Service Manual: General [PDF]

Zitiervorschau

205, 255, 305 355, 365, 405 455, 465, 555 565, 665, 865 600, 700, 800 900, 415M, A75, A85, A95 Service Manual

10

General

20

Engine

30

Electrical system

40

Power transmission

50

Brakes

60

Front axle and steering system

70

Frame and wheels

80

Cab and shields

90

Hydraulics

Tractors

Valtra Inc. FIN---44200 Suolahti, FINLAND Phone +358 2045501 Telefax +358 204550387 www.valtra.com

100

Tools

Order no 39 200 212 ENGLISH Copyright E 2006 by Valtra Inc.

10. General

11. Layout

12. Maintenance

1

2

To the reader The Service Manual for the Valtra ---Valmet 205---900 tractors is intended to be a practical reference source to be used in workshop. The repair instructions in the manual are based on methods which have been worked out in practice during normal workshop conditions and which are based on the use of special tools from the manufacturer when stated in the instructions. The manual also contains descriptions of the design and function of the components. Detailed maintenance instructions can be found in Operator’s Manual. The Service Manual will be continually updated with new revised pages which should be inserted in the manual. Alterations and additions will first appear as service bulletins. Only genuine Valmet spare parts should be used to ensure the best possible function of the machine. Certain operations should be carried out with the aid of special tools designed by Valmet. Valtra Inc. Tractor Service

Note! This Manual also includes tractors 600, 700, 800 and 900 as follows: --- The build ---up of brakes, cab (not roof), front axles and hydraulic power lifts on 600 ---900 tractors is the same as on 865 ---tractor. If no separate instructions are given, the instructions for 865 tractor are good for 600 ---900 tractors. Transmission on 600 ---900 tractors is the same as on 865, except that 600 ---900 tractors have a modified low gear and also an alternative Overdrive is available. These new components require some minor changes in the main gearbox and for these reasons 600 ---900 tractors have transmission 270 (865 has transmission 250). --- Electric system on 600 ---900 has been shown in section 31. --- Engine differences are described in sections 21, 22 and 23. 600 and 700 tractors have a Bosch in ---line fuel injection pump and 800 ---900 a Stanadyne rotary distribution pump.

3

4

1. 9. 2001

10. General

Model

1.4.2006

Code

205-- 900

110

The following supplements have been published for the Valmet 205---900 Service Manual:

Service Manual

Supplements

Ordering number

Date

Content

39 200 211

04/1986

First edition

39 251 211 1.7.1989

---------

technical modifications model 455 new hydraulic power lift (610312---) fitting instructions for optional equipment

39 251 212 10.1.1992

-----------

technical modifications models 205, 355, 555 and 415M Autocontrol power lift Agrodata performance monitor fitting instructions for optional equipment

39 251 213 1.9.1992

-----------

technical modifications models 565 and 665 20---series engines Sige front axle Danfoss steering valve

39 251 214 15.4.1994

-----------

technical modifications models 255 and 465 2---speed PTO unit hydraulic system with priority valve fitting instructions for optional equipment

39 251 215 15.9.1995

-----------

technical modifications PTO shaft brake front PTO unit front lift fitting instructions for optional equipment

39 251 216 31.1.1996

--- only for 665---4MOD models

39 251 217 1.5.1996

--- model 865 --- Kontak valves for auxiliary hydraulics --- technical modifications

39 251 218 1.3.1997

---------

AD ---instrument Control Stop AC power lift on 865 technical modifications

39 251 219 1.1.1998

---------

tractors 600, 700, 800, 900 modified low gear overdrive technical modifications

39 259 211 1.6.1998

---------

air conditioning HiShift technical modifications latest fitting instructions for optional equipment

39 259 212 15.4.1999

-------------

ACB power lift new front PTO new E ---engines for 700 and 800 new control valve of ACB power lift pressure ait brakes for trailer technical modifications

39 259 213 1.9.2001

---------------

E ---engine on 600 and 900 tractor new coolant pump on 600---900 expansion tank for engine coolant Infoline and Agroline instruments PTO HiShift updated fitting instructions for optionl equipment technical modifications

39 259 214 10.10.2003

--- 12+12R gearbox --- shuttle --- technical modifications

39 259 215 1.4.2004

--- Bosch VE rotary pump --- wiring diagrams (M21101---) --- technical modifications

5

Page

0

Model

10. General

Service Manual

1.4.2006

Ordering number

Date

Content

39 200 212

04/2006

Second edition

6

205-- 900

Code

110

Page

0

Model

10. General

1. 12. 1986

Code

205-- 865

110

Page

1

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

10. General 20. Engine, fuel and cooling systems 30. Electrical system 40. Power transmission a.s.o.

The number designation for each group is given in the top left box of the respective pages (and the first figure in the code designation).

Code 410

Page 1

50 60 70 80 90 100

2. Division into components or sub ---groups Each group is further divided into components or sub ---groups. The number and the name of each component is given in the top left box on each page (and comprise the two first figures in the code designation). Example. 41. Clutch 42. Gearbox 44. Low gear 45.Final drives etc.

7

Model

10. General

Code

205-- 865

1. 12. 1986

110

Page

2

3. Tractor model At the top of each page it is indicated for which tractor the page is valid.

4. Code designation Three ---digit code designations are used to separate the different document groups for the respective components. The same code is also used in the Time list as a reference to the text in this manual. The code designation numbers appear in the box at the top of the page and also in the headings. Example:

Code 410 --- Group: power transmission (4) --- Component: clutch (41) --- Document group: general (410)

5. Page numbers The instructions for all components are numbered in consecutive order in the right---hand box at the top of the page. The page numbers begin with page 1 for each component.

8. 11. 1990

41. Clutch

15. 5. 1993

Model

205---665

Code

Page

410

1

6. Date At the top of each page there are two boxes for dates. In a case of revised issue, the date of the earlier issue is printed in the crossed ---over box and and the date of the current issue is printed in the proper date box.

7. Additions and amendments of the service manual New and up ---dated pages will be continuously added to the service manual. The new pages should be inserted as indicated by the code: the first digit (also the first digit on the index leaf) indicates the group: --- the two first digits indicate the component or sub ---group. --- the third digit indicates the document group for the respective components --- the page number indicates the definite position of the page within the service manual. If there are two pages with the same code and page number, it is the page with the later date in the date box and the old date in the crossed ---over box which is valid or which is the current page. When an entirely new set of repair instructions is issued, it will be accompanied by instructions on where the pages should be inserted in the file.

8

1. 12. 1986

10. General

1. 3. 1997

Code designations in the Service Manual

110

Page

3

61. Steering system 610 Technical data, description, tools 611 Steering valve 612 Priority valve 613 Steering cylinder

20 Engine

62. Non ---powered front axle 620 Technical data, description, tools 621 Front axle

210 Technical data, description, tools 211 Cylinder block and flywheel housing 212 Cylinder head and valve mechanism 213 Crank mechanism 214 Auxiliary drive gears (timing gears) 215 Lubrication system and oil sump 216 Induction and exhaust system, turbocharger 219 Removing and fitting engine

64. Powered front axle 640 Technical data, description, tools 641 Housing and central pivot bearings 642 Drive shafts 643 Hubs 644 Differential 645 Adjustments

22. Fuel system 220 Technical data, description, tools 222 Fuel feed pump and fuel filters 223 Injection pump and injectors

70 Frame and wheels 710 Frame 720 Wheels

23. Cooling system 230 Technical data, description, tools 231 Cooling system

80 Cab and shields 810 Cab 820 Shields 830 Air conditioner

30 Electrical system 310 Tractor electrical system, wiring diagrams 320 Autocontrol hydraulic power lift 330 Agrodata performance monitor 331 AD ---instrument

90 Working hydraulics, power lift 91 Working hydraulics and mechanical power lift 910 Technical data, description, tools 911 Pump and pipe system 912 Hydraulic power lift 913 Adjustments 914 Power lift, 610312---

40 Power transmission 41. Clutch

205-- 865

Code

60. Front axle and steering system

10. General 110 General, lay out 120 Maintenance

21. Engine

Model

410 Technical data, description, tools 411 Clutch assembly and pedal rods

92. Electro---hydraulic power lift

42. Gearbox 420 Technical data, description, tools 421 Selector forks 422 Gear levers 423 Shafts and gear wheels in gearbox 424 Differential

100 Special tools 101 Special tools ETV 102 Locally prepared tools ET

43. Torque converter and shuttle on 415 M 44. Low gear 440 Technical data, description, tools 441 Low gear 45 Final drives 450 Technical data, description, tools 451 Final drives 46. Power take off 460 Technical data, description, tools 462 Power take off 50 Brake system 510 Technical data, description, tools 511 Service brakes 512 Parking brake

9

1. 12. 1986

10. General

1. 3. 1997

Model

205-- 865

Code

110

Page

4

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

Sealing compound and glue

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

Tightening torques and setting values

All necessary tightening torques and setting values for each repair operation are given at the beginning of each repair section under the heading Technical Data. The most important values can also be found in the repair instructions. Table 1 later gives the tightening torques in order of dimension, quality and surface treatment. The values given in the table should be used if the tightening torque is not given in the repair instructions.

Safety Always bear safety in mind when repairing or servicing the tractor. Use tools and lifting devices in the correct way . When you are removing tractor components or splitting the tractor, every tractor part must be supported in such a way, that no risk of accident exists. Avoid working under the supported tractor part if it is not absolutely necessary. When supporting the tractor the centre of gravity of the frame part must always be checked. For instance the wedges must always be fitted between front axle and engine to prevent axle oscillation when splitting the front frame of the tractor.

Trouble ---shooting The following procedure, combined with the information contained in the workshop manual will be helpful in tracing faults accurately. It consists of following a number of logical steps to locate and correct the problem: a) Determine the problem b) List possible causes c) Differentiate the causes d) Conduct checks in logical order to determine the exact cause e) Consider approximate remaining service life against cost of parts and labour.. f) Make any necessary repairs. g) Recheck the parts and functions for correct operation

10

Model

10. General

1. 12. 1986

Code

205-- 865

Page

110

Table Table 1. Tightening torques, metric standard thread (ISO)

Tightening torques Nm1) Dim.

Quality, surface treatment, material and so on 8.8 lubr.

tol.±

8.8 Zne2)

M4

---

M5

6,4

0,6

5,7

M6

11

1

M8

25

M10

50

M12

tol±

tol. ±

10.9 lubr.

tol. ±

12.9 lubr

tol. ±

---

---

0,5

---

9

1

11

1

10

1

12

1,2

15

1,5

18

2

2

23

2

30

3

35

4

45

5

5

45

5

60

5

70

7

90

10

90

10

80

8

100

10

125

10

151

15

M14

140

15

125

10

160

15

200

20

240

20

M16

220

20

195

20

250

25

300

30

370

40

M18

300

30

270

30

350

35

430

40

510

50

M20

430

40

380

40

480

50

600

60

720

70

M22

570

60

500

50

650

65

800

80

970

100

M24

740

70

660

70

830

80

1030

100

1250

120

M27

1100

100

950

100

1200

120

1500

150

1800

180

M30

1500

150

1300

130

1600

160

2040

200

2500

250

1) 2) 3)

---

8.8 Znk3)

1 Nm=0,102 kpm Zne=zinc electroplating Znk=hot galvanized

If the bolts differs from the standard range the values in the table must not be used.

11

---

5

Model

10. General

1. 7. 1989

Conversion table for common units Quantities and units

Conversion factors

Overall and detail dimensions millimetres (mm)

100 mm=3,94 inches 1 inch=25,4 mm

Short distances e.g. turning circles metres (m)

1 m=3,28 ft 1 ft=0,305 m

Travel distances kilometres

1 km=0,62 mile 1 mile=1,61 km

Tractor weights, axle loadings kilograms (kg)

1 kg=2,2 lbs 1 lb=0,454 kg

Travel speed kilometres per h (km/h)

1 km/h=0,62 mph 1 mph=1,61 km/h

Drawbar pull kilonewtons (kN)

1 kN=224,8 lbs 1 lb=4,448 N

Power (identified by such terms as crankshaft power, pto power, belt power, drawbar power, indicating the point at which the measurement was taken) kilowatts (kW)

1 kW=1,34 hp 1 hp=0,746 kW

Engine torque newton metres (Nm)

1 Nm=0,74 ft lb 1 ft lb=1,356 Nm

Fuel consumption by weight (kilograms per hr, kg/h) (by volume) litres per hr (l/h)

1 kg/h=2,2 lb/hr 1 lb=0,454 kg 1 l/h=0,22 gal/hr 1 gal=4,54 l

Fuel economy (specific fuel consumption) grams per kilowatt hr (g/kWh)

304 g/kWh=0,5 lb/hp hr

Engine displacement litres (l)

1 l=61,02 m cu in 100 cu in=1,639 l

Hydraulic pump pressure ---mecapascal (MPa) delivery ---millimetres per sec (ml/s)

1 MPa=145 psi 1000 psi=6,9 MPa 100 ml/s=1,32 gpm 1 gpm=75,77 ml/s

Tyre pressure ---kilopascal (kPa)

100 kPa=14,5 psi 1 psi=6,9 kPa

Area acres---hectare

To convert multiply by 0,404686

Volume bushel---litre

To convert multiply by 39,3687

Quantity pound per acre ---kilogram per hectare

Multiply by 1,12085

Volume superficial foot---cubic metre

Multiply by 0,002360

12

205-- 865

Code

110

Page

6

1. 5. 1996

12. Maintenance

1. 1. 1998

Model

205 -- 900

Code

120

Page

1

Maintenance 205---900 Note! Detailed maintenance procedures are given in the Operator”s Manual.

--- When changing the oil, bear in mind that the oil can be very hot when it drains from the tractor. Waste oil and oil filters should be handled carefully and disposed of properly. --- After completion of the service work always replace all safety covers etc.

When servicing: --- Always stop the engine before doing any servicing work. --- Apply the parking brake to ensure the tractor cannot move. If the ground is uneven the wheels should be scotched --- Always observe the utmost cleanliness in all maintenance work. ---Thoroughly wipe off filler caps and plugs as well as surrounding parts of the tractor before filling up with fuel or oil. --- Inspect the oil and filters when changing. Large amounts of dirt (e.g. heavily clogged filters) can point to a fault which could cause extensive and costly repairs if not corrected in time. --- When carrying out checks the tractor should stand on level ground. --- Levels should be checked in the morning when the oil is cold and has had time to run down to the bottom of the unit concerned.

Lubrication of points provided with grease nipples --- Always clean the grease nipples before applying the grease gun. --- Pump in grease to the nipples until clean grease is squeezed out (unless otherwise instructed). --- Wipe off all surplus grease which has been squeezed out at the lubricating points. --- Preferably carry out lubrication with bearing points and joints unloaded and with the bearings in different position ( e.g. lubricate the steering knuckle bearing on the steering axle with the wheels at both full left and right lock and with the front axle lifted up).

Lubrication and maintenance schedule All intervals are counted from zero on the hour recorder. For example, 1000---hour service is carried out every 1000 and 2000 hours according to the hour recorder (yearly or every other year) even if the operates have been carried out at the guarantee service. Example: The 1000---hour service includes all operates listed under daily/every 10 hours,weekly/every 50 hours,250, 500 and 1000 hours.

13

12. Maintenance

7

Model

1. 5. 1996

205 -- 900

1. 1. 1998

6

12

1

Code

Page

120

9 10

2

4

7

7

6

11

Maintenance daily/weekly

4

2

Weekly/every 50 hours

3

5

4

4

4. Lubricate front axle and steering nipples 2 ---wheel drive --- axle mountings (2 nipples) --- steering knuckles (2 nipples) --- tie ---rod ends (4 nipples: not on later models) 4 ---wheel drive --- universal joints (ZF: 4 nipples, Sige: 2 nipples) --- front axle mountings (ZF: 6 nipples, Sige: 4 nipples) --- steering knuckles (on later models 4 nipples) 5. Lubricate propeller shaft, 4WD (3 nipples). On later models there are no grease nipples for propeller shaft. 6. Lubricate brake and clutch pedals (2 nipples) 7. Lubricate top link and lifting links (5 nipples) 8. Lubricate extra lifting cylinder nipples (if fitted) 9. Check fluid level in windscreen washer 10. Check fan and alternator belt 11. Check electrolyte level in battery 12. Drain water from fuel filter (20---series engines). 865, 800 and 900 tractors also have a separate water trap.

Daily/every 10 hours

1. Check engine oil level 2. Check coolant level 3. Clean the cyclone cleaner (check oil elevel in filter on 205). 865, 800 and 900 tractors have not a cyclone but an ejector pipe.

14

1. 1. 1998

12. Maintenance

39

Model

205 -- 900

1. 6. 1998

28

33

35 19 15 41 40 15

21

Code

37

120

36 41 14

Page

3

32 25 31

29 26 30 23

39

19 17 16 27

13

20

43 33 42

37

25 24 32 3055--- 69

Every 250 hours

Every 1000 hours/yearly

13. Clean heating system air filter. 600---900: Clean air filter of roof fan. 14. Clean air filter (change if necessary) (on 255 change oil in filter) 15. Change engine oil and oil filter 16. Change hydraulic system pressure filter. First change at 100 hours Service inspection. The second change at 250 running hours and the third at 500 hours. After that at intervals of 500 running hours. 17.Lubricate gear lever joints 18.Check tyre pressures and wheel nuts

29. Change oil in hydraulic system 30. Change oil in power transmission 31. Change oil in differential, 4---wheel drive 32. Change oil in hub reduction gears, 4---wheel drive 33. Clean hydraulic pump suction strainer 34. Drain fuel tank 35. Change fuel filter. 865, 800 and 900 with Stanadyne water trap: also change the water trap filter. 36. Change safety filter in air cleaner (om 255, clean the filter) 37. Check, adjust and lubricate front wheel bearings, 2---wheel drive 38. Check and adjust front wheel toe ---in 39. Lubricate drive axle bearings (2 nipples) 40. Adjust valves 40a. 600---900: Change air filter of roof fan. 40b. 600---900: Change breather filter (in filling cap)

Every 500 hours 19. Clean separate water trap on 865 (not 865, 800 and 900, if a Stanadyne water trap has been fitted). 20. Check brake pedal free travel 21.Check propulsion clutch pedal free travel 22. Check PTO lever free travel 23. Check oil level in power transmission 24. Check oil level in differential, 4---wheel drive 25.Check oil level in hub reduction gears, 4---wheel drive 26. Check oil level in hydraulic system 27.Change pressure filter in hydraulic system 28. Change oil filter in transmission

Every 2000 hours/every other year 41. Clean cooling system 42. Check alternator 43. Check starter motor 44. Check and clean injectors

Every 4000 hours (not 205, 355, 365 and 665) 45. Turbo unit checked at authorized workshop

15

15. 4. 1999

12. Maintenance

1. 9. 2001

Model

Code

205 -- 900

Page

120

4

Recommended fuel and lubricants (All volumes are incl. of filters) Part of machine

SAE class

API grade

Volume (litres)

Engine --- 205, 255, 355, 365, 600 --- 305, 405, 455, 465, 700, 555, 565 --- 665, 800, 865, 900

15W/40 (+40... ---10˚C) 10W/30 (+30... ---20˚C)

CE CF/CF ---4

7 7 9

Working hydraulics

HT60: ---30˚C...+30˚ HT100: ---10C...+40C 32: ---30 ˚C...+30˚C 46: ---10˚C...+40˚C

ISO VG 32 ISO VG 46

35 (upper mark) 25 (lower mark)

Power transmission

HT60: ---30˚C...+30˚ HT100: ---10C...+40C

GL ---4 (G2---98)

23 (865, 600---900: 27)

Powered front axle ZF: --- differential --- hubs Powered front axle Sige (Dana): --- differential --- hubs

80W/90

GL ---5 (LS)

Fuel tank --- 205---865 --- 600---900

Diesel fuel

Cooling system without expansion tank: --- 205---565, 600, 700 --- 665, 865, 800, 900

Anti ---feeze agent+water (standard ASTM D3306---86a or BS 6580:1985)

4,5 2x0,5 6,5 2x0,8 73 79 (extra tank 103)

Cooling system with expansion tank: 600---700 800---900

10 (600, 700: 11,5) 11,5 (800, 900: 13,5) 13,5 15.5

Windscreen washer

Washer fluid

Front PTO

See code 460.

1,5

Note! The following Valtra oils are recommended: Valtra Engine in engine Valtra transmission in Power Transmission Valtra Hydraulic in hydraulic system Valtra Axle in Powered front axles. Note! Recommended oil in front PTO, see code 460.

415M -- tractor Oil specification in torque converter/reverse shuttle: --- automatic transmission fluid (ATF), which meets requirements: Dexron, type A Suffix A Oil volume: --- total volume 8,3 litres --- change volume 6 litres Other maintenance instructions and filling quantities are the same as on 405 tractor.

16

20. Engine

21. Engine (309--- and 311---engines)

22. Fuel system (309--- and 311---engines)

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

21A. Engine (320,420---engines)

22A. Fuel system (320,420---engines)

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

17

18

Model

21. Engine

1. 12. 1986

205-- 555

Contents General (Op. no. 210): Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Repair instructions Cylinder block and flywheel housing (Op. no. 211): 1. Cylinder block and cylinder liners: A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Fitting plug at rear end of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Fitting cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 2 2 2 3

2. Flywheel housing: A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cylinder head and valve mechanism (Op. no. 212): 1. Cylinder head: A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Changing copper sleeve for injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 3 4 4 4 4

2.Valve mechanism: A. Reconditioning rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 B. Changing camshaft/camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 C. Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Crank mechanism (Op. no. 213): 1. Crankshaft: A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2

2. Connecting rods and pistons: A. Removing piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

19

Code

210

Page

1

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21. Engine

10. 1. 1992

Modell

205 -- 555

Code

Page

210

2

Engine timing gears (Op. no. 214)

1. Timing gear casing: A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 C. Changing crankshaft front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Lubrication system and oil sump (Op. no. 215)

1. Lubrication system: A. Reconditioning lubricating oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing lubricating oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 3

Inlet and exhaust systems, turbocharger (Op. no. 216)

1. Inlet and exhaust systems: A. Checking air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Checking inlet and exhaust systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. Turbocharger: A. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Reconditioning turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 2 4

Removing and fitting engine (Op. no. 219)

1. Removing and fitting engine by parting tractor: A. Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Fitting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. Removing and fitting engine without parting tractor: A. Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 B. Fitting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Technical data Tractor 205 Designation D27D2 Turbocharger no No of cylinders 3 2,7 Displ. dm3 Stroke mm 114 Cyl. bore mm 100 Compr. ratio 18:1 Output kW DIN 36/2350 Torque Nm/rpm 175/1450 Idling speed rpm 650 Valve clear. mm 0,30 Compr. press. bar24 1) 1)

305 TD27DS3 yes 3 2,7 114 100 18:1 39/2350 195/1400 650 0,30 24 1)

355 TD33D no 3 3,3 120 108 17:1 44,5/2350 220/1400 750 0,30 24 1)

405 TD27DS4 yes 3 2,7 114 100 18:1 45/2350 220/1450 650 0,30 24 1)

455 TD33DS4 yes 3 3,3 120 108 16:1 49/2350 240/1450 750 0,30 24 1)

555 TD33DS 555 yes 3 3,3 120 108 16:1 53/2350 260/1450 750 0,30 24 1)

Minimum value at starter motor speed (warm engine). The greatest allowable difference between cylinders is 0,3 bar.

Note! From tractor no 656316 tractors 355, 455 and 555 have new 20---series engines. See sections 21A, 22A and 23 A.

20

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

210

3

Valves, rocker arms and tappets (205---555) Valve timing At a valve clearance of 0,30 mm: --- inlet valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- inlet valve closes at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve closes at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve clearance, cold or warm engine: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat angle in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve head diameter: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stem diameter, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stem diameter, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance, valve stem ---guide, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance, valve stem ---guide, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum wear limit, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum wear limit, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide I.D. (before fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore in cylinder head for valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height of valve guide above cylinder head face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distance between cylinder head and valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve spring, free length: --- inner spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- outer spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading when valve spring is compressed to: --- inner spring, 41.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- outer spring, 47 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm bushing I.D. (bushing fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm bushing O.D. (before fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pushrod length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pushrods must be straight to within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm shaft spring, free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading when rocker arm shaft spring is compressedto 58 mm . . . . . . . . . . . . . . . . . . . . . . . . . Tappet O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore in cylinder block for tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10˚ B.T.D.C. 42˚ A.B.D.C. 42˚ B.B.D.C. 10˚ A.T.D.C. 0,30 mm 0,30 mm 30˚±5’ 1,0---1,5 mm 29_30’±5’ 39 mm (45 mm, 355,455, 555) 39 mm (40 mm, 355, 455, 555) 9.465---9.480 mm 9.445---9.460 mm 0.040---0.070 mm 0.060---0.090 mm 0.30 mm 0.35 mm 9.520---9.535 mm 16.028---16.039 mm 16.000---16.018 mm 21 mm 1.2---1.4 mm 57 mm 61 mm 70---90 N 190---210 N 19.959---19.980 mm 19.990---20.010 mm 23.035---23.048 mm 23.000---23.021 mm 231 ---1 (238 ---1, 455) 0.4 mm 80 mm 80---100 N 29.939---29.960 mm 30.000---30.021 mm

Camshaft (205, 305, 405) Bearing journal no. 1, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing journal nos 2---4, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing no. 1, bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings nos 2---4, bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radial clearance no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radial clearance nos. 2---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerance, 1st bushing in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft end float (with 0.5 mm gasket betweencylinder block and timing gear casing and betweentiming gear casing and front cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam height (distance between cam lobe top and opposite side).41.44 mm Cam lift (lobe top height above the “circle”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permissible figure for out---of ---roundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

49.925---49.950 mm 49.885---49.910 mm 50.040---50.060 mm 50.000---50.025 mm 0.090---0.135 mm 0.090---0.140 mm 0.025---0.080 mm 0.045---1.550 mm 7.44 mm 0.03 mm

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

210

4

Camshaft (355, 455, 555) Bearing journal no. 1, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing journal nos 2---4, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing bores, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radial clearance no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radial clearance nos 2---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerance, 1st bushing in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft end float (with 0.5 mm gasket between cylinderblock and timing gear casing and between timing gearcasing and front cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam height (distance between cam lobe top and opposite side) . . . . . . . . . . . . . . . . . . . . . . . . Cam lift (lobe top height above the “circle”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permissible figure for out---of ---roundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.905---49.930 mm 49.885---49.910 mm 50.000---50.025 mm 0.070---0.120 mm 0.09---0.140 mm 0.023---0.072 mm 0.450---1.550 mm 41.44 mm 7.44 mm 0.03 mm

Cylinder liners (205, 305, 405) Height above block face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. height difference between cylinder liners under thesame cylinder head . . . . . . . . . . . . . . Cylinder liner I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, 1st oversize, part no 8365 36828 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, 2nd oversize, part no 8365 36829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, 3rd oversize, part no 8365 36830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner flange, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.030---0.080 mm 0.020 mm 100.015---100.037 mm 8.03---8.05 mm 8.08---8.10 mm 8.13---8.15 mm 8.23---8.25 mm 121.90---122.00 mm

Cylinder liners (355, 455, 555) Height above block face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. height difference between cylinder liners under thesame cylinder head . . . . . . . . . . . . . . Cylinder liner I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, 1st oversize, part no 8353 29829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, 2nd oversize, part no 8353 29830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner flange height, 3rd oversize, part no 8353 29831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner flange, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.030---0.080 mm 0.020 mm 108.000---108.022 mm 9.03---9.05 mm 9.08---9.10 mm 9.13---9.15 mm 9.23---9.25 mm 131.700---131.800 mm

Piston, piston rings and piston pin (205, 305, 405) Minimum distance between piston and cylinder head, measured with a piece of lead wire through the injector location hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston diameter: --- 26 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston pin hole, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring groove width: --- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- groove 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring clearances in grooves: --- upper compression ring, hard chromed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- maximum wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring widths: --- ring 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- ring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring gap: --- compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- maximum wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.900---1.150 mm 99.873---99.887 mm 36.003---36.009 mm 35.995---36.000 mm 2.580---2.600 mm 3.040---3.060 mm 4.040---4.060 mm 0.09---0.122 mm 0.05---0.082 mm 0.05---0.082 mm 0.15 mm 2.478---2.490 mm 2.978---2.990 mm 3.978---3.990 mm 0.4---0.6 mm 0.25---0.55 mm 1.0 mm

Max permissible weight difference between pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 g Heat piston to 100_C before fitting piston pin.

22

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

210

5

Piston, piston rings and piston pin (355, 455, 555) Piston diameter: --- 19 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 75 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 93.5 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 108.5 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston pin hole, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston pin, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring groove widths: --- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- groove 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- groove 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring clearance in grooves: --- upper compression ring, hard chromed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- maximum wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring width: --- ring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- ring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston ring gap, new ring kit no. 8363 39201: --- upper compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- maximum wear limit, ring 1 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- maximum wear limit, ring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107.853---107.867 mm 107.742---107.757 mm 107.580---107.600 mm 107.510---107.530 mm 40.000---40.006 mm 39.995---40.000 mm 2.560---2.580 mm 3.030---3.050 mm 5.040---5.060 mm 0.07---0.102 mm 0.04---0.072 mm 0.05---0.082 mm 0.15 mm 2.478---2.490 mm 2.978---2.990 mm 4.978---4.990 mm 0.3---0.55 mm 0.75---1.00 mm 0.3---0.6 1.0 mm 1.4 mm

Max. permissible weight difference between pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 g Heat piston to 100_C before fitting piston pin.The combustion chamber should be turned towards the injectors.

Connecting rod (205, 305, 405) Connecting rod bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bushing O.D. (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bushing, (oversize 8360 38605) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interference fit: connecting rod bushing/connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bushing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bushing location, diameter (oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36.025---36.040 mm 40.060---40.076 mm 40.580---40.620 mm 0.035---0.120 mm 40.000---40.025 mm 40.500---40.525 mm 65.730---65.749 mm

Connecting rod (355, 455, 555) Connecting rod bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bushing O.D. (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bushing O.D. (oversize 8353 28326) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interference fit: connecting rod/connecting rod bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bushing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod end ---float on crank shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.025---40.040 mm 44.082---44.120 mm 44.580---44.620 mm 0.057---0.120 mm 44.000---44.025 mm 71.730---71.749 mm 0.200---0.312 mm

Weight marking (letter) at lower end. Max. permissible weight difference between connectingrods in the same engine . . . . . . . . . . 20 g

23

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

210

6

Crankshaft (205, 305, 405) Big end journals, diameter: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st undersize, 0.25 mm (bearing 8360 97266) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd undersize, 0.50 mm (bearing 8360 97267) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd underside, 1.00 mm (bearing 8360 97269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 4th undersize, 1.50 mm (bearing 8360 97271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end journals, length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing journals, diameter: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st undersize, 0.25 mm (bearing 8360 97273) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd undersize, 50 mm (bearing 8360 97274) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd undersize, 1.00 mm (bearing 8360 97276) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 4th undersize, 1.50 mm (bearing 8360 97278) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of thrust bearing journal on crankshaft (nearest flywheel): --- standard (2 std thrust bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st undersize (one std and one 0.2 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . --- 2nd oversize (two 0.2 mm oversize thrust washers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other bearing journals must not be ground so as to make them longer. Crank shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end and main bearing journals, max. permissible figure for out---of ---roundness or other deformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft balancing accuracy, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61.981---62.000 mm 61.731---61.750 mm 61.481---61.500 mm 60.981---61.000 mm 60.481---60.500 mm 40.000---40.160 mm 0.046---0.098 mm 69.988---70.018 mm 69.738---69.768 mm 69.488---69.518 mm 68.988---69.018 mm 68.488---68.518 mm 0.051---0.101 mm 47.000---47.080 mm 47.200---47.280 mm 47.400---47.480 mm 0.100---0.320 mm 0.03 mm 1.0 Ncm Max

Crankshaft (355, 455, 555) Big end journals, diameter: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st undersize, 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd undersize, 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd undersize, 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 4th undersize, 1.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end journals, length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing journals, diameter: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st undersize, 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd undersize, 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd undersize, 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 4th undersize, 1.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing location (in block), diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of thrust bearing journal on crankshaft (nearest flywheel): --- standard (2 std thrust bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st oversize (one std and one 0.1 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd oversize (one std and one 0.2 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . . --- 3rd oversize (one 0.1 mm and one 0.2 mm oversize thrust washer . . . . . . . . . . . . . . . . . . . . . --- 4th oversize (two 0.2 mm oversize thrust washers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other bearing journals must not be ground so as to make them longer.Crankshaft end float . Big end and main bearing journals, max. permissible figure for out---of ---roundness or other deformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft balancing accuracy, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67.981---68.000 mm 67.731---67.750 mm 67.481---67.500 mm 66.981---67.000 mm 66.481---66.500 mm 40.000---40.160 mm 0.046---0.098 mm 84.985---85.020 mm 84.735---84.770 mm 84.485---84.520 mm 83.985---84.020 mm 83.485---83.520 mm 91.000---91.022 mm 0.050---0.127 mm 45.000---45.080 mm 45.100---45.180 mm 45.200---45.280 mm 45.300---45.380 mm 45.400---45.480 mm 0.100---0.350 mm 0.03 mm 1.0 Ncm Max

Flywheel (205---555) Flywheel ring gear, number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interference fit: ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When fitting the ring gear should be heated to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel balancing accuracy, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Permissible throw of flywheel friction surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

128 0.422---0.600 mm 150---200_C 1.0 Ncm Max 0.06:ø200

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

210

6.1

Timing gears (205---555) Tooth backlash: --- Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All timing gears, max. radial throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.05---0.25 mm 0.05---0.25 mm 0.05---0.25 mm 0.05 mm 54.951---54.970 mm 55.000---55.030 mm

Timing gear markings: When the timing gear markings are opposite each other the piston in the first cylinder is at T.D.C. between the compression and power stroke. On the crankshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On the idler gear: --- against the crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- against the camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- against the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On the camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On the fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft must be rotated 6 turns before all gear markings fall into line again.

2 punch marks on teeth. 0 on a tooth 1 punch mark on a tooth 1 punch mark at a tooth gap 1 punch mark at a tooth gap 1 punch mark on a tooth

Lubrication (205---555) Lubricating oil pressure at working temperature: --- at low idling speed, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring for oil relief valve, free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring for oil relief valve, loading when 52 mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil relief valve, diameter of valve cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil relief valve, diameter of hole in insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter by ---pass valve opens at a pressure difference of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 kPa (1.5 kp/cm@) 300---500 kPa (3---5 kp/cm@) 80 mm 54+5 N (5.4+0.5 kp) 19.602---19.635 mm 19.700---19.752 mm 20.5 bar

Lubrication oil pump (205---555) Tooth backlash when crankshaft is resting on the main bearings: --- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holes in body and cover, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear wheel I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear clearance on fixed drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance of fixed shaft end ---face of body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasket thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump gear O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear clearance in body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear location in body, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear wheel end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pump body, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of teeth on gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

0.05---0.25 mm 0.16---0.26 mm 0.016---0.052 mm 18.000---18.018 mm 18.060---18.078 mm 0.021---0.050 mm 0.5---1.0 mm 0.06---0.08 mm 43.486---43.525 mm 0.125---0.264 mm 43.650---43.750 mm 18.000---18.027 mm 0.03---0.11 mm 18.000---18.043 mm 41

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

210

6.2

Coolant pump (205---555) Bearings O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing location, diameter (in pump body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal location, diameter (in pump body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The impeller should be mounted on the shaft so thatthe distance between the rear face of the impeller and therear face of the pump body is . . . . . . . . . . . . . . . . . . . . . . . The hub should be mounted on the shaft so that the distance between the contact face for the fan and the rear face of the pump body is . . . . . . . . . . . . . . . Fan guide (shoulder) on hub, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan, max. balancing accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan, max. throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . At correct belt tension it should be possible to deflect the belts . . . . . . . . . . . . . . . . . . . . . . . . . .

38.087---38.100 mm 38.058---38.083 mm 15.907---15.920 mm 15.881---15.899 mm 36.450---36.489 mm 1---1.7 mm 157 mm 25.00---25.20 mm 0.3 Ncm max 0.3 mm 15---20 mm

Thermostat (205---555) Spare part number

Diam./Type

8360 15156 8360 15486

ø54/79˚ C ø54/83˚ C

Opening commences 80˚ ---3˚C 83˚ ---3˚ C

Fully open 94˚ C 95˚ C

Max. stroke mm 7,5 7,5

Cylinder block (205, 305, 405) Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner location, diameter: --- at upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- at lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft bearing bushing, I.D. when fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.000---13.043 mm 76.000---76.019 mm 116.012---116.047 mm 115.000---115.035 mm 50.040---50.060 mm

Cylinder block (355, 455, 555) Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner location, diameter: --- at upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- at lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft bearing bushing, I.D. when fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.000---13.043 mm 91.000---91.022 mm 123.514---123.554 mm 122.000---122.040 mm 50.000---50.025 mm

Cylinder head (205---555) Seat for copper sleeve, diameter: --- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copper sleeve O.D.: --- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head minimum thickness after machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head bolts, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

28.000---28.033 mm 27.000---27.033 mm 27.979---28.000 mm 27.073---27.090 mm 104.90---105.10 mm 104.70 mm 160 Nm

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

210

7

Turbocharger Holset H1D (not 205 and 355) Oil pressure at rated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbine housing mounting bolts (M8x12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor housing mounting bolts (M6x12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing housing mounting bolts (M6x16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut at end of shaft (LH thread on shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

min. 2 bar 0.10---0.16 0.30---0.46 11.3 Nm 5.7 Nm 5.7 Nm 14.0 Nm

Turbocharger Schwitzer S2A (not 205 and 355) Oil pressure at rated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V ---band nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

min. 2 bar 0.05---0.12 mm max 1.0 mm (dry) 10.5 Nm 7.0 Nm

Partial vacuum and counter pressure Partial vacuum at air cleaner, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 kPa (500 mm, water gauge) Counter pressure at exhaust pipe, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 kPa (600 mm, water gauge)

Tightening torques Engine fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust pipe ---turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Big end bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear bolts: ---M 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ---M 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel housing bolts: --- outer ring, M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 Nm (8 kpm) 60 Nm (6 kpm) 23 Nm (2.3 kpm) 90 Nm (9 kpm) 160 Nm (16 kpm) 600 Nm (60 kpm) 120 Nm (12 kpm) 60 Nm (6 kpm) 140 Nm (14 kpm) 160 Nm (16 kpm) 110 Nm (11 kpm)

--- inner ring, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (6 kpm)

Special tools 21. Engine A Part number 1. 8360 97532 2. 8360 97336 3. 8361 97470 4. 8360 97463 5. 8360 86085 6. 8360 97315 7. 9030 15200 8. 8360 85499 9. 8360 13091 10. 9025 58000

Description Lever for compressing valve spring (505---905) Counterhold nut for above (505---905) Milling tool for injector seat (505---905) Drift for fitting injector sleeve (505---905) Extractor for injector sleeve (505---905) Drift for fitting crankshaft rear seal (505---905) Drift for fitting crankshaft front seal (505---905) Puller for coolant pump impeller (505---905) Puller for coolant pump hub (505---905) Cylinder head spanner (505---905): earlier number 8360 97328

21. Engine B Part number 11. 8360 97337 12. 8360 97457 13. 8360 97434

Description Drift for removing valve guide (505---905) Drift for fitting valve guide (505---905) T ---handle for valve seat milling cutter (505---905)

27

1. 7. 1989

21. Engine

10. 1. 1992

14. 8360 97435 15. 8360 97436 16. 8360 97437 17. 8361 97468 18. 7314 03506 19. 8360 97327 20. 9025 79200 21. 9025 78100 22. 9025 98900 23. 9051 40200 24. 9025 98800 25. 9025 98700 26. 9051 73100* 26A. 8365 39293 26B. 8353 39292 27. 9051 72900* 27A. 9051 72800 28. 9051 71300*

Model

205 -- 555

Code

Page

210

8

Milling cutter for facing exhaust and inlet valve seat(505---905) Milling cutter for exhaust and inlet valve seat (505---905) Inner milling cutter for exhaust and inlet valve seat (505---905) Drift for fitting 16 mm cap plug (505---905) Drift for fitting 36 mm cap plug (505---905) Puller for crankshaft gear (505---905) Holder for dial gauge (505---905) Press tool for cylinder liner (505---905) Drift for fitting dust cover, crankshaft front seal (505---905) Drift for fitting coolant pump seal (505---905) Drift for fitting tubular pin in timing gear casing (505---905) Drift for fitting tubular pin in timing gear casing (505---905) Puller for cylinder liner Puller flange, 205, 305, 405 Puller flange, 355, 455, 555 Milling cutter for fitting cylinder liner, 205, 305, 405 Milling cutter for fitting cylinder liner, 355, 455, 555 Puller for injector

Locally prepared tools 29. 9051 64900 30. ET(893 760)

Drift for fitting coolant pump shaft (505---905) Support between front end and front axle to prevent oscillation

3

4

5

1

2

7 6

8

9 10

28

Model

21. Engine

1. 12. 1986

14

205 -- 555

Code

Page

210

9

13

19

15 12

11

16

17

18

21

20

22

23 26

25

24

27

26A 28

29

Model

21. Engine

1. 12. 1986

205 -- 555

29 30

30

Code

Page

210

10

Model

21. Engine

1. 12. 1986

Engine, description The engine on tractors 305---555 is a liquid ---cooled, four --stroke, turbocharged, direct---injection diesel engine. The peripherals of the engine are shown in Figs. 210 1 and 210---2.

309 left side 1. Turbocharger 2. Injector 3. Fuel filter 4. Water trap 5. Oil pressure gauge sender 6. Oil dipstick 7. Oil filter 8. Oil pressure relief valve 9. Engine heater 10. Timing indicator 11. Fuel feed pump 12. Fuel injection pump 13. Oil filler 14. Thermostat housing 15. Serial number

31

205 -- 555

Code

Page

210

11

Model

21. Engine

1. 12. 1986

309 right side 1. Thermostart device fuel reservoir 2. Thermostart glow plug 3. Breather hose 4. Temperature gauge sender unit 5. Coolant pump 6. Timing gear casing cover 7. Alternator 8. Starter motor

32

205 -- 555

Code

Page

210

12

Model

21. Engine

1. 12. 1986

Longitudinal section of engine 309

33

205 -- 555

Code

Page

210

13

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

210

14

Cylinder block Figure 210 4 1. Cylinder block 2. Cylinder liner 3. O ---ring 4. Bearing sleeve 5. Bearing cap 6. Bearing cap with thrust bearing 7. Guide sleeve 8. Bolt 9. Plug 10. Threaded plug 11. Guide pin 12. Threaded connection 13. Cylinder head bolt 14. Plug (camshaft end) 15. Pressure sender unit 16. Sealing ring 17. Plug 18. Pipe for oil dipstick

The cylinder block is the main body of the engine, to which other engine parts are attached. The cylinder liners are so called wet liners, which means that the coolant is in direct contact with the outer surface of the liners. The seal between the cylinder liner lower part and the cylinder block is achieved by two O ---rings (3), which are fitted in grooves in the liner. The upper part is sealed by the cylinder head gasket. The distance between the cylinder liner flange and the face of the cylinder block plays a major role in sealing the upper part. Bear this in mind when fitting the cylinder liner.

The camshaft is located in the cylinder block. The camshaft front bearing location is provided with a separate bearing sleeve (4). The remaining bearing locations are machined directly in the cylinder block. The drilling for the camshaft rear end is covered with a plug. There is space on both sides of the rear main bearing for guide bearing shims (the camshaft thrust bearing).

Flywheel housing Figure 210 5 1. Flywheel housing 2. Bolt M12x35 3. Socket head bolt M10x30 4. Crankshaft oil seal 5. Rubber plug 6. Tubular pin 7. Screw stud 10x25 8. Washer 9. Nut M10 The flywheel housing is fitted to the rear end of the cylinder block. The starter motor and the crankshaft rear oil seal are also fitted in the flywheel housing. There is also a hole in the flywheel housing for inserting a tool in order to crank the engine. The return oil flow from the engine lubricating system is channelled through the flywheel housing.

The lower face of the flywheel housing fits up against the oil sump and its front face against the cylinder block. This has to be taken into account when fitting the flywheel housing, which is guided partly by the guide pin (6).

34

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

210

15

Cylinder head Figure 210 6 1. Cylinder head 2. O ---ring 3. Sleeve for injector 4. Plug 5. Valve guide 6. Plug 7. Valve cover 8. Gasket 9. Nut 10. Washer 11. Rubber seal 12. Breather hose 13. Lifting bracket 14. Screw stud 15. Sealing ring 16. Hose coupling 17. Bolt 18. Cylinder head gasket

The cylinder head is made of cast iron, and each cylinder has its own inlet port and common exhaust port. The stiffness and even spread of attaching bolts give a good seal for the cylinder head gasket. The directed flow of the coolant ensures that the valve seats are effectively.

The inlet and exhaust valve guides (1) are identical and can be interchanged. The injectors are surrounded by replaceable copper sleeves (2) which are in contact with the coolant, thus the injectors are effectively cooled.

Cross---section of cylinder head 1. Valve guide 2. Injector sleeve 3. O ---ring seals

35

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

210

16

Valve mechanism 1. Circlip 2. Shim 3. Nut 4. Rocker arm 5. Bearing sleeve 6. Adjusting screw 7. Holder 8. Spring 9. Shaft 10. Plug 11. Pushrod 12. Tappet 13. Valve keepers 14. Spring guide 15. Valve spring 16. Valve spring 17. Spring guide 18. Exhaust valve 19. Inlet valve 20. Gear wheel 21. Key 22. Camshaft 23. Threaded plug

The valve mechanism is operated by the camshaft (22) which is located in the cylinder block. The drive is transferred with the help of tappets (12) and pushrods (11). The camshaft gear wheel (20) is fitted with a press fit and fixed with a key (21). Each bearings is lubricated by the force feed lubrication system through drilled oilways in the camshaft.

Crank mechanism 1. Crankshaft 2. Key 3. Cylindrical pin 4. Main bearing 5. Thrust bearing 6. Flywheel 7. Ring gear 8. Bolt 9. Hub 10. Shaft seal boot 11. Deflector ring 12. Gear wheel 13. Gear wheel 14. V ---belt pulley 15. Nut 16. Socket head bolt M8x16 17. Piston 18. Piston rings 19. Piston pin 20. Retaining ring 21. Connecting rod 22. Bearing bushing 23 Bolt 24. Nut 25. Crankshaft bearing The crankshaft (1) is forged from chrome alloy special steel and is induction hardened at the bearing and sealing surfaces. Gear wheels (12 and 13) are located at the front end of the crankshaft. They are fitted with a press fit, and drive the idler wheel and oil pump. In addition, the front end of the crank ---

shaft has splines for the hub (9) of the V ---belt pulley (14). An oil deflector ring (11) is fitted between the hub and the gear wheel, and a dust shield (10) is fitted to the hub in order to seal the shaft.

36

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

210

17

The flywheel (6) is fitted to the rear end of the crankshaft. The ring gear (7) is fitted to the flywheel with a press fit. The forged connecting rod has an I ---shaped cross---section. The bearing location at the bottom end of the connecting rod is split, and the bearing cap is secured by two special bolts (23) and nuts (24). The upper end of the rod has a fixed bearing location, in which the piston pin bearing bushing (22) is fitted with a press fit.

Piston 1. Combustion chamber 2. Circlip 3. Piston pin 4. Bearing bushing 5. Connecting rod 6. Chromed compression ring 7. Compression ring 8. Spring loaded oil control ring chromed slide surfaces

Bearing shell 1. Indium ---lead alloy 2. Lead ---bronze 3. Steel shell

The piston is made of an eutectic aluminium alloy. In the upper part of the piston there is a combustion chamber (1). The shape of the chamber is intended to maximise the mixture of air and fuel. The number of piston rings is three, of which the upper (6) has a barrel face, chromed slide surface. The second compression ring (7) is tapered at an angle of 1,5˚, and the third ring is a spring loaded oil control ring (8). The piston pin (3) has a close tolerance in the piston and a floating fit in the connecting rod.

The crankshaft has four main bearings, one on either side of each cylinder. The thrust bearing is located on either side of the rear main bearing journal. The main and big ---end bearings are three ---layer bearings, which have a tough lead bronze alloy, with good heat dissipating properties, inside the steel shell. The actual sliding surface is covered by a layer of indium ---lead, which makes the running ---in period easier.

37

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

210

18

Timing gear casing 1. Timing gear casing 2. Bolt 3. Gasket 4. Screw stud 5. Tubular pin 6. Gasket 7. Front cover 8. Sealing ring 9. Protective ring 10. Nut 11. Gasket 12. Filler pipe 13. O ---ring 14. Cap 15. Washer 16. Spacer ring 17. Bearing housing 18. Gasket 19. Bearing 20. Circlip 21. Shaft 22. Plug 23. Sealing washer 24. Timing indicator 25. Attaching plate 26. Rubber plug

timing gear casing. Sealing ring (8) is fitted to the front end of the crankshaft and the protective ring (9) is positioned inside the location in the front cover. The timing gears drive the camshaft, fuel injection pump and oil pump.

The timing gear train consists of hardened, helically cut gear wheels. The gears are encased by the timing gear casing (1) which is fitted to the front of the engine. The fuel injection pump, alternator and hydraulic pump with its drive are fitted to the timing gear casing. The front cover (7) is fitted to the

Idler gear with securing parts 1. Bolt M10x55 2. Bolt M14x65 3. Locking flange 4. Bearing bushing 5. Gear wheel 6. Shaft stud The bearing for the idler gear (5) is a sliding bearing (4) and is located on the axle (6). It is fitted to the cylinder block with two bolts (1 and 2). The crankshaft and camshaft gears are fitted to the shafts with a press fit and key. The fuel injection pump gear is fitted on the pump shaft, which is tapered, with a nut and key. In order to ensure the correct timing of the gears, there are punch marks on each gear.

38

1. 12. 1986

21. Engine

1. 7. 1989

Lubrication system, 305---405 1. Oil pump 2. Suction strainer 3. Pressure relief valve 4. Oil filter 5. Main oil gallery 6. Main bearing oilway 7. Turbocharger 8. Camshaft 9. Idler gear 10. Valve mechanism

39

Model

205 -- 555

Code

210

Page

19

1. 7. 1989

21. Engine

10. 1. 1992

The engine has a pressure lubricating system, in which the oil pump (1) pumps the oil to the different lubricating points. The oil is sucked up by the pump through a suction strainer (2). After the pump the oil is ducted through an oilway to the relief valve (3) and the oil filter (4). After the filter, the oil is supplied through the main oil gallery (5) from which the oilways for the main bearings branch out. Through the oilways in the crankshaft the oil is supplied to the big ---end bearing.

Model

205 -- 555

Code

Page

210

20

Oil is also taken from the main gallery to the injection pump and turbocharger (7), and via oilways in both ends of the cylinder block, to the camshaft (8). The remaining camshaft bearings are lubricated through drillings in the camshaft. Oil is also fed from the oilway in the front of the cylinder block, to the idler gear (9) bearing. The oilway at the rear end of the camshaft leads to the valve mechanism (10). The oil returns from the cylinder head through the pushrod bores to the oil sump.

Oil pump with oil sump 1. Nut 2. Washer 3. Gear wheel 4. Body 5. Key 6. Gear wheel 7. Gear wheel 8. Shaft 9. Gasket 10. End cover 11. Bolt 12. Pipe union 13. Compression ring 14. Nut 15. Suction pipe 16. Supply pipe 17. Socket head bolt 18. Shims

gears can be adjusted by varying the number of gaskets (9) between the body and the cover. The tooth backlash between the pump gear and the crankshaft gear can be adjusted with shims (18) between the pump body and cylinder block. The flow is 45 litres/min at an engine speed of 2350 rpm.

The oil pump is a gear pump and is attached to the lower face of the cylinder block. It is driven by the gear at the front end of the crankshaft. The gear wheels (6 and 7) and their shafts are carried in bearings in the body (4). An end cover (10), to which suction pipe (15) and supply pipe (16) are connected, is bolted to the body. The end float of the

Relief valve

1. Screw stud 2. Washer 3. Cover 4. Gasket 5. Washer 6. Spring 7. Valve cone 8. Cylinder insert 9. o---ring 10. Nut The oil pressure relief valve is located in the cylinder block below the oil filter (205, 305, 405) or in the timing gear casing (355, 455, 555). The valve regulates the engine lubricating oil pressure so that it is kept constant, regardless of the engine speed. The “O” ring (9) seals against the cylinder insert (8). The valve cone (7) closes the front end of the lower oil passage. When the oil pressure exceeds the force exerted by the spring (6), some of the oil is allowed to flow back to the sump. Normal pressure is 3 ---5 kgf/cm@ depending on the properties of the oil; at low idling speed the pressure is 1.5 kgf/ cm@.

40

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

210

21

Oil filter The oil filter is of the disposable type and is a full---flow filter. A by ---pass valve is located at the bottom of the filter to allow for cold ---starting and if the filter should become clogged. In addition, there is a non ---return valve which stops the filter from being completely emptied of oil.

Induction and exhaust system

Induction system 1. Cyclone type precleaner 2. Dust collector 3. Nut 4. Main filter element 5. Sealing washer 6. Safety filter 7. Air cleaner housing 8. Clamp 9. Rubber hose 10. Inlet pipe 11. Induction manifold 12. Gasket 13. Bolt be cleaned when necessary. The inner, safety filter (6) prevents impurities from entering the engine, should the main filter element break, or be fitted incorrectly. The safety filter should not be removed except when being changed. The inlet system also includes the pipes between the air cleaner and the turbocharger and the turbocharger and the induction manifold (11).

The filter system for the engine induction air comprises a cyclone type precleaner and a paper filter which acts as the main filter. The incoming air is made to rotate in the cyclone (1). This causes most of the impurities to separate out and collect in the cyclone precleaner dust collector (2). The paper filter comprises two replaceable filter elements. The impurities in the air collect on the outside of the large filter element (4) which can

41

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

210

22

Turbocharger

1. Turbocharger 2. Gasket 3. Manifold 4. Screw stud M10x25 5. Nut M10 6. Screw stud M10x50 7. Screw stud M10x90 8. Bolt M8x30 9. Gasket 10. Pressure oil pipe 11. Sealing washer 12. Banjo bolt 13. Gasket 14. Socket head bolt M8x20 15. Return oil pipe 16. Hose 17. Clamp 18. Nut M6 19. Clamp for oil pipe 20. Bolt M6x30

The turbocharger (1) which is connected to the exhaust manifold (3), is lubricated by the engine pressure lubricating system, via a pressure oil pipe (10) and return oil pipe (15).

Function of turbocharger The principle of the turbocharger is that is uses the energy in the exhaust gases in order to force more air into the combustion chambers. The turbocharger is fitted directly to the exhaust manifold. The energy in the exhaust gases causes the turbine wheel to rotate, which in turn drives the compressor wheel. The rotating compressor wheel forces air into the combustion chambers under pressure. Thus more air enters the cylinders, allowing more fuel to be burnt and thereby increasing the output. As the turbine wheel is driven by the engine exhaust gases, the turbocharger automatically adjusts itself to the workload and speed of the engine. The turbine shaft runs in bearings with two floating bearing bushings located in the bearing housing. The bearings are lubricated and cooled by the engine pressure lubricating system. Piston ring type sealing rings prevent oil leakage from the bearing housing.

AIR

GAZ D’ECHAPPEMENT

HUILE

42

1. 7. 1989

21. Engine

10. 1. 1992

Repair instruction

Model

205 -- 555

Code

Page

211

1

B. Removing cylinder liners 1. If the cylinder liners are to be used again they should be marked so that they can be fitted in the same position.

Cylinder block and flywheel housing (Op. no. 211) 1. Cylinder block and cylinder liners

9051 73100

A. Measuring cylinder liner wear 1. Zero the cylinder bore gauge to the original dimension 100.015 mm (205, 305, 405) or 108.00 mm (355, 455, 555) using a micrometer or a new cylinder liner.

2. Remove the cylinder liners using cylinder liner puller 9051 73100.

2. Clean the cylinder bore.

C. Checking cylinder block

3. Measuring should be done in both the transverse and the longitudial direction of the engine, at both the top and bottom dead centre positions as well as in the middle.

1. Clean the cylinder block. Do not forget the oilways.

4. Note the wear and out---of ---roundness. Compare with the Technical Data.

3. Check the cylinder block for cracks and the sealing of plugs. Check all sealing surfaces.

2. Check the cooling channels and remove any scale.

4. Measure the camshaft bearings and compare with Technical Data.

D. Changing camshaft bushing 1. Extract the bushing with an internal puller, for example Sykes 854. If the camshaft rear end plug is removed the bushing can be forced out with a long drift. 2. Clean the bushing location.

43

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

211

2

F. Fitting plug at camshaft rear bearing 1. Clean the seat for the plug. 2. Apply sealing compound, part no. 6909 30008, on the contact surface.

3. Press in the new bushing. Note the position of the oil hole. The bushing is of nominal size and does therefore not have to be reamed.

E. Oversize bushings for camshaft

9025 87400

If the location of the camshaft bushing (front bearing) is damaged, an oversize bushing can be fitted. Bushings are also available for other camshaft bearings which are not normally fitted with bushings. Part numbers and machining dimensions for the bushing locations are shown in Fig. 211 4. The bushings can be fitted using “locally prepared tool” no. 8359 7536. 75,5

3. Drive in the plug with fitting drift 9025 87400 which ensures the correct fitting depth. N.B. If the plug is driven in too far it will affect the camshaft end float.

213,5

+0,030

G. Fitting pipe for oil dipstick

ø55,62

+0,030

ø55

ø55

ø56,02

+0,030

+0,030

6+0,2

1. Clean the seat for the pipe.

8363 22610

8363 24661

2. Apply locking fluid part no. 6909 30012, on the lower end of the pipe.

8363 22609

Oversize bushings for camshaft 205, 305, 405

75,5

213,5

8353 36463

45 ø55,60

+0,030

ø55

+0,030

ø55

+0,030

ø61

+0,030

6+0,2

8363 22610 8363 22609

Oversize bushings for camshaft 355, 455, 555

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

NOTE: When pressing in the new front and rear bushings, ensure that the oil holes in the bushings align with the oilways in the cylinder block. Shorten the threaded part of the plug at the rear camshaft bearing by 1.5 mm. The plug for the rear end of the camshaft is, after machining, replaced by plug 8363 24391 and “O” ring 6146 05125.

44

1. 7. 1989

21. Engine

10. 1. 1992

H. Fitting cylinder liners

Model

205 -- 555

Code

Page

211

3

6. If the cylinder liner height is too low, a liner with a higher flange is fitted.

1. Clean the cylinder liner and its recess in the cylinder block. Without o---rings the liner should rotate easily in its recess. 2. Apply a thin layer of marking paint on the underside of the cylinder liner flange. Fit the cylinder liner without o---rings and turn it forwards and backwards. Lift out the liner and check that paint has been deposited on the whole contact surface.

3. If the recess is damaged, or the cylinder liner height needs to be adjusted, use milling cutter 9051 72900 (205, 305, 405) or 9051 72800 (355, 455, 555). If necessary, light lapping can be executed after milling with the help of the cylinder liner. Apply lapping paste to the underside of the cylinder liner flange, and twist the liner with twisting tool 9051 73100. Lapping is not suitable for adjusting the cylinder liner.

7. Cylinder liners with oversize flanges (higher flanges) are marked with grooves on the outer circumference of the flange, as follows (standard liners have no grooves): 1st oversize, 0,05 mm = 1 marking groove 2nd oversize, 0,10 mm = 2 marking grooves 3rd oversize, 0,20 mm = 3 marking grooves

4. Clean the contact surfaces. 0,03---0,08 mm

8. If the liner height of a cylinder liner is not the same all the way round, the cylinder liner flange and the cylinder block recess depth should be checked. Cylinder liners with warped flanges should be discarded. Recess depth is adjusted with a cylinder liner recess cutter, see point 3.

9025 79200

9025 78100 5. Fit the cylinder liners and fix each liner with two press tools 9025 78100. Measure the cylinder liner height with a dial gauge and holder 9025 79200. Zero the dial gauge against a flat surface, for example, the cylinder block face. Measure each liner in four places. The height of the liner above the cylinder block face should be 0,03 ---0,08 mm. The height difference between cylinder liners under the same cylinder head must not exceed 0,02 mm, nor must an intermediate cylinder liner lie lower than an outer one.

9. Fit the “O” rings in the grooves on the cylinder liners and lubricate them with a solution of soft soap.

45

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

211

4

4. Centre the housing and fit the tubular pins with drift 9025 98700. 5. Tighten the bolts, the inner ring of socket head bolts (8 mm) to 60 Nm and the outer ring of hexagonal bolts (19 mm) to 110 Nm.

Ø 3 musta/svart/black schwartz/noir

B. Changing crankshaft rear oil seal

Ø 3 vihreä/green/grön grün/vert

1. Part the tractor at clutch and remove the clutch assembly (Op no. 411 1A).

Fitting the “O” rings to the cylinder liner.

2. Loosen the bolts (19 mm) and remove the flywheel.

N.B. Fit the o---rings from beneath and ensure that they are not stretched too much. If they are stretched more than 6 % they will not return to their original length.

3. Prize out the seal. Ensure that the crankshaft is not damaged. 4. Clean the sealing location and grind off any burrs.

Fit the cylinder liners in the cylinder block. They should fall into place under fairly light pressure. Check that they do not rise

8360 20054

up again. N.B. With effect from engine number 88946 has cylinder liner lower end three o---rings. The two upper o---rings are black and the lowest is green. As a spare part is delivered only liners with three o---ring grooves.

2. Flywheel housing A. Fitting flywheel housing The flywheel housing is centred on the cylinder block by two tubular pins. Even the flywheel housings which are delivered as spare parts have pre ---drilled holes for the tubular pins. 1. Clean the sealing surfaces between the cylinder block and the flywheel housing.

N.B. If the crankshaft is worn at the sealing location, a 2 mm spacer ring, part no. 8360 20054, can be fitted inside of the crankshaft rear oil seal.

2. Apply sealing glue as shown in the figure. 3. Lift the flywheel housing into place and fit all the bolts.

46

Model

21. Engine

1. 12. 1986

8360 97315

5. Lubricate the sealing surfaces on the crankshaft and on the seal. Place the seal on the crankshaft and drive it until it bottoms using drift 8360 97315. Other tools may cause the seal to be damaged or mounted askew, resulting in leakage.

47

205 -- 555

Code

Page

211

5

48

Model

21. Engine

1. 12. 1986

205 -- 555

Code

212

Page

1

Cylinder head and valve mechanism (Op. no. 212) 8360 97336

1. Cylinder head A. Removing cylinder head 1. Clean the engine externally and drain the coolant . Undo the water hoses from the cylinder head and thermostat housing. 2. Remove the inlet pipes between the air filter and turbocharger and also the pipes between the turbocharger and the induction manifold. 3. Remove the turbocharger pressure and return oil pipes (13 mm, 22 mm and socket head bolt 6 mm).

8360 97532

4. Remove the pipes to the thermostarter fuel reservoir.

2. Compress the valve springs using lever 8360 97532. Remove the valve cotters, spring guide and spring. Remove the valves and place them in a valve stand.

5. Remove the bolt (socket head 8 mm), which holds the engine compartment partition wall against the cylinder head. Also remove the attaching bolts between the supports and the induction manifolds. 6. Remove the injector leak ---off fuel pipes (10 mm) and the delivery pipes (17 mm). Remove the injectors (13 mm). Fit blanking ---off caps on all open connections.

C. Checking cylinder head

7. Remove the induction manifold (13 mm), exhaust manifold (17 mm), thermostat housing (8 mm socket head) and the front end lifting eye (17 mm).

1. Remove carbon deposits from the exhaust ports, clean the sealing surfaces and wash the cylinder head.

Note! The cylinder head can be removed with these parts still in place.

2. Check for cracks and other damage.

8. Remove the valve cover (17 mm) and the breather hose. 9. Remove the rocker arm mechanism (17 mm) and the pushrods. 10. Loosen the cylinder head bolts first by a 1/4 turn and then remove them. Remove the cylinder head.

B. Removing valves Ensure that valves which are to be re ---used are marked, so that they are fitted in their original locations. 1. Thread the counterhold nuts 8360 97336 onto a screw stud for the rocker arm mechanism. On the 309---engines there is not a screw stud at the valves for the centre cylinder. A bolt of suitable length should be used instead.

3. Check the flatness of the cylinder head by using a straight edge. An uneven or warped surface should be surface ground. The height of the cylinder head, after grinding, should not be less than 104,70 mm (equivalent to a machinery allowance of 0,20 mm. If further machining is required the piston should be shortened correspondingly, i.e. 0,20 mm. However, the height of the cylinder head must not be less than 104,50 mm.

49

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

212

2

8360 97457

2. Lubricate the outside of the new guides and fit them using drift 8360 97457.

4. Measure the clearance between the valve stem and the valve guide with a dial gauge. Lift the valve so that the valve head is 15 mm from the face of the cylinder head, and measure the clearance. It must not be greater than 0,30 mm for the inlet valves and 0,35 mm for the exhaust valves. In order to establish the valve guide wear, a new valve should be used when measuring.

Note! Earlier the fitting height of the valve guides was 18 mm and that was reached by using above mentioned drift. Now the fitting height is 21 mm and thus a 3 mm thick spacer ring must be used with tool 8360 97457.

D. Changing valve guides

21

3. The guides are the same for the inlet and outlet valves. Ensure that the steepest chamfer on the guide, faces the valve head. Check that the valves do not bind in the guides.

1. Press or knock out the old guides using drift 8360 97337. Clean the valve guide locations.

50

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

212

3

E. Changing copper sleeve for injector

8360 97463 8360 86085

4. Apply sealing compound 6909 30008 to the lower end of the sleeve. Lubricate the O ---rings and fit them on the sleeve. Drive in the sleeve with drift 8360 97463.

1. Tighten the threaded tap part of the extractor for injector sleeve 8360 86085 in the copper sleeve.

8361 97470

8360 86085

5. If necessary, clean and adjust the seat (the lowest surface inside the sleeve) using milling tool 8361 97470.

2. Fit the support sleeve and nut, and extract the copper sleeve.

N.B. If required, the ordinary copper sleeve can be replaced by a sleeve with an oversize of 0,4 mm at the upper end of the sleeve. Before fitting the oversize sleeve, the location in the cylinder head has to be enlarged by 0,4 mm. The order number for the oversize copper sleeve is 8360 38723.

3. Clean the seat for the copper sleeve and check that the upper edge of the hole is not sharp enough to damage the O ---rings when fitting the new sleeve.

51

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

212

4

F. Machining valve seats

4. Lap the valves with lapping paste and check the contact surface with marking paint. 1. Machine the damaged valve seats with cutters 8360 97434---97437, or with grind stones. If the width of the seat exceeds 1,5 mm it should be reduced, primarily at the outer edge. The seat angle is 30˚.

5. Clean the cylinder head and valves of any remaining lapping paste.

G. Grinding valves

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

I. Fitting cylinder head 1. Check that the two screw studs are fitted in the cylinder block. Fit the valve tappets if the have been removed.

In order to ensure that there is a proper seal around the valves, there is a difference in the sealing surface angles of 0,5˚. Thus there is a very narrow sealing surface which seals effectively even after prolonged running.

2. Check that the sealing surfaces are clean and position the cylinder head gasket. 3. Position the cylinder head. Clean, lubricate and fit the bolts.

1. Grind damaged valves clean in a valve grinding machine. The angle should be 29,5˚. 2. If the edge of the valve head is less than 1,5 mm after it has been ground, or if the valve stem is bent, the valve should be discarded. 3. If necessary, grind the end of the valve stem.

52

10. 1. 1992

21. Engine

31. 8. 1995

Model

205 -- 555

Code

Page

212

5

205, 305, 405

355, 455, 555 2. Check the straightness of the pushrods by rolling them on a surface table. Check also the spherical surfaces at the ends. 3. Dismantle and clean the rocker arm mechanism. Check the shaft for wear and that the oilways are clean.

4. Tighten the bolts in stages. The tightening sequence is shown in figures above. It is also marked on the cylinder head. Tighten all bolts to 80 Nm in the first stage, to 140 Nm in the second stage and to 160 Nm in the third and final stage. 5. Fit the pushrods and rocker arm mechanism. Tighten the rocker shaft bearing brackets so that the washers on the inside of the circlips on the rocker arm shaft can rotate freely. 6. Adjust the valve clearance, see Op. no. 212 2C. 7. Fit the remaining parts, see Op. no. 212 1A.

4. Check that the rocker arm bushes are not worn. Ensure that the oil hole is positioned correctly when pressing in new bushes. After pressing in the bushes they should be reamed to 19,990 ---20,010 mm. Where necessary grind the rocker arm valve contact surface to the correct shape. Do not grind more than necessary as the hardened layer is thin.

8. Run the engine until it is warm and check tighten the cylinder head. Follow the tightening diagram and loosen each bolt slightly, before finally tightening to the correct torque while the bolts is in motion. Adjust the valve clearance.

5. Lubricate the bearing surfaces and assemble the rocker arm mechanism. Check that the plugs at either end of the shaft are secure.

2. Valve mechanism A. Reconditioning rocker arm mechanism 1. Check the valve tappets, especially the contact surface against the camshaft. Worn or damaged tappets should be discarded.

53

10. 1. 1992

21. Engine

15. 4. 1994

Model

205 -- 555

Code

Page

212

6

bands to prevent them from falling through. Crank the engine so that all the tappets are in their upper positions. Note! Do not connect the pushrods too tightly as this might cause them to bend or snap. 6. Crank the engine until the aligning marks on the idler gear and camshaft gear are facing each other. Extract the camshaft.

N.B. The rocker shaft lubrication system has been improved by adding lubricating holes which are drilled obliquely (60˚) to the valve side (see point 3). At the same time marking grooves A have been removed (point 2). In connection with repairs, it is recommended that these new oil holes are drilled in rocker shafts which have downwards directed holes (point 2). The drilling is unnecessary if shafts which have horizontally drilled holes (point 1). Point 3 shows the later shaft which has ready ---made oblique holes.

7. Separate the camshaft from the gear wheel using a press or suitable drift. 8. Clean the parts which are to be refitted.

B. Changing camshaft/camshaft gear

9. Fit the threaded plug in the rear end of the camshaft and fit the key in its groove. Heat the camshaft gear to 200˚ C (392˚F) in an oven and fit it on the shaft.

1. Remove the inlet pipe between the turbocharger and the induction manifold. Remove the valve cover (17 mm) and the breather pipe. Remove the rocker arm mechanism (17 mm).

10. Lubricate bearing surfaces and lobes and insert the shaft in the cylinder block. Ensure that the aligning marks on the gears agree.

2. Remove the cooling fan (13 mm) and the alternator (13 mm) including the stay and belt.

11. Fit the timing gear casing cover and the crankshaft V ---belt pulley and hub, see Op. no. 214 1B.

3. Remove the crankshaft nut using spanner 9024 74200. Remove the V ---belt pulley including the hub.

12. Free the pushrods and fit the rocker arm mechanism, see Op. no. 212 1J 5. Fit the valve cover, the breather pipe and the inlet pipe between the turbocharger and the induction manifold.

4. Remove the timing gear casing cover (13 mm).

13. Fit the alternator with stay and belt, and fit the cooling fan.

5. Connect the pushrods in pairs, using o---rings or elastic

54

1. 7. 1989

21. Engine

10. 1. 1992

C. Adjusting valves The valve clearance, which can be adjusted on a hot or cold engine, is 0,30 mm (0,012 in) for both inlet and exhaust valves. The clearance is adjusted when the respective piston is at T.D.C. in the compression stroke. The valves for the different cylinders are adjusted in the same sequence as the order of injection. 1. Remove the valve cover (17 mm) and the breather pipe. Remove the rubber plug in the flywheel housing. 2. Crank the engine using a screwdriver against the flywheel ring gear, until the exhaust valve of no. 3 cylinder (valve no. 5) is completely open. Adjust the valves of no. 1 cylinder.

A6181--- 106

205, 305, 405 3. Crank the engine in the direction of rotation until no. 1 cylinder exhaust valve (valve no. 2) is completely open. Adjust the valves of no. 2 cylinder. 4. Continue cranking the engine in the direction of rotation until no. 2. cylinder exhaust valve (valve no. 4) is completely open. Adjust the valves of no. 3 cylinder.

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

55

Model

205 -- 555

Code

Page

212

7

56

Model

21. Engine

1. 12. 1986

Code

205 -- 555

213

Page

1

Crank mechanism (Op. no 213) 1. Crankshaft A. Removing crankshaft 1. Disconnect all leads, lines and controls from the engine according to Op. no. 219 1A or 2A. 2. Free the oil pump pressure pipe (6 mm socket head) from the cylinder block. Remove the oil pump (8 mm socket head) together with suction and delivery pipes. 3. Remove the flywheel (19 mm) and the flywheel housing (19 mm and 8 mm socket head). 4. Remove the timing gear casing Op. no. 214 1A. 5. Remove the crankshaft bearing caps (19 mm) and push the connecting rods out of the way of the crankshaft. 6. Remove the main bearing caps (24 mm) and lift out the crankshaft.

3. Refit the bearing caps with new bearing shells and tighten them to the correct torque. Measure the I.D. with a dial gauge which has been zeroed to the dimensions obtained in point 2. With this method the indicator shows the actual bearing clearance.

B. Checking crankshaft 1. Clean the crankshaft. Do not forget the oilways.

4. If the bearing clearance exceeds 0,18 mm for main bearings or 0,14 mm for connecting rod big ---end bearings with new bearing shells, the bearing journals on the crankshaft should be ground. Refer to the specifications for the relevant correct undersize and the corresponding bearings. Ensure that the radii are not changed when grinding.

C. Changing crankshaft gears 8360 97327

2. Measure both the crank and main bearing journals in several places. Out---of ---round, taper or other wear must not exceed 0,03 mm.

1. Apply puller 8360 97327 for the crankshaft gears and pull off both gears.

57

1. 7. 1989

21. Engine

Model

10. 1. 1992

205 -- 555

Code

Page

213

2

2. Clean the seat on the crankshaft with, for example, a wire brush. 3. Heat the new gears to 200˚C in an oven. Tap them onto the shaft with a suitable sleeve or soft drift. Note the position of the key and ensure that the aligning marks on the front gear are visible. Leave it to cool.

0,10-- 0,35 mm

D. Fitting crankshaft 1. Clean the oilways, bearing shells and bearing locations. Check that the crankshaft is clean. If it is ground, the oil holes should be checked. 2. Fit the correct size shell bearings. Ensure that guide pins and oil holes are fitted facing their respective sockets and holes. 3. Lubricate the bearing surfaces and fit the crankshaft. Fit the crankshaft thrust bearings with the lubricating grooves facing the crankshaft. 5. Check that the crankshaft can rotate without binding. Check the end float using a dial gauge. The correct end float is 0,10 ---0,35 mm. If the end float is too large, oversize thrust bearings should be fitted. N.B. Bearing shells should never be reamed or machined in any other way, nor should the sides of the bearing caps be filed.

4

3

4

4 3

2. Connecting rods and pistons A. Removing piston together with connecting rod.

4

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

4. Fit the main bearing caps in the order indicated by the numbering; the rear bearing cap should be fitted with thrust bearings provided with guide lugs. Lubricate the bolts and tighten them to 160 Nm (205, 305, 405) or 200 Nm (355, 455, 555).

5. Push up the piston and connecting rod with the shaft of a hammer or similar wooden tool. 6. Remove the piston pin circlips and push out the piston pin. Where a piston is to be re ---used, the piston pin should not be knocked out. If the piston pin does not become loose under thumb pressure the piston should be heated to 100˚C.

58

1. 7. 1989

21. Engine (11---series)

10. 1. 1992

B. Changing connecting rod bearing

Model

205 -- 555

Code

Page

213

3

NOTE: When necessary, an oversize bushing, part no. 8360 38605 (205, 305, 405) or 8353 28326 (355, 455, 555) is available. Before driving this bushing in, the connecting rod should be machined to 40.500...40.525 mm (205, 305, 405) or 44.500...44.525 mm (355, 455, 555). After fitting, the oversize bushing should also be reamed to the correct size.

1. Clean the connecting rod and bearing shells. Fit them together and tighten the bolts to 90 Nm.

C. Checking connecting rod The connecting rod is checked in a special fixture, intended for the purpose (e.g. Carl Larsson). 1. Fit the bearing caps and tighten the bolts (19 mm) to 90 Nm. 2. Fit the connecting rod in the fixture and fit the piston pin which corresponds to that connecting rod.

2. Measure the I.D. using a cylinder gauge which has been zeroed to the diameterof the appropriate bearing journal. If the clearance exceeds 0.14 mm with new bearing shells, the big end journals require grinding. Refer to the Technical Data section for the correct undersize and the corresponding bearing. Ensure that the radii at the end of the bearing journals are not altered when grinding. 3. If the small---end bearing bushing is worn, it should be driven out using a suitable drift.

3. Check that the connecting rod is not twisted by positioning the measuring tool with the horizontally placed measuring points against the face of the fixture.

4. Drive in the new bushing and ensure that the oil hole is in the correct position. Ream the bushing after it is fitted to 36.025...36.040 mm (205, 305, 405) or 40.025...40.040 mm (355, 455, 555).

59

10. 1. 1992

21. Engine (11---series)

15. 9. 1995

Model

205 -- 555

Code

Page

213

4

The connecting rods are divided into weight classes with intervals of 20 g. The weight class (indicated by a letter) is stamped on the side face of the connecting rod. The sequence number of the cylinder is stamped next to the letter (but not on the latest connecting rods). All the connecting rods in an engine should be of the same weight class; in other words the greatest permissible weight difference is 20 g. Note! Connecting rods of the 20---series engines replace as a spare part the connecting rods of the 11---series engines. Connecting rod bolts of the 20---series engines should be tightened progressively, 40 Nm+90˚. When ordering separate connecting rods, the weights classes of the rods must be observed. Table below shows the equivalents of the weight classes on the 11---, and 20---series engines: The letters show the weight classes as follows: 205, 305, 405 (309 ---engines): Weight Part number H 1990---2010 g 8360 36562 I 2010---2030 g 8360 36563 J 2030---2050 g 8360 36564 K 2050---2070 g 8360 36565 L 2070---2090 g 8360 36566 M 2090---2110 g 8360 36567 N 2110---2130 g 8360 36568 O 2130---2150 g 8360 36569 P 2150---2170 g 8360 36570 R 2170---2190 g 8360 36571 S 2190---2210 g 8360 36572 T 2210---2230 g 8360 38116 U 2230---2250 g 8360 38117 V 2250---2270 g 8360 38118

4. Turn the measuring tool round with the vertically placed measuring points against the face, and check the straightness of the connecting rod.

