(11)

(6)

Hydraulic fitting with O-ring

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Component Packing and detent seal Steering cylinder housing Piston rod Cylinder head cover plate Piston detent expander O-ring and seal assembly

Steering - Cylinders

Cylinders - Exploded view

CUIL17TR00279FA

Reference (1) (2) (3) (4) (5) (6)

Component Piston and conrod assembly Cylinder Extension Tube End of conrod link Dust ring Clamp bolt

1

Reference (7) (8) (9) (10) (11) (12)

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Component Clamp Nut Sealing ring kit Nut End of conrod link Clamp bolt

Steering - Cylinders

Steering cylinder - Exploded view

CUIL16TR01354FA

Reference (1) (2) (3) (4)

Component Cylinder Wiper seal Locking ring Seal nut

1

Reference (5) (6) (7) (8)

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Component Cylinder connecting rod Bushing and seal set Piston Nut

Steering - Cylinders

Steering cylinder - Exploded view

CUIL16TR01230AA

Reference (1) (2) (3)

Component Articulated pin Articulated pin D washer

1

Reference (4) (5) (6)

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Component Spacer Spacer Locking ring

Steering - Cylinders

Steering cylinder - Remove WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Front wheels - Remove (44.511).. 1. Put the tractor on a flat surface and apply the parking brake. 2. Disconnect the flexible tubes, plug the open ends of the tubes, removing their clamps. NOTE: The position of the flexible tubes and the orientation of the joints must be the same after reinstallation. 3. Remove the lock ring (6) securing the steering arm to the articulated pin of the cylinder piston. Remove the articulated pin. 4. Remove the fixing bolt from the articulated pin attached to the end of the steering cylinder, removing the pin (1). Remove the cylinder from the vehicle.

CUIL16TR01230AA

Next operation: Steering cylinder - Disassemble (41.216)..

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1

Steering - Cylinders

Steering cylinder - Disassemble Prior operation: Steering cylinder - Remove (41.216).. 1. Use a C hook wrench to remove the seal nut. 2. Using a punch, push the front cover of the steering cylinder inside the cylinder and remove the lock ring. 3. Pull the rod assembly and the front cover of the cylinder. 4. Remove the cylinder rod nut and disassemble the cylinder to replace the seal rings.

CUIL16TR01231AA

Next operation: Steering cylinder - Inspect (41.216)..

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1

Steering - Cylinders

Steering cylinder - Inspect Prior operation: Steering cylinder - Disassemble (41.216).. 1. Inspect the cylinder bore and replace it if scratched. 2. Replace all cylinder seal components. 3. Assemble the cylinder in reverse order to the disassembly process, lubricating all of the components as they are assembled. 4. Install the cylinder in the tractor by following the reverse order described in Steering cylinder - Remove (41.216).

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Index Steering - 41 Cylinders - 216 Cylinders - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Cylinders - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Steering cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Steering cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Steering cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Wheels 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

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44

Wheels - 44 Front wheels - 511

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Wheels - 44 Front wheels - 511

TECHNICAL DATA Front wheels Tires - Compatibility table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Front wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adjust the front axle stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Wheels - Front wheels

Tires - Compatibility table The compatibility table shows the combinations that you can use when you choose new tractor tires. Cells with “X” indicate released combinations of front and rear tires. Empty cells indicate combinations that have not been tested or released. NOTE: Never use tires from unapproved combinations. NOTICE: The compatibility tables are continually reviewed by NEW HOLLAND. New combinations that may be more suitable to your activity are often released. See your NEW HOLLAND dealer when you change your machine’s tires. Table of Acronyms Acronym GY BF T TR MI FI PI S-ARZ S-ARZ TD8 SSG TD8 TFR STR SAT FWD CF-151 CGG CSG II S-LM TRC-CA

Meaning Goodyear Bfgoodrich Titan Trelleborg Michelin Firestone Pirelli Super Rice Tire Super Rice Tire TD8 Special Sure Grip TD8 Traction Field & Road ST Radial Super All Traction FWD Champion F-151 Champion G.G. Champion Space Grid II. Super Mud Tire Cultivator Tractor

Acronym ALLT DYT II DYT III MXB AGB 125A6 RDT 23 SAT 23 T 414 PWT PWG R1 R2 GZ CAP F.T. R.T. MANUF

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Meaning All Traction Dyna Torque II Dyna Torque III Maxibib Agribib Power Grip 125 A6 Radial DT 23° Super All Traction 23° Twin 414 Power Torque Power Gripper Normal grip High Grip Guizhou Load capacity Front Tires Rear Tires Manufacturer

F.T.

CAP

MeaMANUCAP R.T. sure F PWT GY 13.6x38 6 PR R1 TM 75 PI DYT II GY TM 95 PI TM 93 PI 18.4x34 10 CF-15 FI R1 PR 1 125A6 BF SAT FI 23 18.4x34 S-ARZ 8 PR GY R2 TD8 PI 18.4x38 10 TM 95 R1 PR DYT II GY S-ARZ GY 23.1x26 10 PD 22 PI R2 PR FI CSG II CF-15 FI 1 PI 23.1x30 12 TM 95 R1 PR DYT III GY SAT FI 23 23.1x30 10 PD 22 FI R2 PR

Check the acronyms in Table 01

Measure 12.4x24 R1

X

GY

GY

FI X

FI X

GY X

FI

X

X X

GY

8 PR 10 PR DYT S-LSAT DYT SAT DYT CGG II II II 23 M 23

12.4x24 R1

Compatibility table for front and rear tires. Table code 47643358D

X X

X X

X

X

X X

X X X

FI

X X X

PI

X X X

X

X X

BF

6 PR TM SAT 125 95 23 A6

14.9X24 R1

14.9x28 R1

X X X X X X

X X

X

X

X X X

X

X

X

GY

X

X

X

PI

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X X

X X

X

X

X

FI

X

X X

FI

X

X X

GY

X

X

X

X

X

X

GY

X

X

X X

BF

6 PR 6 PR PD S-ADYT SAT PWPWT TFR 22 II G RZ 23

14.9X24 R1

X

X X

PI

TM 93

X

X

X X

PI

X

PI

TM PD 22 95

14.9 x28 R2 8 PR

Wheels - Front wheels

Wheels - Front wheels

Front wheels - Remove WARNING Crushing hazard! The wheels on this vehicle are very heavy. Always use a wheel remover or chain hoists to remove and install the wheels. Use an assistant as required. Failure to comply could result in death or serious injury. W0149A

1. Insert the wedges (1) on one of the sides of the shaft knuckle so that the shaft knuckle cannot oscillate or lift the tractor. Use a service jack if necessary.

CUIL16TR01370AA

1

CUIL16TR01382AA

2

CUIL16TR01371AA

3

2. Place two nylon cables (1) around the front axle and fasten the cables to the lifting hook.

3. Raise the tractor using the lifting hook (or using a hydraulic jack beneath the tractor) and place the support (1) under the front support.

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Wheels - Front wheels

4. Loosen the bolts and remove the front wheels.

CUIL16TR01372AA

Next operation: Front wheels - Install (44.511)..

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4

Wheels - Front wheels

Front wheels - Install WARNING Crushing hazard! The wheels on this vehicle are very heavy. Always use a wheel remover or chain hoists to remove and install the wheels. Use an assistant as required. Failure to comply could result in death or serious injury. W0149A

Prior operation: Front wheels - Remove (44.511).. 1. With the front part of the tractor suspended by cables, install the front wheels. Torque to 211.0 N·m (155.6 lb ft).

CUIL16TR01372AA

1

CUIL16TR01371AA

2

CUIL16TR01370AA

3

2. Raise the tractor and remove the support (1)under the front support.

3. Remove the lifting cables bolts from the front axle. 4. Remove the wedges (1).

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Wheels - Front wheels

Front wheels - Adjust the front axle stops Two steering stops are incorporated in the axle, one at each end. The stops are adjustable and must be adjusted to provide a minimum clearance of 20 mm (0.8 in) between the tires and all parts of the machine whenever the steering wheel is fully turned to the left or fully turned to the right.

CUIL16TR01373AA

1

CUIL13TR01092AA

2

To adjust the steering angle, proceed as described below: 1. Turn the wheels fully to the right or fully to the left. 2. Loosen the cotter nut (2) and adjust the screw length (1). 3. Adjust the bolt (1) so that no part of the fenders and the tire touches the machine. Having obtained the desired angle, loosen the jam nut (2) to a torque of 150 N·m (110.6 lb ft) . NOTE: Whilst making this adjustment, take into consideration the fact that the end of the stop's travel should not reach the end of the hydraulic cylinder's travel.

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Index Wheels - 44 Front wheels - 511 Front wheels - Adjust the front axle stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Tires - Compatibility table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Wheels - 44 Rear wheels - 520

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Wheels - 44 Rear wheels - 520

SERVICE Rear wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Wheels - Rear wheels

Rear wheels - Remove WARNING Crushing hazard! The wheels on this vehicle are very heavy. Always use a wheel remover or chain hoists to remove and install the wheels. Use an assistant as required. Failure to comply could result in death or serious injury. W0149A

DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Lock the front wheels using chocks. 2. Remove the lift arm and the left-hand stabilizer support. 3. Lift the rear of the tractor. Place a fixed trestle (1) under the flex bar support.

CUIL16TR01380AA

1

CUIL16TR01381AA

2

4. Remove cap screws (1). 5. Remove the left-hand side rear wheel. NOTE: If necessary, follow the same procedures for the wheel on the right-hand side. 6. The installation of the rear wheels follows the same procedure as removal, in the reverse order. NOTE: For installation of rear wheels, torque to 540.0 – 610.0 N·m (398.3 – 449.9 lb ft).

Next operation: Rear wheels - Install (44.520)..

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Wheels - Rear wheels

Rear wheels - Install WARNING Crushing hazard! The wheels on this vehicle are very heavy. Always use a wheel remover or chain hoists to remove and install the wheels. Use an assistant as required. Failure to comply could result in death or serious injury. W0149A

WARNING Overturning hazard! Always try to park the machine on firm level ground. Avoid parking on slopes. Block the wheels in both directions. Failure to comply could result in death or serious injury. W0051A

1. With the rear axle supported on a suitable trestle, position the wheel on the axle. 2. Gradually tighten the bolts (1) to a torque of 540 – 610 N·m (398 – 450 lb ft), following the crossed sequence. NOTE: When installing the wheels, ensure that the "V" on the tires stays facing the forward movement. NOTE: If necessary, follow the same procedures for the wheel on the right-hand side. 3. Raise the rear of the tractor. Remove the trestle. CUIL16TR01381AA

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1

Index Wheels - 44 Rear wheels - 520 Rear wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Rear wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Electrical systems 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Electrical systems - 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

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Electrical systems - 55 Harnesses and connectors - 100

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Electrical schematic sheet 02 SH02 - GRID HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical schematic sheet 03 SH03 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - Electrical schematic sheet 04 SH04 - INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wiring harnesses - Electrical schematic sheet 05 SH05 - FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical schematic sheet 06 SH06 - RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical schematic sheet 07 SH07 - SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical schematic sheet 08 SH08 - LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORIES / SAFETY SWITCHES . . . 18 Electrical schematic sheet 10 SH10 - GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Wire connectors Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Component diagram 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Component diagram 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Component diagram 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Component diagram 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Component diagram 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Component diagram 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Component diagram 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Component diagram 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Electrical components Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 SH02 - GRID HEATER Type Fuse Relay Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid Solenoid

Component F-001 K-001 X-004 X-018 X-019A X-019B X-020 X-021 X-022 X-023 X-024 Y-002 Y-003

Connector / Link

Description

X-021 X-022 X-020 X-004 X-018 X-019A X-019B X-020 X-021 X-022 X-023 X-024 X-018 X-023 X-024

POWER RELAY - GRID HEATER CONTROLLER EYE TERMINAL - 10 mm GRID HEATER CONTROLLER HARNESS - COLD START GRID HEATER CONTROLLER ENGINE HARNESS - COLD START COLD START HARNESS - POWER RELAY EYE TERMINAL - 6 mm EYE TERMINAL - 6 mm EYE TERMINAL - 8 mm EYE TERMINAL - 6 mm GRID HEATER CONTROLLER GRID HEATER

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Electrical systems - Harnesses and connectors

6

5

4

3

2

1

Y-002 GHC - GRID HEATER CONTROLLER

D

D

C

C

10

9

8

7

6

5

4

3

2

1

F-001 1

1142A BR 25.0

125.0 A

2

1142 BR 25.0

SH3: D-6

X-018

39C GN 1.0

57HA BK 1.0

1141B BR 1.0

1140B PK 1.0

1001C WH 1.0

1006C BR 1.0

1140 PK 1.0

1135B GN 1.0

CHICOTE GHC - PARTIDA A FRIO

K-001 POWER RELAY - GHC 87A X-021

30 X-022

87 1

1140A PK 1.0 SP-1140

86

85

2

X-020

B

B X-019A GHC CONTROLLER

SH3: C-4

EN-1006B BR 1.0

1

1

SH3: A-2

EN-1001A WH 1.0

2

2

SH3: A-5

EN-057G BK 1.0

3

3

SP-57A

SH3: B-3

EN-039A GN 1.0

4

4

SH3: A-2

EN-1141 BR 1.0

5

5

SH3: A-2

EN-1135 GN 1.0

6

6

57H BK 1.0

57HB BK 1.0

Y-003 GRID HEATER

A

X-024

P

N

A

1143 BR 25.0

57VB BK 25.0 X-023

X-019B CHICOTE MOTOR - PARTIDA A FRIO

GND9

6

5

4

3 SHT_2

1

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2

1

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03 SH03 - ENGINE Type Sensor Sensor Sensor Voltage source Voltage source Motor Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid

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Component B-001 B-002 B-003 G-001 G-002 M-001 S-001 X-001 X-002 X-003 X-004 X-005 X-006 X-007 X-008 X-009 X-010 X-011 X-012 X-013 X-014 X-015 X-016 X-017A X-017B X-066 X-1000A X-1000B Y-001

Connector / Link X-012 X-015 X-016 X-008 X-009 X-010 X-001 X-002 P19P25 X-013 X-001 X-002 X-003 X-004 X-005 X-006 X-007 X-008 X-009 X-010 X-011 X-012 X-013 X-014 X-015 X-016 X-017A X-017B X-066 X-1000A X-1000B X-014

Description ENGINE OIL PRESSURE SWITCH ENGINE TEMPERATURE SENSOR WATER IN FUEL SENSOR ALTERNATOR - 65 A·h BATTERY 100 A·h STARTER MOTOR 3 kW AIR FILTER CLOGGING EYE TERMINAL 10 – 50 mm - 90° EYE TERMINAL - 17 mm EYE TERMINAL - 10 mm EYE TERMINAL - 10 mm STARTER MOTOR EYE TERMINAL - 10 mm - 90° STARTER MOTOR D+ B+ W ENGINE GROUND ENGINE OIL PRESSURE SWITCH AIR FILTER CLOGGING FUEL SHUT OFF ENGINE TEMPERATURE SENSOR WATER IN FUEL SENSOR ENGINE HARNESS TO MAIN HARNESS FUSEBOX 3 STARTER SOLENOID FUEL SHUT OFF

Electrical systems - Harnesses and connectors

6

5 SH2: C-1

4

3

2

1

1142 BR 25.0

G-002 BATTERY 100 Ah NEG X-002

M-001

POS

1 RD 50.0

STARTER MOTOR 3.0 kW

X-001

X-004 SP-150

X-005 PWR

X-006 X-007

D X-1000A 1

GND SH5: A-5

CB-150A BR 2.5

M

D

A

1 X-1000B

CB-150B BR 2.5

SH5: A-5

X-003

1

GND4

CB-150 BR 10.0

CB-150C BR 1.5

SH5: C-5

CB-150D BR 6.0

SH6: B-4

CB-150E BR 1.0

SH5: A-5

GND1

EN-2003 WH 2.5

EN-001A RD 6.0

X-017A SH2: B-6

EN-1006B BR 1.0

EN-1006 BR 1.0 1

1

CB-031A YE 1.0

SH4: A-5

2

2

CB-039B GN 1.0

SH4: A-5

3

3

CB-1005A GY 1.0

SH4: A-5

4

4

CB-2041A VT 1.0

SH7: D-4

5

5

CB-2040A GN 1.0

SH4: A-3

6

6

CB-1135A GN 1.0

SH4: A-3

7

7

CB-1141A BR 1.0

SH5: B-2

8

8

CB-1006A BR 1.0

SH4: A-5

9

9

CB-1001B WH 1.0

SH6: C-2

10

10

CB-2003A WH 2.5

SH6: C-2

11

11

CB-2015A WH 1.0

SH4: A-4

12

12

CB-1003B GN 1.0

SH5: D-2

13

13

EN-031 YE 1.0 1

C

C

X-012 2

1

GND8

G-001

B-001

EN-057U BK 1.5

ENGINE OIL PRESSURE SWITCH

ALTERNATOR 65 AH X-008 CHARGE D+ INDICATOR A

B+

1 1

S-001

X-009

AIR FILTER CLOGGING

SP-057G X-011

W PHASE X-010

2

EN-057V BK 1.0

1

2

1

EN-1005 GY 1.0

X-013

X-013

GND7 Y-001 FUEL SHUT OFF

EN-057G BK 1.0

P

1

EN-2041 VT 1.0

X-014

EN-057Q BK 1.0

B

N

GND5

B-002

B

ENGINE TEMPERATURE SENSOR A

EN-039 GN 1.0 B

SH2: A-6

EN-039A GN 1.0 C

X-015 B-003

SH2: A-6

WIF SENSOR 1

EN-2040 GN 1.0

2

EN-057X BK 1.0

3 X-016

A

A

X-017B

EN-1003A RD 1.0

EN-1141 BR 1.0

SH2: A-6

EN-1001A WH 1.0

SH2: B-6

EN-1135 GN 1.0

SH2: A-6

EN-057X BK 1.0 EN-2015 WH 1.0

6

5

4

3 SHT_3

1

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2

1

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 04 SH04 - INSTRUMENT CLUSTER Type Connector Connector Connector Solenoid