355, 455, 555 (11 ---series engines on which are used the connecting rods of the 20 ---series engines): Letter of Weight Letter of Part number 11 ---series 20 ---series 2170---2189 A 8366 52104 H 2190---2209 B 8366 52105 I 2210---2229 C 8366 52106 J 2230---2249 D 8366 52107 K 2250---2269 E 8366 52108 L 2270---2289 H 8366 52109 M 2290---2309 I 8366 52110 N 2310---2329 J 8366 52111 O 2330---2349 K 8366 52112 P 2350---2369 L 8366 52113 R 2370---2389 M 8366 52114 S 2390---2409 N 8366 52115 T 2410---2429 O 8366 52116 U 2430---2449 P 8366 52117 V 2450---2469 R 8363 52118 X 2470---2489 S 8366 52119 Z 2490---2509 T 8366 52120 A 2510---2529 U 8366 52121

5. Also check the S ---bending of the connecting rod by using sliding calipers to measure the distance between the edge of the small---end bearing bushing and the face of the fixture. Turn the connecting rod round so that the other side of the connecting rod faces the fixture. Then measure the same distance. The accepted deviation is 0,6 mm.

E. Changing piston rings

D. Connecting rods, weight classes

2

1. Remove the piston rings. Do not open the rings more than necessary. If the rings are to be used again ensure that they are fitted in the same groove.

2 L

60

1. 7. 1989

21. Engine

10. 1. 1992

Model

205 -- 555

Code

Page

213

5

4. Fit the piston rings on the piston using the piston ring pliers. Ensure that the rings are fitted in the correct groove and that ”TOP”, or the manufacturer’s designation, faces upwards.

F. Fitting piston pin

2. Clean the piston ring groove and measure the piston ring clearance, which must not exceed 0,15 mm. Determine whether too large a clearance is due to worn rings or a worn groove. Change worn parts.

1. Heat the piston to 100˚C. Fit the connecting rod and press in the piston pin.

3. Measure the piston ring gap by pushing one piston ring at a time into the cylinder bore using an inverted piston. The gap should be measured above the upper turning point or below the lower turning point. The piston ring gap must not exceed 1.0 mm (except for the 2nd compression ring on 355, 455 and 555: 1.4 mm).

N.B. The combustion chamber in the piston and the sequence number on the connecting rod should be on opposite sides, facing away from each other!. 2. Fit the circlips for the piston pin.

61

1. 7. 1989

21. Engine

1. 12. 1986

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

3. Fit the piston with the marking on the connecting rod (weight class) facing the camshaft (an arrow on the piston must point forward). 4. Lubricate the big ---end bearing journal and bearing shells, and push the piston down. Fit the bearing cap so that the notches for the guide lugs are in the same side. Tighten the connecting rod bolts to 90 Nm. 5. Check that the connecting rod has sufficient end float on the big ---end bearing journal.

62

Model

205 -- 555

Code

Page

213

6

Model

21. Engine

1. 12. 1986

205 -- 555

Code

214

Page

1

9. Remove the timing gear casing (13 mm). Ensure that all sealing surfaces are not damaged.

Engine timing gears (Op. no. 214)

10. Remove the sealing ring and clean all the parts that have been removed.

1. Timing gear casing A. Removing timing gear casing

B. Fitting timing gear casing

As the timing gear casing forms a seal against the oil sump, the casing cannot be removed without first removing the oil sump.

The position of the timing gear casing and cover is determined by two tubular pins. Therefore centring should not be undertaken in connection with fitting. However, the tooth backlash between the different gears should be checked. casing and covers that are delivered as spare parts also have holes for the tubular pins already machined.

1. Remove the engine, see Op. no. 219 1A or 2A. 2. Remove the fan (13 mm) and the alternator (13 mm) including the stay and belt.

1. Fit the casing with a new gasket against the cylinder block. Drive in the tubular pins with drift 9025 98700. Tighten bolts and nuts (13 mm). 2. Fit the injection pump together with gear wheel. 3. Lubricate the camshaft bearings and insert the shaft in the cylinder block. Release the pushrods and tappets if they have been suspended in some way.

3. Loosen the crankshaft nut with key (socket) 9024 74200. Remove the V ---belt pulley hub. 4. Remove the transmission casing cover (13 mm). Ensure that the sealing surfaces are not damaged. 5. Remove the oil deflector ring. 6. Remove the injection pump, see Op. no. 223 1C.

1. Crankshaft gear 2. Lubricating oil pump gear 3. Camshaft gear 4. Idler gear 5. Injection pump gear

N.B. If the timing gear casing is not to be changed, the injection pump remain in place. In which case disconnect all leads and pipes from the pump. 7. Remove the idler gear (17 and 22 mm), flange and bearing journal.

4. Fit the idler gear with shaft stud and ensure that the markings are in the correct position. Fit the washer and tighten the bolts to 60 Nm and 180 Nm respectively.

8. Extract the camshaft. N.B. If the cylinder head and valve mechanism have not been removed, the tappets must be prevented from falling down, see Op. no. 212 2B 5.

63

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

214

2

9030 15200 5. Check that the tooth backlash is 0,05 ---0,25 mm. 7. Fit the oil deflector ring and then the crankshaft oil seal with drift 9030 15200. 9025 98700 9025 98800

9025 98900

6. Fit the oil deflector ring on the crankshaft and fit the timing gear casing cover using a new gasket. Drive in the tubular pins with drifts 9025 98700 and 9025 98800 respectively (the tubular pin round the screw stud).

8. Fit the dust shield on the crankshaft V ---belt pulley hub, if it has been removed. Use drift 9025 98900. 9. Lubricate both the seal and sealing surfaces and fit the crankshaft V ---belt pulley with hub. 10. Tighten the crankshaft nut with key (socket) 9024 74200 to 600 Nm. 11. Fit the alternator and the belt. 12. Fit the breather hose and the fan (13 mm).

64

Model

21. Engine

1. 12. 1986

C. Changing crankshaft front oil sea

1. Remove the fan belt. 2. Loosen the crankshaft nut with key (socket) 9024 74200 and remove the V ---belt pulley and hub. 3. Remove the old seal and clean the sealing location. Tap on the new seal with drift 9030 15200. 4. Lubricate both seal and sealing surfaces and fit the crankshaft V ---belt pulley and the hub. Tighten the crankshaft nut to 600 Nm. 5. Fit the alternator and the belt.

65

205 -- 555

Code

Page

214

3

66

Model

21. Engine

1. 12. 1986

Lubricating system (Op no 215)

205 -- 555

Code

215

Page

1

B. Removing and dismantling lubricating oil pump

A. Reconditioning of oil relief valve for lubricating oil pressure

1. Remove the oil sump. 2. Remove the oil pump suction pipe (13 mm).

If the engine lubricating oil pressure is insufficient or if it varies, the relief valve should be checked after first checking the oil level.

3. Remove the oil pump pressure pipe (6 mm socket head) and pipe union. 4. Remove the oil pump (8 mm socket head) together with any shims. 5. Open the oil pump (13 mm) and remove the loose pump wheel (gear wheel). 6. Clamp the pump gear across the teeth in a vice fitted with soft jaws, and loosen nuts (17 mm). Knock the gear wheel off by hitting the end of the shaft with a soft hammer. 7. Clean the parts and check for wear and other damage. Compare with the Technical Data. Change damaged parts and all seals.

1. Remove the cover over the valve (13 mm) and spring. Take care of the washer between the cover and spring. Remove the valve insert together with the valve cone and ensure that the o---ring is also removed. 2. Clean the parts and check that the valve cone slides freely in the insert and that the sealing surface are undamaged. Minor damage can be adjusted, but in general, damaged parts should be changed. Scrape off any remains of the gasket. 3. Assemble the valve with a new o---ring and insert it in the cylinder block. Place the washer and spring in the cover and fit it with a new gasket.

C. Assembling and fitting lubricating oil pump 1. Fit the gear wheels in the pump body. Fit the cover using a new gasket. Partly tighten the bolts. Rotate the pump shaft and tap the side of the cover lightly until the position is reached where the shaft rotates most freely. Tighten the bolts and check that the shaft still rotates. 2. Fit the pump gear on the shaft together with a key. Position a locking washer and tighten the nut.

4. Note that the relief valve cover is not symmetrical. The greater distance between the spring housing and bolt should be turned downwards.

67

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

215

2

E. Changing lubricating oil filter The lubricating oil filter is usually changed in connection with changing the oil. See the Operator’s Manual. 1. Clean the filter externally. Remove the filter and wipe off any spilt oil.

3. Fasten the oil pump in a vice and check the end float between gear and pump housing. The clearance which should be 0,03 ---0,11 mm, is adjusted by the number of gaskets between the cover and body. 2. Clean the sealing surfaces and lubricate the new filter seal. Tighten the filter by hand. 3. Start the engine and check that there is no leakage. N.B. The guarantee of the engine is only valid on the assumption that a Valmet original oil filter is used.

4. Fit the pump and check the tooth backlash against the crankshaft gear. The clearance, which should be 0,05 ---0,25 mm, is adjusted with shims between the pump body and the cylinder block (shims 0,2 mm, order no 8360 07871). One shims increases/decreases the backlash about 0,07 mm. Note! When measuring the tooth backlash, the engine should be the correct way up as the crankshaft bearing clearance affects the tooth backlash. 5. Connect suction and pressure pipes together with new seals. 6. Fit the engine (or the oil sump).

68

Model

21. Engine

1. 12. 1986

205 -- 555

Code

Page

215

3

E. Lubricating oil quality requirements 1. QUALITY (API ---CLASS) --- naturally aspirated engines CCMC D2 API CC 1) --- turbocharged engines CCMC D4/D5 API CD

---30

---10

---20

TEMPERATURE ˚C 0 +10

5W---20 5W---30 5W---40 SAE---CLASS

10W 10W---20 10W---30 10W---40 15W---30 15W---40 20W---20 20W---30 20W---40 30 1)

After running ---in period, API ---CD can also be used in conventionally aspirated engines.

69

+20

+30

70

Model

21. Engine

1. 12. 1986

Inlet and exhaust system, turbocharger (Op no 216)

205 -- 555

Code

216

Page

1

B. Checking inlet and exhaust system Important! Leaks in the inlet or exhaust system markedly lower the effect of the turbocharger. Because of the pressure, even small leaks in the manifold or in the turbine inlet contact flange quickly increase in size. For this reason all leaks must be dealt with immediately.

1. Inlet and exhaust systems

An engine that is equipped with a turbocharger is a great deal more sensitive to disturbances and impurities in the inlet and exhaust systems than a conventionally aspirated engine. Therefore special attention should be given to the whole inlet and exhaust system.

1. Inspect the pipes and sealing surfaces between the air cleaner and the turbocharger, as well as between the turbocharger and the induction manifold. If the induction manifold is dusty on the inside, there is a leak in either the air cleaner or the induction pipes. Remedy the leak.

A. Checking air cleaner The engine performance and length of service life depend to a great extent on the state of the air cleaner. A defective air cleaner allows impurities to pass through, which in time damage the turbocharger and the engine. A blocked air cleaner lowers the engine output and also causes oil leakage through the sealing ring on the turbocharger shaft.

2. Clean the induction manifold sealing surface. Check that the sealing surface is flat using a straight ruler. 3. Fit a new gasket and fasten the induction manifold. Tighten the manifold fixing screws to a torque of 30 Nm.. 4. Check that the exhaust manifold is air tight. Tighten the bolts to 60 Nm and inspect for any damage (cracks, deformation, corrosion etc.). Check also the connection between the turbocharger and the exhaust manifold. 5. Remove the manifold if necessary. Clean the sealing surfaces and remove any carbon deposits. Check that the sealing surfaces are flat. 6. Fit new gaskets on the exhaust manifold. Check the tightening torque (60 Nm) after the engine has been run warm. 7. Ensure that no loose objects or impurities have entered the exhaust pipe or the silencer.

2. Turbocharger 1. Remove the main filter element by loosening the nut (13 mm) at the end of the filter housing, and pull out the element. The safety filter inside the main filter should only be removed when it is to be changed. It should not be removed for cleaning.

A. Checking turbocharger In order for the turbocharger to obtain trouble ---free performance, it is important that the engine lubricating and inlet systems are serviced according to the given instructions. Ensure that lubricating oil of the correct type is used and, likewise, original filters.

2. Clean the filter element with either a vacuum cleaner or with compressed air (max. 500 kPa), directed fron the inside, out. The main filter element should be changed after it has been cleaned five times or if it shows any signs of damage.

1. Visually inspect the turbine and compressor wheels. The vanes must not show any signs of damage, deformation or wear caused by foreign objects.

3. Insert a lamp inside the filter element and inspect the filter. If there are any holes in the filter element or if it is damaged (lighter parts which let the light shine through), it should be changed. 4. Clean the inside of the air cleaner housing so that it is free of dust and dirt. Check that the seals are not damaged and that the contact surfaces are clean. Insert the filter element in the housing and check that it is fitted in pace correctly. Tighten the locking nut (13 mm) approx. 1---1,5 turns after there is contact between the seal and the bottom of the filter housing. Note! The safety filter inside the main filter should not be removed unnecessarily, for checking or cleaning. The safety filter must not be cleaned, but should be changed once a year or when necessary (see Operator’s Manual).

71

Model

21. Engine

1. 12. 1986

2. Investigate any oil leaks through the sealing rings on the shaft in the turbine and compressor housing.

205 -- 555

Code

Page

216

2

If the engine does not work correctly and the turbocharger is not defective or too worn, the fault could be traced to one of the following items:

N.B! At low idling there is always a certain amount of oil leakage on the compressor side. However, this should not cause too much concern unless the oil consumption is too great.

--- Blocked air filter --- Leakage in the inlet or exhaust systems. Leaking flange seal --- Defective or wrongly adjusted injection pump. --- Wrongly adjusted throttle linkage --- Defective or wrongly adjusted injectors --- Low fuel pressure (e.g. blocked fuel filter) --- Low compression, wrong valve clearance

B. Removing turbocharger 1. Loosen the attaching bolts for the exhaust pipe and remove it. Loosen the inlet pipe to the turbocharger. 2. Loosen the pipe clamp attaching bolt (10 mm) which holds the oil pipe. Loosen the attaching bolts (13 mm) for the pressure oil pipe and the lower banjo bolt (22 mm). Remove the pressure oil pipe. Remove the return oil pipe (6 mm socket head).

3. Check the turbine shaft running clearance. Place the stylus of a dial gauge against the shaft and move the shaft sideways. refer to the clearance given in the specifications on page 210/9.

3. Remove the attaching bolts (17 mm) and lift off the turbocharger. 4. Fit protective plugs in the holes of all connections.

C. Reconditioning turbocharger N.B! The same degree of cleanliness should be observed when removing the turbocharger as with repairing the fuel system. Only remove the compressor and turbine covers if the requisite special tools, e.g. for adjusting the balance, are not available. In general, when the turbocharger is damaged it is more economical to fit a factory reconditioned turbocharger.

4. Check the shaft end float. Place the stylus of the dial gauge against the end of the shaft and move the shaft axially. Refer to the clearance given in the specifications on page 210/9. If any defects or wear are confirmed, the turbocharger should be reconditioned. N.B. In terms of cleanliness and accuracy, the reconditioning of the turbocharger can be compared to repairing the fuel system. In addition, special tools are needed, e.g. for balancing rotating parts. In general, when the turbocharger is damaged it is more economical to use a factory reconditioned turbocharger.

72

1. 12. 1986

21. Engine

1. 7. 1989

Model

Code

205 -- 555

216

Page

3

6. Remove the bolts (22) which keep the back plate and the bearing housing together and remove the locking strips (21). Remove the back plate (4) and the oil deflector ring (10) from the shaft. Press out the oil deflector ring from the thrust collar and remove the sealing ring (5) from the back plate. Remove the oil deflector (11). 7. Remove the thrust bearing locking bolts (12). Remove the oil deflector (11). 7. Remove the thrust bearing locking bolts (12). Remove the thrust collar (13) and the thrust bearing (14). 8. Remove the turbine wheel and the shaft (25), together with the sealing ring (24), and lift the turbine protective cover (23) off the shaft. Remove the outer locking rings (16) which fix the bearing housing. Insert a finger into the bearing (15) and pull out both bearings. Remove the inner locking rings (16). Turbocharger (Holset) 1. Compressor housing 14. Thrust bearing 2. Nut for compressor wheel 15. Bearing 3. Compressor wheel 16. Locking ring 4. Back plate 17. Bearing housing 5. ”SQ” ---sealing ring 18. Socket head bolt 6. Locking strip 19. Locking strip 7. Washer 20. Attaching strip 8. Socket head bolt 21. Locking strip 9. Sealing ring 22. Socket head bolt 10. Oil deflector ring 23. Protective cover 11. Oil deflector 24. Sealing ring 12. Bolt 25. Turbine wheel and shaft 13. Thrust collar 26. Turbine housing

Cleaning parts of turbocharger N.B. Use conventional cleaning agents. Do not clean with corrosive substances as parts of the turbocharger may be damaged. 1. Wash off all dirt with a detergent solution. Use plastic tools or brush when cleaning aluminium parts. 2. Clean all oilways with compressed air. Check that all contact surfaces are clean and in good condition.

Checking parts of turbocharger

Dismantling Holset turbocharger

1. Shaft and turbine wheel unit: --- Inspect the bearing surfaces for wear and scoring. Minor scoring is permissible --- Inspect the walls of the sealing ring seat for scoring. Minor scoring is permissible. --- Inspect the vanes of the turbine wheel for damage, deformation and breakage. On no account must the vanes be bent.

NOTE: The construction of the Schwitzer turbo unit differs in certain details from that of the Holset turbo. Nevertheless general repair instructions also concern the Schwitzer turbo. See Technical Data page 210/7. 1. Clean the turbocharger externally and fix it by the outlet flange in a vice fitted with soft jaws.

2. Thrust bearing set: --- Change worn or defective parts --- The oil grooves should be clean

2. Mark the compressor housing (1), back plate (4), bearing housing (17) and turbine housing (26) in relation to each other. Bend down the locking strips (19 and 21).

3. Compressor wheel: --- Inspect the compressor wheel for damage, deformation and breakage. On no account must the vanes be bent!.

3. Remove the attaching bolts (8) for the compressor housing. Remove the washers (7) and the locking strips (6) and lift off the compressor housing.

4. Bearings: --- Change worn or scored bearings

4. Remove the attaching bolts (18) for the turbine housing. Remove the locking strips (19) and the strips (20) and lift the bearing housing out of the turbine housing.

5. Bearing housing: --- Change the bearing housing if the bearing surfaces or the grooves for the sealing rings are considerably worn or scored.

5. Hold the turbine wheel and remove the nut (2) for the compressor wheel. Pull the compressor wheel (3) off the shaft.

6. Rotating parts: --- Check the balance of rotating parts

N.B. The nut has a left---hand thread.

7. ”SQ” ---sealing ring --- Change the sealing rings.

73

Model

21. Engine

1. 12. 1986

205 -- 555

Code

216

Page

4

8. Compressor and turbine housing --- Check for damage and scoring caused by contact with the compressor or turbine wheels, and defects caused by overheating. Minor damage is acceptable. If the damage is extensive, the housing should be changed.

8. Place the stylus of a dial gauge against the end of the shaft and measure the end float. The float should be within 0,10 ---0,16 mm.

Assembling turbocharger

10. Tighten the bolts (22 mm) between the bearing housing and the back plate (4) to 5,7 Nm, the compressor housing attaching bolts (8) to 5,7 Nm and the turbine housing attaching bolts (18) to 11,3 Nm.

9. Place the stylus of a dial gauge against the side of the shaft and measure the running clearance. The clearance should be within 0,30 ---0,46 mm.

When the parts of the turbocharger have been carefully cleaned, inspected, and any defective parts changed, the turbocharger can be assembled. The assembling of the turbocharger is carried out in the reverse order to dismantling. Make note of the following:

11. Check that the shaft rotates freely. 12. Fix the locking washers (19 and 21).

1. Rotating parts should be balanced to within 1,44 grammes at both ends. Ensure that the parts are fitted in the same position relative to each other, as before (according to the markings). 2. Fit the locking rings with the chamfered side facing the bearing.

D. Fitting turbocharger

3. Lubricate all bearings, pressure and sealing surfaces with clean engine oil.

Locate the cause of the defects on the turbocharger. Remedy the fault before fitting the new turbocharger.

4. Great care should be exercised when fitting the shaft in the bearing housing. The seals are easily damaged when fitting.

In order for the turbocharger to work satisfactorily, it is important that the engine oil is in good condition. Likewise the correct oil quality should be used, according to the Technical Data. Even the oil filter and air filter should be cared for according to the instructions.

5. Tighten the bolts in the thrust bearing to 4,5 Nm. 6. Take care not to damage the ”SQ” ---sealing ring when fitting the end cover in the bearing housing.

The setting of the injection pump critically affects the function of the turbocharger. The injection pump should be adjusted according to the manufacturers instructions. 1. Check the seals on the induction and exhaust pipes, and that they are securely fastened. Ensure that there are no loose carbon or rust particles, or other foreign objects in the pipes. 2. Connect the turbocharger to the exhaust manifold and tighten down using new gaskets. 3. Connect the induction pipe and the silencer. 4. Pour clean engine oil into the bearing housing through the in ---going oilway. This is very important in order to ensure that the turbocharger is lubricated at the time of starting. 5. Connect the pressure and return oil pipes. Use new seals. Check that there are no tensions in pipes when tightening. 6. Before starting, pull out the stop control and crank the engine round with the starter motor so that the oil pressure rises. Start the engine and check that there are no leaks.

1. Compressor housing 2. Back plate 3. O ---ring 6146 12114 4. ”SQ” ---seal 7. Tighten the lock nut for the turbine wheel to 14,0 Nm. N.B. The nut has a left---hand thread. Take care that the shaft is not bent. Use a suitable T ---handle or a torque wrench.

74

Model

21. Engine

1. 12. 1986

Code

205 -- 555

219

Page

1

Removing and fitting engine (Op. no. 219) 1. Removing and fitting engine by parting tractor N.B. It is easier to remove the engine if the tractor is parted at the clutch. The engine can also be removed without parting the tractor, it is fitted with equipment which makes parting difficult.

A. Removing engine 1. Remove the exhaust pipe and all engine hood plates. Drain the coolant (10 litres).

4. Disconnect the lower and the upper radiator hoses at the radiator and disconnect the induction pipe from the turbocharger.

2. Open the radiator cowl and disconnect the leads for the horn and the headlights. Pull the leads into the engine compartment.

5. Unscrew the bolts for the fan guard ring.

6. Unscrew the engine attaching bolts (19 mm). 7. Remove the battery and the battery shelf. 3. Disconnect the radiator frame support (13 mm).

8. Split the tractor frame at the clutch (see Op. no. 411 1A points 2 ---11).

75

Model

21. Engine

1. 12. 1986

Code

205 -- 555

219

Page

2

80 Nm

3. Tighten the engine attaching bolts to 80 Nm.

9. Disconnect the oil pipes for the steering cylinder (on the right side of the engine) (13 mm).

4. Connect the pipes for the steering cylinder on the right--hand side of the engine and clamp the oil pipes and the leads together with a strip clamp. 5. Connect the lower and the upper radiator hoses and the induction pipe for the turbocharger.

10. Attach lifting hooks to the lifting points on the engine (eylet at the front and hole in plate at the rear) and lift the engine straight up. N.B. Attach the rear hook so the plate does not bend. 6. Connect the radiator frame support (13 mm) and secure the fan guard ring. 7. Connect the leads for the horn and headlights.

B. Fitting engine

8. Fill with coolant (10 litres) and with hydraulic oil (35 litres). Air ---bleed the fuel system. Fill with engine oil (7 litres).

1. Lift the engine into the frame and guide the guide pins into the holes.

9. Tighten the exhaust pipe to 23 Nm and fit all engine hood plates. Connect the windscreen washer hose to the nozzle at the upper hood plate.

N.B. Position the guard ring for the fan over the fan blades before lifting the engine into place.

10. Start the engine and check that the indicator lamp for the engine oil pressure goes out. Test---run the tractor.

2. Push the tractor frame together at the clutch (see Op. no. 411 1C, points 1 ---10).

76

Model

21. Engine

1. 12. 1986

2. Removing and fitting engine without parting tractor

Code

205 -- 555

219

Page

3

6. Attach lifting hooks to the lifting point on the engine (eyelet at the front and plate with hole at the bac) and lift up the engine out of the engine compartment. N.B. Connect the rear hooks so that it does not bend the plate.

A. Removing engine 1. Remove the PTO and the long PTO shaft (Op. no. 462 1A). Pull the clutch shaft out of the clutch through the hole in the cab floor (Op. no. 411 2A, points 1 ---13).

B. Fitting engine N.B. On tractors fitted with a low gear, the clutch should preferably be fitted to the flywheel before fitting the engine.

2. Carry out the instructions for removing the engine according to 1A, points 1 ---6 and 411 1A, points 3 ---7.

N.B. Position the fan guard ring before lifting the engine into position.

80 Nm

3. Disconnect the delivery pipe for the hydraulic lift at the joint on the RH side of the engine (27 mm and 26 mm). Disconnect the engine breather pipe under the front edge of the cab.

1. Lift the engine into position and guide the guide pins into the holes. 2. Tighten the engine attaching bolts to 80 Nm. 3. Fit the clutch shaft and clutch through the hole in the cab floor (Op. no. 411 2B, points 1 ---16). 4. Push the hydraulic system suction pipe in under the cab floor and connect the pipe at its rear end. 5. On the right---hand side of the engine connect and secure: ---------

4. Disconnect the pipes for the steering cylinder on the RH side of the engine. 5. Disconnect the hydraulic system suction pipe under the cab. Loosen the pipe clamps and pullout the pipe from the front of the cab.

77

hydraulic system suction pipe at pump (45 Nm). hydraulic system delivery pipe at pump (45 Nm) pipes for steering cylinder (60 Nm) pipe clamps and leads using a strip clamp

Model

21. Engine

1. 12. 1986

6. Fit the PTO (Op. no. 462 1E). Fill the gearbox with oil (23 litres). 7. Secure the lower part of the engine heater pipe. Connect the electrical leads to the front wall of the cab. 8. Carry out the instructions for fitting the engine (Op. no. 1B, points 5 ---10)

78

205 -- 555

Code

219

Page

4

Model

22. Fuel system

1. 12. 1986

205-- 555

Contents General (Op. no. 220) Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Fuel reservoir for thermostart device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Table of fuel metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Table of fuel equipment parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 3 4 5 6 7 7 8 8 10 10

Repair instructions Fuel feed pump and fuel filter (Op. no. 222) 1. Checking and repairing fuel feed pump: A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Measuring fuel system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Checking overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Removing fuel feed pump and checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 2

2. Fuel filter A. Changing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fuel injection pump and injectors (Op. no. 223)

1. Adjusting fuel injection pump: A. Checking injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Removing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fitting injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Checking/changing delivery valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 2 3 3 4

2. Checking/reconditioning injectors: A. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fitting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5 6 7

3. Delivery pipes for injectors: A. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

79

Code

220

Page

1

1. 7. 1986

22. Fuel system

10. 1. 1992

Model

205-- 555

Code

Page

220

2

Technical Data Fuel injection pump Type (pump/governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order of injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump plunger, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump timing: --- 305, 405, 455, 555 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 205, 355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacity 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch PES ---A/RSV 1---2---3 clockwise 9,5 mm 8 mm 21˚ B.T.D.C. 24˚ B.T.D.C. 0,3 litres

Fuel feed pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch FP/KS 22 AD 6/2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston pump with separate hand priming pump Fuel feed pressure (overflow valve opening pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60---100 kPa Pressure from fuel feed pump (without overflow valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 kPa

Injectors 305, 405 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting pressure @) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch, four ---hole nozzle 200±5 bar (19.6 MPa) 210±5 bar (20.6 MPa) 8999 01495

Injectors 205, 355, 455, 555 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting pressure @) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch, five ---hole nozzle 230±5 bar 235+5 bar 8999 01495

!) When fitting fuel injection pump

@) Value to be used when adjusting the opening pressure of a new or used injector.

Tightening torques Nut for fuel injection pump gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery valve retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector securing nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

90 Nm 40 Nm 60 Nm 15 Nm

Model

22. Fuel system

1. 12. 1986

Code

205-- 555

220

Special tools 22. Fuel system A Order no. (8360 13091) 8360 97339 9025 99000

Description Puller for injection pump drive gear (see Engine A) Control (calibrating) pipe for injection timing (505---905) Sleeve for limiting control rod travel (505---905)

22. Fuel system B Order no. 6541 30600 8360 83288

Description Pressure gauge for checking delivery valve (505---905) Cleaning tools for injectors (505---905)

8360 13091

6541 30600

8360 97339

9025 99000

8360 83288

81

Page

3

Model

22. Fuel system

205-- 555

1. 12. 1986

Code

220

Page

4

Fuel system, description Design and function

7

8 4 6

2 9

5

3

1. Fuel tank 2. Water trap 3. Fuel feed pump 4. Filter 5. Fuel injection pump 6. Injector 7. Fuel reservoir, Thermostart device 8. Glow plug 9. Overflow valve Fuel feed pump (3) draws fuel from tank (1) through water trap (2) and forces it through filter (4) to fuel injection pump (5) at the so called feed pressure. The injection pump pumps fuel at high pressure through the delivery pipes to injectors (6) which inject the fuel in the form of a fine mist into the combustion chambers. Excess fuel lubricates the nozzle valve (needle) and flows in return through the thermostart device reservoir (7) and then on back to the fuel tank. When the thermostart is on (glowing) fuel runs from reservoir (7) through glow plug (8) and is ignited in the induction manifold. Excess fuel returns from the fuel injection pump through overflow valve (9) back to the fuel tank.

82

1

Model

22. Fuel system

205-- 555

1. 12. 1986

Page

220

5

The purpose of the fuel injection pump is to meter fuel to the combustion chamber at the correct time. Plunger (3) which is driven by the pump camshaft (7) via roller tappet (6) forces the fuel through delivery valve (2) and further through the delivery pipe to the injector.

Fuel injection pump 1

8

Code

3 2

7

4

5

6

2

1

6

3 7

5 4

1. Oil filter 2. Governor control lever 3. Hand pump 4. Lubricating oil for injection pump 5. O ---ring 6. Return of lubricating oil to engine 7. Drive gear 8. Type plate.

A

B

C

Two---hole pump element (maximum feed)

The fuel injection pump is of the in ---line type made by Bosch. It is flange mounted and sealed by one O ---ring (5) in the timing gear casing. The injection pump is driven from the crankshaft through an idler gear. The injection pump is connected to the engine forced ---feed lubrication system through an external hose (4).

A. Bottom dead centre B. Fuel injection begins C. Fuel injection ends 1. Inlet passage 2. Cylinder 3. Starting groove 4. Release passage 5. Plunger 6. Metering edge 7. Vertical groove The pump element consists of one plunger (5) and one cylinder (2) which are a matched pair and because of the fine tolerances the whole element should be changed as a complete unit. The cylinder has two passages: inlet passage (1) and release passage (4). Both passages allow fuel to enter the pressure space. The side of the plunger has one vertical groove (7) and one metering edge (6) which are used for adjusting the amount of fuel injected into the combustion chamber of the engine. The top of the plunger is provided with a starting groove (delay groove) which delays the injection timing by approx. 7---8˚. (This should be borne in mind when checking the fuel injection timing). This groove improves the cold starting properties of the engine. It works fully automatically. When the engine has stopped the control rod in the injection pump turns the plungers so that the starting groove faces towards the release passage. When the engine has started and when the injection pump has reached a certain speed, the governor pulls the control rod back into running position.

1. Retainer for delivery valve 2. Delivery valve 3. Pump element 4. Control rod 5. Return spring for pump plunger 6. Roller tappet 7. Camshaft.

83

1. 7. 1986

22. Fuel system

10. 1. 1992

Model

205-- 555

Code

220

Page

6

Delivery valve

Governor 1 2 5 3 6 4

7

1. Holder for delivery valve 2. Valve spring 3. Valve cone 4. Valve guide 5. Valve head 6. Pressure ---reducing piston 7. Vertical groove The delivery valve is fitted on top of the pump element and its purpose is to close the connection between the pump element and the delivery pipe to the injector. This happens when the metering edge of the plunger passes the lower edge of the release passage, and the pressure begins to drop. Its second purpose is to reduce the pressure in the delivery pipe. This is important as it enables the nozzle valve (needle) to close more quickly.

1. Governor weight 2. Control rod 3. Starting spring 4. Main lever 5. Idler screw 6. Governor spring 7. Additional spring, idling 8. Spring for equalizer 9. Governor control arm

Delivery valve cone (3) contains a pressure ---reducing piston (6) which, when the valve closes, is first lowered into guide (4) and then closes the connection between the delivery pipe and the pump element. Then valve head (5) is pressed against its seat and the fuel in the delivery pipe is given the same space as the displacement of the pressure ---reducing piston.

The governor is of the centrifugal type and is fitted at the rear end of the injection pump. The governor controls the rotational speed of the engine throughout the whole speed range, and identifies the rotational speed by means of the governor weights (1). The position of the governor control and of the governor weights is transferred through the governor lever linkage to control rod (2). The governor has one governor spring (6). Starter spring (3), which is attached to the upper end of control lever (9), pulls control rod (2) to the starting position when the engine stops. This means that the amount of fuel injected when the engine is started automatically becomes greater.

Fuel injection pump type plate

The injection pump type plate shows one particular letter indicating the user application, see figure above. This letter should always be quoted when ordering a replacement pump or when looking for setting values. Concerning letter indications for different models , see pages 220/10 ---11.

84

1. 7. 1986

22. Fuel system

10. 1. 1992

Model

205-- 555

Code

220

Page

7

Fuel feed pump (earlier model)

1. Manual priming pump 2. Pipe union 3. Sealing ring 4. Spring 5. Valve 6. Washer 7. Tappet 8. Body 9. “O” ring 10. Nut 11. Piston 12. Spring 13. Sealing ring 14. Plug 15. Gasket

A. Pressure stroke B. Intermediate stroke 1. Injection pump camshaft 2. Tappet 3. Pressure valve 4. Pressure chamber 5. Piston 6. Suction valve 7. Suction chamber

Fuel feed pump (later model)

The eccentric (cam) on the injection pump camshaft (1) pushes down piston (5) of the fuel feed pump. This makes the fuel flow from suction chamber (7) through pressure valve (3) into pressure chamber (4), at the same time as the spring under the piston is compressed. This is called the intermediate stroke. When the highest point of the eccentric has passed, it is followed by the piston and the tappet (2), which is pushed upwards by the piston spring. The fuel above the piston is then delivered through the filter to the fuel injection pump. At the same time new fuel is sucked through suction valve (6) into the suction chamber of the fuel feed pump. This stroke is called the pressure stroke. Nearly the whole output from the fuel feed pump takes place during the pressure stroke. During the intermediate stroke the amount of fuel supplied is only small, and corresponds to the volume of the pushrod within the pressure chamber. When the pressure in the fuel feed pipe exceeds the force of the spring, the piston moves only as far as is required to maintain the pressure in the system. Thus it is the force of the spring that determines the system pressure.

1. Manual priming pump 2. Sealing ring 3. Pipe union 4. “O” ring 5. Body 6. Plug 7. Gasket 8. Washer 9. Nut 10. Spring plate 11. Spring 12. Valve 13. Sealing ring 14. Piston 15. Tappet body 16. Tappet

Injectors

NOTE: With effect from engine no. 77340 tractors 205---555 are fitted with a new fuel feed pump. This new pump is exchangeable as a complete unit with the earlier type pump. In the same manner the manual pumps are exchangeable.

The main components of the injectors are the nozzle body and the holder. The purpose of the injectors is to inject the fuel so that it atomizes (forms a mist) in the combustion chamber. This is done through four (305, 405) or five (205, 355, 455, 555) small holes in the nozzle. It is extremely important that the injector is opened and closed rapidly to achieve the best possible combustion of the fuel. The operation of the injectors is controlled entirely by the pressure from the injection pump.

The fuel feed pump pressure which fills the high pressure pump elements with fuel is created by a piston pump which is attached to the side of the fuel injection pump. The piston pump is driven from an eccentric on the camshaft of the injection pump. The fuel feed pump supplies more fuel than the injection pump needs. The excess fuel is conducted through the overflow valve back to the fuel tank. The fuel cools the injection pump and also takes any air bubbles with it back to the tank.

85

Model

22. Fuel system

1. 12. 1986

205-- 555

Code

Page

220

8

The filter consists of a filter head which is provided with inlet and return passages for the fuel, and a filtering part which consists of a paper element (3) in a filter casing (5). The internal pipe in the filter cartridge is threaded at the top for securing the filter to the filter head.

1

2

Fuel reservoir for thermostart device

3 4 5 6 7 8 9 1. Fuel inlet 2. Leak ---off fuel connection 3. Shims 4. Spring 5. Valve stop spacer 6. Nozzle body 7. Nozzle valve 8. Pressure chamber 9. Nozzle hole The fuel pressure acts on the tapered part of nozzle valve (7) inside pressure chamber (8). When the pressure exceeds the force of spring (4), it lifts the nozzle valve from its seat and the fuel is forced out through holes (9) of nozzle (6), into the combustion chamber of the engine cylinder. The force of spring (4) which determines the injector opening pressure, can be adjusted with shims (3). Excess fuel is conducted up through the injector and lubricates the moving parts before it leaves through the leak ---off connection (2).

1. Supply port to reservoir 2. To glow plug 3. Return to fuel tank 4. Breather valve The leak ---off fuel from the injectors is pipes into the fuel reservoir for the thermostart device. The fuel required for cold --starting is stored in this reservoir. The excess fuel is piped back to the fuel tank.

Fuel filter

N.B. As the breather valve on the thermostart fuel reservoir is the only passage through which the fuel tank is ventilated, it is important that it does not become clogged up.

1. Filter head 2. Sealing ring 3. Paper element 4. Internal pipe 5. Filter casing 6. Bleeder screw

86

Model

22. Fuel system

1. 12. 1986

87

205-- 555

Code

220

Page

9

Model

22. Fuel system

Code

Page

220

10

205-- 555

1. 12. 1986

Table of fuel metering 309 Test equipment ISO 4008, Fluid ISO 4113, Nozzle ISO 4010 173 bar (S), Pipe diam. ø6x2x600 ISO 4093 Engine

Tractor

Injection pump

Governor

Pump timing˚ Max. output r/min Low idling r/min

Injected amount mm3/isku rpm

309 DS3 305

309 DS4 405

RW mm

Control rod at least 1 mm rpm

Control rod pos. 4 mm rpm

1225

1270

1225

1280

mm3

PES 3A 95 D 320 RS 2655 /R

RSV 325---1200 AOC 2178

21 2350 650

1175 1000 900 700 600 325

63---65 62---64 62---64 64---67 64---67 11---13

8,3 8,4

PES 3A 95 D 320 RS 2655 /J

RSV 325---1200 AOC 2178

21 2350 650

1175 1000 900 700 600 325

72---74 71---73 74---76 78---80 75---78 11---13

9,0 9,1 9,4 9,9 9,9

9,2 9,3

Table of fuel equipment parts (part numbers) Engine Tractor

Injection pump

Element

Delivery valve

Governor spring

Injector compl.

Nozzle

Nozzle der

309 DS 3 Valmet 305

8365 31793

8353 31161

8353 31162

8353 31780

8353 31100

8353 31101

8353 31102

309 DS 4 Valmet 405

8365 31752

8353 31161

8353 31162

8353 31780

8353 31100

8353 31101

8353 31102

hol-

Note! Both tables above apply to earlier production tractors

Table of fuel metering Test equipment ISO 4008, Fluid ISO 4113, Nozzle ISO 4010 173 bar (S), Pipe diam. ø6x2x600 ISO 4093.

Engine

Tractor

Injection pump

Governor

Pump timing˚ Max. output r/min Low idling r/min

Injected amount mm3/isku rpm

309 DS3 305

309 DS4 405

PES 3A 95 D 320 RS 2711 /A

RSV 325---1175 AOC 2178---3R

21 2350 650

1175 985 500 325

PES 3A 95 D 320 RS 2711

RSV 325---1175 AOC 2178---3R

21 2350 650

1175 985 500 325

RW mm

Control rod at least 1 mm rpm

Control rod pos. 4 mm rpm

9,5 +0,6---0,8 +1,0---1,1 5,4

1250

1330

10,2 +0,6---0,8 +1,0---1,1 5,4

1325

1330

mm3 65---67 12---15 76---78 12---15

Table of fuel equipment parts (part numbers) Engine Tractor

Injection pump

Element

Delivery valve

Governor spring

Injector compl.

Nozzle

Nozzle der

309 DS 3 Valmet 305

8365 39091

8353 31161

8353 39126

8353 31780

8353 31100

8353 31101

8353 31102

309 DS 4 Valmet 405

8365 31796

8353 31161

8353 39126

8353 31780

8353 31100

8353 31101

8353 31102

88

hol-

Model

22. Fuel system

1. 12. 1986

Code

Page

220

11

205-- 555

Table of fuel metering 205---555 (With effect from serial no 610312) Test equipments ISO 4008 Fluid ISO 4113 Nozzle ISO 4010 173 bar (S) Pipe diam. ø6x2x600 ISO 4093 Engine

309 D

Tractor

205

Injection pump

Governor

PES 3A 95 D 320 RS 2711 /N

309 DS 3 305

RSV 325--- 1175 A0C 2178 R

PES 3A 95 D 320 RS 2711 /A

RSV 325--- 1175 AOC 2178--- 3R

309 DS 4 405

PES 3A 95 D 320 RS 2711

311 D 355

PES 3A 95 D 320 RS 2655 /BA

311 DS

311 DS 555

355

455

PES 3A 95 D 320 RS 2655 / AP

555

PES 3A 95D 320 RS 2655 /BI

Pump timing ˚ Max. output r/min Low idling r/min

24˚ 2350 650

Injected amount mm3 / stroke r/min

mm3

1175 1000 800 700 500 325

52--- 54

21˚ 2350 650

1175 985 500 325

RSV 325--- 1175 AOC 2178--- 3R

21˚ 2350 650

1175 985 500 325

RSV 325--- 1175 A2C 2178--- 1R

24˚ 2350 750

1175 1000 800 700 600 375

RSV 325--- 1175 A2C 2178 1R

RSV 325--- 1200 A2 C 2178 1R

21˚ 2350 750

1175 1000 800 700 600 375

21˚ 2350 650

1175 1000 800 700 500 375

11--- 14 65--- 67 12--- 15 76--- 78 12--- 15 71--- 73

11--- 13 74--- 76

11--- 13 72--- 74

11--- 13

RW mm

Control rod at least 1 mm:n r/min

Control rod position 4 mm

8,1--- 8,3 +0,5--- 0,7 +1,2--- 1,4 +1,4--- 1,5 +1,4--- 1,6 4,7--- 4,9

1190--1210

1250--1270

9,5--- 9,6 +0,6--- 0,8 +1,0--- 1,1 5,3--- 5,5

1225--1255

1330--1360

10,2--- 10,3 +0,6--- 0,8 +1,0--- 1,1 5,3--- 5,5

1225--1255

1330--1360

8,9--- 9,0 +0,3--- 0,4 +0,6--- 0,9 +0,7--- 0,9 +0,7--- 0,9 4,5--- 5,0

1215--1230

1280--1300

9,1--- 9,3 +0,4--- 0,6 +0,9--- 1,1 +1,1--- 1,2 +1,1--- 1,2 4,5--- 4,7

1215--1230

1270--1285

9,0--- 9,2 +0,3--- 0,5 +0,9--- 1,1 +1,1--- 1,3 +1,2--- 1,4 4,5--- 4,7

1200--1220

1265--1280

r/min

Table of fuel equipment parts (part numbers) 205 -- 555 (With effect from serial number 610312) Engine Tractor

Injection pump

Element

Delivery valve

Governor spring

Injector compl.

Nozzle

Nozzle der

309 D Valmet 205

8365 39910

8365 39944

8353 39126

8353 31780

8363 40034

8363 39985

8366 39971

309 DS 3 Valmet 305

8365 39091

8365 39944

8353 39126

8353 31780

8353 31100

8353 31101

8353 31102

309 DS 4 Valmet 405

8365 31796

8365 39944

8353 39126

8353 31780

8353 31100

8353 31101

8353 31102

311 D Valmet 355

8364 39958

8353 31161

8353 31162

8353 31163

8363 39088

8363 39087

8353 31102

311 DS Valmet 455

8364 39895

8353 31161

8353 31162

8353 31163

8363 39088

8363 39087

8353 31102

311 DS Valmet 555

8364 40134

8353 31161

8353 31162

8353 31163

8363 40034

8363 39965

8366 39971

89

hol-

90

1. 12. 1986

22. Fuel system

1. 7. 1989

Model

205 -- 555

Code

222

Page

1

Repair instructions N.B. This text deals only with the general repair and service measures which may have to be carried out on the fuel system. This applies in particular to the fuel injection pump which may only be repaired by a specially trained person. Work on the fuel injection pump requires special tools and testing devices. Special cleanliness must be exercised during service and repair work.

Fuel feed pump and fuel filter (Op. no. 222)

1. Checking and repairing fuel feed pump A. Bleeding fuel system

3. Slacken the injection pump overflow valve (19 mm). Pump with the hand priming pump until the fuel flowing out is free from air bubbles. Tighten the overflow valve and screw down the hand priming pump piston.

1. Unscrew the manual priming pump piston (on the latest fuel feed pumps the piston is not locked).

4. Wipe off fuel from the engine

B. Measuring fuel system pressure 1. Clean the injection pump and the filter carefully.

2. Slacken the bleeder screw (10 mm) on the filter head. Pump with the hand priming pump until the fuel flowing out at the bleeder screw is free from air bubbles. Then tighten the bleeder screw. 2. Fit the gauge at the banjo connection on the pump, as shown above.

91

Model

22. Fuel system

1. 12. 1986

3. Run the engine at low idling for a while and compare the gauge reading with the prescribed value (0,6 ---1,0 bar).

205-- 555

Code

222

Page

2

5. Remove the valve springs and the valves from the pump body. Check the sealing surfaces of the valves. Change any damaged or worn parts.

N.B. If the measured pressure is below the prescribed value, this may be caused by: --- faulty overflow valve --- clogged fuel filter --- faulty fuel feed pump --- blocked or leaking fuel pipes or unions

6. Fit valves and springs. The suction and pressure valves are identical. Secure the hand pump and the plug, or the union, using new seals. 7. Clean the contact surface between the fuel feed pump and the injection pump and fit the feed pump together with a new gasket.

C. Checking overflow valve If the fuel feed pressure deviates from the prescribed value, check the opening pressure of the overflow valve.

1. Fuel filter

1. Connect a pressure gauge to the banjo union at the supply connection from the fuel feed pump, (see instructions under 222 B).

A. Changing fuel filter

2. Pump with the hand pump until the overflow valve opens. Compare the reading on the gauge at the moment the valve opens with the prescribed value (0,6 ---1,0 bar).

1. Carefully clean the outside of the fuel filter and the area around it.

3. If the recorded opening pressure deviates from the prescribed value, the valve should be changed.

2. Remove the filter using a suitable tool.

N.B. If the recorded pressure is considerably lower than the prescribed value, there may be a fault in the hand pump or the fuel feed pump valves.

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

3. Check that the sealing ring of the new filter is correctly positioned. Moisten the seal with fuel. Screw on the filter until the seal just touches the sealing surface and then tighten the filter further 1/4 of a turn. 4. Open the bleeder screw (10 mm) on the filter head and pump with the hand pump until the fule flowing out is free from air bubbles. Tighten the bleeder screw. 5. Start the engine and check for any leaks.

92

Model

61. Fuel system

1. 12. 1986

205-- 555

Code

223

Page

1

Fuel injection pump and injectors (Op. no. 223)

5. Disconnect the delivery pipe for the number one cylinder injector at the pump.

1. Adjusting fuel injection pump

6. Clean the delivery valve of fuel. Slowly turn the crankshaft in the correct direction of rotation until the fuel level in the delivery valve just begins to rise.

A. Checking injection timing N.B. The exact time at which the fuel should be injected into the number one cylinder (21˚ B.T.D.C) is marked on the crankshaft belt pulley. The mark has been positioned on the assumption that the cold ---starting device has been disengaged. Therefore this has to be done first so that the control rod is moved to the ”running position”, otherwise the injection timing will be incorrect. Checking procedure 1. Carefully clean the outside of the injection pump. 2. Remove the inspection hole rubber plug fron the flywheel housing.

7. Check if the mark on the crankshaft belt pulley is at the point of the indicator. If it is, the injection timing is correct. If the injection pump needes to be adjusted, follow the instructions under B. 8. After checking or adjusting, fit the delivery pipe and the protecting cap for the control rod on the injection pump front face after having removed the adjusting tool which was used to limit the control rod travel. Start the engine and let it run for a few minutes. This will remove any air which may have been left in the system and which may cause incorrect timing.

3. Turn the crankshaft until the piston in the number one cylinder has reached its T.D.C. when in its compression stroke. Then turn the crankshaft backwards approx. 1/2 of a turn.

9025 99000

4. Remove the protecting cap for the control rod on the injection pump front face. Fit adjusting tool (sleeve for limiting control rod travel) 9025 99000. The tool moves the control rod to the ”running position”.

93

Model

22. Fuel system

1. 12. 1986

B. Adjusting injection timing

205-- 555

Code

223

Page

2

C. Removing injection pump

1. Slacken the injection pump attaching nuts (17 mm) and disconnect the delivery pipes for the injectors (17 mm).

1. Clean the outside of the pump and all connections and pipes. 2. Remove the delivery pipes (17 mm). Remove the banjo bolts at the supply and return fuel connections (19 mm). Disconnect the lubricating oil line (14 mm). Plug all connections.

A

M A=Earlier point of injection M=Later point of injection 2. If the injection occurs too early, turn the pump clockwise, as seen from the front. If the injection occurs too late, turn the pump anti ---clockwise, as seen from the front of the pump. 3. Again check the injection timing and adjust if necessary. 4. When the injection timing is correct, tighten the pump attaching nuts and connect the delivery pipes.

94

Model

22. Fuel system

1. 12. 1986

3. Unscrew the oil filler pipe nuts (13 mm) and remove the pipe. Remove the oil filler pipe attaching lugs (not necessary when using the new puller).

205-- 555

Code

Page

223

3

2. Lubricate the O ---ring and turn the injection pump camshaft to the position where the key on the shaft and the key in the gear align. Fit the pump and tighten the attaching nuts (17 mm).

4. Remove the nut for the injection pump drive gear (22 mm).

3. Tighten the nut for the pump drive gear (22 mm) to 90 Nm.

8360 13091

4. Fit the attaching lugs for the oil filler pipe. Apply silicone sealing compound to the screw studs and secure the filler pipe. 5. Connect the supply and return fuel lines (19 mm) and the lubricating oil line (14 mm). Use new sealing washers. 6. Bleed the fuel system, see instructions no. 222 1A. 7. Adjust the injection timing, see instructions no 223 1B. 8. Connect the delivery pipes for the injectors.

5. Use puller 8360 13091 and loosen the gear from the injection pump camshaft. 6. Remove the injection pump attaching nuts (17 mm). Remove the injection pump. N.B. If the engine is not to be disturbed while the pump is removed, there is no need to secure the pump gear. The gear rests against the idler gear.

D. Fitting injection pump

9. After fitting the fuel injection pump it should always be filled with oil. This is done by removing the hexagon socket plug (10 mm) from the pump. The amount of oil required is 0,3 litres.

1. Check the O ---ring on the pump attaching flange. If necessary change it.

E. Checking/changing delivery valve The checking and changing of delivery valves should be carried out by specially trained personnel using tools and equipment specially required for this work. The requirements on cleanliness are high if this work is to be carried out satisfactorily.

95

Model

22. Fuel system

1. 12. 1986

205-- 555

Code

223

Page

4

F. Adjusting low idling speed

6. Screw in the damping spring adjusting screw so that the idling speed increases to the value given in the Technical Data. Lock the adjusting screw (17 mm) in this position.

If the low idling speed of the engine deviates from the value given in the Technical Data, adjust as follows:

7. Fit the adjusting screw protective nuts.

1. Remove the protective nut (10 mm) for the idling screw and the protective nut for the damping spring (17 mm).

N.B. Other adjustments, such as output and high idling speed must only be done by a specially trained person with access to the necessary special tools and measuring devices.

2. Set the engine speed control to the low idling speed position. 3. Start the engine and unscrew the damping spring adjusting screw so that it no longer affects the speed.

4. Adjust the idling screw until the engine speed is approx. 20 revolutions below the prescribed value. Lock the screw in this position. 5. Rev up the engine a couple of times and check that the idling speed has not changed.

96

Model

22. Fuel system

1. 12. 1986

205-- 555

Code

223

Page

5

2. Checking/reconditioning injectors

B. Checking injectors

A. Removing injectors

N.B. When pressure testing the injectors, it is important to avoid the nozzle end as the fuel jetting out easily penetrates the skin. Also bear in mind that the fuel ”mist” is dangerous to inhale.

1. Clean the injectors and the area around them.

1. Clean the injector with cleaning fluid and a soft brush. The carbon deposits must not be knocked off or removed in any other way which may damage the nozzle.

2. Disconnect the delivery pipe (17 mm) and the leak ---off line (10 mm) from the injectors.

3. Remove the injector attaching nuts (13 mm) and remove the injector from the cylinder head. Fit protective plugs to all connections.

2. Secure the injector in a test bench and check the following: --- injector opening pressure --- the properties of the chattering (creaking) sound and the form of the spray pattern. --- sealing of nozzle valve against its seat

4. Remove the sealing washers from the injector location in the cylinder head if they do not come out with the injector

B1. Opening pressure Pump a few times to fill the injectors. Increase the pressure in the injector until the chattering (creaking) sound becomes audible. Read off the opening pressure of the injector. See the Technical Data. If the opening pressure is too low, the injector should be taken apart and checked.

97

1. 7. 1989

22. Fuel system

10. 1. 1992

Adjustment is carried out by changing the shims (item 2 in fig. 223 16). The thickness of the shims varies from 1.00---1.98 mm and they are available in increments of 0.02 mm. A thicker shim raises the opening pressure while a thinner one lowers it. A difference in shim thickness of 0.02 mm changes the opening pressure by approx. 3 bar. As the opening pressure of the injector drops slightly after adjustment, it should be adjusted to approximately 210±5 bar (305, 405) or 235+5 bar (205, 355, 455, 555) above the value given in the Technical Data section. These values apply to both new and used injectors.

Model

205-- 555

Code

223

Page

6

1. Secure the injector in a suitable way. 2. Remove the nozzle cap nut (19 mm). Remove the nozzle and the parts inside the holder.

B2. Chattering (creaking) sound properties Testing with a hand powered pump does not create the same circumstances as when the injector is fitted in the engine. Only with new nozzles are the test results reliable. With used nozzles , there is no chattering sound when the tester is pumped at a certain rate. This has to do with the design of the nozzles. However, with a rapid pumping on the tester handle, it should be possible to hear the chattering sound or see a mist of the fuel jetting out. When there is no creaking sound, there is more of a jet than a mist of fuel.

3. Clean the nozzle in cleaning fluid both inside and outside.

B3. Tightness of nozzle valve Press down the tester pump lever gradually until the pressure rises to approx. 20 bar below the adjusting value. Maintain this pressure for approximately 10 seconds and check whether drops of fuel are formed on the point of the nozzle. If the injector leaks, it should be cleaned or the nozzle should be changed

C. Reconditioning injectors

4. Clean the nozzle holes with a needle (included in cleaning set 8360 83288).

1. Nozzle holder 2. Shims 3. Spring 4. Spring guide

5. Valve stop spacer 6. Nozzle body 7. Nozzle cap nut

98

Model

22. Fuel system

1. 12. 1986

Code

205-- 555

223

Page

7

D. Fitting injectors

5. Test the movement of the nozzle valve as follows: Rinse the parts thoroughly in fuel or testing fluid. Pull the valve out of the nozzle body to 1/3rd of its length. If the fit is correct, the valve should be able to slide down in the nozzle body under its own weight. Turn the valve slightly and repeat the test. Should the nozzle valve bind slightly, it should be changed.

1. Attaching clamp 2. Washer 3. Rubber seal 4. Sealing washer 1. Clean the injector sealing surface in the cylinder head. If necessary use a reamer 8361 97470.

6. Before assembling, all parts should be carefully cleaned in clean fuel or testing fluid.

2. Fit the injector in the cylinder head using a new sealing washer.

7. Put the same number of shims back as were fitted earlier. Assemble the rest of the injector. Note the position of the spring guide and the valve stop spacer.

N.B. The spray pattern from the injectors is not symmetrical on purpose. It is therefore important that the injector is fitted correctly in the cylinder head. The connection for the leaf ---off line should be facing the valve mechanism.

8. Tighten the nozzle cap nut by hand and then to 60 Nm.

3. Fit the attaching clamp and tighten the nuts (13 mm) evenly to 15 Nm. 4. Connect the leak ---off oil line (10 mm) together with new sealing washers and connect the delivery pipes (17 mm). N.B. The screw studs in the cylinder head for the injectors should only be finger tight. If tools have to be used the studs should be tightened only lightly.

3. Delivery pipes for injectors A. Fitting delivery pipes 1. Check the state of the pipes. If there are kinks, damage by chafing, or if the tapered sealing end is damaged, the pipes should be changed. 2. Fit the pipes without tension and check that they are at right angles to the union. 3. Fit the clamps for the pipes.

99

100

Model

23. Cooling system

1. 12. 1986

205-- 555

Contents General (Op. no. 230)

Technical Data, see code 210 page 6 Special tools, see code 210 page 7 Description and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Repair instructions (Op. no. 231) 1. Thermostat: A. Removing and checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. Coolant pump: A. Removing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Reconditioning coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 C. Fitting coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

101

Code

230

Page

1

Model

23. Cooling system

1. 12. 1986

Description and function

205-- 555

Code

230

Page

2

Coolant pump

1. Hub 2. Circlip 3. Shaft 4. Pump body 5. Sealing ring and ceramic washer 6. Impeller

1. Thermostat 2. By ---pass passage 3. Radiator 4. Coolant pump

The coolant pump is of the centrifugal type and is fitted at the front end of the cylinder block. The pump is driven by a V ---belt from a belt pulley on the crankshaft. The pump shaft and the bearing are built together to form one unit (3). One ball bearing and one roller bearing are used (for the belt pulley). Impeller (6) is pressed onto the shaft. Sealing is achieved between one sealing ring (5) fitted in the pump body (4), and a ceramic washer (5). The pump body has connections for coolant hoses to the cab heater and engine heater.

A cross---section of the cooling system is shown in figure above. Coolant pump (4) draws coolant from the lower part of radiator (3) and delivers the coolant to the water jackets round the cylinders in the cylinder block. The coolant rises through the passages in the upper part of the cylinder block to the cylinder head, and further towards the thermostat (1). While the coolant temperature is below the opening temperature of the thermostat, the coolant flows through the by ---pass passage direct to the coolant pump, and back into the engine. As the coolant temperature rises to the opening temperature of the thermostat, it will open and some of the coolant will circulate through the radiator and some through the by ---pass passage. Because of the by ---pass passage, the engine coolant can be kept at a constant temperature regardless of the ambient air temperature.

The flow through the coolant pump is 150 litres at 2350 rpm.

102

Model

23. Cooling system

1. 12. 1986

Thermostat

1. Hexagon socket bolt 2. Hose connection 3. Gasket 4. Thermostat 5. Thermostat housing 6. By ---pass passage 7. Rubber seal 8. Temperature sender unit 9. Sealing washer Thermostat (4) is of the single ---acting type and distributes the flow of coolant between the engine and the radiator. The thermostat is positioned in thermostat housing (5) at the front end of the cylinder head. There is a by ---pass passage (6) with seals (7) between the thermostat housing and the coolant pump. The thermostat opens at 79˚C (174 ˚F). During the cold season, a thermostat with an opening temperature of 83˚C (181 ˚F), can be used.

Coolant A mixture of a glycol based anti ---freeze (30---50 %) and water is used as a coolant. In order to obtain sufficient corrosion protection, also use the anti ---freeze mixture during the warm season. The coolant should be changed every second year.

103

205-- 555

Code

230

Page

3

104

Model

23. Cooling system

1. 12. 1986

Repair instructions

205-- 555

Code

231

Page

1

B. Reconditioning coolant pump

Cooling system (Op. no. 231) 1. Thermostat A. Removing and checking thermostat

8360 13091

1. Drain sufficient coolant to lower the level to below the thermostat housing. 2. Disconnect the upper coolant hose from its connection. Unscrew the attaching bolts (8 mm socket head) and remove the hose connection and the thermostat. 3. Lower the thermostat into a vessel containing water, making sure that the thermostat does not touch the sides or the bottom of the vessel. 4. Slowly heat the water and check with a thermometer when the thermostat begins to open and when it is fully open, and compare the readings with the Technical Data. 5. If the thermostat binds or does not open at the prescribed temperatures, it should be changed. 6. Clean the contact surfaces. Fit the thermostat and the hose connection together with a new gasket. Connect the upper coolant hose.

1. Pull of fan hub (4) using puller 8360 13091. Remove circlip (2).

7. Fill with coolant. Start the engine and check for leaks. Run the engine at light loading until it can be established that the thermostat works normally.

8360 85499

2. Coolant pump A. Removing coolant pump 1. Drain the coolant. Disconnect the upper and the lower coolant hoses. Unscrew the attaching bolts (8 mm hexagon socket) for the thermostat housing. Remove the thermostat housing and the by ---pass passage. 2. Disconnect the connection for the cab heater and the engine heater (27 mm) from the coolant pump. 3. Slacken the alternator attaching bolts (13 mm). Unscrew the attaching bolts (13 mm) for the fan and remove the fan, the belt pulley on the pump and the V ---belt. 4. Unscrew the attaching bolts (13 mm) and remove the pump. Remove the plate and the gasket between the pump and the cylinder block and clean the contact surfaces. 2. Pull the impeller (6) off the shaft using puller 8360 85499. 3. Press the shaft out of the housing towards the fan side.

105

Malli

23. Cooling system

1. 12. 1986

205-- 555

Koodi

231

Sivu

2

4. Drive the shaft seal out of the pump housing using a drift. Clean and check the parts. Change faulty or worn parts.

C. Fitting coolant pump

5. Press the shaft into the pump housing, applying the force on the outer circumference, and then fit the circlip ET 9051 64900 (on shaft 8353 30994).

1. Fit a new gasket between the pump and the cylinder block. Align the pump and tighten the attaching bolts evenly and alternately on both sides. 2. Fit the belt pulley, the V ---belt and the fan. Tighten the alternator attaching bolts. 3. Fit the connections for the cab heater and the engine heater. 4. Fit the by ---pass passage together with new seals on the pump. Align the thermostat housing to the cylinder head and at the same time fit the by ---pass passage between the pump and the thermostat housing.

9051 40200

5. Connect the upper and the lower coolant hoses. Fill with coolant, start the engine and check for leaks. N.B. If the coolant pump has been fitted with a new seal and circlip, coolant may drip from the draining hole under the pump during the first hours of operation. This leak should stop once the sealing surfaces have run against each other for a while.

6. Clean the shaft and the surface for the seal in the pump housing. Fit the saling ring and the ceramic washer together with plastic ring on the shaft. Lubricate with coolant. Tap the seal into position using drift 9051 40200. If the plastic ring does not come away with the drift afterwards, it must be removed before fitting the impeller.

1---1,7

7. Press impeller and hub onto the shaft whilst guiding the shaft from the other hand. Check that the shaft can rotate freely.

106

10. 1. 1992

21A. Engine (20---series)

Model

1. 9. 1992

255-- 865

Contents General (Op. no. 210): Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Repair instructions Cylinder block and flywheel housing (Op. no. 211): 1. Cylinder block and cylinder liners: A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Fitting plug at rear end of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Fitting cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 2 3 4 4

2. Flywheel housing: A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Changing flywheel starter gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 6 7 7

Cylinder head and valve mechanism (Op. no. 212): 1. Cylinder head: A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Changing valve seat inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2 3 3 3 4

2.Valve mechanism: A. Reconditioning rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 B. Changing camshaft/camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 C. Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Crank mechanism (Op. no. 213): 1. Crankshaft: A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing crankshaft ring gear (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2

2. Connecting rods and pistons: A. Removing piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

107

Code

210A

Page

1

10. 1. 1992

21A. Engine (20---series)

1. 9. 1992

Model

255-- 865

D. Connecting rods, weight classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Changing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Fitting piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Fitting piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 5 6 6 6

3. Balancer unit, 420 ---engines: A. Removing and dismantling balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 B. Reconditioning balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 C. Fitting balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engine timing gears (Op. no. 214)

A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Reconditioning idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 C. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Lubrication system and oil sump (Op. no. 215): A. Reconditioning oil relief valve for lubrication oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 3

Inlet and exhaust system, turbocharger (Op. no. 216): A. Checking air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Checking inlet and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Reconditioning turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 3 5

Working orders (Op. no. 219) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

108

Code

210A

Page

2

15. 4. 1999

21A. Engine (20---series)

1. 9. 2001

Model

Code

255-- 900

210A

Page

3

Technical Data Note! With effect from tractor ser. no 656316 tractors below have 20---series engines. Tractor

255

355

365

455

465

555

565

665

865

Engine type Turbo No of cylinders Displacement (dm3) Cyl. diam. (mm) Stroke (mm) Compr. ratio Output (kW/r/min DIN) Torque (Nm/r/min) Torque rise % Idling speed (r/min) Max. idling (r/min) Compr. pressure (bar)

320 D no 3 3,3 108 120 16,5:1 39/2350 200/1400 26 750 2550 24 1)

320 D no 3 3,3 108 120 16,5:1 45/2350 220/1400 20 750 2550 24 1)

320D no 3 3,3 108 120 16,5:1 45/2350 220/1400 20 750 2550 241)

320 DS yes 3 3,3 108 120 16,5:1 49/2350 240/1450 22 750 2550 24 1)

320 DS yes 3 3,3 108 120 16,5:1 51/2350 260/1450 24 750 2550 24 1)

320 DS yes 3 3,3 108 120 16,5:1 53/2350 260/1450 21 750 2550 24 1)

320DS yes 3 3,3 108 120 16,5:1 55/2350 275/1450 23 750 2550 24 1)

420 D no 4 4,4 108 120 16,5:1 59/2350 290/1450 21 750 2550 24 1)

420 DS yes 4 4.4 108 120 16.5:1 64/2350 310/1450 21 750 2550 24 1)

1)

Minimum value at operating temperature and starting revs. Max permitted difference between cylinders 3,0 bar.

Engine type Turbo No of cylinders Displacement (dm3) Cyl. diam. (mm) Stroke (mm) Compr. ratio Output (kW/r/min DIN) Torque (Nm/r/min) Idling speed (r/min) Torque rise % Max. idling (r/min) Compr. pressure (bar)

600 320D no 3 3,3 108 120 16,5:1 44/2270 220/1400 750 19 2470 241)

600 320DE no 3 3,3 108 120 16,5:1 44/2270 220/1400 750 19 2470 241)

700 320DS yes 3 3,3 108 120 16,5:1 51/2270 290/1400 750 34 2470 241)

700 320DSRE yes 3 3,3 108 120 16,5:1 51/2270 290/1400 750 34 2470 241)

800 420DR no 4 4,4 108 120 16,5:1 59/2270 290/1400 750 17 2470 241)

800 420DSRE yes 4 4,4 108 120 16,5:1 59/2270 315/1400 750 27 2470 241)

900 420DSR yes 4 4,4 108 120 16,5:1 66/2270 330/1400 750 18 2470 241)

900 420DSRE yes

4

4,4 108 120 16,5:1 66/2270 350/1400 750 26 2470 241)

Valves, rockers and tappets With a valve clearance of 1,0 mm: --- inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- inlet valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve clearance cold and hot: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle of valve seat in cylinder head: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of valve seat in cylinder head: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle of valve face: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of valve head: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max valve movement: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

0˚±2˚ B.T.D.C 16˚±2˚ A.B.D.C 39˚±2˚ B.B.D.C 1˚±2˚ A.T.D.C 0,35 mm 0,35 mm 35˚+20’ 45˚+20’ 2,9...3,7 mm 1,3...2,3 mm 35˚ ---20’ 45˚ ---20’ 48 mm 41 mm 10,9 mm 12,1 mm 8,960...8,975 mm 8,925...8,940 mm 0,025...0,055 mm 0,30 mm

1. 1. 1998

21A. Engine (20---series)

1. 6. 1998

Exhaust valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of valve guide before fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protrusion of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . . . . Depth of valve face below cylinder head surface: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring pressure when spring compressed to a length of: --- 48,6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 37,4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of rocker arm bearing bush: --- (when fitted in position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of rocker arm bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permissible push rod deflection (when free) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Free length of rocker arm spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring pressure when spring compressed to a length 58 mm . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engines from week 34 1996: Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model

255-- 900

Code

210A

0,060...0,090 mm 0,35 mm 9,000...9,015 mm 16,028...16,039 mm 16,000...16,018 mm 21 mm 0,7±0,05 mm 0,6±0,05 mm 69,8 mm 327±17 N 500±23 N 19,959...19,980 19,990...20,010 mm 23,035...23,075 mm 23,000...23,021 mm 0,4 mm 80 mm 80...100 N 29,939...29,960 mm 30,000...30,043 mm 22,970...22,990 mm 23,000...23,021 mm

Camshaft Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of camshaft bearing journals (others that no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of camshaft bearing bushes (when fitted in position) . . . . . . . . . . . . . . . . . Diameter of camshaft bearing bores (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft clearance in bearing bush no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft clearance in bearing bushes (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing bush tolerance in block (press fit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of bearing bush bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft end play with 0,5 mm gasket between cylinder block and timing gear housing and between timing gear housing and front cover . . . . . . . . . . . . . . . . . . . . . . . . . Cam height (distance between back of cam and tip of cam): --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam lift: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft max permissible deflection (total indicator reading) . . . . . . . . . . . . . . . . . . . . . . .

49,925...49,950 mm 49,885...49,910 mm 50,010...50,070 mm 50,000...50,025 mm 0,060...0,145 mm 0,090...0,140 mm 0,025...0,080 mm 55,620...55,650 mm 0,5...1,0 mm 41,180...41,430 mm 40,080...40,330 mm 7,38 mm 8,28 mm 0,03 mm

Cylinder liners Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permissible height difference between liners (under same head) . . . . . . . . . . . . . . . . Outer diameter of cylinder liner guide: --- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- at lower end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height of cylinder liner flange, 1st oversize, part no 8366 47933 . . . . . . . . . . . . . . . . . . . . . Height of cylinder liner flange, 2nd oversize, part no 8366 47934 . . . . . . . . . . . . . . . . . . . . Height of cylinder liner flange, 3rd oversize, part no 8366 47935 . . . . . . . . . . . . . . . . . . . . . Outer diameter of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,030...0,080 mm 0,02 mm 124,475...124,500 mm 122,961...122,986 mm 108,000...108,022 mm 9,03...9,05 mm 9,08...9,10 mm 9,13...9,15 mm 9,23...9,25 mm 131,700...131,800 mm

Piston, rings and gudgeon pin Minimum distance between piston and cylinder head (measured with a piece of lead wire thought the injector location hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston diameter: --- 17 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 64,4 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 97,5 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

0,900...1,150 mm 107,873...107,887 mm 107,761...107,779 mm 107,500...107,520 mm

Page

4

10. 1. 1992

21A. Engine (20---series)

Pin bore in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of ring grooves: --- 1st groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd grove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side clearance of piston rings in their grooves: --- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. 9. 1992

Model

255-- 865

Code

210A

40,003...40,009 mm 39,991...40,000 mm 2,560...2,580 mm 2,520...2,540 mm 4,040...4,060 mm 0,07...0,102 mm 0,03...0,062 mm 0,05...0,082 mm 0,15 mm

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

0,30...0,45 mm 0,60...0,80 mm 0,30...0,60 1,0 mm

Max. permissible weight difference between pistons in same engine . . . . . . . . . . . . . . . . . . . . . 25 g Piston to be heated up to 100˚C before fitting gudgeon pin. Piston position in cylinder: combustion chamber of piston to face towards injector.

Connecting rod Inside diameter of piston pin bush (with bush pressed into connecting rod) . . . . . . . . . . . . . . . 40,025...40,040 mm Outside diameter of piston pin bush . . . . . . . . . . . . . . . . . . . 44,082...44,120 mm Interference fit: connecting rod small end bushing ---connecting rod . . . . . . . . . . . . . . . . . . . . . . 0,057...0,120 mm Connecting rod small end bore . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025 Connecting rod big end bore . . . . . . . . . . . . . . . . . . . . . . . . . 71,730...71,749 mm Big end bearing shell thickness: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835...1,842 mm --- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,960...1,967 mm --- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,085...2,092 mm --- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,335...2,342 mm --- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,585...2,592 mm Big ---end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0,046...0,098 mm End float (side clearance) at big ---end on crankshaft . . . . . . 0,200...0,410 mm Piston pin bushing location perpendicular to longitudinal axis of connecting rod to be within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15:100 Piston pin bushing location and big ---end bearing location to be parallel to within . . . . . . . . . . 0,05:100 Weight marking (letter) at lower end. Max. permissible weight difference between connecting rods in the same engine . . . . . . . . . . 20 g Position of connecting rod; order no at valve mechanism side (away from the combustion chamber in the piston)

Crankshaft Crankpin diameter: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,981...68,000 mm --- 1. undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,731...67,750 mm --- 2. undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,481...67,500 mm

111

Page

5

1. 9. 1992

21A. Engine (20---series)

1. 6. 1998

Model

255-- 865

Code

210A

--- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,981...67,000 mm --- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,481...66,500 mm Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000...40,160 mm Main bearing journal diameter: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd undersize 0,50mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing location diameter (in cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84,985...85,020 mm 84,735...84,770 mm 84,485...84,520 mm 83,985...84,020 mm 83,485...83,520 mm 91,000...91,025 mm

Main bearing shell thickness: --- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing 8361 40950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,955...2,965 mm 3,080...3,090 mm 3,205...3,215 mm 3,455...3,465 mm 3,705...3,715 mm 3,705...3,715 mm

Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Length of thrust bearing journal (journal nearest to flywheel): --- standard (2 standard thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 1st oversize (one std and one 0,1 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . . . . . --- 2nd oversize (one std and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . . . . . --- 3rd oversize (one 0,1 mm and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . --- 4th oversize (two 0,2 mm overthick thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,050...0,127 mm 45,000...45,080 mm 45,100...45,180 mm 45,200...45,280 mm 45,300...45,380 mm 45,400...45,480 mm

Other crankshaft journals may not be ground longer. Crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permissible ovality and other deformity of crankpins or journals . . . . . . . . . . . . . . . . . . . . Crankshaft unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancing unit ring gear location, diameter (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancing unit ring gear I.D. (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,100...0,380 mm 0,03 mm 1,0 Ncm Max. 150,220...150,260 mm 150,000...150,040 mm

Flywheel Flywheel ring gear no. of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interference fit between ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before fitting the ring gear, heat up to a temperature of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max permissible axial wobble of flywheel clutch face, measured at inner edge of clutch face on diameter 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133 pcs 0,425...0,600 mm 150...200˚C 1,0 Ncm Max 0,06:ø200

Timing gears Tooth backlash: Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permissible side wobble of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner diameter of idler gear bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner diameter of Idler gear hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft gear hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft end diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

0,05...0,25 mm 0,05...0,25 mm 0,05...0,25 mm 0,05 mm 54,951...54,970 mm 55,000...55,030 mm 60,000...60,030 mm 32,000...32,025 mm 32,043...32,059 mm

Page

6

15. 4. 1994

21A. Engine (20---series)

1. 6. 1998

Model

255-- 865

Code

210A

Page

7

Timing marks: Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre between compression and power strokes. On crankshaft gear . . . . . . . . . . 2 dots on tooth On idler gear: --- against crankshaft gear mark 0 on tooth --- against camshaft gear mark 1 dot on tooth --- against fuel injection pump gear mark . . . . . . . . . . 1 dot on notch On camshaft gear . . . . . . . . . . . 1 dot on notch On injection pump gear . . . . . . 1 dot on tooth Crankshaft must be rotated 6 turns before all gear markings fall into line again

Cylinder block Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing location diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner location, diameter: --- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner diameter of camshaft bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13,250...13,320 mm 91,000...91,025 mm 124,514...124,554 mm 123,000...123,040 mm 50,010...50,070 mm

Distance between piston and top dead centre at different crank shaft angle Angle

Distance mm 320/ 420

Angle

Distance mm 320/ 420

10˚ 11˚ 12˚ 13˚ 14˚ 15˚ 16˚ 17˚ 18˚ 19˚ 20˚

1,173 1,418 1,686 1,976 2,289 2,625 2,983 3,363 3,765 4,188 4,633

21˚ 22˚ 23˚ 24˚ 25˚ 26˚ 27˚ 28˚ 29˚ 30˚

5,100 5,587 6,095 6,624 7,173 7,742 8,331 8,939 9,567 10,213

Cylinder head Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height of cylinder head after repair machining (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Straightness of cylinder head: --- lateral direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- longitudinal direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide I.D. (not fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve guide fixing hole I.D. in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height of valve guide upper end from cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve disc depth from cylinder head surface: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat surface angle: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat surface width: --- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104,800...105,000 mm 104,000 mm

Exhaust valve seat ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve seat ring location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve seat diameter (repair part 8366 52269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve seat location, diameter (repair part 8366 52269) . . . . . . . . . . . . . . . . . . . . . . . . . .

44,070...44,132 mm 44,000...44,025 mm 44,270...44,332 mm 44,200...44,225 mm

Inlet valve seat ring diameter (8366 47936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet valve seat ring location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet valve seat ring diameter (repair part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet valve seat ring location, diameter (repair part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . . . .

48,570...48,632 mm 48,500...48,525 mm 48,770...48,832 mm 48,700...48,725 mm

113

max. 0,05 mm max. 0,1 mm 9,000---9,015 mm 16,028...16,039 mm 16,000...16,018 mm 21 mm 0,7±0,05 mm (max. 1,70 mm) 0,6±0,05 mm (max. 1,60 mm) 35˚+20’ 45˚+20’ 2,9...3,7 mm 1,3...2,3 mm

Model

21A. Engine (20---series)

1. 9. 1992

Code

255-- 865

210A

Page

8

Lubricating system Oil pressure at normal running temperature: --- at idling speed (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- at running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Free length of oil pressure valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring pressure when valve spring is compressed to a length of 52 mm . . . . . . . . . . . . . . . . . . Diameter of oil pressure valve plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of oil pressure valve cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter by ---pass valve opens at a pressure difference of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 kPa (1,0 kp/cm2) 250---400 kPa (2,5---4,0 kp/cm2) 80 mm 54+5 N (5,4+0,5 kp) 19,602...19,635 mm 19,700...19,752 mm 2±0,5 kp/cm2

Oil pump Backlash between gears when crankshaft lies firmly against the lower side of main bearings: --- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of drive shafts: --- at bearings for body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- at gear wheel pressed on shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of shaft holes on body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of gear wheel holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft gear (press fit), distance between side gear (thread side) and first shoulder . . . . . Fixed shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protrusion of fixed shaft end below pump body face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of cover gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End play of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Depth of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of teeth on drive gear (320 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of teeth on drive gear (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

0,05...0,25 mm 0,16...0,26 mm 17,966...17,984 mm 18,099...18,109 mm 18,000...18,018 mm 18,060...18,078 mm 14,80...15,20 mm 18,028...18,039 mm 0,5...1,0 mm 0,06...0,08 mm 43,486...43,525 mm 43,650...43,750 mm 24,000...24,027 mm 0,03...0,11 mm 24,000...24,043 mm 51 pcs 46 pcs

1. 6. 1998

21A. Engine (20---series)

15. 4. 1999

Model

255-- 900

Code

210A

Balancing unit (420 engines) Tooth backlash: --- crankshaft ring gear ---balancer weight gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- between the balancer weights gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancing weights end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft diameter at bearing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing bushing inner diameter (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of holes in body for shafts, rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of holes in body for shafts, front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shim thickness, cylinder block ---balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,1...0,3 mm 0,05...0,250 mm 0,1...0,5 mm 36,000...36,016 mm 36,050...36,075 mm 36,058...36,083 mm 35,958...35,983 mm 0,2 mm

Turbocharger Schwitzer S1A (320-- engines) Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft radial clearance 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schwitzer S1B (420 DS-- engines)

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft radial clearance1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slotted nut---end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1)

max 0,14 mm max 0,61 mm 22 Nm 6,8 Nm

max 0,14 mm max 0,51 mm 22 Nm 8,1 Nm

Measured at nut at end of shaft.

Tightening torques Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head studs to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel bolts: --- 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel housing bolts: --- outer ring M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- inner ring M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear bolts: --- M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant pump v ---belt pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancing weights, 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancing weights, 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery valve retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil sump fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil pump fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

80 Nm+90˚+90˚+60˚ 30 Nm 200 Nm 40 Nm + 90˚ 600 Nm 140 Nm 160 Nm 110 Nm 60 Nm 60 Nm 200 Nm 90 Nm 45 Nm 160 Nm 50 Nm 30 Nm 15 Nm 40 Nm 60 Nm 80 Nm 60 Nm 60 Nm

Page

9

Model

1. 9. 1992

21A. Engine (20---series)

Code

255-- 865

15. 4. 1994

Page

210A

10

Special tools Order no 1 9051 73100 2 9101 65600 *) 3 9052 46400 4 9052 46300 5 9030 15200

Description Puller for cylinder liner Milling cutter for cylinder liner seat Centring tool for flywheel housing Drift for fitting rear crankshaft seal Drift for fitting front crankshaft seal

6 9052 46620 7 9052 46650 8 9025 87400 9 9101 66300 *) 10 9025 79200

Drift for 40 mm cap plug Drift for 16 mm cap plug Drift for fitting camshaft cup plug Press tool for cylinder liner Holder for dial gauge

11 9101 66100 *) 12 9101 71100 *) 13 9101 65502 *) 14 9101 65503 *) 15. 9101 75800 *)

T ---handle for valve seat milling cutter Milling cutter for facing exhaust valve seat Milling cutter for exhaust valve seat Inner milling cutter for exhaust valve seat Milling cutter for facing inlet valve seat

16 17 18 19 20 21 22 23 25

9101 65505 *) 9101 65506 *) 9101 66200 *) 9052 47200 9101 66000 *) 9052 46660 9101 65800 *) 9101 65900 *) 9101 65700 *)

Milling cutter for inlet valve seat Inner milling cutter for inlet valve seat Lever for compressing valve spring Counter nut for lever above Milling tool for injector seat Drift for 36 mm cup plug Drift for removing valve guide Drift for fitting valve guide Spanner for crankshaft nut

26 27 28 29 30

9052 48800 9020 01100 9025 98900 9025 98800 9025 98700

Puller for crankshaft gears Conical sleeve for fitting pistons Drift for fitting dust cover, crankshaft front seal Drift for fitting tension pin in timing gear casing Drift for fitting tension pins in timing gear casing and flywheel housing

*)

New tools for 20---series engines. Other tools are the same as for 11---series engines.

3

6

1

2

7

4 9 5

116

10

8

Model

21A. Engine (20---engines)

Code

255-- 865

1. 9. 1992

210A

11

15

12

13

18

19

16

14

17

22

21 20

23

24

27

26

25

29

28

31

117

30

Page

11

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

210A

Page

12

Engine, description When fitting the flywheel housing, its position is determined by tension pins.

General The Valmet 20---series engines (3---, 4---, or 6---cylinders) are water ---cooled, four stroke, turbocharged (not 355 and 665), direct---injection in ---line diesel engines. Technical values, see page 210/3. The engines have a rigid and ribbed cylinder block. The crank mechanism is designed for supercharging. The cylinder liners are wet and supported at the middle, the cylinder head bolts are high tensile bolts.

Cylinder block The cylinder block is the main body of the engine, to which other engine parts are attached. Wet and replaceable cylinder liners are supported at the middle which reduces vibrations and directs coolant circulation mainly to the upper part of the liners. The seal between the cylinder liner lower part and the cylinder block is achieved by three o---rings, which are fitted in grooves in the liner. The upper part is sealed by the cylinder head gasket. The camshaft is located in the cylinder block. The camshaft front bearing location is fitted with a separate bearing sleeve. The remaining bearing locations are machined directly in the cylinder block. The drilling for the camshaft rear end is covered with a plug. There are spaces on both sides of the rear main bearing for guide bearing shims (the crankshaft thrust bearings).

Flywheel housing The flywheel housing is fitted at the rear end of the cylinder block. The seal for the crankshaft rear end is placed in a bore in the housing. The starter motor fixing point is fitted in the flywheel housing.

118

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

210A

Page

13

Crank mechanism The crankshaft is forged from chrome alloy special steel and is induction hardened at the bearing and sealing surfaces. This makes it possible to grind bearings four times without a new heat treatment. Gear wheels are located at the front end of the crankshaft. They are a press fit, and drive the idler wheel and oil pump. In addition, the front end of the crankshaft has splines for the hub of the V ---belt pulley. An oil deflector ring is fitted between the hub and gear wheel, and a dust shield is fitted on the hub in order to protect the seal. The v ---belt pulley has a timing mark. Thus the pulley must be fitted in right position which is determined by a guide pin. The crankshaft is supported on the cylinder block by main bearings which are placed on both sides of each cylinder. Thus there is one main bearing more than cylinders. The crankshaft thrust washers are placed in both sides of the rearmost main bearing. At the rear end of the crankshaft there is fitted a flywheel on which is a press fit a starter ring gear. The forged connecting rod has an I ---section cross---section. The bearing location at the bottom end of the connecting rod is split, and the bearing cup is secured by two special bolts and nuts. The upper part has a wedge ---shaped bearing location, in which the piston pin bearing bushing is fitted with a press fit.

Cylinder head 320--- and 420---engines have one cylinder head. Each cylinder has its own inlet and exhaust ports located on either side of the head. Between hot exhaust valves a cool inlet valve is fitted to balance the thermal load.

The piston is made of an eutectic aluminium alloy. In the upper face of the piston there is a combustion chamber. The shape of the chamber is intended to maximise the mixture of air and fuel. The piston has three rings. The middle ring is tapered and it fits into its groove so the taper taking up the clearance. The oil control ring is spring loaded and it has a two--stage, chromed scraping edge.

Cylinder head bolts are high tensile bolts which are tightened up to yield limit using angle tightening principle. Due to the large stretch the tightening forces are kept constant during the whole lifetime and retightening is unnecessary.

On the turbocharged engines the piston sides are graphitized to ensure correct running ---in.

The injector locations are machined directly into the cylinder head. The inlet and exhaust valve guides are identical and can be interchanged. In addition, the exhaust valves are equipped with replaceable valve seat inserts.

Four ---cylinder engines (420) are equipped with a balancer unit. The eccentric weights, which rotate at twice the engine speed, even out the vibration forces exerted by the movement of the pistons and the crank mechanism.

Valve mechanism The valve mechanism is operated by the camshaft which is located in the cylinder block. The drive is transferred with the help of tappets and pushrods. The camshaft gear wheel is fitted with a press fit and fixed with a key. Each bearing is lubricated by the force feed lubrication system through drilled oilways in the motor block.

119

Model

21A. Engine (20---series)

1. 9. 1992

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

120

255-- 865

Code

210A

Page

14

1. 9. 1992

21A. Engine (20---series)

1. 1. 1998

Model

255-- 900

Code

210A

Page

15

Lubricating system (3--- and 4---cylinder engines have similar lubricating systems). 1. Lubricating oil pump 2. Pressure ---relief valve 2a. Draining hole downwards 3. Oil filter 4. Turbocharger (if fitted) 5. Main oil gallery 6. Lubricating oil to fuel injection pump (in ---line pump) 7. Lubrication of hydr pump drive mechanism (665, 800) 8. Balancer unit (4---cyl. engines) 9. Oil pressure sensor

Lubricating system The engine has a pressure lubricating system in which the oil pump (gear pump) is attached to the cylinder block lower face. The oil is sucked up by the pump through a suction strainer. After the pump the oil is led through an oilway to the relief valve and to the oil filter. After the filter, the oil is led through the main oil gallery from which oilways branch out. The oil is led through the oilways in the main bearings and through the crankshaft to the big ---end bearings.

The oil pressure relief valve is located under the oil filter on the left hand side of the engine. The valve regulates the lubricating oil pressure so that it is kept constant, regardless of the engine speed. Oil pressure is about 2,5 ---4 bar depending on revs, oil quality and temperature, and at engine idling speed the pressure is min 1,0 bar. The oil filter is full---flow disposable type and is fitted on the left---hand side of the engine. A by ---pass valve is located at the base of the filter to ensure safe cold ---starting or to ensure adequate lubrication in case the filter becomes blocked. In addition, there is a non ---return valve which stops the filter from being emptied of oil.

The oil is further directed from the main gallery to the injection pump, turbocharger, balancing unit (420) and to a possible compressor. In addition, the idler gear bushing, the camshaft bearing points and the valve mechanism get their lubrication oil via the main oil gallery.

121

1. 6. 1998

21A. Engine (20---series)

15. 4. 1999

Model

255-- 900

Code

210A

Page

16

1. Cyclone (not 865, 600---900) 2. Air filter 3. Safety filter 4. Turbo (not 205, 355, 665, 600 and 800) 5. Intake manifold 5a. Glow plug 6. Exhaust manifold 7. Exhaust pipe 8. Vacuum switch

Induction and exhaust system The filter system for the engine inlet air comprises a cyclone type precleaner (205---665), and a paper filter which acts as the main filter. The incoming air is made to rotate in the cyclone precleaner. This causes most of the impurities to settle out and collect in the cyclone precleaner dust collector. The paper filter comprises two replaceable filter elements. The paper is corrugated and surrounded by a metal support.

The exhaust manifold is attached to the cylinder head with high tensile bolts without a separate gasket. Retightening of the manifold bolts is unnecessary. The turbocharger is small and thus it reacts sensitively at low engine revs. The turbocharger gets lubricating oil and cooling from the engine lubricating and cooling system. Note! 865, 800 and 900 tractors have not a cyclone but an ejector pipe, which removes impurities from the filter with the aid of the suction created by exhaust gas flow. On the 600, 700. 865, 800 and 900, there is also a warning light in the dashboard for a blocked engine air filter. On 600---900 tractors the air filter housing is the same. On 600---700 there is a valve in place of the ejector pipe, through which impurities are removed. The valve does not require service. In connection with maintenance work, the valve/ejector pipe connection must be directed downwards.

The impurities in the air collect at the larger filter element which can be cleaned when necessary. The inner safety filter prevents impurities form entering the engine should the main filter element break, or be fitted incorrectly. The inlet system also includes the hoses between the air cleaner and the turbocharger and the turbocharger and the induction manifold.

122

Model

21A. Engine (20---series)

1. 9. 1992

Code

255-- 865

211A

Page

1

Repair instructions 9051 73100

Cylinder block and flywheel housing (Op no 211) 1. Cylinder block and cylinder liners A. Measuring cylinder liner wear Note! Cylinder liner wear can be measured when the engine is attached to the tractor. Remove only the cylinder head and crank the engine so that the piston is in the lower position. 1. Using a micrometer, set the dial gauge to zero using a new cylinder liner indicating the initial dimension of the bore: 108,00 mm. 2. Clean the inner surface of the cylinder liner thoroughly before measurement.

C. Checking cylinder block 1. Clean the cylinder block and all oilways. 2. Check the cooling channels and remove the scale and sediment to ensure engine cooling. 3. Check the tightness of the cup plugs and threaded plugs in the cylinder block as well as the condition of the cylinder block and sealing faces. 4. Measure the wear of the camshaft bearing points (compare with rating on page 210/4). Note! If it is necessary to machine the upper face of the cylinder block, the pistons must be shortened by the same dimension. Observe the valve disc spaces on the piston upper face.

3. Perform the measurement crosswise at the liner top end, lower end and middle.

D. Changing camshaft bushing

4. Check the gauge reading for maximum wear and ovalness (compare with rating on page 210/4).

Note! Working order, see page 219/2. 1. Extract the bushing with an internal puller, for example Sykes 854. If the camshaft rear end plug is removed the bushing can be forced out with a long drift.

B. Removing cylinder liner

Note! See also page 219/1 for working order.

2. Clean the bushing location.

1. If the cylinder liners are to be used again they should be marked so that they can be fitted in the same position. 2. Remove the cylinder liners using cylinder liner puller 9051 73100.

123

Model

21A. Engine (20---series)

Code

255-- 865

1. 9. 1992

211

Page

2

0,1---0,4 mm

3. Press in a new bushing. Note the position of the oil hole. It is unnecessary to ream the bushing because it has a correct inner diameter when it is fitted in place.

E. Oversize bushings for camshaft 140 mm

134 mm

6---7 mm

If the location of the camshaft bushing (front bearing) is damaged, a bushing with a 0,4 mm oversize outer diameter can be fitted. Bushings are available even for other camshaft bearings which do not normally have bushings. Part numbers and machining dimensions for the bushing locations are shown in the figure.

4

3

2

1

Observe the position of the bushing oil holes. It is unnecessary to ream the bushings after fitting. Oversize camshaft bushings for 320---engines. Numbering begins from the front end of the engine.

124

Order no

Hole diameter

1. 8363 24661 2. 8368 52460 3. 8368 52460 4. 8368 52461

56,02...56,05 55,40...55,43 55,40...55,43 55,62...55,65

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

211

Page

3

134 mm

272 mm 6---7 mm

4

3

2

1

Camshaft oversize bearing bushings for 420---engines. Numbering begins from the front end of the engine.

Order no

Hole diameter

1. 8363 24661 2. 8368 52460 3. 8368 52460 4. 8368 52461

56,02...56,05 55,40...55,43 55,40...55,43 55,62...55,65

F. Fitting plug at camshaft rear end 1. Clean the seat for the plug. 2. Apply sealing compound to the contact surface of the plug

The camshaft rear end plug is replaced with plug 8363 24391 and o---ring 6146 05125 after machining.

3. Drive in the plug with fitting drift 9025 87400. Note! Do not drive in the plug too far because it will affect the camshaft end float.

125

Model

21A. Engine (20---series)

1. 9. 1992

G. Fitting pipe for oil dipstick

Code

255-- 865

211A

Page

4

9101 65600

1. Clean the seat for the pipe.

116 mm

2. Apply locking fluid Loctite 601 to the lower end of the pipe.

3. Tap the pipe in to the correct fitting height shown in figure above. Note! The position of the pipe affects an oil level in the engine. 0,03---0,08 mm

9025 79200

H. Fitting cylinder liner 1. Clean the cylinder liner and its recess in the cylinder block. Without o---rings the liner should rotate easily in its recess. 2. Apply a thin layer of marking paint on the underside of the cylinder liner flange. Fit the cylinder liner without o---rings and turn it forwards and backwards. Lift out the liner and check that paint has been deposited on the whole contact surface. 9101 66300

3. If the recess is damaged, or the cylinder liner height (see point 5) needs to be adjusted, use milling cutter 9101 65600. If necessary, a light lapping can be executed after milling with the help of the cylinder liner. Apply lapping paste to the underside of the cylinder liner flange, and twist the liner with twisting tool. Lapping is not suitable for adjusting the cylinder liner height.

5. Fit the cylinder liners and fix each liner with two press tools 910166300. Measure the cylinder liner height with a dial gauge and holder 9025 79200. Zero the dial gauge against a flat surface, for example, the cylinder block face. Measure each liner in four places. The height of the liner above the cylinder block face should be 0,03 ---0,08 mm. The height difference between cylinder liners under the same cylinder head must not exceed 0,02 mm, nor must an intermediate cylinder liner lie lower than an outer one.

4. Clean the contact surfaces.

126

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

211A

Page

5

6. If the cylinder liner height is too low, a liner with a higher flange is fitted.

H

Order no

H

Marking grooves pcs

8266 47420 8366 47933 8366 47934 8366 47935

9,03+0,02 9,08+0,02 9,13+0,02 9,23+0,02

--- (norm) 1 2 3

9. Press the cylinder liners into the cylinder block. It should be easy to press them fully home. Make sure that the liners do not rise up after fitting.

Cylinder liners with oversize flanges (higher flanges) are marked with grooves on the outer circumference as follows: 1st oversize, 0,05 mm = 1 marking groove 2nd oversize, 0,10 mm = 2 marking grooves 3rd oversize, 0,20 mm = 3 marking grooves Note! Recess depth is adjusted with a cylinder liner recess cutter 9101 65600. 7. If the liner height of a cylinder liner is not the same all the way round, the cylinder liner flange and the cylinder block recess depth should be checked. Cylinder liners with warped flanges should be discarded.

Musta/Black/Svart/Noir Schwartz/Juodi Vihreä/Green/Grön/Vert Grün/Žalias

8. Fit the o---rings into the grooves in the cylinder lower part and lubricate them with a liquid soap (not with engine oil). Note! Stretch the o---rings as little as possible when fitting them. Max allowable stretching is 6 %.

127

1. 9. 1992

21A. Engine (20---series)

1. 3. 1997

Model

255-- 865

Code

211A

Page

6

8360 20054

2. Flywheel housing A. Fitting flywheel housing The flywheel housing is centred on the cylinder block by two tension pins. Even the flywheel housings which are delivered as spare parts have ready ---made holes for the pins. 1. Clean the sealing surfaces between the cylinder block and the flywheel housing.

Note! If the crankshaft is worn at the sealing location, a 2 mm spacer ring, part no 8360 20054, can be fitted in front of the crankshaft rear oil seal.

2. Apply silicone sealant as shown in figure above. 3. Lift the flywheel housing into place and fit all the bolts. 4. Centre the housing and fit the tension pins with drift 9025 98700. 5. Tighten the fixing bolts, the inner ring socket head bolts to 60 Nm and outer ring hexagonal bolts to 110 Nm.

9052 46300

B. Changing crankshaft rear oil seal 1. Split the tractor at clutch. Remove the clutch assembly.

5. Lubricate the sealing surfaces on the crankshaft and on the seal. Place the seal on the crankshaft and drive it in until it bottoms using drift 9052 46300. Other tools may cause the seal to be damaged or mounted askew, resulting in leakage.

2. Remove the flywheel. 3. Remove the oil seal. Do not damage the crankshaft.

Note! The cranckshaft rear oil seal has been changed to a Teflon type. The spare part seals have a mounting sleeve, which must not be removed before fitting. The spare part numbers do not change. When fitting the seal, place the plastic sleeve on the crankshaft and push the seal on the sleeve into place. Remove the sleeve and fit the seal with the special tool. The seal must be fitted as dry.

4. Clean the seal location and grind off any burrs.

128

1. 6. 1998

21A. Engine (20---series)

15. 4. 1999

C. Changing starter ring gear on flywheel

Model

Code

255-- 900

211A

Page

7

Note! If a flywheel must be changed on the E ---engines, an injection timing mark must be made on a new flywheel as follows:

If the ring gear is worn, change it with a new one. The ring gear cannot be turned around because its teeth are chamfered and hardened on the starter motor side.

--- Rotate the crankshaft so that the piston in the first cylinder is in the top dead centre. Drop a valve down against the piston top. Place a dial gauge stylus against the valve upper end and zero the gauge to the top dead centre. Rotate the crankshaft in the running direction until the dial gauge shows value 4,633 mm after the top dead centre).

1. Split the tractor at clutch (see Op 411 1A). Detach the clutch assembly and the flywheel. 1. Detach the earlier ring gear by tapping it with a drift. Clean the ring gear seat on the flywheel with a steel---wire brush.

--- Drill the injection timing mark in the flywheel with the aid of a drill shown below.

5 mm drill

7

8 mm guide

2. Warm the ring gear to the temperature of 150 ---200˚C. Fit the ring gear with the inner diameter chamfering turned against the flywheel and the teeth chamfering against the starter motor. 3. Allow the ring gear to cool freely without using any coolant.

D. Fitting the flywheel 1. Clean the contact surfaces on the crankshaft rear flange and on the flywheel. Note! In the E ---engines there is an injection timing register mark on the flywheel and the flywheel has been positioned with a guide sleeve to the crankshaft. 2. Fasten the flywheel to the crankshaft rear end. As a guide pins can be used screws M12 (2 pcs) which are screwed in to the flywheel fixing bolt holes. 3. Tighten the flywheel fixing bolts evenly to a torque of 140 Nm (10.9) or 160 Nm (12.9).

129

130

10. 1. 1992

21A. Engine (20---series)

1. 9. 1992

Cylinder head and valve mechanism (Op

Model

255-- 865

Code

212A

Page

1

2. Compress the valve springs using lever 9101 66200. Remove the valve cotters, spring guide and spring. Remove the valves.

no 212) 1. Cylinder head

C. Checking cylinder head

A. Removing cylinder head

1. Remove carbon deposits from the exhaust ports, clean the sealing surfaces and wash the cylinder head.

1. Remove the engine hood plates. Clean the engine externally and drain the coolant. Disconnect the coolant hoses from the cylinder head and the thermostat housing.

2. Check for cracks and other damage.

2. Remove the suction hoses between the turbocharger and the air filter and between the turbocharger and the inlet manifold (turbocharger only on 455---565 tractors). 3. Disconnect the turbocharger pressure and return oil pipes. 4. Remove the pipes to the thermostart fuel reservoir. 5. Remove the injector leak ---off fuel pipes and the delivery pipes. Remove the injectors. Fit blanking ---off caps on all open connections. 6. Remove the inlet and exhaust manifolds and the thermostat housing. Note! It is possible to remove the cylinder head even thought these parts are attached to the head. 7. Remove the valve cover and the breather hose.

3. Check the flatness of the cylinder head by using a straight edge. An uneven or warped surface should be surface ground. The height of the cylinder head, after grinding, should not be less than 104,00 mm. The valve disc depth from the cylinder head surface should be 0,60 mm for the exhaust valves and 0,70 mm for the inlet valves.

8. Remove the rocker arm mechanism and the push rods. 9. Loosen all the cylinder head bolts first by a 1/4 turn and then remove them. Remove the cylinder head.

B. Removing valves Ensure that valves which are to be re ---used are marked, so that they are fitted in their original locations.

9101 66000

9052 47200

1. Thread the counterhold nuts 9052 47200 onto a screw stud for the rocker arm mechanism. On the 320---engines there is not a screw stud at the valves for the centre cylinder. A bolt of suitable length should be used instead.

4. Straighten and clean the injector location seat in the cylinder head with cutter 9101 66000.

131

10. 1. 1992

21A. Engine (20---series)

1. 9. 1992

Model

255-- 865

Code

212A

Page

2

9101 65900

5. Measure the clearance between the valve stem and the valve guide with a dial gauge. Lift the valve so that the valve head is 15 mm from the face of the cylinder head, and measure the clearance. It must not be greater than 0,20 mm for the inlet valves and 0,25 mm for the exhaust valves. In order to establish the valve guide wear, a new valve should be used when measuring.

21 mm

D. Changing valve guides 9101 65800

3. The guides are the same for the inlet and exhaust valves. Ensure that the steepest chamfer on the guide, faces the valve head. Check that the valves do not bind in the guides.

E. Machining valve seat

1. Press or knock out the old guides using drift 9101 65800. Clean the valve guide locations. 2. Lubricate the outside of the new guides and fit them using drift 9101 65900, which ensures the correct fitting height (21 mm over the spring face)

Machine the damaged valve seat with milling cutter (see page 210/10). If the width of the seat exceeds 2,3 mm in exhaust and 3,7 mm in intake, it should be reduced primarily at the outer edge. The valve seat angle is 45˚+20’ for exhaust valve and 35˚+20’ for inlet valve.

132

Model

1. 9. 1992

21A. Engine (20---series)

1. 3. 1997

Code

255-- 865

212A

Page

3

F. Changing valve seat inserts Exhaust valves are fitted with separate valve seat inserts. If the sealing surface is damaged so badly that it cannot be repaired with machining, the seat inserts should be changed.

B A

1. Grind the valve head on a discarded valve so that it sits down in the valve seat. Fit the valve and weld it in place in the seat. Cool with water. 2. Turn the cylinder head over and knock out the valve and seat. 3. Clean the valve seat location. Cool the new seat in liquid nitrogen until it stops bubbling, or alternatively place it in dry ice. INLET EXHAUST

4. Fit the seat with a suitable drift. Machine the seat.

A 35˚ ---20’ 45˚ ---20’

B

35˚+20’ 45˚+20’

N.B. Where necessary, standard size seats can be replaced by inserts with a larger outer diameter. See Specifications. 1. Grind the damaged valve disc with a valve refacer. Adjust angles to 45˚ ---20’ for exhaust valves and 35˚ ---20’ for inlet valves.

11±0,1

2. If the edge of the valve head is less than 1,5 mm after it has been ground, or if the valve stem is bent, the valve should be discarded. 3. If necessary, grind the end of the valve stem. 4. Lap the valves with lapping paste and check the contact surface with marking paint.

48,500...48,525

5. Clean the cylinder head and valves of any remaining lapping paste.

The inlet valve seat machined direct on the cylinder head, can be provided with a separate valve seat insert, order no 8366 47936. Machine the seat insert location on the cylinder head (see figure above). Fit the insert like a seat of the exhaust valve.

H. Fitting valves

Note! From March 96 the V ---marked cylinder heads have the valve seat inserts also on the inlet valves. The V is stamped on the cylinder head front upper surface on the exhaust side. As a spare part these heads can be fitted on all engines. The V ---marked cylinder heads are also available for the 4---cylinder engines.

1. Check the valve springs for straightness, length and tension using a spring tester. Compare with specifications. 2. Lubricate the valve stems and fit the valves in the correct order in the cylinder. 3. Fit the springs, spring guides and valve keepers with the aid of a lever for compressing valve springs, 9101 66200.

G. Grinding valves

4. Tap the end of the valve stems lightly after fitting the valve in order to ensure that they are secure.

In order to ensure that there is a proper seal around the valves, there is a difference in the sealing surface angles. Thus there is a very narrow sealing surface which seals effectively even after prolonged running.

133

Model

1. 6. 1998

21A. Engine (20---series)

Code

255-- 865

15. 4. 1999

Page

212A

4

I. Fitting cylinder head 1. Measure the length of the cylinder head bolts. Compare with dimensions shown in figure below. Change too long bolts.

14

10

16

max. 142

12

5

7

1

2

4

8

15

9

3

17

6

11

13

320 max. 188,5

21

22

19

12 10

6 2

20

18

11 7

3

14

17 16

9

1

8 2. Screw the cylinder head stud bolts in to the cylinder block to a torque of 30 Nm. Fit the valve tappets if removed.

4

5

13

15

420

3. Check that the sealing surfaces are clean and fit the cylinder head gasket. Clean and lubricate and fit the bolts. Note! The spare part number of the cylinder head gasket is 8366 46351 (320---engines) and 8367 46354 (420---engines).

4. Pictures above show the correct tightening order of the cylinder head bolts. The order has also been marked on the cylinder heads. 5. Tighten the cylinder head bolts progressively as follows: 1. First tightening to 80 Nm 2. Tightening a further 90˚ 3. Tightening a further 90˚ 4. Adjust valve clearances 5. Warm engine to normal operating temperatur with light load (up to about +75˚C) 6. Tightening a further 60˚. 7. Adjust valves. Note! Tighten the exhaust manifold bolts to the cylinder head to a torque of 50 Nm. Do not tighten more.

134

1. 9. 1992

21A. Engine (20---series)

1. 9. 1995

Model

255-- 865

2. Valve mechanism

Code

212A

Page

5

60˚

A. Reconditioning rocker arm mechanism 1. Check the valve tappets, especially the contact surface against the camshaft. Worn or damaged tappets should be discarded.

5. Fit the plug to the other end of the rocker arm shaft. Lubricate the shaft and fit various parts in a correct order. Note the correct position of the shaft and the bearing brackets. The split side of the bracket and the shaft oil holes must be turned to the valve side (see figure above). Fit the other end plug.

B. Changing camshaft/camshaft gear Note! Working order, see page 219/2. 2. Check the straightness of the pushrods by rolling them on a surface table. Check also the spherical surfaces at the ends.

1. Remove the inlet pipe between the turbocharger and the induction manifold. Remove the valve cover and the breather pipe. Remove the rocker arm mechanism.

3. Dismantle and clean the rocker arm mechanism. Check the shaft for wear and that the oilways are clean.

2. Remove the radiator, cooling fan, alternator and the v ---belt. 3. Remove the crankshaft nut. Remove the V ---belt pulley including the hub. 4. Remove the timing gear casing cover (engine front cover). 5. Connect the pushrods in pairs, using o---rings or elastic bands to prevent them from falling through.

19,990...20,010 4. Check that the rocker arm bushes are not worn. Ensure that the oil hole is positioned correctly when pressing in new bushes. After pressing in the bushes they should be reamed to 19,990 ---20,010 mm. Where necessary grind the rocker arm valve contact surface to the correct shape. Do not grind more than necessary as the hardened layer is thin.

Note! Do not connect the pushrods too tightly as this might cause them to bend or snap.

135

Model

1. 9. 1992

21A. Engine (20---series)

Code

255-- 865

15. 9. 1995

Page

212A

6

320 ---engines

6. Crank the engine until the aligning marks on the idler gear and camshaft gear are facing each other. Extract the camshaft.

Check the valve clearances in the injection order of the engine. Injection order is 1---2---3. --- check valves in the 1st cylinder, when the exhaust valve of no. 3 cylinder is completely open (valve no. 6) --- check valves in the 2nd cylinder, when the exhaust valve of no. 1 cylinder is completely open (valve no. 2). --- check valves in the 3rd cylinder, when the exhaust valve of no. 2 cylinder is completely open (valve no. 4).

7. Separate the camshaft from the gear wheel using a press or suitable drift. 8. Clean the parts which are to be refitted. 9. Fit the key in its groove. Heat the camshaft gear to 200˚C in an oven and fit it on the shaft.

420 ---engines

10. Lubricate bearing surfaces and lobes and insert the shaft in the cylinder block. Ensure that the aligning marks on the gears agree.

--- rotate the crankshaft in the running direction until the valves in the 4th cylinder are rocking (exhaust closes, inlet opens). Check the valve clearance of the 1st cylinder --- Rotate the crankshaft by 1/2 of a turn in the running direction so that valves in the 3rd cylinder are rocking. Check valves in the 2nd cylinder --- continue according to the order of injection:

11. Fit the timing gear casing cover and the crankshaft V ---belt pulley and hub. 12. Free the pushrods and fit the rocker arm mechanism. Adjust the valves. Fit the valve cover and the breather pipe and the inlet pipe between the turbocharger and the induction manifold. 13. Fit the alternator. Fit the fan and the fan belt. Fit the radiator.

Injection order

1 2 4 3

Valves rock in cyl. no

4 3 1 2

C. Adjusting valves I

P

I

P

I

P

I

P

320 0,35

I

P

I

P

I

P

420 I=inlet

The valve clearance, which can be adjusted on a hot or cold engine, is 0,35 mm for both inlet and exhaust valves. The clearance is adjusted when the respective piston is at T.D.C. in the compression stroke. The valves for the different cylinders are adjusted in the same sequence as the order of injection.

P=exhaust

Note! From engine number C6828, the support strips have been added onto the valve covers. These strips prevent the gasket from moving inwards. At the same time the cover manufacturing accuracy has been improved. Spare part numbers of the covers do not change.

--- slacken the lock nut of the adjusting screw --- measure clearance with a feeler gauge. The clearance is correct when a 0,35 mm feeler gauge is slightly tight---fitted between the rocker arm and the valve stem end. Adjust clearance by rotating the adjusting screw. --- tighten the locking nut and check the clearance

136

1. 9. 1992

21A. Engine (20---series)

1. 3. 1997

Crank mechanism (Op. no 213)

Model

Code

255-- 865

213A

Page

1

3. Refit the bearing caps with new bearing shells and tighten them to the correct torque. Measure the I.D. with a dial gauge which has been zeroed to the dimensions obtained in point 2. With this method the indicator shows the actual bearing clearance. Measure in several points in case the worn bearing housing is not round.

1. Crankshaft A. Removing crankshaft 1. Split the tractor at the clutch, remove the clutch assembly and the flywheel. Remove the engine (see also page 219/1). 2. Disconnect the balancing unit lubricating oil pipe from the cylinder block and unscrew the balancing unit fixing bolts. Remove the balancing unit and the lubricating oil pipe (only 420---engines). 3. Unscrew the lubricating oil pump pressure pipe fixing screws from the cylinder block. Remove the oil pump and the suction and pressure pipes. 4. Remove the flywheel housing. 5. Detach the belt pulley/hub from the crankshaft front end (see instr. timing gears). 6. Remove the connecting rod bearing caps and push the connecting rods out of the way of the crankshaft. 7. Remove the main bearing caps and lift out the crankshaft.

4. If the bearing clearance exceeds 0,18 mm for main bearings or 0,14 mm for connecting rod big ---end bearings with new bearing shells, the bearing journals on the crankshaft should be ground. Refer to the specifications for the relevant correct undersize and the corresponding bearings. Ensure that the radii are not changed when grinding.

B. Checking crankshaft 1. Clean the crankshaft. Do not forget the oilways.

Note! Main bearings are available, which are 1,0 mm oversize (outer diameter) and 0,5 mm undersize (inner diameter). The cylinder block must then be machined to a dimension of 92,000---92,025 mm. The crankshaft must be machined to a dimension of 84,485---84,520 mm. The bearing shell with a hole and an oil groove must be fitted to the cylinder block and the other shell to the bearing cap.

C. Changing crankshaft gears 9052 48800

2. Measure the journal wear in several points. Out---of ---round, taper or other wear must not exceed 0,03 mm.

1. Apply puller for the crankshaft gears and pull off both gears.

137

15. 9. 1995

21A. Engine (20---series)

1. 6. 1998

3. Heat the new gears to 200˚ C. Tap them onto the shaft with a suitable sleeve or soft drift. Note the position of the key and ensure that the aligning marks on the front gear are visible. Leave it to cool.

ring

255-- 865

Code

213A

Page

2

2. Fit the bearing shells with the oil hole/groove into the cylinder block and the shells without groove into the bearing caps. Ensure that the bearing shell clamping claws fit into their notches and that the shell holes coincide with the oil ports.

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

D. Changing camshaft (420---engines only)

Model

3. Lubricate the bearing surfaces and fit the crankshaft. Fit the crankshaft thrust bearings with the lubricating grooves facing the crankshaft.

gear

20˚

200 Nm

4. Fit the main bearing caps according to their numbering, the rear with thrust bearings provided with guide lugs. Lubricate the bolts and tighten them to 200 Nm. Note! The figure above shows a rear view of the crankshaft and no 2 cylinder big end bearing journal.

0,10-- 0,35 mm

1. Mark the position of the ring gear on the shaft. 2. Heat the ring gear with a welding torch and drive it off using a suitable drift. 3. Heat the new ring gear to max. 250˚C. Fit the ring gear with the chamfer facing the crankshaft flange, and with the teeth according to markings or according to figure above. Tap the ring gear down and leave it to cool.

E. Fitting crankshaft 1. Clean the oilways, bearing shells and bearing locations. Check that the crankshaft is clean. Note! From engine no. E1619 incl. the main bearing shells have been changed by deleting the oil grooves on the lower shell. When fitting the bearing shells, it is necessary to note the places of the shells. The shell without groove must be fitted onto the bearing cup i.e. to the lower side and the shell with the groove to the upper side i.e. on the cylinder block. The order number of the bearing shells (in pairs) is 8366 55514. The new bearing shells are fully interchangeable with the earlier ones.

5. Check that the crankshaft can rotate without binding. Check the end float using a dial gauge. The correct end float is 0,10 ---0,35 mm. If the end float is too large, oversize thrust bearings should be fitted. Note! Bearing shells should never be reamed or machined in any other way, nor should the sides of the bearing caps be filed.

138

1. 9. 1995

21A. Engine (20---series)

1. 6. 1998

Model

255-- 865

Code

213A

Page

3

3. If the piston pin bushing is worn, it should be driven out using a suitable drift.

2. Connecting rods and pistons A. Removing pistons together with connecting rods

5

Note! Pistons and connecting rods can be removed from the engine when the engine is attached to the tractor by removing the propeller shaft guard and the shaft and then the oil sump (see page 219/1).

40,025... 40,040

1. Detach the oil sump and the lubricating oil pressure and suction pipes. 2. Detach the cylinder head. 3. Scrape off the carbon edge in the cylinder liner. If the turning edge is clearly marked, smooth it down carefully with a scraper. 4. Remove the big ---end bearing caps and bearing shells. Place the shells in order if they are to be re ---used.

4. Drive in the new bushing and ensure that the oil hole aligns with the corresponding hole in the connecting rod. After fitting, drill the oil hole with ø 5 mm drill. Ream the bushing after fitting to a correct dimension.

5. Push up the piston and connecting rod with the shaft of a hammer or similar wooden tool. 6. Remove the piston pin snap rings. Push out the pin. Note! If the piston pin does not move under thumb pressure the piston should be heated to 100˚C.

C. Checking connecting rod The connecting rod is checked in a special fixture, intended for the purpose (e.g. Carl Larsson).

B. Changing connecting rod bearings 1. Clean the connecting rod and bearing shells. Fit them together and tighten the bolts to 40 Nm+90˚.

208,00

40 Nm+90˚

1. Fit the big ---end bearing caps and tighten the bolts to 40 Nm+90˚. 2. Fit the connecting rod in the fixture and fit the piston pin which corresponds to that connecting rod. 2. Measure the I.D. using a cylinder gauge which has been zeroed to the diameter of the respective bearing journal. If the clearance exceeds 0,14 mm with new bearing shells, the big ---end journals require grinding. Refer to the specifications for the correct undersize and the corresponding bearing. Ensure that the radii at the end of the bearing journals is not altered when grinding.

139

Model

21A. Engine (20---series)

1. 9. 1992

3. Check that the connecting rod is not twisted by positioning the measuring tool with the horizontally placed measuring points against the face of the fixture.

255-- 865

Code

213A

Page

4

5. Also check the S ---bending of the connecting rod by using sliding calipers to measure the distance between the edge of the small---end bearing bushing and the face of the fixture. turn the connecting rod round so that the other side of the connecting rod faces the fixture. Then measure the same distance. The accepted deviation is 0,6 mm.

max 86,50

6. Measure the length of the connecting rod bolts. The length should be max 86,50 mm. If the bolt is longer, change it with a new one. It is recommended that the bolts are always changed when they are unscrewed.

D. Connecting rod weight classes The connecting rods are divided into weight classes with intervals of 20 g. The weight class (a letter) is stamped on the side face of the connecting rod. All the connecting rods in one engine should be of the same weight class, that is to say the greatest permissible weight difference is 20 g.

4. Turn the measuring tool round with the vertically placed measuring points against the face, and check the straightness of the connecting rod

140

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

213A

Page

5

The letters show the weight classes as follows: A B C D E

Weight 2170---2189 g 2190---2209 g 2210---2229 g 2230---2249 g 2250---2269 g

Part no 8366 52104 8366 52105 8366 52106 8366 52107 8366 52108

H I J K L

2270---2289 g 2290---2309 g 2310---2329 g 2330---2349 g 2350---2369 g

8366 52109 8366 52110 8366 52111 8366 52112 8366 52113

M N O P R

2370---2389 g 2390---2409 g 2410---2429 g 2430---2449 g 2450---2469 g

8366 52114 8366 52115 8366 52116 8366 52117 8366 52118

S 2470---2489 g T 2490---2509 g U 2510---2529 g

8366 52119 8366 52120 8366 52121 3. Measure the piston ring gap by pushing one piston ring at a time into the cylinder bore. The piston ring gap must not exceed 1 mm on 1. and 3. piston rings and 1,5 mm on 2. piston ring.

E. Changing piston rings

4. Fit the piston rings on the piston using the piston ring pliers. Ensure that the rings are fitted in the correct groove and that ”TOP”, or the manufacturer’s designation, faces upwards.

1. Remove the piston rings with piston ring pliers. Do not open the rings more than necessary. If the rings are to be used again ensure that they are fitted in the same groove.

Picture above shows the piston rings.

2. Clean the piston ring groove and measure the piston ring clearance, which must not exceed 0,15 mm. Determine whether too large a clearance is due to worn rings or a worn groove. Change worn parts.

141

1. 9. 1992

21A. Engine (20---series)

1. 9. 1995

F. Checking pistons

Model

255-- 865

Code

213A

Page

6

H. Fitting piston together with connecting rod.

Check the condition of the pistons and piston pins. Pay special attention to possible cracks on the edge of the combustion chamber and on the upper edge of the piston pin hole. Measure the diameter of the piston at the point shown in the figure below. Renew a piston if needed.

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

320, 420 620:

G. Fitting piston pin 1. Place the connecting rod inside the piston and push the piston pin in to place.

3. Fit the piston with the marking on the connecting rod (weight class) facing the camshaft (an arrow on the piston must point forward). 4. Lubricate the big ---end bearing journal and bearing shells, and push the piston down. Fit the bearing cap so that the notches for the guide lugs are in the same side. Tighten the connecting rod bolts to 40 Nm+90˚. 5. Check that the connecting rod has sufficient end float on the big ---end bearing journal.

Note! The combustion chamber and the weight class letter should be on opposite sides! 2. Fit the piston pin circlips. Ensure the circlips are pressed correctly into the grooves. The circlip ends must point upwards.

142

1. 9. 1995

21A. Engine (20---series)

1. 4. 2004

3. Balancer unit, 420---engines

Model

255-- 900 A75-- A95

Code

213A

Page

7

3. Place the weights in the body, observing the notch markings. The gear wheel with the punch mark runs against the crankshaft and should therefore be placed highest. Insert the shafts, remembering the thrust bearings. Apply thread lock fluid Loctite 270 to the locking screws, and lock the shafts.

A. Removing and dismantling balancer unit Note! Working order, see page 219/1. 1. Remove the engine (Note! The balancer unit can also be detached when the engine is attached to the tractor. In this case, remove the oil sump). 2. Disconnect the lubricating oil pipe of the balancer unit. 3. Remove the balancer unit. Take care of any shims. 4. Loosen the locking screws and press out the shafts in the direction of the locking screws. Remove the counterweights and thrust washers. 5. Clean all parts.

0,1---0,5 mm

B. Reconditioning balancer unit Check the shafts, gear wheels and bushings for wear and damage. 1. If one of the gear wheels is damaged, change both counter weights as a complete unit. The gear wheels are not available separately as a spare part.

4. Check that the tooth backlash is 0,05 ---0,25 mm and that the end float is 0,1 ---0,5 mm

2. Remove, if necessary, the old bearing bushings with a suitable drift. Before removing them, mark the position of the bushing oil groove on the counter weight. Press in new bushings in the correct position. After fitting, the bushings should be reamed to a correct dimension, see Specifications.

1. Synchronization marking (notch) 2. Marking against crankshaft (punch mark)

143

Model

21A. Engine (20---series)

1. 9. 1992

C. Fitting balancer unit

255-- 865

Code

213A

Page

8

Changing crankshaft gear rim

1. Fit the tension pins in the balancer unit body.

1.

Mark the position of the gear rim on the shaft.

2.

Heat the gear rim with a welding torch and drive it off using a suitable drift.

3.

Heat the new gear rim to max. 250°C. Fit the gear rim with the chamfer facing the crankshaft flange, and with the teeth according to markings or according to figure above. Tap the gear rim down and leave it to cool. 20˚

2. Turn the crankshaft and weights so that the markings agree, and lift the unit into place. 3. Tighten the bolts to 45 Nm. Check that the tooth backlash between the crankshaft and counterweight is 0,1 --- 0,3 mm. The backlash can be increased by placing shims 0,2 mm thick (order no 8361 19920) between the cylinder block and balancer unit body. One shims (0,2 mm) changes tooth backlash about 0,07 mm. Note! The picture above shows a rear view of the crankshaft and no. 2 cylinder big end bearing journal.

4. Fit the lubricating oil pipe, using new seals. 5. Fit the engine or the oil sump.

144

1. 9. 1992

21A. Engine (20---series)

15. 9. 1995

Timing gears (Op no 214)

Model

Code

255-- 865

214A

Page

1

6. Unscrew the idler gear bolts (17 and 22 mm). Remove the flange, gear wheel and bearing journal.

A. Removing timing gear casing

7. Extract the camshaft.

Note! Working order, see page 219/2.

Note! If the cylinder head and valve mechanism have not been removed, the tappets must be prevented from falling down, see Op. 212 2B.

As the timing gear casing forms a seal against the oil sump, the casing cannot be removed without first removing the oil sump.

8. Remove the timing gear casing (13 mm). Ensure that all sealing surfaces are not damaged.

1. Detach the engine (or the oil sump).

9. Remove the crankshaft front sealing ring from the front casing and clean all the parts that have been removed.

2. Remove the cooling radiator, alternator and the fan belt (if not removed earlier).

B. Reconditioning idler gear If the idler gear bushing is changed, press in a new bushing so that its rear edge is 0,1 ---0,25 mm inside the gear wheel rear edge (see picture on next page).

1 2

9101 65700 3. Loosen the crankshaft nut (special tool 9101 65700) and remove the belt pulley/hub. 4. Remove the timing gear casing cover and the oil deflector ring at the front end of the crankshaft.

1. Chuck of lathe 2. Roller ø=5 mm

5. Remove the injection pump.

Machine the idler gear bushing inner diameter to a correct dimension after fitting. Centre the idler gear according to figure above so that tooth backlash is kept the same.

Note! If the timing gear casing is not to be changed, the injection pump can remain in place. In which case disconnect all leads and pipes from the pump.

Note! Tractors that have a hydraulic oil pump of 54 litres, the idler gear bearing has been reinforced with effect from serial number 662885 (engine number D2187). To standardize the production, this same modification has been carried out on all tractors from ser. no. 663410 incl. (engine no. D3397). The modification can be recognized by a sheet metal housing in the middle part of the timing gear casing. The new parts are not interchangeable separately. As a spare part both new and earlier parts are supplied.

145

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

214A

Page

2

C. Fitting timing gear casing 4. Fit the idler gear with shaft stud and ensure that the markings are in the correct position. Fit the washer and tighten the bolts to the correct torque.

The position of the timing gear casing and cover is determined by two tension pins. Therefore centring should not be undertaken in connection with fitting. However, the tooth backlash between the different gears should be checked. Casing and covers that are delivered as spare parts also have holes for the tension pins already machined. 1. Fit the casing with a new gasket against the cylinder block. Drive in the tension pins with drift 9025 98700. Tighten bolts and nuts. 2. Fit the injection pump together with gear wheel (if removed). 3. Lubricate the camshaft bearings and insert the shaft in the cylinder block. Release the pushrods and tappets if they have been suspended.

5. Check the tooth backlash which should be 0,05 ---0,25 mm.

146

Model

21A. Engine (20---engines)

1. 9. 1992

255-- 865

Code

214A

Page

3

9025 98700 9025 98800

9025 98900

6. Fit the oil deflector ring on the crankshaft and fit the timing gear casing cover using a new gasket. Drive in the tension pins with drifts 9025 98700 and 9025 98800 respectively (the tubular pin round the screw stud). Tighten bolts and nuts.

8. Fit the dust shield on the crankshaft V ---belt pulley hub, if it has been removed. Use drift 9025 98900.

9030 15200

600 Nm (320, 420) 1000 Nm (620, 634)

7. Fit the protective plate into the seal location and fit the crankshaft front seal with special tool 9030 15200.

9. Lubricate both the seal and sealing surfaces and fit the crankshaft V ---belt pulley with hub.

Note! The crankshaft front oil seal can be changed while the engine is attached to the tractor. In this case, remove the cooling radiator and belt pulley/hub at the front end of the crankshaft.

10. Lubricate the crankshaft nut threads. Tighten the nut (with tool 9101 65700) to 600 Nm. 11. Fit the other detached parts.

147

148

Model

1. 9. 1992

21A. Engine (20---series)

255-- 900

1. 9. 2001

Lubricating system (Op no 215)

Code

215A

Page

1

Latest lubricating oil pressure relief valve (J7589---).

A. Reconditioning of oil relief valve for lubricating oil pressure

2 Loctite 638

If the engine lubricating oil pressure is insufficient or if it varies, the relief valve should be checked after first checking the oil level.

3 25 Nm

1

4 5 6

1. Valve seat insert 2. Valve head 3. Spring, dark colour Note! The spring expanded end towards the valve head. In autumn 99, the spring end shape will be changed to prevent wrong mounting of the valve. 4. Gasket 5. Cover 6. Bolt, 2 pcs 1. Remove the cover over the valve (13 mm) and spring. Take care of the washer between the cover and spring. Remove the valve insert together with the valve cone and ensure that the o---ring is also removed.

Note! As a spare part the earlier complete valve can be replaced with the new valve fitting kit.

2. Clean the parts and check that the valve cone slides freely in the insert and that the sealing surface are undamaged. Minor damage can be adjusted, but in general, damaged parts should be changed. Scrape off any remains of the gasket.

B. Removing and dismantling lubricating oil pump

3. Assemble the valve with a new o---ring and insert it in the cylinder block. Place the washer and spring in the cover and fit it with a new gasket.

1. Detach the oil sump, see page 219/1. 2. Remove the oil pump suction and pressure pipe. 3. Remove the oil pump together with any shims between the pump and the cylinder block. 4. Remove the pump cover and the gasket. Remove the gear on the dead axle. 5. Clamp the pump gear across the teeth in a vice fitted with soft jaws, and loosen the drive gear nut. Knock the gear wheel off by hitting the end of the shaft with a soft hammer. Pull out the drive shaft---gear wheel 6. Clean the parts and check for wear and other damage. Compare with the specifications. Change damaged parts and all seals.

4. Note that the relief valve cover is not symmetrical. The greater distance between the spring housing and bolt should be turned downwards.

149

1. 9. 1992

21A. Engine (20---series)

15. 9. 1995

Model

255-- 865

Code

215A

Page

2

C. Assembling and fitting lubricating oil pump 1. Fit the gear wheels in the pump body. Fit the cover using a new gasket. Partly tighten the bolts. Rotate the pump shaft and tap the side of the cover lightly until the position is reached where the shaft rotates most freely. Tighten the bolts and check that the shaft still rotates freely. 2. Fit the key (not on the latest pumps) and drive gear onto the shaft. Apply Loctite 242 onto nut threads and tighten the nut to 60 Nm. Remember the washer under the nut. Note! With effect from engine ser. no. C1474 (320) and C1328 (420), the engine lubricating oil pump has been modified. The fitting between the gear and the shaft has been changed from a cylindrical type with key to a taper type without key. As a spare part the complete new pump is exchangeable with the earlier pump. The new drive gear and the shaft can be fitted in pairs on the earlier pump. 4. Fit the pump and check the tooth backlash against the crankshaft gear. The clearance, which should be 0,05 ---0,25 mm, is adjusted with shims between the pump body and the cylinder block (shims 0,2 mm, order no 8360 07871). One shims increases/decreases the backlash about 0,07 mm. Note! When measuring the tooth backlash, the engine should be the correct way up as the crankshaft bearing clearance affects the tooth backlash. 5. Connect suction and pressure pipes together with new seals. 6. Fit the engine (or the oil sump).

3. Fasten the oil pump in a vice and check the end float between gear and pump housing. The clearance which should be 0,03 ---0,11 mm, is adjusted by the number of gaskets between the cover and body.

150

1. 9. 1992

21A. Engine

Model

1. 4. 1999

Code

255-- 865

215A

+20

+30

E. Lubricating oil quality requirements (see also page 130/4) 1. QUALITY (API ---CLASS) --- naturally aspirated engines --- turbocharged engines 1)

CCMC D2 CCMC D4/D5

API CC 1) ACEA E2 ---96 API CD ACEA E2 ---96/E3 ---96

API ---CD can also be used in conventionally aspirated engines.

Note! Valtra Engine oil is recommended for use in Valmet engines.

---30

---10

---20

TEMPERATURE ˚C 0 +10

5W---20 5W---30 5W---40 SAE---CLASS

10W 10W---20 10W---30 10W---40 15W---30 15W---40 20W---20 20W---30 20W---40 30

151

Page

3

152

Model

21A. Engine (20---series)

1. 9. 1992

Inlet and exhaust system, turbocharger (Op no 216)

255-- 865

Code

216A

Page

1

4. Check that the exhaust manifold is air tight. Tighten the bolts to 50 Nm and inspect for any damage (cracks, deformation, corrosion etc.). Check also the connection between the turbocharger and the exhaust manifold.

An engine that is equipped with a turbocharger is a great deal more sensitive to disturbances and impurities in the inlet and exhaust systems than a conventionally aspirated engine. Therefore special attention should be given to the whole inlet and exhaust system.

5. Remove the manifold if necessary. Clean the sealing surfaces and remove any carbon deposits. Check that the sealing surfaces are flat. If the fastening flanges are twisted or there are scratches on the sealing surfaces, machine the flanges or renew the exhaust manifold. 6. Ensure that no loose objects or impurities have entered the exhaust pipe or the silencer. Any such loose objects or impurities can increase the back pressure for the exhaust gases from the turbine wheel.

A. Checking air cleaner

C. Checking turbocharger

The engine performance and length of service life depend to a great extent on the state of the air cleaner. A defective air cleaner allows impurities to pass through, which in time damage the turbocharger and the engine. A blocked air cleaner lowers the engine output and also causes oil leakage through the sealing ring on the turbocharger shaft.

If a fault is suspected in the turbocharger it can be located in the following way: 1. Visually inspect the turbine and compressor wheels. The vanes must not show any signs of damage, deformation or wear caused by foreign objects.

Note! The safety filter inside the main filter should not be removed unnecessarily, for checking or cleaning. The safety filter must not be cleaned, but should be changed once a year or when necessary (see Operator’s Manual)

2. Investigate any oil leaks through the sealing rings on the shaft in the turbine and compressor housing. N.B! At low idling there is always a certain amount of oil leakage on the compressor side. However, this should not cause too much concern unless the oil consumption is too great.

B. Checking inlet and exhaust system Important! Leaks in the inlet or exhaust system markedly lower the effect of the turbocharger. Because of the pressure, even small leaks in the manifold or in the turbine inlet contact flange quickly increase in size. For this reason all leaks must be dealt with immediately. 1. Inspect the pipes and sealing surfaces between the air cleaner and the turbocharger, as well as between the turbocharger and the induction manifold. If the induction manifold is dusty on the inside, there is a leak in either the air cleaner or the induction pipes. Remedy the leak. 2. Clean the induction manifold sealing surface. Check that the sealing surface is flat using a straight ruler. If the surface is not flat or it has scratches, machine or renew the induction manifold. 3. Fit a new gasket and fasten the induction manifold. Tighten the manifold fixing screws to a torque of 30 Nm. Fasten the air pipes carefully.. 3. Check the turbine shaft running clearance. Place the stylus of a dial gauge against the shaft and move the shaft sideways. refer to the clearance given in the specifications on page 210/9.

153

Model

21A. Engine (20---series)

1. 9. 1992

4. Check the shaft end float. Place the stylus of the dial gauge against the end of the shaft and move the shaft axially. Refer to the clearance given in the specifications on page 210/9. If any defects or wear are confirmed, the turbocharger should be reconditioned. If the engine does not work correctly and the turbocharger is not defective or too worn, the fault could be traced to one of the following items: --- Blocked air filter --- Leakage in the inlet or exhaust systems. Leaking flange seal --- Defective or wrongly adjusted injection pump. --- Wrongly adjusted throttle linkage --- Defective or wrongly adjusted injectors --- Low fuel pressure (e.g. blocked fuel filter) --- Low compression, wrong valve clearance

154

255-- 865

Code

216A

Page

2

1. 9. 1995

21A. Engine (20---series)

1. 5. 1996

Model

255-- 865

Code

216A

Page

3

D. Reconditioning turbocharger (Schwitzer S1A and S1B) N.B! The same degree of cleanliness should be observed when removing the turbocharger as with repairing the fuel system. Only remove the compressor and turbine covers if the requisite special tools, e.g. for adjusting the balance, are not available. In general, when the turbocharger is damaged it is more economical to fit a factory reconditioned turbocharger.

Dismantling turbocharger

5. Hold the turbine wheel at hub and unscrew the compressor wheel nut (left---hand thread). Remove the compressor wheel.

1. Mark the compressor housing, turbine housing and the bearing housing in relation to each other.

6. Remove the turbine wheel/shaft carefully by tapping at the shaft end with a soft hammer. Do not bend the shaft.

2. Fix the turbocharger by the outlet flange in a vice fitted with soft jaws.

7. Place the bearing housing on a table so that the turbine side is against the table. Remove the support flange circlip.

3. Remove the compressor housing circlip and remove the housing.

8. Remove the support flange and the oil deflector ring by prying with two levers behind the support flange grooves. Press the deflector ring out of the support ring.

4. Unscrew the turbine housing fixing screws and remove the fixing plate. Detach the bearing housing from the turbine housing.

9. Remove the oil deflector plate, thrust bearing and thrust sleeve from the bearing housing. Remove the bearing outer circlips and remove the bearings and the inner circlips.

155

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

216A

Page

4

Cleaning parts of the turbocharger

Assembling the turbocharger

N.B. Use conventional cleaning agents. Do not clean with corrosive substances as parts of the turbocharger may be damaged.

It is recommended to use a repair kit when assembling the turbocharger. This kit includes necessary seals and parts which are exposed to wear.

1. Wash off all dirt with a detergent solution. Use plastic tools or brush when cleaning aluminium parts.

1. Fit the inner circlips into the bearing housing. Lubricate the bearing points. Push the bearings into place and fit the outer circlips.

2. Clean all oilways with compressed air. Check that all contact surfaces are clean and in good condition.

2. Fit a new sealing ring into the groove and push the rear plate onto the shaft against the turbine wheel. 3. Lubricate the shaft bearing points and the sealing ring. Push the shaft into the bearing housing. Do not damage the sealing ring. 4. Place the bearing housing vertically resting on the turbine housing.

Checking parts of the turbocharger

5. Fit the thrust sleeve into the thrust bearing and place the parts into the bearing housing according to the position of the guide pins. Place the oil deflector plate onto the thrust bearing.

1. Bearing housing --- Inspect the bearing surfaces for damages and wear. --- make sure that the turbine side sealing surface is undamaged.

6. Fit a new o---ring into the groove of the support flange. Fit a new o---ring onto the deflector ring. Press the deflector ring into the middle of the support flange. Do not damage the sealing ring and its counter surface.

2. Compressor wheel --- check for bends, cracking or corrosion and possible wear on the wheel rear face. Small faults can be accepted. Change the wheel if damages affect on balancing accuracy. Never bend the vanes. Check the balancing accuracy (0,21 gm mm).

7. Lubricate the o---ring and push the support flange into the bearing housing. Fit the circlip the chamfered side outwards. 8. Push the compressor wheel onto the shaft. Tighten the shaft nut to a torque of 7 Nm. Secure the nut with locking fluid Loctite 601.

3. Shaft and turbine wheel unit --- check the bearing point wear, min diameter is 7,615 mm. --- check the width of the sealing groove, max 1,630 mm. --- measure the shaft ovality, max 0,005 mm. --- check balancing accuracy (0,21 gm mm), change the part if given values are exceeded.

9. Pass the compressor housing circlip over the bearing housing the circlip chamfered side towards the turbine housing. Fit the o---ring into the groove on the bearing housing. Fit the compressor housing according to the markings. Fit the circlip into groove.

4. Compressor and turbine housing --- check if there are damages, cracks or overheating faults caused by wheel contact in the housings. Small damage can be accepted, otherwise change the housing.

10. Fit the bearing housing and the turbine housing according to the markings. Fit the fixing plate and tighten the screws to 22 Nm.

5. Turbine side rear plate --- change the rear plate if it is bent or cracked. 6. Oil deflector ring --- check the groove width on the sealing ring, max 1,226 mm. Check also for other possible damage and wear. Reject worn part. 7. Support flange --- Check wear and cracking of the seal ring counter surface. Only small wear can be accepted. In general, even a small wear causes sealing problems.

156

Model

21A. Engine (20---series)

1. 9. 1992

E. Fitting turbocharger Locate the cause of the defects on the turbocharger. Remedy the fault before fitting the new turbocharger. In order for the turbocharger to work satisfactorily, it is important that the engine oil is in good condition. Likewise the oil should be to the correct quality specification. The air filter and oil filter should be serviced according to the handbook specification. The setting of the injection pump critically affects the function of the turbocharger. The injection pump should be adjusted according to the manufacturers instructions. 1. Check the tightness of the induction and exhaust manifolds, and that they are securely fastened. Ensure that there are no loose carbon or rust particles, or other foreign objects in the manifolds. 2. Connect the turbocharger to the exhaust manifold and tighten down using a new gasket. 3. Connect the induction pipe and the silencer. 4. Pour clean engine oil into the bearing housing through the inlet oilway. This is very important in order to ensure that the turbocharger is lubricated at the time of starting. 5. Connect the pressure and return oil pipes. Use a new seal. Check that there are no tensions in the pipes when tightening. 6. Before starting, pull out the stop control and crank the engine over with the starter motor so that the oil pressure rises. Start the engine and check that there are no leaks.

157

255-- 865

Code

216A

Page

5

158

Model

21A. Engine (20---series)

31. 1. 1996

Code

665-- 4 MOD

Page

217

1

Sentinel diesel engine protection system On the engine there is an automatic stopping system. If the engine oil pressure lowers or engine cooling liquid temperature rises too much, the automatic system will stop the engine in about 40 seconds. The stopping time depends on the engine load (= fuel consumption). If the engine has stopped through this system, find and repair the fault before starting. After repairing turn the fuel valve lever (G), on the master control unit 180_ clockwise on the left side of the engine. After the engine starts the lever rotates automatically 180_ anticlockwise to the normal position.

G Fig. 1 LH side of engine

B

Fig. 2. Sentinel Protection System on Valmet

C

A. Master Control B. Heat Valve C. Fuel from filter into Master Control D. Fuel from Master Control into fuel injection pump E. Engine oil pressure into Master Control F. Engine oil pressure into Heat Valve G. Fuel valve lever

D

A

F

G

159

E

Model

21A. Engine (20---series)

31. 1. 1996

665-- 4 MOD

Code

Page

217

2

Operation of engine protection system Fuel valve

Fuel in

Fuel out

Vent filter

Dump Engine oil pressure from Master Control

Engine oil pressure

Oil to crankcase MASTER CONTROL (open position)

HEAT VALVE (closed position) Fig.3. Operation of engine protection system

Under normal operation conditions, oil pressure from the engine will keep the fuel valve of the Master Control in the raised position allowing the fuel to flow through to the engine. Loss of oil pressure will automatically cause the fuel valve to drop, shutting off the fuel flow and the engine will stop.

When engine coolant temperatures exceeds the setting of the Heat Valve, the seal will open and dump oil pressure from under the Master Control piston. This in turn will cause the fuel valve to fall and block fuel flow to the engine.

160

Model

21A. Engine (20---series)

31. 1. 1996

Code

665-- 4 MOD

Page

217

3

C. Trouble shooting

A. Servicing

a) If engine will not start, or stops during operation, make a careful inspection of the engine and Sentinel System:

The Sentinel System should be checked at every engine oil change and serviced as required.

---------

Visually inspect the complete system for leaks, worn hoses, correct plumbing etc. Inspect the vent filter on the Master Control for fuel or engine oil leakage. Replace vent filter if dirty.

Check engine oil and coolant levels Check coolant temperature Check oil, coolant and fuel lines for leaks or damage Check sentinel system for leaks or damage

Important! Coolant thermometer in the dashboard. Engine oil pressure warning light in the dashboard. b) If completely satisfied that everything is in good order, and engine will not start, check Sentinel operation:

B. Other information The Sentinel engine protection units monitors directly from the engine and are normally very accurate and superior to gauges in their response to abnormalities.

Master Control housing

Master Control (Model DTF-- 15) Monitors engine oil pressure in lower chamber. Activates shutdown when oil pressure falls below unit setting, normally 10/15 psi.

Cam lever

Heat Valve (Model HM -- 212) --- Turn cam lever on the Master Control 180˚ clockwise and back several times to check piston moving freely. --- Override Sentinel by turning cam lever 180˚ clockwise. Watch lever and try for engine start. If engine starts and lever returns 180˚, Sentinel system operative. --- If lever does not return in 30 seconds, stop engine.

Monitors coolant temperature. Activates when temperature rises above unit setting, normally 212˚ F. Master Control serial no.: 9401790 Heat Valve serial number: 9310592

N.B. Master Control unit and Heat Valve should be changed as a complete unit. When changing Master Control unit, prevent dirt from entering into the fuel system, when you open the fuel line unions. Clean pipes, unions and Master Control housing before work. c) If engine stops shortly after starting, bring rpm up to about 1200 rpm for three seconds. This will increase oil pressure enough to open Master Control.

161

162

Model

21A. Engine (20---series)

1. 9. 1992

Working orders

255-- 865

Code

219A

Page

1

D. Lubricating oil pump

A. Crankshaft seals

(Lubricating oil pump, see page 215/1)

(Rear seal, see page 211/6). (Front seal, see page 214/3).

--- Drain the engine oil.

--- Before changing the crankshaft rear oil seal, split the tractor at the clutch (see Op 411 1A) and detach the clutch assembly and the flywheel.

--- Remove the propeller shaft guard and the propeller shaft. Unscrew the oil sump fixing bolts and remove the oil sump.

--- When changing the crankshaft front seal, drain the coolant from the cooling system. Remove the cooling radiator and the belt pulley/hub at the front end of the crankshaft.

--- The oil pump can now be removed from the lower face of the cylinder block.

E. Balancer unit (only 420---engines) (Balancer unit, see page 213/7)

B. Cylinder head and valve mechanism

--- Drain the engine oil.

(Cylinder head and valves, see page 212/1) (Rocker arm mechanism, see page 212/5)

--- Remove the propeller shaft guard and the propeller shaft. Unscrew the oil sump fixing bolts and remove the oil sump.

--- Before removing the cylinder head, remove the engine hood plates, engine coolant and detach all parts which are attached to the cylinder head. After that the cylinder head can be removed.

--- The balancer unit is now accessible and can be detached from the cylinder block lower face.

--- Rocker arm mechanism is accessible after removing the valve cover.

F. Crankshaft

--- Pushrods can be removed after removing the valve cover and the rocker arm mechanism.

(Crankshaft, see page 213/1) --- Split the tractor at the clutch. Remove the clutch assembly and the flywheel and the flywheel housing.

C. Pistons and connecting rods

--- Drain the engine coolant and engine oil and remove the radiator. Detach the engine and the oil sump.

(Pistons and connecting rods, see page 213/3)

--- Remove the timing gear casing cover.

If only pistons/connecting rods are to be changed, the simplest working order is as follows:

G. Cylinder liners

--- Drain the engine coolant and the engine oil.

(Cylinder liners, see page 211/1)

--- Remove the propeller shaft guard and the propeller shaft. Unscrew the oil sump fixing bolts and remove the oil sump.

--- Drain the engine coolant and the engine oil. --- Remove the propeller shaft guard and the propeller shaft. Unscrew the oil sump fixing bolts and remove the oil sump.

--- Remove the cylinder head. --- Loosen the connecting rod big ---end bearing caps and push the pistons together with connecting rods upwards and remove them through the cylinder bore.

--- Remove the cylinder head. --- Loosen the connecting rod big ---end bearing caps and push the pistons together with connecting rods upwards and remove them through the cylinder bore. --- Remove the cylinder liners upwards.

163

Model

21A. Engine (20---series)

1. 9. 1992

255-- 865

Code

219A

Page

2

H. Timing gears

I. Camshaft

(Timing gears, see page 214/1)

(Camshaft, see page 212/5)

As the timing gear casing forms a seal against the oil sump, the casing cannot be removed without first removing the oil sump. The timing gear casing cover, however, can be removed without removing the oil sump.

Before removing the camshaft the following steps should be taken: --- Remove the timing gear casing cover (see under previous heading H Timing gears).

--- Remove the oil sump if the timing gear casing is to be removed. Remove the cooling radiator.

--- Remove the valve cover and the rocker arm mechanism.

--- Remove the fan, alternator and the v ---belt. --- Unscrew the crankshaft nut and remove the belt pulley/ hub. --- Remove the timing gear casing front cover and remove the oil deflector ring at the front end of the crankshaft.

--- Support the pushrods (at the same time tappets which are against the camshaft) to the upper position in pairs by using for instance o---rings (see picture on page 212/5). --- Rotate the crankshaft so that the timing markings on the idler gear and the camshaft gear become opposite each other (see picture on page 214/2).

--- Remove the fuel injection pump if the timing gear casing is to be removed. Otherwise disconnect all the pipes from the fuel injection pump.

--- Pull out the camshaft from the cylinder block.

--- The timing gears are now accessible.

Note! Take care when fitting the camshaft that the timing marks align.

In addition, the following steps should be taken if the entire timing gear casing has to be changed: --- Unscrew the idler gear fixing bolts and remove the idler gear. --- Pull out the camshaft from the cylinder block. Note! If the cylinder head and valve mechanism have not been removed, the tappets must be prevented from falling down when the camshaft is removed, see page 212/5. --- The timing gear casing can now be removed.

164

15. 4. 1999

22. Fuel system (20---series)

Model

1. 4. 2004

255-- 900

Contents General (Op no 220): Bosch in ---line injection pump: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Stanadyne distributor pump: Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Bosch VE distributor pump: Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Fuel system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Repair instructions Fuel feed pump and fuel filters, Bosch in-- line pump (Op no 222):

A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Bleeding Thermostart system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Checking overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Changing fuel feed pump valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2

Fuel injection pump and injectors, Bosch in-- line pump (Op no 223): A. Checking fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Removing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fitting injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Checking/changing delivery valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J. Fitting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 2 3 4 5 5 6 7 7

2. Stanadyne rotary distributor pump

A. Removing distributor pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Fitting pump and adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Bleeding Themostart---system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Checking dynamic injection advance, E ---engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch VE rotary distributor pump (Op no 224)

A. Removing fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Fitting pump and adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Fitting injector in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165

8 8 9 9 9 10 10 11 1 2 5 5 6 6 6 7 8

Code

220A

Page

1

15. 4. 1999

22. Fuel system (20---series)

1. 9. 2001

Model

255-- 700

Code

220A

Page

2

Specifications, Bosch in ---line injection pump Note! Stanadyne rotary distributuon pump, see page 220A/9.

Bosch fuel injection pump Type (pump/governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection order: --- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of pump piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection advance: --- 255, 355, 365, 665, 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 455---565, 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 600 with E ---engine 320DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch PES...A/RSV 1---2---3 1---2---4---3 clockwise 9,5 mm 8 mm 21˚ 19˚ 17˚

Oil fillings 1): --- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 l --- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 l

Fuel feed pump Type: --- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction: piston pump, separate hand pump Fuel feed pressure (overflow valve opening pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure from fuel feed pump (without overflow valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch FP/KSG 24 AD 207 Bosch FP/KEG 24 AD 504 0,7---1,2 bar (70---120 kPa) 2,7 bar (270 kPa)

Injectors (see also page 220/14) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening pressure: --- 255---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 600, 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting pressure 2): --- 255---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 600, 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1) 2)

five hole nozzle 230 bar (23 MPa) 270 bar (27 MPa) 235+5 bar (23,5 MPa) 270+8 bar (27,8 MPa) 8999 01495

When fitting fuel injection pump. Value to be used when adjusting the opening pressure of a new or used injector.

Tightening torques Injection pump gear nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery valve retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

166

90 Nm 40 Nm 60 Nm 15 Nm

1. 3. 1997

22A. Fuel system (20---series)

15. 4. 1999

Malli

Koodi

255-- 900

220A

Special tools Note! Measuring equipment for fuel feed pressure, see page 101/4C. 9052 47800 *) 9052 48900 *) 9052 47600 *) 9025 99000 *) 9051 71300 *) 8366 62022

*)

Pressure gauge for checkinh delivery valve. Puller for injection pump drive gear. Control pipe for injection timing Sleeve for limiting control rod travel Extractor for injectors. Tester (TimeTrac) to check dynamic injection advance, E ---engines: 1. 836662121 Magnetic detector 2. 836662122 Cable 3. 836662123 Fastening part 4. 836662120 Timing light (not illustrated) 5. 836859466 TimeTrac in ---line sensor (not illustrated) 6. 836662124 Clamp ---on Transducer 4,5 mm (not ill.) 7. 836662125 ---” ---, 5,0 mm (not ill.) 8. 836662126 ---” --- ,6,0 mm (not ill.) 9. 836662127 ---” --- ,8,0 mm (not ill.) 10. 836662128 ---” --- ,1/4 inches (not ill.)

Same tool as for fuel system on 11---series engines.

905248900

15±1

9052 47800

3

902547600

9025 99000

2

8366 62022 1

167

9051 71300

Sivu

3

Model

22. Fuel system (20---series)

1. 9. 1992

255-- 665

Code

Page

4

220A

6

7 3 5

1 8 1. Fuel tank 2. Fuel feed pump 3. Fuel filter 4. Fuel injection pump 5. Injector 6. Thermostart fuel reservoir 7. Glow plug 8. Overflow valve

4

2

Fuel system, description

Fuel tank: --- Empty/clean the fuel tank at every 1000 running hours or yearly.

Fuel feed pump (2) draws fuel from tank (1) and forces it through combined water trap/filter (3) to fuel injection pump (4). The fuel injection pump pumps fuel at high pressure through the delivery pipes to injectors (5) which inject the fuel in the form of a fine mist into the combustion chamber. Excess fuel lubricates the nozzle valve (needle) and flows in return through the thermostart device reservoir (6) and then on to the fuel tank. When the thermostart is on (glowing) fuel runs from reservoir (6) through glow plug (7) and is ignited in the induction manifold. Excess fuel returns from the fuel injection pump through overflow valve (8) to the fuel tank.

Injectors --- Reconditioning of the injector should be carried out by an authorised workshop. Symptoms of dirty or faulty injectors are: --- Knocking is an indication that one of the injectors is faulty. When a cold engine ticks over a certain amount of knocking is unavoidable. If the engine knocks after it has reached normal operating temperature, it is very likely that one of the injectors is faulty. Air in the fuel system can also cause knocking (which should disappear after the system has been bled of air). --- Smoky exhaust gases may indicate impaired performance of the injectors. However, this can also be caused by other faults such as a blocked air cleaner.

Maintenance Fuel filter/water trap: --- Empty the water trap at every 50 running hours/weekly. --- Change the fuel filter at intervals of 1000 running hours or yearly.

The fuel system should always be bled when the fuel system has been emptied (e.g. the fuel tank has been emptied during driving, in connection with maintenance or repair work or after a long idle period).

168

Model

22. Fuel system (20---series)

1. 9. 1992

Fuel injection pump

355-- 665

Code

Page

220

5

1 8

Valmet 355---665 tractors have a Bosch ---make injection pump which is an in ---line pump and its basic construction is similar on engines with the different number of cylinders.

2

7

Fuel injection pump 1. Oil filling plug 2. Governor control lever 3. Hand pump on fuel feed pump 4. Lubricating oil into injection pump 5. O ---ring 6. Return of lubricating oil to engine 7. Drive gear 6 3

5

4

The fuel injection pump is flange mounted and sealed by one o---ring (5) in the timing gear casing. The injection pump is driven from the crankshaft through an idler gear. The injection pump is connected to the engine force ---feed lubrication system through an external pipe (4). Lubricating oil returns to the engine via the hole (6) at the front end of the injection pump. The fuel feed pressure which fills the high pressure pump elements with fuel is created by a piston pump which is attached to the side of the fuel injection pump. The piston pump is driven from an eccentric on the camshaft of the injection pump. The fuel feed pump supplies more fuel than the injection pump needs. The excess fuel flows through the overflow valve back to the fuel tank. The fuel cools the injection pump and also takes any air bubbles with it back to the tank.

169

Model

22. Fuel system (20---series)

355-- 665

1. 9. 1992

Code

Page

220

6

The pump element consists of one plunger and one cylinder which are a matched pair and because of the fine tolerances the whole element should be changed as a complete unit. The cylinder has two passages: inlet passage and release passage. Both passages allow fuel to enter the pressure space. The side of the plunger has one vertical groove and one metering edge which are used for adjusting the amount of fuel injected into the combustion chamber of the engine. The top of the plunger is provided with a starting groove (delay groove) which delays the injection timing by approx. 8˚. (This should be borne in mind when checking the fuel injection timing). This groove improves the cold starting properties of the engine. It works fully automatically. When the engine has stopped the control rod in the injection pump turns the plungers so that the starting groove faces towards the release passage. When the engine has started and when the injection pump has reached a certain speed, the governor pulls the control rod back into running position.