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Component X-043 X-053 X-072 Y-004

Connector / Link X-043 X-053 X-072 X-043

Description INSTRUMENT CLUSTER TRANSMISSION OIL PRESSURE SWITCH DIODE INSTRUMENT CLUSTER

SH3: C-1

6 SP-1005A

5

A 1

X-072 P N

SHT_4 CB-2012 YE 1.0

CB-2040A GN 1.0

SH9: D-6

SH3: B-1

4 3

1

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20

COLD START

19

AIR FILTER

18

TEMPERATURE

17

S

16

15

D

14

13

12

11

10

MOTOR OIL

9

8

4

CB-1135A GN 1.0

CB-1003 GN 1.0

SH5: D-2

7

6

5

SH3: B-1

CB-057D BK 1.0

CB-1013D RD 1.0

SH5: C-2

5

4

S

SH10: B-3

CB-2015A WH 1.0

CB-029 GN 1.0

3

2

1

BATTERY

SH3: B-1

SH9: B-6

CB-039B GN 1.0

SH3: C-1

CB-031B YE 1.0 CB-1006A BR 1.0

SP-031

SH3: B-1

CB-031A YE 1.0

CB-1005B GY 1.0

B

SH3: C-1

CB-1005A GY 1.0

6

CB-1005C GY 1.0

Electrical systems - Harnesses and connectors

3 2

S TACHOMETER

C WATER IN FUEL

2

1

INSTRUMENT CLUSTER

Y-004

D

HOUR METER

S FUEL

TRANS OIL

C

X-043 INSTRUMENT CLUSTER

B

CB-031 YE 1.0

V-002 2

A

X-072

1

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 05 SH05 - FUSES Type Connector Connector Connector Connector

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Component X-033 X-064 X-065 X-066

Connector / Link X-033 X-064 X-065 X-066

Description HAZARD SWITCH FUSEBOX 1 FUSEBOX 2 FUSEBOX 3

Electrical systems - Harnesses and connectors

6

5

4

3

2

1

FH-001 FUSEBOX

CB-1003B GN 1.0

SH3: A-1

CB-1003 GN 1.0

SH4: A-4

1 SH6: B-2

6A

CB-1011A YE 1.5

D

1

5.0

A

2

PIN33

2

PIN34

6B

SP-1003

CB-1003A GN 1.0

D

2 SH6: B-2

5A

CB-1011B YE 1.5

1

5.0

A

5B

SH6: A-2

CB-1011C YE 1.5

SH7: C-4

CB-1028 YE 1.5

4A

1

3A

1

2A

1

5.0

SP-3020C A

2

PIN35

2

PIN36

2

PIN37

4B

SH9: A-5

CB-840 GN 1.0

3

CB-3020D YE 1.0

CB-3020E YE 1.0

SH7: B-5

CB-3020C YE 1.0

SH7: A-4

4 15.0 A

3B

SH8: D-6

CB-1027 BL 1.0

10.0 A

SH8: C-4

CB-997A GN 1.0

5

CB-1031A RD 1.5

2B

CB-997 GN 1.0

SP-997 SH8: A-6

CB-997B GN 1.0

SH7: C-4

CB-1031 RD 1.5

CB-1031B RD 1.5

1A

1

10.0 A

2

PIN38

SP-1031

SP-1013

1B

CB-1013 RD 1.0

X-064

6A

PIN45

1

15.0 A

2

PIN47

6B

CB-150C BR 1.5

SH7: C-3

CB-3000 GN 1.0

SH6: B-2

CB-1011H YE 2.5

5A

PIN44

4A

PIN43

10.0 A

PIN46

SH8: A-6

PIN48

C

SH4: A-4

SP-376

5B

CB-376A VT 1.0

9 10.0 A

CB-1013C RD 1.0

SH8: D-6

CB-1030 BL 1.0

8 SH3: D-1

CB-1013B RD 1.0

SH8: C-6

CB-1013D RD 1.0

7

CB-1029 BL 1.5

SH8: B-4

CB-1013A RD 1.0

X-064

C SH7: C-4

SH8: A-5

CB-1013E RD 1.0

6

4B

CB-376 VT 1.0

SH6: D-4

CB-376B VT 1.0

SH9: B-6

CB-3000A GN 1.0

SH6: B-3

CB-1023 BR 2.5

SH7: C-6

CB-1050 GN 1.0

SH9: C-6

CB-1141A BR 1.0

SH3: B-1

10 3A

3B

25.0 A 11

SH6: A-2

CB-1011D YE 1.5

SH6: A-2

CB-1011E YE 1.5

2A

PIN41

1A

PIN40

15.0 A

PIN50

2B

PIN51

1B

12

B

15.0 A

X-065

B

X-065

13 SH6: B-2

CB-1011F YE 1.5

SH6: B-2

CB-1011G YE 1.5

SH3: D-1

CB-150A BR 2.5

6A

15.0 A

6B

CB-1070 RD 1.5

SH7: D-3

CB-1025 GN 1.0

SH7: C-1

CB-155 GN 2.5

SH6: C-4

CB-1021 VT 1.0

SH7: C-1

14 5A

10.0 A

5B

15 4A

20.0 A

4B

16 3A

0.0 A

3B

17 SH3: C-1

2A

CB-150E BR 1.0

10.0 A

2B

A

A 18 SH3: D-1

1A

CB-150B BR 2.5

7.5 A

5

CB-155A GN 4.0

SH7: D-6

X-066

X-066

6

1B

4

3 SHT_5

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 06 SH06 - RELAYS Type Relay Relay Relay Relay Connector Connector Connector Connector Connector

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Component K-002 K-003 K-004 K-005 X-038 X-039 X-040 X-041 X-066

Connector / Link X-038 X-040 X-039 X-041 X-038 X-039 X-040 X-041 X-066

Description HORN RELAY (RL1) FLASHER UNIT (RL3) STARTER RELAY (RL2) IGNITION RELAY (RL4) HORN RELAY STARTER RELAY FLASHER UNIT IGNITION RELAY FUSEBOX 3

Electrical systems - Harnesses and connectors

6

5

4

3

2

1

K-002 HORN RELAY (RL1)

D SH5: C-2

CB-376 VT 1.0

SH9: B-4

CB-1004A GN 1.0

2

30

87

4

85

86

X-038

D 8

6

CB-2011 VT 1.0

SH8: D-6

CB-057H BK 1.0

SH10: B-5

X-038

K-004 STARTER RELAY (RL2)

SH5: A-2

CB-155 GN 2.5

87

30

2

8

SH3: B-1

CB-2003A WH 2.5 SP-1001

SH10: B-5

CB-057F BK 1.0

86

85

6

4

CB-1001 WH 1.0

SH9: A-1

CB-1001A WH 1.0

X-039

X-039

SH3: B-1

CB-1001B WH 1.0

C

C

K-003

SH10: B-5 SH7: B-3

49 X-040

6

8

4

31

49a

FLASHER UNIT (RL3)

SH5: B-2

CB-3000A GN 1.0

CB-057R BK 1.0 CB-044D GN 1.0

B

B K-005

CB-1011G YE 1.5

SH5: B-5

CB-1011F YE 1.5

SH5: B-5

CB-1011H YE 2.5

SH5: B-5

CB-1011A YE 1.5

SH5: D-5

CB-1011B YE 1.5

SH5: D-5

CB-1011C YE 1.5

SH5: D-5

CB-1011D YE 1.5

SH5: B-5

CB-1011E YE 1.5

SH5: B-5

IGNITION RELAY (RL4)

SH3: D-1

SH7: D-4

CB-150D BR 6.0

CB-1010 GN 1.0

5

3

30

85

87

86

2

4

SP-1011

CB-1011 YE 6.0

CB-057E BK 1.0 SH10: B-5

X-041

X-041

A

A

6

5

4

3 SHT_6

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 07 SH07 - SWITCHES Type Switch Switch Switch Switch

Component S-002 S-005 S-006 S-007

Switch

S-008

Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

S-009 S-010 X-028 X-029 X-030 X-031 X-032A X-032B X-032C X-032D X-033 X-034 X-035 X-036 X-037 X-063 X-066 X-068 X-070 X-073

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Connector / Link X-035 X-063 X-068 X-029 X-028 X-031 X-030 X-032A X-032B X-032C X-032D X-034 X-033 X-036 X-037 X-028 X-029 X-030 X-031 X-032A X-032B X-032C X-032D X-033 X-034 X-035 X-036 X-037 X-063 X-066 X-068 X-070 X-073

Description TURN LIGHTS SWITCH STARTER SWITCH AUXILIARY FRONT WHEEL DRIVE (AFWD) SWITCH FRONT WORKLIGHTS SWITCH LIGHTS SWITCH HAZARD SWITCH DUAL POWER SWITCH AUXILIARY FRONT WHEEL DRIVE (AFWD) SWITCH LAMP AUXILIARY FRONT WHEEL DRIVE (AFWD) SWITCH FRONT WORKLIGHT LAMP FRONT WORKLIGHT SWITCH LIGHTS SWITCH B+ SIDE LAMP DIP BEAM MAIN BEAN HAZARD SWITCH HAZARD SWITCH LAMP TURN LIGHTS SWITCH DUAL POWER SWITCH DUAL POWER SWITCH LAMP STARTER SWITCH FUSEBOX 3 KEY SWITCH 30 DIODE DIODE

Electrical systems - Harnesses and connectors

6

5

4

3

2

1

S-005 STARTER SWITCH S-007 FRONT WORKLIGHTS SWITCH

D

D SH5: A-2

1

15

5

15/1

6 8

30

CB-2041A VT 1.0

SH3: C-1

SH5: B-2

CB-1070 RD 1.5

CB-1010 GN 1.0

SH6: A-4 SH9: A-5

SH10: B-5

CB-057Q BK 1.0

2

2

1

01

02

1

SH8: A-4

CB-1073 VT 1.0

CB-155A GN 4.0 X-068

50

X-031

X-031

CB-1000 WH 1.0

A

X-063

B

SH8: A-4

CB-1073A VT 1.0

X-030

X-030

S-008 LIGHTS SWITCH S-009

OFF

HAZARD SWITCH

HALF LIGHT

0 1

LOW LIGHT

HIGH LIGHT X-032B

C

CB-1023 BR 2.5 SH5: B-2

1

30

57

SH5: B-5

1

CB-1031 RD 1.5

CB-3000 GN 1.0

6

D

7

I

T V

2 1

L H

3 4

U

5

2

B

SH5: B-2

CB-1025 GN 1.0 CB-1021 VT 1.0

SH5: A-2

SH5: C-5

X-032A

CB-044A GN 1.0

C CB-044C GN 1.0

X-033

X-032C 1 1

SH10: C-5

CB-057K BK 1.0

SH5: C-5

CB-1029 BL 1.5 CB-1028 YE 1.5

SH5: C-5

X-034

X-034

X-032D

CB-049A GN 1.0

56b 56a

CB-050A GN 1.0

X-033 1

A

S-002 TURN LIGHTS SWITCH

SP-044 SH6: B-4

CB-044D GN 1.0

1

CB-044 GN 1.0

R

3

L

2

SP-049

CB-049B GN 1.0

CB-049 GN 1.0 SH8: A-6

M SP-050

X-035

CB-050B GN 1.0

CB-050 GN 1.0 SH8: B-4

X-035

B

B S-006 4WD SWITCH

SP-3025 7

CB-3025 YE 1.0 SH5: D-2

5

1

X-029

X-029

A

B

CB-3025A YE 1.0

SH9: C-3

CB-3020E YE 1.0 S-010

CB-057A BK 1.0

CB-3045 YE 1.0 X-028

X-028

CB-3025B YE 1.0

SH10: C-5

DUAL POWER SWITCH

CB-057X BK 1.0

SH10: B-5

CB-057V BK 1.0

1

X-073 1

X-070

N

P

SH10: C-5

CB-057B BK 1.0

7

1

1

2

A

01

02

X-037

SP-3020

CB-3020 YE 1.0

CB-3020A YE 1.0

SH9: B-3

CB-3022 YE 1.0

X-036 B

X-037

X-073

V-003 P

CB-3020C YE 1.0

7 5

X-036

V-001 SH10: C-5

SH5: D-2

5

N

2

CB-3020B YE 1.0 X-070

A

A

6

5

4

3 SHT_7

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 08 SH08 - LIGHTS Type Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Speaker Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component E-001 E-002 E-003 E-004 E-005 E-006 E-007 E-008 E-009 E-010 E-011 E-012 E-013 E-014 E-015 E-016 E-017 E-018 E-019 H-002 X-031 X-043A X-043B X-044A X-044B X-045 X-046 X-047 X-048 X-049 X-050 X-051 X-052 X-064A X-064B X-065A X-065B X-066A X-066B X-066C X-066D X-067A X-067B X-067C X-068A X-068B X-069A X-069B X-070A X-070B X-070C X-071 X-071A X-075 X-080A X-080B X-080C X-080D

Connector / Link X-070B X-070C X-070A X-045 X-046 X-047 X-069B X-069A X-080C X-080B X-080D X-080A X-048 X-065B X-065A X-066D X-066C X-066B X-066A X-067C X-067B X-067A X-064B X-064A X-068B X-068A X-075 X-044A X-044B X-031 X-043A X-043B X-044A X-044B X-045 X-046 X-047 X-048 X-049 X-050 X-051 X-052 X-064A X-064B X-065A X-065B X-066A X-066B X-066C X-066D X-067A X-067B X-067C X-068A X-068B X-069A X-069B X-070A X-070B X-070C X-071 X-071A X-075 X-080A X-080B X-080C X-080D

Description FRONT TURN LIGHT - RIGHT SIDE RH FRONT SIDE LIGHT - RIGHT SIDE SIDE LIGHT HEADLIGHTS - LEFT SIDE HEADLIGHTS - RIGHT SIDE REAR WORKLIGHT REAR TURN LIGHT - LEFT SIDE REAR SIDE LIGHT STOP LIGHT SIDE LIGHT REAR WORKLIGHT STOP LIGHT REAR SIDE LIGHT REAR TURN LIGHT - RIGHT SIDE FRONT SIDE LIGHT FRONT TURN LIGHT - RIGHT SIDE FRONT WORKLIGHT - RIGHT SIDE FRONT WORKLIGHT - LEFT SIDE LICENSE PLATE LIGHT HORN FRONT WORKLIGHT SWITCH HOOD INTERFACE MAIN HARNESS - HOOD

FENDER CONNECTOR - LEFT SIDE MAIN HARNESS - FENDER FENDER CONNECTOR - RIGHT SIDE MAIN HARNESS - FENDER

LICENSE PLATE HARNESS MAIN HARNESS LICENSE PLATE

Electrical systems - Harnesses and connectors

6

5

4

1

H-002

1

PIN1

REAR WORKLIGHT

HORN

X-069B

2

1

997D GN 1.0

1

57SC BK 1.0

2 E-006

X-044A

2011A PRP 1.5

3

PIN2 1

57RC BK 1.0

1

X-044B X-069A

E-007 LH REAR TURN LIGHT

D 1

SH6: D-3

1

CB-2011 VT 1.0

1

SH10: B-3

CB-057O BK 1.0

2

2

SH5: C-2

CB-1030 BL 1.0

3

3

1030A BL 1.5

SH5: C-2

CB-1027 BL 1.0

4

4

1027A BL 1.5

SH5: C-2

CB-1013B RD 1.0

57SB BK 1.0

57SD BK 1.0

5

5

6

6

57SA BK 1.0

E-003 2

2

SIDE LIGHT

X-045

X-080C

E-001

E-008

RH FRONT TURN LIGHT

SP-34

REAR SIDE LIGHT 2 2 1

1013D RD 1.0

1013A RD 1.0

1

50D GN 1.0

1

1

1014C RD 1.0 X-070B X-080B

X-043B

57SE BK 1.0

X-043A

1

1

50E GN 1.0

SP-37

PRINCIPAL - CAPO

HOOD INTERFACE

D

2

1

SP-30

E-002

E-009

RH FRONT SIDE LIGHT

STOP LIGHT

E-004 X-080D

LH HEADLIGHTS

1030B BL 1.5

2

1

B

57SF BK 1.0

SP-45

B

1014B RD 1.0

1

1 X-070A

SP-35

C

57RB BK 1.0

57RD BK 1.0

X-070C

A

1

2

1

1

X-080A

57RA BK 1.0

A

C

SP-31 X-049 SH10: C-5

SP-36

C

C

1027B BL 1.5

E-018

LH FENDER CONNECTOR

CB-057T BK 1.0

LH FRONT WORKLIGHT

1

1

2

2

X-068B

57RE BK 1.0

1

2

1

1

SH9: A-4

X-046

57SG BK 1.0

CB-830C BL 1.0

820A RD 1.0

X-068A

SH5: C-2

CB-997A GN 1.0

E-005

3

3

CB-1013A RD 1.0

4

4

1014A RD 1.0

CB-050 GN 1.0

5

5

50C GN 1.0

6

6

1073E PRP 1.0

RH HEADLIGHTS

SP-46

SH5: C-2 B

B

1030C BL 1.5

SH7: B-1

SP-47 E-011

57SH BK 1.0

A

A

REAR WORKLIGHT

CB-1073B VT 1.0

SP-32

X-065B 1

X-050 PRINCIPAL - PARA LAMA

1027C BL 1.5

C

57PC BK 1.0

C

2

1

1 X-065A

E-012

X-047

STOP LIGHT

B

B

X-066D

57PB BK 1.0

E-015 E-010

FRONT SIDE LIGHT

SIDE LIGHT 2

57SJ BK 1.0

1

1013E RD 1.0

2

1 2

2

57PD BK 1.0

1

1

E-013 REAR SIDE LIGHT

1013H RD 1.0

1013G RD 1.0

2

SP-43 2

X-048 X-071A

1

1 X-066C

X-067B

LICENSE PLATE LIGHT

2

SP-42

1 1

E-019

X-067C 1

1

LI-057 BK 1.0

E-016 1

LI-1013 RD 1.0

2

1

RH FRONT TURN LIGHT X-066B

SH5: C-2

CB-1013E RD 1.0

2

X-075

SH10: D-5

CB-057S BK 1.0

1

1

2

E-014

X-071

CB-1073 VT 1.0 X-051 RH FENDER CONNECTOR SH10: C-5

CB-057M BK 1.0

1

SH7: D-1

RH REAR TURN LIGHT

1

49D GN 1.0

49E GN 1.0

SP-1073

1

1

SP-44

X-067A

SH7: D-1

CB-1073A VT 1.0

2 1

57PE BK 1.0

1

X-066A

A

SH9: A-4

CB-830 BL 1.0

2

2

SH5: C-2

CB-997B GN 1.0

3

3

830A BL 1.0 E-017

SH5: C-2

CB-1013C RD 1.0

4

997C GN 1.0

4

RH FRONT WORKLIGHT

1013F RD 1.0 57PA BK 1.0

SH7: B-1

CB-049 GN 1.0

CB-1073C VT 1.0

5

6

5

49C GN 1.0

6

X-064B 1

2

1

1

X-064A

1073D PRP 1.0 X-052 PRINCIPAL - PARA LAMA

6

5

4

3 SHT_8

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORIES / SAFETY SWITCHES Type Sensor Sensor Lamp Speaker Switch Switch Switch Switch Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component B-004 B-005 E-020 H-001 S-003 S-004 S-011 S-012 S-013 S-014 S-015 S-016 X-026 X-027 X-053 X-054A X-054B X-055 X-056 X-057A X-057B X-058 X-059A X-059B X-060 X-061 X-062 X-063 X-067 X-076 X-077 X-078