1 1. Retainer for delivery valve 2. Delivery valve 3. Pump element 4. Control rod 5. Return spring for pump plunger 6. Roller tappet 7. Camshaft

2 5 3 6 4

The purpose of the fuel injection pump is to meter out fuel to the combustion chamber at the correct time. Plunger (3) which is driven by the pump camshaft (7) via roller tappet (6) forces the fuel through delivery valve (2) and further through the delivery pipe to the injector. 3

4

5

Delivery valve

6

2

1. Holder for delivery valve 2. Valve spring 3. Valve cone 4. Valve guide 5. Valve head 6. Pressure ---reducing piston 7. Vertical grooves

1

The delivery valve is fitted on top of the pump element and its purpose is to close the connection between the pump element and the delivery pipe. This happens when the metering edge of the plunger passes the lower edge of the release passage, thus reducing the pressure in the space above the plunger. Its second purpose is to reduce the pressure in the delivery pipe. This is important as it enable the nozzle valve (needle) to close more quickly.

7

A

B

C

Two---hole pump element (maximum feed) A. Bottom dead centre B. Fuel injection begins C. Fuel injection ends

7

Delivery valve cone contains a pressure ---reducing piston which, when the valve closes, is first lowered into the guide and then closes the connection between the delivery pipe and the pump element. The valve head is then pressed against its seat and the fuel in the delivery pipe is given the same space as the displacement of the pressure ---reducing piston.

1. Inlet passage 2. Cylinder 3. Starting groove 4. Release passage 5. Plunger 6. Metering edge 7. Vertical groove

170

Model

22. Fuel system (20---series)

1. 9. 1992

Governor

255-- 665

Code

220A

Page

7

Fuel injection pump type plate The injection pump type plate shows one particular letter indicating the user application, see figure below. This letter should always be quoted when ordering a replacement pump or when looking for setting values.

The letters for different pumps on 6100---8100 tractors can be found in the table on next page.

1. Governor weight 2. Control rod 3. Starting spring 4. Main lever 5. Idler screw 6. Governor spring 7. Additional spring, idling 8. Spring for equalizer 9. Governor control arm

The governor is of the centrifugal type and is fitted at the rear end of the injection pump. The governor controls the rotational speed of the engine throughout the whole speed range, and identifies the rotational speed by means of the governor weights. The position of the governor control and of the governor weights is transferred through the governor lever linkage to the control rod. The governor has one governor spring. Starter spring, which is attached to the upper end of the control lever, it pulls the control rod to the starting position when the engine stops. This means that the amount of fuel injected when the engine is started automatically becomes greater.

171

15. 4. 1999

22A. Fuel system (20---series)

10. 10. 2003

Model

Code

255-- 700

Page

220

8

Table of fuel metering, Bosch in ---line pump, 255---700 Koevarustus ISO 4008, Neste ISO 4113, Suutin ISO 4010 173 bar, Putket ø6x2x600 ISO 4093 Engine

Tractor

Injection pump

Governor

Pump timing ˚ Max. output r/min Low idling r/min

Injected amount mm3 / stroke rpm mm3

RW mm

Control rod at least 1 mm rpm

Control rod position 4 mm rpm

320 D

255 355 365

PES 3A 95 D 320 RS 2810 /B

RSV 375--- 1175 A2C 2178--- 10R

21˚˚ 2350 750

1150 1000 800 500 325

9,8±0,2 +0,3--- 0,5 +0,5--- 0,7 +0,5--- 0,7 4,4±0,3

1200--1220

1270--1300

10,2±0,2 +0,2--- 0,3 +0,5--- 0,6 +0,5--- 0,6 4,4±0,3

1200--1220

1270--1300

11,1--- 10,8 +0,2--- 0,3 +0,5--- 0,6 +0,5--- 0,6 4,4±0,3

1200--1225

1255--1285

11,4--- 11,8 +0,3--- 0,5 +0,5--- 0,7 +0,5--- 0,7 4,4±0,3

1200--1220

1270--1300

10.0±0,2 +0,4--- 0,5 +0,8--- 0,9 +0,8--- 0,9 4,2±0,3

1195--1205

1270--1285

9,3±0,2 9,6±0,2 9,8±0,2 10,0±0,2 10,2±0,2 10,2±0,2 4,4±0,3

1170--1190

1240--1260

12,1±0,2 12,4±0,2 12,6±0,2 12,6±0,2 4,4±0,3

1170

1230--1238

12,6±0,2 13,0±0,2 13,3±0,2 13,3±0,2 5,5±0,2

1160

1235--1265

320 DS

320 DS

320 DS

420 D

320 D

320 DE 46kW

320 DS

455

555 465

565

665

600

600

700

PES 3A 95 D 320 RS 2810 /A

PES 3A 95 D 320 RS 2810

PES 3A 95 D 320 RS 2810 /P

PES 4A 95 D 320 RS 2807 / BE

PES 3A 95D 320 RS 2810 /AR

PES 3A 95D 320 RS 2810 /BA

PES 3A 95D 320 RS 2810 /AO

RSV 375--- 1175 A2C 2178--- 10R

RSV 375--- 1175 A2C 2178--- 10R

RSV 375--- 1175 A2C 2178--- 10R

RSV 375--- 1175 A2C 2178--- 7R

RSV 375--- 1175 A2C 2178--- 10R

RSV 375--- 1175 A2C 2178--- 10R

RSV 375--- 1175 A2C 2178--- 10R

1150 1000 800 500 325

19˚˚ 2350 750

1175 990 800 500 375

19˚˚ 2350 750

1150 1000 800 500 375

19˚˚ 2350 750

1150 1000 900 600 375

21˚˚ 2350 750

21˚ 2270 750

17˚ 2270 850

19˚ 2270 750

75--- 77

12--- 15 79--- 81

10--- 15 88--- 90

10--- 15 95--- 97

12--- 15 73--- 74

11--- 15

1150 1000 950 800 700 600 400

88--- 90

1135 950 800 500 425

96--- 98 100--- 101 99--- 100

1135 950 800 500 375

99--- 101

90--- 92 90--- 92 12--- 16

10--- 15

16

Table of fuel equipment parts, 355---700 Engine/Tractor

Injection pump

Element

Delivery valve

Governor spring

Injector compl.

Nozzle

Nozzle holder

320 D Valmet 255 Valmet 355 Valmet 365

8366 40198

8353 31161

8353 39126

8353 31163

8366 39956

8366 39957

8366 39971

320 DS Valmet 455

8366 40197

8353 31161

8353 39126

8353 31163

8366 39956

8366 39957

8366 39971

320 DS Valmet 465 Valmet 555

8366 40156

8353 31161

8353 39126

8353 31163

8366 39956

8366 39957

8366 39971

320 DS Valmet 565

8366 40438

8353 31161

8353 39126

8353 31163

8366 39956

8366 39957

8366 39971

420 D Valmet 665

8367 40392

8353 31161

8353 39126

8353 31163

8366 39956

8366 39957

8366 39971

320 D Valmet 600

8366 54789

8353 31161

8353 39126

8353 31163

8368 54755

8368 54757

8366 39971

320 DE Valmet 600

8366 54886

8353 31161

8353 39126

8353 31163

8368 54755

8368 54757

8368 54756

320 DS Valmet 700

8366 54781

8353 31161

8353 39126

8353 31163

8368 54755

8368 54757

8366 39971

172

15. 4. 1999

22A. Fuel system (20---series)

Model

1. 9. 2001

865, 700 800, 900

Code

220A

Page

9

Specifications with Stanadyne distributor pump Note! 865, 800 and 900 tractors have Stanadyne rotary distributor pump. The pump is equipped with an an electric running solenoid (ignition switch stop) and with an automatic bleeding system. Stanadyne pump is lubricated by fuel. A separate fuel feed pump is of a membrane type and it is driven by the engine camshaft. The system includes also the Thermostart glow plug. Note! 700, 800 and 900 tractors with E ---engines (DSRE) have also the Stanadyne rotary distributor pump. Picture. Stanadyne distributor pump (conserning E ---engines, see picture on page 12A). 1. Sealing ring 8368 40858 2. Type plate with pump part number (836754665) 3. Timing marks under the cover 4. Fuel inlet 5. Return fuel/overflow valve 6. Revolution lever 7. Connector for wire to electric stop solenoid

Stanadyne distributor pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection order: --- 420---engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection advance, see table on page 220/13: Tightening torque of pump gear wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DB 4 (four pumping plungers) 1---2---4---3 Clockwise 90 Nm

Fuel feed pump Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . membrane pump, separate hand pump Fuel feed pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar (48 kPa)

Injectors (see also page 220/14) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector nozzle sleeve, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

Stanadyne five hole nozzle no 8999 01495 60 Nm 15 Nm

1. 3. 1997

22A. Fuel system (20---series)

1. 1. 1998

Model

865 800, 900

Code

Page

220A

10

Fuel system with distributor pump Stanadyne water trap on 865 from Spring ---97 and on 800 and 900 tractors.

1. Fuel tank 2. Water trap 3. Fuel feed pump 4. Fuel filter 5. Distributor pump 6. Injector 7a,b,c. Return fuel to tank 8. Thermostart reservoir 9. Glow plug 10. Bleeding screw

A B C

In this fuel system, there is a separate fuel feed pump (3) on the RH side of the engine.

when securing band (B) is rotated for hand and the filter is pulled downwards. When fitting a new filter, rotate the securing band until it locks the filter (click).

The system includes a separate water trap (2) and a fuel filter (4). The lower part of the fuel filter housing has a space for possible impurities and there is a drain tap under the filter housing.

Maintenance

--- Check/empty the water trap weekly/every 50 running hours. --- Open and clean the water trap at every 500 running hours (not 865, 800 and 900 with Stanadyne water trap). At the same time open the tap under the filter housing and allow possible impurities to run out. --- Clean the fuel tank every 1000 running hours/yearly and change the fuel filter (on 865, 800 and 900, change the Stanadyne water trap filter). --- Check/clean injectors at every 2000 running hours/every other year. Faulty injectors cause knocking, smoky exhaust gases and loss of engine power.

The fuel feed pump has a washable metal gauze filter. There is also a tapered metal net filter inside the distributor pump in the inlet line before the pump transfer pump. Important! The Stanadyne water trap also includes a filter. There is a draining tap (C) in the bottom of the housing. Before emptying this water trap, slacken the bleeding screw (A) . After emptying, close the screws and pump fuel with the feed pump (3) lever, until the water trap is full of fuel. The Stanadyne water trap filter loosens,

174

Model

22A. Fuel system (20---series)

1. 5. 1996

865

Code

220A

Page

11

Stanadyne distributor pump 1. Drive shaft 2. Governor weights 3. Governor spring 4. Stop solenoid 5. Overflow valve 6. Metering valve 7. Cam ring rollers 8. Hydraulic head 9. Pressure regulator valve 10. Transfer pump blades 11. Distributor rotor 12. Delivery valve 13. Cam ring 14. Automatic advance 15. Centrifugal governor 16. Pumping plungers (4 pcs in picture. 865 has 2 pcs).

The main rotating components are the drive shaft, transfer pump blades, distributor rotor and governor.

The distributor rotor incorporates two charging ports and a single axial port (pressure chamber), in which is placed the delivery valve. After the delivery valve, there is one discharge port to serve all head outlets to the fuel injection pipes.

The drive shaft engages the distributor rotor in the hydraulic head. The drive end of the DB4 rotor incorporates four pumping plungers.

The hydraulic head contains the bore in which the rotor revolves, the metering valve bore, the charging ports and the connections to the fuel injection pipes.

The plungers are actuated toward each other simultaneously by an internal cam ring through rollers and shoes which are carried in slots at the drive end of the rotor. The numbers of cam lobes normally equals the number of cylinders (not 3---cyl. engines).

The pump contains a mechanical governor. The centrifugal force of the weights is transferred to the metering valve via a linkage. The metering valve can be closed electrically with aid of the solenoid in the pump housing.

The transfer pump at the rear of the rotor is of the positive displacement vane type and is enclosed in the end cap. The end cap also houses the fuel inlet strainer and transfer pump pressure regulator. The face of the regulator assembly is compressed against the distributor rotor and forms an end seal for the transfer pump. The pump axial force acts against the pressure regulator valve front face.

The automatic advance is a hydraulic mechanism which turns the cam ring and advances or retards the beginning of the fuel delivery from the pump.

175

Model

22A. Fuel system (20 series)

1. 5. 1996

865

Code

220A

Page

12

Housing pressure Transfer pump pressure 1. Fuel tank 2. Water trap 3. Fuel feed pump 4. Fuel filter 5. Transfer pump 6. Pressure regulator valve 7. Automatic advance 8. Air vent passage 9. Stop solenoid

Injection pressure 10. Regulator spring 11. Centrifugal weights 12. Overflow valve 13. Hydraulic head connecting passage 14. Metering valve 15. Hydraulic head charging pasage 16. Distributor rotor 17. Delivery valve 18. Injector

Function The fuel feed pump draws fuel from the tank via the water trap and the filter into the fuel injection pump.

While the discharge post is opened, the rollers contact the cam lobes forcing the plungers together. Fuel trapped between the plungers is then pressurised and delivered by the nozzle to the combustion chamber.

In the pump fuel flows through the inlet filter screen into the vane type fuel transfer pump. Some fuel is bypassed through the pressure regulator assembly to the suction side.

The injection pump is self ---lubricating, and it has not been connected to the engine lubrication system.

Fuel under transfer pump pressure (1---6 bar) flows through the center of the transfer pump into the circular groove on the rotor. It then flows through a connecting passage in the head to the automatic advance and up through a radial passage and then through a connecting passage to the metering valve. The metering valve adjusts amount of injected fuel and position of the metering valve is controlled by the governor (revolution lever) and the stop solenoid. From the metering valve fuel flows to the radial charging passage and further to the head charging ports.

As fuel at transfer pump pressure reaches the charging ports, slots on the rotor shank allow fuel and any entrapped air to flow into the pump housing cavity. In addition, an air vent passage in the hydraulic head connects the outlet side of the transfer pump with the pump housing. This allows air and some fuel to be bleed back to the fuel tank via the overflow valve. The fuel thus bypassed fills the housing, lubricates the internal components, cools and carries off any small air bubbles. The pump operates with the housing completely full of fuel; there are no dead air spaces anywhere within the pump.

As the rotor revolves, the two rotor inlet passages register with the charging ports in the hydraulic head, allowing fuel to flow into the pumping chamber. With further rotation, the inlet passages close and port to the injectors opens.

176

15. 4. 1999

22A. Fuel system

1. 9. 2001

Model

865, 700-- 900

Code

220A

Page

12A

Stanadyne distributor pump

1. 2. 3. 4. 5. 6.

Type plate with ordering number Timing marks under the cover Fuel inlet Fuel return flow/overflow valve Revolution lever Connector for wire to electric stop solenoid

Possible equipment on Stanadyne distributor pump (e.g. E-- engines) G. Compact cold advance CCA Electric advancing of the injection during starting and at low engine revs (below 1100 rpm) in order to decrease the cold smoking. In addition to the injection pump solenoid, the pump has a separate control unit, which follows up the engine revs.

A. Interrupted screw (ordering no. 8366 59038) B. Detector for injection timing C. Fuel limiter FL The fuel limiter limits the amount of injected fuel at low engine revs, when the air coefficient is too small. D. Light load advance LLA Adjustment of the injection advance according to the engine revs and loading. This is controlled by the fuel feed pressure after the quantity governing valve. E. Aneroid control AC Aneroid control (limitation of acceleration smoke) allows a full fuel injection during acceleration just when the boost pressure has risen enough.

H. Torque screw TS (inside the housing). With this screw the engine specific curves for output and torque can be canged into desired form. I. Vented metering valve VMV (inside the pump housing). The valve makes the inner bleeding of the pump better.

F. Boost pressure

177

178

320 DSRE L24101---

420 DSRE L24101---

420 DSRE L24101---

700

800

900

DB 4429---5375/E

DB4429---5375/C

DB4327---5575/B

DB 4427---5218 /F

8367 54885 (8367 54776) *)

8367 54853 (8367 54776) *)

8366 54861 (8366 54724) *)

8367 54780 (8367 54665) *)

8367 54776 8367 54665

Order no.

14°

15°

15°

14˚

22˚ 14˚

Static injection advance

7°

8°

>4°

---

-----

Low idling

11°

11°

16,5°

---

-----

Ø

±1,0°

Max. revs

TS

TS

ø 1,75 mm

ø 1,75 mm

ø 1,75 mm

ø 2.0 mm

ø 1,5 mm ø 2.0 mm

Delivery pipe inner diameter ***)

The latest pipes have numbers on nut. without numbers, Ø 1,5 mm 1.8, Ø 1,75 mm 2.0, Ø 2,0 mm

TS, LLA

TS

TS TS

Extra equipment **)

***) Delivery pipe inner diameter

17° (2270 rpm)

17,5° (2270 rpm)

15° (2270 rpm)

---

±1,0° -----

2200 rpm (full loading)

without notch, Ø 1,5 mm 1 notch, Ø 1,75 mm 2 notches, Ø 2,0 mm

13°

15°

14°

---

-----

1400 rpm (full loading) ±1,0°

Dynamic injection advance (°/rpm)

10. 10. 2003

Model

865, 700-- 900

Code

220A

179

’) Base pump niumber, marked on the pump type plate. Note! Adjusting values of Bosch in ---line pumps, see pages 220/2 and 220/8 **) Extra equipment 220/12A.

420 DSR

900

DB 4429---5375 DB 4427---5218

Type

Type

420 DR 420 DSR

Fuel injection pump

Engine

800 865

Tractor

Valtra---tractors with Stanadyne rotary distributor pump and delivery pipes

22A. Fuel system (20---series) 1. 9. 2001 Page

13

--S/736 M/423

M/358 /

355, 455 (610312---656315. 311--- and 411---engines)

255, 355, 365, 455, 465, 555, 565, 665 (656316---)

600, 700 (Bosch ---inline pump, not E ---engine) 800 (Stanadyne ---pump, not E ---engine) 600 (Bosch ---inline pump, E ---engine)

700R,, 800,, 900 ((L24101---)) (E ---engine, S Stanadyne ---pump)

180

S/655

205, 555 (610312---656315), 865, 900 (Stanadyne ---pump, not E ---engine)

Value to be used both with new and used nozzles.

---

305, 405 (311--- and 411---engines)

1)

Type of injector

Tractor

ValtraValmet ---tractors, Stanadyne injectors

8366 59808

8368 54755

8366 39956

8363 39088

8363 40034

8353 31100

Order no of compl. injector

8366 59902

8368 54757

8366 39957

8363 39087

8363 39985

8353 31101

Nozzle order no

270+8

270+8

230+10

230+10

230+10

205+10

Opening pressure, bar

278

278

240

240

240

215

8368 62000...8368 62020

8368 62000...8368 62020

8366 40104...8366 40122

---

8366 40104...8366 40122

---

Adjusting pres- Shim no sure, bar 1)

358

423

736

---

655

---

Code C

22A. Fuel system (20---series) 1. 9. 2001

10. 10. 2003

Model

255-- 900

Code

220A

Page

14

1. 4. 2004

22A. Fuel system (20 series)

Model

23. 8. 2004

A75-- A95

Code

220A

Page

15

Technical specifications Injection pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting position º BTDC (static): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston distance of the injection pump (in assembling): --- A75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- A85 and A95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation from the engine front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection order: - 44-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 66-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch VE rotary pump 5º 0,20 mm 0,25 mm Clockwise 1-2-4-3 1-5-3-6-2-4

Fuel system

VE ---pump: Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filters: - Pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel feed pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel feed pressure min. (used pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The fuel must be according to norm EN 590 Stanadyne 30 μ, element no. 8368 66575 Stanadyne 5 μ, element no. 8368 66577 Diaphragm pump, separate hand lever 0,48 bar 0,20 bar / max. rpm

Injectors

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 bar Setting pressure* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 bar Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 899901495 *) Value to be used when adjusting the opening pressure of a new or used injector.

Tightening torques VE ---pump: Injection pump retaining nuts M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump gear retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump coupling flange retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery pipe attaching nut to pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181

30 Nm 35 Nm 92,5 Nm 25 Nm

Model

22A. Fuel system (20 series)

1. 4. 2004

Code

A75-- A95

220A

Page

16

Fuel system, description 4

7

2

9

3

8 5 6

1

Fuel system (Injection pump Bosch VE) 1. Fuel tank 6. Injection pump 2. Pre ---filter 7. Injector 3. Water separator (optional) 8. Overflow valve 4. Feed pump 9. Feed pressure sensor (0,05-0,2 bar) 5. Fuel filter The fuel is pumped by feed pump from the tank via a prefilter, through the filter to the injection pump. The injection pump forces the fuel into the injector with feeds fuel into the combustion space in a fine spray. Excess fuel returns from the fuel injection pump through an overflow valve to the fuel tank. The overflow pipe between filter and injectors helps the automatic bleeding of the system.

The fuel system is equipped with a pressure sensor that alarms before interference has developed. An option the pre-filter can be equipped with a see-trough water trap and with an electronic water in fuel sensor.

182

1. 3. 1997

22A. Fuel system (20---series)

1. 9. 2001

Repair instructions

Model

255-- 700

Code

222A

Page

1

B. Bleeding thermostart system 355---700)

Fuel feed pump and fuel filter (Op no 222)

Always remove air from the glow plug fuel pipe when the pipe or reservoir has been emptied during repair work etc. This prevents damages to the glow plug caused by lack of fuel during starting.

A. Bleeding fuel system (Bosch in ---line pump)

1. If the reservoir is empty, fill it e.g. with a drip pot through the breather hole on the reservoir. 2. Open the glow plug pipe connector and drain fuel from the pipe. Connect the pipe. Note! From engine no. H16734 incl. the outer diameter of the glow plug fuel pipe has been enlarged from 4,76 mm to 5,0 mm. These new pipes can be used on earlier manufactured tractors, when simultaneously is fitted a new connector nut and a new sealing cone. The new nut can be recognized by grooves on the outer circumference.

C. Measuring fuel feed pressure Note! Pressure measuring equipment, see page 101/4C. 1. Clean the fuel injection pump and the filter and the pipes between them.

1. Slacken the bleeder screw on the filter head. Pump with the hand pump until the fuel flowing out at the bleeder screw is free from air bubbles. Then tighten the bleeder screw.

2. Fit the gauge at the banjo connection on the pump, as shown above (between filter and injection pump). 3. Run the engine at low idling for a while and compare the gauge reading with the prescribed value (0,6 ---1,0 bar). 3. Slacken the injection pump overflow valve. Pump with the hand pump until the fuel flowing out is free from air bubbles. Tighten the overflow.

N.B. If the measured pressure is below the prescribed value, this may be caused by: ---------

4. Wipe off any fuel from the engine.

183

faulty overflow valve blocked fuel filter faulty fuel feed pump blocked or leaking fuel pipes or unions

Model

22A. Fuel system (20---series)

1. 9. 1992

255-- 700

Code

222A

Page

2

D. Checking overflow valve

E. Changing fuel feed pump valves

If the fuel feed pressure deviates from the prescribed value, check the opening pressure of the overflow valve.

1. Clean the feed pump. Disconnect fuel pipes to the feed pump. Remove the feed pump.

1. Connect a pressure gauge to the banjo union in the same way as in previous instruction C. 2. Pump with the hand pump until the overflow valve opens. Compare the reading on the gauge at the moment the valve opens with the prescribed value (0,6 ---1,0 bar). 3. If the recorded opening pressure deviates from the prescribed value, the overflow valve should be changed. N.B. If the recorded pressure is considerably lower than the prescribed value, there may be a fault in the hand pump or the fuel feed pump valves.

2. Secure the pump in a vice provided with soft jaws. Loosen the tappet body from the pump and remove the piston, seal rings, suction valve and the spring. 3. Detach from the pump body the outlet side threaded connector, in which is placed the pressure valve. 4. Rinse the valves with clean fuel and check the function and possible wear. 5. Change the valve if needed and assemble the pump using new o---rings and gasket

184

10. 1. 1992

22A. Fuel system (20---series)

1. 9. 1992

Model

255-- 665

Code

Page

223A

1

Fuel injection pump and injectors (Op no 223) A. Checking injection timing

9025 99000

Note! The exact time at which the fuel should be injected into no. 1 cylinder is marked on the crankshaft belt pulley. Due to the excess fuel flowing into the injection pump the control rod must be moved to the drive position when checking the injection timing. Otherwise the timing will be incorrect! IMPORTANT! Governors of the Bosch in ---line pumps have been changed with effect from engine no. G4720 (320 D, DS) and G2358 (420 D, DS). These modified pumps can be recognized by a plug in the governor housing (the same as on Valtra 6800 and 8750 tractors) and they are exchangeable with the earlier pumps. Spare part numbers of the pumps are not changed. Checking/adjusting injection timing on these modified pumps, see page 223A/4A. Checking method:

4. Remove the control rod cover from the injection pump. Turn the control rod to drive position with tool 9025 99000.

1. Clean the injection pump and its surroundings carefully.

5. Disconnect the injection pipe (at the pump) for the 1st cylinder (nuts 17 mm and support piece 8 mm).

2. Remove the inspection hole rubber plug from the flywheel housing.

6. Wipe off the fuel on top of the delivery valve. Turn the crankshaft in the correct direction of rotation until the fuel level in the delivery valve just begins to rise.

3. Turn the crankshaft until the piston in the number one cylinder has reached its T.D.C. when in its compression stroke. The turn the crankshaft backwards until the timing mark on the belt pulley passes by the point of the indicator.

7. Check if the mark on the crankshaft belt pulley is at the point of the indicator. If it is, the injection timing is correct. If the injection pump needs to be adjusted, follow the next instruction. 8. After checking and if necessary adjusting the timing install the injection pipe and the control rod cover. Run the engine for a few minutes and recheck. Thus you can ensure that there is no air left in the fuel system which might affect the timing.

185

10. 1. 1992

22A. Fuel system (20---series)

1. 9. 1992

B. Adjusting injection timing

Model

Code

255-- 665

223A

Page

2

9052 48900

1. Loosen the retaining nuts (17 mm) of the injection pump and remove the injection pipes (17 mm).

A

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

M 2. If the injection timing is retarded, turn the pump anti ---clockwise (viewed from the front end of the pump). If the timing is advanced, turn the pump clockwise.

N.B. If the engine is not to be disturbed while the pump is removed, there is no need to secure the pump gear. The gear rests against the idler gear.

3. Check once again the injection timing and set again if needed. 4. When the timing is correct tighten the retaining nuts of the pump and fix the delivery pipes.

D. Fitting fuel injection pump 1. Check the condition of the o---ring between the pump and the timing gear casing. Change the o---ring if necessary.

C. Removing fuel injection pump 1. Clean the injection pump and surrounding engine parts and the pipes and connectors on the injection pump. 2. Disconnect the delivery pipes and the banjo bolts at the supply and return fuel connections. Disconnect the lubricating oil line. Plug all connections. 3. Detach the oil filler pipe/cover from the front cover. Unscrew the pump drive gear nut.

2. Lubricate the o---ring and place the injection pump so that the key on the pump shaft aligns with the key slot inside the gear. Tighten the pump attaching nuts. 3. Tighten the gear nut to 90 Nm . Fix the oil filler pipe/cover. 4. Connect the supply and return fuel lines. Connect the lubricating oil line. Use new sealing washers.

186

Model

22A. Fuel system (20---series)

1. 9. 1992

255-- 665

Code

Page

223A

3

E. Checking/changing delivery valve

5. Bleed the fuel system (Op no 222 A). 6. Adjust the injection timing (Op B).

1. Clean the injection pump, injectors and surrounding parts. Disconnect the delivery pipes.

7. Fit the delivery pipes.

9052 47800

8. If the injection pump is changed or if the lubricating oil has been drained from the pump, fill the pump with lubricating oil before starting the engine. Open the hexagonal socket plug on the governor housing and pour in oil. Filling quantity: 320---engines 0,3 l 420---engines 0,4 l Same oil specification as in the engine. 2. Connect the pressure gauge 9052 47800 to the delivery valve holder which is to be checked. 3. Rotate the engine with the starter motor, until the gauge reading is about 330 bar. Note! Pressure rises fast, do not damage the gauge. Get ready to pull the stop control out as soon as the gauge reading reaches an adequate pressure value. 4. Let the gauge reading lower at first about 30 bar. When the gauge shows 300 bar, observe the reading during one minute. During this time the gauge reading must not lower too much (max 30---50 bar). If the pressure lowers faster than specified, the delivery valve must be cleaned or replaced. Note! The delivery valve plunger and guide should always be replaced in pairs. 5. Open the delivery valve holder locking and holder. Remove the valve spring, plunger and the guide. 6. Rinse the plunger and guide in clean fuel or test liquid and at the same time rotate the plunger in its guide and press the sealing surfaces against each other.

187

Model

22A. Fuel system (20---series)

1. 9. 1992

255-- 665

Code

223A

Page

4

2. Ensure that the throttle lever is in the idling position and that the engine is at normal operating temperature. 3. Start the engine and loosen the adjusting screw of the additional spring so that it does not affect the idling speed.

7. Fit the delivery valve into the fuel injection pump. Place the spring in place and tighten the holder.

4. Adjust the idling speed using the adjusting screw to about 20 RPM below rated speed and lock the adjusting screw (10 mm).

Note! Renew the sealing ring and o---ring.

5. Run the engine a few times and ensure that the idling speed remains as set.

8. Tighten the holder as follows: --- Tighten first to 30 Nm. --- Open the holder about 1/2 a turn and tighten to 40 Nm. --- Open the holder about 1/2 a turn and tighten to 45 Nm.

6. Tighten the adjusting screw of the additional spring until the idling speed rises to the rated value. Lock the adjusting screw (17 mm) in this position. 7. Fix the safety caps of the adjusting screws. Note! Other adjustments (output and max. speed) of the injection pump can only be performed by a specially trained person who has the necessary special tools and gauges available.

F. Adjusting low idling speed If the idling speed of the engine deviates from the value given in the specifications or if the engine revs vary at the idling speed, adjust the idling speed as follows:

1

2

1. Unscrew the idling speed adjusting nut cap (1) and the cap (2) on the idling speed additional spring adjusting screw.

188

Model

22A. Fuel system (20---series)

1. 6. 1998

255-- 665 600, 700

Code

223A

Page

4A

F.1. Adjusting injection timing on modified Bosch in ---line pumps IMPORTANT! Governors of the Bosch in ---line pumps have been changed with effect from engine no. G4720 (320 D, DS) and G2358 (420 D, DS). These modified pumps can be recognized by a plug in the governor housing (the same as on Valtra 6800 and 8750 tractors) and they are exchangeable with the earlier pumps. Spare part numbers of the pumps are not changed. Note! On these modified pumps the injection starting point in the 1st cylinder has been positioned with aid of an indicator pin in the pump governor housing.

2. Unscrew the plug on the side of the injection pump. Take out the indicator pin. 3. Turn the indicator pin and push it into the hole so that the groove at the end of the pin points towards the pump. 4. If the pin groove fits on the boss on the governor weight assembly, the injection timing is correct. Otherwise, turn the pump to a position where the boss and the pin groove align. Warning! Do not rotate the crankshaft when the groove end of the pin is inside the pump, since the pin end damages easily and metal pieces remain in the governor housing. 5. When the adjustment is correct, turn the indicator pin so that the groove points outwards (running position) and push the pin into the hole. Refit the plug. 1. Turn the crankshaft to a position where the 1st cylinder piston reaches its compression stroke top dead centre. Then turn the crankshaft backwards until the timing mark on the belt pulley is at the point of the indicator.

189

190

Model

22A. Fuel system (20---series)

1. 9. 1992

255-- 665

Code

223A

Page

5

G. Removing injectors 1. Clean the injectors and the area around them. Disconnect the delivery pipes and the leak ---off pipes.

9051 71300

2. Secure the injector in a test bench and check the following: --- injector opening pressure --- the properties of the chattering (creaking) sound and the form of the spray pattern --- sealing of nozzle valve against its seat

Opening pressure

3. Remove the injector attaching nuts (13 mm) and remove the injector from the cylinder head. Fit protective plugs to all connections. If the injector does not rise by hand, use puller 9051 71300.

Pump a few times to fill the injector. Increase the pressure in the injector until the chattering (creaking) sound becomes audible. Read off the opening pressure of the injector. If the opening pressure deviates from the given value (230±5 bar), the injector should be taken apart and checked.

4. Remove the sealing washers from the bottom of the injector location in the cylinder head if they do no come out with the injector

Adjustment is achieved by changing the shims. The thickness of the shims varies from 1.00---1,90 mm and they are available in increments of 0,05 mm. A thicker shim will raise the opening pressure while a thinner one lowers it. A difference in shim thickness of 0,05 mm changes the opening pressure by approx. 5,0 bar. As the opening pressure of the injector drops slightly after adjustment, the opening pressure should be set to approximately 10 bar above the value given in the specifications. This value applies both to new and used injector.

H. Inspecting injectors

Chattering sound properties

N.B. When pressure testing the injectors, it is important to avoid the nozzle end as the fuel jetting out easily penetrates the skin. Also bear in mind that the fuel ”mist” is dangerous to inhale.

Testing with a hand powered pump does not create the same circumstances as when the injector is fitted in the engine. Only with new nozzles are the test results reliable. With used nozzles, there is no chattering (creaking) sound when the tester is pumped at a certain rate. This has to do with the design of the nozzles.

1. Clean the injector with cleaning fluid and a soft brush. The carbon deposits must not be knocked off or removed in any other way which may damage the nozzle.

However, with a rapid pumping on the tester handle, it should be possible to hear the chattering (creaking) sound or/and see a mist of the fuel jetting out.

191

Model

22A. Fuel system (20---series)

1. 9. 1992

Code

255-- 665

Page

223A

6

1

Tightness of nozzle Press down the tester pump lever until the pressure rises to approx. 20 bar below the adjusting value. Maintain this pressure for approximately 10 seconds and check whether drops of fuel are formed on the point of the nozzle. If the injector leaks, it should be cleaned or the nozzle should be changed.

2

I. Reconditioning injectors 1. Secure the injector in a suitable way.

3

2. Unscrew the nozzle cap nut. Remove the nozzle and the parts inside the holder.

4

3. Clean the nozzle in cleaning fluid both inside and outside. 4. Clean the nozzle holes with a needle (including in cleaning set 8360 83288).

5

5. Test the movement of the nozzle valve as follows:

6 7

8 9 Injector 1. Fuel inlet 2. Leak ---off fuel 3. Shims 4. Pressure spring 5. Valve stop spacer

6. Nozzle body 7. Pressure chamber 8. Nozzle valve 9. Nozzle hole

6. Before assembling, all parts should be carefully cleaned in clean fuel or testing fluid.

Rinse the parts thoroughly in fuel or testing fluid. Pull the valve out of the nozzle body to 1/3rd of its length. If the fit is correct, the valve should be able to slide down in the nozzle body under its own weight. Turn the valve slightly and repeat the test. Should the nozzle valve bind slightly, it should be changed.

7. Put the same number of shims back as were fitted earlier. Note possible adjustment of the opening pressure. Assemble the rest of the injector. Note the position of the spring guide and the valve stop spacer. 8. Tighten the nozzle cap nut by hand and then to 60 Nm.

192

Model

22A. Fuel system (20---series)

1. 9. 1992

255-- 665

Code

223A

Page

7

K. Fitting delivery pipes J. Fitting injector in engine

1. Check the state of the pipes. If there are kinks, damage by chafing, or if the tapered sealing end is damaged, the pipes should be changed.

1. Clean the injector sealing surface in the cylinder head. If necessary use a reamer 9101 66000.

2. Fit the pipes without tension and check that they are at right angles to the union. 3. Fit the clamps for the pipes.

1 2

3 1. Washer 2. Rubber ring 3. Sealing washer 2. Fit the injector in the cylinder head using a new sealing washer. N.B. The spray pattern from the injector is not symmetrical on purpose. It is therefore important that the injector is fitted correctly in the cylinder head. The connection for the leak ---off line should be facing the valve mechanism. 3. Fit the attaching clamp and tighten the nuts (13 mm) evenly to 15 Nm. 4. Connect the leak ---off line (10 mm) together with new sealing washers and connect the delivery pipes (17 mm). N.B. The screw studs in the cylinder head for the injectors should only be finger tight. If tools have to be used the studs should be tightened only lightly. Note! Make sure, that the injector is of a correct type. Wrong injectors cause malfunctions and can damage the engine.

193

22A. Fuel system (20---series)

15. 4. 1999

Model

1. 9. 2001

865, 700-- 900

Code

223A

Page

8

2. Stanadyne distributor pump A. Removing pump 1. Make the procedures shown i paragraph 1 below. Clean the pump and the surrounding parts carefully. Remove the delivery pipes, the throttle cable wire from the revolution lever and the stop solenoid wire from the pump. Fit protective caps on the delivery pipe unions. 2. Remove the cover (+oil filler tube) of the front plastic covering so that the pump gear wheel becomes accessible. 4. Unscrew the gear wheel attaching nut. Detach the gear wheel by using puller 9052 48900. Note! If the timing gear casing has not been removed, the injection pump gear wheel remains in contact with the idler gear and it is unnecessary to mark the positions of the gears. Note! In the E ---engines one injection pump fixing bolt is so called interrupted screw (i.e, it cuts off when it is tightened). Open this bolt by striking to the bolt outer edge with a chisel (strike to the opening direction).

2. Remove the small cover plate on the side of the injection pump. Rotate the pump shaft until the timing marks align (see arrow in picture above).

5. Detach the injection pump from the timing gear casing. Clean the sealing surfaces.

Note! In 420---engines the side cover bolts are special bolts, which require special key. Cover seal no. is 8366 62296. 3. Place a new sealing ring on the pump flange. Push the pump into place so that the key on the shaft engages with the key slot on the gear wheel.

B. Fitting injection pump and adjusting injection timing

4. Tighten the pump into position, where the timing marks align. 5. Tighten the gear wheel nut to a torque of 90 Nm. Fit the small cover onto the side of the pump. Fasten the pump gear wheel covering (+oil filler tube). 6. Remove the protective caps from the delivery pipe unions and fasten the delivery pipes. Fit the overflow pipe, throttle cable wire and the stop solenoid wire. Bleed the fuel system (see instruction C). Note! Lubrication is not needed in the distributor pump as fuel in the pump lubricates the internal parts.

1. Turn the crankshaft until the piston in the number one cylinder has reached its T.D.C when in its compression stroke and then turn the crankshaft a little so that the timing mark on the belt pulley is at the point of the indicator (injection in no. 1 cylinder begins). Note! Distance between the piston top face and the top dead center with different crankshaft angles, see page 210/7.

194

22A. Fuel system (20--- series) C. Bleeding fuel system

1. 3. 1997

Model

1. 6. 1998

865, 800, 900

Code

Page

223A

9

D. Fuel feed pump

Note! This fuel system removes automatically small amounts of air bubbles from the filter and the pump. However, bleed the system always, when the system has been opened or fuel has been exhausted during driving (to avoid long starting time).

Separate spare parts are not available for the membrane type fuel feed pump. The feed pump must be changed for a new one, if the feed pressure has dropped noticeably (rated feed pressure is 0,2 ---0,5 bar at low idling speed and max 0,2 bar less when engine is accelerating) or if the fuel feed pump has damaged.

Metal gauze filter under the cover

Measuring fuel feed pressure Pressure measuring equipment, see page 101/4C. Note! If the feed pressure value is below the rated value, possible reason can be: --- blocked fuel filter/fuel feed pump metal gauze filter --- faulty fuel feed pump --- blocked or leaked fuel pipes or pipe connections Important! Under the fuel feed pump cover there is a washable metal gauze filter. If many impurities have gathered on this filter, fuel cannot flow to the feed pump and further to the injection pump and this causes malfunctions in the fuel system. Always when malfunctions appear, the feed pump cover should be removed and the metal gauze filter must be checked and cleaned.

1. Pump by hand the fuel feed pump lever. If the pumping seems to be ineffective, turn the engine a little so that the camshaft cam is not at the feed pump lifter.

Note! From manufacturing week G42 incl. the fuel feed pump gasket no. 836640335 has been removed and the sealing has been done with sealing glue T61050 (Weicon Lock AN 305---10 TAI 75), which must also be used in connection with possible leakages. Run the engine, until the cylinder block temperature is at least +60˚C. Clean the sealing surfaces well by using suitable solution. Apply sealing glue onto the pump sealing face and fasten the pump. Let the sealing glue dry about one hour before the engine is started (if a fuel feed pump, which has been tightened with the sealing glue, should be changed, the pump fastening flange must be warmed up to about +200˚C before removing the pump).

10a

New fuel feed pump In the tractor production has been started to fit a new fuel feed pump (420: H7663 ---), which has an o---ring seal and four fixing bolts. This pump can be fitted also on earlier manufactured tractors, although they should have the earlier, with two bolts attached pump (mounting kit no. 8366 62052). In the cylinder block there are four fixing holes from the beginning of the year 98. The Spare Part Centre dispatches only the new pump.

2. Loosen the bleeding screw (10a) on the filter. Pump with the hand pump until no air bubbles flow out of the bleeding screw hole. Tighten the bleeding screw. 3. Pump further with the hand pump and loosen the fuel inlet connection (10b) on the pump, until the fuel coming out is free from air bubbles. Tighten the connection.

On the next page there is an instruction on, how to fit the new pump.

Note! When the bleeding is done in this way, fuel flows immediately into the internal transfer pump when the starter motor is rotating and the distributor pump housing is filled quickly with fuel. In the pump housing there is a stop solenoid, which must not be switched on for longer periods when the pump housing is empty of fuel. 4. Start the engine and assure, that no leaks exist.

195

1. 6. 1998

22A. Fuel system (20---series)

1. 9. 2001

Model

865, 700-- 900

Code

223A

Page

10

F. Adjusting low idling speed

Fitting new fuel feed pump (H7663-- )

Revolution lever

Max. revs

Low idling speed

A

4 --- Remove the old feed pump and fuel pipes --- Clean the sealing surface on the cylinder block --- Place an o---ring into the groove on the pump. --- Engines with two fixing bolts: apply sealing compound T61050 (Weicon Lock AN ---305---74) on the cylinder block side of the flange 4 (if four fixing holes the flange is not fitted) --- Apply sealing compound also on the threads of the bolts (2 pcs or 4 pcs) and fasten the pump. Tightening torque is 30 Nm. --- Bend the pipe between the filter ---pump or use a flexible pipe which incl. in the kit.

The low idling speed can be adjusted with a limiting screw in front of the revolution lever. The adjusting screw for max. revs has been sealed. This adjustment has been done in the factory, and adjustment of max. revs afterwards is prohibited. Note! The throttle cable is attached to the revolution lever lower hole. To the upper hole is fastened a return spring.

Note! If the cylinder block has already four threaded bolt holes, remove plugs from points A, and fasten the pump with four bolts (sealing compound on the threads of all bolts) without the intermediate flange (4). Sealing compound (50 ml) Sealing compound (250 ml)

Other information The injection pump housing upper cover has been sealed to prevent adjustment of engine output afterwards. Also the stop solenoid is fitted under this cover. If the injection pump is damaged during the warranty period, replace with a new spare part pump. After the warranty period it is recommended, that all pump repairs are made by an authorised Stanadyne workshop.

6909 30030 6909 30016

E. Injectors

G. Bleeding Thermostart system

Injectors are checked and serviced according to instructions G ---J on pages 223/5 ---7.

Always remove air from the glow plug fuel pipe when the pipe or reservoir has been emptied during repair work etc. This prevents damage to the glow plug caused by lack of fuel during starting.

Opening pressure of the injectors, see pages 220/14. Adjustment is achieved by changing the shims. The thickness of the shims varies from 1.00---1,90 mm and they are available in increments of 0,05 mm. A thicker shim will raise the opening pressure while a thinner one lowers it. A difference in shim thickness of 0,05 mm changes the opening pressure by approx. 5,0 bar. As the opening pressure of the injector drops slightly after adjustment, the opening pressure should be set to approximately 10 bar above the value given in the specifications. This value applies both to new and used injector.

1. If the reservoir is empty, fill it e.g. with a drip pot through the breather hole on the reservoir. 2. Open the glow plug pipe connector and drain fuel from the pipe. Connect the pipe. Note! From engine no. H16734 incl. the outer diameter of the glow plug fuel pipe has been enlarged from 4,76 mm to 5,0 mm. These new pipes can be used on earlier manufactured tractors, when simultaneously is fitted a new connector nut and a new sealing cone. The new nut can be recognized by grooves on the outer circumference.

196

15. 4. 1999

22A. Fuel system

1. 9. 2001

Model

700, 800

Code

223A

Page

11

I. Dynamic adjustment of injection timing

1. Let the engine run to a normal working temperature before adjustment.

Note! Ensure before engine start that the wires do not touch the exhaust manifold or movable parts.

Note! Stop the engine before connecting and disconnecting the adjusting device.

8. If the revolution reading is correct, press ENTER after which text ”Calibrating...”. is visible in the display

2. Remove the protective plug on the fly wheel housing on the LH side of the engine and fit the magnetic sensor A into the 8 mm hole. Press the sensor against the fly wheel . The sensor must not touch the fly wheel so pull it a little out (0,5...1,0 mm) . Connect the sensor connector to the test device plug MP.

Note! If the revs signal disapperas or engine stops , in the display flashes text ”Eng. Not running” and the device returns to the revs mode. Start again by pressing button MAG PROBE (return to point 5). 9. If the engine is running at 850 r/min and the pump advance is 6˚ btdc, in the display there is visible ”R=850 MP + 6.0”. Now the device is ready for adjustment.

3. Fit fastener B on the brass ring between the pump and pipe and tighten the screw. Ensure, that the screw end touches the brass ring. Connect the injection sensor connector to the test device plug SR. Connect the earth wire to the clean metal surface on the engine or fuel system.

Note! If the magnetic sensor signal is cut or the sensor is lacking, in the display there is text ”R=850 No Probe”. When the signal returns, the device shows again the injection advance.

4. Switch on the test device by pushing ON/CLEAR button. In the display is visible ”Time Trac” and ”Model TT 1000” and then i ”R= 0”. Now the device can be used as a rpm counter without other procedures.

10. The injection time is checked at high idling revs [TT (HI)]. Adjust if necessary. The function of the pump injection advance governor is assured by checking the injection timing at a low idling speed [TT (LI)].

5. Press button MAG PROBE. In the display appears ”Trig Level 30%”. Confirm by pushing ENTER.

Adjusting values, see pages 220/13 and 14.

6. In the display is visible ”Offset 20.0˚”. Confirm by pushing ENTER.

See also instructions of the device manufacturer.

7. In the display is visible ”Calibrate?”. Start the engine and let it run at low idling. Press ENTER so that in the display is visible ”R=Set RPM”. Compare the revs to the specifications, see page 210/3.

197

Model

22A. Fuel system

15. 4. 1999

Possible disturbances If the injection timing deviates much from the specified value, check the following points: 1. Vibrating delivery pipe, hold to the pipe with one hand. 2. The distance between the magnetic sensor and the flywheel is incorrect, reposition the sensor. 3. Offset or Trig Level value incorrect, reset the values. 4. Disturbing grooves on the flywheel. 5. The mutual position of the flywheel and the crankshaft incorrect, remove the flywheel and fit it to the correct position in relation to the crankshaft.

8366 62022 Electronic device for injection timing

198

700, 800

Code

223A

Page

12

Model

22A. Fuel system (20---series)

1. 4. 2004

A75 -- A95

Code

224A

Page

1

Bosch VE distributor pump (Op no 224) A. Removing fuel injection pump

5. 1.

2. 3.

Unscrew the retaining screws of the gear (4 pcs)

Turn the crankshaft to a position where the 1st cylinder piston reaches its compression stroke top dead centre. Turn the crankshaft backwards until the mark on the pulley passes the timing indicator. Then rotate the crankshaft slowly in the running direction until the mark on the pulley is at the point of the timing indicator. Clean the injection pump and surroundings. Remove the fuel delivery pipes, the throttle cable wire from the lever and the stop solenoid wire from the pump. Fit protective caps on the delivery pipe unions.

Note! If the front cover of the timing housing has not been removed, the pump gear and the idler gear will stay in mesh with each other. Note! Do not remove the coupling flange from the shaft of the pump.

4.

Remove the injection pump gear cover. Don’t open the nut of the coupling flange.

6.

199

Unscrew the retaining nuts of the pump (3x13 mm).

Model

22A. Fuel system (20---series)

1. 4. 2004

A75 -- A95

Code

224A

Page

2

B. Fitting the injection pump and adjusting injection timing

7.

8.

Remove the injection pump.

1.

If the coupling flange is separate: Clean the conical connection between the shaft of the injection pump and coupling flange. Fit the separate coupling flange into the timing gear housing.

2.

Tighten the screws of the flange to 35 Nm (4 pcs).

Don’t open the nut of the coupling flange.

Note! Injection pump delivered as exchange part includes coupling flange for the gear (1) and banjo bolt (2) for fuel overflow. Those must be included also when returning injection pump core.

200

Model

22A. Fuel system (20---series)

3.

Code

A75 -- A95

1. 4. 2004

224A

Page

3

Note! The shaft of the injection pump is locked by a lock screw. If the shaft slips when tightening the flange nut, the injection pump will be damaged and must be replaced! Prevent crankshaft from rotating by locking the flywheel.

Check the marks. The groove and the mark must be in the same line.

7.

Fix and pretighten the nut to 15 Nm.

2

4. 5.

Remove the nut and washer Check the condition of the o-rings between the pump and the timing housing. Change the o-rings if needed. Lubricate the o-rings and fit the assembling ring into the timing housing.

1

Note! Use gasket sealant on the surfaces against the timing housing.

8.

Open the lock screw (1) a little and fit the plate (2), that came with the pump, under the screw. Tighten the screw to 12,5 Nm. The shaft of the injection pump is free now.

6.

9.

Prevent crankshaft from rotating by locking the flywheel.

Place a new seal on the pump flange. Push the injection pump into place (to the middle of the adjusting holes) on the timing gear housing. Pretighten the retaining nuts of the pump (3x13 mm).

10. Tighten the nut of the coupling flange to 92,5 Nm.

201

Model

22A. Fuel system (20---series)

1. 4. 2004

A75 -- A95

Code

224A

Page

4

ETV 894 580

Setting tool for the injection pump. Adapter 8366 62521 and dial gauge (1/100 mm).

14. When distance of the pump piston is correct, tighten the retaining nuts of the injection pump (3x13 mm).

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

15. Fit the injection pump gear cover. 16. Fit the injection pipes. Check that they are in the correct angles to the unions. Tighten the delivery pipe attaching nuts to 25 Nm. Do not overtighten! 17. Fit the fuel pipes, throttle cable and the electric wire. 18. The fuel system bleeding starts with opening the fuel return pipe connection and pumping with the hand pump until the injection pump housing is filled with fuel. Tighten the connection. Open the injection pipe connections from the injector end (only about half a turn, not more). Crank the engine for about 5 seconds, until fuel comes out from every injection pipe. Tighten the injection pipe connections and start the engine. Clean off the over flown fuel.

13. Rotate the crankshaft slowly in the running direction until the mark on the crankshaft pulley is at the point of the timing indicator. Read the distance of the injection pump piston from the dial gauge, it should be: --- In A75 model 0,20 mm --- In A85 and A95 models 0,25 mm

Note! If needed, a vacuum pump can be connected to the fuel return connection. The pump sucks the fuel from the tank via the injection pump. Connect the return pipe when fuel flows out from the return connection.

If the dial gauge shows a different distance, turn the injection pump, accordingly and check again.

202

Model

22A. Fuel system (20---series)

1. 4. 2004

A75 -- A95

Code

224A

Page

5

C. Bleeding the fuel system Note! This fuel system bleeds automatically small amounts of air bubbles from the filter and the pump when the engine is running. However, bleed the system always, when the fuel filters have been replaced or fuel has run out during driving.

1

Crank the engine (about 5 seconds), until fuel comes out from every injection pipe.

2

Retighten connections and start the engine. Clean off the over flown fuel.

D. Measuring fuel feed pressure 1.

Pump by hand the fuel feed pump lever. If the pumping seems to be ineffective, turn the engine a little so that the camshaft cam is not at the feed pump lifter.

2.

Start the engine to idling speed, do not race. If the engine is not starting, loosen the connection of the bleeding pipe from the fuel filter to the injector. Pump with the hand pump until fuel flows out of the connection. Tighten the connection and clean off the over flown fuel. Start the engine and make sure that there are no leaks.

3.

1.

Clean up the pre-filter and the fuel filter and related fuel pipes from outside.

2.

Disconnect the pressure switch from the fuel filter and connect the gauge instead (the thread is M14x1,5).

3.

Run the engine at low idling for a while and compare the gauge reading with the prescribed value (0,48 bar, minimum 0,20 bar at max. rpm).

Note! If the measured pressure is below the prescribed value, this may be caused by:

Note! In connection with service- or repair work (like change of injection pump), there might be a situation where bleeding the air requires special measures. In this case open the injection pipe connections from the injector end (only about half a turn, not more).

203

•

Clogged fuel filters.

•

Malfunction of the feed pump.

•

Suction piping clogged or leaking air.

•

Empty fuel tank or unsuitable fuel (e.g. summer fuel in the winter).

Model

22A. Fuel system (20---series)

1. 4. 2004

A75 -- A95

Code

224A

Page

6

E. Removing injectors 1.

Opening pressure

Clean the injectors and the area around them. Disconnect the delivery pipes and the leak-off pipes.

Pump a few times to fill the injector. Increase the pressure in the injector until the chattering (creaking) sound becomes audible. Read off the opening pressure of the injector. If the opening pressure deviates from the given value, the injector should be taken apart and checked.

9051 71300

Adjustment is achieved by changing the shim. The thickness of the shims varies from 1,00...1,90 mm and they are available in increments of 0,05 mm. A thicker shim will raise the opening pressure while a thinner one lowers it. A difference in shim thickness of 0,05 mm changes the opening pressure by approx. 5,0 bar. As the opening pressure of the injector drops slightly after adjustment, the opening pressure should be set to approximately 10 bar above the value given in the specifications. This value applies both to new and used injector.

Chattering sound properties 2.

Remove the injector attaching nuts and remove the injector from the cylinder head. Fit protective plugs to all connections. If the injector does not withdraw by hand, use puller 9051 71300.

3.

Remove the sealing washers from the bottom of the injector location in the cylinder head if they do no come out with the injector.

Testing with a hand powered pump does not create the same circumstances as when the injector is fitted in the engine. Only with new nozzles are the test results reliable. With used nozzles, there is no chattering (creaking) sound when the tester is pumped at a certain rate. This has to do with the design of the nozzles. However, with a rapid pumping on the tester handle, it should be possible to hear the chattering (creaking) sound or/and see a mist of the fuel jetting out.

F. Inspecting injectors Note! When pressure testing the injectors, it is important to avoid the nozzle end as the fuel jetting out easily penetrates the skin. Also bear in mind that the fuel ”mist” is dangerous to inhale. 1.

Tightness of nozzle Press down the tester pump lever until the pressure rises to approx. 20 bar below the adjusting value. Maintain this pressure for approximately 10 seconds and check whether drops of fuel are formed on the point of the nozzle. If the injector leaks, it should be cleaned or the nozzle should be changed.

Clean the injector with cleaning fluid and a soft brush.The carbon deposits must not be knocked off or removed in any other way which may damage the nozzle.

G. Reconditioning injectors 1. 2.

2.

Secure the injector in a test bench and check the following:

•

injector opening pressure

•

the properties of the chattering (creaking) sound and the form of the spray pattern

•

sealing of nozzle valve against its seat.

204

3.

Secure the injector in a suitable way. Unscrew the nozzle cap nut. Remove the nozzle and the parts inside the holder. Clean the nozzle in cleaning fluid both inside and outside.

4.

Clean the nozzle holes with a suitable needle.

Model

22A. Fuel system (20---series)

1. 4. 2004

Code

A75 -- A95

Page

224A

7

H. Fitting injector in engine 5.

Test the movement of the nozzle valve as follows:

9101 66000

Rinse the parts thoroughly in fuel or testing fluid. Pull the valve out of the nozzle body to 1/3rd of its length. If the fit is correct, the valve should be able to slide down in the nozzle body under its own weight. Turn the valve slightly and repeat the test. Should the nozzle valve bind slightly, it should be changed.

1.

1. Washer 2. Rubber ring 3. Sealing washer

1

9 Injector 1. Fuel inlet 2. Leak off pipe connection 3. Adjusting shim 4. Pressure spring 5. Pressure pin 6. Nozzle body 7. Pressure chamber 8. Injector needle 9. Number code

Clean the injector sealing surface in the cylinder head. If necessary use a reamer 9101 66000.

2

1 2 3 4

5 3

6 7 2. 8

6.

Before assembling, all parts should be carefully cleaned in clean fuel or testing fluid.

7.

Put the same thickness of shim back as were fitted earlier. Note possible adjustment of the opening pressure. Assemble the rest of the injector. Note the position of the spring guide and the valve stop spacer.

8.

Fit the injector in the cylinder head using a new sealing washer.

Note! The spray pattern from the injector is not symmetrical on purpose. It is therefore important that the injector is fitted correctly in the cylinder head. The connection for the leakoff line should be facing the valve mechanism. 3. 4.

Tighten the nozzle cap nut by hand and then to 60 Nm.

Fit the attaching clamp and tighten the nuts evenly to 15 Nm. Connect the leak-off line together with new sealing washers and connect the delivery pipes.

Note! The screw studs in the cylinder head for the injectors should only be finger tight. If tools have to be used the studs should be tightened only lightly. Note! Make sure, that the injector is of a correct type. Wrong injectors cause malfunctions and can damage the engine.

205

Model

22A. Fuel system (20---series)

1. 4. 2004

I. Fitting delivery pipes 1.

2.

3.

Check the state of the pipes. If there are kinks, damage by chafing, or if the tapered sealing end is damaged, the pipes should be changed. Fit the pipes without tension and check that they are at right angles to the union. Tighten the delivery pipe attaching nuts to 25 Nm. Do not overtighten! Fit the clamps for the pipes.

206

A75 -- A95

Code

224A

Page

8

10. 1. 1992

23A. Cooling system (20---series)

1. 9. 1992

Model

255-- 865

Contents General (Op no 230): Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cooling system, description and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Repair instructions (Op no 231): A. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Reconditioning coolant pump (320---, and 420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 D. Quality requirements of engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

207

Code

230A

Page

1

1. 5. 1996

23A. Cooling system (20---series)

1. 1. 1998

Model

255-- 900

Code

Page

230A

2

Specifications Coolant pump (320, 420 engines) Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of bearing housing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of the seal recess in the pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The impeller is pressed onto the shaft until the distance between the rear face of impeller and the rear face of the pump body is . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distance of belt pulley from rear face of body: --- 320D/DS; ---E7535, 420D/DS; ---E7054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 320D/DS; E7536---, 420D/DS; E7055--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan guide diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancing precision of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permissible eccentricity of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38,087...38,100 mm 38,058...38,083 mm 15,910...15,920 mm 15,881...15,899 mm 36,450...36,489 mm 1,8---2,2 mm 178,3...178,7 mm 174,4---174,6 25,00...25,20 mm 0,3 Ncm max ±0,3 mm 15...20 mm

Fan diameter 255---565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600---700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ø 430 mm, 6 fan blades ø 460 mm, 6 fan blades ø 432 mm, 6 fan blades ø 483 mm, 8 fan blades

600---900 tractors have new and more effective cooling radiators (600---700: four ---line radiator. 800---900: five ---line radiator). The larger radiator and fan are also fitted on 600---700 tractors, if they are equipped with an air conditioning.

Thermostat Spare part number

Type

8361 15646 8361 15718

ø67/79˚C ø67/83˚C

Opening begins at 79˚±2˚C 83˚±2˚C

Fully open at 94˚C 97˚C

208

Max stroke mm 8 8

Model

23A. Coolant pump (20---series)

1. 9. 1992

255-- 865

Special tools Order no 9022 03500 *) 9051 40200 *) 9051 79300 *) 9051 64900 *) 9052 48900 *) *)

Description Puller for coolant pump impeller (earlier no 8360 85499) Drift for fitting coolant pump seal (seal no 8353 31202) Drift for fitting coolant pump seal (seal no 8353 39425) Drift for fitting coolant pump shaft, 320--- and 420---engines Puller for fan hub (see Fuel system)

Same tool as for engines on 305---405 tractors.

905140200

905179300

9022 03500

9052 48900

905164900

209

Code

230A

Page

3

1. 9. 1992

23A. Cooling system (20---series)

1. 5. 1996

Model

255-- 865

Code

230A

Page

4

Cooling system, 4---cylinder engine 1. Coolant pump 2. Thermostat 3. By ---pass passage 4. Radiator

Caution! Open the radiator cap carefully, if the coolant is hot as there will be overpressure in the system. Carefully turn the radiator cap to the first stop. This will allow the overpressure to be released from system.

Description The belt driven, centrifugal type coolant pump is attached at the front end of the cylinder block and the thermostat housing is fitted above the pump. The system has an internal coolant circulation via the by ---pass passage and the circulation is controlled by a two---way thermostat. With this is achieved a even warming in all conditions.

N.B! The coolant pump is provided with a drainage hole on its underside. This hole must not be blocked. If coolant drips out of the hole, the pump seal is faulty. There may be slight leakage on a new engine before the pump has been run in.

Freezing point of coolant

The pump shaft and the bearings are built together to form one unit (320--- and 420 engines).

Check the freezing point of the coolant at the beginning of the cold season. If the freezing point is too low, drain off some of the coolant and top up with anti ---freeze. Run the engine for a while until the anti ---freeze has been mixed in, then re --check the freezing point of the coolant. Drain the cooling system completely every second year and refill with new coolant. Never use just water as a coolant.

The thermostat opens at 79˚C. During a cold season, a thermostat with the opening temperature of 83˚C can be use.

Maintenance Check the coolant level daily. The level of the coolant should be slightly above the radiator core. Check the condition of the fan belt since it drives the coolant pump. Stop the engine immediately if the coolant

Clean regularly the radiator externally from insects and other impurities.

temperature rises too much.

210

Model

23A. Cooling system (20---series)

15. 4. 1999

205-- 900

Code

230A

Temperature sensor, engine coolant temperature The sensor is placed on the engine beside the thermostat housing:

Warning light

Temperature gauge pin

40

11

M14x1,5

40

19 mm

Order no

Alarm temperature

6542 71208

98 ± 3˚C (used on Valtra ---tractors)

8366 40772

106 ± 3˚C (used on Valtra ---tractors)

211

Resistance value, temperature gauge side: 60˚C=134± 13,5 Ω 90˚C=51,2± 4,3 Ω 100˚C=38,5± 3,0 Ω

Page

5

212

Model

23A. Coolant system (20---series)

1. 9. 1992

Repair instructions (Op no 231)

255-- 865

Code

231A

Page

1

B. Reconditioning coolant pump

A. Thermostat

1. Drain the engine coolant. Disconnect the water hoses from the thermostat housing and from the coolant pump. Remove the thermostat housing and the by ---pass hose. 2. Slacken the alternator fixing bolts. Remove the fan and the pump belt pulley. Remove the v ---belt. 3. Detach the coolant pump. Remove the pump rear plate and clean the sealing surfaces.

9052 48900

4. Remove the fan hub using puller 9052 48900. Remove the circlip from the pump body.

9022 03500 The thermostat is of a two---way type. Its opening temperature is 79˚C. In winter a thermostat can be used with an opening temperature of 83˚C. Check the function of the thermostat as follows: --- lower the thermostat into a vessel off boiling water so that the thermostat does not touch the sides or bottom. --- opening must begin under 20 seconds. --- The thermostat must be fully open under 50 seconds. Stroke, see specifications.

5. Remove the impeller using puller 9022 03500. Press the shaft out of the pump body in the direction of the fan. Use a hydraulic press. Support the body so that the shaft bearing unit has enough space for releasing.

213

15. 9. 1995

23A. Cooling system (20---series)

1. 5. 1996

Model

255-- 865

Code

231A

Page

2

178,5 mm

6. Tap out the shaft seal in the body using a suitable drift. Clean all parts and inspect their condition. Replace damaged parts with new ones.

174,5 mm 320 DS: E7536--420 D/DS: E7055---

N.B. If the pump shaft has to be changed, use a reconditioning kit. This kit also contains all seals (see Parts Catalogue). 7. Press the shaft into its location in the body using special tool 9051 64900 and fit the circlip.

1,8---2,2 mm

320 420

905140200

9051 79300

D. Quality requirements of coolant The coolant used must meet the standards ASTM D3306---86a or BS 6580:1985. --- Mixing proportion should be 40---60 % of ethyls---glycol based coolant and the rest water. The best ratio is 50/50 %.

8353 39425

--- In warm climates the 30 % mixture ratio gives enough good protection against corrosion.

8353 31202

--- Water used should be clean and soft water i.e. that it does not include metals and their salts.

8. Fit the shaft seal. Use as a ”lubricating liquid” coolant between the shaft and the seal. Two different seal types are used. Both these seals are fitted with their own drift (see figure above).

--- Check the coolant frost resistance every now and then. Change the coolant every other year. Never use just water as a coolant.

9. Press the impeller and the hub to the correct depth (see figure) and support the shaft at the other end. Ensure that the shaft can rotate freely. Fit the rear plate using a new gasket. Note! The coolant pumps (and crankshaft belt pulleys) have been modified from the following engine numbers incl.: --- 320 D/DS ---engines: E7536 ---. --- 420 D/DS ---engines: E7055 ---. This modification must be observed, when ordering spare parts. The distance between the belt pulley hub and the pump body rear face has been changed, see the next picture.

214

Model

23A. Engine cooling system (20---series)

1. 9. 2001

E. Cooling system with expansion tank

Code

600-- 900

Page

231

3

--- Drain the water pump by cranking the engine a few revs with the drain plugs removed.

1

2

1 3

2 69--- 84,2

Draining the cooling system:

Filling

---Always stop the engine before draining the coolant. DANGER: The radiator cap can not be opened when the system is hot, because the cap has not the clamp position, which should remove the pressure before opening.

Mix the antifreeze and water according to the manufacturer’s instructions. --- Fill up the radiator (1) with a mixture of anti ---freeze fluid and water completely full, close the filler cap. The expansion tank’s cap has to be open when filling. --- Fill the expansion tank (2) with fluid up to the fluid level sign (3).

---

Open the expansion tank’s cap (1). Open the expansion tank cap carefully, if the coolant is hot as there will be over pressure in the system. Carefully turn the expansion tank cap to the first stop. This will allow the overpressure to be released from system. After this press the cap down and unscrew it. --- Loosen the lower water pipe (2) (remove the finger shield if necessary). The best way to drain the system is to loosen the upper end of the pipe and then a little loosen the lower end, then the pipe can be bent to the side and the fluid drained into a vessel. The radiator has a draining plug GR0202

NOTE! If the finger shield is removed make sure you re ---fit it.

Coolant volume: ---------

600 700 800 900

........................................ ........................................ ........................................ ........................................

13,5 l 13,5 l 15,5 l 15,5 l

Ensure that a recommended coolant is always used. WARNING: Never fill up with cold fluid while the engine is warm. Do not use plain water as coolant. After changing the fluid run the engine for a time and check the level of fluid.

3

69--- 84,3

--- Open the plug (3) (or tap) on the cylinder block --- Turn on the heater control in cab. Drained the fluid into a vessel.

215

Model

23A. Engine cooling system (20---series)

1. 9. 2001

600-- 900

Code

231

Page

4

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

(left hand threads)

As a spare part the earlier coolant pump can be replaced with the modified one, when the modified parts are observed: New part number 8367 64215 8367 64046 8367 64045 5798 04602 5818 04602 5298 01420 5817 05425 8367 64239 8367 64241 8367 64242 8367 64243

Earlier part number 8367 55471 8361 20128 8361 20109 5288 01062 --- --- --- ----- --- --- ----- --- --- ----- --- --- --8366 59745 8366 55469 8366 55468

Description Coolant pump Gasket (pump --- rear plate)*) Rear plate*) Bolt (fastening of rear plate)*) Bolt (fastening of rear plate) Bolt (fastening of pump, 2 pcs) Bolt (fastening of belt pulley) Guide sleeve (fastening of belt pulley) Belt pulley ∅191 Valtra Valmet 600 Belt pulley ∅166 Valtra Valmet 700 Belt pulley ∅145 Valtra V. 800 / 900

*) These parts incl. in the earlier pump assy. The gasket between the pump rear plate and the cylinder block has not been changed. The connection ports for the expansion tank and the boost air and the oil cooler have been observed. The threaded holes are plugged, when the pump is fitted on engines without this equipment: Part nos of the plugs: Plug 6403 25018, M18x1,5+sealing ring 6158 81822, 18x22. Plug 6400 45022, M22x1,5+sealing ring 6158 82227, 22x27

216

Model

23A. Engine cooling system (20---series)

1. 9. 2001

Code

600-- 900

231

Page

5

25 Nm (M8, 8.8)

Loctite 572

Reconditioning the coolant pump:

Note! If the pump ball bearings must be changed, it is best to fit the pump repair kit, which also includes all seals (see Spare part Catalogue).

Disassembling the pump: 1. Drain the engine coolant. Disconnect the water hoses from the thermostat housing and from the pump. Remove the thermostat housing and disconnect the side ---circulation pipe. Remove the fan and the v ---belt.

Assembling the pump: 7. Fit a new shaft seal with the aid of a suitable drift. Place the bearings together with the intermediate bushing onto the shaft. Grease the bearings with heat---resistant ball bearing grease. Fit the shaft and bearings into place so that the pressing force does not affect the bearing balls. Refit the snap ring.

2. Remove the coolant pump and clean the sealing surfaces. 3. Unscrew the belt pulley bolts (left---hand threads!). Remove the guide sleeve and the pulley. When necessary, use puller 9052 48900.

8. Refit the axial seal, see paragraph 8 in instr. B. 9. Press the impeller into place while supporting the shaft other end. The impeller fitting depth: distance between the pump body and the even recess in the impeller should be 9,0 ---9,3 mm (see picture on previous page). Ensure, that the shaft rotates freely.

4. Remove the impeller on the shaft using puller 9104 27700. 5. Remove the snap ring in the pump body. Press the shaft together with the ball bearings out of the pump body to the fan side (use e.g. a hydraulic press). Support the pump body so that the bearings can freely move out.

10. Refit the belt pulley and the guide sleeve and tighten the fixing bolt to a torque of 140 Nm.

6. Tap out the axial seal and the shaft seal by using a suitable drift. Clean the parts and check the condition. Change worn parts.

11. Refit the assembled pump, connect all detached parts and fill the engine with coolant. Test---run the engine and check for leaks.

217

218

31. Tractor’s elec--trical system

30. Electrical system

32. AC power lift ACB power lift

33. Agrodata AD---instrument

34. Infoline and Agroline---instrument

219

220

1. 1. 1998

30. Electrical system

Model

1. 9. 2001

Code

205 -- 900

310

Page

1

31. Electrical equipment for engine Alternator, Magneti Marelli (Lucas) A 115 (up to engine number 65224) (Order number 8353 31379) Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. current, 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush length, new brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush spring pressure, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator, no. of poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator, no. of phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for belt pulley, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 V 45 A (---) negative 15000 rpm 20 mm 10 mm 1,3---2,7 N 12 3 0,092 ohm±5% 3,2 ohm±5% 13,6---14,4 V 47 Nm

Alternator Magneti Marelli (Lucas) A 127/45 (from engine no. 65225) (part no 8353 39303) Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. current, 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush length, new brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush spring pressure, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator, no. of poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator, no. of phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt pulley securing nut, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 V 45 A (---) negative 15000 rpm 17 mm 5 mm 1.3---2.7 N 12 3 0.25 ohm 2.9 ohm 13.6---14.4 V 50 Nm

Note! Alternator on earlier 600---900 tractors is Magneti Marelli 127/65. Latest 600---900 tractors have alternator Iskra AAK 1333 14 V 65 A as follows: 600 (J7159---), 700 (J6774---), 800 (J8027---), 900 (J6781---)

Starter motor, Magneti Marelli (Lucas) M 127/2,8 12 V

(Order number 8353 31592) Test values, unloaded: --- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test values, loaded: --- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locked rotor: --- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5500---8000 rpm max. 115 A 11 V 1000 rpm 670 A 20,8 Nm 8V 0 rpm 1160 A 45,4 Nm 5V

Brush spring pressure, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,6---15,5 N Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 mm Commutator, min. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 mm Important! Starter motor on 865 and on earlier 800 and 900 tractors is ISKRA 12V 3,6 kW (Stanadyne rotary injection pump). Starter motor on later 205---665 tractors and on 600 and 700 tractors with Bosch ---in ---line pump: 3---cyl. engines F4506--- and 4---cyl. engines F3792---; ISKRA 12 V 3,1 kW. Latest 600---900 tractots have starter motor Iskra AZJ 3319 12 V 3 kW as follows: 600 (J7159---), 700 (J6774---), 800 (J8027---), 900 (J6781---).

221

Model

15. 9. 1995

30. Electrical system

Code

205-- 900

1. 1. 1998

310

Page

2

Battery

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Ah Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (---) negative

Bulbs: -------------

headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . working lights (2 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . parking lights, brake lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cabin lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dashboard lights, warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60/55 W H4 55 W H3 5 W, 5/21 W 21 W 5W 2 W --- 1,2 W

A. Fuses on 05---models and on 55---models up to cab no. 75192

16 A

8A

8A

8A

16 A

8A

8A

8A

8A

8A

8A

5A

The fuse box is located under the instrument panel. It is divided into two parts, in one of which there are eight fuses (A ---box) and in the other four fuses (B---box). The fuse rating is as follows: 5 A (3 off), 8 A (9 off) and 16 A (2 off). In the component list the fuses are numbered from right to left.

4

3

2

1

8

7

6

5

4

3

2

1

B

A

3055--- 121

Fusebox A:

Fusebox B:

FA1: Gauges, PTO and oil pressure control lamps (5 A) FA2: Radio, roof fan, cabin light, cigarette lighter, wiper return (8 A) FA3: Heater unit, windscreen wiper and washer pump (8 A) FA4: Brake lights, headlight switch illumination light (8 A) FA5: Direction indicator flashers (8 A) FA6: Left parking lights, instrument light, working light switch (8 A) FA7: Right parking light (8 A) FA8: Working lights (8 A) (603606---, 16 A)

FB1: Dipped beams (8 A) FB2: Main beams, indicator lamp (8 A) FB3: Horn, trailer socket, rotating warning light (8 A) FB4: Thermostart unit (16 A) FC1: Radio, speedometer (5 A) (only on tractors which have a main current switch). This fuse is placed in the engine compartment F1E: Autocontrol power lift (5 A). This fuse is situated under the Autocontrol switch panel.

222

1. 3. 1997

30. Electric system

1. 1. 1998

Model

255 -- 900

Code

Page

310

2A

B. Fuses on 65---models up to ser. no. 670319 and on 55---models from cab number 75193 incl. Fusebox A FA1 FA2 FA3 FA4 FA5 FA6

Fusebox B

FB1 Dipped beams (16A) FB2 Main beams, ---pilot light (16A) FB3 Horn, trailer socket, front working lights, hazard warning flashers, Autocontrol (16A) FB4 Thermostart (16 A)

Gauges, pilot lights, Autocontrol (5A) Cab light, Cigarette lighter, Agrodata (8A) Fan, wiper+washer, rear window wiper+washer (8A) Brake lights, headlight switch illumination light (8A) Direction indicator flashers, rear buzzer (8A) LH parking light, instr. light, working light switch (8A)

(FC1) Radio, speedometer (5 A) (in engine compartment) F1E. Autocontrol power lift (5 A). This fuse is situated under the Autocontrol switch panel.

FA7 Right parking light (8A) FA8 Rear working lights, rot. warning light, radio (16A)

1 2 3 4 5

1 2 3 4 5

A

B

5A 5A

5A

5A

5A

C. Fuses on 65---models from ser. no. 670320 incl.

1 2 3 4 5

A3565--- 131,1

Fusebox A FA1 Illumination of gauges, pilot lights, Autocontrol, AD ---instrument (5 A) FA2 Rotating varning light, radio (10 A) FA3 Fan, wiper+washer, rear wiper and washer, Agrodata, clock/speedometer (15 A) FA4 Front PTO, headlight switch illumination light (5 A) FA5 Direction ind. flashers, reverse buzzer, pneumatic seat (15 A)

Fusebox B FB1 Headlights, pilot light (15 A) FB2 Parking light (10 A) FB3 Horn, trailer socket, front working lights, hazard warning flashers (15 A) (FB4) Autocontrol (5 A) FB5 Starter switch, control stop (15 A)

Fusebox C FC1 Brake lights, cigarette lighter, cabin light (10A) FC2 Rear working lights (15A) FC3 Thermostart (15A) FC4 Left parking light, instrument light, working light switch illumination light (5A) FC5 Right parking light (5 A) (F1C) Radio, AD ---instrument (5A). In the rear part of engine compartment. (F2C) Air conditioning, roof fan (20 A). Under dashboard.

Note! Fuses on 600---900 tractors, see page 310/19.

223

1. 3. 1997

30. Tractor electrical system

Position of electric components on 865 tractor

1. 1. 1998

224

Model

865

Code

310

Page

2B

1. 1. 1998

30. Tractor electrical system

Positions of electrical equipment on 600---900 tractors

15. 4. 1999

225

Model

600, 700 800, 900

Code

310

Page

2C

Model

30. Electrical system

1. 9. 2001

600, 700 800, 900

Code

310

Page

2D

600---900, position of electrical components (with Infoline (L26206---) or Agroline (L22101) ---instrument).

226

15. 9. 1995

30. Tractor electrical system

Position of electrical components on 205---665 tractors

1. 3. 1997

227

Model

205 -- 665

Code

310

Page

3

1. 12. 1986

30. Electric system

1. 9. 1992

Model

305, 405

Code

Page

310

Wiring diagram 305/405 Note! This diagram concerns tractors 305---405 up to serial number 603605. Code C6 A2

Radio (extra equipment)

C2 C2

B1 B2

Sender unit (engine temperature) Sender unit (fuel gauge)

C3 C3 C4 C4 C4 C3 C6 C1 C4 C4 C5 C5 C3 C3 C7

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15

Headlight, right Headlight, left Front direction indicator, right front direction indicator, left Rear light, right Rear ight, left Cab light Thermostart Rear working light, right rear working light, left Front working light, right (extra equipment) front working light, left (extra equipment) Light, combination instrument Light, revolution counter Cigarette lighter (extra equipment)

A2

B1

FA1 Instrument light, warning lamps (engine oil pres--sure and PTO (5 A) FA2 Cab light, cigarette lighter, radio, windscreen wiper return (8 A) FA3 Fan motor, wiper motor and washer pump (8 A) FA4 Brake lights, warning lamp (headlamps (8 A) FA5 Direction indicators (8 A) FA6 Parking light (left), instrument light, control lamp (working lights (8 A) FA7 Parking light, right (8 A) FA8 Working lights, front and rear (8 A) FB1 Dipped beams (8 A) FB2 Full beams (8 A) FB3 Horn, trailer socket and rotating warning beacon (8 A) FB4 Thermostart (16 A)

C1 B1

G1 G2

Battery Alternator

B2 B2 A4 C3 B2 B4 B5

H1 H2 H3 H4 H5 H6 H7

A3 C5

H8 H9

Warning lamp, engine oil pressure Warning lamp, charging Control lamp, direction indicators Control lamp, full beams Control lamp, PTO Control lamp, rear working lights Control lamp front working lights (extra equip --ment) Horn Rotating warning beacon (extra equipment)

A6 A6 A3 A5 B4 B4 B5 B3 B3 A3

C5 A2 A6 A6 A7 B2

H10 H11 H12 H13 H14 H15

Control lamp, rotating warning beacon Control lamp, main beam headlights Control lamp, fan Control lamp, windscreen washer Control lamp, reserve (rear window wiper) Control lamp, differential lock

B1 A4 C5 C4 A3

K1 K2 K3 K4 K5

Auxiliary relay, main switch Direction indicator relay Relay, front working lights (optional) Relay, rear working lights Headlight dipper switch relay

B1 C6 B6 B6

M1 M2 M3 M4

Starter motor Fan motor Windscreen wiper motor Windscreen washer pump

B2 B2 B2 B2

P1 P2 P3 P4

Engine temp gauge Fuel gauge Revolution counter Hour recorder

B6

R1

Series resistor, fan motor (1,2 ohm.)

A1 A6 A6 A2 B4 B5 A4 B1 A3 C2 C2 C2 A3

S1 S4 S5 S7 S8 S9 S10 S12 S13 S14 S15 S17 S18

Ignition switch Switch, windscreen wiper and washer Switch, heater fan Switch, headlights Switch, rear working lights Switch, front working lights (optional) Combination control Starter motor safety switch Brake light switch Switch, control lamp PTO Switch, engine oil pressure Switch, control lamp differential lock Switch, parking brake

X1 X2 X3 X4 X5 X6 X8 X9

Connector, 9---pin (front cab wall, left) Connector, 9---pin (front cab wall, right) Connector, 1---pin (front working lights) Trailer socket, 7---pin Connector, 9---pin (mudguard, right) Connector, 9---pin (mudguard, left) Connector, 9---pin (hazard warning lights) Conector, 1---pin, reserve (rear window wiper)

1 Earth lead (battery) 2 Earth lead (starter motor) 3 Earth lead (instrument panel) 4 Earth lead (rear, right) 5. Earth lead (front working lights)

228

4

1. 7. 1989

30. Electrical system

1. 9. 1995

Wiring diagram B

23 16 26 25 6 31 33 37 7

(with effect from tractor serial number 603606) NOTE: With effect from ser. no. 609977 the hazard warning flasher switch S16 is fitted as standard on Valmet 205---555 tractors. Ref. Sym--- Component no. bol 30 (A2) Radio 9 9

B1 B2

Sender unit (engine temperature) Sender unit (fuel gauge)

12 13 18 17 19 16 36 5 21 20 23 23 14 15 37 14

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 (E11) (E12) E13 E14 (E15) E16

Headlight, right Headlight, left Front direction indicator, left Front direction indicator, right Rear light, right Rear light, left Cab light Thermostart Rear working light, right Rear working light, left Front working light, right Front working light, left Light, combination instrument Light, revolution counter Cigarette lighter Number plate light, (equipment for Norway).

5

FA, FB Fusebox FA1 Instrument light, warning lamps (PTO and en gine oil pressure) (5 A) FA2 Cab ventilator, cab light, radio, cigarette lighter, windscreen wiper return (8 A) FA3 Heater fan, wiper motor and washer pump (8 A) FA4 Brake lights, headlight switch illuminating lamp (8 A) FA5 Direction indicator flashers (8 A) FA6 Left parking lights, instrument light, working light switch illuminating lamp (8 A) FA7 Right parking lights (8 A) FA8 Working lights (16 A) FB1 Dipped beams (8 A) FB2 Main beams, indicator lamp (8 A) FB3 Horn, trailer socket, rotating warning beacon (8A) FB4 Thermostart unit (16 A)

1 2

G1 G2

Battery Generator

6 6 17 12 8 20

H1 H2 H3 H4 H5 H6

Warning lamp, engine oil pressure Control lamp, charging Indicator lamp, direction indicators Indicator lamp, main beam headlights Warning lamp, PTO ---clutch lever Indicator lamp, rear working lights

9 36 32 15

13 12 16

(H 7) H8 (H 9) (H10) H11 H12 H13 (H14) H15

Model

Code

305-- 455

310

Auxiliary relay, starter (main switch) Direction indicator relay Relay, front working lights Relay, rear working lights Headlight dipper switch relay

2 32 35 34

M1 M2 M3 M4

Starter motor Heater fan motor Windscreen wiper Windscreen washer

9 9 10 11

P1 P2 P3 P4

Temperature gauge (engine) Fuel gauge Revolution counter Hour recorder

32

R1

Series resistor, fan motor (1.2 ohm) S 1 Ignition switch S 4 Switch, windscreen wiper and washer S 5 Switch, heater fan motor S 7 Switch, headlights S 8 Switch, rear working lights (S 9) Switch, front working lights S10 Switch, combination control S12 Contact, starter motor safety circuit S13 Brake light contact S14 PTO warning light contact S15 Indicator light switch, engine oil pressure S16 Switch, hazard warning flashers S17 Indicator light switch, differential lock S18 Hand brake contact

X1 X2 X3 19---20 X4 X5 X6 X8 X9 /1 /2 /3 /4 (/5) /6

Connector, 9---pin (front cab wall, left) Connector, 9---pin (front cab wall, right) Connector, 1---pin (front working lights) Trailer socket, 7 pin Connector, 9---pin (mudguard, right) Connector, 9---pin (mudguard, left) Connector, 9---pin (hazard warning flashers) Connector, 1---pin (reserve) Earth lead, battery Earth lead, starter motor Earth lead, instrument panel Earth lead, rear right Earth lead, front working lights Earth lead, cab ventilator

Optional or alternative equipment shown in brackets.

229

5

Indicator lamp, front working lights Horn Rotating warning beacon Indicator lamp, rotating warning beacon Switch light, headlights Switch light, heater fan Switch light, windscreen washer Switch light, reserve Indicator lamp, differential lock

4 K1 18 K2 24 (K3) 22 K4 12---14 K5

2 33---35 30---32 6---9 20---22 22---24 19---22 4 15 8 6 26---29 7 15

Page

15. 4. 1994

30. Electrical system

15. 9. 1995

Wiring diagram C

Code no

(A2) Radio (A4) Speedometer/clock (A6) Agrodata

23

B1 Engine temperature sender unit B2 Fuel gauge sender unit (B8) Wheel sensor (Agrodata)

9 10

E1 Headlight, right E2 Haedlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E7 Cabin light E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left (E15) Cigarette lighter (E16) Number plate light (E17) Raised headlights, right (E18) Raised headlight, left

30 29 37 35 36 34 17 24 24 26 25 18 33 28 27

FA, FB Fuses 5A Instruments, ind.lights, Autocontrol 8A Cab light, cig. lighter, Agrodata 8A Fan, wiper+washer, rear wiper+washer 8A Brake lights, light switch illum. light 8A Direction indicators, reverse buzzer 8A Left parking light, instr. light, illumin. light in working light switch FA7 8A Parking light, right FA8 16A Rear work. lights, rot. warning light, radio,

19

FA1 FA2 FA3 FA4 FA5 FA6

10 18 13 34 38

FB1 8A Dipped beams FB2 8A Full beams, --- indication light FB3 16A Horn, socket, front working lights, hazard warning flashers, Autocontrol FB4 16A Thermostart (FC1)16A Radio, speedometer

29 29

G1 Battery G2 Alternator H1 Warning light, engine oil pressure H2 Control lamp, charging H3 Indicator lamp, direction indicators H4 Indicator lamp, main beam headlights H5 Warning lamp, PTO clutch lever H6 Switch illumin. light, rear working lights (H7) Switch illumin. light, front working lights H8 Horn (H9) Rotating warning light (H10)Switch illuminating light, rot. warning light H11 Switch illuminating light, headlights H12 Switch illuminating lamp, fan H13 Switch illuminating lamp, front wiper (H14)Switch illuminating lamp, rear wiper H15 Indicator lamp, differential lock (H16)Switch illumin. lamp, raised headlights (H17)Reverse buzzer H18 Ind. light, first trailer H19 Ind. light, second trailer

Code

355-- 665

310

Sym--bol Component

Note! This diagram concerns tractors 365, 565 and 665 up to ser. no. 670319 and 55 ---models from cab no. 75192 incl. Diagram no. 31005010D. Sym--bol Component

Model

6

Code no

K1 K2 (K3) K4 K5

Auxiliary relay, starter (ignition switch) Direction indicator relay Relay, front working lights Relay, rear working lights Headlight dipper switch relay

3 39 26 25 29

M1 M2 M3 M4 (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Rear window wiper Rear window washer

2 13 16 15 21 20

P1 P2 P3 P4

Engine temperature gauge Fuel gauge Rev counter Hour recorder

9 10 11 12

(Q2) Main circuit breaker R1

35 36 24

Page

1

Resistance, heating fan (1,2 ohm)

13

S1 Ignition switch (S3) Switch, rear window wiper and washer S4 Switch, windscreen wiper and washer S5 Switch, heater fan (S6) Switch, rotating warning light S7 Switch, headlights S8 Switch, rear working lights (S9) Switch, front working lights S10 Switch, combination control (S11) Toggle switch, raised headlights S12 Contact, starter interlock S13 Brake light contact S14 PTO warning light contact S15 Indicator light switch, engine oil press. S16 Switch, hazard warning flashers S17 Indicator light switch, diff. lock S18 Hand brake contact S19 Contact, reverse light+buzzer (S49) Rocker switch, RPM ---/flow meter (S50) Rocker switch, km/h, tractor/implement

5 20 16 14 22 29 25 27 33 29 3 35 8 6 37 7 35

X1 Connector, 9---pins, engine X2 Connector, 9---pins, engine (X3) Connector, 3---pins, front working lights/ raised headlights X4 Connector, 7---pins, trailer socket 37 X5 Connector, 9---pins, mudguard right X6 Connector, 9---pins, mudquard left (X7) Connector, 3---pins, front work. light relay+switch (X9) Connector, 1---pins, rear wiper (X53) Connector, 7---pins, Agrodata implement socket (X54) Connector, 9---pins, Agrodata sensors

40 5 2 1 4 6 5 39 31 8 26 27 40 23 22 28 14 15 19 7 28

/1 /2 /3 /4 /5

Earth lead, battery Earth lead, cab+headlights (starter) Earth lead, instrument panel Earth lead, rear right Earth lead, front wiper

Note! Autocontrol power lift, see under code 320. Wire color key VA = WHITE HA = GREY KE = YELLOW VI = GREEN

40 40

230

SI = BLUE LI = LILAC PU = RED RU = BROWN MU = BLACK

15. 4. 1994

30. Electric system

15. 9. 1995

Model

355-- 665

Code

310

Page

7

Wiring diagram C 31005010 D

5565--- 1

5565--- 2

231

15. 9. 1995

30. Electric system

1. 3. 1997

Wiring diagram D

This diagram concerns 65 ---models from ser. no. 670320 incl. Diagram no. 31005020B. Sym--bol A1 (A2) (A4) (A6)

Component Current screw, cabin supply Radio Speedometer/clock Agrodata

B1 B2 (B8)

Engine temperature sender unit Fuel gauge sender unit Wheel sensor (Agrodata)

9 10

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 (E11) (E12) (E15) (E16) (E17) (E18)

Headlight, right Headlight, left Front direction indicator, left Front direction indicator, right Rear light, right Rear light, left Cab light Thermostart--- unit Rear working light, right Rear working light, left Front working light, right Front working light, left Cigarette lighter Number plate light Raised headlights, right Raised headlight, left

30 29 37 35 36 34 17 5 25 25 26 26 18 33 28 27

FA, FB, FC Fuses from right to left 5A Instruments, ind.lights, Autocontrol 10A Rotating light, radio 10A Fan, wiper+washer, rear wiper+washer, Agrodata, clock / speedometer FA4 5A Front PTO, light sw. illum. light FA5 10A Direction indicators, back buzzer FB1 15A Dipped beams, high beams, --- indicator light FB2 10A Parking lights FB3 15A Horn, rear socket, front working lights hazard warning flashers (FB4) 5A Autocontrol FB5 15A Starter switch, electric stop FC1 10A Brake lights, cigarette lighter, cabin light FC2 15A Rear working lights FC3 15A Thermostart FC4 5A Parking lights L.H, meter lights, working light switches FC5 5A Parking lights R.H (F1C) 5A Radio FA1 FA2 FA3

Code no 1 23 23 19

10,44 24 13 28 38 29 29 40 42 5 18 25 5 35 36 1

G1 G2

Battery Alternator

1 4

H1 H2 H3 H4 H5 H6 (H7) H8 (H9) (H10) H11 H12 H13 (H14) H15

Warning light, engine oil pressure Control lamp, charging Indicator lamp, direction indicators Indicator lamp, main beam headlights Warning lamp, PTO clutch lever Switch illumin. light, rear working lights Switch illumin. light, front work. lights Horn Rotating warning light Switch illum. light, rot. warning light Switch illuminating light, headlights Switch illuminating lamp, fan Switch illuminating lamp, front wiper Switch illuminating lamp, rear wiper Indicator lamp, differential lock

6 5 39 31 8 26 27 40 24 24 28 14 15 19 7

Model

Code

355-- 665

310

8

Sym--bol (H16) (H17) H18 H19

Component Switch illum. lamp, raised headlights Back buzzer Indicator light, dir.ind. trailer 1 Indicator light, dir.ind. trailer 2

40 40

K1 K2 (K3) K4 K5 K6

Auxiliary relay, starter (ign. switch) Direction indicator relay Relay, front working lights Relay, rear working lights Headlight dipper switch relay Auxiliary relay, starter switch

3 39 26 25 29 6

M1 M2 M3 M4 (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Rear window wiper Rear window washer

2 13 16 15 21 20

P1 P2 P3 P4

Engine temperature gauge Fuel gauge Rev counter Hour recorder

9 10 11 12

(Q2)

Main circuit breaker

1

R1

Resistance, heating fan, 1,2 ohm

13

S1 Ignition switch (S3) Switch, rear w. wiper and washer S4 Switch, windscreen wiper and washer S5 Switch, heater fan (S6) Switch, rotating warning light S7 Switch, headlights S8 Switch, rear working lights (S9) Switch, front working lights S10 Switch, combination control (S11) Toggle switch, raised headlights S12 Safety switch S13 Switch, brake lights S14 PTO warning light contact S15 Indicator light switch, engine oil press. S16 Switch, hazard warning flashers S17 Indicator light switch, diff. lock S18 Hand brake contact (S19) Switch, back light +buzzer (S38) Switch, front PTO (S49) Rocker switch, RPM ---/flow meter (S50) Rocker switch, km/h, tractor/implement

5 20 16 14 24 29 25 27 33 29 3 35 8 6 37 7 35

X1 X2 X4 X5 X6 (X7) (X9) (X10) (X53)

Connector, 9---pins, engine Connector, 9---pins, engine Connector, 7---pins, trailer socket Connector, 9---pins, mudguard right Connector, 9---pins, mudquard left Connector, 2---pins, air condition Connector, 1---pins, rear wiper Connector, 1---pin, supply, air condition Connector, 7---pins, Agrodata implement socket (X54) Connector, 9---pins, Agrodata sensors

232

Page

(Y1) (Y9)

Solenoid, electric stop Solenoid, front PTO

/1 /2 /3 /4 /5 /6

Earth lead, battery Earth lead, cab+headlights (starter) Earth lead, instrument panel Earth lead, rear right Earth lead, front wiper Earth lead, front wall of cabin

Code no 28

22

37

4 22

15. 9. 1995

30. Electric system

1. 3. 1997

Model

355-- 665

Code

310

Page

9

Wiring diagram D 31005020 B 65--- 1

65--- 2

233

15. 9. 1995

30. Electric system

15. 4. 1996

Model

665-- 4 MOD

Code

310

Page

10

Wiring diagram for some special equipment on Valmet 665---4 MOD Note! Earlier electrical system with fuse box of two parts

Sym--bol

Component

(A7)

A/V Warning, loader

(H17)

Back Buzzer

(S19) (S20) (S21)

Switch, back buzzer+lights Pressure switch, loader 180 bar Pressure switch, loader 200 bar

(X8R) (X9R)

12---pole, Nato socket 2---pole, auxiliary start socket

FA3

This wiring diagram and components list are for special equipment on Valmet 665---4 MOD. Concerning other special system of Valmet 665---4 MOD, see pages 310/1 ---9).

234

15. 9. 1995

30. Electric system

15. 4. 1996

Model

665-- 4 MOD

Code

Page

310

11

Wiring diagram for some special equipment on Valmet 665---4 MOD Note! Later electrical system with fuse box of three parts. This wiring diagram and component list are for special equipment on Valmet 665---4 MOD. Concerning other electrical system of Valmet 665---4 MOD, see pages 310/1 ---9. A1R Current screw A7 A/V Warning, loader

2 49

F1

80 A Main fuse

H1 H2 H3 H17 H18

Led, green, A/V Warning Led, yellow, A/V Warning Led, red, A/V Warning Back Buzzer Buzzer, A/V Warning

K7

2 49 49 49 47 49

Relay, horn

50

S19 Switch, back buzzer + lights S20 Pressure switch, loader 155 bar S21 Pressure switch, loader 175 bar

47 49 49

X8R 12---pole, Nato socket X9R 2---pole, auxiliary start socket

48 2

F1C fuse not mounted in 665---4 MOD ---models. 31005020 B

A

665MOD--- 7

F1

The main fuse (F1) is situated under the instrument panel. For checking it, loosen the front shield (A) of the instrument panel.

235

Model

30. Electric system

15. 4. 1996

665-- 4 MOD

Code

Page

310

12

Front loader overloading indicator Function The Green Light:

The Yellow Light:

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

When this light is illuminated the operating conditions are becoming unstable. The load should not be raised any further. Take extreme care. The buzzer gives sound on later tractors.

The Red Light and the Alarm signal: When the red light is illuminated and the horn is sounding, the load is in a dangerous situation. All operations must be ceased and the load slowly lowered. Operating in these conditions is very dangerous.

Setting specifications Yellow light:

Red light:

The yellow light is illuminated when the Hydraulic pressure exceeds 155 bar ( -- 10 bar) (earlier 180 bar ( -- 10 bar)) in the lift cylinders. Also buzzer alarms

The red light and the horn operated when the pressure is over 175 bar ( -- 10 bar) (earlier 200 bar ( -- 10 bar)) in the lift cylinders.

How to calibrate the front load overloading indicator lights Place a suitable pressure gauge into the lift cylinder line. Increase the load on the loader until the pressure rises to 155 bar (earlier 180 bar). The yellow light must be illuminated and the buzzer must aralm when the pressure is 145---155 bar (earlier 170---180 bar) . The yellow light will go off when the pressure drops by approx. 30 bar. The pressure limiting screw in the end of the pressure switch can be adjusted in order to give these readings. The red light must be illuminating and the horn must be sounding when the pressure is 165-- 175 bar (earlier 190---200 bar). After adjusting the pressure switches recheck the functions of the overload indicator.

236

1. 1. 1998

30. Tractor electrical system Wiring diagram 865

1. 6. 1998

(No 33202000)

Note! Also 600---900: H06401 ---H06508. Sym--bol Component

Code no

A1 (A2) (A3) (A5)

Current screw, cabin supply Radio Control unit, front PTO Pneumatic seat

1 38 22 32

B1 B2 (B3) (B6)

Engine temperature sender unit Fuel gauge sender unit Gearbox temperature sender unit*) Sensor, gearbox speed*)

8, 59 9 49 47

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 (E11) (E12) E13 (E15) (E16) (E17) (E18) (E19) (E22)

Headlight, right Headlight, left Front direction indicator, right Front direction indicator, left Rear light, right Rear light, left Cab light Thermostart---unit Rear working light, right Rear working light, left Front working light, right Front working light, left Instrument light Cigarette lighter Number plate light Raised headlights, right Raised headlights, left Rear fog light Roof panel light

30 29 36 35 37 34 18 4 25 25 26 26 8, 10 16 34 28 27 52 57

Fuse box (From right to left) FA1 FA2 FA3 FA4 FA5

5A Instruments, ind. light, Autocontrol *) 10A Rotating light, radio 15A Fan, wiper+washer rear wiper+washer, Agrodata 5A Front PTO, light sw. illum. light 15A Direction ind., back buzzer, pneum. seat

9, 44 24 12 28 38, 58

FB1 FB2 FB3

15A Dipped beams, high beams, ---ind. light 29 10A Parking lights 29 15A Horn, rear socket, front working lights hazard warning flashers 40 (FB4) 5A Autocontrol 43 FB5 15A Starter switch, control stop 3, 52, 60 FC1 FC2 FC3 FC4

10A Brake lights, cig. lighter, cab light 15A Rear working lights 15A Thermostart 5A Parking lights L.H, meter lights, working light switches FC5 5A Parking lights R.H. (F1C) 5A Radio, (Clock*)) (F2C) 20A Air conditioner, roof fan

17 25 4 35 36 1 56

G1 G2

Battery Alternator

1 3

H1 H2 H3 H4 H5 H6 (H7) H11

Ind. lamp, direction ind. flashers III Ind. lamp, direction ind. flashers II Ind. lamp, direction ind. flashers Warning light, engine air filter Warning light, engine oil pressure Warning light, Stop, engine temperature Warning light, gearbox oil pressure Warning light, parking brake

40 39 39 6 7 7, 59 9

237

Model

865

Code

Page

310

13

Sym--bol Component

Code no

(H12) H13 H14 H15 H16 H20 H23 (H24) (H27)

Warning light, Thermostart *) Warning light, PTO clutch Warning light, main beams Warning light, low fuel level Warning light, charging Warning light, differential lock Horn Rotating warning light Back buzzer

5 6 31 9 4 5 40 24 58

K1 K2 (K3) K4 K5 K6 (K7) (K8) (K18)

Auxiliary relay, starter (ign. switch) Direction indicator relay Relay, front working lights Relay, rear working lights Headlight dipper switch relay Auxiliary relay, starter switch Relay, rear fog light Relay, roof fan, III speed Relay, control stop

2 39 26 26 29 4 52 56 60

M1 M2 M3 M4 (M5) (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Roof fan Rear window wiper Rear window washer

2 12 15 14 55 20 19

P1 P2 P3 P4 (P5)

Engine temperature gauge Fuel gauge Rev counter Hour recorder/AC (.../Speed*)) Clock, AC, Dist., Gearbox temp*)

8 9 10 11 47

(Q2)

Main circuit breaker

1

R1

Resistance, heating fan, 1,2 ohm

12

S1 (S2) (S3) S4 S5 (S6) S7 S8 (S9) S10 (S11) S12 S13 S14 S15 S16 S17 S18 (S19) S20 S21 (S22) (S23) (S26) (S36) (S37) (S38) (S42) (S43)

Ignition switch Switch, roof fan Switch, rear w. wiper and washer Switch, windscreen wiper and washer Switch heater fan Switch, rotating warning light Switch, headlights Switch, rear working lights Switch, front working lights Switch, combination control Toggle switch, raised headlights Safety switch Switch, brake lights PTO warning light contact Ind. light switch, engine oil pressure Switch, hazard warning flashers Indicator light switch, diff. lock Hand brake contact Switch, back buzzer Warning light switch, engine temp, Stop Warning light switch, engine air filter Switch, air conditioner Switch, compressor pressure Switch, rear fog light Switch, control stop Switch, cursor+program *) Switch, front PTO Door switch, cab light, right Door switch, cab light, left

2, 60 55 18 15 13 23 29 25 27 32 29 2 35 6 7 36 6 35 58 8, 56 6 54 54 51 61 47 22 18 18

1. 5. 1996

30. Tractor electrical system

1. 1. 1998 Wire colours

X1 X2 X4 X5 X6 (X7) (X8) (X9) (X10) (X15) X20 (X22) (X25) (X26) X27 (X44) (X49) (X56)

Connector, 9---pins, engine Connector, 9---pins, engine Connector, 7---pins, trailer socket Connector, 9---pins, mudguard right Connector, 9---pins, mudguard left Connector, 2---pins, air condition Connector, current socket Connector, 1---pins, rear wiper Connector, 1---pin, supply, air condition Connector, 3---pins, air conditioner, diodes Connector, 9---pins, front direction ind. Connector, 2 pins, rotating warn. light Connector, 9---pins, AD ---instrument Connector, 26 pins, Instrument white Connector, 26---pins, instrument blue Connector, 1 pin, control stop Connector, 2---pins, pneumatic seat Connector, 1 pin, Gearbox oil pressure

59 32 48

(Y1) (Y5) (Y9)

Solenoid, electric stop Magnetic clutch, compressor Solenoid, front PTO

5, 60 54 22

GR1 GR2 GR3 GR4 GR5 GR6

Earth lead, battery Earth lead, headlights (starter) Earth lead, wiring assy, instrument panel Earth lead, rear / right Earth lead, roof of cab Earth lead, cab front wall

Ru = brown Pu = red Ke = yellow Si = blue Mu = black Vi = green Va = white Ha = grey Li = lilac

37, 53

53 17 56 54

*) AD ---instrument Note! Autocontrol power lift, see page 320/3C.

238

Model

Code

Page

865

310

14

1. 3. 1997

30. Tractor electrical system

1. 1. 1998

Model

865

Code

Page

310

15

Wiring diagram 865 33202000

865

865

239

1. 5. 1996

30. Tractor eletrical system

1. 1. 1998

Model

865

Code

310 865

240

Page

16

Model

30. Tractor electrical system

1. 3. 1997

865

Code

310

Page

17

Control stop

Picture. Wiring diagram of control stop (option, 865) S1=Ignition switch S36=Control stop switch in the dashboard Y1=Fuel distributor pump stop solenoid K18=Control stop relay (under the dashboard) S15=Engine oil pressure sensor S20=Engine coolant temperature sensor H5=Warning light, engine oil pressure H6=Central warning light, Stop S10=Combination switch S16=Switch for hazard warning flashers K2=Direction indicator relay GR3=Earth terminal in the cab front wall

Note! The Stop ---light wire must be equipped with a diode. Otherwise, when the driver uses the direction indicator lever S4 or hazard warning flashers, relay K18 becomes earthed via bulbs E3---E6 causing the engine stop. The diode is in ---built in the instrument. The engine oil pressure sensor is fitted on the RH side of the engine and the temperature sensor on the engine beside the thermostat housing.

Testing the function

Function

The function of the control stop can be tested while the engine is running and switch S36 in the ON position. When a wire of one of the sensors S15 or S20 is connected to the tractor frame, the warning light must come on and the engine must stop. Stop light flashes, when the engine temperature sensor becomes earthed.

When switch S36 is in the OFF position (in picture), current can affect the solenoid Y1 when the starter switch is turned to the starting position and the engine can be started (engine does not start, if the switch is in the ON position). When the switch S36 is turned ON, current flows to the solenoid Y1 via relay K18. If one of the sensors S15 or S20 becomes grounded, the relay K18 breaks the circuit and the engine stops. Warning lights illuminate normally (also stop ---light flashes).

241

Model

30. Tractor electrical system

1. 1. 1998

242

600, 700 800, 900

Code

310

Page

18

1. 1. 1998

30. Tractor electrical system

1. 6. 1998

Model

600, 700 800, 900

Code

Page

310

19

Wiring diagram, 600---900 (No 33202000C) H06206-- (except H06401-- H06508) Sym--bol Component

Code no

A1 (A2) (A3) (A5)

Current screw, cabin supply Radio Control unit, front PTO Pneumatic seat

1 38 22 32

B1 B2 (B3) (B6)

Engine temperature sender unit Fuel gauge sender unit Gearbox temperature sender unit*) Sensor, gearbox speed*)

8, 59 9 49 47

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 (E11) (E12) E13 (E15) (E16) (E17) (E18) (E19) (E22)

Headlight, right Headlight, left Front direction indicator, right Front direction indicator, left Rear light, right Rear light, left Cab light Thermostart---unit Rear working light, right Rear working light, left Front working light, right Front working light, left Instrument light Cigarette lighter Number plate light Raised headlights, right Raised headlights, left Rear fog light Roof panel light

30 29 36 35 37 34 18 4 25 25 26 26 8, 10 16 34 28 27 52 57

Fuse box (From left to right) FA1 FA2 FA3 FA4 FA5

5A Instruments, ind. light, Autocontrol 10A Rotating light, radio 15A Wiper+washer, rear wiper+washer 5A Front PTO, light sw. illum. light, current socket 15A Direction ind., back buzzer, pneum. seat, roof fan I --- and II ---speed.

9, 44 24 12 28 38, 58

FB1 FB2 FB3

15A Dipped beams, high beams, ---ind. light 29 10A Parking lights 29 15A Horn, rear socket, front working lights hazard warning flashers 40 (FB4) 5A Autocontrol 43 FB5 15A Starter switch, elecric stop, rear fog light 3, 52, 60 FC1 FC2 FC3 FC4 FC5

10A Brake lights, cig. lighter, cab light 15A Rear working lights 15A Thermostart 5A Parking lights L.H, meter lights, working light switches 5A Parking lights R.H.

17 25 4 35 36

FD1 FD2 FD3 FD4 FD5

10A Fan 20A Air conditioning, upper fan III ---speed 10A Hi ---Shift 25A Current socket 5A Radio, (Clock*))

12 56 62---63 64 1

G1 G2

Battery Alternator

1 3

H1 H2

Ind. lamp, direction ind. flashers III Ind. lamp, direction ind. flashers II

40 39

243

Sym--bol Component

Code no

H3 H4 H5 H6 (H7) H11 (H12) H13 H14 H15 H16 H20 H23 (H24) (H27)

Ind. lamp, direction ind. flashers Warning light, engine air filter Warning light, engine oil pressure Warning light, Stop, engine temperature Warning light, gearbox oil pressure Warning light, parking brake Warning light, Thermostart Warning light, PTO clutch Warning light, main beams Warning light, low fuel level Warning light, charging Warning light, differential lock Horn Rotating warning light Back buzzer

39 6 7 7, 59

K1 K2 (K3) K4 K5 K6 (K7) (K8) K9 (K18) (K24)

Auxiliary relay, starter (ign. switch) Direction indicator relay Relay, front working lights Relay, rear working lights Headlight dipper switch relay Auxiliary relay, starter switch Relay, rear fog light Relay, roof fan, III speed Auxiliary relay, starter switch Relay, control stop Relay, Hi ---Shift

2 39 26 26 29 6 52 56 6 60 63

M1 M2 M3 M4 (M5) (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Roof fan Rear window wiper Rear window washer

2 12 15 14 55 20 19

P1 P2 P3 P4 (P5)

Engine temperature gauge Fuel gauge Rev counter Hour recorder/AC (.../Speed*)) Clock, AC, Dist., Gearbox temp*)

8 9 10 11 47

(Q2)

Main circuit breaker

1

R1

Resistance, heating fan, 1,2 ohm

12

S1 (S2) (S3) S4 S5 (S6) S7 S8 (S9) S10 (S11) S12 S13 S14 S15 S16 S17

Ignition switch Switch, roof fan Switch, rear w. wiper and washer Switch, windscreen wiper and washer Switch heater fan Switch, rotating warning light Switch, headlights Switch, rear working lights Switch, front working lights Switch, combination control Toggle switch, raised headlights Safety switch Switch, brake lights PTO warning light contact Ind. light switch, engine oil pressure Switch, hazard warning flashers Indicator light switch, diff. lock

2, 60 55 18 15 13 23 29 25 27 32 29 2 35 6 7 36 6

9 5 6 31 9 4 5 40 24 58

Model

30. Tractor electrical system

1. 1. 1998 Wire colours

Sym--bol Component

Code no

S18 Hand brake contact (S19) Switch, back buzzer S20 Warning light switch, engine temp, Stop S21 Warning light switch, engine air filter (S22) Switch, air conditioner (S23) Switch, compressor pressure (S26) Switch, rear fog light (S36) Switch, control stop (S37) Switch, cursor+program *) (S38) Switch, front PTO (S42) Door switch, cab light, right (S43) Door switch, cab light, left (S45) Switches, Hi ---Shift (S45.1) Extra switches, Hi ---Shift

35 58 8, 56 6 54 54 51 61 47 22 18 18 62---63 62

X1 X2 X4 X5 X6 (X7) (X8) (X9) (X15) X20 (X22) X25 X26 X27 (X44) (X49) X50

Connector, 37---pins, engine Connector, 9---pins, head lights Connector, 7---pins, trailer socket Connector, 9---pins, mudguard right Connector, 9---pins, mudguard left Connector, 4---pins, air conditioner Connector, current socket Connector, 1---pins, rear wiper Connector, 3---pins, air conditioner, diodes Connector, 9---pins, front direction ind. Connector, 2 pins, rotating warn. light Connector, 9---pins, AD ---instrument Connector, 26 pins, Instrument white Connector, 26---pins, instrument blue Connector, 1 pin, control stop Connector, 2---pins, pneumatic seat Connector, 3---pin, current socket

59 32 64

(Y1) (Y5) (Y9) (Y14) (Y15)

Solenoid, electric stop Magnetic clutch, compressor Solenoid, front PTO Solenoid valve, Hi ---Shift Solenoid valve, Hi ---Shift, retardation

5, 60 54 22 62 63

GR1 GR2 GR3 GR4 GR5 GR6

Earth lead, battery Earth lead, headlights (starter) Earth lead, wire loom, instrument panel Earth lead, rear / right Earth lead, roof of cab Earth lead, cab front wall

Ru = brown Pu = red Ke = yellow Si = blue Mu = black Vi = green Va = white Ha = grey Li = lilac

29---30 37, 53

38 17 54

*) AD ---instrument Note! Autocontrol power lift, see page 320/3C.

244

600, 700 800, 900

Code

310

Page

20

Model

30. Tractor electrical system

1. 1. 1998

Wiring Diagram 600---900

600, 700 800, 900

Code

310

Page

21

33202000C 600--- 900.1

600--- 900.2

245

Model

30. Tractor electrical system

1. 1. 1998

600, 700 800, 900

Code

310

Page

22 600--- 900.3

600--- 900.4

246

15. 4. 1999

30. Tractor eletrical system Wiring diagram 600---900

1. 9. 2001

tors with ACB power lift.

A1 (A2) (A3) (A5)

Current screw, cabin supply Radio Control unit, front PTO Pneumatic seat

B1 B2 (B3) (B6)

Engine temperature sender unit Fuel gauge sender unit Gearbox temp sender unit* Sensor, gearbox speed*

E1 Headlight, right E2 Headlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E7 Cab light E8 Thermostart---unit E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left E13 Instrument light (E15) Cigarette lighter (E16) Number plate light (E17) Raised headlights, right (E18) Raised headlights, left (E19) Rear fog light (E22) Roof panel light

1 38 22 32 8, 59 9 49 47 30 29 36 35 37 34 18 4 25 25 26 26 8, 10 16 34 28 27 52 57

Fuse box (from left to right) 0. 0. 5A Instruments, ind. light, Autocontrol 9, 44 10A Rotating light, radio 24 15A Wiper+washer, rear wiper+washer 12 5A Front PTO, light sw. illum. light, current socket 28 15A Direction ind., back buzzer, pneum. seat, 38, 58

FB1 FB2 FB3 FB4 FB5

25A Light switch 29 10A Dipped beams 29 15A Main beams, pilot light 29 5A Autocontrol 43 20A Starter switch, eletric stop, rear fog light control stop 3, 52, 60

G1 Battery G2 Alternator H1 H2 H3 H4

Ind. lamp, direction indicator flashers III Ind. lamp, direction indicator flashers II Ind. lamp, direction indicator flashers Warning light, engine air filter

310

40 39 39 6

247

Code no 7 7, 59 9 5 6 31 9 4 5 40 24 58

M1 M2 M3 M4 (M5) (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Roof fan Rear window wiper Rear window washer

2 12 15 14 55 20 19

P1 P2 P3 P4 (P5)

Engine temperature gauge Fuel gauge Rev counter Hour recorder/AC (.../Speed*) Clock, AC, Dist., Gearbox temp*

8 9 10 11 47

Resistance, heating fan 1,2 ohm

S1 Ignition switch (S2) Switch, roof fan (S3) Switch, rear w. wiper and washer S4 Switch, windscreen wiper and washer S5 Switch, heater fan (S6) Switch, rotating warning light S7 Switch, headlights S8 Switch, rear working lights (S9) Switch, front working lights S10 Switch, combination control (S11) Toggle switch, raised headlights S12 Safety switch S13 Switch, brake lights S14 PTO warning light contact S15 Ind. light switch, engine oil pressure S16 Switch, hazard warning flashers S17 Ind. light switch, diff. lock S18 Ind. lamp, hand brake (S19) Switch, back buzzer S20 Warning light switch, engine temp, (Stop) S21 Warning light switch, engine air filter (S22) Switch, air conditioning (S23) Switch, compressor pressure (S26) Switch, rear fog light (S36) Switch, control stop (option in 800 and 900) (S37) Switch, cursor+program *

1 3

23

2 39 26 26 29 5 52 56 6 60 63

R1

12 56 62---63 64 1

Page

K1 Auxiliary relay, starter (ign. switch) K2 Direction indicator relay (K3) Relay, front working light K4 Relay, rear working lights K5 Headlight dipper switch relay K6 Auxiliary relay, starter switch (K7) Relay, rear fog light (K8) Relay, roof fan , III speed K9 Auxiliary relay, starter switch (K18) Relay, control stop (K24) Relay, HiShift

(Q2) Main circuit breaker

FC1 10A Brake lights, cig. lighter, cab light 17 FC2 15A Rear working lights 25 FC3 15A Horn, rear socket, front working lights, hazard warning flashers 40 FC4 5A Parking lights LH, meter lights, working lights switches 35 FC5 5A Parking lights RH 36 FD1 20A Fan, roof fan I and II speeds, air conditioning FD2 20A Upper fan III speed FD3 10A HiShift FD4 25A Current socket FD5 5A Radio, (clock*)

Code

H5 Warning light, engine oil pressure H6 Warning light, Stop, engine temperature (H7) Warning light, gearbox oil pressure H11 Warning light, parking brake H12 Warning light, Thermostart H13 Warning light, PTO clutch H14 Warning light, main beams H15 Warning light, low fuel level H16 Warning light, charging H20 Warning light, differential lock H23 Horn (H24)Rotating warning light (H27)Back buzzer

Code no

FA1 FA2 FA3 FA4 FA5

600, 700 800, 900

Sym--bol Component

(No 33202000F), trac-

Sym--bol Component

Model

1 12 2, 60 55 18 15 13 23 29 25 27 32 29 2 35 6 7 36 6 35 58 8, 59 6 54 54 51 61 47

15. 4. 1999

30. Tractor eletrical system Sym--bol Component

1. 9. 2001 Wire colours

Code no

(S38) Swtch, front PTO (S42) Door switch, cab light, right (S43) Door switch, cab light, left (S45) Switches, HiShift (S45.1)Extra switches, HiShift

22 18 18 62---63 62

(V5) Diodit, HiShift

62---63

VA = white HA = grey KE = yellow VI = green SI = blue LI = lilac PU = red RU = brown MU = black

Connectors X1 Connector, 37 pins, engine X2 Connector, 9 pins, head lights X4 Connector, 7 pins, trailer socket X4.1 Connector, 3 pins, rear socket X4.2 Connector, 3 pins, rear socket X5 Connector, 9 pins, mudguard right X6 Connector, 9 pins, mudguard left (X7) Connector, 4 pins, air conditioning (X8) Connector, 2 pins, current socket (X9) Connector, 1 pin, rear wiper (X15) Connector, 3 pin, air conditioning, diodes X20 Connector, 9 pins, front direction ind. (X22) Connector, 2 pins, rotating warning light X25 Connector, 9 pins, A ---instrument X26 Conector, 26 pins, instrument white X27 Connector, 26 pins, instrument blue (X44) Connector, 1 pin, control stop (X49) Connector, 2 pins, pneumatic seat X50 Connector, 3 pins, current socket X51 Connector, 1 pin, reversing buzzer (Y1) Solenoid,electric stop (800, 900) (Y5) Magnetic clutch, compressor (Y9) Solenoid, front PTO (Y14) Solenoid valve, HiShift (Y15) Solenoid valve, HiShift, retardation

29---30 37, 53 37, 53 37, 53

38 17 54

59 32 64 5, 60 54 22 62 63

Earth points GR1 GR2 GR3 GR4 GR5 GR6

Earth cable, Battery Earth cable, headlights (starter) Earth cable, wire loom, instrument panel Earth cable, rear/right Earth cable, roof of cab Earth cable, cab front wall

*) AD ---instrument

47---49

AC power lift, see code 320. ACB power lift, see code 321. Note! Electric stop is a standard equipment on models 800 and 900. Electric stop is not available as an option. Control stop is an option in models 800 and 900.

248

Model

600, 700 800, 900

Code

310

Page

24

15. 4. 1999

30. Tractor electric system

1. 9. 2001

33202000F

249

Model

600, 700 800, 900

Code

310

Page

25

Model

30. Tractor electrical system

15. 4. 1999

250

600, 700 800, 900

Code

310

Page

26

Model

30. Tractor electrical system

1. 9. 2001

(No 33202000H) (incl. e.g. electric main current switch, PTO ---HiShift)

A1 (A2) (A3) (A5)

Current screw, cabin supply Radio Control unit, front PTO Pneumatic seat

B1 B2 (B3) (B6)

Engine temperature sender unit Fuel gauge sender unit Gearbox temp sender unit* Sensor, gearbox speed*

E1 Headlight, right E2 Headlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E7 Cab light E8 Thermostart---unit E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left E13 Instrument light (E15) Cigarette lighter (E16) Number plate light (E17) Raised headlights, right (E18) Raised headlights, left (E19) Rear fog light (E22) Roof panel light

1 38 22 32 8, 59 9 49 47 30 29 36 35 37 34 18 4 25 25 26 26 8, 10 16 34 28 27 52 57

FA1 FA2 FA3 FA4 FA5

5A Instruments, ind. light, Autocontrol 9, 44 10A Rotating light, radio 24 15A Wiper+washer, rear wiper+washer 12 5A Front PTO, light sw. illum. light, current socket 28 15A Direction ind., back buzzer, pneum. seat, 38, 58

FB1 FB2 FB3 FB4 FB5

25A Light switch 29 10A Dipped beams 29 15A Main beams, pilot light 29 5A Autocontrol 43 20A Starter switch, eletric stop, rear fog light control stop 3, 52, 60

Ind. lamp, direction indicator flashers III Ind. lamp, direction indicator flashers II Ind. lamp, direction indicator flashers Warning light, engine air filter

40 39 39 6

251

Code no 7 7, 59 9 5 6 31 9 4 5 40 24 58

M1 M2 M3 M4 (M5) (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Roof fan Rear window wiper Rear window washer

2 12 15 14 55 20 19

P1 P2 P3 P4 (P5)

Engine temperature gauge Fuel gauge Rev counter Hour recorder/AC (.../Speed*) Clock, AC, Dist., Gearbox temp*

8 9 10 11 47

Resistance, heating fan 1,2 ohm

S1 Ignition switch (S2) Switch, roof fan (S3) Switch, rear w. wiper and washer S4 Switch, windscreen wiper and washer S5 Switch, heater fan (S6) Switch, rotating warning light S7 Switch, headlights S8 Switch, rear working lights (S9) Switch, front working lights S10 Switch, combination control (S11) Toggle switch, raised headlights S12 Safety switch S13 Switch, brake lights S14 PTO warning light contact S15 Ind. light switch, engine oil pressure S16 Switch, hazard warning flashers S17 Ind. light switch, diff. lock S18 Ind. lamp, hand brake (S19) Switch, back buzzer S20 Warning light switch, engine temp, (Stop) S21 Warning light switch, engine air filter (S22) Switch, air conditioning (S23) Switch, compressor pressure (S26) Switch, rear fog light (S36) Switch, control stop (S37) Switch, cursor+program *

1 3

27

2 39 26 26 29 5 52 56 6 60 63 65 69

R1

FD1 20A Fan, roof fan I and II speeds, air conditioning 12 FD2 20A Upper fan III speed 56 FD3 10A HiShift 62---63 FD4 25A Current socket 64 FD5 5A Radio, (clock*) 1 In engine compartment: (F51) 15 A electrically controlled main current switch 1

Page

K1 Auxiliary relay, starter (ign. switch) K2 Direction indicator relay (K3) Relay, front working light K4 Relay, rear working lights K5 Headlight dipper switch relay K6 Auxiliary relay, starter switch (K7) Relay, rear fog light (K8) Relay, roof fan , III speed K9 Auxiliary relay, starter switch (K18) Relay, control stop (K24) Relay, HiShift (K25) Relay, starter interlock, PTO ---HiShift (K51) Relay, pilot light, main current switch

(Q2) Main circuit breaker

FC1 10A Brake lights, cig. lighter, cab light 17 FC2 15A Rear working lights 25 FC3 15A Horn, rear socket, front working lights, hazard warning flashers 40 FC4 5A Parking lights LH, meter lights, working lights switches 35 FC5 5A Parking lights RH 36

H1 H2 H3 H4

310

H5 Warning light, engine oil pressure H6 Warning light, Stop, engine temperature (H7) Warning light, gearbox oil pressure H11 Warning light, parking brake H12 Warning light, Thermostart H13 Warning light, PTO clutch H14 Warning light, main beams H15 Warning light, low fuel level H16 Warning light, charging H20 Warning light, differential lock H23 Horn (H24)Rotating warning light (H27)Back buzzer

Code no

Fuse box (from left to right) 0. 0.

G1 Battery G2 Alternator

Code

Sym--bole Component

Wiring diagram 600---900 Sym--bole Component

600, 700 800, 900

1 12 2, 60 55 18 15 13 23 29 25 27 32 29 2 35 6 7 36 6 35 58 8, 59 6 54 54 51 61 47

Model

30. Tractor electrical system Sym--bole Component

1. 9. 2001

22 18 18 62---63 62 67 66

(V5) Diodes, HiShift (V6) Diodes, PTO ---HiShift

62---63 65---66

Connectors X1 Connector, 37 pins, engine X2 Connector, 9 pins, head lights X4 Connector, 7 pins, trailer socket X4.1 Connector, 3 pins, rear socket X4.2 Connector, 3 pins, rear socket X5 Connector, 9 pins, mudguard right X6 Connector, 9 pins, mudguard left (X7) Connector, 4 pins, air conditioning (X8) Connector, 2 pins, current socket (X9) Connector, 1 pin, rear wiper (X15) Connector, 3 pin, air conditioning, diodes X20 Connector, 9 pins, front direction ind. (X22) Connector, 2 pins, rotating warning light X25 Connector, 9 pins, A ---instrument X26 Conector, 26 pins, instrument white X27 Connector, 26 pins, instrument blue (X42) Connector, 4 pins, frontPTO supply (X44) Connector, 1 pin, control stop (X49) Connector, 2 pins, pneumatic seat X50 Connector, 3 pins, current socket X51 Connector, 1 pin, reversing buzzer (Y1) Solenoid,electric stop (800, 900) (Y5) Magnetic clutch, compressor (Y9) Solenoid, front PTO (Y14) Solenoid valve, HiShift (Y15) Solenoid valve, HiShift, retardation (Y16) Solenoid valve, PTO ---HiShift (Y17) Solenoid, PTO ---HiShift, retarding

29---30 37, 53 37, 53 37, 53

38 17 54

22 59 32 64

28

Sym--bole Component

Code no

A1E ACB control unit A2E Control switch circuit card

42-- 44 45

B1E Position sensor B2E Draft sensor

41 41

E1E Illumination, switch circuit card E2E Illumination, position potentiometer

45 46

R1E Potentiometer, position control

45

S1E Push button, mudguard, lifting, right S2E Push button, mudguard, lowering, right S3E Push button, mudguard, lifting, left S4E Push button, mudguard, lowering, left S5E Switch, cabin, lifting/lowering S7E Selector, lowering speed S8E Selector, transport height S9E Selector, position control/draft control S10E Switch, lift/stop/lowering S11E Switch, forced lowering S12E Switch, oscillation damping (DBC)

43 43 42 42 44 45 45 45 45-- 46 44-- 45 45

X2E Connector, 9 pins, supply & rear buttons

42

Y1E Solenoid valve, lowering Y2E Solenoid valve, lifting

41 41

VA = white HA = grey KE = yellow VI = green SI = blue LI = lilac PU = red RU = brown MU = black

5, 60 54 22 62 63 65 66

Note! Electric stop is a standard equipment on models 800 and 900. Electric stop is not available as an option. Control stop is an option in models 800 and 900.

Earth cable, Battery Earth cable, headlights (starter) Earth cable, wire loom, instrument panel Earth cable, rear/right Earth cable, roof of cab Earth cable, cab front wall

*) AD ---instrument

310

Page

Wire colours

Earth points GR1 GR2 GR3 GR4 GR5 GR6

Code

ACB Autocontrol nostolaite

Code no

(S38) Swtch, front PTO S42 Door switch, cab light, right S43 Door switch, cab light, left (S45) Switches, HiShift (S45.1)Extra switches, HiShift (S68) Switch, electric main circuit breaker (S69) Switch, PTO ---HiShift

600, 700 800, 900

47---49

252

Model

30. Tractor electrical system

1. 9. 2001

600, 700 800, 900

Code

310

Page

29

33202000H

69--- 1H

69--- 2H

253

Model

30. Tractor electrical system

1. 9. 2001

600, 700 800, 900

Code

310

Page

30

69--- 3H

69--- 4H

254

Model

30. Tractor electrical system

1. 9. 2001

600, 700 800, 900

Code

310

Page

31

69--- 5H

255

256

Model

30. Tractor electrical system

1. 9. 2001

(No 33202000K) (Incl. e.g. Infoline (L26206---) and Agroline (L22101---) instruments) Optional or alternative equipment listed in brackets.

Current screw, cabin supply Radio Controller, front PTO Air suspension seat

B1 B2 (B3) (B6)

Sensor, engine temperature gauge Sensor, fuel gauge Sensor, gearbox temperature* Sensor, gearbox*

1 38 22 32 8, 59 9 49 47

E1 Headlight, right E2 Headlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E7 Cab light E8 Thermostart E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left E13 Instrumentation lights (E15) Cigarette lighter (E16) Number plate light (E17) Raised headlights, right (E18) Raised headlight, left (E19) Fog light, rear (E22) Lights on roof console

FA, FB, FC, FD Fuses

30 29 36 35 37 34 18 4 25 25 26 26 8, 10 16 34 28 27 52 57

1.

FA1 5A Instruments, ind.lights, Autocontrol fuel gauge FA2 10A Rot. warning light FA3 15A Wiper+washer, rear wiper+washer FA4 5A Front PTO, light switch illum. light, current socket FA5 15A Direction indicators, reverse buzzer, air suspen. seat, hazard warning flashers FB1 FB2 FB3 FB4 FB5

25A Light switch 15A Dipped beams 15A Full beams, ---indication light 5A Autocontrol 20A Starter switch, electric---stop, rear fog light, control stop, thermostart

9, 44 24 12 28 38, 58 29 29 29 43

FD1 20A Fan (FD2)20A Air ---conditioner, upper fan III-speed FD3 10A HiShift, PTO ---HiShift, radio FD4 25A Current socket FD5 5A Radio, (clock*), light alarm buzzer

40 35 36

12 56 62---63 64 1

G1 Battery G2 Alternator

70 1 3

257

Code no 40 39 6 7 7, 59 9 5 6 31 9 4, 68 5 40 24 58 4 39 35 2 39 26 26 29 5 52 56 6 60 63 65 69

M1 M2 M3 M4 (M5) (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Roof fan Rear window wiper Rear window washer

2 12 15 14 55 20 19

P1 P2 P3 P4 (P5)

Engine temperature gauge Fuel gauge Rev counter Hour recorder/AC (.../speed*) Clock, AC, trip, gearbox oil temperature*

8 9 10 11 47

Resistance, heating fan 1,2 ohm

S1 Ignition switch (S2) Switch, roof fan (S3) Switch, rear window wiper and washer S4 Switch, windscreen wiper and washer S5 Switch, heater fan (S6) Switch, rotating warning light S7 Switch, headlights S8 Switch, rear working lights (S9) Switch, front working lights S10 Combined switch (S11) Toggle switch, raised headlights S12 Contact, starter interlock S13 Brake light contact S14 PTO warning light contact S15 Indicator light switch, engine oil press. S16 Switch, hazard warning flashers

17 25

33

K1 Auxiliary relay, starter (ignition switch) K2 Direction indicator relay (K3) Relay, front working lights K4 Relay, rear working lights K5 Headlight dipper switch relay K6 Auxiliary relay, starter switch (K7) Relay, rear fog light (K8) Relay, roof fan III ---speed K9 Auxiliary relay, starter switch (K18) Relay, control stop (K24) Reley, HiShift (K25) Relay, PTO ---HiShift (K51) Relay, indicator light, contr. main current switch

R1

In engine room (F51) 15A Electrically controlled main circuit breaker

310

(Q2) Main circuit breaker

3, 52, 60

FC1 10A Braking lights, cigarette lighter, cab light FC2 15A Rear working lights FC3 15A Horn, rear socket, front working lights,hazard warning flashers FC4 5A Left parking light, illumin. light in working light switch, light in hazard light switch FC5 Parking light, right

Page

H1 Indicator light, direction indicators III H2 Indicator light, direction indicators II H4 Indicator light, air filter H5 Indicator light, engine oil pressure H6 Warning light, Stop, engine temperature (H7) Indicator light, gearbox oil pressure H11 Indicator light, parking brake (H12)Indicator light, Thermostart H13 Indicator light, PTO clutch H14 Indicator light, high beams H15 Indicator light, fuel reverse H16 Indicator light, charging H20 Indicator light, differential lock H23 Horn (H24)Rotating light (H27)Rear buzzer H30 Light alarm buzzer H31 Direction indicator, left H32 Direction indicator, right

Code no

(A1) (A2) (A3) (A5)

Code

Sym--bol Component

Wiring diagram 600---900

Sym--bol Component

600, 700 800, 900

1 12 2, 60 55 18 15 13 23 29 25 27 32 29 2 35 6 7 36

Model

30. Tractor electrical system

Sym--bol Component

1. 9. 2001

Y1 Solenoid valve, on electric stop models (Y5) Magnetic clutch, compressor, air condition (Y9) Solenoid valve, front PTO (Y14) Solenoid valve, HiShift (Y15) Solenoid valve, HiShift, retardation (Y16) Solenoid valve, PTO ---HiShift (Y17) Solenoid valve, PTO ---HiShift, retardation

62---63 65---66

22 59 32 64 5, 60 54 22 62 63 65 66

Ground leads

47---49

ACB Autocontrol power lift A1E Autocontrol electronic unit A2E Switch panel

42---44 45

258

34 Code no 41 41

E1E Lightning, switch panel E2E Lightning, position control potentiometer

45 46

R1E Potentiometer, position control

45 43 43 42 42 44 45 45 45 45---46 44---45 45

X2E Connector, 9 pins, supply+rear drive switch

42

Y1E Solenoid valve, lowering Y2E Solenoid valve, lifting

41 41

VA = white HA = grey KE = yellow VI = green SI = blue LI = lilac PU = red RU = brown MU = black

38 17 54

Page

B1E Position sensor B2E Draft sensor

Wire colours 29---30 37, 53 37, 53 37, 53

GR1 Battery GR2 Headlights (starter) GR3 Instrument panel GR4 Earth lead, rear right GR5 Cabin roof GR6 Cabin front wall *) Agroline ---instrumentation

310

S1E Push button, RH mudguard, lifting S2E Push button, RH mudguard, lowering S3E Push button, LH mudguard, lifting S4E Push button, LH mudguard, lowering S5E Push button, lift/lower, inside S7E Switch, lowering speed S8E Switch, transport height S9E Switch, position/draft control sensitivity S10E Rocker switch, lift/stop/lower S11E Switch, AC---bypass S12E Switch, drive balance control

Connectors X1 37---pins, engine X2 9---pins, head lights X4 7---pins, trailer socket X4.1 3---pins, trailer socket X4.2 3---pins, trailer socket X5 9---pins, mudguard right X6 9---pins, mudquard left (X7) 4---pins, air condition (X8) 2---pins, current socket (X9) 1---pins, rear wiper (X15) 3---pins, air conditioning, diodes X20 9---pins, front direction indicators (X22) 2---pins, rotating light X25 9---pins, Agrodata ---instrumentation X26 26---pins, instrumentation, white X27 26---pins, instrumentation, blue (X42) 4---pins., front---PTO supply (X44) 1---pin, control stop, optional equipment (X49) 2---pins, air suspension seat X50 3---pin, current socket X51 1---pin, rear buzzer

Code

Sym--bol Component

Code no

S17 Indicator light switch, diff. lock 6 S18 Indicator light switch, hand brake contact 35 (S19) Contact, reverse buzzer 58 S20 Indicator light switch, engine temperature, (Stop) 8, 59 S21 Indicator light switch, air cleaner 6 Optional or alternative equipment listed in brackets (S22) Switch, air conditioning 54 (S23) Switch, compressor pressure 54 (S26) Switch, rear fog light 51 (S36) Switch, control stop 61 (S37) Switch, cursor+program* 47 (S38) Contact, front PTO 22 S42 Door switch, cab light, right 18 S43 Door switch, cab light, left 18 (S45) Switches, HiShift 62---63 (S45.1)Extra switch, HiShift 62 (S68) Switch, controlled main current switch. 70 (S69) Switch, PTO ---HiShift 69 (V5)Diodes, HiShift (V6)Diodes, PTO ---HiShift

600, 700 800, 900

Model

30. Tractor electrical system

1. 9. 2001

33202000K

259

600, 700 800, 900

Code

310

Page

35

Model

30. Tractor electrical system

1. 9. 2001

260

600, 700 800, 900

Code

310

Page

36

Model

30. Tractor electrical system

1. 9. 2001

261

600, 700 800, 900

Code

310

Page

37

Model

30. Tractor electrical system

1. 4. 2004

(No 33202000M) Incl. e.g. fluid brakes (M21101---)

A1 (A2) (A3) (A5)

Current screw, cabin supply Radio Controller, front PTO Air suspension seat

B1 B2 (B3) (B6)

Sensor, engine temperature gauge Sensor, fuel gauge Sensor, gearbox temperature* Sensor, gearbox*

E1 Headlight, right E2 Headlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E7 Cab light E8 Thermostart E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left E13 Instrumentation lights (E15) Cigarette lighter (E16) Number plate light (E17) Raised headlights, right (E18) Raised headlight, left (E19) Fog light, rear (E22) Lights on roof console

(F51) 15A Electrically controlled main circuit breaker Code no

G1 Battery G2 Alternator

1 38 22 32

H1 Indicator light, direction indicators II H2 Indicator light, direction indicators I H4 Indicator light, air filter H5 Indicator light, engine oil pressure H6 Warning light, Stop, engine temperature (H7) Indicator light, gearbox oil pressure H11 Indicator light, parking brake H12 Indicator light, Thermostart H13 Indicator light, PTO clutch H14 Indicator light, high beams H15 Indicator light, fuel reverse H16 Indicator light, charging H20 Indicator light, differential lock H23 Horn (H24)Rotating light (H27)Rear buzzer H30 Light alarm buzzer H31 Direction indicator, left H32 Direction indicator, right

8, 59 9 49 47 30 29 36 35 37 34 18 4 25 25 26 26 8, 10 16 34 28 27 52 57

FA, FB, FC, FD Fuses

25A Light switch 15A Dipped beams 15A Full beams, ---indication light 5A Autocontrol 20A Starter switch, electric---stop, rear fog light, control stop, Thermostart

29 29 29 43 3, 52, 60

38 Code no

20A Fan, upper fan I ---II-speed, Air ---conditioner 12 20A Air ---conditioner, upper fan III-speed 56 10A HiShift, PTO ---HiShift, radio 62---63 25A Current socket 64 5A Radio, (clock*), light alarm buzzer 1

262

70 1 3 40 39 6 7 7, 59 9 5 6 31 9 4, 68 5 40 24 58 47 39 35

K1 Auxiliary relay, starter (ignition switch) K2 Direction indicator relay (K3) Relay, front working lights K4 Relay, rear working lights K5 Headlight dipper switch relay K6 Auxiliary relay, starter switch (K7) Relay, rear fog light (K8) Relay, roof fan III ---speed K9 Auxiliary relay, starter switch (K18) Relay, control stop (K24) Reley, HiShift (K25) Relay, PTO ---HiShift (K51) Relay, indicator light, contr. main current switch

2 39 26 26 29 5 52 56 6 60 63 65 69

M1 M2 M3 M4 (M5) (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Roof fan Rear window wiper Rear window washer

2 12 15 14 55 20 19

P1 P2 P3 P4 (P5)

Engine temperature gauge Fuel gauge Rev counter Hour recorder/AC (.../speed*) Clock, AC, trip, gearbox oil temperature*

8 9 10 11 47

(Q2) Main circuit breaker

FC1 10A Cigarette lighter, cab light 17 FC2 15A Rear working lights 25 FC3 15A Horn, rear socket, front working lights, hazard warning flashers 40 FC4 5A Left parking light, instrumentation lights, working light switches, hazard warning flashers illum. light 35 FC5 5A Parking light, right 36 FD1 FD2 FD3 FD4 FD5

310

In engine room

FA1 5A Instruments, ind.lights, Autocontrol, fuel gauge 9, 44 FA2 10A Rot. warning light, radio 24 FA3 15A Wiper+washer, rear wiper+washer 12 FA4 5A Front PTO, light switch illum. light, current socket 28 FA5 15A Direction indicators, braking lights, reverse buzzer, air suspen. seat, warning flashers 38, 58 FB1 FB2 FB3 FB4 FB5

Page

Sym--bol Component

Wiring diagram 600 --- 900

Sym--bol Component

600 -- 900

Code

R1

Resistance, heating fan 1,2 ohm

S1 (S2) (S3) S4 S5 (S6) S7 S8 (S9)

Ignition switch Switch, roof fan Switch, rear window wiper and washer Switch, windscreen wiper and washer Switch, heater fan Switch, rotating warning light Switch, headlights Switch, rear working lights Switch, front working lights

1 12 2, 60 55 18 15 13 23 29 25 27

Model

30. Tractor electrical system

Sym--bol Component

1. 4. 2004

Code no

(Y1) Solenoid valve, electric stop (Y5) Magnetic clutch, compressor, air condition (Y9) Solenoid valve, front PTO (Y14) Solenoid valve, HiShift (Y15) Solenoid valve, HiShift, retardation (Y16) Solenoid valve, PTO ---HiShift (Y17) Solenoid valve, PTO ---HiShift, retardation

*) AL ---instrumentation

39

no

47---49

ACB Autocontrol power lift A1E Autocontrol electronic unit A2E Switch panel

62---63 65---66

29---30 37, 53 37, 53 37, 53

41 41

E1E Lightning, switch panel E2E Lightning, position control potentiometer

45 46

R1E Potentiometer, position control

45

42

Y1E Solenoid valve, lowering Y2E Solenoid valve, lifting

41 41

VA = white HA = grey KE = yellow VI = green SI = blue LI = lilac PU = red RU = brown MU = black

22 59 32 64 5, 60 54 22 62 63 65 66

Battery Headlights (starter) Instrument panel Earth lead, rear right Cabin roof

263

43 43 42 42 44 45 45 45 45---46 44---45 45

X2E Connector, 9 pins, supply+rear drive switch

Wire colours

38 17 54

42---44 45

B1E Position sensor B2E Draft sensor

S1E Push button, RH mudguard, lifting S2E Push button, RH mudguard, lowering S3E Push button, LH mudguard, lifting S4E Push button, LH mudguard, lowering S5E Push button, lift/lower, inside S7E Switch, lowering speed S8E Switch, transport height S9E Switch, position/draft control sensitivity S10E Rocker switch, lift/stop/lower S11E Switch, AC---bypass S12E Switch, drive balance control

Ground leads GR1 GR2 GR3 GR4 GR5

Page

GR6 Cabin front wall

Connectors X1 37---pins, engine X2 9---pins, head lights X4 7---pins, trailer socket X4.1 3---pins, trailer socket X4.2 3---pins, trailer socket X5 9---pins, mudguard right X6 9---pins, mudquard left (X7) 4---pins, air condition (X8) 2---pins, current socket (X9) 1---pins, rear wiper (X15) 3---pins, air conditioning, diodes X20 9---pins, front direction indicators (X22) 2---pins, rotating light X25 9---pins, Agrodata ---instrumentation X26 26---pins, instrumentation, white X27 26---pins, instrumentation, blue (X42) 4---pins., front---PTO supply (X44) 1---pin, control stop, optional equipment (X49) 2---pins, air suspension seat X50 3---pin, current socket X51 1---pin, rear buzzer

310

Sym--bol Component

S10 Combined switch 32 (S11) Toggle switch, raised headlights 29 S12 Contact, starter interlock 2 S13 Brake light contact 35 S14 PTO warning light contact 6 S15 Indicator light switch, engine oil press. 7 S16 Switch, hazard warning flashers 36 S17 Indicator light switch, diff. lock 6 S18 Indicator light switch, hand brake contact 10 (S19) Contact, reverse buzzer 58 S20 Indicator light switch, engine temperature, (Stop) 8, 59 S21 Indicator light switch, air cleaner 6 (S22) Switch, air conditioning 54 (S23) Switch, compressor pressure 54 (S26) Switch, rear fog light 51 (S36) Switch, control stop 61 (S37) Switch, cursor+program* 47 (S38) Contact, front PTO 22 S42 Door switch, cab light, right 18 S43 Door switch, cab light, left 18 (S45) Switches, HiShift 62---63 (S45.1)Extra switch, HiShift 62 (S68) Switch, controlled main current switch 70 (S69) Switch, PTO ---HiShift 69 (V5)Diodes, HiShift (V6)Diodes, PTO ---HiShift

600 -- 900

Code

Model

30. Tractor electrical system

33202000M

1. 4. 2004

600 -- 900

Code

Page

310

40

M21101--->

69--- 1

69--- 2

264

Model

30. Tractor electrical system

1. 4. 2004

600 -- 900

Code

310

Page

41

M21101--->

69--- 3

69--- 4

265

Model

30. Tractor electrical system

1. 4. 2004

600 -- 900

Code

310

Page

42

M21101--->

69--- 5

266

Model

30. Tractor electrical system

1. 4. 2004

267

Code

310

Page

43

Model

30. Tractor electrical system

1. 4. 2004

(No 33391700G) Incl. e.g. fluid brakes (M21101---)

A1 Current screw, cabin supply (A3) Controller, front PTO B1 B2

Sensor, engine temperature gauge Sensor, fuel gauge

E1 Headlight, right E2 Headlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E8 Heater unit E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left E13 Instrumentation lights (E16) Register plate light (E19) Fog light, rear

K1 Auxiliary relay, starter K2 Direction indicator relay (K3) Relay, front working lights K4 Relay, rear working lights K5 Headlight dipper switch relay K6 Auxiliary relay, starter switch (K7) Relay, rear fog light (K18) Relay, control stop

Code no 1 21 8, 24 9

M1 Starter motor P1 P2 P3 P4 (P5)

30 29 36 35 37 34 4 15 14 19 18 8, 10 34 27

FA1 FA2 FA4 FA5

5A Instruments, ind.lights, fuel gauge 9 10A Rot. warning light, radio 13 5A Front PTO, ligth for light switch 28 15A Direction indicators, braking lights, back buzzer, Stop warning light 38

FB1 FB2 FB3 FB5

25A Light switch, lower beams/high beams 15A Light switch, parking lights 15A Horn, front working light 20A Starter switch, electric---stop, fog light rear, Control stop, Thermostart

10A Reserve 15A Rear working lights 15A Light alarm buzzer, Hour recorder, Clock 5A Left parking light, instrumentation lights, working light switches, illumin. light for hazard warning flasher switch FC5 5A Parking light, right

H1 Indicator light, direction indicators III H2 Indicator light, direction indicators II H4 Indicator light, air filter H5 Indicator light, engine oil pressure H6 Warning light, Stop, engine temperature H11 Indicator light, parking brake H13 Indicator light, PTO clutch H14 Indicator light, high beams H15 Indicator light, fuel reverse H16 Indicator light, charging H20 Indicator light, differential lock H23 Horn (H24)Rotating light H30 Light buzzer H31 Direction indicator, left H32 Direction indicator, right

Page

44 Code no 2 39 18 16 29 4 27 24 2 8 9 10 11 11 1

S1 Ignition switch 2, 25 (S6) Switch, rotating warning light 13 S7 Switch, headlights 29 S8 Switch, rear working lights 16 (S9) Switch, front working lights 18 S10 Combined switch 32 S12 Safety switch 2 S13 Switch, brake light contact 35 S14 Indicator light switch, PTO clutch 6 S15 Indicator light switch, engine oil press. 7 S16 Switch, hazard warning flashers 36 S17 Indicator light switch, diff. lock 6 S18 Indicator light switch,hand brake contact 5 S20 Indicator light switch, engine temperature, (Stop) 8, 24 S21 Indicator light switch, air cleaner 6 (S26) Switch, rear fog light 27 (S36) Switch, control stop 26 (S38) Contact, front PTO 21

29 29 40

Connectors

3, 25

X1 37---pins, engine X2 9---pins, head lights X4 7---pins, trailer socket X4.1 3---pins, trailer socket X4.2 3---pins, trailer socket X5 9---pins, mudguard right X6 9---pins, mudquard left X20 9---pins, front direction indicators (X22) 2---pins, rotating light X27 26---pins, instrumentation, blue (X42) 4---pins., front---PTO supply (X44) 1---pin, control stop, optional equipment

32 15 11 35 36

In engine room G1 Battery G2 Alternator

Engine temperature gauge Fuel gauge Rev counter Hour recorder Clock, AC, trip, gearbox oil temperature*

(Q2) Main circuit breaker

FA, FB, FC Fuses

FC1 FC2 FC3 FC4

310

Sym--bol Component

Wiring diagram 600L --- 900L, open cab Sym--bol Component

600L -- 900L

Code

1 3

(Y1) Solenoid valve, electric stop (Y9) Solenoid valve, front PTO

40 39 6 7 7 5 6 31 9 4 5 40 13 11 39 38

Ground leads GR1 GR2 GR3 GR4 GR5

Battery Headlights (starter) Instrument panel Earth lead, rear right Cab of roof

Wire colours VA = white HA = grey KE = yellow VI = green SI = blue LI = lilac PU = red RU = brown MU = black

268

29, 40 25 37 37 37

22 24 4, 25 21

Model

30. Tractor electrical system

1. 4. 2004

600L -- 900L

Code

310

Page

45

M21101---> 33391700G

69L --- 1_2

69L --- 2_2

269

Model

30. Tractor electrical system

1. 4. 2004

270

Code

310

Page

46

Model

30. Tractor electrical system

1. 4. 2004

600 -- 900 A75 -- A95

Code

Page

310

Sym--bol Component

Wiring diagram 600---900 and A75 --- A95 (Nro 33202000P) Incl. e.g. drizzle operation (relay K26) and a new combined switch S10 (M49302---)

(F51) 15A Electrically controlled main circuit breaker

Sym--bol Component

G1 G2

A1 (A2) (A3) (A5)

Current screw, cabin supply Radio Controller, front PTO Air suspension seat

B1 B2 (B3) (B6)

Sensor, engine temperature gauge Sensor, fuel gauge Sensor, gearbox temperature* Sensor, gearbox*

E1 Headlight, right E2 Headlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E7 Cab light E8 Thermostart E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left E13 Instrumentation lights (E15) Cigarette lighter (E16) Number plate light (E17) Raised headlights, right (E18) Raised headlight, left (E19) Fog light, rear (E22) Lights on roof console

47 Code no

In engine room

Code no

Battery Alternator

H1 Indicator light, direction indicators II H2 Indicator light, direction indicators I H4 Indicator light, air filter H5 Indicator light, engine oil pressure H6 Warning light, Stop, engine temperature (H7) Indicator light, gearbox oil pressure H11 Indicator light, parking brake H12 Indicator light, Thermostart H13 Indicator light, PTO clutch H14 Indicator light, high beams H15 Indicator light, fuel reverse H16 Indicator light, charging H20 Indicator light, differential lock H23 Horn (H24)Rotating light (H27)Rear buzzer H30 Light alarm buzzer H31 Direction indicator, left H32 Direction indicator, right

1 38 22 32 8, 59 9 49 47 30 29 36 35 37 34 18 4 25 25 26 26 8, 10 16 34 28 27 52 57

FA, FB, FC, FD Fuses FA1 5A Instruments, ind.lights, Autocontrol, fuel gauge 9, 44 FA2 10A Rot. warning light, radio 24 FA3 15A Wiper+washer, rear wiper+washer 12 FA4 5A Front PTO, light switch illum. light, current socket 28 FA5 15A Direction indicators, braking lights, reverse buzzer, air suspen. seat, warning flashers 38, 58 FB1 25A Light switch 29 FB2 15A Dipped beams 29 FB3 15A Full beams, ---indication light 29 FB4 5A Autocontrol 43 FB5 20A Starter switch, electric---stop, rear fog light, control stop, Thermostart 3, 52, 60 FC1 10A Cigarette lighter, cab light 17 FC2 15A Rear working lights 25 FC3 15A Horn, rear socket, front working lights, hazard warning flashers 40 FC4 5A Left parking light, instrumentation lights, working light switches, hazard warning flashers illum. light 35 FC5 5A Parking light, right 36 FD1 20A Fan, upper fan I ---II ---speed, Air ---conditioner 12 FD2 20A Air ---conditioner, upper fan III ---speed 56 FD3 10A HiShift, PTO ---HiShift, radio 62---63 FD4 25A Current socket 64 FD5 5A Radio, (clock*), light alarm buzzer 1

1 3 40 39 6 7 7, 59 9 5 6 31 9 4, 68 5 40 24 58 47 39 35

K1 Auxiliary relay, starter (ignition switch) K2 Direction indicator relay (K3) Relay, front working lights K4 Relay, rear working lights K6 Auxiliary relay, starter switch (K7) Relay, rear fog light (K8) Relay, roof fan III ---speed K9 Auxiliary relay, starter switch (K18) Relay, control stop (K24) Relay, HiShift (K25) Relay, PTO ---HiShift K26 Relay, drizzle (K51) Relay, indicator light, contr. main current switch

2 39 26 26 5 52 56 6 60 63 65 15 69

M1 M2 M3 M4 (M5) (M6) (M7)

Starter motor Heater fan Windscreen wiper Windscreen washer pump Roof fan Rear window wiper Rear window washer

2 12 15 14 55 20 19

P1 P2 P3 P4 (P5)

Engine temperature gauge Fuel gauge Rev counter Hour recorder/AC (.../speed*) Clock, AC, trip, gearbox oil temperature*

8 9 10 11 47

(Q2) Main circuit breaker

271

70

R1

Resistance, heating fan 1,2 ohm

S1 (S2) (S3) S4 S5 (S6) S7 S8 (S9)

Ignition switch Switch, roof fan Switch, rear window wiper and washer Switch, windscreen wiper Switch, heater fan Switch, rotating warning light Switch, headlights Switch, rear working lights Switch, front working lights

1 12 2, 60 55 18 15 13 23 29 25 27

Model

30. Tractor electrical system

Sym--bol Component

1. 4. 2004

Code no

(Y1) Solenoid valve, electric stop (Y5) Magnetic clutch, compressor, air condition (Y9) Solenoid valve, front PTO (Y14) Solenoid valve, HiShift (Y15) Solenoid valve, HiShift, retardation (Y16) Solenoid valve, PTO ---HiShift (Y17) Solenoid valve, PTO ---HiShift, retardation

*) AL ---instrumentation

48 Code no

47---49

ACB Autocontrol power lift A1E Autocontrol electronic unit A2E Switch panel

62---63 65---66

29---30 37, 53 37, 53 37, 53

41 41

E1E Lightning, switch panel E2E Lightning, position control potentiometer

45 46

R1E Potentiometer, position control

45

42

Y1E Solenoid valve, lowering Y2E Solenoid valve, lifting

41 41

VA = white HA = grey KE = yellow VI = green SI = blue LI = lilac PU = red RU = brown MU = black

22 59 32 64 5, 60 54 22 62 63 65 66

Battery Headlights (starter) Instrument panel Earth lead, rear right Cabin roof

272

43 43 42 42 44 45 45 45 45---46 44---45 45

X2E Connector, 9 pins, supply+rear drive switch

Wire colours

38 17 54

42---44 45

B1E Position sensor B2E Draft sensor

S1E Push button, RH mudguard, lifting S2E Push button, RH mudguard, lowering S3E Push button, LH mudguard, lifting S4E Push button, LH mudguard, lowering S5E Push button, lift/lower, inside S7E Switch, lowering speed S8E Switch, transport height S9E Switch, position/draft control sensitivity S10E Rocker switch, lift/stop/lower S11E Switch, AC---bypass S12E Switch, drive balance control

Ground leads GR1 GR2 GR3 GR4 GR5

310

Page

GR6 Cabin front wall

Connectors X1 37---pins, engine X2 9---pins, head lights X4 7---pins, trailer socket X4.1 3---pins, trailer socket X4.2 3---pins, trailer socket X5 9---pins, mudguard right X6 9---pins, mudquard left (X7) 4---pins, air condition (X8) 2---pins, current socket (X9) 1---pins, rear wiper (X15) 3---pins, air conditioning, diodes X20 9---pins, front direction indicators (X22) 2---pins, rotating light X25 9---pins, Agrodata ---instrumentation X26 26---pins, instrumentation, white X27 26---pins, instrumentation, blue (X42) 4---pins., front---PTO supply (X44) 1---pin, control stop, optional equipment (X49) 2---pins, air suspension seat X50 3---pin, current socket X51 1---pin, rear buzzer

Code

Sym--bol Component

S10 Combined switch 32 (S11) Toggle switch, raised headlights 29 S12 Contact, starter interlock 2 S13 Brake light contact 35 S14 PTO warning light contact 6 S15 Indicator light switch, engine oil press 7 S16 Switch, hazard warning flashers 36 S17 Indicator light switch, diff. lock 6 S18 Indicator light switch, hand brake contact 10 (S19) Contact, reverse buzzer 58 S20 Indicator light switch, engine temperature, (Stop) 8, 59 S21 Indicator light switch, air cleaner 6 (S22) Switch, air conditioning 54 (S23) Switch, compressor pressure 54 (S26) Switch, rear fog light 51 (S36) Switch, control stop 61 (S37) Switch, cursor+program* 47 (S38) Contact, front PTO 22 (S42) Door switch, cab light, right 18 (S43) Door switch, cab light, left 18 (S45) Switches, HiShift 62---63 (S45.1)Extra switch, HiShift 62 S62 Switch, windscreen washer 14 (S68) Switch, controlled main current switch 70 (S69) Switch, PTO ---HiShift 69 (V5) Diodes, HiShift (V6) Diodes, PTO ---HiShift

600 -- 900 A75 -- A95

Model

30. Tractor electrical system

33202000P

1. 4. 2004

600 -- 900 A75 -- A95

Code

310

Page

49

M49302--->

69--- 1

69--- 2

273

Model

30. Tractor electrical system

1. 4. 2004

600 -- 900 A75 -- A95

Code

310

Page

50

M49302--->

69--- 3

69--- 4

274

Model

30. Tractor electrical system

1. 4. 2004

600 -- 900 A75 -- A95

Code

310

Page

51

M49302--->

69--- 5

275

Model

30. Tractor electrical system

1. 4. 2004

(Nro 33391700H) Incl. e.g. a new combined switch S10 (M49302---)

A1 Current screw, cabin supply (A3) Controller, front PTO B1 B2

Sensor, engine temperature gauge Sensor, fuel gauge

E1 Headlight, right E2 Headlight, left E3 Front direction indicator, right E4 Front direction indicator, left E5 Rear light, right E6 Rear light, left E8 Heater unit E9 Rear working light, right E10 Rear working light, left (E11) Front working light, right (E12) Front working light, left E13 Instrumentation lights (E16) Register plate light (E19) Fog light, rear

K1 Auxiliary relay, starter K2 Direction indicator relay (K3) Relay, front working lights K4 Relay, rear working lights K6 Auxiliary relay, starter switch (K7) Relay, rear fog light (K18) Relay, control stop

Code no 1 21

M1 Starter motor

8, 24 9

P1 P2 P3 P4 (P5)

30 29 36 35 37 34 4 15 14 19 18 8, 10 34 27

FA1 FA2 FA4 FA5

5A Instruments, ind.lights, fuel gauge 9 10A Rot. warning light, radio 13 5A Front PTO, ligth for light switch 28 15A Direction indicators, braking lights, back buzzer, Stop warning light 38

FB1 FB2 FB3 FB5

25A Light switch, lower beams/high beams 15A Light switch, parking lights 15A Horn, front working light 20A Starter switch, electric---stop, fog light rear, Control stop, Thermostart

10A Reserve 15A Rear working lights 15A Light alarm buzzer, Hour recorder, Clock 5A Left parking light, instrumentation lights, working light switches, illumin. light for hazard warning flasher switch FC5 5A Parking light, right

H1 Indicator light, direction indicators III H2 Indicator light, direction indicators II H4 Indicator light, air filter H5 Indicator light, engine oil pressure H6 Warning light, Stop, engine temperature H11 Indicator light, parking brake H13 Indicator light, PTO clutch H14 Indicator light, high beams H15 Indicator light, fuel reverse H16 Indicator light, charging H20 Indicator light, differential lock H23 Horn (H24)Rotating light H30 Light buzzer H31 Direction indicator, left H32 Direction indicator, right

Page

52 Code no 2 39 18 16 4 27 24 2 8 9 10 11 11 1

S1 Ignition switch 2, 25 (S6) Switch, rotating warning light 13 S7 Switch, headlights 29 S8 Switch, rear working lights 16 (S9) Switch, front working lights 18 S10 Combined switch 32 S12 Safety switch 2 S13 Switch, brake light contact 35 S14 Indicator light switch, PTO clutch 6 S15 Indicator light switch, engine oil press. 7 S16 Switch, hazard warning flashers 36 S17 Indicator light switch, diff. lock 6 S18 Indicator light switch,hand brake contact 5 S20 Indicator light switch, engine temperature, (Stop) 8, 24 S21 Indicator light switch, air cleaner 6 (S26) Switch, rear fog light 27 (S36) Switch, control stop 26 (S38) Contact, front PTO 21

29 29 40

Connectors X1 37---pins, engine X2 9---pins, head lights X4 7---pins, trailer socket X4.1 3---pins, trailer socket X4.2 3---pins, trailer socket X5 9---pins, mudguard right X6 9---pins, mudquard left X20 9---pins, front direction indicators (X22) 2---pins, rotating light X27 26---pins, instrumentation, blue (X42) 4---pins., front---PTO supply (X44) 1---pin, control stop, optional equipment

3, 25 32 15 11 35 36

In engine room G1 Battery G2 Alternator

Engine temperature gauge Fuel gauge Rev counter Hour recorder Clock, AC, trip, gearbox oil temperature*

(Q2) Main circuit breaker

FA, FB, FC Fuses

FC1 FC2 FC3 FC4

310

Sym--bol Component

Wiring diagram 600L --- 900L, open cab Sym--bol Component

600L -- 900L

Code

1 3

(Y1) Solenoid valve, electric stop (Y9) Solenoid valve, front PTO

40 39 6 7 7 5 6 31 9 4 5 40 13 11 39 38

Ground leads GR1 GR2 GR3 GR4 GR5

Battery Headlights (starter) Instrument panel Earth lead, rear right Cab of roof

Wire colours VA = white HA = grey KE = yellow VI = green SI = blue LI = lilac PU = red RU = brown MU = black

276

29, 40 25 37 37 37

22 24 4, 25 21

Model

30. Tractor electrical system

33391700H

1. 4. 2004

M49302--->

600L -- 900L

Code

Page

310

53

69L --- 1_2

69L --- 2_2

277

Model

30. Tractor electrical system

1. 4. 2004

278

Code

310

Page

54

10. 1. 1992

32. Electro---hydraulic power lift

Model

355-- 865

1. 3. 1997

Code

320

Page

1

7

4 6

8

5

3

2

Picture 1. Electro---hydraulic power lift 1. Hydraulic pump 2. Control valve 3. Lifting cylinder 4. Electronic unit 5. Draft sensor 6. Position sensor 7. Switch panel 8. Top link bracket

1

1. Autocontrol hydraulic lift, electri --cal system

This unit determines the differences between the two sets of signals (i.e. from the sensors and switches) and feed the necessary control signal to the control valve solenoid.