Connector / Link X-053 X-067 X-078 X-055 X-056 X-054A X-054B X-027 X-026 X-057A X-057B X-058 X-062 X-061 X-060 X-059A X-059B X-026 X-027 X-053 X-054A X-054B X-055 X-056 X-057A X-057B X-058 X-059A X-059B X-060 X-061 X-062 X-063 X-067 X-076 X-077 X-078

Description TRANSMISSION OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH REVERSE LAMP BUZZER REVERSE ALARM SWITCH HORN FUEL LEVEL SENDER STOP LIGHT SWITCH AUXILIARY FRONT WHEEL DRIVE (AFWD) SOLENOID DUAL POWER SOLENOID POWER TAKE OFF (PTO) SAFETY SWITCH TRANSMISSION SAFETY SWITCH HORN 1 HORN 2 TRANSMISSION OIL PRESSURE SWITCH REVERSE ALARM SWITCH 2 REVERSE ALARM SWITCH 1 BUZZER 1 BUZZER 2 FUEL LEVEL SENDER 1 FUEL LEVEL SENDER 2 BRAKE SWITCH TRANSMISSION SAFETY SWITCH 2 TRANSMISSION SAFETY SWITCH 1 PTO SAFETY SWITCH DUAL POWER SOLENOID AUXILIARY FRONT WHEEL DRIVE (AFWD) SOLENOID STARTER SWITCH OIL TEMPERATURE SWITCH

Electrical systems - Harnesses and connectors

6

5

4

3

2

1

D

D

CB-2012 YE 1.0

RL-057H BK 0.0

REVERSE ALARM SWITCH 2

X-054B

1

1

2

1

B-005 OIL TEMPERATURE SWITCH

REVERSE LAMP

H-001 BUZZER X-055

X-054A

2

X-078

CB-1160 RD 1.0

C

X-076

S-003

1

1

2

E-020

RL-987 RD 1.0

CB-1050 GN 1.0

1

1

X-067

A 1

B

X-053

2 B-004

TRANSMISSION OIL PRESSURE SWITCH

SH5: B-2

SH10: D-5

CB-057P BK 1.0

CB-2012A YE 1.0

2

SH4: A-3

PIN1

S-013

C

SH10: C-5

X-056

CB-057G BK 1.0

X-077

4WD SOLENOID PIN2 SH7: B-4

1

CB-3025A YE 1.0

P

N

X-062 GND11

S-004 HORN SH5: C-2

CB-376B VT 1.0

SH6: D-4

CB-1004A GN 1.0 X-026

X-027 HORN 2

HORN 1

S-014 DUAL POWER SOLENOID

S-011 FUEL LEVEL SENDER

SH4: A-4

CB-029 GN 1.0

1

N

P

SH7: B-2 1

N

X-061

SH10: D-5

CB-057C BK 1.0

P

1

CB-3020A YE 1.0

GND10 X-057A

B

X-057B

B

S-012

2 3 3 4

1 2

X-058

4 1

STOP LIGHT SWITCH

CB-830C BL 1.0

SH8: C-4 S-015

SH5: D-2

SP-830

CB-840 GN 1.0

PTO SAFETY SWITCH

CB-830 BL 1.0

SH8: A-6

X-060

S-016 TRANSMISSION SAFETY SWITCH SH7: D-4

CB-1000 WH 1.0

1 X-059B

2

1

1

CB-1000A WH 1.0

1 2 3 4

4 1 2 3

CB-830A BL 1.0

SH6: C-2

CB-1001A WH 1.0

X-059A

A

A

6

5

4

3 SHT_9

1

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2

1

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 10 SH10 - GROUND Type Connector Connector

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Component X-042 X-070

Connector / Link X-042 X-070

Description CHASSIS GROUND DIODE

Electrical systems - Harnesses and connectors

6

5

4

3

2

1

D

D SH8: A-5

CB-057S BK 1.0

SP-057C SH9: D-2

SH9: C-5

SH8: A-6

CB-057AA BK 1.0

SH9: B-4

CB-057P BK 1.0

CB-057C BK 1.0

CB-057G BK 1.0

CB-057M BK 1.0 X-042 CHASSIS GND 1

SH8: C-4

CB-057T BK 1.0

CB-057 BK 4.0

GND12

C

SH7: A-5

C

CB-057X BK 1.0 SP-057A

SH7: B-5

CB-057A BK 1.0

SH7: A-4

CB-057B BK 1.0

SH7: C-3

CB-057K BK 1.0

SH7: D-3

CB-057Q BK 1.0

SP-057

CB-057Y BK 1.0

CB-057D BK 1.0

SH7: A-5

SH4: A-4

CB-057V BK 1.0

SP-057E SH6: B-4

CB-057R BK 1.0

CB-057Z BK 1.0

B

B SH6: A-3

CB-057E BK 1.0

SH6: C-4

CB-057F BK 1.0 CB-057O BK 1.0

SH6: D-3

SH8: D-6

CB-057H BK 1.0

A

A

6

5

4

3 SHT_10

1

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2

1

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 00 X-001 - EYE TERMINAL 10-50 MM (90 DEGREES) [ G-002] (84138052) (Plug)

84138052

1

84138052 Pin 1

From X-006 (Plug) pin 1 EYE TERMINAL 90° - 10 mm

Wire

Description

Color-Size

Frame

1

1

RD - 50.0

SHEET 03

Description 1142

Color-Size BR - 25.0

Frame SHEET 02

Color-Size BR - 10.0

Frame SHEET 03

X-002 - EYE TERMINAL 17 MM [ G-002] (Plug) X-003 - EYE TERMINAL 10 MM (Plug) X-004 - EYE TERMINAL - 10 MM [ SH3: D-6] (Plug) Pin PIN1

From F-001-P-2

Wire 1142

X-005 - STARTER MOTOR (87605006) (Plug)

87605006

2

87605006 Pin 1

From SP-150-P-X

Wire CB-150

Description CB-150

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Electrical systems - Harnesses and connectors

X-006 - EYE TERMINAL 90 DEGREES - 10 MM (87349595) (Plug)

87349595

3

87349595 Pin 1

From X-001 (Plug) pin 1 EYE TERMINAL 10 – 50 mm - 90°

Wire

Description

Color-Size

Frame

1

1

RD - 50.0

SHEET 03

Color-Size RD - 6.0

Frame SHEET 03

Frame

X-007 - STARTER MOTOR (84140737) (Plug)

84140737

4

84140737 Pin 1

From X-009 (Plug) pin 1 B+

Wire EN-001A

Description EN-001A

X-008 - D+ [ G-001] (84426123) (Plug)

84426123

5

84426123 Pin 1 1

From X-017B (Plug) pin 8 TO MAIN HARNESS X-019A (Receptacle) pin 1 GRID HEATER CONTROLLER

Wire

Description

Color-Size

EN-1006

EN-1006

BR - 1.0

EN-1006B

EN-1006B

BR - 1.0

SHEET 03

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Electrical systems - Harnesses and connectors

X-009 - B+ [ G-001] (84426136) (Plug)

84426136

6

84426136 Pin 1 1

From X-007 (Plug) pin 1 STARTER MOTOR X-016 (Receptacle) pin 3 WATER IN FUEL SENSOR

Wire

Description

Color-Size

EN-001A

EN-001A

RD - 6.0

EN-1003A

EN-1003A

RD - 1.0

Frame SHEET 03

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 X-010 - W [ G-001] (84426122) (Plug)

84426122

1

84426122 X-011 - ENGINE GROUND (84426126) (Plug)

84426126

2

84426126 Pin 1

From SP-057G-P-X

Wire EN-057U

Description EN-057U

Color-Size BK - 1.5

Frame SHEET 03

X-012 - ENGINE OIL PRESSURE SWITCH [ B-001] (87687239) (Receptacle)

87687239

3

87687239 Pin 1

From X-017B (Plug) pin 1 TO MAIN HARNESS

Wire

Description

Color-Size

Frame

EN-031

EN-031

YE - 1.0

SHEET 03

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Electrical systems - Harnesses and connectors

X-013 - AIR FILTER CLOGGING [ S-001] (87694651) (Receptacle)

87694651

4

87694651 Pin 1 2

From X-017B (Plug) pin 3 TO MAIN HARNESS SP-057G-P-X

Wire

Description

Color-Size

EN-1005

EN-1005

GY - 1.0

EN-057V

name

BK - 1.0

Frame SHEET 03

X-014 - FUEL SHUT OFF [ Y-001] (87687239) (Receptacle)

87687239

5

87687239 Pin 1

From X-017B (Plug) pin 4 TO MAIN HARNESS

Wire

Description

Color-Size

Frame

EN-2041

EN-2041

VT - 1.0

SHEET 03

X-015 - ENGINE TEMPERATURE SENSOR [ B-002] (87418311) (Receptacle)

87418311

6

87418311

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Electrical systems - Harnesses and connectors

Pin A B C

From X-017B (Plug) pin 2 TO MAIN HARNESS X-019A (Receptacle) pin 4 GRID HEATER CONTROLLER SP-057G-P-X

Wire

Description

Color-Size

EN-039

EN-039

GN - 1.0

EN-039A

EN-039A

GN - 1.0

EN-057Q

EN-057Q

BK - 1.0

Frame

SHEET 03

X-016 - WATER IN FUEL SENSOR [ B-003] (84806091) (Receptacle)

84806091

7

84806091 Pin 1 2 3

From X-017B (Plug) pin 5 TO MAIN HARNESS SP-057G-P-X X-009 (Plug) pin 1 B+

Wire

Description

Color-Size

EN-2040

EN-2040

GN - 1.0

EN-057X EN-1003A

EN-057X EN-1003A

BK - 1.0 RD - 1.0

X-017A - ENGINE HARNESS [ SH7: D-4] (84284807) (Receptacle)

84284807

8

84284807

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Frame SHEET 03

Electrical systems - Harnesses and connectors

Pin 1 2 3 4 5 6 7 8 9 10 11 12

From SP-031-P-X X-043 (Receptacle) pin 4 INSTRUMENT CLUSTER SP-1005A-P-X X-063 pin 5 STARTER SWITCH X-043 (Receptacle) pin 19 INSTRUMENT CLUSTER X-043 (Receptacle) pin 20 INSTRUMENT CLUSTER X-065 (Receptacle) pin 1B FUSEBOX 2 X-043 (Receptacle) pin 3 INSTRUMENT CLUSTER SP-1001-P-X X-039 (Receptacle) pin 8 STARTER RELAY X-043 (Receptacle) pin 6 INSTRUMENT CLUSTER SP-1003-P-X

Wire CB-031A

Description CB-031A

Color-Size YE - 1.0

CB-039B

CB-039B

GN - 1.0

CB-1005A

CB-1005A

GY - 1.0

CB-2041A

CB-2041A

VT - 1.0

CB-2040A

CB-2040A

GN - 1.0

CB-1135A

CB-1135A

GN - 1.0

CB-1141A

CB-1141A

BR - 1.0

CB-1006A

CB-1006A

BR - 1.0

CB-1001B

CB-1001B

WH - 1.0

CB-2003A

CB-2003A

WH - 2.5

CB-2015A

CB-2015A

WH - 1.0

CB-1003B

CB-1003B

GN - 1.0

Frame

SHEET 03

X-017B - TO MAIN HARNESS [ SH2: A-6] (84284806) (Plug)

84284806

9

84284806 Pin 1

2 3 4 5 6 7 8 9 10

From X-012 (Receptacle) pin 1 ENGINE OIL PRESSURE SWITCH X-015 (Receptacle) pin A ENGINE TEMPERATURE SENSOR X-013 (Receptacle) pin 1 AIR FILTER CLOGGING X-014 (Receptacle) pin 1 FUEL SHUT OFF X-016 (Receptacle) pin 1 WATER IN FUEL SENSOR X-019A (Receptacle) pin 6 GRID HEATER CONTROLLER X-019A (Receptacle) pin 5 GRID HEATER CONTROLLER X-008 (Plug) pin 1 D+ X-019A (Receptacle) pin 2 GRID HEATER CONTROLLER X-1000A (Receptacle) pin 1 STARTER SOLENOID

Wire

Description

Color-Size

EN-031

EN-031

YE - 1.0

EN-039

EN-039

GN - 1.0

EN-1005

EN-1005

GY - 1.0

EN-2041

EN-2041

VT - 1.0

EN-2040

EN-2040

GN - 1.0

EN-1135

name

GN - 1.0

EN-1141

EN-1141

BR - 1.0

EN-1006

EN-1006

BR - 1.0

EN-1001A

name

WH - 1.0

EN-2003

EN-2003

WH - 2.5

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Frame

SHEET 03

Electrical systems - Harnesses and connectors

X-018 - GRID HEATER CONTROLLER HARNESS - COLD START [ Y-002] (87628060) (Receptacle)

87628060

10

87628060 Pin 1 3 4 5 6 7 8 10

From X-019B (Plug) pin 6 ENGINE HARNESS - COLD START SP-1140-P-X X-019B (Plug) pin 1 ENGINE HARNESS - COLD START X-019B (Plug) pin 2 ENGINE HARNESS - COLD START SP-1140-P-X X-019B (Plug) pin 5 ENGINE HARNESS - COLD START SP-57A-P-X X-019B (Plug) pin 4 ENGINE HARNESS - COLD START

Wire

Description

Color-Size

1135B

1135B

GN - 1.0

1140

1140

PK - 1.0

1006C

1006C

BR - 1.0

1001C

1001C

WH - 1.0

1140B

1140B

PK - 1.0

1141B

1141B

BR - 1.0

57HA

57HA

BK - 1.0

39C

39C

GN - 1.0

Frame

SHEET 02

X-019A - GRID HEATER CONTROLLER [ SH3: A-5] (87543123) (Receptacle)

87543123

11

87543123 Pin 1 2 3 4 5 6

From X-008 (Plug) pin 1 D+ X-017B (Plug) pin 9 TO MAIN HARNESS SP-057G-P-X X-015 (Receptacle) pin B ENGINE TEMPERATURE SENSOR X-017B (Plug) pin 7 TO MAIN HARNESS X-017B (Plug) pin 6 TO MAIN HARNESS

Wire EN-1006B

Description EN-1006B

Color-Size BR - 1.0

EN-1001A

name

WH - 1.0

EN-057G

EN-057G

BK - 1.0

EN-039A

EN-039A

GN - 1.0

EN-1141

EN-1141

BR - 1.0

EN-1135

name

GN - 1.0

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Frame

SHEET 02

Electrical systems - Harnesses and connectors

X-019B - ENGINE HARNESS - COLD START (87688721) (Plug)

87688721

12

87688721 Pin 1

2 3 4

5

6

From X-018 (Receptacle) pin 4 GRID HEATER CONTROLLER HARNESS - COLD START X-018 (Receptacle) pin 5 GRID HEATER CONTROLLER HARNESS - COLD START SP-57A-P-X X-018 (Receptacle) pin 10 GRID HEATER CONTROLLER HARNESS - COLD START X-018 (Receptacle) pin 7 GRID HEATER CONTROLLER HARNESS - COLD START X-018 (Receptacle) pin 1 GRID HEATER CONTROLLER HARNESS - COLD START

Wire

Description

Color-Size

1006C

1006C

BR - 1.0

1001C

1001C

WH - 1.0

57HB

57HB

BK - 1.0

39C

39C

GN - 1.0

1141B

1141B

BR - 1.0

1135B

1135B

GN - 1.0

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Frame

SHEET 02

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 X-020 - COLD START HARNESS - RELAY [ K-001] (82012083) (Receptacle)

82012083

1

82012083 Pin 1

From SP-1140-P-X

Description 1140A

Color-Size PK - 1.0

Frame SHEET 02

Wire

Description

Color-Size

Frame

1143

1143

BR - 25.0

SHEET 02

Wire

Description

Color-Size

Frame

1143

1143

BR - 25.0

SHEET 02

Description 57VB

Color-Size BK - 25.0

Frame SHEET 02

Color-Size VT - 1.0

Frame SHEET 09

Wire 1140A

X-021 - EYE TERMINAL 6 MM [ K-001] (Plug) X-022 - EYE TERMINAL 6 MM [ K-001] (Plug) Pin PIN1

From X-023 (Plug) pin PIN1 EYE TERMINAL 8 mm

X-023 - EYE TERMINAL 8 MM [ Y-003] (Plug) Pin PIN1

From X-022 (Plug) pin PIN1 EYE TERMINAL 6 mm

X-024 - EYE TERMINAL 6 MM [ Y-003] (Plug) Pin PIN1

From GROUND 9-P-1

Wire 57VB

X-026 - HORN 1 [ S-004] (84352277) (Plug)