Note! The Electro---hydraulic power lift on Valmet 355---865 tractors is the same as on Valmet Mezzo---series. However, 355---865 tractors have only one draft sensor on the top link bracket.

The position sensor (6) is in permanent contact with an eccentric on the lift shaft. When the lower links are lifted or lowered the eccentric moves the pin, which sends a signal to the electronic unit; thus the hydraulic lift always ”knows” the position of the lower links.

A. Description The Valmet Autocontrol is an electrically controlled hydraulic lift. All mechanical levers have been replaced with knobs and switches. Ideal mixing/sensitivity values for draft control have been pre ---programmed and can be controlled with one switch.

The draft sensor (5) is placed on the top link bracket (8). When the push/pull force in the top link increases the loading on the draft sensor also increases. This loading is then converted into electrical signals by the draft sensor.

Operation:

These signals are amplified by an electronic device which is built into the the draft sensor.

The pump (1) draws oil from the oil reservoir and delivers it to the control valve (2). The control valve directs the oil to the lifting cylinders (3) for the operation of the lifting arms (lifting, lowering and holding functions). The values set on the switch panel (7), and the actual values detected by the draft sensors (5) and position sensor (6), are fed into the electronic unit (4).

The signals are sent to the Autocontrol hydraulic lift. If the draft force increases the hydraulic lift will raise the implement, the draft control sensitivity depending on the setting of the switches in the cab and on the top link fastening point on the bracket.

283

15. 9. 1995

32. Electro---hydraulic power lift

1. 3. 1997

Model

355-- 665

Code

320

Page

2

Picture 1. Wiring diagram of Autocontrol

Wiring diagram up to cab number 64093

284

10. 1. 1992

32. Electro---hydraulic power lift

1. 9. 1992

Model

355-- 665

Code

320

Page

3

Component list of wiring diagram A1E . . . . Autocontrol electronic unit A2E . . . . Switch panel B1E . . . . Position sensor B2E . . . . Draft sensor R1E . . . . Potentiometer, position control S1E . . . . S2E . . . . (S3E) . . . (S4E) . . . S5E . . . . S6E . . . . S7E . . . . S8E . . . . S9E . . . . S10E . . . S17E . . .

Push button, RH mudguard, lifting Push button, RH mudguard, lowering Push button, LH mudguard, lifting Push button, LH mudguard, lowering Push button in cab, lifting Push button in cab, lowering Switch, lowering speed Switch, transport height Switch, position/draft control sensitivity Rocker switch, lift/lower Limit switch

(X2E) . . . Connector, 3 pins, push buttons on LH side mudguard. X7E . . . . . Connector, 3 pins, limit switch Y1E . . . . . Solenoid valve. lowering Y2E . . . . . Solenoid valve, lifting Fuses FA1 (in fuse box; current via starter switch): 5 A, porcelain fuse FB3 (in fuse box; permanent current): 8 A, porcelain (665: 16 A) 665: F1E (on wire under Autocontrol switch panel): 5 A, flat fuse. Fuse FA9 on tractors 355---565 and on some 665 tractors in same place as fuse F1E.

Wire colours Ru = brown Pu = red Ke = yellow Si = blue Mu = black Vi = green Va = white Li = lilac

285

Model

32. Electro---hydraulic power lift

15. 9. 1995

355-- 665

Code

320

Page

3A

Wiring diagram on 65---models from cab no. 64094 incl.

65--- 3

286

Model

32. Electro---hydraulic power lift

15. 9. 1995

Component list of wiring diagram Code A1E . . . . . . . Autocontrol electronic unit A2E . . . . . . . Switch panel

42---44 45

B1E . . . . . . . Position sensor B2E . . . . . . . Draft sensor

41 41

R1E . . . . . . . Potentiometer, position control

45

S1E . . . . . . . S2E . . . . . . . (S3E) . . . . . . (S4E) . . . . . . S5E . . . . . . . S6E . . . . . . . S7E . . . . . . . S8E . . . . . . . S9E . . . . . . . S10E . . . . . . S17E . . . . . .

43 43 42 42 44 44 45 45 45 45---46 41---42

Push button, RH mudguard, lifting Push button, RH mudguard, lowering Push button, LH mudguard, lifting Push button, LH mudguard, lowering Push button in cab, lifting Push button in cab, lowering Switch, lowering speed Switch, transport height Switch, position/draft control sensitivity Rocker switch, lift/lower Limit switch

(X2E) . . . . . . Connector, 3 pins, push buttons . . . . . . . . . . . . on LH side mudguard. X7E . . . . . . . . Connector, 3 pins, limit switch

42 41---42

Y1E . . . . . . . . Solenoid valve. lowering Y2E . . . . . . . . Solenoid valve, lifting

41 41

Fuses FA1 Current via starter switch (5 A) FB4 Permanent current (5 A)

Wire colours Ru = brown Pu = red Ke = yellow Si = blue Mu = black Vi = green Va = white Li = lilac

287

355-- 665

Code

Page

320

3B

1. 1. 1998

Wiring diagram for 865 and 600---900 tractors

288

Model

865 600-- 900

Code

Page

320

3C

Figure 1B. Autocontrol power lift

1. 5. 1996

32. Electro---hydraulic power lift

1. 3. 1997

32. Electro---hydraulic power lift

1. 1. 1998

Component list of wiring diagram, tractors 865 and 600---900 Sym--bol Component

Code

A1E A2E A3E

Autocontrol electronic unit Switch panel Compensator

42---44 45 42

E1E E2E

Switch panel illumination 45 Illumination, position control potentiometer 46

B1E B2E

Position sensor Draft sensor

41 41

R1E

Potentiometer, position control

45

S1E S2E S3E S4E S5E S7E S8E S9E S10E S11E

Push button, RH mudguard, lifting Push button, RH mudguard, lowering Push button, LH mudguard, lifting Push button, LH mudguard, lowering Rocker switch in cab, lifting/lowering Switch, lowering speed Switch, transport height Switch, position/draft control sensitivity Autocontrol rocker switch, lift/stop/lower Switch, forced lowering

43 43 42 42 44 45 45 45 45---46 44---45

(X2E) X5 X6 B1E B2E

Connector, 9 pins, push buttons+supply RH mudguard push button connector LH mudguard push button connector Position sensor connector Draft sensor connector

42---45

Y1E Y2E

Solenoid valve, lowering Solenoid valve, lifting

41 41

Current via starter switch (5 A) Permanent currect (5 A)

44 43

Fuses: FA1 FB4

Wire colours Ru = brown Pu = red Ke = yellow Si = blue Mu = black Vi = green Va = white Li = lilac IMPORTANT! Instructions for 865---tractor under code 320 are also good for 600, 700, 800 and 900 tractors.

289

Model

865 600-- 900

Code

Page

320

3D

Model

32. Electro---hydraulic power lift

10. 1. 1992

7

Code

355-- 665

Page

320

4

8

Blue (to fuse FB3)

6 Brown (to fuse FA1)

665: F1E

Connector for LH side mudguar push buttons (optional)

5

3

4 10

P

2

9

1

Figure 2. Electro---hydraulic power lift, Valmet 355---665 1. Control valve (Bosch) 2. Draft sensor (B2E) 3. Top link 4. Electronic unit (A1E) 5. Position sensor (B1E) 6. Switch panel (A2E) 7. Push buttons (in cab) 8. Push buttons (on RH side mudguard) 9. Solenoid valve (2 pcs, Y1E, Y2E) 10. Limit switch (S17E)

290

Model

32. Electro---hydraulic power lift

1. 3. 1997

865

Code

320

Page

4A

P

Picture 2a. AC---power lift on 865 tractor Note! The electric functions of the 865 tractor AC power lift are the same as on 355---665 tractors:

1. Control valve 2. Draft sensor B2E 3. Top link sensing 4. Control unit A1E 5. Position sensor B1E 6. Autocontrol---switch S10E 7. Position control potentiometer R1E 8. Lowering speed selector S7E 9. Transport height selector S8E 10. Position control/draft control selector S9E 11. Rocker switch, lifting / lowering S5E 12. Push buttons S1E and S2E in the rear mudguards 13. Forced lowering button S11E 14. Indication lights for lifting/lowering 15. Indication lights, position control / draft control

--- Functional check, see pages 320/8 ---9. --- Checking switch panel, see pages 320/11 ---12. --- Position sensor, see page 320/6. Adjusting position sensor on 865, see page 320/10A. --- Draft sensor, see page 320/7. --- Checking position control potentiometer and solenoid valves, see page 320/15.

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Picture 2b. Control switch console on the 865 tractor 6. Autocontrol---rocker switch S10E 7. Position control potentiometer R1E 8. Lowering speed selector S7E 9. Transport height selector S8E 10. Position control/draft control selector S9E 11. Rocker switch in cab, lifting/lowering S5E 12. Push buttons S1E and S2E in the rear mudguards (not illustrated) 13. Forced lowering button S11E 14. Indication lights, lifting and lowering 15. Indication lights, position control/draft control Note! On the 865 tractor the positions of the control switches have been changed, but their electrical functions are the same as on 355---665 tractors, see the following page 320/5. On the 865 the forced lowering button S11E is a standard equipment. The two push buttons for the lifting/lowering in the cab have been replaced with one rocker switch.

292

865

Code

Page

320

4B

1. 5. 1996

32. Electro---hydraulic power lift

1. 3. 1997

4

Model

Code

355-- 665

320

Page

5

5 6

7

8

2 1

Figure 3. Control switches for power lift on 355---665.

a middle position and the both extreme positions have the same functions as the push buttons. A spring returns the rocker switch to the middle position.

1. Position control potentiometer --- max. clockwise, lower links at the transport height (with switch 5) --- max. anti ---clockwise, lower links in the lowest position --- does not function if the system has not been activated with switch 2.

4. Lowering speed selector --- six different lowering speeds --- lowering speed is independent of the load

2. Lift/lower switch (Autocontrol switch) --- activates the control system (after the main power has been switched off or if the mudguard push buttons (or rocker switch in cab on 865) have been used). --- lifts to the transport height determined by the switch 5. --- lowers to the position determined by the position control knob 1

5. Transport height selector --- six different upper position --- push buttons override these settings

Note! From the beginning of the year 1994, the lift/lower switch has three positions. The middle position stops the movement of the lower links. The two other positions are the same as earlier.

7. Lift/lower indicator lights --- lifting (red) --- lowering (green)

6. Position control/draft control --- position P is the position control mode --- positions 1---5 are for the draft control

8. Indicator lights for the position control/draft control --- light for the position control (position P) --- light for the draft control (positions 1---5)

3. Lift/lower push buttons in the mudguards --- in the cabin and on the RH side rear mudguard --- lift button raises the lower links to max. upper position (higher than max transport position with switch 5) --- push button does not function, if the lift/lower switch (2) is in the lifting position. --- after using the push buttons, the system must be activated with the switch (2).

9. Forced lowering switch (see page 320/4B) 865---tractor has as standard a forced ---lowering switch (as on some Mezzo---tractors). The switch is a spring returned push button beside the position potentiometer. When this button is depressed, the Autocontrol adjustment is overidden and the lower links lower as long as the button is depressed. The forced ---lowering button does not override the lowering speed control. When the button is released, the lower links will find the position determined by the position potentiometer. The forced ---lowering button does not lower the lower links, if the lift/lower switch is in the transport or in the middle position.

Note! 355---665: The lifting arms are provided with a limit switch which limits the max lifting height when push buttons are used (the pick ---up hitch lifting links limit the upper position if they are fitted on the tractor). Note! On 865---tractor, the push buttons in the cab have been replaced with a three ---position rocker switch. The switch has

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Model

Code

355-- 865

320

Page

6

USignal 5 USupply Direction A Figure 4. Position sensor 1

1. Locking nut (Loctite 270 on threads) 2. Permatex Super 300 on threads 3. Eccentric on lifing arm shaft 4. Hydraulic housing cover 5. Connector (on RH side under cab)

4 2

Note ! The position sensor must be changed if it is damaged. If the sensor lead is damaged it can be repaired using three pin connector. USignal USupply 3

10 mm (max. 13 mm)

Position sensor USupply=6,3---7,7 Veff (AC) (f4---7kHz) USignal=33---67 % x USupply (lower links down ---up)

The position sensor is fitted on the hydraulic housing cover in the rear of the tractor. It supplies information on the actual position of the lower links.

Measuring position sensor signal and supply voltages, see page 320/14.

The sensor detects the lower link position by means of an eccentric fitted to the lifting arm shaft. The construction of the position sensor can be compared to that of a solenoid. Inside the electromagnetic housing there is a pin which moves with the eccentric on the lifting arm shaft.

Adjusting the limit switch and the position sensor Concerning 355---665 tractors with the limit switch, see page 320/10. Adjustment of the position sensor on the 865 tractor, see page 320/10A.

Alternating current is fed to the coil, and the voltage in the middle of the coil depends on the position of the pin inside the housing. Thus the voltage is proportional to the position of the lower links.

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10. 1. 1992

32. Electro---hydraulic power lift

Model

355-- 865

15. 9. 1995

OSCILLATOR

FILTER

DEMODULATOR

Code

320

Page

7

F

Ua Us F/2

F/2

2 Figure 5. Draft sensor 1. Draft sensor 2. Top link bracket

A

45 Nm

(8--- 12 V DC)

1

A

Draft sensor

Measuring signal and supply voltages See page 320/14.

The draft sensor acts as a lower mounting bolt of the top link bracket. The sensor converts draft forces into electrical signals.

Short circuit in draft sensor line --- Short circuit in the supply line causes deadlock of the whole system (current breaks also in the selector panel A2E ). If this short circuit is only momentary, the system starts normally with the lift/lower switch. If the short circuit is sustained, the power lift remains locked.

The draft sensor is housed in a tube manufactured from a special steel. Inside the sensor there is a carrier wave electronics unit, a signal amplifier, and a transformer which produces a magnetic field at the measuring point. The draft force causes a shearing stress on the sensor and this changes the magnetic properties of the metal, which causes a variation in the voltage in the transformer.

--- Short circuit in the signal line causes the lifting reaction on the lower links during the short. The system returns automatically to the normal function after the short circuit (”ghost lifts”).

USupply = 8 ---12 V (DC) USignal = 2,5 ---7,5 V (DC) (max. draft --- max. push) (signal voltage is 5 V when the sensor is unloaded).

--- Contact between the supply and signal lines causes the full lowering reaction on the lower links during the short circuit.

The draft pin must be changed if it is damaged. If the sensor lead is damaged it can be repaired using three pin connectors.

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4

Model

Code

355-- 865

320

Page

8

5 6

7

8

2 1

Functional checks

A. Checking rear push buttons --- Start the tractor --- Set the lift/lower switch (2) in the lowering position --- Press the buttons on the RH side mudguard and check if the lower links actually move upwards and downwards:

If a malfunction should occur, the reasons may be either in the electric control system or in the hydraulic system:

1. Distinguishing between electrical and hydraulic malfunctions

a) If the lower links respond to the push buttons, then this section is in working order

---Start the tractor. Apply the parking brake. Ensure that the lower links are in the working position. --- Press the push buttons at the ends of the solenoids on the control valve. This moves the valve plunger mechanically (the rearmost solenoid is for lifting). --- If the lower links move upwards and downwards, the hydraulic circuit is in order --- If the lower links fail to move when the buttons are depressed, check the condition of the pump and oil pipes. If necessary, the control valve must be checked (see section 90).

b) If the lower links do not move when the buttons are pressed: ---check the power lift fuses FA1 and FB3 in the fuse box (on 665 is also fuse F1E on wire under the switch panel. On 355---565 and on some 665 fuse FA9 in the same place. On the latest 65---models fuse FB4 in the fuse box. --- check the constant current and current passing through the ignition switch from the power lift inlet connection (blue and brown wires. 865: blue and red wires, connector X2E/1 and 2) --- check the connectors for breaks and repair if necessary c) If the lower links e.g. lift but will not lower: --- Change round wires to the solenoids and try the buttons again: --- If the lower links still move upwards only, the lower solenoid is defective and must be changed --- If the lower links move downwards only, the valve is in order, but the other solenoid is not receiving current. In this case, check the lead connectors.

Warning! 355 ---665: Do not lift the lower links to the max. upper position with the push buttons at the solenoid valve ends because the limit switch could be damaged and the inner lever in the hydraulic lift housing can damage the rear wall of the housing. Note! The 865 tractor has not the limit switch and the warning above is unnecessary. On this tractor the hydraulic housing resists the force caused by the inner lever.

B. Checking the lift/lower switch

2. Checking the electrical operation

The power lift control system is activated with this switch. (2). If the unit is not receiving current or information about the position of the lower links (e.g. the position sensor lead is damaged), the control system will not start to function and the power lift will not respond to the position control knob (1)

Important! The most likely causes of malfunction are poor contacts in the connectors and switches. In case of malfunction, all connectors and switches must be checked and cleaned.

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If the control system does not start to function, but the lower links respond to the push buttons:

355-- 865

Code

320

Page

9

--- rotate selector (4) to position 6 (max lowering speed) --- connect a suitably heavy load to the three ---point linkage

--- Check the lift/lower switch and the associated connections (if the power lift is left unused for some time the switch may become oxidized, and the control system will fail to activate). --- Check the position sensor and its connector (see pages 320/10 ---10A and 320/14) --- Check the electronic unit connector

Put the lift/lower switch (2) in the lifting position, so that the lower links are raised to an upper position. Lower them by putting the switch in the lowering position and use a timer to measure the lowering speed. Six different speeds should be found according to the position of the selector (4) (1=slowest, 6=fastest)

If no defect is found, the whole electronic unit must be replaced.

Note! The lowering speed for the slowest position (1) should be at least 6 seconds regardless of the load.

C. Checking the position control potentiometer (1)

Checking the switch panel, see page 320/11.

--- Activate the control system (switch 2) --- Turn switch (5) to position 9. --- Rotate the position control knob slowly to its extreme positions. The movement of the lower links should be steady (clockwise extreme position=max transport height. Anti --clockwise extreme position=lowest position of lower links.

G. Checking the draft control operation When the draft control is in use (Eg. during ploughing), the lift and lower indicator lights will flash. If the draft control is out of order, the power lift operates in the position control mode (as if selector were in position P.

Note! The numbers beside the position control knob and the transport height selector correspond to each other.

Quick checking of the draft control ranges

Note! Checking the position control potentiometer, see page 320/15.

--- start the engine and activate the power lift (switch 2) --- use the position control knob (1) to set the lower links to position 4 (selector (6) in position P) --- stop the engine but leave the ignition on --- turn the draft control selector to position 2 --- use the position control knob to stop the power lift fairly near the beginning of the lift cycle, ie. rotate the knob until the lift and lowering indicator lights are off, fairly close to the area where the lift light is lit --- turn the draft control selector to position 3. The lift indicator light should now be lit --- again use the position control knob to stop the power lift. --- turn the draft control selector to position 4. Now the lift indicator light should be lit --- use the position control knob to stop the power lift and turn the draft control selector to position 5. Once again, the lift indicator light should be lit.

D. Checking the indicator lights on switch panel --- Check that the position control indicator light (8) is lit when the draft control selector (6) is in position P --- Check that the draft control indicator light (8) is lit, when the draft control selector is in position 1---5 --- Raise the lower links by rotating the position control knob =red lift indicator light (7) is lit --- Lower the lower links =green light (7) is lit Note! The lift/lower indicator lights are connected in parallel with the control valve solenoids. Therefore, if the indicator lights are lit this means that the solenoids are receiving current.

Note! The graduation between the areas 3 and 4 is greater than elsewhere. It can be tested by turning the draft control in area 3 a little further to the lowering side. Returning to area 4, the lift indicator light is lit again.

Note! Reconditioning indicator lights, see page 320/13.

E. Checking the transport height selector ---------

Model

Note! Checking draft control selector (switch panel), see page 320/11.

Activate the control system (switch 2) Rotate the transport height selector (5) to position 9 Rotate the draft control selector (6) to position P Rotate the knob (1) max clockwise (to position 9)

H. Forced lowering button

The transport height selector (5) should at this point provide 6 different upper position for the lower links: the maximum upper position 9 and five lower positions, but not the lowest position

As standard on 865, see pages 320/4B and 320/5. When this button is depressed, the control unit pin 8 is earthed, see wiring diagram. --- Activate the power lift. Adjust the lower links to the working position with the position control potentiometer. --- Depress the forced lowering button at which time the lower links are lowered to the lowest position. --- Release the button and the lower links should find a level determined by the position control potentiometer. --- lift the lower links to the transport position with the Autocontrol---switch. Now the use of the button must not cause a lowering reaction of the lower links. Not even when the Autocontrol---switch is in the middle position. --- the lowering speed of the forced lowering button depends on the position of the lowering speed selector.

Checking the selector, see instruction on page 320/11. Adjusting max. transport height, see page 320/10 ---10A.

F. Checking the lowering speed selector Note! The lower links must have load when this check is carried out. --- Activate the control system (switch 2) --- rotate selector (6) to position P --- rotate selector (5) to position 9

297

Checking/adjusting switch on 355---665

Model

1. 9. 1995

32. Electro---hydraulic power lift

355-- 665

1. 3. 1997

limit

Code

Page

320

10

2 1

Note! The limit switch prevents the lifting arms from rising too high when the push buttons are used (if the towing hook lifting links do not limit the lifting height). If the limit switch has been detached, it can be readjusted according to this instruction: --- unscrew the position sensor so much that the eccentric on the lifting arm shaft does not damage it when the lifting arms are raised to the max. upper position. --- detach the lifting links from the lifting arms. --- disconnect the limit switch connector X7E under the cab floor mat on the LH side rear corner. Connect an ohmmeter to the pins of the connector. --- raise the lifting arms by hand and check when the limit switch switches off. --- after the limit switch has switched off the lifting arms must rise about 5 mm more at the lifting arm ends before the inner lever touches the hydraulic housing rear wall. --- adjust the limit switch and tighten its fixing screws. --- connect the limit switch connector. --- start the engine and raise the lifting arms with the push buttons until the limit switch stops the lifting movement at the adjusted level (about 5 mm (at the lifting arm ends) before the inner lever touches the housing rear wall) --- adjust the position sensor (see the following instruction).

3 Figure 5. Hydraulic lift housing 1. Limit switch 2. Position sensor 3. Inner lever

1 4

Adjusting position sensor on 355---665

2

(=Max. transport height adjustment)

Note! Make sure that the limit switch is correctly adjusted (see instruction above). 1. Unscrew the position sensor so much that the eccentric on the lifting arm shaft does not damage the sensor when the arms are raised to the max. upper position. Start the engine and raise the lifting arms with the push buttons until the limit switch stops the lifting movement.

3

3.Turn the position sensor clockwise until it reaches the bottom and then turn it back one turn. Lower the lifting arms with the lift/lower switch and raise them to the max. transport height with the same switch (selector 5 in position 9). 4. Check that the push button for lifting raises the lifting arms about 5 mm higher than the max transport height. Note! If the lifting arms rise too much with the push button, screw the sensor carefully clockwise and vice versa. Note that the push buttons do not function if the lift/lower switch is in the lifting position. Figure 6. Position sensor 1. Locking nut (Loctite 270 onto threads) 2. Permatex super 300 onto threads 3. Eccentric on the lifting arm shaft 4. Hydraulic housing cover

5. Tighten the position sensor locking nut. Apply Permatex Super 300 sealant onto the sensor threads. Locking nut is locked with Loctite 270. . 6. Fit and adjust the towing hook lifting links (if fitted) (see instruction in section 90 on page 920/7).

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1. 5. 1996

32. Electro---hydraulic power lift

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Adjusting position sensor on 865

Model

865

Code

320

Page

10A

With the new unit the position sensor must be adjusted as follows:

(Note! The 865 tractor has not a limit switch).

--- remove the lifting links of the towing hook (if fitted). --- lift the lower links to the max. transport height with the Autocontrol rocker switch --- check by lifting the lifting arms, that the lifting links rise about 10 mm before the mechanical stop (at the ends of the lifting arms about 20 mm.

Normally the position sensor does not require any adjustment. If the sensor has been removed for repair works, the sensor must be adjusted. 1. Apply sealant to the sensor threads (Permatex Super 300). Screw in the sensor, but not too deep. Warning! If the sensor is screwed too deep, the eccentric on the lifting arm shaft damages the sensor end, when the push buttons are used.

Malfunctions of position sensor Up to manufacturing date 980331 of the digital unit the position sensor has had malfunctions. The faulty units are used in the tractor production from week 810 up to tractor serial number H24542. From the unit date 980401 the faulty functions have been removed.

2. Start the engine. Raise the lower links to the max. transport height (pos. 9) with the Autocontrol rocker switch. Turn the sensor and find the position where the pump relief valve is blowing off *) and turn then the sensor inwards about 1/4 of a turn.

Note! The spare part units 31287220 do not cause the malfunctions.

3. Lower the lower links. 4. Raise the lower links again to the max. transport height and ensure that the relief valve is not blowing off.

If the AC power lift transport height has been adjusted wrongly, the lift activation can disappear and the lower links remain in the upper position. At this time, stop the engine and switch off current. Restart the engine and lower the lower links downwards by using the push buttons. After this activate the lift normally. Carry out repair by adjusting the position sensor a little outwards, check the function..

5. Check, that the lifting arm ends rise further 5 ---10 mm when using the push button. 6. After adjustment, tighten the sensor locking nut (Loctite 270). *) When the pump is on, the load on the engine can be heard

easily.

1. Special instructions A. Control unit A1E Note! The internal function of the unit has been changed from analog into digital and the analog units are not manufactured any more. In addition, in the store, there is a limited number of the analog units. The new digital unit replaces the old one. All spare part orders with number 31287210 (old analog) will be sent with number 31287220 (new digital). Unit 31287220 is suitable for models 365---865 and 600---900. Note! When the new digital unit is fitted on earlier 865---900 tractors, the compensator A3E (32634500) must be removed (remove from its connector). The compensator has been removed in the production on new tractors.

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300

10. 1. 1992

32. Electro---hydraulic power lift

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Model

Code

355-- 865

320

Page

11

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

S7E S8E

S9E

2 A2E

3 X6E

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

A. Removing the switch panel for checking on 355---665 tractors 1. Detach the panel for switches and circuit card by unscrewing four fixing screws.

Note! The terminals of connector 4 have been numbered from 1 to 12.

Note! The fixing screws have loose nuts. It is easier to unscrew/screw the screw on the left upper corner by using a ring spanner (10 mm) with a washer welded to one side of the ring to keep the nut in place. Also the ring spanner is more useful if it has a special long arm.

Note! On the 865 tractor, the console on the driver’s right must be removed before the circuit card is accessible. When removing the console, unscrew the console fixing screws, one screw in the front part on the lower corner and another in the rear part lower corner. Then raise the console until it releases from the attachment on the upper part beside the side window.

2. Turn the panel upside down so that the voltage measurements can be done on the circuit card rear side from the tinned terminals of connector 4. Do not detach the connector from the circuit card.

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32. Electro---hydraulic power lift

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12

355-- 865

1. 3. 1997

B. Voltage measurements

Code

Checking transport height selector

Turn the current on with the ignition switch and activate the control system with the Autocontrol---switch (lift/stop/lower switch) (do not detach the connector from the circuit card). Carry out measurements on the rear side terminals according to the figures a ---d below. 12

Checking supply voltage

1 8

V 12

7 6

1

Figure c) Checking transport height selector: Measure voltage between terminals 1 (or any frame contact) and terminal 8 with every selector (S8E) positions. Position 4 5 6 7 8 9

V Figure a) Measuring supply voltage: measure voltage between terminals 1 and 6 Correct value is 8---12 V

12

Terminal 8 9,5---10,5 V 7,6---8,4 V 5,7---6,3V 3,8---4,2 V 1,9---2,1V ~0

Checking draft control selector

5

1 1 11 10 9

V V

Checking lowering speed selector Figure b) Checking lowering speed selector: Measure voltage between terminals 1 (or any frame contact) and terminal 5 with every selector (S7E) positions: Position 1 2 3 4 5 6

Figure d) Checking draft control selector: Measure voltage between terminals 1 (or any frame contact) and terminals 9, 10 and 11 separately with every selector (S9E) positions:

Terminal 5 0,9---1,1 V 1,7---1,9 V 2,4---2,8 V 4,3---4,9 V 6,0---6,8 V 9,5---10,5 V

Pos. P 1 2 3 4 5

302

Terminal 10 9,5---10,5 V 3,7---4,1 V 1,8---2,0 V 1,8---2,0 V ~0 ~0

Terminal 9 0---0,2 0---0,2 0---0,2 0---0,2 0,6---0,8 V 0,6---0,8 V

Terminal 11 9,5---10,5 V 7,7---8,5V 7,7---8,5 V 9,5---10,5 V 7,7---8,5 V 9,5---10,5 V

Note! If the supply voltage deviates from the value given above, a possible fault can be poor contacts in supply connectors (+ or --- side). If other measuring values deviates from values above, the circuit card is faulty and must be changed (see instr. C).

Model

32. Electro---hydraulic power lift

10. 1. 1992

C. Changing circuit card N.B: If the voltage measurements show that the circuit card is defective the card must be replaced as a complete unit as follows: 1. Detach the circuit card from the panel by removing selector knobs and by unscrewing ring nuts and by removing the cup washers. 2. Remove also the dust seals. Detach the circuit card connector so that the card can be removed.

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

D. Checking circuit card indicator lights If Autocontrol power lift functions properly, but indicator lights on the circuit card do not function correctly the following steps must be taken: --- Detach the switch panel (instr. A) and move the connector on the circuit card so that possible poor contacts disappear. --- If an indicator light is still out of order the voltage measurements shown in instruction B must be carried out. --- If voltages are between allowable limits but light is still out of order the fault is in the bulb and the whole circuit card has to be changed as a complete unit (see instruction C)

303

355-- 865

Code

320

Page

13

1. 5. 1996

32. Electro---hydraulic power lift

1. 3. 1997

Model

355-- 865

Code

Page

320

14

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

Special tool ETV 894 100

Position sensor Supply voltage = 6,3---7,7 Veff (AC) (f4---7 kHz) Signal voltage = 1,2...2,5 V --- 3,0...5,0 V (AC) (lower links down ---up) The supply voltage is measured between the red and black connectors and the signal voltage between the blue and black connectors. Draft sensor Supply voltage = 8---12 V (DC) Signal voltage = 2,5---7,5 V DC (max pull---max push) Note! The signal voltage should be 5 V DC, when the draft sensor is unloaded. The supply voltage is measured between the red and black connectors and the signal voltage between the blue and black connectors.

Blue

Yellow ---green

Note! If the sensors do not receive the supply voltage, check the power lift fuses and the lead connectors. If these are OK the possible fault may be inside the electronic unit which should be replaced.

Brown

665: F1E

Black (1) 1

Blue (2)

3

2

Red (3)

A

Figure 1. Tool for measuring sensor signal and supply voltage Red = supply voltage=3 Blue = signal voltage=2 Black = earth lead=1

View A

1

3

Sensor connectors (X3E and X4E. 865: B1E and B2E) are placed under the cab on the RH side. They are accessible when the sensor wire bands are cut and the connectors are pulled up into the cab through the rubber bellows on the RH side of the driver’s seat.

2

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1. 3. 1997

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3. Checking the position control potentiometer

Model

355-- 865

Code

320

Page

15

4. Checking control valve and its solenoid valves If the lifting or lowering speeds do not function correctly, it is necessary to clear up whether the fault lies in the electric system or in the control valve (valve spools can get trapped etc.).

Potentiometer

Checking electric system:

1. Stop the engine and switch off current. 2. Detach the switch panel (see page 320/11) and part the position control potentiometer connector (X6E) under the panel (865: connector R1E under the side console).

Connect an ampere ---meter in series with control valve solenoids. Y1E lowering (inner) and Y2E lifting (outer). Use ETV 894 220 when measuring, see page 101/4F.

3. Measure resistance (between blue and black leads) in knob positions 1, 4 , 7 and 9. Resistance values should be: Position 1 Position 4 Position 7 Position 9

. . . . . . . . . . . . . . . . . . . . . . ~ 145 ohm . . . . . . . . . . . . . . . . . . . . . . ~ 1355 ohm . . . . . . . . . . . . . . . . . . . . . . ~ 3215 ohm . . . . . . . . . . . . . . . . . . . . . . ~ 4,5 kilo---ohm

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . ~ 3,45 A Lowering (yellow buttons) . . . . . . . . ~ 1,96 A Lowering speed positions: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 1,40 A 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 1,55 A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 1,70 A 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 2,15 A 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 2,60 A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 3,45 A

4. Then rotate the position control knob slowly from one extreme position to the other and make sure that the resistance value changes linearly without steps.

Resistance of solenoid . . . . . . . . . . . ~ 1,6 Ω

Checking control valve: If the measured values agree with the correct values above, but malfunctions occur in the lowering and lifting functions, the control valve should be removed and checked (see page 920/6). Note! The control valve solenoids have been changed. The new solenoids are round and the coils can be changed separately. The electric control of the new solenoids is the same and ithey are exchangeable with the earlier solenoids. A repair kit is available for the new solenoids, which includes the coil, seals, fixing nut and the protecting cap.

305

306

Model

32. ACB power lift

15. 4. 1999

Code

600-- 900

321

Page

1

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

6

2

1

3

4

7

5

8

B

Picture 1. ACB power lift switch panel 1. Lowering speed selector (9 positions) 2. Transport height selector (9 position) 3. Position control/Draft control selector (position P is for position control. The draft control has 6 different positions) 4. Drive Balance Control --- OFF; Drive Balance Control switched off --- Drive Balance Control switched on (situation in picture) 5. Indicator light, Drive Balance Control switched on 6. Diagnostic light 7. Indicator light, lifting 8. Indicator light, lowering Note! The functions of the position control potentiometer, lifting/lowering switch and the forced ---lowering switch are the same as earlier (see code 320). The push buttons in the cab have been replaced with one rocker switch, but the function is the same as earlier (also on AC power lift). There are push buttons on the rear mudguards. The draft sensor is the same as earlier. Functional check of ACB power lift, see page 321/6.

307

Model

32. ACB Power lift

15. 4. 1999

Picture 2. . Control switch console on 600 ---900 tractor 6. Autocontrol ---rocker switch S10E 7. Position control potentiometer R1E 8. Lowering speed selector S7E 9. Transport height selector S8E 10. Position control/draft control selector S9E 11. Rocker switch in cab, lifting/lowering S5E 12. Push buttons S1E and S2E in the rear mudguards (not illustrated) 13. Forced lowering button S11E 14. Indication lights, lifting and lowering 15. Oscillation damping switch S12E Note! On the 600---900 tractors, the console on the driver’s right must be removed before the circuit card or control unit of ACB are accessible. When removing the console, unscrew the console fixing screws, one screw in the front part on the lower corner and another in the rear part lower corner. Then raise the console until it releases from the attachment on the upper part beside the side window.

308

600-- 900

Code

321

Page

2

Model

32. ACB Power lift

15. 4. 1999

600-- 900

Code

321

P

Picture 3. ACB Power lift on 600 ---900 tractors 1. Control valve (earlier type in picture) 2. Draft sensor B2E 3. Top link sensing 4. Control unit A1E 5. Position sensor B1E 6. Autocontrol ---switch S10E 7. Position control potentiometer R1E 8. Lowering speed selector S7E 9. Transport height selector S8E

10. Position control/draft control selector S9E 11. Lifting/lowering rocker switch S5E 12. Push buttons on rear mudguards, S1E and S2E 13. Forced lowering button S11E 14. Ind. lights for lifting/lowering 14a,. Diagnostic light 15. Oscillation damping switch S12E (+ind. light) 15a. Indication light for oscillation damping

309

Page

3

Model

32. ACB---Power lift

1. 9. 2001

ACB---Power lift with Bosch EHR5 Control Valve. Compare with picture on page 321/3.

310

600-- 900

Code

321

Page

3A

311

15. 4. 1999

32. ACB Power lift

1. 9. 2001

Wiring diagram, ACB Power lift

312

Model

600-- 900

Code

321

Page

4

15. 4. 1999

32. ACB Power lift

1. 9. 2001

Model

600-- 900

Code

321

Page

5

General

Wiring diagram A1E ACB control unit A2E Control switch circuit card

42-- 44 45

B1E Position sensor B2E Draft sensor

41 41

E1E Illumination, switch circuit card E2E Illumination, position potentiometer

45 46

R1E Potentiometer, position control

45

S1E Push button, mudguard, lifting, right S2E Push button, mudguard, lowering, right S3E Push button, mudguard, lifting, left S4E Push button, mudguard, lowering, left S5E Switch, cabin, lifting/lowering S7E Selector, lowering speed S8E Selector, transport height S9E Selector, position control/draft control S10E Switch, lift/stop/lowering S11E Switch, forced lowering S12E Switch, oscillation damping (DBC)

43 43 42 42 44 45 45 45 45-- 46 44-- 45 45

X2E Connector, 9 pins, supply & rear buttons

42

Y1E Solenoid valve, lowering Y2E Solenoid valve, lifting

41 41

Connector X2E for the supply voltage is placed in the lever console. If the Power lift does not start and does not respond, when the rear push buttons are used, check fuses FA1 and FB4. If the fuses are OK, check connector X2E (pins 1 and 2). Also check the earth point GR4 on the cab rear horizontal beam on the RH side (under the mat and the plate). The wires from the LH side push buttons (on the mudguard) have been drawn via connector X6 (in the cab on the LH side) and the wires from the RH side push buttons via connector X5. In addition, the push button wires have been connected to connector X2E. If the rear push buttons function, but the Power lift cannot be activated with the Autocontrol---switch , check the wires of the Autocontrol---switch. If these are OK, the fault can lie in the control unit A1E, which should be changed. Note! When malfunctions occur, check the connectors. Poor contacts in the connectors is the most common fault in this kind of system. The hydraulic system can be tested by pushing buttons at the end of the control valve solenoids. Note! If the tractor has the earlier type control valve (solenoids on the different sides of the valve), the pins 7 and 13 of the control unit have been connected with wire 169 yellow. If a new valve is fitted (solenoids on the same side of the valve, see code 920), the wire has been removed. The new type valve does not cause other modifications in the ACB Power lift.

Wire colours: Ru = braun Pu = red Ke = yellow Si = blue Mu = black Vi = green Va = white

313

Model

32. ACB Power lift 1

8

15. 4. 1999 9

10

600-- 900

Code

321

Page

6

15

2 3

5

B

B. Functional check of ACB Power lift 7. Lift the lower links up step by step (1---9) by using the position control potentiometer (7); The lifting intervals are almost the same and the red light (2) is lit when the links move up. Leave the knob (7) in the max. position; the display shows 100 Ac (in AD ---instrument 99 Ac).

Note! The Power lift must function in the way shown in this instruction. 1. Start the engine. The red diagnostic light (1) comes on. Activate the Power lift with the Autocontrol---switch (6), at which time the diagnostic light goes out. Leave the Autocontrol---switch (6) in the lowering position and adjust the lower links with the position control potentiometer (7) to the lowest position.

8. Raise the lower links to the topmost position with switch (11), diagnostic light (1) comes on and shows that the Power lift is locked. Release the towing hook and lower the lower links together with the towing hook. Check that the mudguard push buttons and switch (11) function (the buttons function in all positions of the Autocontrol---switch (6)).

2. Set the lowering speed (8) and transport heights (9) to the minimum and position control/draft control switch (10) to position P.

9. Turn the Autocontrol---switch (6) to the transport position and immediately back to the middle position; the lower links start to rise but stop immediately, when the switch is turned to the middle position. The standard instrument shows running hours in the middle and transport position (display of AD ---instrument does not depend on the position of the switch (6)).

3. Turn the Autocontrol---switch (6) into the transport position. The standard instrument shows running hours and the decimal point is flashing, when the engine is running (The display of AD ---instrument does not change with Autocontrol---switch, but with a switch of its own). 4. Turn step by step the transport height selector (9). The lower links rise with even intervals, the red lifting ind. light (2) is lit when the lower links move up. Leave the transport height selector to the max. value (pos. 9).

10. Turn switch (6) to the transport position, at which time the lower links rise up and the towing hook is locked by the pawl. 11. Adjust the lower links to horizontal with knob (7) (switch (10) in pos. 6) so that the ind. lights (2 and 3) do not light. Press the top link bracket, at which time the ind. light (2) comes on and the lower links go up.

5. Turn the draft control switch (10) to the max. value (pos 6) and press the Autocontrol switch (6) to the lowering position. When the lower links go down, turn the lowering speed selctor (8) to the max. value. The lowering speed increases clearly and the green light (3) is lit. Leave the lowering speed in the max. value.

12. Switch on the position control mode (P). Push switch (13), at which time the lower links go down. Release the switch, at which time the lower links return to the original position. Check the position of the lower links in the Ac---display.

6. When the lower links are in the bottom position, the green light (3) is lit (floating position), the standard instrument shows between 0---15 and text Ac (in the AD ---instrument, the Ac---display must be selected in the upper display).

13. Turn the Autocontrol---switch (6) to the transport position, switch on the drive balance control (DBC) with switch (15). The lower links lower then about 4 cm. Switch off the DBC, at which time the lower links rise up.

314

Model

32. ACB Power lift

Code

600-- 900

15. 4. 1999

321

Page

7

C. Position sensor

5

A

B1E

4 2

SIGNAALI

3

SYÖTTÖ 1 Suunta A Picture 4. Position sensor in ACB Power lift 1. Eccentric on the lifting ram shaft 2. Hydraulic housing cover 3. Permatex Super 300 on the threads 4. Locking nut 5. In ---built amplifier Connnector A: 1. Earth pin 2. Signal pin 3. Supply pin

Measuring position sensor supply and signal voltages

Direct current (DC) is fed into the ACB position sensor. USUPPLY = 9,5±0,3 VDC USIGNAL = 25 ---75 % x USUPPLY (lower links down ---up)

Sensor voltages can be measured as earlier by using special tool ETV 894 100 and a universal instrument, see page 321/9.

The position sensor connector is fitted at the end of the sensor.

Measuring values --- Supply voltage . . . . . . . . . . . . . . . 9,2 ---9,8 VDC --- Signal, lower links down . . . . . . . 2,3 ---2,5 VDC --- Signal, lower links up . . . . . . . . . . 6,9 ---7,4 VDC

Note! The positon sensor cannot be repaired but a defect sensor must be changed for a new one. Important! Fault code number 22 indicates, that the position sensor does not function. Diagnostic light and fault codes, see instr. E.

Adjusting position sensor, see page 321/14.

315

Model

32. ACB Power lift

Code

600-- 900

15. 4. 1999

321

Page

8

D. Draft sensor (same as on AC Power lift) OSCILLATOR

FILTER

DEMODULATOR

F

Ua Us F/2

F/2

Picture 5. Draft sensor 1. Draft sensor 2. Top link bracket

2

A

45 Nm

(8---12 VDC)

1

A Short circuit in draft sensor line

The draft sensor acts as a lower mounting bolt of the top link bracket. The sensor converts draft forces into electrical signals.

--- Short circuit in the supply line causes deadlock of the whole system (current breaks also in the selector panel A2E ). If this short circuit is only momentary, the system starts normally with the lift/lower switch. If the short circuit is sustained, the power lift remains locked.

USUPPLY = 8 ---12 V (DC) USIGNAL = 2,5 ---7,5 V (DC) (max. draft --- max. push) (signal voltage is 5 V when the top link is unloaded).

--- Short circuit in the signal line causes the lifting reaction on the lower links during the short. The system returns automatically to the normal function after the short circuit (”ghost lifts”).

The draft sensor internal voltages can be measured with tool ETV 894 100, see the next page. The sensor can be loaded e.g. with a mounting lever, so that the function of the sensor can be verified.

--- Contact between the supply and signal lines causes the full lowering reaction on the lower links during the short circuit.

A damaged draft pin must be changed . If the sensor wire is damaged it can be repaired using three pin connectors. Fault codes 31 and 32 indicate the fault in the sensor.

316

Model

32. ACB Power lift

15. 4. 1999

Code

600-- 900

321

Page

9

Measuring internal voltages of position sensor and draft sensors

Open the position sensor connector at the end of the position sensor or the draft sensor connector under the cab on the RH side (the draft pin connector is accessible when the plastic bind is cut after which the connector can be pulled up through the rubber bellows). Connect ETV 894100 between the sensor connector. During measuring the current must be switched on and the lift must be activated.

Ordering no ETV 894 100

Below are given the correct voltage values (DC): Position sensor: --- supply voltage . . . . . . . . . . . . . . . . . . . . . 9,2 ---9,8 VDC --- Signal, when lower links down . . . . . . . . 2,3 ---2,5 VDC --- Signal, when lower links up . . . . . . . . . . 6,9 ---7,4 VDC Draft sensor: --- supply voltage . . . . . . . . . . . . . . . . . . . . . 8 ---12 VDC --- signal voltage . . . . . . . . . . . . . . . . . . . . . . 2,5 ---7,5 V VDC (max. pull --- max. push). Signal voltage is 5 V when the top link is unloaded. The supply voltage is measured between the red and black connectors and the signal voltage between the blue and black connectors.

Blue

Note! If the sensors do not receive the supply voltage, check the power lift fuses and the lead connectors. If these are OK, the possible fault may lie inside the electronic unit which should be replaced. If the signal voltages are incorrect, the fault lies in the sensor or in its adjustment.

Yellowgreen Brown

Black (1)

1 Blue (2) Red (3)

3

2

A

Picture 1. Tool to measure internal voltages of sensors Black connector = earth=1 (brown wire) Blue connector= signal voltage=2 (yellowgreen wire) Red connector= supply=3 (blue wire)

1

3 2 Direction A

317

Model

32. ACB Power lift

15. 4. 1999

600-- 900

Code

Page

321

10

E. Function of diagnostic light and fault codes When the current is switched on with the ignition switch, the diagnostic light is lit for a while (book symbol). This is the self --testing of the ACD system. After a short time the diagnostic light is lit continuously. This indicates that the power lift is locked. When the light is on, all functions are locked, but the push buttons function. The power lift is activated by turning the lift/lower switch first to the lifting and then to the lowering position, at which time the diagnostic light goes out and the power lift responds to all switches. Immediately after the activating the ACD limits the supply current to the solenoid valves for safety. This limit delays movements of the lower links. The current supply limit disappears, when the function limit of the control unit has been achieved or if the lift/lower switch is used anew. After use of the push buttons the ACB is locked and the diagnostic light is illuminated.

Fault codes ACB power lift continually monitors possible malfunctions in the system. The faults are divided into three different levels according to their seriousness as follows: 1. Serious faults: --- the power lift is locked --- relay closes (protects outputs) --- diagnostic light indicates the fault --- Remedy: Repair the fault, start the tractor and activate the power lift. 2. Medium serious faults: --- the power lift is locked. --- diagnostic light indicates the fault --- Remedy: Repair the fault and activate the power lift with the lift/lower switch 3. Minor faults --- the power lift continually functions --- diagnostic light indicates the fault. When the lift/lower switch is turned, the diagnostic light goes out, if the fault has disappeared. A possible fault can be localised with the aid of the diagnostic light, which displays by flashing the number of the fault code. For example, if the signal wire to the draft control selector is damaged or there is poor contacts in connectors (fault code 36), the diagnostic lights flashes as follows: --- Long pause --- three flashes --- short pause --- six flashes. During momentary faults, the diagnostic light flashes, until the lift/lower switch is turned, although the fault has already disappeared. THE FAULT CODES ARE LISTED ON THE NEXT PAGE.

318

Model

32. ACB Power lift

15. 4. 1999

Code

600-- 900

321

Page

11

Fault codes of ACB Power lift 1. Serious faults Fault code number

Fault

Control unit connector pin

Description

11

Output/lifting

2

Output signal to lifting solenoid faulty or poor contacts in solenoid wire to pin 6.

12

Output lowering

14

Output signal to lowering solenoid faulty or poor contacts in solenoid wire to pin 6.

13

Short circuit

6

Measured current in pin 6 too high. Short circuit between pins 2 and 6 or between pins 14 and 6 (solenoid in short circuit)

14

Push button in mudguard, upwards

10

Signal from push buttons not OK. Push button or its wire damaged.

15

Push button in mudguard, downwards

20

Signal from push buttons not OK. Push button or its wire damaged.

16

Supply

12

Control unit supply not in order. Supply of 9,5 V and earthing not in order

2. Medium serious fault Fault code number

Fault

Control unit connector pin

Description

22

Position sensor

19

Signal from sensor faulty --- Poor contact or position sensor disconnected --- Possible short circuit or earthing --- Position sensor faulty adjusted

23

Position control potentiometer

16

Signal from potentiometer faulty. Poor contacts or wire loose.

24

Transport height selector

22

Signal from selector faulty. Poor contacts or wire loose.

28

Up/stop/down switch

8

Signal from switch faulty. Poor contacts or wire loose.

3. Minor faults Fault code numbers

Fault

Control unit connector pin

Description

31 *) 32 *)

Draft sensor

18, 17

Signal from sensor faulty: --- Poor contact or wire disconnected --- Possible short circuit or earthing --- Sensor overloaded

34

Lowering speed selector

24

Signal from selector faulty. Poor contacts or wire disconnected.

36

Position control/ draft control selector

4

Signal from selector faulty. Poor contacts or wire disconnected.

*) The diagnostic light flashes by turns fault codes 31 and 32, since in 100---series tractors the Power lift has only one draft sensor, but it is connected to two pins (17 and 18) of the control unit.

319

Model

32. ACB Power lift

15. 4. 1999

F. Drive Balance Control (DBC)

600-- 900

Code

321

Page

12

Verifying the function of the DBC When the tractor is driven in transport driving on an uneven road or field with an heavy implement attached to the power lift linkage, the shocks caused by the implement must light the indicator lights for lifting and lowering. This indicates that the DBC is functioning (the draft sensors react to shocks from the implement). When the DBC is activated, the indicator light for the lowering must light for a while, since the lower links lower about 40 mm to the intermediate limit position. Note! Checking the function of the DBC switch, see page 321/13.

Ind. light

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

Drive Balance Control is activated, when: a) Power lift is activated. b) Power lift is in the transport position c) The DBC switch is in the ON position (indication light is lit). When these four terms are valid, the lower links lower about 4 % from the upper limit position to the intermediate limit position. The lower links can lower 4 % from the intermediate limit position to the lower limit position. Thus the max. distance between the upper limit position to the lower limit position is 8 %. All percentages are counted from the total movement range of the lower links (100 %). Note! Position of the lowering speed selector does not affect the Drive Balance Control speed. The DBC can be switched off with the selector.

320

Model

32. ACB Power lift

15. 4. 1999

G. Checking switch panel of ACB

600-- 900

Code

321

Page

13

3. Checking transport height selector S8E

Remove the switch panel from the lever console (do not disconnect the connector). Switch on currrent and activate the ACB power lift. Measure from the terminals on the rear side of the circuit card (DC).

1. Measuring supply voltage

Picture c) Measure voltage between pins 8 and 5 with all selector positions: Position 1 2 3 4 5 6 7 8 9

Picture a) Measure supply voltage between pins 21 (---) and 10 (+): Correct value is 9,2 ---9,8 V (DC). Measure also voltage between pins 21 and 8. Correct value is about 1,6 V. Note! If the supply voltage is incorrect, the fault lies in connectors/wires.

Pin 5 0 0,9---1,2 V 1,9---2,3 V 2,9---3,3 V 3,9---4,3 V 4,9---5,4 V 5,9---6,4 V 6,8---7,5 V 7,6---8,2 V

4. Draft control selector S9E

2. Checking lowering speed selector S7E

Picture b) Measure voltage between pins 8 and 6 with all selector positions: Position Pin 6 1 0,3---0,5 V 2 0,7---1,1 V 3 1,1---1,5 V 4 1,6---2,0 V 5 2,3---2,9 V 6 3,1---3,7 V 7 4,1---4,7 V 8 5,6---6,0 V 9 7,6---8,2 V

Picture d) Measure voltage between pins 8 and 3 with all selector positions: Pos. P 1 2 3 4 5 6

321

Pin 3 7,6---8,2 V 4,0---4,4 V 3,3---3,6 V 2,4---2,9 V 1,6---2,6 V 0,7---1,0 V 0

15. 4. 1999

32. ACB Power lift

1. 9. 2001

Model

600-- 900

Code

321

Page

14

H. Changing switch panel

5. Checking DBC selector S12E

Note! If the voltage measurements show that the switch panel is faulty, the panel should be changed as a complete unit. 1. Remove the cab RH side console. Remove the circuit card on the panel by removing the selector knobs and by unscrewing the ring nuts under the knobs and remove the lock washers. Remove the dust protectors. 2. Disconnect the connector of the switch card.

Picture e) Measure voltage between pins 21 and 1 (DBC) with two selector positions: Position OFF DBC switched on

Pin 1 2,0---2,4 V 0

Note! If the measured values in points 2 ---5 deviate from the given values, the fault lies in the switch panel circuit card which should be changed.

6. Checking lift/stop/lowering switch S10E

3. Fit onto new selectors washers with lugs. These washers limit selector positions. Before fitting the washers turn every selector anti ---clockwise as far as possible to their extreme positions. After this fit washers so that the lugs engage in the holes given below: --- lowering speed selector; hole 9. --- transport height selector; hole 9. --- draft control selector; hole 7. --- Drive Balance Control; hole 2. 4. Ensure by rotating the selectors, that the lowering speed and transport height selectors have 9 positions, draft control selector 7 position and DBC selector 2 positions. 5. Connect the connector to the new switch panel. Fit the dust covers (no 317 204 20) onto the washers and fasten the circuit card to the switch panel with the ring nuts (under the nuts locking washers JE 9423).

Picture f. Measure voltage between pins 8 and 9 with all three switch positions: Position Lowering Middle position (Stop) Transport position

6. Fit the knobs and fasten the DPS circuit card. Attach the selector panel onto the lever console.

Pin 9 2,4---2,8 V 3,5---4,0 V 4,9---5,4 V

7. Refit the side console in the cab.

Note! If the measured values deviate from the given values, check the switch connector. If the values are further incorrect, the fault lies in the circuit card which should be changed.

322

15. 4. 1999

32. ACB Power lift

1. 9. 2001

I. Checking switch panel indicator lights

Model

600-- 900

Code

321

Page

15

L. Adjusting position sensor (in connection with repairs)

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

J. Checking function of position control potentiometer 27,2 mm

1. Stop the engine and switch off current. 2. Remove the side console in the cab (see page 321/2) and disconnect the potentiometer R1E connector near it. 3. Measure the potentiometer resistance (between blue and black wires) in pos. 1, 4 , 7 and 9. Resistance values (±20%): ~ 145 ohms ~ 1355 ohms ~ 3215 ohms ~ 4,5 k ---ohms

1. Apply sealant (Permatex Super 300) onto the sensor threads. Screw the sensor into place so deep, that the distance between the locking nut lower face (when in contact with housing) and sensor end lower side (see picture) is 27,2 mm.

4. Then rotate the position control knob slowly from one extreme position to the other and make sure that the resistance value changes linearly without steps.

Warning! If the sensor is turned too deep, the eccentric on the lifting ram shaft damages the sensor, if the lower links are raised up with the push buttons.

Note! Fault code 23 indicates problems in the position potentiometer.

2. Start the engine. Lower the lower links. Raise the lower links up to the max. trasnport height (pos. 9) with the Autocontrol---switch.

K. Control valve solenoids (Y1E and Y2E). Note! Control valve EHR4 in picture below. Concerning control valve EHR5, see page 920/8.

3. Check that the lifting arm ends rise a further 5 ---10 mm before the mechanical stop.

Position 1 Position 4 Position 7 Position 9

............................ ............................ ............................ ............................

Note! If the arm ends rise more than 5 ---10 mm, turn the sensor outwards a little and vice versa. 4. After adjustment tighten the locking nut (Loctite 270). Do not affect the adjusment when tightening the locking nut. 5. Check again the adjustment. Ensure, that the pressure --relief valve does not blow off in the transport position. Note! Fault code 22 indicates problems in the position sensor. Important! In the rear side of the ACB hydraulic housing there is a limiter bolt, see picture on page 920/13 point 5. The bolt is adjusted so that the lifting arms do not touch the cabin when the yellow push buttons are used. When using the position potentiometer or the Autocontrol rocker switch the lifting movement must stop before the inner lever in the housing touches the bolt.

The diagnostic light indicates faults in the solenoids or in their signals. Fault code 11 indicates, that signal to the lifting solenoid Y2E is incorrect (e.g. poor contacts). Code 12 indicates that the signal to lowering solenoid Y1E is incorrect (e.g. poor contacts). Fault code 13 indicates that one of the solenoids is in short circuit. If the solenoid resistance is zero (short circuit) or infinite (break), change the solenoid coil. The correct resistance value is about 1,6 ohms.

323

324

Model

33. Valmet Agrodata

10. 1. 1992

205-- 665

Code

Page

330

1

Agrodata---performance monitor N.B. These instructions deal with trouble shooting on the Agrodata unit. Instructions on how to install Agrodata on the Valmet tractor will be sent for inserting into the Workshop Manual. For detailed instructions concerning the use of the Agrodata system, please see the Operator’s Manual.

Number keys (1---9) Zeroing key for time, area (trip), area (total) and litres. Also used to input the figure 0 Wheel circumference input key Working width input key Function code Flow meter calibration Time (hours and minutes) Speed Area meter (trip) and distance travelled Area meter (total) Engine rpm and application rate (litres per hectare) Piece counter and total litres consumed

1

2

1. Selects between tractor and implement wheel sensor for measurement of speed and area.

2. Selects between measurement of engine revs or implement functions (e.g. piece counter or flow rate).

Figure 1. Agrodata function keys

General

Before the Agrodata unit can be used the following three values must be input: --- the circumference of the wheel (cm) on which the magnetic sensor is mounted (LH rear wheel of the tractor) divided by the number of magnets used. --- the effective working width (cm) of the implement. --- the function code (9999 except when measuring flow rate and total consumption)

Agrodata can be fitted on Valmet 205---555 tractors as an optional accessory. Agrodata is meant to be used in agricultural and contract work for measuring tractor and implement functions and work performance. Agrodata can monitor: --- Time (h, min) --- Area (ha) --- Speed (km/h) --- Flow rate (l/ha) --- Total consumption (litres) --- Revs (rpm) --- Number of items (piece counter) --- Distance (current metres)

Important: Before measuring flow rate and total consumption, the Agrodata unit and flow meter must be calibrated in order to obtain the correct function code. The data listed above is retained in the Agrodata unit’s memory even if the battery cables are disconnected from the battery terminals.

The different keys are pressed to call up a display of a particular function (for instructions on how to use function keys, see the Operator’s Manual).

325

Model

33. Valmet Agrodata

10. 1. 1992

Figure 2. Agrodata unit fitted on 205---555 tractors

326

205-- 665

Code

330

Page

2

1. 9. 1995

33. Valmet Agrodata

1. 3. 1997

Figure 2. Agrodata unit on 205---555 tractors A6 = display unit and function keys E7 = supply voltage connector (placed in the cab light) Note! On the latest models, the supply voltage is taken from the windscreen wiper motor M3. B8 = sensor for detecting LH side rear wheel rotation speed B9 =hydraulic lift linkage sensor, which stops the area meter when the implement is raised. The sensor is activated by a magnet on the position control lever (not on the tractors which have an electro---hydraulic power lift (Autocontrol) B10 = sensor for detecting engine revs X49 = socket for connecting sensors on an implement. X1E = lift/lower ---switch (Autocontrol power lift), which sends a signal to the display unit when an implement is raised. This function corresponds to the function of sensor B9. S50 = rocker switch selects between tractor and implement wheel sensor for measurement of speed and area. S49 =rocker switch selects between measurement of engine revs or implement functions (e.g. piece counter or flow rate). X47 = connector for sensor wires. Sensor wires are connected according to the picture in the right lower corner of figure 2. Note! Position of different component is shown in the side view of the tractor

Equipment The Agrodata unit consists of a monitor in the cab, sensors, leads connecting monitor and sensors and supply voltage leads (there is a fuse in the fuse box). On the monitor rear cover there are terminals for sensor leads and supply voltage leads. The terminals are numbered from one to nine (1---9) and the leads are numbered correspondingly (lead no 19, however, to terminal 9) The Agrodata system uses magnetic sensors. When the magnet and the sensor are in close proximity the sensor is activated and an electrical signal is transmitted to the monitor display. The following sensors are fitted on the tractor: --- The engine rotation speed sensor; this measures engine speed from the crankshaft. The sensor magnet is fitted on the belt pulley at the front end of the crankshaft. --- The wheel sensor; this is fitted on the LH rear wheel mounting flange. Several magnets can be fitted on the wheel, evenly spaced, for more accurate measurement of driving speed. Correct speed measurement is not possible if too few magnets are used with a big wheel. --- The power lift linkage sensor is fitted on the position control lever. Its function includes stopping the area meter when the implement is raised. Autocontrol hydraulic lift doesn’t have this sensor but the signal is sent to the display unit from the lift/lower ---switch. In addition to the tractor sensors, implement sensors can also be connected to the Agrodata unit (flow meter, piece counter etc.). For this purpose a socket is fitted at the rear of the tractor. These sensors are not included in the Agrodata installation kit. These should be ordered separately from the spare parts center.

327

Model

205-- 665

Code

330

Page

3

Model

33. Valmet Agrodata

10. 1. 1992

1

1 ---

2

Linkage sensor

sign.

3

4 ---

sign.

Wheel sensor

2

3

5 ---

4

6 +

Supply voltage

5

6

7

7

330

Page

4

9

8

8

sign.

205-- 665

Code

---

9 +

Rotation speed sensor Implement sensors

Figure 3. Monitor unit rear panel (wires have corresponding numbers) Terminals 1 and 2; Hydraulic lift linkage sensor wires (or wires from lift/lower ---switch on Autocontrol models) Terminals 3 and 4; Wheel sensor wires. Terminals 5 and 6; Supply voltage leads (battery voltage). Terminals 7, 8 and 9; Engine rev sensor wires and wires from implement sensors (e.g. flow meter, piece counter, rev counter etc). Terminal 8 is without lead on tractors with a mechanical hydraulic power lift.

1. Trouble shooting A. Checking display operation 3. If the power supply is in order, but the monitor fails to operate, the defect is in the unit itself. In this case the monitor must be replaced (the condition of the other leads and sensors is irrelevant if the monitor is defective).

The Agrodata unit receives its power supply from connector E7 (in the cab light). 1. Turn on the ignition. Check that: --- the monitor display is lit --- the display flashes the word ”AGRO”

4. If the monitor responds to commands (eg. working width, wheel circumference), it is in working order.

2. If this does not happen: --- check fuse FA2 in the fuse box (second fuse from right) --- disconnect the monitor (not the leads) and make sure that the unit is receiving power (measure voltage between terminals 5 (---) and 6 (+))

5. If the monitor displays or flashes the word ”FEJL”, this indicates that the supply voltage to the unit is not adequate (12 V). Check the condition of the battery and the battery connections.

328

Model

33. Valmet Agrodata B. Checking the sensors and leads

--- input the working width by pressing the

Page

330

5

6. The wheel sensor and the linkage sensor (not Autocontrol) can also be tested with an ohmmeter: --- disconnect the monitor (not the leads) --- disconnect lead 1 from terminal 1 --- measure the resistance between terminal 1 and lead 4. Wheel sensor resistance should be 33 ohms when the magnet is close to sensor, otherwise 10 kilo---ohms or greater --- measure the resistance between terminal 1 and lead 2. Linkage sensor resistance should be 33 ohms when the magnet is close to the sensor, otherwise 10 kilo---ohms or greater

1. Turn on the ignition and: key followed

by 8888. --- press the time function key

205-- 665

10. 1. 1992

Code

. Following this the display

should be clear (this indicates that the unit is in order).

7. Check the earth connection by measuring the voltage between leads 8 (---) and 6 (+); this should equal battery voltage.

--- set switches 1 and 2 for the unit to measure tractor operations (front side pressed) 2. Now the unit will display the following symbols:

8. The defects may be either in the sensors or in the leads. First check the connectors and leads. If the connection is in order, the sensor has to be changed. The implement sensors are checked in the same manner. When this is being done, selectors 1 and 2 must be in implement position (the rear side pressed).

--- ”h” (only flashes), when the wheel sensor is activated. Activation can be done while driving the tractor --- ”r” (lit), when the hydraulic lift linkage is in the upper position. On Autocontrol hydraulic lift ”r” is lit when the lift/lower --switch is in the lifting position. --- ”F” (lit), when the engine rotation speed sensor is activated (rocker switches in tractor position) or when the flow meter paddle wheel is revolving (rocker switches in implement position). The engine speed sensor cannot be tested while the engine is running.

C. Connecting the leads from the implement sensor to the plug poles

3. If the letters listed above do not appear in the display, check that the sensors and magnets are correctly fitted.

Flow meter leads Blue to pole 5 Black to pole 6 Brown to pole 2

(---) (+) (signal)

Piece counter leads/rotation speed sensor Brown to pole 5 (---) Blue to pole 6 (+) Black to pole 2 (signal) Wheel sensor leads Blue to pole 3 Brown to pole 1

Max. 5 mm

4. The distance between the magnet and sensor is max. 5 mm. The magnet must be mounted the right way round (yellow dot points towards the sensor).

(signal) (---)

Sensor for detecting position of part of implement Blue to pole 7 (signal) Brown to pole 5 (---)

5. If the sensors are correctly fitted then:

1

--- disconnect the monitor (not the leads) --- disconnect the lead 1 from terminal 1 --- turn on the ignition --- measure the voltage between terminal 1 (---) and the following leads; --- lead 9 (+) input voltage (approx. battery voltage) --- lead 4 (+), wheel sensor: voltage ~ 0 when the magnet is close to sensor, otherwise 11 ---13,5 V. --- lead 2 (+), linkage sensor: voltage ~ 0 when the magnet is close to sensor, otherwise 11 ---13,5 V. On Autocontrol lift voltage is ~ 0 when the lift/lower ---switch is in the lifting position, otherwise 11 ---13,5 V. --- lead 7 (+), rotation speed sensor: voltage ~ 0 when the magnet is close to sensor, otherwise 11 ---13,5 V.

6

2 .7

5

3 4

The numbering of poles can be found in the plug by the corresponding pole Note! Figure shows the plug from the lead side.

Note! The line from the Agrodata unit to the socket can be checked as follows: --- input working width of 8888 and press the time key --- shunt between the socket terminals no 5 (---) and 2 (signal) and the display should show ”F” (flow meter, piece counter) --- shunt between terminals no 1 (---) and 3 (signal). The display should show letter ”h” (only flashes) (wheel sensor). --- then shunt between terminals no 5 (---) and 7 (signal). The display should show letter ”r”.

Note! Voltmeter should have such measuring heads which can be pricked through the cable shoe plastic cover.

329

Model

33. Valmet Agrodata

10. 1. 1992

Spare part numbers for sensors and plug Wheel sensor, linkage sensor, sensor for detecting position of part of implement: 31703200 (2---pole sensor) Piece counter/rotation speed sensor: 31703000 (3---pole sensor) Plug: 31702900

C. Further information on Agrodata operation --- The linkage sensor should be adjusted so that the symbol ”r” is displayed when the implement is in the upper position. If the max. height of the implement is re ---set, the position of the sensor must be adjusted. --- Any short---circuit device may be used (eg. mechanical relays). --- Only original magnets should be used. If the magnet is not strong enough malfunctions will occur. --- The full supply voltage should not be connected to the sensor, because this may cause damage to the sensors. --- The unit will not be damaged if the power supply wires are connected in reverse. --- The monitor bulbs cannot be changed in the present models. They are 10000 hour bulbs, and they not only illuminate the display but also dry out internal moisture.

330

205-- 665

Code

330

Page

6

1. 3. 1997

33. Agrodata---instrument

1. 9. 2001

Model

865, 600-- 900

Code

331

Page

1

Agrodata---instrument Note! The AD ---instrument on the 865 and 600---900 tractors is the same as on Mezzo---series. However, on the 865 and 600---900 tractors the AD ---instrument does not show the PTO shaft revs. AD ---instrument is a factory fitted option up to chassis no. L21546 after which the Agroline ---instrument replaces the AD ---instrument (see code 340).

A

B

C

The upper digital display A shows:

Agrodata ---instrument includes two digital displays. The instrument is fitted in place of the standard instrument. The AD ---instrument has in ---built electronics.

1. Time (allways when ignition is switched off) 2. Position of lower links (0---99) (if AC power lift) 3. Distance travelled (up to1000 km, after which is zeroed) 4. Gearbox temperature (from +40˚C. LO is shown at lower temperatures).

The AD ---instrument has a rev counter, engine temperature gauge and fuel gauge and warning lights as in the standard instrument.

The different functions of the upper display can be changed by pressing the right edge (spring returned) of the switch C in the dashboard. The black arrow indicates which function is selected.

In addition, the lower digital display B shows: 1. Running hours, when the tractor is stationary (also when the current is switched off). 2. Driving speed, when the tractor is moving (from 0,3 km/h. There is letter L in front of the value, when the driving speed is slower than 4 km/h). Note! The AD ---instrument wire loom includes also the indicator light function for the engine glowing.

331

1. 3. 1997

33. Agrodata---instrument

1. 9. 2001

Model

Code

865, 600-- 900

B3: Sensor, gearbox oil temperature B6: Sensor, gearbox P4: Agrodata Instrument: Hour recorder/ Speedometer (in standard model AC---display) P5: Agrodata --- instrument: Clock / AC / Trip / gearbox oil temp. S1: Ignition switch S37: Switch, AGRODATA ---instrument, cursor+ program F1C: 5A Radio, (clock), not in models 600---900 X25: 9---os., Agrodata ---instrument (from G27101---> ) X26: 26 pins., instrument, left, white GR3: Ground, wire loom of dashboard

865

600---900

865 (G27101--- >): X25, X55

332

331

Page

2

1. 3. 1997

33. Agrodata---instrument

1. 9. 2001

Agrodata---instrument

Model

865, 600-- 900

Code

331

Page

3

Zeroing the travelling distance

(see picture on the previous page)

--- select travelling distance into the display by pressing the switch right edge. --- press the switch left edge until the display is zeroed.

Note! The AD ---instrument can only be fitted on the 4WD models. The mounting requires a new undershield for the propeller shaft. Current from the ignition switch (12 V) comes to the AD ---instrument as on the standard instrument via fuse FA1. AD --instrument is supplied with permanent current (12 V) for the clock via fuse F1C (865) or via fuse FD5 (600---900). This voltage can be measured between pins 23 (ground) and 24 (supply) of the connector X26. Voltage via the starter switch can be measured on pin 26 of the connector X27. Always when the instrument does not function, check the fuses. If the fuses and supply voltages are OK, but the instrument does not function, the fault lies in the instrument section in question.

Time setting

--- select time into the display by pressing the switch right edge. --- press the switch left edge, until the hours are flashing. --- set the hours by pressing the switch right edge --- press the switch left edge, until the minutes are flashing. --- set the minutes by pressing the switch right edge --- when the time has been set, press the left edge, until the correct time appears into the display (flashing stops). Calibrating the instrument for different tyres, see page 331/5.

The rev counter and fuel and temperature gauges can be replaced separately and also the smaller circuit card (or bigger basis circuit card) which includes the digital displays. Warning light bulbs and instrument light bulbs can be changed separately without opening the instrument casing.

Wiring diagram, engine glowing indicator light

Switch S37 earths pin X26/12, when the right edge is depressed. When depressing the left edge, pin X26/13 gets earthed. Note! Agrodata ---instrument is accessible after opening the hatch in the steering wheel console rear face. Unscrew via the hatch screws on the upper rear corners of the dashboard and unscrew also the dashboard upper front screws on the sides of the dashboard. When necessary, unscrew the lower bolts of the console side plates via the hatch, after which the AD ---instrument is accessible.

333

Model

33. Agrodata---instrument

1. 3. 1997

1. Sensors

865

Code

Page

331

4

B. Gearbox temperature sensor B3

A. Gearbox speed sensor B6 Note! The sensor resistance should be 1,0 ---1,10 kΩ. It can be measured on pins 9 and 10 of the white connector behind the instrument. If the resistance is infinity, it should be measured from the sensor pins in order to clear up possible breaks. The sensor is the same as on AD ---instrument on tractors 6000---8750.

Changing the speed sensor:

Washer

Note! The gearbox oil temperature must be higher than +40˚C, before the display shows the temperature. At the lower temperatures the display shows LO. If the AD ---instrument does not show the gearbox oil temperature, check the sensor and its wiring. The sensor is the same as on AD ---instrument for 6000---8750 tractors. Sensor resistance values: --- 34 ---40 Ω (~ +120˚ C) --- 75 ---90 Ω (~ +90˚ C) --- 200 ---250 Ω (~ +60˚ C) (resistance value increases when temperature lowers).