84352277

2

84352277 Pin 1

From SP-376-P-X

Wire CB-376B

Description CB-376B

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Electrical systems - Harnesses and connectors

X-027 - HORN 2 [ S-004] (84352277) (Plug)

84352277

3

84352277 Pin 1

From X-038 (Receptacle) pin 4 HORN RELAY

Wire

Description

Color-Size

Frame

CB-1004A

CB-1004A

GN - 1.0

SHEET 09

X-028 - AUXILIARY FRONT WHEEL DRIVE (AFWD) - SWITCH LAMP [ S-006] (84146684) (Receptacle)

84146684

4

84146684 Pin A B

From SP-057A-P-X X-029 (Receptacle) pin 1 AUXILIARY FRONT WHEEL DRIVE (AFWD) SWITCH

Wire CB-057A

Description CB-057A

Color-Size BK - 1.0

CB-3045

CB-3045

YE - 1.0

Frame SHEET 07

X-029 - AUXILIARY FRONT WHEEL DRIVE (AFWD) SWITCH [ S-006] (87717631) (Receptacle)

87717631

5

87717631

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Electrical systems - Harnesses and connectors

Pin 1 5 7

From X-028 (Receptacle) pin B AUXILIARY FRONT WHEEL DRIVE (AFWD) SWITCH LAMP SP-3020C-P-X SP-3025-P-X

Wire

Description

Color-Size

CB-3045

CB-3045

YE - 1.0

Frame

SHEET 07 CB-3020E CB-3025

CB-3020E CB-3025

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YE - 1.0 YE - 1.0

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 X-030 - FRONT WORKLIGHT LAMP [ S-007] (84146684) (Receptacle)

84146684

1

84146684 Pin A B

From SP-057A-P-X SP-1073-P-X

Wire CB-057Q CB-1073A

Description CB-057Q CB-1073A

Color-Size BK - 1.0 VT - 1.0

Frame SHEET 07

X-031 - FRONT WORKLIGHT SWITCH [ SH7: D-1] (87745322) (Receptacle)

87745322

2

87745322 Pin 1 2

From SP-1073-P-X X-066 (Receptacle) pin 6B FUSEBOX 3

Wire CB-1073

Description CB-1073

Color-Size VT - 1.0

CB-1070

CB-1070

RD - 1.5

X-032A - LIGHTS SWITCH B+ [ SH7: C-6] (82944111) (Receptacle)

82944111

3

82944111

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Frame SHEET 07

Electrical systems - Harnesses and connectors

Pin 1

From X-065 (Receptacle) pin 3B FUSEBOX 2

Wire

Description

Color-Size

Frame

CB-1023

CB-1023

BR - 2.5

SHEET 05

Color-Size RD - 1.5

Frame SHEET 05

X-032B - SIDE LAMP [ SH5: C-5] (82944111) (Receptacle)

82944111

4

82944111 Pin 1

From SP-1031-P-X

Wire CB-1031

Description CB-1031

X-032C - DIP BEAM [ S-008] (82944111) (Receptacle)

82944111

5

82944111 Pin 1

From X-065 (Receptacle) pin 6A FUSEBOX 2

Wire

Description

Color-Size

Frame

CB-1029

CB-1029

BL - 1.5

SHEET 05

X-032D - MAIN BEAN [ SH7: C-4] (82944111) (Receptacle)

82944111

6

82944111

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Electrical systems - Harnesses and connectors

Pin 1

From X-064 (Receptacle) pin 3A FUSEBOX 1

Wire

Description

Color-Size

Frame

CB-1028

CB-1028

YE - 1.5

SHEET 05

Frame

X-033 - HAZARD SWITCH [ SH5: B-5] (87745327) (Receptacle)

87745327

7

87745327 Pin 1 2 5 6 7

From X-066 (Receptacle) pin 2B FUSEBOX 3 X-066 (Receptacle) pin 5B FUSEBOX 3 X-034 (Receptacle) pin B HAZARD SWITCH LAMP X-065 (Receptacle) pin 4A FUSEBOX 2 SP-044-P-X

Wire

Description

Color-Size

CB-1021

CB-1021

VT - 1.0

CB-1025

name

GN - 1.0

CB-044C

CB-044C

GN - 1.0

CB-3000

CB-3000

GN - 1.0

CB-044A

CB-044A

GN - 1.0

SHEET 05

X-034 - HAZARD SWITCH LAMP [ S-009] (84146684) (Receptacle)

84146684

8

84146684 Pin A B

From SP-057A-P-X X-033 (Receptacle) pin 5 HAZARD SWITCH

Wire CB-057K

Description CB-057K

Color-Size BK - 1.0

CB-044C

CB-044C

GN - 1.0

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Frame SHEET 07

Electrical systems - Harnesses and connectors

X-035 - TURN LIGHTS SWITCH [ S-002] (84253534) (Receptacle)

84253534

9

84253534 Pin 1 2 3

From SP-044-P-X SP-050-P-X SP-049-P-X

Wire CB-044 CB-050B CB-049B

Description CB-044 CB-050B CB-049B

Color-Size GN - 1.0 GN - 1.0 GN - 1.0

Frame SHEET 07

X-036 - DUAL POWER SWITCH [ S-010] (87717631) (Receptacle)

87717631

10

87717631 Pin 1 5 7

From X-037 (Receptacle) pin B DUAL POWER SWITCH LAMP SP-3020C-P-X SP-3020-P-X

Wire

Description

Color-Size

CB-3022

CB-3022

YE - 1.0

CB-3020C CB-3020

CB-3020C CB-3020

YE - 1.0 YE - 1.0

Frame

SHEET 07

X-037 - DUAL POWER SWITCH LAMP [ S-010] (84146684) (Receptacle)

84146684

11

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Electrical systems - Harnesses and connectors

Pin A B

From SP-057A-P-X X-036 (Receptacle) pin 1 DUAL POWER SWITCH

Wire CB-057B

Description CB-057B

Color-Size BK - 1.0

CB-3022

CB-3022

YE - 1.0

Frame SHEET 07

X-038 - HORN RELAY [ SH9: B-4] (84260285) (Receptacle)

84260285

12

84260285 Pin 2 4 6 8

From SP-376-P-X X-027 (Plug) pin 1 HORN 2 SP-057E-P-X X-043A (Plug) pin 1 HOOD INTERFACE

Wire CB-376 CB-1004A CB-057H

Description CB-376 CB-1004A CB-057H

Color-Size VT - 1.0 GN - 1.0 BK - 1.0

CB-2011

CB-2011

VT - 1.0

Frame

SHEET 06

X-039 - STARTER RELAY [ SH5: A-2] (84260285) (Receptacle)

84260285

13

84260285 Pin 2 4 6 8

From X-066 (Receptacle) pin 4B FUSEBOX 3 SP-1001-P-X SP-057E-P-X X-017A (Receptacle) pin 10 ENGINE HARNESS

Wire

Description

Color-Size

Frame SHEET 05

CB-155

CB-155

GN - 2.5

CB-1001 CB-057F

CB-1001 CB-057F

WH - 1.0 BK - 1.0

CB-2003A

CB-2003A

WH - 2.5

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SHEET 06

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 04 X-040 - FLASHER UNIT [ SH6: B-3] (84260285) (Receptacle)

84260285

1

84260285 Pin 4 6 8

From SP-057E-P-X X-065 (Receptacle) pin 4B FUSEBOX 2 SP-044-P-X

Wire CB-057R

Description CB-057R

CB-3000A

CB-3000A

GN - 1.0

SHEET 05

CB-044D

CB-044D

GN - 1.0

SHEET 06

Description CB-1011

Color-Size YE - 6.0

Frame

CB-1010

CB-1010

GN - 1.0

SHEET 06

CB-057E CB-150D

CB-057E CB-150D

BK - 1.0 BR - 6.0

SHEET 03

Color-Size BK - 1.0

Frame SHEET 06

X-041 - IGNITION RELAY [ SH6: B-4] (84566001) (Receptacle)

84566001

2

84566001 Pin 2 3 4 5

From SP-1011-P-X X-063 pin 6 STARTER SWITCH SP-057E-P-X SP-150-P-X

Wire CB-1011

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Electrical systems - Harnesses and connectors

X-042 - CHASSIS GROUND (84140737) (Plug)

84140737

3

84140737 Pin 1

From SP-057-P-X

Wire CB-057

Description CB-057

Color-Size BK - 4.0

Frame SHEET 10

X-043 - INSTRUMENT CLUSTER [ Y-004] (87689502) (Receptacle)

87689502

4

87689502 Pin 1 2 3 4 5 6 7 8 9 18 19 20

From SP-1005A-P-X SP-031-P-X X-017A (Receptacle) pin 8 ENGINE HARNESS X-017A (Receptacle) pin 2 ENGINE HARNESS X-057A (Receptacle) pin 1 FUEL LEVEL SENDER 1 X-017A (Receptacle) pin 11 ENGINE HARNESS SP-1013-P-X SP-057-P-X SP-1003-P-X X-053 (Receptacle) pin B TRANSMISSION OIL PRESSURE SWITCH X-017A (Receptacle) pin 5 ENGINE HARNESS X-017A (Receptacle) pin 6 ENGINE HARNESS

Wire CB-1005B CB-031B

Description CB-1005B CB-031B

Color-Size GY - 1.0 YE - 1.0

CB-1006A

CB-1006A

BR - 1.0

CB-039B

CB-039B

GN - 1.0

CB-029

CB-029

GN - 1.0

CB-2015A

CB-2015A

WH - 1.0

CB-1013D CB-057D CB-1003

CB-1013D CB-057D CB-1003

RD - 1.0 BK - 1.0 GN - 1.0

CB-2012

CB-2012

YE - 1.0

CB-2040A

CB-2040A

GN - 1.0

CB-1135A

CB-1135A

GN - 1.0

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Frame SHEET 04 SHEET 03

SHEET 04

Electrical systems - Harnesses and connectors

X-043A - HOOD INTERFACE [ SH8: D-6] (84155471) (Plug)

84155471

5

84155471 Pin 1 2 3 4 5

From X-038 (Receptacle) pin 8 HORN RELAY SP-057-P-X X-065 (Receptacle) pin 6B FUSEBOX 2 X-064 (Receptacle) pin 3B FUSEBOX 1 SP-1013-P-X

Wire

Description

Color-Size

Frame

CB-2011

CB-2011

VT - 1.0

SHEET 06

CB-057O

CB-057O

BK - 1.0

SHEET 08

CB-1030

CB-1030

BL - 1.0

CB-1027

CB-1027

BL - 1.0

CB-1013B

CB-1013B

RD - 1.0

SHEET 08

Color-Size PRP - 1.5 BK - 1.0 BL - 1.5 BL - 1.5 RD - 1.0

Frame

SHEET 05

X-043B - MAIN - HOOD (87688721) (Plug)

87688721

6

87688721 Pin 1 2 3 4 5

From X-044A (Receptacle) pin 1 SP34-P-X SP35-P-X SP36-P-X SP37-P-X

Wire 2011A 57SA 1030A 1027A 1013A

Description 2011A 57SA 1030A 1027A 1013A

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SHEET 08

Electrical systems - Harnesses and connectors

X-044A - [ H-002] (87581782) (Receptacle)

87581782

7

87581782 Pin 1

From X-043B (Plug) pin 1 MAIN HOOD

Wire

Description

Color-Size

Frame

2011A

2011A

PRP - 1.5

SHEET 08

Color-Size BK - 1.0

Frame SHEET 08

X-044B - [ H-002] (87581782) (Receptacle)

87581782

8

87581782 Pin 1

From SP30-P-X

Wire 57SC

Description 57SC

X-045 - [ E-003] (82012083) (Receptacle)

82012083

9

82012083 Pin 1 2

From SP30-P-X SP37-P-X

Wire 57SD 1013D

Description 57SD 1013D

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Color-Size BK - 1.0 RD - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

X-046 - [ E-004] (87715168) (Receptacle)

87715168

10

87715168 Pin A B C

From SP31-P-X SP35-P-X SP36-P-X

Wire 57SF 1030B 1027B

Description 57SF 1030B 1027B

Color-Size BK - 1.0 BL - 1.5 BL - 1.5

Frame SHEET 08

X-047 - [ E-005] (87715168) (Receptacle)

87715168

11

87715168 Pin A B C

From SP32-P-X SP35-P-X SP36-P-X

Wire 57SH 1030C 1027C

Description 57SH 1030C 1027C

X-048 - [ E-010] (82012083) (Receptacle)

82012083

12

82012083

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Color-Size BK - 1.0 BL - 1.5 BL - 1.5

Frame SHEET 08

Electrical systems - Harnesses and connectors

Pin 1 2

From SP32-P-X SP37-P-X

Wire 57SJ 1013E

Description 57SJ 1013E

Color-Size BK - 1.0 RD - 1.0

Frame SHEET 08

X-049 - FENDER CONNECTOR - LEFT SIDE [ SH5: C-2] (82002274) (Receptacle)

82002274

13

82002274 Pin 1 2 3 4 5 6

From SP-057C-P-X SP-830-P-X SP-997-P-X SP-1013-P-X SP-050-P-X SP-1073-P-X

Wire CB-057T CB-830C CB-997A CB-1013A CB-050 CB-1073B

Description CB-057T CB-830C name name name CB-1073B

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Color-Size BK - 1.0 BL - 1.0 GN - 1.0 RD - 1.0 GN - 1.0 VT - 1.0

Frame SHEET 08 SHEET 05 SHEET 08

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 05 X-050 - MAIN - FENDER (87688721) (Plug)

87688721

1

87688721 Pin 1 2 3 4 5 6

From SP45-P-X X-080A (Receptacle) pin 1 X-069B (Receptacle) pin 1 SP46-P-X SP47-P-X X-068B (Receptacle) pin 1

Wire 57RE 820A 997D 1014A 50C 1073E

Description name name name name name name

Color-Size BK - 1.0 RD - 1.0 GN - 1.0 RD - 1.0 GN - 1.0 PRP - 1.0

Frame

SHEET 08

X-051 - FENDER CONNECTOR - RIGHT SIDE (82002274) (Receptacle)

82002274

2

82002274 Pin 1 2 3 4 5 6

From SP-057C-P-X SP-830-P-X SP-997-P-X SP-1013-P-X SP-049-P-X SP-1073-P-X

Wire CB-057M CB-830 CB-997B CB-1013C CB-049 CB-1073C

Description CB-057M CB-830 CB-997B CB-1013C name CB-1073C

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Color-Size BK - 1.0 BL - 1.0 GN - 1.0 RD - 1.0 GN - 1.0 VT - 1.0

Frame SHEET 08 SHEET 05 SHEET 08

Electrical systems - Harnesses and connectors

X-052 - MAIN HARNESS - FENDER (87688721) (Plug)

87688721

3

87688721 Pin 1 2 3 4 5 6

From SP42-P-X X-066C (Receptacle) pin 1 X-065B (Receptacle) pin 1 SP43-P-X SP44-P-X X-064B (Receptacle) pin 1

Wire 57PE 830A 997C 1013F 49C 1073D

Description name name name name name name

Color-Size BK - 1.0 BL - 1.0 GN - 1.0 RD - 1.0 GN - 1.0 PRP - 1.0

Frame

SHEET 08

X-053 - TRANSMISSION OIL PRESSURE SWITCH [ SH9: D-6] (87679438) (Receptacle)

87679438

4

87679438 Pin A B

From X-067 (Receptacle) pin 2 OIL TEMPERATURE SWITCH X-043 (Receptacle) pin 18 INSTRUMENT CLUSTER

Wire

Description

Color-Size

CB-2012A

name

YE - 1.0

CB-2012

CB-2012

YE - 1.0

Frame SHEET 04

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Electrical systems - Harnesses and connectors

X-054A - REVERSE ALARM SWITCH 2 [ S-003] (84120007) (Receptacle)

84120007

5

84120007 Pin 1

From X-055 (Plug) pin 1 BUZZER 1

Wire CB-1160

Description CB-1160

Color-Size RD - 1.0

Frame SHEET 09

X-054B - REVERSE ALARM SWITCH 1 [ SH9: C-6] (84120006) (Plug)

84120006

6

84120006 Pin 1

From X-065 (Receptacle) pin 2B FUSEBOX 2

Wire

Description

Color-Size

Frame

CB-1050

CB-1050

GN - 1.0

SHEET 05

X-055 - BUZZER 1 [ H-001] (84352277) (Plug)

84352277

7

84352277 Pin 1

From X-054A (Receptacle) pin 1 REVERSE ALARM SWITCH 2

Wire

Description

Color-Size

Frame

CB-1160

CB-1160

RD - 1.0

SHEET 09

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Electrical systems - Harnesses and connectors

X-056 - BUZZER 2 [ H-001] (84352277) (Plug)

84352277

8

84352277 Pin 1

From SP-057C-P-X

Wire CB-057G

Description CB-057G

Color-Size BK - 1.0

Frame SHEET 09

X-057A - FUEL LEVEL SENDER 1 [ SH4: A-4] (87675193) (Receptacle)

87675193

9

87675193 Pin 1

From X-043 (Receptacle) pin 5 INSTRUMENT CLUSTER

Wire

Description

Color-Size

Frame

CB-029

CB-029

GN - 1.0

SHEET 04

X-057B - FUEL LEVEL SENDER 2 [ SH10: D-5] (87675193) (Receptacle)

87675193

10

87675193 Pin 1

From SP-057C-P-X

Wire CB-057C

Description CB-057C

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Color-Size BK - 1.0

Frame SHEET 09

Electrical systems - Harnesses and connectors

X-058 - BRAKE SWITCH [ SH9: A-5] (82918052) (Receptacle)

82918052

11

82918052 Pin 2 3

From X-064 (Receptacle) pin 5B FUSEBOX 1 SP-830-P-X

Description

Color-Size

CB-840

CB-840

GN - 1.0

SHEET 05

CB-830A

CB-830A

BL - 1.0

SHEET 09

Wire

Frame

X-059A - TRANSMISSION SAFETY SWITCH 2 [ S-016] (84120006) (Plug)

84120006

12

84120006 Pin 1

From X-060 (Receptacle) pin 1 POWER TAKE OFF (PTO) SAFETY SWITCH

Wire

Description

Color-Size

Frame

CB-1000A

CB-1000A

WH - 1.0

SHEET 09

X-059B - TRANSMISSION SAFETY SWITCH 1 [ S-016] (84120007) (Receptacle)

84120007

13

84120007

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Electrical systems - Harnesses and connectors

Pin 1

From X-063 pin 8 STARTER SWITCH

Wire

Description

Color-Size

Frame

CB-1000

CB-1000

WH - 1.0

SHEET 09

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 06 X-060 - POWER TAKE OFF (PTO) SAFETY SWITCH [ S-015] (82918052) (Receptacle)

82918052

1

82918052 Pin 1 4

From X-059A (Plug) pin 1 TRANSMISSION SAFETY SWITCH 2 SP-1001-P-X

Wire

Description

Color-Size

CB-1000A

CB-1000A

WH - 1.0

CB-1001A

CB-1001A

WH - 1.0

Frame SHEET 09

X-061 - DUAL POWER SOLENOID [ S-014] (84120007) (Receptacle)

84120007

2

84120007 Pin 1

From SP-3020-P-X

Wire CB-3020A

Description CB-3020A

Color-Size YE - 1.0

Frame SHEET 09

X-062 - AUXILIARY FRONT WHEEL DRIVE (AFWD) SOLENOID [ S-013] (84567745) (Receptacle)

84567745

3

84567745

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Electrical systems - Harnesses and connectors

Pin 1

From SP-3025-P-X

Wire CB-3025A

Description CB-3025A

Color-Size YE - 1.0

Frame SHEET 09

Color-Size RD - 1.5 RD - 1.5

Frame

X-063 - STARTER SWITCH [ SH6: A-4] (87714250) (Plug)

87714250

4

87714250 X-064 - FUSEBOX 1 [ FH-001] (84260288) (Receptacle)

84260288

5

84260288 Pin 1A 2A 3A 4A 5A 6A 1B 2B 3B 4B 5B 6B

From SP-1031-P-X SP-1031-P-X X-032D (Receptacle) pin 1 MAIN BEAN SP-1011-P-X SP-1011-P-X SP-1011-P-X SP-1013-P-X SP-997-P-X X-043A (Plug) pin 4 HOOD INTERFACE SP-3020C-P-X X-058 (Receptacle) pin 2 BRAKE SWITCH SP-1003-P-X

Wire CB-1031B CB-1031A

Description CB-1031B CB-1031A

CB-1028

CB-1028

YE - 1.5

CB-1011C CB-1011B CB-1011A CB-1013 CB-997

CB-1011C CB-1011B CB-1011A CB-1013 CB-997

YE - 1.5 YE - 1.5 YE - 1.5 RD - 1.0 GN - 1.0

CB-1027

CB-1027

BL - 1.0

CB-3020D

CB-3020D

YE - 1.0

CB-840

CB-840

GN - 1.0

CB-1003A

CB-1003A

GN - 1.0

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SHEET 05

Electrical systems - Harnesses and connectors

X-064A - [ E-017] (84120007) (Receptacle)

84120007

6

84120007 Pin 1

From SP42-P-X

Wire 57PA

Description name

Color-Size BK - 1.0

Frame SHEET 08

X-064B - [ E-017] (84120007) (Receptacle)

84120007

7

84120007 Pin 1

From X-052 (Plug) pin 6 MAIN HARNESS - FENDER

Wire

Description

Color-Size

Frame

1073D

name

PRP - 1.0

SHEET 08

X-065 - FUSEBOX 2 [ FH-001] (84260288) (Receptacle)

84260288

8

84260288

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Electrical systems - Harnesses and connectors

Pin 1A 2A 3A 4A 5A 6A 1B 2B 3B 4B 5B 6B

From SP-1011-P-X SP-1011-P-X SP-1011-P-X X-033 (Receptacle) pin 6 HAZARD SWITCH SP-150-P-X X-032C (Receptacle) pin 1 DIP BEAM X-017A (Receptacle) pin 7 ENGINE HARNESS X-054B (Plug) pin 1 REVERSE ALARM SWITCH 1 X-032A (Receptacle) pin 1 LIGHTS SWITCH B+ X-040 (Receptacle) pin 6 FLASHER UNIT SP-376-P-X X-043A (Plug) pin 3 HOOD INTERFACE

Wire CB-1011E CB-1011D CB-1011H

Description CB-1011E CB-1011D CB-1011H

Color-Size YE - 1.5 YE - 1.5 YE - 2.5

CB-3000

CB-3000

GN - 1.0

CB-150C

CB-150C

BR - 1.5

CB-1029

CB-1029

BL - 1.5

CB-1141A

CB-1141A

BR - 1.0

CB-1050

CB-1050

GN - 1.0

CB-1023

CB-1023

BR - 2.5

CB-3000A

CB-3000A

GN - 1.0

CB-376A

CB-376A

VT - 1.0

CB-1030

CB-1030

BL - 1.0

Frame

SHEET 05

SHEET 03

SHEET 05

X-065A - [ E-011] (84120007) (Receptacle)

84120007

9

84120007 Pin 1

From SP42-P-X

Wire 57PC

Description name

Color-Size BK - 1.0

Frame SHEET 08

X-065B - [ E-011] (84120007) (Receptacle)

84120007

10

84120007 Pin 1

From X-052 (Plug) pin 3 MAIN HARNESS - FENDER

Wire

Description

Color-Size

Frame

997C

name

GN - 1.0

SHEET 08

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Electrical systems - Harnesses and connectors

X-066 - FUSEBOX 3 [ SH7: D-3] (84260288) (Receptacle)

84260288

11

84260288 Pin 1A 2A 4A 5A 5A 6A 6A 1B 2B 4B 5B 5B 6B 6B

From SP-150-P-X SP-150-P-X SP-150-P-X SP-1011-P-X 14-P-13A 13-P-13A SP-1011-P-X X-068 (Receptacle) pin 1 Key Switch 30 X-033 (Receptacle) pin 1 HAZARD SWITCH X-039 (Receptacle) pin 2 STARTER RELAY 14-P-13B X-033 (Receptacle) pin 2 HAZARD SWITCH 13-P-13B X-031 (Receptacle) pin 2 FRONT WORKLIGHT SWITCH

Wire CB-150B CB-150E CB-150A CB-1011G WIRE512 WIRE490 CB-1011F

Description CB-150B CB-150E CB-150A CB-1011G WIRE512 WIRE490 CB-1011F

Color-Size BR - 2.5 BR - 1.0 BR - 2.5 YE - 1.5

CB-155A

CB-155A

GN - 4.0

CB-1021

CB-1021

VT - 1.0

CB-155

CB-155

GN - 2.5

WIRE511

WIRE511

CB-1025

name

WIRE491

WIRE491

CB-1070

CB-1070

Frame

YE - 1.5

SHEET 03

GN - 1.0

RD - 1.5

X-066A - [ E-014] (87705140) (Receptacle)

87705140

12

87705140 Pin 1

From SP44-P-X

Wire 49E

Description name

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Color-Size GN - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

X-066B - [ E-013] (87705140) (Receptacle)

87705140

13

87705140 Pin 1

From SP43-P-X

Wire 1013H

Description name

Color-Size RD - 1.0

Frame SHEET 08

X-066C - [ E-012] (87705140) (Receptacle)

87705140

14

87705140 Pin 1

From X-052 (Plug) pin 2 MAIN HARNESS - FENDER

Wire

Description

Color-Size

Frame

830A

name

BL - 1.0

SHEET 08

Color-Size BK - 1.0

Frame SHEET 08

X-066D - [ E-012] (87705140) (Receptacle)

87705140

15

87705140 Pin 1

From SP42-P-X

Wire 57PB

Description name

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Electrical systems - Harnesses and connectors

X-067 - OIL TEMPERATURE SWITCH [ B-005] (82012083) (Receptacle)

82012083

16

82012083 Pin 1 2

From SP-057C-P-X X-053 (Receptacle) pin A TRANSMISSION OIL PRESSURE SWITCH

Wire CB-057P

Description name

Color-Size BK - 1.0

CB-2012A

name

YE - 1.0

Frame SHEET 09

X-067A - [ E-016] (87705140) (Receptacle)

87705140

17

87705140 Pin 1

From SP44-P-X

Wire 49D

Description name

Color-Size GN - 1.0

Frame SHEET 08

Color-Size RD - 1.0

Frame SHEET 08

X-067B - [ E-015] (87705140) (Receptacle)

87705140

18

87705140 Pin 1

From SP43-P-X

Wire 1013G

Description name

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Electrical systems - Harnesses and connectors

X-067C - [ E-015] (87705140) (Receptacle)

87705140

19

87705140 Pin 1

From SP42-P-X

Wire 57PD

Description name

Color-Size BK - 1.0

Frame SHEET 08

X-068 - KEY SWITCH 30 [ SH7: D-6] (87747155) (Receptacle)

87747155

20

87747155 Pin 1

From X-066 (Receptacle) pin 1B FUSEBOX 3

Wire

Description

Color-Size

Frame

CB-155A

CB-155A

GN - 4.0

SHEET 05

Color-Size BK - 1.0

Frame SHEET 08

X-068A - [ E-018] (84120007) (Receptacle)

84120007

21

84120007 Pin 1

From SP45-P-X

Wire 57RA

Description name

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Electrical systems - Harnesses and connectors

X-068B - [ E-018] (84120007) (Receptacle)

84120007

22

84120007 Pin 1

From X-050 (Plug) pin 6 MAIN HARNESS - FENDER

Wire

Description

Color-Size

Frame

1073E

name

PRP - 1.0

SHEET 08

Color-Size BK - 1.0

Frame SHEET 08

X-069A - [ E-006] (84120007) (Receptacle)

84120007

23

84120007 Pin 1

From SP45-P-X

Wire 57RC

Description name

X-069B - [ E-006] (84120007) (Receptacle)

84120007

24

84120007 Pin 1

From X-050 (Plug) pin 3 MAIN HARNESS - FENDER

Wire

Description

Color-Size

Frame

997D

name

GN - 1.0

SHEET 08

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 07 X-070 - DIODE [ V-003] (87475492) (Plug)

87475492

1

87475492 Pin 1 2

From SP-057A-P-X SP-3020-P-X

Wire CB-057V CB-3020B

Description CB-057V CB-3020B

Color-Size BK - 1.0 YE - 1.0

Frame SHEET 07

X-070A - [ E-002] (87705140) (Receptacle)

87705140

2

87705140 Pin 1

From SP46-P-X

Wire 1014B

Description name

X-070B - [ E-001] (87705140) (Receptacle)

87705140

3

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Color-Size RD - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

Pin 1

From SP47-P-X

Wire 50D

Description name

Color-Size GN - 1.0

Frame SHEET 08

Color-Size BK - 1.0

Frame SHEET 08

X-070C - [ E-002] (87705140) (Receptacle)

87705140

4

87705140 Pin 1

From SP45-P-X

Wire 57RD

Description name

X-071 - LICENSE PLATE HARNESS (82012083) (Receptacle)

82012083

5

82012083 Pin 1 2

From SP-057C-P-X SP-1013-P-X

Wire CB-057S CB-1013E

Description CB-057S CB-1013E

X-071A - MAIN HARNESS (87687244) (Plug)

87687244

6

87687244

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Color-Size BK - 1.0 RD - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

Pin 1 2

From X-075 (Receptacle) pin 1 LICENSE PLATE X-075 (Receptacle) pin 2 LICENSE PLATE

Wire

Description

Color-Size

LI-057

LI-057

BK - 1.0

LI-1013

LI-1013

RD - 1.0

Frame SHEET 08

X-072 - DIODE [ V-002] (87475492) (Plug)

87475492

7

87475492 Pin 1 2

From SP-1005A-P-X SP-031-P-X

Wire CB-1005C CB-031

Description name name

Color-Size GY - 1.0 YE - 1.0

Frame SHEET 04

X-073 - DIODE [ V-001] (87475492) (Plug)

87475492

8

87475492 Pin 1 2

From SP-057A-P-X SP-3025-P-X

Wire CB-057X CB-3025B

Description CB-057X CB-3025B

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Color-Size BK - 1.0 YE - 1.0

Frame SHEET 07

Electrical systems - Harnesses and connectors

X-075 - LICENSE PLATE [ E-019] (82012083) (Receptacle)

82012083

9

82012083 Pin 1 2

From X-071A (Plug) pin 1 MAIN HARNESS X-071A (Plug) pin 2 MAIN HARNESS

Wire

Description

Color-Size

LI-057

LI-057

BK - 1.0

LI-1013

LI-1013

RD - 1.0

Wire RL-987

Description RL-987

Color-Size RD - 1.0

Frame SHEET 09

Wire RL-057H

Description RL-057H

Color-Size BK

Frame SHEET 09

Wire RL-057H RL-987

Description RL-057H RL-987

Color-Size BK RD - 1.0

Frame

Frame SHEET 08

X-076 - (Plug) Pin PIN1

From X-078 (Plug) pin 2

X-077 - (Plug) Pin PIN1

From X-078 (Plug) pin 1

X-078 - [ E-020] (Plug) Pin 1 2

From X-077 (Plug) pin PIN1 X-076 (Plug) pin PIN1

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SHEET 09

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 08 X-080A - [ E-009] (87705140) (Receptacle)

87705140

1

87705140 Pin 1

From X-050 (Plug) pin 2 MAIN HARNESS - FENDER

Wire

Description

Color-Size

Frame

820A

name

RD - 1.0

SHEET 08

Color-Size RD - 1.0

Frame SHEET 08

Color-Size GN - 1.0

Frame SHEET 08

X-080B - [ E-008] (87705140) (Receptacle)

87705140

2

87705140 Pin 1

From SP46-P-X

Wire 1014C

Description name

X-080C - [ E-007] (87705140) (Receptacle)

87705140

3

87705140 Pin 1

From SP47-P-X

Wire 50E

Description name 47793462 14/03/2017

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Electrical systems - Harnesses and connectors

X-080D - [ E-009] (87705140) (Receptacle)

87705140

4

87705140 Pin 1

From SP45-P-X

Wire 57RB

Description name

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Color-Size BK - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 100 X-1000A - STARTER SOLENOID (87702238) (Receptacle)

87702238

1

87702238 Pin 1

From X-017B (Plug) pin 10 TO MAIN HARNESS

Wire

Description

Color-Size

Frame

EN-2003

EN-2003

WH - 2.5

SHEET 03

X-1000B - (82944111) (Receptacle)

82944111

2

82944111

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Electrical systems - Harnesses and connectors

Electrical components - Sensor description B-001 - ENGINE OIL PRESSURE SWITCH (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 03 X-012 (Receptacle)

B-002 - ENGINE TEMPERATURE SENSOR (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 03 X-015 (Receptacle)

B-003 - WATER IN FUEL SENSOR (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 03 X-016 (Receptacle)

B-004 - TRANSMISSION OIL PRESSURE SWITCH (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 09 X-053 (Receptacle)

B-005 - OIL TEMPERATURE SWITCH (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 09 X-067 (Receptacle)

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Electrical systems - Harnesses and connectors

Electrical components - Lamp description E-001 - FRONT TURN LIGHT - RIGHT SIDE (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-070B (Receptacle)

E-002 - FRONT SIDE LIGHT - RIGHT SIDE (Lamp) Component Type Wiring frames

Lamp SHEET 08 X-070C (Receptacle) X-070A (Receptacle)

Connectors E-003 - SIDE LIGHT (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-045 (Receptacle)

E-004 - HEADLIGHTS - LEFT SIDE (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-046 (Receptacle)

E-005 - HEADLIGHTS - RIGHT SIDE (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-047 (Receptacle)

E-006 - REAR WORKLIGHT (Lamp) Component Type Wiring frames

Lamp SHEET 08 X-069B (Receptacle) X-069A (Receptacle)

Connectors E-007 - REAR TURN LIGHT - LEFT SIDE (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-080C (Receptacle)

E-008 - REAR SIDE LIGHT (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-080B (Receptacle)

E-009 - STOP LIGHT (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-080D (Receptacle) X-080A (Receptacle)

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Electrical systems - Harnesses and connectors

E-010 - SIDE LIGHT (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-048 (Receptacle)

E-011 - REAR WORKLIGHT (Lamp) Component Type Wiring frames

Lamp SHEET 08 X-065B (Receptacle) X-065A (Receptacle)

Connectors E-012 - STOP LIGHT (Lamp) Component Type Wiring frames

Lamp SHEET 08 X-066D (Receptacle) X-066C (Receptacle)

Connectors E-013 - REAR SIDE LIGHT (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-066B (Receptacle)

E-014 - REAR TURN LIGHT - RIGHT SIDE (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-066A (Receptacle)

E-015 - FRONT SIDE LIGHT (Lamp) Component Type Wiring frames

Lamp SHEET 08 X-067C (Receptacle) X-067B (Receptacle)

Connectors E-016 - FRONT TURN LIGHT - RIGHT SIDE (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-067A (Receptacle)

E-017 - FRONT WORKLIGHT - RIGHT SIDE (Lamp) Component Type Wiring frames

Lamp SHEET 08 X-064B (Receptacle) X-064A (Receptacle)

Connectors E-018 - FRONT WORKLIGHT - LEFT SIDE (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-068B (Receptacle) X-068A (Receptacle)

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Electrical systems - Harnesses and connectors

E-019 - LICENSE PLATE LIGHT (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 08 X-075 (Receptacle)

E-020 - REVERSE LAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 09 X-078 (Plug)

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Electrical systems - Harnesses and connectors

Electrical components - Fuse description F-001 - (Fuse) Component Type Wiring frames

Fuse SHEET 02

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Electrical systems - Harnesses and connectors

Electrical components - Voltage source description G-001 - ALTERNATOR 65 AH (Voltage source) Component Type Wiring frames Connectors

Voltage source SHEET 03 X-008 (Plug) X-009 (Plug) X-010 (Plug)