--- Remove the faulty sensor and clean the threads where the sensor fits --- Screw in a new sensor until its end touches the measuring wheel and open it then, until the clearance is 0,6 ---0,8 mm (use e.g. 0,7 mm feeler gauge). --- Secure the sensor with a lock nut and connect the wires --- Carry out a test---drive and assure that the instrument shows the driving speed and the driving distance. --- Connect the connectors to the sensor and protect the pins with grease UC1913 (vaseline spray HHS 2000 (Würth)). --- Fold the wire on the sensor and fasten it with a plastic cable tie.

The resistance can be measured between pins 23 and 26 in the white connector X26 behind the instrument casing. If the resistance value is infinity, measure it once again on the sensor pins, so that possible breaks can be cleared up. If you doubt that the sensor wiring is faulty, switch on the ignition. Select the gearbox temperaure into the Agrodata display (follow the black arrow). Detach the wire from the sensor and connect it to the tractor frame. When the wire is earthed, some temperature values must flash in the display and three lines must be visible in the display, if the display and the wiring is OK.

Note! If the measuring wheel must be removed, it must be centered with a dial gauge when fitting it. Measure e.g. on every third tooth and rotate the wheel forwards and zero the dial gauge on the first tooth. The greatest allowable total throw is 0,2 mm.

334

1. 3. 1997

33. Agrodata---instrument

Model

1. 1. 1998

2. Calibrating the instrument for different tyres

865 600-- 900

Code

Page

331

5

Code numbers with different tyre sizes Rear wheel

1. Remove the switch C by prying it carefully. Do not disconnect the wires.

r dyn mm

Code no Impulses/m 32 teeth

2. Switch on current with the ignition switch.

C

3. Connect the switch pins 1 and 7 with an auxiliary wire and press at the same time the switch left edge for over 3 seconds. ”P” appears in the lower display and the valid code number (e.g. P143). The first digit is flashing. Remove the wire.

14.9---30/8N

665

162

16.9---30/8N

695

155

16.9R30/8M

695

155

16.9---30/8N

695

155

16.9R30/8M

695

155

16.9R30/8N

695

155

480/70R30

706

153

13.6---36/8N

715

151

13.6R36/8M

715

151

13.6---36/8N

715

151

13.6R36/8M

715

151

13.6---36/8N

715

151

13.6R36/8M

715

151

18.4R30/8M

720

150

13.6R38/8N

740

146

16.9R34/8M

745

145

16.9---34/8N

745

145

480/70R34G

753

143

18.4R34

783

138

16.9R38

800

135

18.4R38

833

129

20.8R38

872

124

Note! If a tractor has tyres which are not listed in the table above, the code number can be calculated as follows:

X= 4. Adjust the hundreds by pressing the switch right edge.

YxV vmax

in which

X= correct code number Y=actual code number in AD ---instrument V= tractor’s constructional speed (30, 40 or 50 km/h) Vmax=tractor’s max driving speed which is shown by AD ---instrument

5. When the hundreds are correctly adjusted, press the switch left edge and tens start to flash. 6. Adjust the tens by pressing the right edge and then press the left edge, at which time single units start to flash.

Example: In the AD ---instrument the actual code number is 170. Tractor’s constructional speed is 40 km/h. AD ---instrument shows the tractor max. driving speed of 38 km/h:

7. Adjust the ones by pressing the right edge. 8. Finally press the left edge for over 2 seconds. Calibrating has been carried out and running hours appear in the lower display. Fit the switch.

X=

Note! The code number value can vary between P100---P299. When pressing the switch right edge, the code value changes from a smaller value to greater one. The code numbers and corresponding tyres are listed in the table.

335

170 x 40 38

= 179

336

Model

34. Infoline and Agroline ---instruments

1. 9. 2001

General The manufacturing of the present dasboard instrumet in 600---900 tractors will be finished and a new instrument will be fitted in place. The new instrument is either a standard Infoline ---instrument (L26206---) or a factory fitted optional Agroline ---instrument (L22101---). If the tractor has as standard the HiShift---buttons, the Agroline instrumet is a standard equipment. The Agroline ---instrument can only be fitted on 4WD tractors. In the Agroline ---instrument there is a digital display in place of a mechanical hour recorder with the Infoline and the Agroline digital display correcponds the earlier AD ---instrument. The other functions are similar in these instruments. In the dashboard in connection with the instrument change there are modifications and a part of the dashboard switches have been moved to the RH side side pillar of the cab. In addition, some switches have been fitted on the RH side of the steering wheel console. Infoline --- and Agroline ---instruments cannot be repaired. Internal light bulbs and the cover glass can be changed. The warning lights are LED ---diodes, which cannot be changed, but the LED ---diodes lifetime is very long. There are connectors X26 and X27 on the rear face of the instrument for wire looms. The Agroline ---instrument is controlled by a microprocessor and it is programmed according to the tractor type. Recarding service or repairs the instrument program cannot be changed. A spare part instrument is ready ---programmed and also the hour recorder reading can be set to the correct value. In this case the tractor chassis number, tractor model, possible front PTO and the actual hour recorder reading must be notified.

337

600-- 900

Code

340

Page

1

Model

34. Infoline and Agroline ---instruments

1. 9. 2001

600-- 900

Code

340

P

Picture 1. Infoline --- and Agroline ---instruments

338

Page

2

Model

34. Infoline and Agroline ---instruments

1. 9. 2001

Picture 1. Infoline --- and Agroline ---instruments.

600-- 900

Code

340

Page

3

Lower row shows: (lower row functions are scanned by pressing the upper edge of switch17b): --- running hours --- driving speed (km/h or miles/h)

1. Revolution counter 2. Fuel gauge 4. Engine temperature gauge 5. Tractor dir. ind. flashers 6. Warning light, blocked engine air filter 7. Not in use 8. First trailer dir. ind. flashers (does not flash if a bulb in the system has blown). 9. Second trailer dir. ind. flashers (does not flash if a bulb in the system has blown). 10. Engine glowing 11. Ind. light, PTO clutch lever 12. Ind. light, parking brake 13. Low fuel level ( 4 km/h 6. Clutch slips and engages

9. In a test---drive with driving speeds under 4 km/h the pedal rises up slower (4) (restriction 1+1/2). With speeds over 4 km/h the pedal rises up faster (restriction (1+1/2)+(2)). Here must be observed, immediately the driving speed exceeds 4 km/h, the pedal rises up faster.

1. Check the clutch fluid level. Raise the tractor on axle stands. Start the engine and use the HiShift several times so that air is removed from the system. Let the engine run for a while, so that the hydraulic oil warms up. 2. Check the HiShift pressure in the test point on the block rear end. Correct value is 13 ---15 bar. 3. Close the foremost restriction spindle (B). The other restriction spindle (A) should be open 2 turns (factory setting).

10. Turn the steering wheel against the stop at which time the pump pressure rises up to 90 bar. Hold the clutch pedal by hand and press the HiShift button and check, that the clutch pedal force is not too great (>250 N). In the HiShift pressure test point, the pressure should be 13 ---15 bar.

4. Press the button in the gear lever knob at which time the clutch pedal moves down. Engage gear L1. Adjust the engine speed to low idling.

11. Check the function of the clutch. Drive over and under 4 km/h and check that the engagement of the clutch occurs softly. Check for leaks.

5. Release the button at which time the clutch pedal raises up quickly to the knee point (3), in which the working cylinder piston rests against the damping piston. Tractor wheels must not rotate.

Note! Tractor driver can adjust the Hi Shift between certain limits according to his own choice. However, the foremost restriction (B) must always be open at least 1 turn, to prevent excess wear of the clutch disc.

6. Open the restriction spindle (B) a little, at which time the pedal starts to rise slowly. The wheels must start to rotate before the pedal has risen 10 mm (ideal value 5 mm) from the knee point.

Fault tracing. If the clutch pedal in paragraph 5 rises immediately to the upper position: --- the foremost restriction spindle leaks. --- solenoid valve Y15 does not function or leaks. --- damping cylinder filling valve leaks.

Note! On account of possible small leakage of the restriction spindle the pedal can start to rise slowly before the restriction spindle is opened. The knee point (3) can, however, be observed from change of rising speed of the pedal.

375

Model

41. HiShift

1. 6. 1998

600-- 900

Code

412

Page

4

1

5 6

2

3

7

4

Picture 2. HiShift hydraulic block Note! The picture above has been changed for visual reasons, so that all galleries can be seen. In the picture, both solenoids are energised i.e. the button is pressed and the driving speed is below 4 km/h.

B. HiShift hydraulic block Note! The tightening torque of the three block fixing bolts is 23 Nm. Check that the cylinder (1) pushes the pedal fully home against the stop. In connection with possible fitting work, all bearing and sliding points must be greased with universal grease. Assure, that the working cylinder push rod functions correctly in the complete stroke of pedal.

Leaking piston seals can be changed after unscrewing the seal flanges. The filling valve spring and ball can be removed by unscrewing plug (7) between the restrictions (3 and 4). The restriction spindles have o---rings, which can be changed. Do not screw in the spindles too hard, otherwise the spindle tapered surfaces can damage. The restriction spindles have securing nuts.

Note! Impurities in the valve block can cause malfunctions, such as jamming of pistons and solenoid valves, blocking of oil passages etc., at which time the valve components can be opened and the valve can be tried to clean.

Important! The seal rings of the damping cylinder solenoid valve Y15 (rearmost) are of different material to the seal rings of the solenoid valve Y14, and they must not be interchanged. In connection with repair works the solenoid valve Y15 seal rings must not be lubricated with oil but, if needed, with clutch fluid.

HiShift working cylinder (1) has been connected to the tractor working hydraulics. There is a relief valve (5) in the block (14 bar) and a pressure ---test point (6). The relief valve has been adjusted in the factory and then sealed. The damping part is not connected to the tractor hydraulic system, but its own circuit uses clutch fluid (=brake fluid). In case of a malfunction, check the clutch fluid level in the reservoir, when the pedal is in the upper position.

376

1. 6. 1998

41. HiShift

1. 9. 2001

Model

600-- 900

Code

412

Page

5

C. Electric system of HiShift

When the buttons in the gear lever knobs are pushed, the foremost solenoid valve Y14 is grounded and it becomes energised and the clutch pedal moves down.

--- if the solenoid valve is OK, measure whether there is a voltage of 12 V in the connector pins of Y14 when the buttons are depressed. If not, the fault can lie in the valve wires or in the push buttons.

When the driving speed is under 4 km/h, AD ---instrument grounds via relay K24 the rearmost valve Y15 (becomes energised) and the pedal rises up slower.

If the pedal rising speed has malfunctions: --- measure whether there is a voltage of 12 V in the connector pins of valve Y15 when the driving speed is under 4 km/h or the tractor is stationary. If not, the fault lies in relay K24 or in valve wires. --- when the driving speed is over 4 km/h, the valve Y15 should be unenergised and the pedal rises up faster.

When the engine is running and the hydraulics are OK, but the pedal does not move down although the button is pressed: --- check fuse FD3 in the fuse box. If the fuse blows repeatedly, the fault can lie in diodes. --- if the fuse is OK, check the resistance of the solenoid valves, which should be 11 ---12 ohms. When voltage of 12 V is fed into solenoid pins, the valve must become magnetic and the spindle must move (click).

Valve Y15 has been connected to the speed sensor B6 of the AD ---instrument. If the instrument shows correct speed and travelling distance, the sensor B6 is OK. Otherwise the sensor should be checked/changed, see page 331/4. Note! If the electric system seems to be OK, but malfunctions still occur, one possible fault can be impurities in the hydraulic block of the HiShift.

377

1. 6. 1998 1. 9. 2001

41. HiShift

HiShift electric components

Model

600-- 900

Code

412

Page

6

Position of components:

Note! The push button (S45) wires have been soldered to the buttons. As a spare part are dispatched wires together with the buttons. The wire lower ends have a connector.

Y14: the foremost solenoid on the hydraulic block lower face under the cab on the LH side of the tractor frame. Y15: the rearmost solenoid on the hydraulic block lower face under the cab on the LH side of the tractor frame. GR3: earthing point on the cab front wall under the dashboard. V5: Diode box under the dashboard (the box is changed as a complete unit) K24: Relay under the dashboard Connector X25 under the dashboard Connector S45 in the lower part of the gear levers.

The wires of the buttons have been drawn up to the lever knobs inside a plastic tube round the gear levers. There is a protective plate in the lower part of the levers to protect the connectors. Note! S45.1 is an optional push button. Note! HiShift is connected to the AD ---instrument via white connector X26/11 on the rear side of the instrument.

378

Model

42. Gearbox

1. 12. 1986

205-- 865

Contents General (Op. no. 420)

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox 220, 250 and 270, description (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Gearbox lubrication system (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Oil filter (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Gearbox lubrication pump (8+4R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox 272, description (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Main shaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Countershaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Bevel pinion shaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 4WD shaft (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Gearbox lubrication pump (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- Gearbox lubrication (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential (8+4R) and (12+12R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 3 6 9 10 11 11A 11C 11D 11E 11F 11G 11H 12 14 16

Selector forks (Op. no. 421)

1. Reconditioning selector forks: A. Changing selector forks for speed gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 B. Changing selector forks for range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Shafts and gear wheels (Op. no. 423)

1. Reconditioning pinion shaft: A. Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Reconditioning synchromesh unit and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Adjusting pinion shaft position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Fitting pinion shaft and adjusting bearing preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Fitting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 3 4 4 5 7

2. Reconditioning layshaft: A. Removing layshaft and changing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 B. Fitting layshaft and adjusting bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3. Reconditioning input shaft: A. Removing input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B. Changing bearings/synchronizing cones and fitting shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C. Changing input shaft front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4. Reconditioning output shaft for powered front axle: A. Removing shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Changing selector fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Fitting shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing shaft front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 14 15 15

Differential (Op. no. 424)

1. Changing/reconditioning differential: A. Removing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Changing differential side gears and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Fitting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Reconditioning differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

379

1 2 4 5

Code

420

Page

1

1. 3. 1997

42. Gearbox

15. 4. 1999

Model

205-- 900

Code

Page

420

Technical Data Fully synchronized gearbox with pressure lubrication. Number of speeds: (numbers within brackets refer to machines with low gear or overdrive) --- forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 (12) --- reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 (8)

Oil (in common for gearbox and final drives) Viscosity and quality grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 120/4. Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 l (205---665), 27 l (865, 600---900) Lubrication of gearbox with gear wheel pump: --- pump volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 cm3/r --- pressure limiting valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7 MPa --- filter, by ---pass valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 MPa --- filtration capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 μm

Gear ratios: ---------

Pinion/crown wheel (30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion/crown wheel (40 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion shaft/output shaft to powered front axle (30 km/h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion shaft/output shaft to powered front axle (40 km/h) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14 (Z=7/43) 4.67 (Z=9/42) 1.57 (Z=30/47) 1.19 (Z=32/38)

Total gear ratio (engine/rear wheel hub) Gear 1 (L1) 2 (L2) 3 (L3) 4 (L4) 5 (H1) 6 (H2) 7 (H3) 8 (H4) R1 R2 R3 R4

30 km/h version 238,042 173,496 110,080 83,133 68,800 50,148 31,818 24,029 175,543 127,953 81,184 61,311

40 km/h version 180,824 131,803 83,627 63,156 52,267 38,097 24,172 18,255 133,358 97,205 61,675 46,577

Tightening torques Gearbox ---fuel tank: --- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox ---PTO: --- 10 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2 pcs, M16 (earlier models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2 pcs M20 (latest models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox ---hydraulic lift: --- ---610311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 610312--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low gear ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draw bar ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion shaft, round nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion shaft, front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input shaft, front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lay shaft, front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output shaft to powered front axle, round nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector shaft locking nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector shaft nut, outgoing shaft to powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil pump: --- 2 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 3 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller shaft drive flanges: --- 8.8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 10.9 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

380

200 Nm 300 Nm 230 Nm 100 Nm 195 Nm 380 Nm 125 Nm 195 Nm 23 Nm 380 Nm 46 Nm 270 23 Nm 23 Nm 23 Nm 127 Nm 23 Nm 120 Nm 23 Nm 6 Nm 23 Nm 35 Nm

2

1. 12. 1995

42. Gearbox

1. 1. 1998

Model

205-- 900

I Input shaft --- clutch shaft, connecting sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low gear --- Clutch shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crown wheel, attaching bolts: --- earlier M10x60 (8.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- later M10x60 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential bearing covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab --- rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rim disc --- hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering system return oil pipe (rear end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic system pressure pipe to pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower links --- rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code

420

55 Nm 55 Nm 46 Nm 60 Nm 46 Nm 220 Nm 330 Nm 50 Nm 120 Nm 200 Nm 380 Nm

Settings Pinion shaft, rolling resistance: --- measured with torsion meter at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential, rolling resistance: 30 km ---transmission --- measured with torsion meter at end of pinion shaft, where the resistance is the rolling resistance of the pinion shaft bearings + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 km ---transmission --- measured with torsion meter at end of pinion shaft, where the resistance is the rolling resistance of the pinion shaft bearings+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counter shaft, end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Imput shaft, end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tooth backlash, pinion/crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1,7---2,3 Nm

0,6---2,0 Nm 0,8---2,6 Nm 0,075---0,150 mm 0,025---0,075 mm 0,18---0,33 mm

Required sealing compounds and locking fluids: Side cover --- gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Silastic 738 RTV Selector rail locking bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 242

Special tools Gearbox A Part no. ETV 893 260 ETV 893 630 ETV 893 640 ETV 893 650

Description Key for round nut, output shaft front wheel drive (505---905) Plate for fitting seal in bearing cover, input shaft Plate for fitting seal in bearing cover, output shaft front wheel drive Drift for fitting needle bearing/sealing ring in input shaft

Gearbox B ETV 890 220 ETV 890 830 ETV 891 220 ETV 891 870 ETV 891 900 ETV 892 210 ETV 892 230 ETV 892 350

Universal handle Sleeve for fitting front bearing on pinion shaft (PTO 505---905) Sleeve for fitting bearing on counter shaft Sleeve for fitting rear bearing on output shaft, front wheel drive Plate for fitting thrust bearings for differential side gears (Gearbox 505---905) Sleeve for fitting outer bearing race for input shaft front bearing (Gearbox 505---905) Sleeve for fitting bearing race for pinion shaft front bearing (Gearbox 505---905) Key for pinion shaft round nut (Gearbox 702---903) Sleeve for fitting front bearing on output shaft, front wheel drive Sleeve for fitting rear bearing on input shaft (Gearbox 505---905)

381

Page

3

1. 12. 1995

42. Gearbox ETV 892 490 ETV 893 660 ETV 893 610

1. 3. 1997

Model

Code

205-- 865

420

Page

4

Plate for fitting pinion shaft rear bearing bearing race (Final drives 702---903) Key for adjusting differential bearings Tool for removing/fitting input shaft and bearings --- ETV 893 611 Spindle --- ETV 893 612 Sleeve for removing shaft --- ETV 893 613 Sleeve for fitting shaft --- ETV 893 614 Drift for removing/fitting shaft --- ETV 893 615 Nut M16, 2 pcs

Locally prepared tools ET 893 570 ET 893 620 (ET 893 760)

Drift for removing/fitting selector shaft Sleeve for fitting rear bearing on pinion shaft Sleeve for fitting counter shaft bearing races Sleeve for fitting rear bearing on input shaft Support for front frame (2 pcs), prevents front axle oscillation when splitting tractor (see Frame and Wheel)

A

ETV 893260

ETV 893630

ETV 893650

ETV 893640

B

ETV 890 220

ETV 891 870

ETV 890 830

ETV 892 210

ETV 891 220

ETV 891 900

ETV 892230

382

1. 12. 1995

42. Gearbox

1. 3. 1997

Model

Code

205-- 865

420

ETV 892 350

ETV 893660 ETV 892 490

ETV 893611 ETV 893612

ETV 893614

ETV 893615

ETV 893613

ETV 893610

Locally prepared tools

ET 893570

ET 893 620

ET 893 760

383

Page

5

1. 5. 1996

42. Gearbox

Model

205-- 865

10. 10. 2003

Code

420

Page

6

Gearbox 220, 250 and 270, description (8+4R) The speed gearbox has eight forward speeds and four reverse speeds. All speed gears and also the range gears are synchromesh. Tractors equipped with an extra low gear have twelve forward speeds and eight reverse speeds.

(1---4) is selected with the speed gear lever. On tractors with a powered front axle, there is a shaft in the lower part of the gearbox which transfers the engine power to the front axle. The gear on this shaft is in mesh with a gear on the pinion shaft. The front wheel drive is engaged with a dog clutch which is operated with a lever by the driving seat.

The gearbox is operated with gear levers to the right of the driving seat. High/low (H/L) and reverse (R) respectively are selected with the range lever and the desired speed gear

R

L

4WD

384

H

1. 12. 1986

42. Gearbox

1. 1. 1998

The shafts in the gearbox are supported in taper roller bearings (ball bearings on the output shaft for the front wheel drive). The gears on the input shaft and on the pinion shaft are carried in plain bearings apart from the front gear (teeth 29/25) on the input shaft which is carried in needle bearings. The layshaft has gears formed integral with the shaft.

Model

205-- 900

Code

420

Page

7

The pinion shaft is fitted with two synchromesh units. The front unit is used for selecting the reverse speeds and the low gear. The rear synchromesh unit engages high gear. The selector forks are fitted in pairs on the selector shafts (see Fig. 2). Two tubular pins on the selector shaft prevent two speeds from becoming engaged at the same time on the input shaft (or on later models, blocking pins, see Fig. 2 item A). These are fitted on the selector shaft. On the pinion shaft, a blocking plate (see Fig. 2 item B) is fitted on the selector shaft.

All gears in the gearbox are helical gears, except for the gear wheel pair for the front wheel drive. The gears rotate in constant mesh with the corresponding idler gears. The input shaft is connected to the clutch shaft with a connecting sleeve (if the tractor is not equipped with a low gear). The input shaft is fitted with two synchromesh units. The front unit is used for selecting speeds L3, L4, H3, H4 or the reverse speeds R3 and R4. The rear synchronization unit is used for engaging speeds L1, L2, H1, H2 or the reverse speeds R1 and R2.

The position of the selector forks relative to the synchronization rings and synchronization unit can be adjusted with nuts at the front end of the selector shaft.

Fig. 2. Selector forks A. Blocking pins which prevent two speeds from becoming engaged at the same time (input shaft) B. Blocking plate which prevents two speeds from becoming engaged at the same time (pinion shaft). In gearbox 270 the blocking plate is different: in the beginning of the series (6) and later (6a) (three parts 6a are different). The 270 gearbox 270 is fitted on 600, 700, 800 and 900 tractors. The 600---900 tractors’ selector mechanism can be equipped with Euro blocking device, which prevents engagement of gear H4 (speed limits). On the tractors with the blocking device, the shifter levers are different.

385

10. 1. 1992

42. Gearbox

15. 9. 1995

Figure 3. Position of selector forks and adjustment 1. Selector shaft locking screw. Loctite 242 on the threads 2. The selector levers are lubricated with universal grease N.B. The shifter levers are attached to the selector lever outer ends with a larger tension pin (see black arrows) and inside it must be fitted a smaller tension pin with the split side to the opposite side as on the larger pin.

386

Model

205-- 865

Code

420

Page

8

15. 4. 1999

42. Gearbox

10. 10. 2003

Model

205-- 900

Code

420

Page

9

Gearbox lubrication system (8+4R) A gear pump fitted to the rear of the input shaft provides the pressurised oil for lubrication. The lubricating oil is fed via an oil filter into a distribution piece and on to the different lubrication points.

The gearbox is lubricated through splash lubrication and through force ---feed lubrication (of the input and pinion shafts). The pressurised oil from the lubrication system is ducted to lubricate the final drives, PTO, brakes and eventually the low gear. The oil to the input shaft is fed via the pump housing in through the space between the input shaft and the long PTO shaft. From there the oil is led through ducts to lubricate the bearings. The oil to the pinion shaft is ducted in through thefront end cover and further through ducts to lubricate the bearings.

Figure 4. Diagram of lubrication system 1. Suction pipe 2. Pump 3. Pressure oil pipe to filter 4. Filter 5. Distribution piece 6. To input shaft 7. To final drives and brakes 8. To pinion shaft 9. To low gear (not this pipe on 600---900) 10. Return oil from low gear 11. To PTO 12. Oil cooler (only 665, 865, 600---900)

Oil is directed to the oil cooler from the filter bracket (oil cooler only on 665, 865 and 600---900 tractors).

Note! 205---565 tractors have no oil cooler. On these tractors the filter bracket ports to the cooler are plugged and it has only one outlet connection to the low gear. The filter bracket is fitted with a by --pass valve. The other lubrication system is similar on 205---665 tractors. The oil cooler on 600---900 tractors is the same as on 865 from frame number G09303 incl. (the same as on Mezzo 6000---series).

387

1. 9. 1992

42. Gearbox

10. 10. 2003

Model

205-- 865

Code

420

Page

10

Oil filter (8+4R) In the filter bracket there is a pressure relief valve with an opening pressure of 0,7 MPa. The filtration capacity of the filter is 0,5 μm (glass fibre filter). The filter is also fitted with a by ---pass valve with an opening pressure of 0,2 MPa.

Fig. 5 Oil filter (205---565) 1. Pressurised oil from pump 2. Lubricating oil to filter 3. Filter bracket 4. Lubricating oil to gearbox 5. Lubricating oil to low gear 6. To oil sump

Path of oil to the filter (fig. 5). Oil comes from the pump through the delivery pipe (1) to the right---hand space of the filter bracket. From there the oil continues to the filter inlet (2). The filtered oil is conducted to the left---hand space (3) of the filter bracket and is supplied via a pipe (4) to the various lubricating points.

If the lubricating oil pressure exceeds 0,7 MPa (102 psi), for some reason, the relief valve in the filter bracket opens and ducts (6) oil direct to the gearbox. The by ---pass valve opens at a pressure of 0,2 MPa (29 psi) if the filter for some reason is blocked, in which case the oil passes through unfiltered.

Oil is supplied to the low gear through the connection (5) (if there is no low gear, this hole is plugged. The tightening torque of the plug is 20 Nm (14 lbf ft)).

Note! Filter bracket on tractor 665, see previous page.

388

1. 1. 1998

42. Gearbox

10. 10. 2003

Model

205-- 900

Code

420

Page

11

Gearbox lubrication pump (8+4R)

355---900

Fig. 6. Gearbox lubricating pump 1. Suction pipe from gearbox 2. Delivery pipe to filter 3. Distribution piece 4. Lubricating oil to input shaft 5. Rear end of input shaft with drive lugs 6. Drive lugs Gerabox 270 is fitted on 600---900 tractors. On these tractors the gearbox lubricating oil pump is larger since the new Overdrive and Low gear needs more lubricating oil.

389

Model

42. Gearbox

10. 10. 2003

600-- 900

Code

420

Page

11A

Gearbox 272, description (12+12R) The present 8+4R gearbox has got an alternative gearbox type 12+12R (in some marketing areas limited to 11+11R).

This alternative needs always a shuttle unit, because the R (reverse) group has been replaced with LL (creeper) --group.

20

24

1) Main shaft 2) Countershaft 3) Bevel pinion shaft 4) 4WD shaft 5) Shuttle unit

Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---step, fully synchronized, operated by lever Speed ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ranges, operated by lever: H = high range, synchronized M = medium range, synchronized LL = creeper range, no synchronized Forward/reverse gear unit . . . . . . . . . . . . . . . . . . . . . . . . synchronized, operated by lever No. of speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12+12

390

Model

42. Gearbox

10. 10. 2003

600-- 900

Code

420

Page

11B

--- Changes:

Assembling the transmission 272 in short:

--- Mechanical shuttle unit + control lever

1. Assemble lubrication pipes into the housing. 2. Assemble the parts of the main shaft on the table. 3. The inner races of the countershaft bearings must be assembled before setting the countershaft to the gearbox. 4. Install the main and counter axles into the housing and fix the bearing covers and check tolerance 5. Assemble the bearings, bush and spacer ring to the Z58 gear wheel of the pinion shaft. Glue the bush and the plate with instant adhesive. Note! Glue should be dropped on the needle bearing. Install the built---up the Z58 gear wheel into the housing. 6. Install the 4WD fork 7. Assemle 4WD axle to the housing. Thread first the gear wheels, bearings, spacer rings, circlip and bush. Then assemble the bearing of the front end side and the bearing of the rear end side and the circlip. 8. Install M ---LL synchromesh units of the pinion shaft with fork to the housing at the same time. 9. Install the pinion shaft into the housing and assemle the gear wheels to the axle. Check the moment of rotation. Note! Measure the location of the axle before settings. 10. Install the pump 11. Install the fork of the lock of differential and axle 12. Install the differentiall and check bearing preload and tooth backlash.

--- The gear ratio difference between 2nd and 3rd gears has been decreased. The syncro of M ---group has been enlarged (before was 82mm now is 90mm). --- The M ---LL selector fork replaces the L ---R selector fork. The spare part numbers of the selector forks of the main gears has been changed (space for pump drive shaft). --- There is a new lubricating oil pump for the gearbox and different pipe work. The pump is driven from the shuttle unit by a shaft. The old and new pumps are not interchangeable. --- The PTO clutch shaft has been changed. The shoulder has been moved forward (because of the pump gasket). The old clutch shaft (45355700) cannot be used in the new gearbox (272) and the new shaft (34806900) can not be used in the old gearbox (270). In the rear end of the new shaft there is a machined a shoulder for identification. --- There are few modifications in the gear levers.

391

Model

42. Gearbox

10. 10. 2003

600-- 900

Code

420

Page

11C

Main shaft (12+12R)

--- The input shaft is fitted with two synchromesh units. The front unit is used for selecting gears 1...4. The synchromesh units are equal and interchangeable (with exception of hubs). The mounting direction is free. After fitting new bearings the bearing clearance has to be adjusted. --- Adjust the bearing end float : --- Fit the spacer ring and select shims so that the bearings have a definite clearance in front of the front bearing and fit the bearing cover. --- Turn the shaft 20 ---30 revolutions, in order to bed in the bearings. --- Position a dial gauge against the front end of the shaft and push the shaft forwards and backwards and note the value of end float on the gauge. The correct value is 0,025 ---0,075 mm --- Increase or decrease the shim thickness if necessary --- Gearbox type 272: --- main shaft doesn’t drive the oil pump ---The front end and bearing cap of main shaft has been changed (no oil seal). The corresponding spacing ring to shims (30382900) has been removed ---The number of teeth for 2nd and 4th gears has been changed (2nd gear; earlier 23 now 24, 4th gear; earlier 32 now 36) ---The bearing for 3rd gear (Z29) has been changed to a sleeve bearing type. ---The reverse gear Z25 has been removed. In it’s place there is a spacer sleeve + pin (30187000).

1) Shims s= 0,10; 0,15; 0,20; 0,50 mm. 2) In connection with repairs, use sliding compound e.g. Molykote 321 R Spray (UC3957) on sliding surfaces or oil them. Clean parts well before treatment! 3) Needle bearing is pushed into the shaft until bearing front side is at level with shaft end. Bearing number side forwards. 4) The bushing pins can be fitted with Loctite 641. Do not allow locking fluid to leak on to the bearing! 5) Lubricating oil pump 6) The new shaft (34806900) has a indication shoulder for identification. The clutch shaft of the PTO has been changed. In the new shaft the (turned) thinning has been moved forward (because of the new location of the pump gasket). The old clutch shaft cannot be fitted into the new gearbox (272) or the new shaft in the old gearbox (270). In the rear end of the new shaft there is a machined shoulder for recognition. Notice after the installation: --- Install the main and counter axles into the housing and fix the bearing covers and check tolerance

392

Model

42. Gearbox

10. 10. 2003

600-- 900

Code

420

Page

11D

Countershaft (12+12R)

--- Gearbox type 272: ---The number of teeth for 2nd and 4th gears has been changed (2nd gear; earlier 30 now 29, 4th gear; earlier 20 now 21) --- Axial play has been changed (earlier 0,075---0,150mm now 0,025 ---0,075mm). --- The bearing in the Z15 gear side has been changed --- Foremost bearing cover has been changed

Notice before the installation: --- The inner races of the countershaft bearings must be assembled before setting the countershaft to the gearbox. Notice after the installation: --- Install the main and counter axles into the housing and fix the bearing covers and check tolerance

--- After fitting new bearings the bearing clearance has to be adjusted. 1) Adjusting bearing clearance: --- place a sufficient number of shims under the end cover to give the bearings a definite clearance and tighten down the cover --- Measure the bearing clearance with a dial gauge. Place the stylus against the rear end of the shaft. Reduce the shim thickness until the bearing clearance is 0,025 ---0,075mm. --- turn the shaft at least 20 ---30 revolutions and check the clearance again. 2) Bearing cover, see main shaft

393

Model

42. Gearbox

10. 10. 2003

600-- 900

Code

420

Page

11E

Bevel pinion shaft (12+12R)

--- The output shaft has ball bearings. The gears have pressure lubrication.

1) Shims (see adjustment of pinion shaft position. 2) Spacer rings (see adjustment of bearing preload

--- The pinion shaft is fitted with two synchromesh units. The front unit is used for selecting the M ---group or LL group. The rear synchromesh unit engages high gear.

3) Sliding lac, e.g. Molykote 321 R spray 4) Glue the bush and the plate with instant adhesive. Note! Glue should be dropped on the needle bearing.

--- The other movement direction of the rear synchromesh unit has been eliminated with a blocking plate (note the mounting direction). Note! the blocking plate must be mounted forward.

Notice before the installation: --- After Installation of the main and counter axles, assemble the bearings, bush and spacer ring to the Z58 gear wheel of the pinion shaft. Glue the bush and the plate with instant adhesive. Note! Glue should be dropped on the needle bearing. Install the built---up the Z58 gear wheel into the housing. --- Install the 4WD axle. --- Install the pinion shaft into the housing and assemle the gear wheels to the axle. Check the moment of rotation. Note! Measure the location of the axle before settings.

--- Note the mounting direction of the bearing sleeve under the gear Z61. --- Gearbox type 272: ---The M ---LL ---range replaces the L ---R ---range, with the twin gear Z58/34 + needle bearings. ---Selection of the range gears has been improved by enlarging the synchro of the M ---group (82mm ---> 90mm). NB! The LL group has no synchronizing ring!

394

Model

42. Gearbox

10. 10. 2003

600-- 900

Code

420

Page

11F

4WD shaft (12+12R)

--- On tractors with a powered front axle, there is a shaft in the lower part of the gearbox which transfers the engine power to the front axle.

Notice before the installation: --- Install first the 4WD fork. --- Assemle 4WD axle to the housing. Thread first the gear wheels, bearings, spacer rings, circlip and bush. Then assemble the bearing of the front end side and the bearing of the rear end side and the circlip.

The output shaft has ball bearings. The gear on this shaft is in mesh with a gear on the pinion shaft. --- The front wheel drive is engaged with a dog clutch which is operated with a lever by the driving seat. Four ---wheel drive can be operated without pressing down the clutch pedal even when the tractor is running. On the other hand, engaging must not be done under heavy loading or if the rear wheels spin. --- Gearbox type 272 : For the LL ---range gear there is a twin gear Z51/23, with a needle bearing 1) To be filled with grease

395

Model

42. Gearbox

10. 10. 2003

600-- 900

Code

420

Page

11G

Gearbox lubrication pump (12+12R)

1) Lubrication oil pump 1a) Drive lug 2) Suction from the tank (gearbox housing) 3) Pressure oil for filter 4) Distribution piece 5) Lubricating oil for main shaft 6) Driving shaft for pump 7) Seal of the PTO drive shaft (needs the new type of the PTO drive shaft)

--- The lubrication pump has been removed from the center line of the input shaft. The pump rotates in one direction (as earlier), but because of space the pump construction is new. Revolution capacity is 9,1 cm3 . The middle gear of the shuttle unit drives the pump. The pump rotates, although the forward ---reverse shuttle is in neutral. The old and the new pump are not interchangeable. Also the shuttle unit become the lubrication by the lubrication pump. --- In connection with repairing, do not block up the tube which comes to the front part of the pinion shaft with silicon. --- If the lubrication pump has been opened, secure the screws with locking fluid Loctite 242 (UK0126).

396

Model

42. Gearbox

10. 10. 2003

Gearbox lubrication (12+12R)

The filter seat (13) has also a by ---pass valve (0,4 MPa), which protects the system when e.g. oil is stiff in the oil cooler. Shuttle unit lubrication (272): The lubrication oil is led through the groove on the joint surface and with help of the tube X to the bearings of the shuttle unit clutch shaft. In the shuttle unit housing there is a throttle (1,0 mm, by which the lubrication oil flow to the shuttle unit is adjusted).

397

600-- 900

Code

420

Page

11H

1. 5. 1996

42. Gearbox

10. 10. 2003

Model

205-- 900

Code

420

Page

12

Differential (8+4R) and (12+12R) The crown wheel together with the differential casing are mounted in the gearbox housing in taper roller bearings. Bearing preload and tooth backlash between the pinion and the crown wheel are adjusted with adjusting nuts.

The differential consists of two differential side gears and two differential pinions. The side gears are journalled in plain bearings in the differential casing. The differential pinions are journalled with locked thrust washers made of bronze. The differential is lubricated with oil from the transmission.

Fig. 7. Section of differential

Differential lock The differential lock is a mechanically engaged pin lock which locks one of the differential side gear against the differential casing with the aid of the engaging sleeve. A lamp lights on the instrument panel when the lock is engaged.

1. Crown wheel 2. Gearbox 220 differential pinion, 2 pcs. Gearbox 250, 270 and 272 4 pcs. 3. Differential side gear 4. Engaging sleeve for differential lock 5. Selector fork 6. Adjusting nuts 7. Switch for differential lock control lamp

The differential lock must only be used when travelling on soft and/or slippery ground. The lock is engaged mechanically with the aid of a spring --loaded control located on the RH side of the driving seat. The lock can be engaged and disengaged when travelling straight forward if the wheels are turning at the same speed.

398

1. 12. 1986

42. Gearbox

1. 7. 1989

Model

205-- 865

Code

420

Page

13

Function of differential lock ( ---610311) When the lever (1) is depressed the movement is transferred by the rod (2) to the pushrod (3) until this moves against the stop on the link (4). Simultaneously the spring on the pushrod (3) is compressed.

of the shaft closes the circuit to the control lamp on the instrument panel. When the lever (1) is lifted, the spring in the rod (2) is tensioned. As soon as the forces between the differential side gear and housing permit, the spring in rod (2) pulls out the lock. The control lamp on the instrument panel goes out.

When the movement between the differential side gear and the casing permits the pins to move, the spring on the pushrod (3) pushes in the shaft. The selector fork (5) on the shaft presses in the coupling device and the differential lock becomes engaged. The switch at the end

Figure 8. Differential lock control (---610311) 1. Operating lever 2. Damping spring 3. Push rod 4. Link 5. Selector fork 6. Adjusting nut

Note! With effect from ser. no. 610312 the differential lock control linkage has been changed (new control linkage, see page 420/17).

399

1. 7. 1989

42. Gearbox

15. 9. 1995

Model

Code

Page

420

14

205-- 865

Synchronization

Synchromesh unit function (pinion shaft)

All gears (even the reverse) are synchronized. The synchromesh units on the input shaft and pinion shaft are of different design. On the input shaft the synchronizing cones have locking lugs and wire springs, whilst locking lugs, ball studs and coil springs are used on the pinion shaft.

Fig. 10. Function of synchromesh unit

A

The synchromesh unit for high gears (H) is single acting and is therefore blocked in the opposite direction.

B

C

A. Gear in neutral B. During the initial stage of the engagement, the sliding coupling presses the locking lugs (ball stud and angle piece) against the synchronizing cone. The cone is pressed against the cup (taper) on the gear wheel under friction. The difference in speed between the synchromesh unit and the gear wheel begins to even out. The teeth on the synchronizing cone still prevent the gear from engaging. C. When the synchromesh unit and gear wheel have the same speed, the cone is turned out of the locked position exactly opposite the teeth on the sliding coupling so that it can engage the teeth on the gear wheel. Fig. 9. Synchromesh units on input shaft and pinion shaft 1. Synchromesh unit engagement lock:

1. Input shaft --- gears 1, 2, 3 and 4 (diam. 68 mm, steel) 2. Pinion shaft --- reverse/low gear (diam. 82 mm, steel) --- high gear (diam. 82 mm, steel)

The shape of the teeth inside the sliding coupling and on the gear, lock the coupling sleeve and prevent it from slipping out of engagement when accelerating or engine braking.

400

Model

42. Gearbox

1. 12. 1986

Code

205-- 865

420

Synchromesh unit function (input shaft) The function is the same as for the pinion shaft synchromesh unit. The sliding coupling presses the syncromesh cone locking lug against the synchronizing cone. This is due to the goove on the inside of the sliding coupling. When the speed of the synchromesh unit and gear wheel is nearly the same the sliding coupling engages with the gear wheel.

2 4 3 1 5

1 5

4

6

Fig. 11. Synchromesh unit on input shaft 1. When assembling it should be noted that the bent ends of the springs are not to be fitted in the same locking lug. 2. Sliding coupling 3. Hub 4. Synchronizing cone locking lug 5. Synchronizing cone 6. Gear wheel

401

Page

15

Model

42. Gearbox

1. 12. 1986

205-- 865

Code

420

Page

16

Gear levers The gear levers are mounted in the floor in ball socket joints. This design creates exact lever movement. Cup springs are fitted in the ball joint to eliminate any play in the joint.

The gearbox is operated by two gear levers on the right side of the driving seat. The range lever is used for selecting low, reverse or high gears. The speed gear lever is used for selecting 1---4.

The engagement of the additional low gear is only possible when the range lever is in the L or R position. It cannot be engaged in the High position as this is prevented by a mechanical lock.

The low gear (L) range and reverse (R) of the range lever are located opposite each other in the gear shifting gate. The range lever is used as a direction selector for all speeds.

Fig. 12. Gear lever system 1. Range gear lever 2. Speed gear lever 3. Low gear operating lever 4. Ball joints are lubricated with universal grease 5. Lubricate the lower joints on the gear levers with grease containing molybdenum 6. Differential lock operating lever 7. PTO selector lever

402

Model

42. Gearbox

1. 3. 1997

Gear levers, 610312---

403

205-- 865

Code

420

Page

16A

1. 7. 1989

42. Gearbox

1. 9. 1995

Model

205-- 865

Code

Page

420

17

Operation of differential lock (with effect from

ser. no. 610312)

When the movement between the differential side gear and casing permits the pins of the engaging sleeve to move, the spring (3) pushes the selector fork shaft, the selector fork (5) and finally the engaging sleeve pins into the differential side gear holes, thus engaging the differential lock.The switch (S17) at the end the selector fork shaft closes the circuit to the indicator lamp on the instrument panel.

When the lever (1) is depressed the inner pipe (2) is turned. The inner pipe has two pitched grooves through which there is a screw (and bearing bushings).The ends of the screw are attached to the outer pipe (4).The axial movement of the inner pipe loads the spring (3). The ends of the pitched grooves are shaped so that the inner pipe is kept in its extreme position.

5

3

7

6

4 2

1 Fig. 13. New differential lock control (610312---) (earlier control linkage, see page 420/13) 1. Differential lock lever 2. Inner pipe 3. Spring 4. Outer pipe 5. Selector fork 6. Adjusting nut. When assembling the control linkage the adjusting nut is tightened until there is no clearance between the coils of the spring (spring not loaded. Lock the adjusting nut with the locking nut. 7. Filled with multi ---purpose grease when assembling.

404

10. 1. 1992

42. Gearbox

15. 9. 1995

Figure 13. Position of selector forks and adjustment 1. Selector shaft locking screw. Loctite 242 on the threads 2. The selector levers are lubricated with universal grease

Model

205-- 865

Code

421

Page

1

Note! On the selector forks for L ---R and H gears (on the pinion shaft) there are fitted two plastic sliding pieces from serial no. 659877 incl up to serial no. 663384. With effect from ser. no. 663835 these forks have 4 pcs sliding pieces. When fitting the forks, the sliding pieces can be fastened on the forks with a little grease.

N.B. The shifter levers are attached to the selector lever outer ends with a larger tension pin (see black arrows) and inside it must be fitted a smaller tension pin with the split side to the opposite side as on the larger pin.

405

1. 12. 1986

42. Gearbox

10. 1. 1992

Model

205-- 865

Code

421

Page

2

1. Reconditioning selector forks A. Changing selector forks for speed gears N.B. In these instructions the gearbox has been removed from the tractor. The selector forks for the speed gears can also be removed through the side cover of the gearbox, i.e. without parting the tractor (if the tractor is not equipped with low gear). In which case the selector shaft is drawn out forwards after the floor plate in the cab has been removed.

4. Withdraw the selector shaft carefully while at the same time ensuring that the ball and spring, located inside the selector forks, do not fall down into the gearbox. 5. Lift the speed gear selector forks out of the gearbox. Assembling:

1. Put the gears in neutral and remove the gearbox side cover (17 mm).

ET 893 570 1. Fit the spring and ball on the front selector fork using ET 893 570. Position the selector fork in the gearbox and push in the selector shaft through the selector fork. 2. Fit the other selector fork by the same method. 2. Remove the selector shaft locking bolt (13 mm) from the front end of the shaft.

N.B. The ET ---tool is pushed out of the selector fork and can be removed from the space between the selector fork and the rear wall of the gearbox. 3. Push the selector shaft into position and turn it so that the grooves in the shaft face the balls. 4. Move the selector forks on the shaft when necessary and tap in the tubular pins (or on later models the locking pins with circlips).

3. Move the selector forks on the shaft. Turn the shaft and tap out the two tubular pins (or on later models two locking pins with circlips).

406

15. 9. 1995

42. Gearbox

1. 1. 1998

N.B. The tubular pins should not be tapped in further than the same level as the shaft.

Model

205-- 900

Code

421

Page

3

B. Changing selector forks for range gears A visual inspection of the selector forks for the range gears can be carried out through the access hole. When changing the selector forks the tractor must be split between the gearbox and fuel tank in order that the selector shaft can be withdrawn forwards. Changing and adjusting selector forks should be carried out according to instruction A. The only difference is the removal and fitting of the tubular pin and locking lug. 1. Before tapping out the tubular pin push the selector shaft towards the rear, until the front end of the shaft is level with the front face of the gearbox. Put the rear synchromesh unit slide coupling in the rear position and the front in neutral. 2. The tubular pin can now be tapped out of the shaft between the selector forks. Turn the shaft slightly if necessary.

5. Adjust the position of the selector forks. Push the shaft axially and check the play on the selector forks. Centre the shaft with the nut. Check that the sliding coupling and the synchromesh cones move freely, when the selector forks are in the middle position (neutral). Adjust when necessary the position of the selector shaft.

3. Fitting occurs in the same way. The tubular pin is tapped through the locking lug and shaft at the same time. N.B. On the selector forks there are plastic sliding pieces. Fasten the sliding pieces on the forks with a little grease when you fit the forks onto the pinion shaft.

C. Others An alternative Overdrive can be fitted on 600, 700, 800 and 900 tractors. Since the Overdrive control lever requires more space, small modifications have been made in the gearbox selector forks, selector arms and gear levers. These modifications do not affect the repair instructions, but the spare part numbers can be different.

6. Tighten the locking bolt on the selector shaft to a torque of 23 Nm (16 lbf ft). Use locking fluis Loctite 242 on the threads. 7. Put the gears in neutral. Clean the side cover sealing surfaces and apply sealing compound (e.g. Silastic 738 RTV black) on the sealing surfaces. Position the gear shift levers in the selector fork grooves. Tighten the side cover bolts (17 mm) to 46 Nm (33 lbf ft).

407

408

1. 12. 1986

42. Gearbox

1. 5. 1996

Model

205-- 865

Code

423

Page

1

Shafts and gear wheels (Op. no. 423) 1. Reconditioning pinion shaft Before removing the pinion shaft, remove: --- gearbox from tractor (Op. no. 423 1A) --- differential from the gearbox (Op. no. 424 1A)

Fig. 14. Pinion shaft 1. Shims (adjusting position of shaft). N.B. One shim (0,3 mm with three lugs) is fitted as standard at the bottom of the bearing location. 2. Spacer rings (adjusting bearing preload) 3. Anti ---friction varnish, Molykote 312 R spary 3. Remove the lower link brackets under the rear axle housings (30 mm). Remove the extra lifting cylinder (if one is fitted), lower links and lifting links. Disconnect the draw bar from underneath the gearbox.

A. Removing gearbox

4. Slacken and remove the rear wheel nuts (24 mm). Lift the rear of the tractor and block it up under the fuel tank.

N.B. The gearbox may be removed by rolling the rear half of the tractor away from the middle frame with the gear wheels still fitted (see Op. no. 441 1A).

5. Remove the rear wheels. Position two axle stands fitted with castors under the gearbox.

1. Fit support plates ET 893 760 on the front axle in order to prevent axle oscillation.

6. On tractors with four wheel drive, remove the guard plate for the propeller shaft and disconnect the propeller shaft at the rear drive flange.

2, Drain oil from the transmission (23 liters) and the hydraulic system (35 litres).

409

1. 7. 1989

42. Gearbox

1. 5. 1996

7. Unscrew the rear mountings for the cab (24 mm). Lift up the rear of the cab and block it up under both mudguards.

Model

205-- 865

Code

423

Page

2

NOTE: Later model tractors (610312---): the pressure oil hose and the auxiliary hydraulic valve lever must be disconnected from the auxiliary hydraulic valve blocks (on the RH side). NOTE! 865---tractor: remove the auxiliary hydraulic valve blocks through the access hole on the RH side rear mudguard and remove, when necessary, also the valve block stud bolts ( 3 pcs). On tractors with Autocontrol, disconect the power lift sensor wire connectors.

8. Remove the final drives (Op. no. 451 1A).

14. Unscrew the bolted joint between the gearbox and fuel tank (19 mm).

9. Remove the PTO (Op. no. 462 1A) and the long PTO shaft. 10. Remove the attaching plate for the hydraulic quick ---action couplings (13 mm) and the oil reservoir (oil reservoir removed with effect from ser. no. 610312---). 11. Remove the knob on the lowering speed control under the driving seat (not Autocontrol). 12. Disconnect from the left side of the tractor: --- leads from the differential lock control lamp --- front wheel drive control lever from selector lever --- hydraulic system pressure pipe from pressure filter --- control lever joints above valves for auxiliary hydraulics and the bracket for the levers.

15. Pull the gearbox rearwards out of the tractor. 16. Remove the clutch shaft from the gearbox input shaft (or if the tractor is equipped with low gear, remove the low gear from the front wall of the gearbox).

NOTE: On the latest model tractors (610312---) the pressure filter and auxiliary hydraulic valve blocks are located on the RH side of the hydraulic housing.

17. Remove the hydraulic lift cover and lifting arm shaft and unscrew the hydraulic lift attaching bolts. Remove the hydraulic lift.

13. Disconnect from the right side of the tractor: --- the lower end of the position control lever from the hydraulic lift control shaft --- gear levers from selector levers (range gear lever, speed gear lever and low gear lever (if fitted) --- low gear selector lever (if fitted) --- differential lock control --- clamp for hydraulic system suction pipe (rear end) --- banjo bolt for steering system return oil pipe --- lifting link gear control from lifting link

N.B. The hydraulic lift is only removed in order to simplify the reconditioning of the gearbox.

410

1. 12. 1986

42. Gearbox

15. 9. 1995

Model

205-- 865

Code

423

Page

3

5. Remove the selector forks (Op. no. 421 1A and B).

B. Removing pinion shaft

Note! Take care of the plastic sliding pieces on the selector forks.

N.B. In the following figures the gearbox is held in a fixture, which simplifies the reconditioning work.

6. Remove the bearing cover at the front end of the pinion shaft (13 mm).

1. Free the circlip from the differential lock selector shaft.

ETV 892 230

7. Undo the shaft nut locking and the nuts using ETV 892 230. Stop the shaft from rotating by engaging two gears at the same time with the synchromesh units.

2. Pull out the selector shaft past the lubricating oil pump at the rear of the input shaft.

3. Remove the two bolts (13 mm) from the oil pump and disconnect the oil pipe from the pump (18 mm). Remove the pump.

8. Tap the pinion shaft free from the bearings. Pull the shaft out backwards from the gearbox. At the same time remove the bearing and the two spacer rings from the front end of the shaft.

4. Put the gears in neutral. Remove the side cover (17 mm) together with the selector levers.

411

Model

42. Gearbox

1. 12. 1986

205-- 865

Code

423

Page

4

9. Lift out the synchromesh units and gears from the gearbox through the access hole. Remove the rear gear and synchromesh unit first. Pull out the flanged sleeve from the middle gears. Remove the middle gears and finally the front synchromesh unit and gear.

4. Tap out the outer bearing races from the gearbox housing with an impact puller. N.B. The outer bearing race of the front bearing is fitted once the shaft is in place in the housing. Under the outer bearing race of the rear bearing there are shims. The outer bearing race is fitted after adjusting the position of the shaft.

10. Remove the intermediate plate from the gearbox and tap out the plate behind the front bearing with a drift.

D. Adjusting pinion shaft position N.B. The position of the pinion shaft must be adjusted if the shaft, the gearbox housing or the taper roller bearings have been changed. The purpose of the adjustment is to determine the number of shims under the rear bearing.

C

C. Reconditioning synchromesh unit and changing bearings

1. Check the wear on the synchromesh unit and change any worn part. When assembling the synchromesh unit, the synchronizing cone locking lug is pushed into the hub. Push the sliding coupling onto the hub so that the teeth in the sliding coupling are opposite the cut---out in the hub.

1. Measure the thickness of the rear taper roller bearing (dimension C) by placing it on two blocks of known thickness and measure the distance from the upper surface of the bearing to the surface of the table with a depth micrometer. Subtract the thickness of the blocks from this measurement.

2. Check the wear of the synchronizing cones. Their inner surfaces should be clearly fluted. Change worn cones.

N.B. The bearing should be rotated at least 20 times under load, before measuring. Carry out a check measurement, rotate the bearing between measurements

3. Remove the rear bearing from the shaft with a drift and fit a new one with ET 893 620.

412

Model

42. Gearbox

1. 12. 1986

205-- 865

Code

423

Page

5

2. Fit the bearing on the pinion shaft using ET 893 620 after measuring. 3. The required thickness (X) of the shims is obtained as follows: (note the shim (thickness 0,3 mm) that is fitted as standard at the bottom of the bearing location).

4. Fix the required number of shims according to the previous calculation with a little grease at the bottom of the bearing location (first fit the shim with the three lugs). Available shim thicknesses are: 0,10 mm, 0,15 mm, 0,30 mm and 0,50 mm.

X = E ---(C+D) C = the thickness of the bearing

D

ETV 892 490

151,85

5. Drive in the outer bearing race for the rear bearing against the shims using ETV 892 490.

D = the measurement stamped into the end surface of the pinion shaft, gives the distance between the top face of the bearing and the centre line of the differential bearing location. 13

E. Fitting pinion shaft and adjusting bearing preload 1. Place the pinion shaft gears and synchromesh units in the correct order and the right way round in the gearbox. The sleeve located inside the first gear wheel and the end plate is pushed onto the shaft from the front. 2. Push in the shaft through gear wheels and synchromesh units.

E = the measurement between the differential center line and the pinion bearing surface. The nominal measurement is 181 mm. Any differences are marked in decimals on the gearbox housing. In the case shown the measurement E = 181,13 mm, of which ”13” is marked. If the tolerance is under 181 mm the whole measurement is marked in the housing

413

Model

42. Gearbox

1. 12. 1986

Code

205-- 865

423

ETV 892 230

Page

6

270 Nm

--- tighten the round nut to 270 Nm using ETV 892 230.

3. Push in the bearing sleeve inside the first gearwheel on the shaft. Fit the end plate and spacer rings (2 pcs) on the shaft. Select the spacer rings in order to achieve a combined thickness of for example 11,50 mm.

--- measure the end float of the bearings using a dial gauge.

4. Tap in the disc in the bearing housing drilling using a drift. 5. Fit the outer bearing race of the front bearing using ETV 892 210.

5,05

5,14

5,50

5,85

6,12

5,08

5,26 5,38

5,62 5,73

5,97 6,09

6,15 6,18

5,11

--- add approx. 0,050 mm to the reading on the dial gauge and reduce the thickness of the spacer rings by the calculated amount. The spacer rings are found in the following thicknesses: 5,05 ---6,18, 15 pcs. ETV 890 830

--- fit new spacer rings on the shaft. Tap the front bearing onto the shaft and tighten the shaft nut to 270 Nm.

6. Adjust the pinion shaft bearing preload as follows: --- fit the front bearing on the shaft using ETV 890 830

414

1. 7. 1989

42. Gearbox

Model

15. 9. 1995

205-- 865

Code

423

Page

7

F. Fitting gearbox 1. Fit the hydraulic lift on the gearbox housing and place the gearbox on axle stands with castors. 2. Connect the clutch shaft to the front end of the input shaft with the connecting sleeve and tighten the locking screws to 55 Nm. 3. If the tractor is fitted with a low gear, connect it to the front wall of the gearbox, tighten to a torque of 23 Nm.

1,7---2,3 Nm

4. Push the gearbox into position and at the same time guide: --- the front end of the propeller shaft onto the splines (note the positions of the universal joints) --- hydraulic system suction pipe into position --- the clutch shaft into the clutch --- hydraulic lift lowering speed control into the cab

ETV 892 230

--- turn the shaft at least 20 revolutions and measure the rolling resistance of the shaft with a torsion meter at the end of the shaft. The rolling resistance should be between 1,7 ---2,3 Nm. If the rolling resistance deviates from the given values, increase or decrease the spacer ring thickness. N.B. Check that the shaft can rotate freely when measuring with the torsion meter, i.e. that the synchromesh units are in neutral and on four ---wheel drive models, that the dog clutch for the front wheel drive is in neutral. 7. Tighten the round nut to 270 Nm using ETV 892230. Fit the locking washer on the shaft and tighten the other round nut. Lock the nuts with the locking washer. 8. Change the o---ring in the front end cover. Fit the cover and tighten the bolts to 23 Nm. 9. Fit the lubricating oil pump at the rear of the input shaft and tighten the bolts to 23 Nm. Connect the oil pipe to the pump (18 mm). N.B. the oil pipe support plate should be placed under one of the attaching bolts for the pump.

5. Connect the gearbox to the chassis and tighten the bolts to a correct torque.

10. Fit the differential lock selector fork and selector shaft. Lock the selector fork with the circlip. N.B. The longer half of the selector fork should face the gearbox wall.

6. Attach the following parts to the right side of the tractor: --- clamp for the hydraulic system suction pipe --- low gear selector lever (if fitted) --- the lower ends of the gear levers to the selector levers --- differential lock control --- the lower part of the position control lever to the end of the control shaft.

11. Fit the selector forks for the speed and range gears (Op. no. 421 1A and B). Fasten the plastic sliding pieces onto the pinion shaft selector forks with a little grease. 12. Clean the access (inspection) cover sealing surfaces. Apply sealing compound (e.g. Silastic 738 RTV) to the sealing surfaces. Fit the cover and tighten to 46 Nm (the gears should be in neutral).

On latest model tractors (610312---) connect the pressure oil hose and the auxiliary hydraulic valve lever to the valve blocks (on the RH side).

13. Fit the differential (Op. no. 424 1C).

7. Connect the following parts on the left side of the tractor: --- leads to the differential lock control lamp --- the four ---wheel drive control lever to the selector lever --- hydraulic system pressure pipe to the pressure filter (120 Nm) --- the auxiliary hydraulic control rods to the valves 8. Fit the final drives (Op. no. 451 1E) On the latest models (610312---) there are no auxiliary hydraulic valve blocks and no pressure oil hose on the LH side of the hydraulic housing.

415

1. 7. 1989

42. Gearbox

1. 3. 1997

Model

205-- 865

Code

423

Page

8

12. Fit the rear wheels and tighten the bolts to 330 Nm, 865: 550 Nm. 13. Lift the tractor and remove the supports from under the gearbox and the fuel tank. 14. Fit the draw bar, lower links and extra lifting cylinder (if fitted) and tighten the bolts to 380 Nm. 15. Fit the rear end of the steering system return oil pipe and extra lifting cylinder oil hose (where applicable) to the hydraulic housing. Tighten the screws to 50 Nm. 16. Connect the propeller shaft rear flange joint (23 Nm (8.8) or 35 Nm (10.9)). Fit the protecting plate under the tractor. 17. Fill the gearbox (23 l (205---665), 27 l (865)) and the hydraulic system (35 l) with oil. Test drive the tractor. 9. Push in the long PTO shaft and fit the PTO (Op. no. 462 1E). 10. Fit the hydraulic system oil reservoir (---610311) and the support plate for the quick ---action couplings. 11. Lower the cab and fit the rubber dampers at the rear of the cab (220 Nm). Fit the support for the auxiliary hydraulic control levers.

2. Reconditioning layshaft Before removing the counter shaft the following parts should be removed: --- gearbox from tractor (Op. no. 423 1A) --- selector forks (Op. no. 421 1A and B) --- differential and pinion shaft (Op. no. 423 1B)

A. Removing layshaft and changing bearings

Fig. 15. Countershaft (4---1044)

416

Model

42. Gearbox

1. 12. 1986

205-- 865

Code

Page

423

9

1. Remove the input shaft bearing cover (13 mm). Push the shaft forward slightly until it is free of the rear bearing. 2. Undo the bearing cover from the front end of the countershaft (13 mm) and remove the spacer ring and shims that are located under the cover. 3. Lift the input shaft slightly. Raise the countershaft with one hand and tap it forward so that the outer bearing race of the front bearing comes free from the housing. Remove the shaft. ETV 891 220

6. Fit new bearings on the shaft using ETV 891 220. 7. Remove the outer bearing race of the rear bearing from the drilling in the housing using a drift or impact puller. Fit the new bearing race ETV 893 620.

B. Fitting countershaft and checking bearing clearance

4. Remove the countershaft from the gearbox through the access hole.

1. Lift the rear end of the input shaft and position the countershaft in the gearbox front end first. Tap in the outer bearing race for the front bearing using ETV 893620.

5. Pull the bearings from the shaft with puller.

2. Adjusting bearing clearance: --- place a sufficient number of shims under the end cover to give the bearings a definite clearance and tighten down the cover

417

10. 1. 1992

42. Gearbox

1. 1. 1998

Model

205-- 900

Code

423

Page

10

--- Increase or decrease the shim thickness as necessary --- fit a new oil seal under the bearing cover. Fit the cover and tighten the bolts to 23 Nm. N.B. The following shims are available; 0,10, 0,15, 0,20, 0,50. 3. Fit the spacer ring and shims under the input shaft bearing cover and tighten the cover to 23 Nm. After fitting the countershaft the following parts should be fitted: --- pinion shaft (Op 423 1 E) --- differential (Op 424 1 C). --- selector forks (Op 421 1 A and B) --- gearbox (Op 423 1 F)

0,075---0,150 mm --- Measure the bearing clearance with a dial gauge. Place the stylus against the rear end of the shaft. --- Reduce the shim thickness until the bearing clearance is 0,075 ---0,150 mm. --- turn the shaft at least 20 ---30 revolutions and check the clearance again.

3. Reconditioning input shaft

Before removing input shaft, the following parts should be removed: --- gearbox from tractor (Op 423 1 A) --- selector forks (Op 421 1 A,B) --- pinion shaft (Op 423 1 B)

A. Removing input shaft

Note! On 600, 700, 800 and 900 tractors the input shaft is different (gearbox 270). This new input shaft can also be fitted into gearbox 250.

Figure 16. Input shaft 1. Shims 2. Anti ---friction varnish e.g. Molykote 321 R spray 3. Needle bearing mounting depth 4. Lubricating oil pump Note! Locking pins of the middle gear (Z25, Z23) bearing bushes are fixed with Loctite 641.

418

1. 12. 1986

42. Gearbox

1. 3. 1997

Model

205-- 865

Code

423

Page

11

1. Remove the bearing cover at the front end of the shaft (13 mm) and remove the shims and spacer ring located under the cover.

ETV 893 611 ETV 893 614

1. Remove the outer bearing race for the input shaft rear bearing through the rear wall of the gearbox using an impact puller.

ETV 893 612

2. Fit the pulling piece ETV 893 614 to the end of the pulling rod ETV 893 611 and insert the rod from behind through the input shaft. Fit the sleeve ETV 893 612 to the front of the pulling rod and pull the shaft forwards with the nut until it is free from the bearings.

2. Fit a new outer bearing race (using ET 893 620 when necessary).

3. Withdraw the input shaft from the front of the gearbox and remove the gear wheels and synchromesh units through the access hole. N.B. Check that the locking pins in the middle sleeve remain in place.

B. Changing bearings/synchronizing cones and fitting input shaft

3. Remove the input shaft front bearing from the shaft using a puller.

419

1. 12. 1986

42. Gearbox

1. 3. 1997

Model

Code

205-- 865

Page

423

12

9. Fit the outer bearing race of the front bearing for the main shaft in the housing using ETV 891 900. N.B. Before the input shaft is fitted in place the counter shaft should be lifted up onto its bearings. Adjust the bearing end float as follows: --- Fit the spacer ring and selected shims so that the bearings have a definite clearance in front of the front bearing and fit the bearing cover. --- Turn the shaft 20---30 revolutions, in order to bed in the bearings.

ETV 892 350

4. Fit the parts to the input shaft according to Fig. 16 and tap the rear bearing onto the shaft using ETV 892 350. N.B. The locking pins should be inside the sliding sleeves of the middle gear wheels. 5. Before fitting the input shaft, remove the counter shaft bearing cover and lower the counter shaft to the bottom of the gearbox. 6. In the same way, the bearing cover for the four wheel drive output shaft is removed on four wheel drive models and the shaft is lifted forwards out of the gearbox, as fas as the gearwheel on the shaft permits.

0,025---0,075 mm

--- Position a dial gauge against the front end of the shaft and push the shaft forwards and backwards and note the value of the end float on the gauge. The correct value is 0,025 ---0,075 mm --- Increase or decrease the shim thickness as necessary. 10 When the correct end float is achieved a new shaft seal and O ---ring is fitted in the bearing cover using ETV 893 630. Apply universal grease to the seal. Wrap some thin plastic foil round the splines in order to protect the seal and push the bearing cover onto the shaft. Tighten the bearing cover bolts to 23 Nm. 11. Tighten down the countershaft bearing cover (13 mm) to 23 Nm. Fit the output shaft and tighten the bearing cover to 23 Nm on four wheel drive models.

7. Insert the complete input shaft in the gearbox. The shaft is inserted with the rear end first after which the front end is angled up in its bearing location and then the shaft is straightened up.

After fitting the input shaft the following parts should be fitted: --- pinion shaft (Op. no. 423 1E) --- selector forks (Op. no. 421 1A and B) --- fit the gearbox (Op. no. 423 1F)

C. Changing input shaft front oil seal The input shaft seal can be changed without parting the tractor on machines which are not equipped with the additional low gear.

ETV 893 613 ETV 893 614 ETV 893 611 8. Fit the pulling piece ETV 893 614 to the pulling rod ETV 894 611 and push in the rod from behind through the input shaft. Fit the bearing for the front end of the input shaft and push the bearing into the housing using sleeve ETV 893 613.

420

1. 12. 1986

42. Gearbox

1. 5. 1996

1. Remove the PTO (Op. no. 462 1A) and the long PTO shaft. Remove the cab floor plate (Op. no. 411 2A 1 ---4) and the cover for the clutch shaft tunnel.

Model

205-- 865

Code

Page

423

13

3. Remove the seal cover at the front of the input shaft. Fit the new seal using ETV 893 630. Wrap e.g. a thin plastic bag around the splines on the input shaft when the seal cover is fitted. Remove the protective plastic bag after fitting the seal cover.

2. Unscrew the lock bolts for the connecting sleeve between the clutch shaft and input shaft, and push the sleeve onto the clutch shaft. Push the clutch shaft forward, which creates enough space between the clutch shaft and input shaft to be able to remove the seal cover.

4. Tighten the seal cover to 23 Nm (17 lbf ft). Fit the connecting sleeve and tighten the bolts to 55 Nm (40 lbf ft). Fit the floor plate in the cab. Fit the long PTO shaft and the PTO (Op. no. 462 1E).

4. Reconditioning output shaft for powered front axle A. Removing shaft Before removing the shaft the following parts should be removed: --- gearbox from tractor (Op. no. 423 1A) --- differential (Op. no. 424 1A) --- pinion shaft (Op. no. 423 1B)

Fig. 17. Output shaft (4---1043) 1. To be filled with grease 2. Dog clutch

2. Lever the shaft forwards until the bearings come free from the housing. Remove the circlip and spacer ring from the rear bearing via the access hole.

1. Remove the bearing cover from the front of the output shaft (13 mm).

421

1. 12. 1986

42. Gearbox

1. 9. 1995

Model

205-- 865

Code

Page

423

14

B. Changing selector fork 1. Disconnect the oil pipe from the differential housing in front of the selector shaft nut. Remove the selector shaft nut (24 mm). Tap the selector fork free once the shaft has been removed from the gearbox housing.

3. Remove the rear bearing using a puller through the access hole.

2. Change the shift lever by first removing the selector lever, circlip, plastic sleeve and O ---ring and then remove the shift lever from the gearbox. When fitting, change the O ---ring on the shaft.

4. Remove the shaft dog clutch. Remove the gear wheel circlip and spacer ring and remove the gear wheel from the shaft. 5. Lift the shaft forwards out of the gearbox.

N.B. When fitting the shift lever, the ball shaped end should be pointing downwards and the selector lever forwards. ETV 893 260 6. Secure the shaft in a vice and unscrew the shaft nut using ETV 893 260. Remove the washer, drive flange and bearing cover from the shaft.

3. Fit the complete selector shaft with fork to the rear wall of the gearbox. Position the shift lever in the groove on the fork and tighten the shaft nut to 120 Nm (88 lbf ft). Connect the oil pipe.

7. Remove the O ---ring from the shaft and pull the front bearing off the shaft using a puller.

422

Model

42. Gearbox

1. 12. 1986

C. Fitting shaft

205-- 865

Code

Page

423

15

D. Changing output shaft front oil seal The shaft can be changed from below without parting the tractor as follows: 1. Drain the oil from the gearbox. Remove the propeller shaft protecting plate under the tractor (17 and 19 mm). 2. Disconnect the rear drive flange of the propeller shaft (13 mm). 3. Engage the front wheel drive and apply the parking brake. Unscrew the shaft nut on the output shaft using ETV 893 260. Remove the washer and the drive flange from the shaft.

ETV 892 350

4. Remove the seal cover and change the seal using ETV 893 640. 5. Tighten the bolts of the seal cover to a torque of 23 Nm. Fit the drive flange and washer.

1. Fit the front bearing on the shaft using ETV 892 350. Fit a new O ---ring on the shaft. Change the bearing cover shaft seal using ETV 893 640 and fill the space between the lips of the seal with grease.

6. Tighten the shaft nut to 127 Nm. Tighten the bolts of the flange to 23 Nm. (8.8) or 35 Nm (10.9).

N.B. When necessary, the shaft seal and O ---ring can be changed without further dismantling the gearbox.

7. Fit the propeller shaft protecting plate and fill the gearbox with oil.

2. Fit the bearing cover, drive flange and washer on the shaft and tighten the shaft nut to 127 Nm using ETV 893 260.

3. Insert the shaft from the front of the gearbox and fit the gear wheel, spacer ring and circlip on the shaft. Position the dog clutch in the selector fork and push the shaft into position and tap it into the front bearing. 4. Secure the bearing cover to the front wall of the gearbox to a torque of 23 Nm. 5. Fit the rear bearing using ETV 891 220 and fit the spacer ring and circlip on the shaft. After fitting the shaft the following parts are fitted: --- pinion shaft (Op. no. 423 1E) --- differential (Op. no. 424 1C) --- gearbox (Op. no. 423 1F)

423

424

Model

42. Gearbox

1. 12. 1986

205-- 865

Code

424

Page

1

Differential (Op. no. 424) 1. Changing/reconditioning differential

Fig. 18 Differential

A. Removing differential First remove the following parts: --- PTO (Op. no. 462 1A) --- final drives (Op. no. 451 1A) --- Gearbox (Op. no. 423 1A) N.B. The rolling resistance of the differential bearings (in common with the pinion shaft bearings) is measured at the front end of the pinion shaft using a torsion meter. Because of this the tractor should be parted between the gearbox and fuel tank when adjusting the differential bearing preload. When only reconditioning the differential or the differential lock there is no need to split the tractor between the gearbox and fuel tank, if the positions of the bearing nuts are marked before the nuts are removed ---

1. Position a wooden wedge under the crown wheel. Unscrew the bolts for the differential bearing housing (17 mm) on both sides of the gearbox.

425

Model

42. Gearbox

1. 12. 1986

2. Pull out the bearing housings using two pinchbars.

205-- 865

Code

424

Page

2

5. Also change the outer bearing races of the differential bearings. The bearing races are removed from the housing by turning the bearing adjusting nuts.

N.B. Mark up the positions of the bearing nuts in relation to the housing in order to simplify the assembly. Also indicate from which side they were removed.

B. Changing differential side gears

3. Remove the differential from the gearbox.

1. Unscrew the crown wheel attaching bolts (17 mm). Remove the differential casing half.

4. Remove the differential bearings by using a puller and a suitable counterhold.

2. Remove the slide bearing for the differential side gear which is located in the casing half.

426

1. 5. 1996

42. Gearbox

10. 10. 2003

Model

Code

205-- 865

424

Page

3

ETV 891 870

ETV 891 870 3. Fit a new bearing using ETV 891 870.

7. Fit a new slide bearing using ETV 891 870.

4. Remove the differential side gear.

8. Lubricate the slide bearing and fit one of the differential side gears in the casing half. There are drillings in the gear for the differential lock. 9. Lubricate the sliding surfaces of the differential pinions and fit them in the housing. Tap in the shaft so that the holes for the tubular pin in the shaft and casing align. 10. Fit the tubular pin. 11. Position the other differential side gear on the differential pinions. Fit the crown wheel on the casing so that the attaching bolt holes marry up.

5. Remove the tubular pin for the differential pinion shaft and tap out the shaft from the drilling. Remove the differential pinions. NOTE! On transmission 250 (865), there are four differential pinions.

12. Fit the differential casing half and tighten the bolts (10.9) evenly to a torque of 60 Nm (43 lbf ft). Check that bolts are M10x60 (10.9).

6. Remove the slide bearing for the other differential side gear using a suitable cranked lever.

13. Fit the differential lock coupling sleeve.

427

1. 12. 1986

42. Gearbox

1. 9. 1995

Model

205-- 865

Code

424

Page

4

C. Fitting differential

0,18---0,33 mm 4. Arrange a dial gauge with the stylus at right angles to the side of a tooth on the crown wheel, and measure the tooth backlash between the pinion and the crown wheel. The correct backlash is 0,18 ---0,33 mm.

1. Lift the differential into place in the gearbox housing and position the differential lock coupling sleeve in the selector fork. Block up the differential with a wooden wedge under the crown wheel.

5. If the recorded backlash deviates from the given value, adjust the backlash by turning both nuts. N.B. Ensure that there is no play in the bearings during the adjustment by turning both nuts equally in the same direction.

Z7 (Z9) Z43 (Z42)

2. Fit the bearing housing and tighten the nuts.

6. After adjusting the tooth backlash, measure using a torsion meter the common rolling resistance of the differential and the pinion shaft at the front end of the pinion shaft. The value on the torsion meter should be the rolling resistance of the pinion shaft bearings + rolling resistance of the differential bearings (see picture above) as follows: On transmission 30 km/h (number of teeth on pinion/differential Z7/43): 2,3 ---4,3 Nm (1.6 ---3.1 lbf ft). On transmission 40 km/h (Z9/42): 2,5 ---4,9 Nm (1.8 ---3.6 lbf ft). ETV 893 660

Adjust the rolling resistance by turning the differential bearing adjusting nuts.

3. Tighten the differential bearings using ETV 893 660 until there is no clearance. Rotate the differential in order to ”bed ---in” the bearings.

7. When the bearing preload is correctly adjusted, fit the locking plates for the adjusting nuts and tighten the bearing housings to a torque of 46 Nm (33 lbf ft). 8. Check the bearing rolling resistance and the tooth backlash between pinion and crown wheel.

428

1. 12. 1986

42. Gearbox

1. 7. 1989

D. Reconditioning differential lock

Model

205-- 865

Code

424

Page

5

2. Withdraw the selector shaft. Remove the selector fork from the differential housing.

Changing selector fork and selector shaft

3. Fit a new selector fork and push in the selector shaft through the fork. Lock the fork on the selector shaft using the circlip.

1. The selector fork can be removed by first removing the final drives (Op. no. 451 1A), the differential (Op. no. 424 1A) and the circlip for the selector fork on the selector shaft.

4. Fit the differential (Op. no. 424 1C) and the final drives (Op. no. 451 1E).

Adjusting the differential lock operating control ( -- 610311) NOTE: These instructions concern tractors up to ser. no. 610311. For instructions regarding the new operating control, see page 420/17.

Fig. 19. Differential lock operating control (---610311)

1. When the differential lock is engaged, the adjusting nut (6) is turned until there is no play on the pushrod (3). Then the nut is tightened 1/3 ---1/2 turns.

1. Operating lever 2. Damping spring 3. Pushrod 4. Link 5. Selector fork 6. Adjusting nut

N.B. At the end of the selector shaft there is a switch for the differential lock control lamp. Adjust the switch as necessary when the differential lock is not engaged according to the figure.

429

430

1. 1. 1998

44. Low gear and Overdrive

Model

10. 10. 2003

Code

205-- 900

440

Page

1

Contents General (Op. no. 440) Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low gear, description: --- general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overdrive, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuttle (12+12R gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 3 5 5 6 8

Repair instructions (Op. no. 441) Low gear and Overdrive

1. Reconditioning low gear and Overdrive: A. Changing low gear/Overdrive front oil seal and o---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Removing low gear/Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Dismantling low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Assembling low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Fitting low gear/Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Dismantling and assembling Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Disassembling/assembling Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 3 4 5 6 12

Technical Data Gear ratios: --- Low gear/Overdrive disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=1:1 --- Low gear engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=4.16:1 --- Overdrive engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=0,87:1 Low gear total gear ratios Number of teeth pinion/crown wheel, Z=7/43 Gear 1 (L1) 2 (L2) 3 (L3) 4 (L4) 5 (H1) 6 (H2)

Direct 283.024 173.496 110.080 83.133 68.800 50.148

Low gear 990.526 721.995 458.093 345.956

Gear 7 (H3) 8 (H4) R1 R2 R3 R4

Direct 31.818 24.029 175.543 127.953 81.184 61.311

Low gear 730.513 532.471 337.844 255.142

Tightening torques Low gear ---gearbox, Overdrive ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox ---fuel tank: --- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch shaft---low gear, clutch shaft---Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil pipe ---low gear on 205---865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic system pressure oil pipe: --- to pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- to oil pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering system return oil pipe, rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locking screw for selector fork shaft, low gear on 205---865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller shaft drive flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 Nm 200 Nm 300 Nm 55 Nm 220 Nm 20 Nm 120 Nm 60 Nm 50 Nm 45 Nm 35 Nm

Setting values Brake pedal free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overdrive/low gear input shaft bearing axial float, tractors 600, 700, 800 and 900 . . . . . . . . . . Adjusting value of Overdrive selector fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between Overdrive/new low gear synchronous couper hub ---input shaft rear end .