G-002 - BATTERY 100 Ah (Voltage source) Component Type Wiring frames Connectors

Voltage source SHEET 03 X-001 (Plug) X-002 (Plug)

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Electrical systems - Harnesses and connectors

Electrical components - Speaker description H-001 - BUZZER (Speaker) Component Type Wiring frames Connectors

Speaker SHEET 09 X-055 (Plug) X-056 (Plug)

H-002 - HORN (Speaker) Component Type Wiring frames Connectors

Speaker SHEET 08 X-044A (Receptacle) X-044B (Receptacle)

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Electrical systems - Harnesses and connectors

Electrical components - Relay description K-001 - POWER RELAY - GRID HEATER CONTROLLER (Relay) Component Type Wiring frames Connectors

Relay SHEET 02 X-021 (Plug) X-022 (Plug) X-020 (Receptacle)

K-002 - HORN RELAY (RL1) (Relay) Component Type Wiring frames Connectors

Relay SHEET 06 X-038 (Receptacle)

K-003 - FLASHER UNIT (RL3) (Relay) Component Type Wiring frames Connectors

Relay SHEET 06 X-040 (Receptacle)

K-004 - STARTER RELAY (RL2) (Relay) Component Type Wiring frames Connectors

Relay SHEET 06 X-039 (Receptacle)

K-005 - IGNITION RELAY (RL4) (Relay) Component Type Wiring frames Connectors

Relay SHEET 06 X-041 (Receptacle)

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Electrical systems - Harnesses and connectors

Electrical components - Motor description M-001 - STARTER MOTOR 3.0 kW (Motor) Component Type Wiring frames

Motor SHEET 03

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Electrical systems - Harnesses and connectors

Electrical components - Switch description S-001 - AIR FILTER CLOGGING (Switch) Component Type Wiring frames Connectors

Switch SHEET 03 X-013 (Receptacle)

S-002 - TURN LIGHTS SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 07 X-035 (Receptacle)

S-003 - REVERSE ALARM SWITCH (Switch) Component Type Wiring frames

Switch SHEET 09 X-054A (Receptacle) X-054B (Plug)

Connectors S-004 - HORN (Switch) Component Type Wiring frames

Switch SHEET 09 X-027 (Plug) X-026 (Plug)

Connectors S-005 - STARTER SWITCH (Switch) Component Type Wiring frames

Switch SHEET 07 X-063 (Plug) X-068 (Receptacle)

Connectors

S-006 - AUXILIARY FRONT WHEEL DRIVE (AFWD) SWITCH (Switch) Component Type Wiring frames

Switch SHEET 07 X-029 (Receptacle) X-028 (Receptacle)

Connectors S-007 - FRONT WORKLIGHTS SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 07 X-031 (Receptacle) X-030 (Receptacle)

S-008 - LIGHTS SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 07 X-032A (Receptacle) X-032B (Receptacle) X-032C (Receptacle) X-032D (Receptacle)

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Electrical systems - Harnesses and connectors

S-009 - HAZARD SWITCH (Switch) Component Type Wiring frames

Switch SHEET 07 X-034 (Receptacle) X-033 (Receptacle)

Connectors S-010 - DUAL POWER SWITCH (Switch) Component Type Wiring frames

Switch SHEET 07 X-036 (Receptacle) X-037 (Receptacle)

Connectors S-011 - FUEL LEVEL SENDER (Switch) Component Type Wiring frames

Switch SHEET 09 X-057A (Receptacle) X-057B (Receptacle)

Connectors S-012 - STOP LIGHT SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-058 (Receptacle)

S-013 - AUXILIARY FRONT WHEEL DRIVE (AFWD) SOLENOID (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-062 (Receptacle)

S-014 - DUAL POWER SOLENOID (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-061 (Receptacle)

S-015 - POWER TAKE OFF (PTO) SAFETY SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-060 (Receptacle)

S-016 - TRANSMISSION SAFETY SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-059A (Plug) X-059B (Receptacle)

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Electrical systems - Harnesses and connectors

Electrical components - Solenoid description Y-001 - FUEL SHUT OFF (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 03 X-014 (Receptacle)

Y-002 - GRID HEATER CONTROLLER (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 02 X-018 (Receptacle)

Y-003 - GRID HEATER (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 02 X-023 (Plug) X-024 (Plug)

Y-004 - INSTRUMENT CLUSTER (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 04 X-043 (Receptacle)

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Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 03 SH03 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Wiring harnesses - Electrical schematic sheet 04 SH04 - INSTRUMENT CLUSTER . . . . . . . . . . . .

8

Wiring harnesses - Electrical schematic sheet 05 SH05 - FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Wiring harnesses - Electrical schematic sheet 06 SH06 - RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Wiring harnesses - Electrical schematic sheet 07 SH07 - SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . .

14

Wiring harnesses - Electrical schematic sheet 08 SH08 - LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORIES / SAFETY SWITCHES

18

Wiring harnesses - Electrical schematic sheet 10 SH10 - GROUND . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Electrical components - Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

Electrical components - Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

Electrical components - Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

Electrical components - Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

Electrical components - Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

Electrical components - Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

Electrical components - Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74

Electrical components - Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77

Electrical components - Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

Wire connectors - Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Wire connectors - Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Wire connectors - Component diagram 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Wire connectors - Component diagram 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

Wire connectors - Component diagram 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

Wire connectors - Component diagram 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

Wire connectors - Component diagram 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

Wire connectors - Component diagram 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

Wire connectors - Component diagram 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

Wire connectors - Component diagram 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67

Wiring harnesses - Electrical schematic sheet 02 SH02 - GRID HEATER . . . . . . . . . . . . . . . . . . . . . .

4

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Electrical systems - 55 Engine starting system - 201

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starter General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine starting system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Engine starter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Test - Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Electrical systems - Engine starting system

Engine starter - General specification 7630

8030 Iskra 3.0 kW

Starter motor Maximum intensity without load at 12 V and 8000 RPM Minimum length of brushes Minimum diameter of manifold Maximum clearance of armature

80 A 7.00 mm 42.5 mm 0.4 mm

Engine starter - Torque Component Starter motor to block fixing bolts Nut for terminal 30 Solenoid cable nuts Starter motor cover nuts Solenoid fixing bolts

Torque value 34 N·m (25.1 lb ft) 24.0 – 32.0 N·m (17.7 – 23.6 lb ft) 7 N·m (5.2 lb ft) 10 N·m (7.4 lb ft) 5 N·m (3.7 lb ft)

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Electrical systems - Engine starting system

Engine starting system - Dynamic description Starter system operation The starter system installed in the machine features several basic components, namely: a key-actuated starter switch, safety switches installed on the clutch pedal and power take-off drive lever, heavy duty cables, a starter motor, a solenoid, and a start relay. The starter motor is a four-pole, four-brush type motor with integrated solenoid assembly and positively engaged transmission. The integrated solenoid incorporates two armatures connected in parallel. One armature constitutes the low resistance coil for “pulling” and is grounded through the motor. The other armature constitutes the high resistance coil for “holding” and is grounded through the solenoid body. When you perform the starting procedure (apply the clutch pedal and keep the power take-off lever in the off position) and activate the starter switch, the solenoid coils are activated and the piston is magnetically attracted to the solenoid core. This movement, which is transmitted through an articulated mechanism, forces the drive pinion to engage in the flywheel rack. When the drive pinion touches the flywheel rack, the solenoid plunger acts to close a group of contacts, which in turn supply energy direct from the battery to the four field coils that deliver all the power to the starter motor. At this point, one end of the “pulling” coil connects to the battery positive through the starter switch, while the other end is connected to the positive through the solenoid contacts. The “pulling” coil this way is deviated from the circuit and does not receive any current, while the holding coil maintains the solenoid piston engaged. The starter motor incorporates a set of single contacts and a two-part solenoid piston that close the contacts completely even if the sprocket and the pinion teeth are misaligned. When this happens the engagement spring is compressed which forces the pinion to engage completely as soon as the starter motor starts to turn. When the starter key switch is released, the current to the solenoid and starter motor is turned off. The solenoid return spring acts through the articulation mechanism and disengages the pinion gears and reopens the solenoid contacts. The drive pinion assembly incorporates a roller clutch. This clutch prevents the armature from turning excessively if the drive pinion remains engaged in the rack after the engine starts.

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Electrical systems - Engine starting system

Engine starting system - Exploded view

CUIL17TR00261GA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Component Fixing bolt Cover Set of collars and rings, command drive Brush cover Brush Brush Coil covering Armature Central support plate Bushing

1

Reference (11) (12) (13) (14) (15) (16) (17) (18) (19)

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Component Coverage Soelnoid Solenoid nuts and bolts Lever Brush spring Brush support Washer Nut Drive Pinion Assembly

Electrical systems - Engine starting system

Engine starter - Test Testing the starting system on the tractor For quicker and easier diagnosis and to obtain a majority of conclusive trials, we recommend you use a device to check the batteries/starter motors (quick discharge verifier) which incorporates a 0 – 20 V voltmeter and a 0 – 500 A ammeter. When using the test equipment, always follow the manufacturer's recommendations. When no test equipment is available, use a 0 – 20 V voltmeter and a 0 – 500 A ammeter and follow the procedures below to determine the correct operation of the starter motor without removing it from the engine. Before tests: • Check whether the battery is fully charged. • Check all wires in the starter system circuit for split, frayed wires or loose connections. • Make sure the motor is not locked.

Demand for current from the starter motor circuit 1. Disconnect the cable from the negative terminal of the battery (3). 2. Disconnect the battery wire on the starter solenoid. Connect the positive wire of the ammeter (1) to the positive terminal of the battery and the negative wire to the solenoid input terminal. 3. Connect the cable to the negative terminal of the battery. 4. Connect the volt meter positive wire (2) to the battery positive terminal and the negative wire to the battery negative terminal. LAIL11TL0157A0A

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1

Electrical systems - Engine starting system

5. Disconnect the solenoid wire (1) from the injection pump. 6. Ask someone to crank the starter motor. Observe the voltmeter and ammeter readings: • The voltage on the voltmeter must remain stable at 12 V. • The current on the ammeter must be between 250 – 300 A. 7. With the values obtained, do the following: • If the current demand is within specifications, the starter motor is working correctly.

CUIL14TR00564AA

2

CUIL14TR00564AA

3

CUIL16TC00130AA

4

• If there is a voltage drop during the test, see the procedures indicated below. • If the demand for current is higher than that specified, check the circuit as specified below. If the starter system circuit tests do not prove satisfactory, then the starter motor is damaged and should be disassembled to determine the causes. • If the demand for current is lower than that specified, the starter motor is damaged and must be disassembled to determine the causes.

Starter system circuit resistance (Voltage drop) If there is an excessive demand for current, the circuit must be checked noting the voltage drops in each circuit component. NOTICE: Disconnect the wire (1) of the shut-off solenoid for the fuel injection pump.

Battery positive wire 1. Connect the voltmeter positive wire to the battery positive terminal. 2. Connect the negative wire of the voltmeter to the starter motor solenoid battery terminal. 3. Ask someone to crank the starter motor. Observe the readings on the voltmeter: • If it is higher than 0.2 V, check and tighten the wire connections. Check the voltage again. If it is still excessive, install new cables.

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Electrical systems - Engine starting system

Ground wiring for the starter motor (Negative) 1. Connect the positive wire of the voltmeter to the housing of the starter motor. 2. Connect the voltmeter negative wire to the engine block. 3. Ask someone to crank the starter motor. Observe the reading on the voltmeter: • If it is higher than 0.2 V, check the connections to the mass between the starter motor flange and the rear plate of the motor.

CUIL16TC00131AA

5

CUIL16TC00132AA

6

Connection wire from the mass to the battery: 1. Connect the voltmeter positive wire to the engine block. 2. Connect the voltmeter negative wire to the battery negative terminal. 3. Turn the starter motor and, at the same time, observe the voltage reading on the volt meter. If it is higher than 0.2 V, check and tighten the wire connections to the mass. Check the voltage again, if it is still excessive, assemble new cables.

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Electrical systems - Engine starting system

Engine starter - Remove 1. Disconnect the cable from the negative terminal of the battery. 2. Remove the solenoid guard plate. 3. Disconnect the positive cable (1). 4. Remove the bolts (2). Remove the starter motor from the machine.

CUIL16TR01378AA

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1

Electrical systems - Engine starting system

Engine starter - Test Starter motor test with no load NOTE: To run this test, you will need a fully charged battery and a battery tester (to check rapid discharge) with a carbon disc rheostat (variable load resistance). 1. Secure the starter motor in a vise. 2. Connect the battery negative cable (4) to the starter motor assembly flange. 3. Make a bridge using a short wire (6) between the terminal on the battery solenoid and the terminal on the solenoid breaker. 4. Connect the positive wire of the voltmeter (3) to the battery's positive terminal and its negative wire to the battery's negative terminal, the positive wire (1) of the ammeter to the battery's positive terminal and its negative wire to the starter motor terminal or to the terminal on the solenoid that will connect to the battery. 5. Secure a manual revolution counter (5) to the point of the armature shaft. Activate the starter motor, adjusting the carbon pile rheostat (2) to give 11.7 V. When the armature's rotation speed is between 6700 RPM, the maximum current demand should not exceed 110 A. 6. If the starter motor does not work as specified, check whether there are holes in the induction coils, the armature is touching somewhere or the shaft is warped.

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CUIL16TR01397AA

1

Electrical systems - Engine starting system

Engine starter - Disassemble See the exploded view of the starter motor in Engine starting system - Exploded view (55.201). 1. Secure the starter motor in a vise. 2. Disconnect the thick plaited cable from the field coil covering to the solenoid. 3. Remove the three bolts from of the covering and disassemble the solenoid. The piston remains on the command engage lever. 4. Separate the solenoid piston from the command lever by holding the piston and lifting its front end to remove it from the command lever. 5. Remove the two nuts and bolts which fasten the brush cover and plate on the covering. Remove clamp ‘C’ and the armature shaft clearance bushings and remove the covering, leaving the brushes on the manifold. Remove the soft metal washer from the armature from the manifold side. 6. At this stage, inspect the brushes and manifold. Check if the brushes are bonded and, if necessary, clean the brushes and their supports using a cloth dampened with gasoline. Check the brushes for wear. If worn beyond the minimum specified length of 7.00 mm, you must replace the starter motor. NOTE: The brushes cannot be obtained separately as spare parts. They are spot welded in place and should not be replaced throughout the useful life of the starter motor. 7. Remove the housing by separating it from the armature and support on the drive side. 8. Remove the engage lever articulation pin out through the drive side of the covering. 9. Remove the drive assembly and the retaining ring from the inside plate out of the armature shaft, extracting the drive collar and fixing outside the retaining ring with a tube of adequate diameter, and then remove the retaining ring from its groove. 10. Extract the armature and drive unit.

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Electrical systems - Engine starting system

Engine starter - Test - Bench tests Armature 1. Clean the manifold surface and, if necessary, eliminate the burnt points. 2. If you need to grind the manifold, make sure that the diameter of the manifold is not below the minimum specified value of 42.5 mm. 3. After rectification, polish the manifold with a very fine emery cloth and then clean with a cloth dampened with petrol. NOTE: Do not cut the manifold metal when cutting out the isolating grooves. 4. Armature insulation can be checked by connecting an ohmmeter between the manifold segments and the armature shaft. The reading must be infinite, that is, no continuity.

CUIL16TR01398AA

1

CUIL16TR01383AA

2

5. To check for short circuit on the armature, suitable equipment will be needed for performing tests on the armature or, alternatively, this can be checked through replacement. 6. If there is evidence that the armature circumference has been in contact with the polar masses, it is likely that the armature bearings are excessively worn. 7. First check if the polar masses are well tightened and if the armature turns freely on a vise. Done that and if necessary, replace the armature bearings.

Induction coils 1. To test the insulation of the induction coils, connect an ohmmeter between each of the brushes and any part of the case that is clean and paint-free. There should not be any continuity. 2. To test the insulation of the inductor spools, connect an ohmmeter between each of the brushes and the main power supply terminal (thick twisted wire). There should be a 1 MΩ reading. 3. If there is damage to the inductor spools the complete inductor coils and the covering assembly must be replaced.

Bearings 1. Examine the bearings on the brush cover and the covering on the drive side for wear. Assemble the armature shaft and check the clearance by replacing the bearings if the clearance seems excessive. Check the polar masses for signs of friction with the armature, which could also have been caused by worn brushes.

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Electrical systems - Engine starting system

Drive Pinion 1. Check the operation of the roller clutch. The pinion should only turn clockwise. If the pinion is stuck, turn it in both directions, or if the teeth are damaged, assemble a new drive assembly. If the drive pinion teeth are clearly damaged, also check the engine flywheel rack teeth.

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Electrical systems - Engine starting system

Engine starter - Backlash Checking the longitudinal clearance of the armature 1. Secure the starter motor in a vise. Mount a calibration gauge on the flange of the cover on the drive side. Place the gauge point on the end of the armature shaft. 2. Move the armature fully forward and set the gauge to zero. Move the shaft completely backward and record the calibration gauge reading. 3. The reading must not exceed 0.4 mm. If the reading exceeds this value, inspect the armature and the brush cover for wear. Replace the worn components and check the longitudinal clearance again.

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Electrical systems - Engine starting system

Engine starter - Assemble Prior operation: Engine starter - Backlash (55.201).. 1. Perform the starter motor test without load before assembly. Consult the procedures in Engine starter Test (55.201). 2. To install the starter motor, follow the removal procedure in reverse order. Consult the procedures in Engine starter - Disassemble (55.201).

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Electrical systems - Engine starting system

Engine starter - Install Prior operation: Engine starter - Assemble (55.201).. 1. Position the starter motor in the engine block housing. Install the screws (2). 2. Connect the positive cable (1). 3. Install the solenoid guard plate. 4. Disconnect the cable from the negative terminal of the battery .

CUIL16TR01378AA

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1

Index Electrical systems - 55 Engine starting system - 201 Engine starter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Engine starter - Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Engine starter - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Engine starter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Engine starter - Test - Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Engine starter - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Engine starter - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Engine starter - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Engine starting system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Engine starting system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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Electrical systems - 55 Alternator - 301

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Alternator Electrical test - Continuity of the wiring to the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical test - Charging current and controlled voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical test - Drop in voltage and charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical test - Alternator maximum output performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electrical test - Testing the rotor field circuit and voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Electrical systems - Alternator

Alternator - General specification 7630 Alternator Polarity Nominal voltage Maximum rotation Maximum current Controlled regulator voltage Rotor field winding resistance Stator field winding resistance Length of new brushes Minimum brush length Brush spring pressure

8030 Iskra - 65 A Negative with earth 12 V 15000 RPM 65 A 13.6 – 14.4 V 2.9 Ω 0.2 Ω 20.0 mm 5.0 mm 1.3 – 2.7 N

Alternator - Torque Torque 5.5 N·m (4.1 lb ft) 70.0 N·m (51.6 lb ft) 4.0 N·m (3.0 lb ft) 2.7 N·m (2.0 lb ft) 2.7 N·m (2.0 lb ft)

Component Bolts that cross the alternator Pulley retaining nut Redresser fixing bolts Voltage regulator and brush box bolts Terminal nuts

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Electrical systems - Alternator

Alternator - Dynamic description The alternator (1) performs battery charging and battery charging maintenance. It generates current to power the machine's electrical components.

CUIL14TR00212AA

1

When the starter switch/ignition key is switched on, there is a low value current that leaves the batter and passes through the rotor field spool. The circuit is established through the warning light that indicates the charge at alternator terminal 'D+', at the rotor field spool, at the alternator voltage regulator and at the ground. In this phase the warning light turns on and the rotor is partially magnetized. When the engine starts and the partially magnetized rotor starts spinning between the stator spools, a three phase current is generated. A constant amount of the generated current is converted into continuous current by the three field diodes incorporated within the rectifier set. This continuous current returns to complement the current passing through the rotor field spool. The result of this action is a continually increasing magnetic induction of the rotor, associated with a rapid rise in the supply of current and voltage. During the increase in the voltage supplied (available in terminal 'D+') the warning light dims and when the tension at terminal 'D+' equals the voltage on the side of the battery, the warning light goes out. The voltage continues to increase until the pre-set regulated voltage level is reached. Should the belt break, voltage will not be generated in the alternator and a warning light will appear on the control panel indicating a fault in the system.

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Electrical systems - Alternator

Alternator - Identification (1).. Connection to earth (Mass) (2).. Connection of engine speed sensor (Terminal W) (3).. Warning light (Terminal D+) (4).. Out connection (Terminal B+) (5).. Terminal protection sleeve

CUIL17TR00336AA

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1

Electrical systems - Alternator

Alternator - Electrical schema Alternator charge circuit

CUIL17TR00280FA

Reference (A) (B) (C) (1) (2) (3)

Component To starter motor To the starter motor relay Rotation sensor terminal to the instrument group (panel) Starter motor solenoid Battery Rotor field spool

1

Reference (4) (5)

Component Voltage Regulator Alternator structure

(6)

Stator output spool

(7) (8) (9)

Redresser assembly Charge indicator lamp Ignition switch/key ignition.

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Electrical systems - Alternator

Alternator - Exploded view

CUIL17TR00281FA

Reference (1) (2) (3) (4) (5)

Component Redresser assembly Pulley retaining nut Pulley Cooling fan Front housing

1

Reference (6) (7) (8) (9)

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Component Stator Rotor Regulator and brush box assembly Rear housing

Electrical systems - Alternator

Alternator - Electrical test - Continuity of the wiring to the alternator 1. Disconnect the negative battery cable. NOTE: Do not disconnect the positive battery cable. 2. Disconnect the cables from terminal B+ and terminal D+ of the alternator. 3. Connect the negative battery cable. 4. Turn the ignition key to the on position but without starting the engine. 5. Connect the voltmeter (1) between each terminal and the earth (ground). There should be voltage on the battery. If there is not, there is a continuity failure in the external circuit cables which must be located and repaired. 6. Connect the terminal D+ wire to earth (ground). The warning light should come on. NOTE: If the warning light does not come on when you reconnect the cable to the alternator, there is a fault in the regulator or alternator rotor circuits. Check that terminal D+ is clean. Then test the alternator components as described in Alternator - Electrical test - Testing the rotor field circuit and voltage regulator (55.301). 7. Disconnect the negative (-) battery cable from the battery. 8. Connect the cables of terminal B+ (2) and terminal D+ (3) of the alternator. 9. Connect the negative (-) battery cable.

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CUIL16TR01398AA

1

Electrical systems - Alternator

Alternator - Electrical test - Charging current and controlled voltage 1. Check that the tractor electrical components are switched off and that the ignition key is in the off position. 2. Disconnect the cable from the negative terminal of the battery. Disconnect the terminal B+ (4) from the alternator. 3. Connect an ammeter (1) between the removed cable (3) and terminal B+ (4). 4. Connect a voltmeter (2) between the terminal B+ (4) and the earth (ground). 5. Connect the cable to the negative terminal of the battery. Run the engine between 2000 RPM. Take readings from the ammeter and from the voltmeter. • The voltmeter should indicate a value above that of the battery voltage and, when the ammeter reading is below 10 A the voltmeter reading should stabilize between 13.6 – 14.4 V. • If the voltmeter reading exceeds 14.4 V, you must replace the alternator regulator. • If the voltmeter reading is below 13.6 V this indicates that there is a damaged alternator component or a fault due to high resistance on the recharge system external connections. • If the ammeter indicates 0 A, this means that there is a defective alternator component. Shut down the engine and perform the "alternator component tests," as indicated in Alternator - Electrical test - Testing the rotor field circuit and voltage regulator (55.301).

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CUIL16TR01402AA

1

Electrical systems - Alternator

Alternator - Electrical test - Drop in voltage and charging circuit Drop in voltage on the insulated side 1. Check that the ignition key is in the off position. 2. Disconnect the negative cable from the battery. Disconnect cable B+ (1) from the alternator. 3. Connect a millivolt meter (4) between the positive battery terminal and cable B+ (5). (connect the cable to the positive side). 4. Connect an ammeter (2) between the alternator terminal B+ and the cable B+. Connect the cable to the negative side. 5. Connect the cable to the negative terminal of the battery. CUIL16TR01407AA

1

CUIL16TR01407AA

2

6. Connect a potentiometer (3) with the cursor on the minimum current passage (maximum resistance) between the battery terminals. 7. Start the engine and adjust its rotation to 2000 RPM. 8. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 65 A. 9. Check the voltmeter reading. value: 400 mV.

Maximum expected

• If the reading is over 400 mV, there is a high resistance defect in the external circuit. • If the expected alternator value cannot be reached and the millivoltmeter reading is below 400 mV, this means there is a defective alternator component. Perform the alternator component tests according to the procedures described in Alternator - Electrical test - Testing the rotor field circuit and voltage regulator (55.301). 10. Shut down the engine.

Drop in voltage on the ground side 1. Check that the ignition key is in the off position. 2. The circuit is the same circuit used in the previous test. However, now the millivoltmeter (4) is connected between the negative terminal and the housing of the alternator. NOTE: Check whether the potentiometer (3) is regulated for the passage of minimum current (maximum resistance). 3. Start the engine and adjust its rotation to 2000 RPM. 4. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 65 A.

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Electrical systems - Alternator

5. Check the voltmeter reading. value: 200 mV

Maximum expected

• If the reading is over 200 mV, there is a high resistance defect in the external circuit. • If the expected alternator value cannot be reached and the millivoltmeter reading is below 200 mV, this means there is a defective alternator component. Perform the alternator component tests according to the procedures described in Alternator - Electrical test - Testing the rotor field circuit and voltage regulator (55.301). 6. Shut down the engine.

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Electrical systems - Alternator

Alternator - Electrical test - Alternator maximum output performance 1. Check that the ignition key is in the off position. 2. Disconnect the cable from the negative terminal of the battery. Disconnect the cable B+ (5) from the alternator. 3. Connect an ammeter (2) between the alternator terminal B+ (1) and the cable B+ to the negative side. 4. Connect a voltmeter (4) between alternator terminal B+ and the earth (ground). 5. Connect the cable to the negative terminal of the battery. CUIL16TR01407AA

6. Start the engine and adjust its rotation to 2000 RPM. 7. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 65 A. 8. Check the voltmeter reading. The minimum expected value is 13.6 V. • If the reading is under 13.6 V, this means that there is a defective alternator component. Perform the alternator component tests according to the procedures described in Alternator - Electrical test Testing the rotor field circuit and voltage regulator (55.301).

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1

Electrical systems - Alternator

Alternator - Remove 1. Disconnect the battery negative (-) cable (1).

CUIL16TR00171AA

1

CUIL14TR00212AA

2

CUIL14TR00213AA

3

2. Disconnect all the electrical connections (2) and (3) located behind the alternator. NOTE: Identify the components to facilitate re-assembly. 3. Remove bolt (1).

4. Loosen the bolt (3). Position the alternator to the side of the engine to facilitate removal of the belt (2). 5. Remove belt (2). 6. Remove the through bolt (3). 7. Remove the alternator (1).

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Electrical systems - Alternator

Alternator - Electrical test - Testing the rotor field circuit and voltage regulator 1. Remove all the cables from the alternator. 2. Connect a 12 V battery and a 2.2 W (2) test lamp in series between the terminal D+ (1) and the alternator housing (connect to the negative side of the housing). 3. The lamp should turn ON. If the light does not illuminate, this means there is a defect in the rotor circuit. Check the brushes, the slide rings and the rotor field spool continuity. 4. If the test shows that these parts are in satisfactory condition, the problem could be in the voltage regulator. CUIL16TR01403AA

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1

Electrical systems - Alternator

Alternator - Install 1. Make sure that the negative cable of the battery is disconnected. 2. Position the alternator (1) in its housing and install the through bolt (3). 3. Move the alternator to the side of the engine to enable installation of the belt on the alternator pulley. 4. Install the belt (2) on the pulleys of the alternator, of the crankshaft and of the water pump.

CUIL14TR00213AA

1

CUIL14TR00212AA

2

5. Position the bolt (1) in its housing. NOTE: If the machine has air conditioning, remove the air conditioning belt to enable installation of the alternator belt. 6. Install all the electrical connections (2) and (3) located behind the alternator. 7. Adjust the tension of the alternator belt. See the procedures described in Alternator - Tension adjust (55.301).

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Electrical systems - Alternator

Alternator - Tension adjust 1. Check whether the belt has a slack between 10 – 11 mm with a load of 64.22 – 76.45 kg (141.5 – 168.5 lb) measured between the pulleys. If the values are not within the specifications, adjust the belt as follows: 2. Loosen the lower bolt (1).

CUIL14TR00213AA

1

CUIL14TR00212AA

2

3. Loosen the upper bolt (1) of the tensioner. Move the alternator to obtain the correct voltage as specified. 4. Retighten the upper bolt (1). Then retighten the lower bolt (1). NOTE: Replace the belt when it appears cut or it requires regular adjustments.

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Index Electrical systems - 55 Alternator - 301 Alternator - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Alternator - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Alternator - Electrical test - Alternator maximum output performance . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Alternator - Electrical test - Charging current and controlled voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Alternator - Electrical test - Continuity of the wiring to the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Alternator - Electrical test - Drop in voltage and charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Alternator - Electrical test - Testing the rotor field circuit and voltage regulator . . . . . . . . . . . . . . . . . .

14

Alternator - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Alternator - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Alternator - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Alternator - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Electrical systems - 55 Battery - 302

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Electrical systems - 55 Battery - 302

TECHNICAL DATA Battery General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Battery Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Battery Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Electrical systems - Battery

Battery - General specification 7630 Capacity Intensity on starting (cold engine) Voltage Elements Mass Terminal

8030 100 A·h 750 A 12 V 6 Negative

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Electrical systems - Battery

Battery - Dynamic description Description and Operation All of the tractor models incorporate a 12 V battery with a grounded negative pole. NOTE: 'Without Maintenance' means that under normal conditions, the battery does not lose water from the electrolyte. There could be water loss under certain conditions, such as during a prolonged charge at over 14.4 volts, giving rise to the production of gasses when full charge is reached. 14.4 V This could be caused by a defective charging system or by the rapid charge equipment. In all models, the battery is located on the right-hand side of the machine, under the toolbox. The batteries have four main functions: • Provide a source of electrical current for starting, lights and instruments. • Help to maintain control of voltage in the electrical installation. • Supply electrical current when the demand exceeds the alternator capacity. The battery is manufactured in such a way that each element contains positive and negative plates arranged alternately one next to the other. Each positive plate is separated from the negative plate by a porous and non-conductor separator. If a positive plate makes contact with a negative plate inside the element, the element will short-circuit and be damaged beyond repair. All positive plates are welded to a bar, forming a positive terminal and the negative plates are welded to another similar bar that forms the negative terminal. Each positive plate is constituted of a lead grid with lead peroxide stuck between the grid openings. The negative plates are constituted of a grid with spongy lead stuck into the grid openings. The plates are immersed in a solution of diluted sulphuric acid liquid electrolyte.

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Electrical systems - Battery

Battery - Remove 1. Lift the engine hood. 2. Disconnect the negative (ground) battery cable. (1) 3. Remove the manual nuts (butterfly) from the battery fixation plate, and remove the plate. 4. Disconnect the positive (+) battery cable. 5. Remove the battery.

CUIL16TR00171AA

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1

Electrical systems - Battery

Battery - Install Install the battery in accordance with the removal procedures, but in the reverse order. Take into account the following: 1. Check that the battery is clean and dry and that all of the stoppers are in place. Lubricate the terminals using Vaseline. Do not use conventional grease as this may cause electrolytic corrosion. 2. Check that the battery installation location is clean and free of stones or objects which could damage it. 3. Position the battery in its housing. 4. Connect the cable of the positive terminal (1). 5. Connect the cable of the negative terminal (2). 6. Install the bolts of the protective cover.

CUIL16TR00171AA

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1

Electrical systems - Battery

Battery - Charging Dry Charged Batteries 1. Remove the battery element stoppers. 2. Fill each element to the recommended level with the electrolyte at a density of 1.260. Dry charged batteries must be prepared for use as follows: NOTE: The electrolyte should be diluted in sulfuric acid, preferably at a temperature between 21 – 31 °C. 3. After filling the elements, let the battery rest for 15 minutes. When this time has elapsed, check the electrolyte level again, and if necessary, top it up. 4. Charge the battery for 4 h at 5 – 8 A and check to see if the gases escape freely from the elements. 5. Place the battery element stoppers on the battery.

Battery Charging Before charging the battery: 1. Thoroughly clean the battery box and the element covers with ammonia or hot water and clean the terminals. 2. Check the electrolyte level at each element, and if it is below the plates, add distilled water to until the level covers the plates.

Normal Charge 1. With a slow charger, apply a charge intensity of 3 – 6 A for as long as necessary for the battery to be fully charged. This may take more than 36 h if the battery is very flat. A seriously sulphated battery may not take charge. 2. When the battery is fully charged the gases leave the elements freely and the relative density remains constant. Switch off the charger after having checked three consecutive times, every hour, that the density checked on the densimeter no longer increases. 3. When a battery is charged by the rapid charge method, the charger manufacturer's instructions must be followed very carefully. Rapid charging increases the temperature of the electrolyte, and if the charger is not fitted with an automatic timer or temperature regulator, the temperature of the electrolyte could rise to above 50 °C, leading to possible violent gasification in the battery and subsequent damage. 4. Check the electrolyte level in each element again and if necessary, top up the level with distilled water. NOTE: When a battery is being charged it produces explosive gases. Do not smoke or use naked flames when checking the electrolyte level and make sure the charger is switched off before turning any component on and off to avoid sparks and the possibility of explosion.

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Electrical systems - Battery

Recharging very flat batteries The method recommended for recharging a Pb-Ca battery without maintenance is to use a constant voltage charger. Greatly depleted batteries require a charging period from 48 h to 16 V with a current limitation ( 47.5 A to 70 A·h). This system is automatically regulated: high current is applied in the beginning (when the battery voltage is low) and when the battery attains full charge (and its voltage is high) the current absorbed is progressively lower. When only constant current chargers are available, the current levels and times indicated in the table below are recommended. The values indicated in the table are applicable to very flat batteries. If the battery is only 50% charged, the indicated times must be reduced by half (slow charge programs). For other battery charge conditions, reduce the charging time proportionally. Whenever possible use the slower charge program to increase the duration of the battery. Where violent gasification or expulsion of the electrolyte is observed, the battery will be hot ( 50 °C or more). Temporarily reduce or suspend charging to prevent damage to the battery. Type of Battery Slow Charging Programs Quick Recharge Program (only in emergency)

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100 A·h (750 CCA) 25 h at 5 A 12.5 h at 10 A 7 h @ 18 A

Electrical systems - Battery

Battery - Preliminary test Tests Before starting battery tests, check the battery to make sure that the stoppers are not dirty, corroded, open and that the box is not damaged. Equipment required for tests: • Densimeter • Appliance for checking batteries (Checking high discharge) • Thermometer • Battery charger.

Density: This test determines the battery charge status. 1. With the buoy in the vertical position take the reading. 2. Adjust the densimeter readouts for the electrolyte temperature variations subtracting 4 points (density of 0.004) for every 5.5 °C below the temperature value to which the densimeter is calibrated and adding 4 points (density of 0.004) for every 5.5 °C above this value. The following examples are calculated for a densimeter calibrated to 30 °C. Example 1: Temperature below Electrolyte temperature Reading on densimeter Subtract 11.0 x 0.004 5.5 =1.262 Corrected density Example 2: Temperature over Electrolyte temperature Densimeter readout Add 10.0 x 0.004 5.5 =1.227 Corrected density

30 °C 19 °C 1.270 0.008

30 °C 40 °C 1.220 0.007

3. Use the table below to determine the battery charge status. Charge Status

Corrected density @ 15 °C

Corrected density @ 25 °C

100% 75% 50% 25% 0%

1.295 1.253 1.217 1.177 1.137

1.287 1.246 1.210 1.170 1.130

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Average battery voltage (Volts) 12.76 V 12.52 V 12.30 V 12.06 V 11.84 V

Electrical systems - Battery

NOTE: The variation in density between each of the elements must not be higher than 0.025. 4. If the density readout is 1.280 or higher, the battery is fully charged and in a good state. 5. If the corrected density is below 1.280, charge the battery and inspect the charging system to determine the reasons for the low battery charge. NOTE: If distilled water has recently been added, the battery should be recharged for a short period, because under these conditions, correct readings will not be obtained on the densimeter without recharge. If charging has been done with the battery always at rest, the electrolyte accumulated in the bottom of each element becomes denser. The battery must therefore be shaken during charge to mix the electrolyte and thus, improve not only the charging rate but also obtain more exact readings on the densimeter at the height of the battery tests.

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Electrical systems - Battery

Battery - Electrical test Performance tests Performance tests determine whether the battery had adequate capacity for starting the engine. The voltage reading obtained is used to determine the state of the battery. Before the tests, check whether the electrolyte level is correct and if the circuit voltage is 12.5 V or higher. The tests can be performed with the battery installed in the tractor. 1. Put the current control switch of the battery verifier appliance (high discharge verifier) in the off position and the voltage at a value equal to or slightly higher than the nominal voltage of the battery. Connect the positive appliance wires to the positive terminal on the battery and the negative wires to the negative battery terminal. 2. Turn the current control button up to the point at which the readout value on the amp meter is half of the value of the nominal battery CCA intensity, and at this point, measure the voltage. • If the reading is equal to or above 9.6 V volts after 15 s seconds the battery has an acceptable output capacity and will accept a normal charge well. However, if the measured voltage is lower than 9.6 V, the battery is not in operational condition and its charge must be tested as indicated below. NOTE: Do not leave discharge on the battery for more than 15 s.

Charge tests These tests were prepared only for batteries that fail the previous capacity tests. 1. Connect the battery verification appliance (high discharge verification) to the positive cables of the appliance on the positive battery terminal and the negative tables on the negative terminal. 2. Connect the charger positive and negative cables respectively to the positive and negative battery terminals. 3. Turn the charger timer to beyond the " 3 min" charge indication and then back again to the " 3 min" mark. 4. Set the charge rate as close as possible to 40 A. 5. After 3 min of quick charge, take the voltage reading on the voltmeter. If the total voltage is above 15.5 V volts the battery is in a poor state, probably sulphated or worn, and must be replaced.

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Electrical systems - Battery

NOTE: A slightly sulphated battery can be recovered with a multiple type battery charger with a maximum voltage in interrupted circuit limited to 50 V. Due to the high resistance of the sulphated battery, it is necessary to have a very high voltage in the beginning to overcome the sulphation resistance, and at first there may be no signs of acceptance of the charge. However, at the end of a few minutes of inactivity, a slight charge may be observed, followed by a rapid increase in charge. The charge must not be higher than 14 A and the battery temperature must not exceed 50 °C. When the intensity has been stably re-established regulate the voltage again until the charge rate is maintained at 5 A. Continue with this charge rate until the electrolyte density ceases to increase and remains at the approximate value of 1275-1278 at 20 °C which could last for up to 48 h of charging. Leave the battery at rest for 24 h and then perform the capacity tests previously described. • If the voltage is below 15.5 V, measure the density in each element and charge the battery again, according to the following scale: Density 1150 or less 1151 to 1175 1176 to 1200 1201 to 1225

Rapid charge at: 60 min 45 min 30 min ( 15 min slow charge only)

NOTE: When problems with the battery are observed, one must first check the fan belt tightening tension and the battery charging system.

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Electrical systems - Battery

Battery - Test Maintenance and battery tests Density The electrolyte relative density of the battery indicates the charge status. When the battery is fully charged the electrolyte density is a minimum of 1280 at 25 °C. Alternatively, it is possible to measure the approximate state of battery charge using a digital voltmeter with good precision ( ±0.10 V): Below 10.5 V, the battery is out of service* Below 11.8 V, the battery is not charged Below 12.3 V, the battery is at half charge Above 12.6 V, the battery is fully charged *Consult the notes under the title "Tests" as regard the possibility of recovering a slightly sulphitated battery. The battery voltage must be taken with the battery disconnected from the installation and: 1. four hours following disconnection from the installation and remain at rest during this time. 2. If the vehicle is left in operation, or the battery has been charged recently, switch on the headlamps for two minutes. When the battery goes flat, the sulphuric acid in the electrolyte combines chemically with the plates, which lowers the solution relative density. A battery densitometer determines the density of the electrolyte in each element and the amount of sulphuric acid not used in the solution is the measure of the degree of charge in this element. The lower the ambient temperature in which the battery will operate, the greater the need to keep the fully charged status. For example, a battery with a low density of 1225 at 27 °C could make a starter motor work at a high ambient temperature, but not at low temperatures, because they diminish its efficiency. Table 1 shows the effect of temperature on the efficiency of a normal battery. Temperature (°C) 25.0 °C -4.5 °C -24.0 °C -27.5 °C -31.0 °C -34.5 °C -37.5 °C

Efficiency of a charged battery 100% 82% 64% 58% 50% 40% 33%

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Electrical systems - Battery

The maximum duration of the battery can be obtained when the battery is periodically inspected and the correct maintenance service effected. It is important for the production capacity not to be exceeded by operating the battery at constant and excessive overloads, and that the charging requirements are observed. NOTE: The batteries contain sulphuric acid and during charging they produce a highly explosive mixture of hydrogen and oxygen gasses. • Never use any equipment that produces flames or sparks to check the electrolyte level. • Do not remove the battery stoppers without hand and eye protection. When servicing the battery, follow these procedures: 1. Keep the electrolyte at the recommended level of 17 mm above the plates. 2. Use only distilled or mineral free water, do not overfill and never use tap water or rain water or from any other source. 3. Always keep the battery charged to at least 75%, otherwise the plates get sulphated and there will be a loss of performance with possible damage due to freezing at low temperatures. 4. Avoid overcharging the battery so as not to cause heat inside it, which in turn will damage the plate grids and cause loss of water. 5. During quick charge make sure the battery temperature does not exceed 50 °C.

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Index Electrical systems - 55 Battery - 302 Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Battery - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Battery - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Battery - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Battery - Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Battery - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SERVICE MANUAL Platform, cab, bodywork, and decals 7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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90

Contents Platform, cab, bodywork, and decals - 90

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

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90

Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

7630 8x2, Tier 3, 7630 16x4, Tier 3, 7630 12x3, Tier 3, 7630 24x6, Tier 3, 8030 8x2, Tier 3, 8030 16x4, Tier 3, 8030 12x3, Tier 3, 8030 24x6, Tier 3

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Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Hood Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove WARNING Rotating parts! Shut off the engine before opening the engine hood. Failure to comply could result in death or serious injury. W1059A

DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Use a strap to lift the hood. 2. Disconnect the electrical connections from the headlight. 3. Remove the gas cylinders (1) and (2) for raising the hood. 4. Remove the clamps that secure the hood to the frame. Remove the linkage pins. 5. Remove the hood.

CUIL13TR00350AA

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1

Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN

SCHEMAS INDEX Reference Electrical components - Fuse description Electrical components - Lamp description Electrical components - Motor description Electrical components - Relay description Electrical components - Sensor description Electrical components - Solenoid description Electrical components - Speaker description Electrical components - Switch description Electrical components - Voltage source description Wire connectors - Component diagram 00 Wire connectors - Component diagram 01 Wire connectors - Component diagram 02 Wire connectors - Component diagram 03 Wire connectors - Component diagram 04 Wire connectors - Component diagram 05 Wire connectors - Component diagram 06 Wire connectors - Component diagram 07 Wire connectors - Component diagram 08 Wire connectors - Component diagram 100 Wiring harnesses - Electrical schematic sheet 05 SH05 - FUSES Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORIES / SAFETY SWITCHES Wiring harnesses - Electrical schematic sheet 04 SH04 - INSTRUMENT CLUSTER Wiring harnesses - Electrical schematic sheet 02 SH02 - GRID HEATER Wiring harnesses - Electrical schematic sheet 03 SH03 - ENGINE Wiring harnesses - Electrical schematic sheet 06 SH06 - RELAYS Wiring harnesses - Electrical schematic sheet 07 SH07 - SWITCHES Wiring harnesses - Electrical schematic sheet 08 SH08 - LIGHTS Wiring harnesses - Electrical schematic sheet 10 SH10 - GROUND

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PAGE 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1 55.1

/ / / / / / / / / / / / / / / / / / / / /

72 69 76 75 68 79 74 77 73 23 26 32 35 40 46 52 61 65 67 10 18

55.1 / 8 55.1 / 4 55.1 / 6 55.1 / 12 55.1 / 14 55.1 / 16 55.1 / 20

SPECIAL TOOL INDEX Genuine 380000541 [Axle Pivot Pin Adaptor (M12 x 1.25) ] NHT-0002 [BASEPLATES FOR EXTRACTOR] NHT-0009 [BEARING EXTRACT ATTACHMENT ] NHT-0011 NHC-00 [Special Tool] FT8503-9 [9 / 16 UNF X 1 / 2 BSP Adapter] NHT-0009 [BEARING EXTRACT ATTACHMENT ] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000249 [Universal Pinion Installation Tool Kit] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000253 [FRONT DIFFERENTIAL BEARING PRELOAD ADJUSTMENT TOOL] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000252 [Front Axle Ring Nut Wrench] NHT-0412 [BEARING FITTER] 75300932 [HEATER FOR BEARINGS] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000252 [Front Axle Ring Nut Wrench]

Reference

PAGE

Mechanical transmission - Special tools

21.1 / 6

Mechanical transmission - Special tools

21.1 / 6

Mechanical transmission - Special tools

21.1 / 6

Mechanical transmission - Special tools

21.1 / 6

Mechanical transmission - Pressure test

21.1 / 31

Four-Wheel Drive

23.2 / 10

Powered front axle - Special tools

25.1 / 4

Powered front axle - Special tools

25.1 / 4

Powered front axle - Disassemble

25.1 / 12

Powered front axle - Disassemble

25.1 / 13

Powered front axle - Disassemble

25.1 / 13

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Front bevel gear set and differential - Remove

25.2 / 11

Front bevel gear set and differential - Remove

25.2 / 11

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Genuine 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000249 [Universal Pinion Installation Tool Kit] 380000248 [Bevel Pinion Bearings Adjusting Guage] NHT-0412 [BEARING FITTER] 380000249 [Universal Pinion Installation Tool Kit] 380000248 [Bevel Pinion Bearings Adjusting Guage] NHT-0412 [BEARING FITTER] 380000249 [Universal Pinion Installation Tool Kit] 380000249 [Universal Pinion Installation Tool Kit] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 75300932 [HEATER FOR BEARINGS] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000249 [Universal Pinion Installation Tool Kit] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000252 [Front Axle Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000269 [Wheel Hub Bearing Ring Socket] 380000469 [Hub Bearing Ring Nut Socket] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000265 [Swivel Housing Pin Pivot Puller]

Reference

PAGE

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion depth

25.2 / 14

Front bevel gear set and differential - Adjust - Pinion shim

25.2 / 16

Front bevel gear set and differential - Adjust - Pinion shim

25.2 / 16

Front bevel gear set and differential - Adjust - Pinion shim

25.2 / 16

Front bevel gear set and differential - Adjust - Pinion shim

25.2 / 16

Front bevel gear set and differential - Adjust - Pinion shim

25.2 / 16

Front bevel gear set and differential - Adjust - Pinion shim

25.2 / 17

Front bevel gear set and differential - Preload

25.2 / 18

Front bevel gear set and differential - Preload

25.2 / 18

Front bevel gear set and differential - Preload

25.2 / 18

Front bevel gear set and differential - Preload

25.2 / 19

Front bevel gear set and differential - Preload

25.2 / 19

Front bevel gear set and differential - Install

25.2 / 20

Front bevel gear set and differential - Install

25.2 / 20

Front bevel gear set and differential - Install

25.2 / 20

Differential - Install

25.2 / 23

Differential - Install

25.2 / 24

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

47793462 14/03/2017

Genuine 380001143 [Front Axle Shaft to Swivel Housing Mounting Guide (Class 3)] 380000235 [Swivel Housing Torque Check Adapter] 380003016 [Retaining Installer of the Front Hub] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000284 [Wheel Hub Seal Installer] 380000265 [Swivel Housing Pin Pivot Puller] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000235 [Swivel Housing Torque Check Adapter] 380001143 [Front Axle Shaft to Swivel Housing Mounting Guide (Class 3)] 380000235 [Swivel Housing Torque Check Adapter] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000469 [Hub Bearing Ring Nut Socket] 380003114 [Small tractor Splitting Stand] 380003114 [Small tractor Splitting Stand] 380000503 [Bevel Pinion Slotted Retainer (Class 3 Axles)] 380000549 [Slide Hammer] NHT-0010 [INTERNAL EXTRACTOR FOR BEARING CAP] 380000991 [Bearings Pre-Load Measurement] 380000503 [Bevel Pinion Slotted Retainer (Class 3 Axles)] 380000503 [Bevel Pinion Slotted Retainer (Class 3 Axles)] 380000549 [Slide Hammer] NHT-0009 [BEARING EXTRACT ATTACHMENT ] NHT-0010 [INTERNAL EXTRACTOR FOR BEARING CAP] 380000549 [Slide Hammer] NHT-0007 [BEARING CAP PULLER] 380000549 [Slide Hammer] NHT-0409 [Special Tool] NHT-0001 [Universal Extractor]

Reference

PAGE

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Steering knuckle and king pin - Replace

25.3 / 8

Steering knuckle and king pin - Replace

25.3 / 8

Steering knuckle and king pin - Adjust

25.3 / 9

Steering knuckle and king pin - Adjust

25.3 / 9

Steering knuckle and king pin - Adjust

25.3 / 9

Wheel hub - Disassemble

25.3 / 13

Wheel hub - Disassemble

25.3 / 14

Powered rear axle - Special tools

27.1 / 3

Powered rear axle - Remove

27.1 / 9

Rear bevel gear set and differential - Special tools

27.2 / 3

Rear bevel gear set and differential - Special tools Rear bevel gear set and differential - Special tools

27.2 / 3 27.2 / 3

Rear bevel gear set and differential - Special tools

27.2 / 3

Bevel gear - Remove

27.2 / 8

Bevel gear - Inspect

27.2 / 10

Bevel gear - Inspect Differential - Disassemble

27.2 / 10 27.2 / 13

Differential - Preload

27.2 / 17

Differential - Preload Planetary and final drives - Special tools

27.2 / 17 27.3 / 3

Planetary and final drives - Special tools Planetary and final drives - Special tools Planetary and final drives - Special tools

27.3 / 3 27.3 / 3 27.3 / 3

47793462 14/03/2017

Genuine NHT-0002 [BASEPLATES FOR EXTRACTOR] NHT-0009 [BEARING EXTRACT ATTACHMENT ] NHT-0001 [Universal Extractor] NHT-0002 [BASEPLATES FOR EXTRACTOR] NHT-0007 NHC-00 [Special Tool] NHT-0001 [Universal Extractor] NHT-0009 [BEARING EXTRACT ATTACHMENT ] 380000549 [Slide Hammer] NHT-0010 [INTERNAL EXTRACTOR FOR BEARING CAP] NHT-0712 [PTO SEAL INSTALLER] 380001740 [Flowmeter Fitting Kit] 380000554 [Remote Valve Coupling] 380001740 [Flowmeter Fitting Kit] NHT-0506 [Special Tool] NHT-0507 [ADAPTERS TO PLACE AND REMOVE BUSHINGS FROM HYDRAULIC LIFT CONTROLLER VALVE] NHT-0506 [Special Tool] NHT-0507 [ADAPTERS TO PLACE AND REMOVE BUSHINGS FROM HYDRAULIC LIFT CONTROLLER VALVE] FT8527 [Control Linkage Rod And Roller Setting Gauge] 380000618 [Steering Adapter Fitting] 380000281 [Rotoglyd Steering Seal Installer] 380000836 [Variable Power Steering Seal Installation Tool (Danfoss)] 380000307 [Power Steering Rotor Locker Lever] 380000281 [Rotoglyd Steering Seal Installer] 380000281 [Rotoglyd Steering Seal Installer] 380000307 [Power Steering Rotor Locker Lever] 380000307 [Power Steering Rotor Locker Lever]

Reference

27.3 / 3

Planetary and final drives - Special tools

27.3 / 3

Planetary final drive - Inspect

27.3 / 6

Planetary final drive - Inspect

27.3 / 6

Final drive housing - Disassemble

27.3 / 10

Final drive housing - Disassemble

27.3 / 10

Final drive housing - Inspect

27.3 / 11

Final drive housing - Inspect Final drive housing - Inspect

27.3 / 11 27.3 / 11

Power Take-Off

31.2 / 23

Remote control valves - Special tools

35.4 / 3

Remote control valves - Special tools

35.4 / 3

Remote control valves - Pressure setting

35.4 / 28

Three-point hitch cylinder - Inspect Three-point hitch cylinder - Inspect

35.5 / 7 35.5 / 7

Three-point hitch cylinder - Inspect Three-point hitch cylinder - Inspect

35.5 / 7 35.5 / 7

Rear three-point hitch - Adjust

37.1 / 22

Hydraulic control components - Special tools

41.2 / 4

Hydraulic control components - Special tools

41.2 / 4

Hydraulic control components - Special tools

41.2 / 4

Hydraulic control components - Special tools

41.2 / 4

Power steering control valve - Assemble

41.2 / 18

Power steering control valve - Assemble

41.2 / 19

Power steering control valve - Assemble

41.2 / 20

Power steering control valve - Assemble

41.2 / 21

OEM 380200170 [Universal Cabe]

PAGE

Planetary and final drives - Special tools

Reference Power Take-Off

47793462 14/03/2017

PAGE 31.2 / 23

Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

PRINTED IN BRASIL © 2017 CNH Industrial Latin America LTDA All rights reserved. No part of the text or illustrations of this publication may be reproduced.

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

47793462 14/03/2017 EN