431

50 mm 0,05---0,15 mm 70,5---70,7 mm min 0,15 mm/min 0,10 mm

1. 12. 1986

44. Low gear and Overdrive

1. 1. 1998

Model

205-- 900

Code

440

Page

2

Special tools 44. Low gear and Overdrive A Part no. ETV 892 440

Description Plate for fitting front oil seal and removing/fitting input shaft bearings (PT0 702---903)

44. Low gear and Overdrive B Part. no. (ETV 892 350) (ETV 893 650)

Description Sleeve for fitting rear oil seal (see Gearbox) Drift for fitting needle bearings/oil seal in main gearbox input shaft (see Gearbox)

Locally prepared tools ET 893 380 Drift for fitting selector fork rail (Gearbox 505---905) (ET 893 760) Support (2 pcs) for front end frame, prevents front axle oscillating when parting tractor (see Frame and Wheels

Low gear and Overdrive A

ETV 892 440

Low gear and Overdrive B

ETV 892 350

ETV 893 650

Locally prepared tools

ET 893 380 ET 893 760

432

1. 12. 1986

44. Low gear

1. 1. 1998

Model

Code

205-- 865

440

Page

3

Low gear, description General The mechanical low gear is located in front of the main gearbox and it has a gear ratio of 4,16:1. When using the low gear much lower speeds are obtained in the low (L) and reverse (R) gear ranges. There is a mechanical blocking device to prevent the low gear from being engaged while the gearbox is in the

high (H) gear range. Machines equipped with a low gear, have 12 forward gears and 8 reverse. The low gear is engaged and disengaged through a straight toothed unsynchronized clutch (dog clutch). Because of this engagement and disengagement should take place with a stationary tractor, depressed clutch and a low engine speed. The low gear may also be fitted at a later date as extra equipment.

20 Nm

20 Nm Fig 1. Low gear on 255---865 tractors

433

1. 1. 1998

44. Low gear

10. 10. 2003

Model

205-- 865

Code

440

Page

4

Picture 2. Section of low gear on 255---865 Low gear control lever: --- forward position=directly connected: i=1,00 --- rearward position=low gear engaged: i=4,16 1. Universal grease (4 g) 2. EP grease (2 g) 3. Anti ---friction varnish (e.g. Molykote 321 R or similar) 4. Cam on gear for fixing engaging sleeve 5. Clutch shaft 6. Tension pin (prevents ring from rotating)

7. Selector fork rail locking screw (Loctite 222 or similar) 8. Lubricating oil inlet 9. Oil filling level 10. Attaching bolt for low gear layshaft Note! When tightening the bolt check that the shaft is located in the ”cut---out” on the bearing retainer. 11. Tubular shaft 12. Layshaft 13. Low gear input shaft 14. Oil flange

434

1. 12. 1986

44. Low gear

1. 1. 1998

Construction and function of low gear on 255---865 tractors (See picture on previous page) The low gear is attached to the front wall of the gearbox with a bolted joint (9 bolts). The bolt located at the front of the low gear passes through the housing. The low gear input shaft (13) has a machined gear (Z24) and splines for the dog clutch. The shaft is connected to the clutch shaft by internal splines and it is carried in two ball bearings in the low gear housing. The long PTO clutch shaft runs through the low gear input shaft and the gearbox input shaft. The hollow low gear layshaft (12) is carried in needle bearings in the tubular shaft (11). The tubular shaft is attached to the housing by a long bolt which also acts as one of the low gear attaching bolts. The gear (Z47) at the front end of the gearbox input shaft is carried in needle bearings. The tubular shaft (11) and the gear teeth 47 are connected by the bearing plate. When the low gear dog clutch is in the forward position the power passes directly through the low gear to the gearbox input shaft (i=1:1). When the dog clutch is in the rearward position the power from the low gear input shaft passes to the layshaft (teeth 24/teeth 34) and on to the gear which is carried in bearings on the front end of the gearbox input shaft (teeth 47). This is in turn connected to the gearbox input shaft by a dog clutch. The gear ratio is then i=4,16:1.

Lubrication (See also picture 4 on page 420/9) The low gear is lubricated by the oil pump in the gearbox. The oil is taken from the oil filter bracket to the end of the low gear selector rail. From there the oil is directed via the drilling (arrows in fig. 2) into the oil flange (14), the tubular shaft (11) and the layshaft needle bearings. The needle bearing for the gear (teeth 47) is splash lubricated. The oil is returned through the gearbox layshaft front bearing and on into the gearbox. Following repairs to the low gear the tractor should be driven in the direct drive position for a while in order to ensure that the oil level has time to rise sufficiently in the low gear.

435

Model

205-- 865

Code

440

Page

5

Model

44. Low gear

1. 1. 1998

Code

600-- 900

Low gear on 600---900 tractors.

Figure 2A. Low gear on 600---900 tractors.

436

440

Page

5A

15. 4. 1999

44. Low gear

10. 10. 2003

Model

600-- 900

Code

440

Page

5B

Low gear on 600---900 tractors. The build ---up of the low gear on 600---900 tractors has been changed so, that some points are similar to the build ---up of the Overdrive, which is shown on the next page. The gear ratio of the low gear is the same as in the low gear on 255---865 tractors. Figure 2A Low gear on 600---900 tractors The lubrication of this low gear is similar to the lubrication of the Overdrive. In addition, the tapered roller bearings of the low gear input shaft are the same as in the Overdrive. Also the adjustment of the bearing axial float is the same.

1. Universal grease (4g) 1a. Grease filling (universal grease) 2. Spread high pressure grease (2g) evenly on the splines. 3. There is a lubricating oil groove between the gearbox bevel pinion shaft front end and the low gear upper shaft rear end. The groove has been machined on the front surface of the low gear housing. 4. The low gear oil level has been raised by changing bearing cover casting. If no extra gear is fitted, the bearing cover must be turned 180° (because of the bearing cover at the front end of the gearbox layshaft). 5. Clutch shaft. 6. Axial float is adjusted to 0,05... 0,15 mm with shims. 7. Selector fork rail. 8. Selector fork locking ball. 9. Oil level (tractor running), see point 4. 10. Fixing bolt of the low gear upper shaft. 11. Axle tube 12. Upper shaft 13. Low gear input shaft 15. Sliding pieces (32888200, 4 off) 16. Paper gasket 17. There must be clearance (0,1---0,3) between the coupler hub and the toothed shaft Z24.

There is a thrust bearing between the gearbox input shaft bearing cover and the low gear rear gearwheel as in Overdrive. Also the gear shift mechanism has been made uniform with the Overdrive.

Position of the input shaft bearing cover

--- If the gearbox has an extra gear, then the bearing cover of the gearbox input shaft must support the layshaft bearing because the layshaft bearing cover can not be fitted with extra gear. (See figure 2B. point A). --- If the gearbox has not an extra gear, the bearing cover has been turned 180° because of the bearing cover at the gearbox layshaft front end.(See figure 2B. point B). IMPORTANT! When the repairing the extra gear, the bearing cover 453 556 00 must be replaced with new bearing cover 453 556 10.

Figure 2B. Position of the input shaft bearing cover in different cases.

437

Model

44. Overdrive

1. 1. 1998

365-- 900

Code

440

Page

6

Overdrive on 600---900 tractors.

Figure 3. Overdrive on tractors 600, 700, 800 and 900

438

15. 4. 1999

44. Overdrive

10. 10. 2003

Figure 3. Overdrive on tractors 600, 700, 800 and 900 1. Universal grease 2. Spread high pressure grease evenly onto the splines. 3. Oil groove on the Overdrive front surface. 4. The Overdrive oil level has been raised by changing bearing cover casting. If a tractor has not an extra gear, the bearing cover has been turned 180° because of the cover at the gearbox layshaft front end. 5. Clutch shaft 6. Bearing axial play is adjusted to 0,05 ---0,15 mm with shims 7. Selector fork rail. 8. Selector fork locking pin. 9. Oil level (engine running), see point 4. 10. Fixing bolt of the upper shaft 11. Axle tube 12. Upper shaft 13. Overdrive input shaft 14. Spring mechanism forces the Overdrive either to position I or II 15. Sliding pieces (32888200, 4 pcs) 16. Paper gasket 17. There must be clearance between the synchronous coupler hub and the toothed shaft Z33 (0,15---0,40 mm).

Model

365-- 900

Code

440

Page

7

Build ---up and function of the Overdrive Figure 3 on the previous page. The gear ratio of the Overdrive is 0,87, and it can alternatively be fitted in place of the low gear on tractors 600---900. The build ---up of the Overdrive resembles the low gear on 600---900 tractors, see page 440/4 (earlier low gear), 440/5A (new low gear) and 440/6 (Overdrive). The Overdrive is synchronized (synchronizing cone ø 68 mm) and it can be used with all gears and with all range gears. A tractor with Overdrive has 16 forward and 8 reverse gears. The driving speed rises about 15 % when the Overdrive is engaged. Direct ratio, when the synchronous coupler is in the front position and faster ratio when the coupler is in the rear position. The gear lever of the Overdrive does not stay in the neutral position, since it is eliminated with a spring mechanism 14 in the Overdrive housing.

Lubrication

On tractors 600---900 with the Overdrive the gearbox input shaft (270) is different to the earlier (220, 250). Also the gearbox input shaft front bearing cover has been modified.

Notice in the fitting

If the Overdrive is fitted as a retro---fitting, the gearbox layshaft front end cover and the o---ring must be removed, shims remain stay in place. In the same way the bevel pinion shaft front end cover must be removed. The oil seal of the long PTO shaft must be removed inside the gearbox input shaft front end and oil plug (mounted with Loctite) shall be taken out. Otherwise the Overdrive lubricating oil cannot flow into various lubricating points.

The lubricating oil flows from the gearbox bevel pinion shaft front end through the machined groove on the Overdrive front surface into the Overdrive upper shaft rear end. There is not a separate oil cap at the front end of the bevel pinion shaft on transmissions with the Overdrive or low gear on 600---900 tractors. The long PTO clutch shaft has a thinning for the lubrication. The shaft can be fitted on all 65---models.

Position of the input shaft bearing cover

Others

--- If the gearbox has an extra gear, then the bearing cover of the gearbox input shaft must support the layshaft bearing because the layshaft bearing cover can not be fitted with extra gear. (See figure 4. point A). --- If the gearbox has not an extra gear, the bearing cover has been turned 180° because of the bearing cover at the gearbox layshaft front end.(See figure 4. point B).

Because of the greater travel of the Overdrive control lever, some small changes have been made in the gearbox selector forks, selector arms and gear levers. On 600---900 tractors without Overdrive or low gear, the splines of the hollow clutch shaft have been modified and also the locking of the clutch shaft.

IMPORTANT! When the repairing the extra gear, the bearing cover 453 556 00 must be replaced with new bearing cover 453 556 10.

Figure 4. Position of the input shaft bearing cover in different cases.

439

Model

44. Shuttle

10. 10. 2003

Code

600-- 900

440

Shuttle with 600---900 tractor (12+12R)

20

A-- A

24

A

C -C

440

Page

8

Model

44. Shuttle

10. 10. 2003

--- The present 8+4R gearbox has got an alternative gearbox type 12+12R. This alternative needs always a shuttle unit, because the R (reverse) group has been replaced with LL (creeper) --- group. The power shuttle lever in the cabin can be fitted either on the left or right side of the seat. This selection must be made when ordering the tractor. The position of the lever can be changed after production, but this will require splitting the tractor. You will also need the following parts: --- To move the lever to the left side: the flange (35137100) and, only if the tractor is fitted with the HiShift ---function, the wiring set (34962600). --- To move the lever to the right side: the flange (30930700), no need for the wire set. The reverse speeds are 1 % faster. The lubrication pump has been removed from the center line of the input shaft. The pump rotates in one direction (as earlier), but because of space the pump construction is new. The middle gear of the shuttle unit drives the pump. The pump rotates, although the forward ---reverse shuttle is in neutral. --- NOTE! Do not put silicon in to the marked area (see picture) of the separation wall between gearbox and power shuttle; the lubrication canal will block up! 1) Multi ---purpose grease 2) High pressure grease (2g Olista long ---time 3EP (UC3907) or equivalent will be smoothly laid to grooving. 3) Lubrication oil to the gear shaft bearings 4) PTO drive shaft 5) Clutch shaft 6) Gear shaft 7) Selector rail 8) Gear shaft (Z22/20) 9) Gear shaft (Z24) 10) Slide pieces (4 pcs) 11) When fitting the shuttle unit onto the main shaft be careful not to pre load the thrust bearing. 12) Grease filling (multipurpose grease) 13) Silicon, Loctite 5900 (UK0067). Do not spread silicon inside the marked lines!

441

600-- 900

Code

440

Page

9

Model

44. Shuttle

10. 10. 2003

Shuttle unit lubrication

R

(347 847 00)

(KATSO MODUULI NRO: 34715700)

A-- A

4X

--- Lubrication for power shuttle via lubrication oil pump. --- In connection with repairing, do not block up the tube which comes to the front part of the pinion shaft with silicon.

442

600-- 900

Code

440

Page

10

1. 5. 1996

44. Low gear and Overdrive

1. 1. 1998

Model

205-- 900

Code

Page

441

1

1. Reconditioning low gear and Overdrive (Op. no. 441)

B. Removing low gear and Overdrive

A. Changing low gear/Overdrive front oil seal and O---ring

N.B. Before removing the low gear/Overdrive the tractor frame must be parted between the gearbox and fuel tank. 1. Remove the engine hood plates and loosen the top plate from its attaching points. Turn it to one side.

1 a) Without splitting the tractor: remove the clutch (Op. no. 411 2A 1 ---14).

2. Remove the hydraulic lift lowering speed control knob under the front edge of the driving seat (not Autocontrol).

1 b) By splitting tractor: Split the tractor at the clutch (Op. no. 411 1A) and remove the cab floor (Op no. 411 2A 1 ---4). Remove the long PTO shaft. Remove the clutch shaft from the low gear/Overdrive (17 mm).

N.B. Removing cab floor plate (Op. no. 411 2A 1 ---4) makes the parting and assembling of the tractor frame easier, but it is not necessary.

2. Remove the circlip from the low gear/Overdrive input shaft (remove also the shims on the Overdrive/latest low gear). Punch a hole in the front oil seal using a centre punch. Screw in a self tapping screw in the hole and pull out the seal.

3. Drain the hydraulic and gearbox oil.

3. Remove the spacer ring and fit a new greased O ---ring on the low gear/Overdrive input shaft. 4. Lubricate a new oil seal and fit it by using ETV 892 440. Fit the spacer ring. Place the circlip on the input shaft (with the tubular pin on the spacer ring in the hole of the circlip on the earlier low gear). On the Overdrive and on the new low gear, fit the same shims in front of the spacer ring before fitting the circlip. 5a) Without splitting the tractor frame: fit the clutch shafts and clutch assembly (see Op. 411 2B). 4. Free the rear ends of the brake rods on top of the rear axle (22 mm). 5. Disconnect on the right---hand side of the tractor under the cab:

--- Ball joints from the speed gear lever, range gear lever and low gear/Overdrive lever (13 and 17 mm) (or free the ball joints of the levers from the cab floor and lift up the levers in the cab. --- Selector lever from the gearbox access hole (lower) --- Engagement blocking device from the end of the low gear selector shaft. --- Lower joints for the hydraulic lift position control lever (11 and 13 mm) (not Autocontrol).

5 b) Parted tractor frame. Fit the clutch shaft and the long PTO shaft and connect the frame joint (Op. no. 411 1C 1 ---10). Fit the cab floor (Op. no. 411 2B, paragraphs 10 and 14 ---19).

443

1. 5. 1996

44. Low gear and Overdrive

1. 1. 1998

Model

205-- 865

Code

441

Page

2

--- Differential lock engagement mechanism and spring (610312---, only lower end of the lever from engagement mechanism). --- Hydraulic system suction pipe, rear clamp. Autocontrol: disconnect sensor wires. --- 610312---: remove, if necessary, the valve block set. --- 610312---: hydraulic system pressure pipe from the pressure filter union.

12. Position axle stands with wheels under the fuel tank and gearbox. 13. Slacken the rear reflector attaching bolts slightly (13 mm) and turn them to the side.

--- Steering system return oil pipe and (earlier models with an extra lifting cylinder) extra lifting cylinder oil hose. --- Lower end of lifting link gear control rod. 7. Disconnect on the left side of the tractor: --- Leads to the differential lock control lamp --- ---610311: Control lever joints at top of valves for auxiliary hydraulics and the bracket for the control levers (not 610312---) --- ---610311: Hydraulic system pressure oil pipe from pressure filter (not 610312---).

14. Unscrew the bolted joint between the gearbox and fuel tank (22 mm). Roll the rear part away by turning the wheels. Ensure that the cab does not damage the auxiliary hydraulic control valves.

N.B. On four ---wheel drive models: remove the guard for the propeller shaft. Disconnect the drive flange at the rear of the propeller shaft and disconnect the four ---wheel drive control lever from the selector lever.

N.B. If the cab does not clear the control valves, the rear of the cab should be lowered slightly. On 865, 600---900: remove the auxiliary hydraulic valve levers, valves and, if needed, studs. 15. Disconnect the clutch shaft from the low gear (17 mm). Remove the long PTO clutch shaft.

8. Remove the rear wheel mudguards (13 mm) 9. Remove the rear attaching bolts for the cab. 10. Lift up the rear of the cab slightly and block it up on both sides in front of the final drives. 11. Support the front of the tractor on the front axle on both sides of the frame using support plates ET 893 760.

16. Disconnect the oil pipe on the earlier low gear (14 mm) and the low gear/Overdrive from the gearbox (13 mm). N.B. Do not forget to loosen the attaching bolt which runs through the low gear housing (see arrow).

444

1. 12. 1986

44. Low gear

1. 1. 1998

Model

205-- 865

Code

Page

441

3

C. Dismantling low gear on 255---865

6. Tap the selector shaft forwards out of the housing (the selector fork ball may fall down in the housing). Remove the selector fork and the oil flange sleeve from the housing. 7. Remove the circlip from the front of the input shaft. 1. Tap out the tubular shaft forwards out of the housing.

2. Remove the bearing plate. 8. Tap the input shaft rearwards out of the housing. Check that the layshaft gear wheel does not interfere. Remove the front oil seal spacer ring from the housing.

3. Remove the large gear wheel and the needle bearing and the sleeve which is located inside. 4. Move the selector shaft to its rear position and remove the engaging sleeve and its hub.

9. Remove the layshaft and oil flange from the housing. Remove the needle bearing and intermediate sleeve from the layshaft. 5. Unscrew the selector shaft locking screw (5 mm socket head).

10. Remove the circlip for the input shaft ball bearings.

445

1. 12. 1986

44. Low gear

1. 1. 1998

Model

205-- 865

Code

441

Page

4

11. Tap out the input shaft front bearing and oil seal forwards out of the housing using ETV 892 440. 12. Change the selector shaft o---ring.

D. Assembling low gear on 255---865 1. Fit the circlips for the input shaft ball bearings.

ETV 892 440

ETV 892440 5. Tap in the input shaft rear bearing in the housing using ETV 892 440. 6. Apply anti ---friction varnish to the ends of the layshaft (e.g. Molykote 321 R). Fit the lubricated needle bearings and the intermediate sleeve in the layshaft. 7. Fit the layshaft and oil flange in the housing.

2. Tap in the front bearing from the front into the bearing housing using ETV 892 440. 3. Remove the o---ring from the input shaft and loosen the inner bearing with a puller.

8. Tap in the input shaft from the rear onto the bearings. ETV 892350

4. Change the oil seal located inside the rear end of the input shaft using ETV 892 350. The lip is turned towards the gearbox when fitting.

9. Fit a lubricated o---ring at the front of the input shaft. 10. Fit the spacer ring and circlip on the input shaft so that the spacer ring tubular pin engages in the hole in the circlip

446

1. 1. 1998

44. Low gear and Overdrive

1. 9. 2001

Model

Code

205-- 900

441

Page

5

16. Tighten the locking screw (5 mm socket head 45 Nm (33 lbf ft) using Loctite 601 on the threads). Fit the oil pipe connection to the front of the shaft (12 mm 20 Nm (14 lbf ft)). ETV 892440

17. Position the engaging sleeve in the selector fork and move the fork to the forward position. Fit the hub on the engaging sleeve splines with the toothed side turned forwards. 18. Apply anti ---friction varnish on to the sliding surface of the large gear wheel (e.g. Molykote 321R) and fit it against the hub with the engaging teeth (dog clutch) turned towards the selector fork.

11. Apply grease between the lips of the input shaft front oil seal and tap in the seal in the housing using ETV 892 440. 12. Change the O ---ring located on the tubular shaft and tap in the shaft from the front of the housing. Leave approx. 3 cm of the shaft projecting outside the housing for fitting the bearing plate.

1

19. Fit the sleeve and the lubricated needle bearing inside the large gear wheel. Fit the bearing plate and push the tubular shaft fully home.

2

N.B. The chamfer at the end of the shaft should be turned outwards in order to enable the end of the shaft to glide through the bearing plate until it is level with the end face of the housing.

E. Fitting Low gear/Overdrive 1. 205 ---865: Check the needle bearings and the oil seals inside the clutch shaft and gearbox input shaft and change them when necessary (ETV 893 650). 600 ---900: See notes on pages 440/ 7 concerning the retro--fitting of the Overdrive or the new low gear.

13. Fit the oil sleeve (1) to the end of the oil flange (2).

2. 600 ---900: Before fitting the Overdrive/Low gear, place the parts, which are situating on the gearbox input shaft front end, on the shaft. In connection with retro---fitting, the bearing cover and o---ring are removed in the gearbox layshaft front end and the bearing cover of the bevel pinion shaft front end.

ET 893 380

14. Fit the selector fork spring and ball using the tool ET 893 380. Fit the fork in the housing. 15. Unscrew the oil pipe connection (12 mm) from the end of the selector fork and change the O ---ring on the shaft. Fit the shaft from the front through the oil sleeve and the selector fork. In this way the tool is forced out of the shaft.

3. Change the gasket between the extra gear and the gearbox. Fit the gear to the gearbox (13 mm, 23 Nm (17 lbf ft)). 4. 600 ---900: After fastening the Overdrive/low gear, check by hand , that the extra gear input shaft has an axial float (adjustment, see page 441/10 instr. C).

N.B. The selector shaft locking groove should be turned towards the locking screw hole.

447

1. 7. 1989

44. Low gear and Overdrive

1. 1. 1998

Model

205-- 865

Code

441

Page

6

5. 205 ---865: Before fastening the low gear, check that the large gear wheel hub is positioned in the hole of the bearing plate and that the sleeve and needle bearing remain inside the gear wheel. 6. 205 ---865: Connect the low gear lubricating oil pipe (14 mm; 20 Nm). 7. Fit a new o---ring on the clutch shaft. Apply EP grease approx. 2 g on the clutch shaft splines. Fit the clutch shaft to the low gear/Overdrive ( 17 mm; 55 Nm). Lock the attaching bolt. Fit the long PTO shaft.

14. Connect the following on the right side of the tractor: --- Steering system return oil pipe (22 mm, 50 Nm). On earlier tractors equipped with an extra lifting cylinder the hose to the cylinder is secured under the same bolt. --- Range gear lever, selector lever to the gearbox service access cover. --- Low gear/Overdrive selector lever to the selector shaft (also functioning as a blocking device) --- Differential lock control mechanism and spring (610312---, only lower joint of lever to the control mechanism) --- Hydraulic lift position control lever, lower joints (13 and 10 mm) (not Autocontrol). --- Ball joints at lower ends of the gear levers (13 and 17 mm) --- Tighten the connection on the hydraulic suction pipe. --- Hydraulic system pressure oil pipe (only 610312---) --- Lever for auxiliary hydraulics to the valve blocks (only 610312---)

8. Push the rear part of the tractor forwards and note the following: --- Guide in the pick ---up hitch release lever above the rear axle. --- Guide in the lifting link gear control rod on the right side of the hydraulic lift control shaft (not Autocontrol). --- Guide in the PTO control rod above the rear axle. --- Guide in the brake rods above the rear axle. --- Guide in the steering system return oil pipe between the hydraulic lift housing and the differential lock control (not 610312---).

15. Connect the following on the left---hand side of the tractor: --- Hydraulic system pressure oil pipe to the pressure filter connection (60 Nm) (not 610312---) --- Electric leads to the differential lock control lamp --- Control lever joints at top of valves for auxiliary hydraulics and associated bracket on the cab floor (not 610312---) --- Autocontrol: reassemble control valve/pipes, if detached.

N.B. The final stages of guiding the tractor parts together is made easier if guide bolts are screwed in on both sides of the frame (M14, length 100---200 mm).

N.B. Four ---wheel drive models: connect the lower part of the control lever to the selector lever and the drive flange at the rear end of the propeller shaft (35 Nm) and fit the guard plate for the propeller shaft.

9. Guide the hydraulic lift lowering speed control in through the hole in the cab floor. Fit the cab rear rubber dampers.

16. Turn the reflectors round to their correct position and tighten them down (13 mm).

10. Guide in the hydraulic suction pipe towards the end of the assembling operation. N.B. If the clutch shaft does not engage its splines, rotate the shaft slightly. 11. Tighten the bolted joint once the tractor parts have been brought together (200 Nm (M14), 300 Nm (M16)). 12. Remove the axle stands under the tractor and the support plates on top of the front axle. 13. Remove the support from under the cab and fit the cab attaching bolts (24 mm, 220 Nm). N.B. Fit the rubber supports under the bolts.

17. Connect the brake rods to the brake levers (22 mm) above the rear axle. Adjust the brake pedal free travel to 50 mm using the adjusting nut.

448

1. 12. 1986

44. Low gear and Overdrive

1. 1. 1998

18. Connect the lifting link gear control rod. 19. Fit the mudguards and engine hood plates. Fill the gearbox and hydraulic system with oil. N.B. Allow the engine to run for a couple of minutes before driving in order to lubricate the low gear/Overdrive. Then test---drive the tractor.

449

Model

205-- 900

Code

441

Page

7

Model

44. Overdrive

1. 1. 1998

600-- 900

Code

441

Page

8

2. Disassembling/assembling Overdrive Changing Overdrive front oil seal, see page 441/1. Removing Overdrive, see page 441/1. Fitting Overdrive, see page 441/5.

A. Disassembling overdrive 1. Remove the rear coupling gear, synchronizing cone, sleeve and the thrust bearing on the gearbox input shaft (if not loosened when the overdrive was removed). 2. Move the overdrive selector fork to the rear position and remove the synchronizing coupler (if not loosened earlier). Remove the front synchronizing cone. 3. Take care of the selector fork plastic sliding pieces (4 off).

7. Tap the input shaft rearwards out of the housing.

4. Remove the selector fork rail circlip in the rail rear end.

8. Tap the layshaft axle tube forwards and remove it. Remove the layshaft out of the housing. 9. Unscrew the screw of the spring mechanism support axle. Pull out the axle and take care of the spacer sleeves. Remove the selector arm.

5. Tap the rail forwards and remove it. The selector fork locking ball also releases. Remove the selector fork. Take care of the spring and the ball.

10. Remove the assembled selector mechanism. Note! If the round shaped selector lever must be replaced, the spring mechanism and the connecting plate must also be changed since they are delivered together. Important! If the selector fork, or the selector mechanism is changed, the position of the selector fork must be adjusted, see instruction B.

6. Remove from the overdrive input shaft front end: circlip, shims, wear ring and the o---ring under the wear ring.

450

Model

44. Overdrive

1. 1. 1998

600-- 900

Code

441

Page

9

11. If the input shaft taper roller bearings must be changed, remove the rear bearing on the shaft and fit a new one.

Note! There may be a spacer ring between the housingand the layshaft rear end.

12. Remove the oil seal from the housing front end and remove the front bearing. Remove the bearing outer races in the housing and fit new ones (fitting e.g. ETV 892 440+universal handle).

2. Push in the input shaft until the rear bearing is against the outer race. 3. Push the front bearing onto the shaft against its outer bearing race.

13. If you change the seal in the input shaft rear end, a new seal can be fitted with sleeve ETV 892 350.

4. Fit an o---ring into its groove on the input shaft front end and place the wear ring on the o---ring and push it against the front bearing.

Note! The synchronizing coupler has the same build ---up as the couplers on the gearbox input shaft, see page 420/15.

5. Grease the oil seal lip and knock it into place so that it is parallel with the housing front edge (the seal can be fitted with ETV 892 440+universal handle).

B. Assembling overdrive Note! If you have changed parts of the selector mechanism, the adjustment of the selector fork is carried out as follows: --- Refit the selector lever together with the spring assembly into the housing (if removed) and refit the spring assembly support axle with its spacer sleeves. Do not fit the layshaft at this stage. --- Refit the selector fork together with its rail and locking mechanism. Refit the circlip at the rear end of the rail. --- Press the fork to the front position.

6. Fit the circlip in front of the wear ring (do not fit yet the shims). Measure with a dial gauge stylus against the input shaft front side the axial play of the taper roller bearings, which should be 0,05 ---0,15 mm. 7. If necessary, place shims (s=0,1 or 0,3) in front of the wear ring, until the axial play is correct. After adjustment ensure that the circlip is placed correctly in its groove. Note! When necessary, measure the clearance between the input shaft rear end and the synchro coupler hub, see instr. C on page 441/10. 8. Position a drift (ø 16 mm, e.g. ET 893 380) inside the selector fork, so that it keeps the locking ball and spring down.

--- Press the rail forwards until the circlip rests against its recess on the housing. Measure with a straight ruler and a vernier caliper the distance between the housing contact surface and the bottom of the plastic sliding piece location on the fork. This distance should be 70,5 ---70,7 mm. --- Adjust the distance, if needed, by turning the nut at the end of the spring assembly in the housing (there is enough space as the layshaft is not fitted). --- After the adjustment, remove the selector fork so that the layshaft can be fitted.

9. Position the selector lever round end in the fork hole and push the rail from front through the fork so that the locking ball remains under the rail and the drift is pushed out.

1. Put the layshaft together with its bearings in the housing. (the greater gearwheel Z27 rearwards). Push the axle tube with its o---ring through the layshaft.

451

Model

44. Overdrive

1. 1. 1998

Code

600-- 900

Page

441

10

Paper gasket

Bearing cover

10. Grease the rail o---ring and press the rail into place. Fit the circlip to the rail. Move the fork to the rear position. 11. Place the synchronizing cone on the gearwheel Z33. Place the synchronizing unit on the fork (also the sliding pieces) and push the fork to the front position. Note! The plastic sliding pieces can be fastened on the fork with a little grease. 12. Fit the bearing ring, thrust bearing and the sleeve on the gearbox input shaft. Place the rear coupling gear on the sleeve. Fit the overdrive and assemble the tractor frame, see page 441/5 instr. E.

2. Place the Overdrive parts, which are situated on the front end of the gearbox input shaft, on the Overdrive input shaft according to the picture above.

C. Checking clearance between input shaft rear end and synchro coupler hub

3. Remove the gearbox input shaft bearing cover and place it to the top. 4. Fit a paper gasket on the housing contact surface. Place a straight ruler against the contact surface and measure with a feeler gauge clearance (S) between the ruler and the gearbox bearing cover (cover surface which is against the gearbox front side).

Note! This checking has to be done, if the parts that affect the clearance have been changed (e.g. gear housing, input shaft and its gearwheels etc). 1. Place the Overdrive housing together with the mounted input shaft on a table so that the weight of the housing rests against the end of the input shaft. Then the bearing clearance comes upwards.

5. The clearance (S) should be at least 0,15 mm. 6. When necessary, the clearance can be made larger by fitting two paper gaskets no. 45355900.

452

Model

44. Low gear

1. 1. 1998

3. Reconditioning low gear on 600---900 Changing low gear front oil seal, see page 441/1. Removing low gear, see page 441/1. Fitting low gear, see page 441/5. Note! This instruction includes briefly some important points concerning the low gear on 600---900 tractors compared with the Overdrive. Picture of the low gear, see page 440/5A.

A. Disassembly/assembly Disassembling order is the same as for Overdrive: 1. Remove the low gear parts on the gearbox input shaft 2. Remove the low gear toothed coupler 3. Remove the layshaft axle tube 4. Remove the selector fork and its rail 5. Remove the input shaft of the low gear 6. Remove the layshaft 7. Remove the selector arm and the selector lever Assembly in the reverse order. The same special tools can be used as for the Overdrive.

B. Adjustments 1. Adjustment of the input shaft bearing clearance is carried out in the same way as for the overdrive, see page 441/9. 2. Checking the clearance between the input shaft rear end and the toothed coupler hub is made in the same way as for the Overdrive, see instr. C on the previous page, but the clearance S should be 0,10---0,30 mm. Note! The selector fork of the low gear has neither an adjustment nor a spring mechanism to eliminate the neutral position.

C. Others The low gear housing is the same as on the Overdrive. Also the paper gasket is the same. The low gear layshaft has the thrust bearing plates on both sides of the shaft. The notches of the plates fits on the selector fork rail to prevent rotation of the plates.

453

600-- 900

Code

441

Page

11

Model

44. Shuttle

10. 10. 2003

600-- 900

Code

441

Page

12

3. Disassembling/assembling Shuttle Disassembling shuttle Tractor split for shuttle disconnected can be done alike as low gear and overdrive

3. Knock off the forks for gear tension pins and remove the selector shaft. Remove the shift lever. Open screw with forks for gear and remove sliding coupling, forks and countershaft. Take care of the selector fork plastic sliding pieces (4 off)

1. Unscrew attaching bolts of the shuttle(13mm) and pull of the shuttle from gearbox.

4. Remove the overdrive input shaft front end: circlip, shims, wear ring and the o---ring under the wear ring. Tap the input shaft rearwards out of the housing.

2. Oil pump drive gear and shuttle rear gear remain with in gearbox. They can be disconnected by pulling.

5. Remove the selector shaft and take care of locking ball. Open the plug on side and remove circlip.

454

Model

44. Shuttle

10. 10. 2003

441

Page

13

4. Put in the spring and ball into the housing of the shuttle. Press the ball with drift (ø 16 mm, obs. ET 893 380) and push in the selector shaft. Turn in the plug.

6. Check the oiltube for bearings. There is a throttle under the oiltube. Check thet the throttle is clear, because the bearings of input shaft will get their lubrication through this throttle.

min. 1,0 mm

600-- 900

Code

min. 1,0 mm

5. Install the o---ring under the wear ring.

7. Check the condition of synchronizing ring and the sliding coupling. Change the parts thet are wore out if needed

Shuttle assemblying

6. Install the new oil seal into the housing and push in the wear ring.

1. Check, and if needed, change the bearings of input shaft. Then advance change also new oil seal with in housing. 2. Thread the input shaft in, and turn the housing upside support, the input shaft and press the shaft in the housing, for example with hydraulic press. 3. If you change the rearside seal of the input shaft, you can install the new one by a socket ET 892 350. Spread some grease into the lip seal.

7. Put in the circlip. Notice that the heads of the circlip must be placed on the both sides of the tension pin, that is installed into the wear ring. By doing this you will make sure that the wear ring doesn’t left turning on the input shaft.

455

Model

44. Shuttle

10. 10. 2003

8. Check, and if needed, change the bearings of both countershaft. Note! Axles second head bearings are in the gearbox head. The lower countershaft also lubrication pump by axle.

Code

600-- 900

441

Page

14

11. If you have disconnected rear gear and lower countershaft of the shuttle, install them to the front side of the gearbox Note! If you have changed the axle of the oil pump make sure thet the axle has enoungh axial slip. The axial slip can be checked by taking off the service hatch of the gearbox. 12. Apply sealing compoud to the contact surface between the housing and the gearbox. Clean coontact surfaces if needed.Note! Put sealing compound only to the outer edge of housing of the shuttle. 13. Install the second syncronizing ring for example using grease and lift the shuttle in its place. By align you can use M8 bolts.

23Nm 9. Install in the selector shaft and lever on the positioning. The plastic sliding pieces can be fastened on the fork with a little grease. Install in the housing, syncronizing ring, sliding coupling, fork and upper countershaft.

14. Tighten the housing srews to a torque of 23Nm and check shuttle float 15. Assemble the tractor frame alike as low gear and overdrive

10.Put in the tension pins of the lever of forks. Notice of the assembly direction, slotted holes must be cross direction of the selector shaft.

456

1. 3. 1997

45. Final drives

Model

15. 4. 1999

Code

205-- 900

450

Contents General (Op no 450) Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Final drives, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Repair instructions Final drives (Op no 451) 1. Reconditioning final drive A. Removing final drive from tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Changing roller bearings in planetary pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Changing bearings and seals on drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Adjusting drive shaft bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Fitting final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 3 4

2. Reconditioning final drives on 865 ---tractor (transmission 250) . . . . . . . . . . . . . . . . . . . . 6

Technical Data Gear ratio, planetary gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=5,6 Rear axle flange distance, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1640 mm Rear axle flange distance, 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 mm

Tightening torques Drive axle housing ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel nuts, rear wheels: --- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil draining plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centre bolt, outer drive shaft, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centre bolt, outer drive shaft, 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check links---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower links---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake mechanism ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230 Nm (24 mm) 330 Nm (24 mm) 550 Nm 105 Nm (36 mm) 10 Nm (24 mm) 3---5 Nm (24 mm) 220 Nm (24 mm) 80 Nm (19 mm) 380 Nm (30 mm) 80 Nm

Setting values End float, outer drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distance between drive shaft end ---rear axle housing contact surface, 205---665 . . . . . . . . . . . Distance between drive shaft end ---rear axle housing contact surface, 865, 600---900 . . . . . . . Brake pedal free travel, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,010---0,075 mm max 129 mm max 128,7 mm 50 mm

Oil (Final drives have oil space in common with gearbox) Viscosity and quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 120/4. Total oil volume: --- 205---665. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 l --- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 l

457

Page

1

Model

45. Final drives

1. 12. 1986

Code

205-- 865

450

Special tools Final drives B Order no ETV 891 710 (ETV 892 210) ETV 893 320 ETV 893 690

Description Sleeve for fitting bearing race for outer drive shaft (Gearbox Valmet 1102---1203) Sleeve for fitting oil seal for outer drive shaft (see Gearbox) Plate for fitting outer shaft seal for outer drive shaft (also Final drives 505---905) Plate for fitting bearing race for outer drive shaft

Locally prepared tools ET 893 410

Support bar for removing bearing race for outer drive shaft (also Final drives 505---905)

Final drive B

ETV 893 320

ETV 893 690

ETV 891 710

ETV 892 210

Locally prepared tools

ET 893 410

458

Page

2

1. 5. 1996

45. Final drives

1. 1. 1998

Model

865 600-- 900

Code

450

Special tools, 865 and 600---900 Part no. Description ETV 890 220 Universal handle ETV 893 310 Plate for fitting drive shaft inner oil seal (Mezzo) ETV 893 320 Plate to fit drive shaft bearing outer races (Mezzo) ETV 894 210 Centring tool foor outer brake application ring when fitting final drives on 865 and 600---900. Locally prepared tools ET 893 410 Support to remove drive shaft bearing outer races (Mezzo)

ETV 893 310

ETV 890220

ETV 893 320

ETV 894 210

Itsetehtävät työvälineet

ET 893 410

459

Page

2A

460

1. 12. 1986

45. Final drives

1. 3. 1997

Model

205-- 865

Code

450

Page

3

Final drives, description drives the planetary pinions and the planetary retainer. The power is then transferred via the splined joint between the planetary retainer and the outer drive shaft and further on to the driving wheels.

The final drives are of the planetary gear type with mechanically operated multi ---disc brakes which run in oil. The rear axle housing is bolted to the gearbox by eight screw studs. The brakes are fitted between the gearbox and the planetary gear in the final drive and the brake control mechanism is fitted on top of the rear axle housing. The construction of the final drives is identical on tractors 205---665.

The outer drive shaft is carried in taper roller bearings in the rear axle housing. The planetary pinions are carried in needle bearings on the shaft studs which are fixed to the planetary retainer.

The power is transmitted from the differential via the inner drive shaft to the planetary gear and on to the outer drive shaft. The gear ratio in the planetary gear is 5,6:1.

The final drives are fully encased and run in the same oil as the gearbox and differential.

The planetary ring gear is fitted in the rear axle housing with a press fit. The planetary sun gear is machined integrally with the inner drive shaft. When the inner drive shaft rotates it

There is a grease nipple on top of the axle housing for greasing the outer bearing of the drive shaft. The inner bearing is lubricated by the gearbox oil.

Picture 2. Final drives 305---405 (up to ser. no. 302139 incl.) 1. Paper gasket (also suitable sealing compound can be used) 2. Locking fluid Loctite 270 or corresponding 3. Locking fluid Loctite 126 or corresponding 4. Universal grease (20 g). 5. Inner drive shaft 6. Planetary pinion 7. Ring gear 8. Outer drive shaft 9. Rear axle housing 10. Centre bolt. Loctite 2701 onto the threads. 11. Brake discs 12. Pressure plate

461

1. 7. 1989

45. Final drives

1. 3. 1997

Fig. 2. Final drive 305---455 (with effect from ser. no. 302140) 1. Paper gasket 2. Extension sleeve 3. Locking fluid (Loctite 242 or similar) 4. Universal grease (20 g) 5. Inner drive shaft 6. Planetary pinion 7. Ring gear 8. Outer drive shaft 9. Rear axle housing 10. Centre bolt. Loctite 2701 onto the threads. 11. Brake discs 12. Pressure plate N.B. With effect from ser. no. 610312 the planetary pinions (6) have been made wider. In connection with this modification the spacer rings between needle bearing races inside the planetary pinions have also been made wider.

462

Model

305-- 665

Code

450

Page

4

1. 3. 1997

45. Final drives

1. 9. 2001

Picture 3. Final drive on 865---tractor (Transmission 250) 1. Paper gasket 2. Wear ring 3. Loctite 242 or equivalent to threads of spring pins 4. Universal grease (20 g) 5. Inner drive shaft (with sun gear). 6. Planetary gears (3 pcs). 7. Ring gear 8. Outer drive shaft 10. Centre bolt for planetary gear unit. Loctite 2701 to threads of the bolt. 11. Brake discs, 4 pcs, Intermediate discs, 3 pcs (organic linings) 12. Brake application ring Note! The final drive outer drive shaft (8) together with the seals and bearings are the same as on Mezzo---transmission 300. The brake discs are also the same as on Mezzo---tractors.

463

Model

865

Code

450

Page

5

464

1. 12. 1986

45. Final drives

1. 7. 1989

Model

205-- 865

Code

451

Page

1

1. Reconditioning final drive (Op. no. 451) N.B. The construction of the final drives is identical in tractors 305---455.

A. Removing final drive 1. Drain the oil (3 drain plugs, max 23 litres). Free the check link bracket from the rear axle housing. 2. Free the lower link (and extra lifting cylinder if fitted) from underneath the rear axle housing. 3. Slacken the wheel nuts. Block up the tractor under the gearbox. Remove the wheel. 8. Pull the rear axle housing straight outwards so that it clears the gearbox. N.B. Removing the rear axle housing from the gearbox is made easier by removing the brake mechanism from the rear axle housing.

B. Changing roller bearings in planetary pinions 1. Remove the final drive (Op. A).

4. Disconnect the rear end of the brake rod from the lever on the rear axle housing. NOTE: (Up to ser. no. 610311): RH side final drive: Disconnect differential lock control mechanism also. 5. Remove the cab rear attaching bolts. Lift the rear of the cab slightly and block it up with suitable supports or a lifting device. 6. Position an axle stand on castors under the rear axle housing.

2. Remove the brake discs and inner drive shaft. Undo the locking washer on the centre bolt which secures the outer drive shaft to the planetary retainer and unscrew the bolt. The attaching plate remains inside the planetary retainer. Pull the planetary retainer off the drive shaft.

3. Cut the locking wire which is located under the locking spring for the planetary pinion shaft studs. Remove the locking wire.

7. Unscrew the rear axle housing nuts (24 mm).

465

Model

45. Final drives

1. 12. 1986

205-- 865

Code

451

Page

2

4. Compress the locking spring with a pair of pliers and pull the shaft studs out of the planetary retainer.

8. Lower the planetary retainer onto the splines on the drive shaft and so that the planetary pinions engage the ring gear. Secure the planetary retainer to the end of the drive shaft by tightening the centre bolt. 9. Adjust the drive shaft bearing clearance (Op. D) and fit the final drive on the tractor (Op. E).

C. Changing bearings and seals on drive shaft 1. Remove the rear axle housing from the chassis (Op. A). Remove the planetary gear (Op B2).

5. Remove the planetary pinions from the planetary retainer. Change the bearing rollers. The easiest way of fixing the rollers in position is by pacing them in a little grease. Note the spacer ring between the two rows of rollers. 6. Press the bearing wear washers against the sides of the planetary pinions and press them into the retainer. Compress the locking spring and push the shaft studs into position and make sure the locking spring engages the groove in the studs. Note! Fit the attaching plate for the planetary retainer before fitting the third planetary pinion.

2. Tap the end of the drive shaft so that it slides out of the bearings. Pull the shaft out of the axle housing.

7. Push in a wire diam. 2,0 mm under the locking spring. Wind the wire ends together one and a half turns and bend them down. Note! The ring gear is fitted in the rear axle housing by a press fit. If the ring gear is damaged the whole rear axle housing must be changed as well as the ring gear.

3. Remove the drive shaft outer bearing using a puller. Heat the new bearing and fit it on the shaft.

466

Model

45. Final drives

1. 12. 1986

205-- 865

Code

451

Page

3

N.B. When necessary the wear ring on the shaft should be changed. Removing and fitting is carried out by heating the metal ring.

4. Remove the shaft outer seal using a puller.

ETV 892210 8. Remove the inner seal. Fit a new seal using ETV 892 210.

ET 893 410 5. Position support bar ET 893 410 against the rear axle housing. Pull out the outer bearing race. Fit a new bearing race using plate ETV 893 690.

ETV 891710 9. Fit a new bearing race using ETV 891 710.

ETV 893 320

10. Grease the bearings thoroughly before fitting. Carefully insert the drive shaft in the axle housing. Ensure that the seals are not damaged.

6. Fit a new seal using ETV 893 320. Lubricate the felt seal.

11. Fit the drive shaft inner bearing on the shaft. Fit the planetary retainer on the splines on the drive shaft and press the planetary retainer home. Secure the planetary retainer to the end of the drive shaft with the attaching plate and the centre bolt. 12. Adjust the drive shaft bearing clearance (Op. D). Fit the final drive (Op. E).

D. Adjusting drive shaft bearing clearance 1. Place the drive shaft with the wheel flange on the floor. Bed in the bearings by rotating the axle housing approx. 20 turns.

ET 893410 7. Remove the inner bearing race using a puller and support bar ET 893 410.

467

1. 7. 1989

45. Final drives

10. 1. 1992

Model

205-- 865

Code

451

Page

4

10 Nm

3. Position an axle stand with castors under the final drive and move it inwards at right angles so that the inner drive shaft engages in the differential.

2. Tighten the bolt fixing the planetary retainer to the shaft to a torque of 10 Nm. Again rotate the axle housing and check the torque. After some time of operation the correct shaft bearing clearance, i.e. 0,010 ---0,075 mm will be established.

N.B. Fit the brake mechanism on the rear axle housing if it has been removed.

3. Lock the planetary retainer attaching bolt (shaft centre bolt) with the locking washer. The correct position is found by moving the washer round to different positions.

E. Fitting final drive

4. Tighten the nuts for the rear axle housing to a torque of 230 Nm. 5. Press in approx. 20 g of grease through the lubricating nipple by the drive shaft outer bearing. Rotate the shaft while doing this. N.B. Right rear axle housing up to ser. no. 610311: fit the differential lock control and the brake mechanism.

1. Fit the inner drive shaft, brake discs and pressure plate (Op. no. 511 1A 5 ---7). N.B. Check that the distance between the end of the inner drive shaft and the contact surface of the rear axle housing is max. 129 mm. 2. Clean the contact surfaces between the gearbox housing and the rear axle housing and fit a new gasket. Also can be used sealing compound (e.g. Hylosil). NOTE: (Up to ser. no. 610311) control setting with differential lock engaged: nut 1 is tightened until there is no spare clearance in pressure rod 2. Then the nut is turned a further 1/3---1/2 of a turn. NOTE: With effect from ser. no. 610312 the differential lock control mechanism has been changed. The new mechanism no longer needs to be removed when the RH side final drive is removed.

468

1. 7. 1989

45. Final drives

10. 1. 1992

6. Connect the brake rod to the brake lever. 7. Secure the check link bracket to the rear axle housing up to a torque of 80 Nm. 8. Secure the lower link (and extra lifting cylinder) to the underside of the rear axle housing, tightening torque is 380 Nm. 9. Lower the cab and tighten the attaching bolts to 220 Nm. 10. Fit the rear wheel and tighten the wheel nuts to 330 Nm. Fill with oil and adjust the brakes (Op. no. 511 1B). Test---drive the tractor.

469

Model

205-- 865

Code

451

Page

5

1. 3. 1997

45. Final drives

1. 1. 1998

2. Reconditioning final drives on 865 and 600---900

Model

865 600-- 900

Code

451

Page

6

B. Reconditioning planetary gear 1. Before reconditioning, remove the rear axle housing, brake application ring, inner drive shaft and brake discs and the brake support behind the discs.

NOTE! This instruction deals with differences between final drives on 205---665 and on 865 and 600---900 tractors.

2. Unscrew the centre bolt and remove the planetary gear.

A. Removing/fitting rear axle housing

3. Reconditioning planetary gear, see instruction B on page 451/1.

Removing:

Note! In assembly the outer drive shaft bearing clearance is adjusted by tightening the centre bolt to a certain torque, see the following instruction.

1. Removing occurs as shown in instruction A on page 451/1. Note! When the rear axle housing is pulled apart from the gearbox housing side, brake balls (6 off) release and fall down. It is possible that the inner brake ring remains on the side of the gearbox housing.

Note! There are four friction discs and three intermediate discs in the brake disc pack. Fit first the friction disc against the brake support and then by turns intermediate disc and friction disc.

Fitting:

Note! On some planetary gears, there can be two tension pins to prevent rotation of the planetary gear shaft stud locking ring. Locking ring ends must be fitted between the pins. Later the rotation of the locking ring is prevented with a modification of the planetary retainer casting.

1. Fitting is done as shown in instruction E on page 451/4 with the following differences:

C. Changing outer drive shaft seals and bearings Note! The drive shaft, bearings and oil seals are the same as on Mezzo---tractors (transmission 300). Also the special tools used in this work are the same as on Mezzo---tractors, see page 450/2A. The drive shaft bearings and seals are changed in the same manner as shown in instr. C on page 451/2. The drive shaft bearing clearance are adjusted in the same way as described in instr. D on page 451/3, but the centre bolts is tightened to a torque of 3 ---5 Nm. ETV 894 210 2. Position the brake discs in place on the inner drive shaft. Push the inner drive shaft fully home. Compress the outer brake application ring against the springs (2 pcs) and fit the centring tool ETV 894 210 into place so that it supports and centres the application ring. Note! The plug of the centring tool ET 894 210 is screwed into the oil draining hole of the rear axle housing and the upper end of the bolt, which goes through the plug, supports the brake application plate. Picture of the tool, see page 102/5. 3. Fasten the brake balls (6 pcs) onto the grooves on the inner brake ring by using thick grease (e.g. Renax). Position the inner brake ring onto the side of the gearbox in correct position. 4. Fit the final drive. Remove the support tool and tighten the rear axle housing bolts to a torque of 230 Nm.

470

Model

1. 3. 1997

46. PTO (Power take ---off)

15. 4. 1999

Code

205-- 900

Page

460

1

Contents General (Op. no. 460): Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---speed PTO (Power take ---off), description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front---mounted PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N.B. Reconditioning PTO clutch, see instruction 41. Clutch.

1 2 2 5 7 8

Repair instructions PTO (Power take-- off) (Op. no. 462)

1. Reconditioning 1 ---speed PTO: A. Removing PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Changing bearings at PTO shaft end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Changing bearings at upper shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Changing selector fork/selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Fitting PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Changing oil seal at PTO shaft end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 3 4 5

2. Reconditioning 2 ---speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. PTO unit with brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Technical Data PTO shaft end (ISO 500---1979 Z6): --- nominal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- number of splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nominal speed, engine/PTO shaft end 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nominal speed, engine/PTO shaft end 540E (=750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nominal speed, engine/PTO shaft end 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 mm 6 1890 rpm /540 rpm 1594 rpm/540 rpm 2074 rpm/1000 rpm

PTO outputs (kW) at a nominal speed of 540 r/min Tractor 205 Output 29

255 32

305 32

355 36

365 37

405 37

455 41

465 42

555 43,5

700 46,5

800 51,5

900 58

565 45,5

665 49

865 52

PTO outputs (kW) at a nominal speed of 1000 r/min Tractor 365 Output 38,5

465 46,5

565 48,5

665 51,5

865 56

600 37,5

Oil Common for gearbox and final drives: --- Viscosity and quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 120/4. --- Total oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 litres, 865, 600---900: 27 litres NOTE: With effect from gearbox no. 406714 a lubricating oil pipe is fitted from the gearbox pressure lubrication system to the power take ---off unit so that the PTO is lubricated in all conditions.

Tightening torques PTO housing ---gearbox: --- 10 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2 pcs, M16 (earlier tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 2 pcs, M20 (latest tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO shaft end guard plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt for top link bracket spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top link bracket lower attaching point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

471

100 Nm 195 Nm 380 Nm 195 Nm 220 Nm 195 Nm

15. 4. 1994

46. Power take ---off

1. 3. 1997

Model

205-- 665

Code

Page

460

2

Special tools Power take ---off A Part no ETV 893 700*

Description Sleeve for fitting PTO shaft end, bearings or oil seal.

Power take ---off B (ETV 892 350) Sleeve for fitting upper shaft or bearings, 1---speed PTO (see gearbox) ETV 894 080 Tool for fitting shifter fork locking ball, 2---speed PTO (also PTO 6000---8400) Note! Part number marked with asterisk has been made specially for 305---665.

ETV 893 700

ETV 892 350

ETV 894 080 (2 ---speed PTO)

(1 ---speed PTO)

PTO, description Function of 1---speed PTO (see fig. 1)

The PTO operates independently of the gearbox. It is equipped with its own clutch disc in the dual clutch which is bolted to the flywheel. The power is transferred from the flywheel to the PTO via a PTO shaft which runs through the gearbox.

When the PTO selector lever (1) is moved forwards, the movement is transferred via the control rod (2) to the selector lever (3), which moves the selector fork (4). The engaging sleeve (6) connects the PTO clutch shaft (5) to the shaft (8).

The PTO is selected with the PTO selector lever to the right of the driving seat and engaged and disengaged with the clutch lever located to the left of the instrument panel.

The PTO shaft end begins to rotate as the clutch shaft (5) begins to rotate.

Before selecting the PTO, the clutch lever should be moved to its rearward position, i.e. clutch disengaged, and after selecting the PTO the clutch lever should be moved to its forward position, i.e. engaged. The clutch lever should only be used for temporarily disengaging the PTO (for at the most 5 minutes).

472

1. 12. 1986

46. Power take ---off

1. 7. 1989

Model

205-- 665

Code

460

Page

3

Fig. 1. Principle diagram, PTO 1. Selector lever 2. Control rod 3. Selector lever 4. Selector fork 5. PTO clutch shaft 6. Engaging sleeve 7. Oil dipstick 8. Upper shaft 9. Locking fluid Loctite 222 or similar A. Selector lever bearings B. Note position of tubular pin

NOTE: With effect from ser. no. 610312 the PTO engaging mechanism has been changed slightly; the position of the lever in the cab is different.

473

Model

46. Power take ---off

1. 12. 1986

Fig. 2. Section of PTO 1. Paper gasket 2. Thrust bearing 3. Needle bearing 4. Clutch disc for PTO 5. PTO shaft end

474

205-- 665

Code

460

Page

4

15. 4. 1994

46. PTO

1. 3. 1997

Model

365-- 865

Code

460

Page

5

2---speed PTO

Note In point 10 between the gearwheel Z63 and the ball bearing, there are fitted on latest units (G07101---) a spacer ring (s=3,0 mm) and possible shims (s=0,1 and 0,3 mm). With these shims are adjusted the play of the two gearwheels on the PTO shaft to 0,05---0,1 mm. The gearwheel Z63 has also been modified. As a spare part only this new gearwheel is delivered , which requires the above mentioned shims.

The foremost gear wheels (Z18/Z63) are for PTO 540 r/min. The rearmost gear wheels are either for PTO 540E (Z21/Z62) or PTO 1000 r/min (Z27/Z56).

475

15. 4. 1994

46. PTO

Model

365-- 865

15. 9. 1995

Code

460

Page

6

2---speed PTO

3 2

1

Lubrication

Picture 4. Lubrication of PTO 1. Lubricating oil inlet 2. Oil space at the rear end of the upper shaft 3. Selector arm

Lubricating oil is directed from the gearbox lubricating system distribution piece via pipe 1 to the front end of the selector rail.

The PTO shaft has a lip ---type oil seal. Both shafts are supported with ball bearings. A paper gasket or a suitable sealing compound is used between the gearbox and the PTO housing.

Oil flows through the rail to the oil space 2 at the rear end of the upper shaft and inside the upper shaft via the oil drillings to the sliding surfaces of the gear wheels.

Important! If the selector fork of the 2---speed PTO unit has been changed due to the excess wear, it is necessary to make a modification also to the PTO control lever linkage. On the earlier PTO units the selector fork wear may be caused by a wrong control lever mounting. This control lever modification has already been carried out in the tractor works for all new tractors.

The lower shaft has a splash lubrication.

476

Model

46. PTO

1. 9. 2001

477

600-- 900

Code

460

Page

6A

Model

46. PTO

1. 9. 2001

478

600-- 900

Code

460

Page

6B

15. 9. 1995

46. PTO

1. 3. 1997

Model

365-- 865

PTO brake With effect from tractor serial number 666440, the 2---speed PTO unit has a brake which ensures, that the PTO shaft stops rotating, when the control lever is moved to the neutral position.

Picture 5. PTO shaft brake 1. Brake shoe 2. Selector fork 3. Selector fork rail 4. Brake spring 5. Pivot pin of the brake shoe upper end 6. Ball for releasing the brake 7. Gearwheel Z63

In the neutral position, spring (4) presses the brake shoe (1) against the big gearwheel (7) on the PTO shaft and prevents the PTO shaft from rotating. When the PTO is engaged, the selector fork moves and ball (6) presses the brake shoe away from the gearwheel. Note It is possible to fit the PTO brake also on the earlier manufactured tractors, which have the 2---speed PTO unit, see page 462/9.

479

Code

460

Page

7

15. 9. 1995

46. PTO

1. 1. 1998

Model

365-- 900

Code

460

Page

8

Front PTO

Without priority valve

600-- 900

Fig. 6. Front PTO (option)

On the tractors with the priority valve, the counter pressure created by the priority valve raises the free flow pressure up to about 11 bar.

1. Hose union from pump to pressure line. 1a) Valve (7 bar) which increases the free flow pressure on tractors which do not have the priority valve. 2. Solenoid valve (solenoid/pressure reduction) 3. Control switch in the dash board (fuse FA4) 4. Front PTO 5. Return oil flow to the tank via T ---connector on the pipe for the auxiliary hydraulic oil.

The front PTO is engaged electro---hydraulically by means of the switch (3) in the dash board. The solenoid valve (2) opens allowing oil pressure of max. 11 bar into the cone clutch of the front PTO. The function of the solenoid valve ensures that the PTO is engaged progressively i.e. the valve raises the clutch pressure gradually up to 11 bar.

The PTO shaft rotates 1000 rpm at engine speed of 1950 rpm. PTO shaft end (grooves/diam.) 6/35 mm (1 3/8”). Direction of rotation (seen from the front).

The electronics of the valve has been adjusted in the factory so that the engaging time is modulated. However, if an operator wants to adjust the engaging time, it can be done by turning the middle potentiometer screw. The screws are covered by a detachable cover.

Front PTO + front linkage is an optional equipment. The front PTO is not fitted without the front three ---point linkage.

NOTE! The longer the engaging time, the greater the cone clutch wear.

In the hydraulic system without the priority valve, the free flow pressure is 4---5 bar, which is not high enough to drive the front PTO (required pressure is 11 bar). In this case, the valve 1a is fitted in the pipe system. The valve causes a pressure drop, which raises the free flow pressure (between pump and valve) up to about 11 bar.

480

Model

46. PTO

15. 9. 1995

460

Page

9

Repairs

Picture 7. Sectional view of front PTO unit 1. Intermediate flange 2. Universal shaft 3. Clutch drum 4. Hub 5. Friction piece (6 off) 6. Spring 7. Bolt (3 off) 8. Spring (6 off) 9. Piston 10. Clutch cylinder

365-- 865

Code

The front PTO clutch is a dry cone clutch, which has six friction pieces (5) pressed by spring (6) against the clutch taper surfaces. The friction pieces are accessible after unscrewing the universal joint (2) attaching flange on the clutch drum (3) and by releasing the clutch drum bearing circlip through holes in the drum. After that the clutch drum/bearings can be pulled out by using puller screws (M10). When the drum/bearings have been removed, the friction pieces can be changed. The clutch assembly can be detached from the PTO housing after removing the clutch drum by unscrewing bolts inside the clutch. In this case, rotation of the clutch should be prevented in a suitable way.

11. Oil passage 12. Support plate 13. Shaft 14. Oil gallery ---in cover 15. PTO shaft 16. Oil level checking plug 17. Oil draining plug 18. Solenoid valve 19. Gasket

The PTO shaft seal can be changed by removing the seal cover circlip after which the seal/cover can be detached. In the same way the upper shaft front seal is changed.

Maintenance

If the PTO shaft or the upper shaft rear seal has to be changed, the PTO housing should be parted by removing the centring pins and by unscrewing the housing halves attaching bolts. Do not tap a wedge between the housing halves since the sealing surfaces can damage.

a) Retighten all fixing bolts after the first 15 --- 25 running hours. b) It is not necessary to change the oil in the PTO housing. Check the oil level at intervals of six months. Top up, if necessary, normal SAE 90 EP transmission oil. The oil level should be at a level of the checking plug. c) Grease the universal joints with grease of a good quality once a year.

When assembling the PTO unit, the universal joints must be alined in a correct way.

481

Model

46. PTO

15. 9. 1995

365-- 865

Code

460

Without priority valve

Attachning plate

Fixing bolts (240 Nm) Picture 8. Explored view of the front---mounted PTO.

482

Page

10

15. 9. 1995

46. PTO

1. 3. 1997

Model

Code

365-- 865

460

Page

11

B

A

To working hydraulics To priority valve

7 bar

0---11 bar

VA=white KEVI=yellow green VI=green SI=blue RU=brown KE=yellow

With priority valve

Without priority valve

Picture 9. Front PTO control valve (solenoid+pressure reduction valve). The engagement of the front PTO is electronically controlled, so that the engagement will happen progressively.

When the rocker switch is turned on, the solenoid is magnetic. If the front PTO shaft does not start to rotate, altought the control switch is turned to the running position, first check the fuse FA4 in the fuse box and check whether the current comes to the solenoid. If it is there, but the solenoid is not magnetic, the fault lies in the solenoid.

1. Solenoid valve 1a. Solenoid valve spool 2. Pressure reduction valve 2a. Pressure reduction valve spool 3. Front PTO unit 4. The electronics have been adjusted to modulate a correct engaging time. However, if the operator wants to adjust the engaging time, it can be done by turning the middle potentiometer screw.

If the electrical system is OK, it is possible, that there there is dirt in the valve. Dirt prevents movement of the valve spools and obstruct oil holes. A worn ---out cone clutch or too low oil pressure can cause clutch slip and noice.

Important! On the latest tractors the electronic box A3 together with its potentiometer screws has been moved from the valve connector into the steering wheel console, see wiring diagram B above. Wiring diagram A shows the earlier version.

If the engagement doesn’t happen ”softly”, the control valve does not function properly.

483

Model

46. Power take ---off

15. 4. 1999

600-- 900

Code

460

Page

12

Later front PTO The front PTO has been renewed in 600---900 tractors. The construction is shown on pages 460/12 ---14. The elctrical system is the same as earlier. The mechanical system is different. I production with effect from ser. no. H47255.

Picture 10. Front PTO of new type (600 ---900). 1. Pressure oil from pump to control valve (2) and into the PTO clutch. 2. Control valve (solenoid Y9+pressure reduction). 3. Front PTO rocker switch S38. 3a. Front PTO control unit A3. 4. Front PTO unit 5. Return oil to tank flows via T ---connection in the return oil connector for the auxiliary hydraulics.

Note! The control unit A3 has an adjusting screw (middle) , with which the engaging time of the front PTO can be adjusted. Adjustment has been done in the factory, and readjustment is normally unnecessary. Too long engaging time causes excess wear in the clutch.

Electrical parts

--- Check the bolt thickness after the first 100 running hours. --- check the condition of the rubber joint at intervals of 500 running hours. Change when necessary. --- change the oil at intervals of 6 months. --- check now and then possible leakages

Maintenance:

FA4, fuse for front PTO S38, rocker switch in the dashboard X42, connector under the dashboard GR3, earth point, cab wire loom. A3, electric control unit

Oil volume 1,4 litres. Oil quality: 10W/30, API CE/SF, API GL 5/4, CCMC D4.

484

Model

46. Power take ---off

15. 4. 1999

Picture 11. Cross ---section, front PTO 1. Elastic rubber joint 2. Flange 3. Tapered joint 4. Upper shaft 5. Clutch drum / gear 6. 5 pcs steel discs 7. 6 pcs friction discs 8. Cylinder / piston 9. Cylinder flange 10. Piston return springs 11. Seal flange 12. PTO shaft 13. Oil filling plug 13a. Draining plug 14. Tension pins, housing halves 15. Brake wear plates

Wiring diagram

600-- 900

Code

460

Page

13

Changing fan belts: --- Unscrew bolts of flange (2) --- Push the shaft into splined sleeve (3), --- Remove the belts through the opening --- If the opening is too small, unscrew the PTO unit fixing bolts and pull the unit forwards until the belts can be changed. --- Fitting in the reverse order: tighten the unit fixing bolts (4 pcs) to 200 Nm. Tighten the flange (2) bolts to 90 Nm (12.9). Elastic joint: Apply grease onto the bolt head lower face. Tighten the bolts to 140 Nm, so that rubber does nor bend (three axial and three radial bolts).

Fault tracing: --- If the front PTO does not start with rocker switch S38, check the fuse FA4. --- If the fuse is OK, check whether the current is in the solenoid Y9 connector, when the rocker switch is in the engaging position. --- If not, check the switch, connector X42, control unit A3 and earth point GR3. --- If there is current in the solenoid, but the PTO does not start, check the solenoid by measuring its resistance. Change , if damaged. --- If the solenoid is OK, the fault may lie in the hydraulics. Check the control valve. --- check that hydraulic pressure affect the PTO clutch. --- if the pressure is OK, the fault lies in the mechanical parts of the PTO unit.

485

15. 4. 1999

46. Front PTO

Model

600-- 900

10. 10. 2003 3

C

Code

460

Page

14

B 1

6

A

10

8

5

2

4

9 7

A. Changing external oil seals

--- Drain the oil in the housing --- Unscrew the bolts of the housing halves and remove the front part (tension pins in the joint). --- Remove the upper shaft bearing (3). --- Tap with a soft mallet on the flange (2), at which time the lower shaft is pushed out of its location. Remove flange (2) and the lower shaft rear bearing (10). --- press with two glue clamps on flange (4) to compress springs (5) and remove the snap ring (6). --- Remove the cylinder/piston (7), after which the clutch discs can be changed. Check/change the clutch seal rings. --- If the entire PTO shaft must be changed, remove bearings and disc pack front flange on the shaft. --- Check wear of plates (9). Change when needed.

Oil seal A can be changed from the front by prying it out of the housing (do not damage the shaft surface). Grease lips of a new seal and strike it in with a suitable sleeve. Reduce oil level in the housing before seal removal. Remove the shaft protecting guard, if necessary. Oil seal B is changed as follows: --- Remove the PTO unit --- Unscrew the bolt (M16, 12.9, 360 Nm) of the tapered joint (1) --- Pry out the seal B and fit a new one with a suitable sleeve --- clean the tapered joint. Connect the joint and tighten the bolt to 360 Nm. The rotation of the shaft can be prevented in a vice/ with pliers. Hold on the splined shaft near the welding joint, but not on the tapered part.

Note when reassembling: --- In connection with repairs the seal A should be changed. --- Joint C has a paper gasket of 0,4 mm, which should be changed during repairs --- It is useful to change the whole disc pack (6 friction and 5 steel discs) --- grease all seals during mounting --- when the lower shaft with the clutch is in its location, place the o---ring of flange (2) against bearing (10) and tap in the flange and fit the snap ring (8). --- Oil volume 1, 4 litres.

The o---ring of the seal flange (2) is accessible after removing securing ring (8) and by pulling the flange out of the bore.

B. Reconditioning multi-- disc clutch/ changing PTO shaft --- Remove the PTO unit (it is unnecessary to open the tapered joint (1)

486

Model

46. PTO---HiShift

1. 9. 2001

600-- 900

Code

461

Page

1

1. PTO---HiShift (option) The PTO ---HiShift hydraulic block (3) pushes electrohydraulically the PTO clutch disc to the disengaged position and back to the engaged position with the aid of the rocker switch (1) in the cab. The PTO clutch lever (6), however, does not move when the switch is used (safety).

a) b) c) d)

Picture 1. PTO ---HiShift in the 600---900 tractors

The slow engagement can be adjusted by means of a restriction screw on the hydraulic block (3). The clutch lever (6) can also be used manually, but the engagement cannot be made faster.

1. Positions of PTO ---HiShift rocker switch (S 69): --- figure a: middle position: PTO ---clutch engaged, the clutch lever in the front position in manual use. --- figure b: left edge down, PTO ---clutch disengaged, the clutch lever in the rear position in manual use. Engine cannot be started in this position. --- figure c: the switch is pressed from position b to the middle position, fast engagement (e.g. light implement) --- figure d: the right edge is held down, slow engagement (e. g. heavy implement). The switch must be held in this position during the whole engagement.

The rocker switch (1) is placed either in the dashboard or on the side console (if ACB power lift). Retro fitting: On tractors without the priority valve (and without the clutch pedal HiShift), a non ---return valve must be fitted (33683100, 10 bar) in order to obtain the correct control pressure for the PTO HiShift.

2. Pump 3. PTO ---HiShift hydraulic block 4. HiShift (for clutch pedal (option)). 5. Return oil into the hydraulic housing 6. PTO clutch lever 7. PTO ---lever

The control pressure in the hydraulic block (3) is limited by a pressure relief valve. Adjusing value is 1,8 Mpa.

487

Model

46. PTO---HiShift

1. 9. 2001

Picture 2. PTO ---HiShift, mechanical parts A. Switch (S 69) in the middle position. PTO ---clutch is in the engaged position (lever is in the front position in manual use). The piston is inside the hydraulic block. B. Switch (S 69) front edge depressed, at which time the piston is pushed out and presses the PTO clutch disc into the disengaged position (in manual use the clutch lever is moved to the rear position). C. Manual control is always possible.

488

600-- 900

Code

461

Page

2

Model

46. PTO---HiShift

1. 9. 2001

600-- 900

Code

461

Page

3

Function when disengaging the PTO--clutch

Picture 3. Hydraulic block, disengagement 1. Restriction screw to adjust the slow engagement. Basic adjustment: 3,5 turns open (adjusting range ±1 turns).

Picture A: The rocker switch S 69 is in the middle position. Solenoid valves Y16 and Y17 are unenergised.

2. Pressure ---limiting valve. This valve reduces the pump pressure to 18 bar (1,8 MPa). The valve is sealed.

Behind piston 7 there is pressure, which holds the piston inside the valve block and the PTO ---clutch disc is in the engaged position (in the manual use the PTO clutch lever is in the front position).

3. Valve block. 4. PTO ---HiShift---pressure test point. The correct value should be 18 ---22 bar. When measuring the pressure, the oil must be in the normal operating temperature and the engine revs about 1500 rpm.

Picture B: The switch S69 left edge is pressed down, at which time the solenoid valve Y16 becomes energised and opens an oil way from the pressure side to the solenoid valve Y17. The valve Y17 is also energised and it allows oil to flow into the valve block cylinder.

5. Pressure from pump. 6. Return oil to the hydraulic housing. 7. Piston (the same seals as on the clutch pedal HiShift piston).

Hydraulic pressure pushes the piston 7 out of the valve block and by means of the external linkage the PTO ---clutch disc is moved to the disengaging position. The solenoid valves are energised as long as the switch S 69 is in this position (left edge down). In the manual use the PTO clutch lever is moved to the rear position.

489

Model

46. PTO---HiShift

1. 9. 2001

Code

600-- 900

461

Page

4

Picture 4. Hydraulic block, engagement

Function when engaging the PTO clutch By means of the restriction screw (1), the retrun oil flow can be adjusted and in this way affected the return speed of the piston (7).

Picture C (fast engagement): The rocker switch S 69 is pressed to the middle position.

The piston returns slow and the PTO is engaged smoothly.

Both solenoid valves become unenergised. Solenoid valve Y17 opens an oil way from the cylinder to the tank. Pressure on the piston rod side presses the piston 7 back into the cylinder and the PTO ---clutch disc moves fast to the engaging position.

General about the hydraulic block: --- in case of leakage various seals and o---rings are available as a spare part. When fitting piston seal KH 3714 special tool ETV 894 320 can be used. --- impurities in oil can block oil ways in the valve and can cause malfunctions. Large particles can prevent movement of the solenoid valve spindles or pressure ---limiting valve (2) may stick in the open or closed position. The valve can, in this case, be removed and disassembled and the oil ways can be tried to be cleaned. --- external damage can also affect the linkages between the piston and the clutch lever lower end.

Picture C1 (slower engagement): The rocker switch S 69 right edge is held down against a spring force. The solenoid valve Y17 becomes energised and it directs oil from the cylinder through valve Y16 (unenergised) and the restriction screw (1) into the tank.

490

Model

46. PTO---HiShift

1. 9. 2001

600-- 900

Code

461

Page

5

Wiring diagram

Picture 5. PTO ---HiShift, electrical connections

--- At the same time the control coil of relay K25 is earthed (via switch S69 pins 8 and 4). --- The relay is functioning and cuts the connection between the ignition switch pin 4 and the safety switch S12. In this position, the engine cannot be started.

Switch S 69 in the middle position (engagement): --- When the ignition is switched on, current is fed into the switch S 69 (pin 3). --- When the switch is in the middle position, current cannot flow forwards from the switch. --- Solenoid valves Y 16 and Y17 are unenergised and the PTO ---clutch lever is in the front position (clutch disc engaged).

Note! The PTO clutch lever varning light H13 is earthed also via switch S 69, and illuminates when the relay K25 is on. This informs the driver, that the PTO ---clutch disc is released. Switch S69 right edge is held down (slow engagement):

Switch S 69 left edge down (disengagement):

--- Solenoid valve Y17 is energised and steers oil from the cylinder via the adjustable restriction hole into the tank.

--- Both solenoid valves Y16 and Y17 are energised. The PTO ---clutch disc is released when the clutch lever is pulled rearwards.

491

Model

46. PTO---HiShift

1. 9. 2001

600-- 900

Code

461

Page

6

Picture 6. Position of main electrical components The elctrical system in general: --- In case of problems, check first fuses FA1, FB5 and FD3. In addition, pins inside the rocker switch S 69 can be checked for oxcidation.

--- If the slow engagement has problems, the fault may lie also in the diodes V6. In case of diode damage, the whole diode housing is replaced.

--- In case of malfunction, check the solenoid valves Y16 and Y17. The resistance of the valves should be between 10 ---12 ohms. When the switch S69 left edge is down, both solenoids must be magnetic and unenergised when the switch is in the middle position. When the switch right edge is held down, only valve Y17 is magnetic.

--- Position of various wire connectors and components can be found in the picture on page 310/2D. The tractor’s whole wiring diagram is shown on pages 310/31 ---33. IMPORTANT! The engine does not start, if the switch S 69 left edge is down, because the circuit is prevented by relay K25.

492

Model

46. PTO (Power take ---off)

1. 12. 1986

205-- 665

Code

Page

462

1

1. Reconditioning PTO (Op. no. 462) A. Removing PTO (1---speed PTO) N.B. Once the PTO has been removed the thrust and roller bearings should be checked. They are located at the end of the long shaft. The roller bearing should be locked, using Loctite 542, applied only at the outermost edge of the bearing . Ensure that the locking fluid does not come into contact with the rollers on the bearing. Important! On the later tractors the roller bearing has been locked in the factory. Only check that the bearing is placed tightly in the boring. 1. Drain the oil from the gearbox. Remove the top link.

6. Remove the PTO shaft end guard plate. Attach a suitable lifting device to the PTO housing and unscrew the attaching bolts.

2. Disconnect the upper ends of the pick ---up hitch lifting links and lower the hitch. 3. Disconnect the lower end of the pick ---up hitch release control. Disconnect the control rod from the selector lever on the right side of the PTO housing.

7. Pull out the PTO housing straight backwards so that it becomes free from the guide pins.

B. Changing bearings at PTO shaft end

4. Slacken and remove the nut for the top link bracket (spring). Remove the tubular pin from the shaft at the top of the bracket (impulse transmitter lock) and remove the shaft and its cup spring.

1. Remove the PTO (Op. A).

N.B. There are shims under the top link bracket spring which become free when the bracket is removed. When fitting the bracket the same number of shims must be placed under the spring. 5. Remove the top link bracket lower shaft in order to free the top link bracket.

2. Remove the circlip in front of the shaft front bearing.

493

Model

46. PTO

1. 12. 1986

205-- 665

Code

Page

462

2

7. Position the gear in the PTO housing with the hub facing rearwards and push the shaft into place through the gear. Tap the shaft home using sleeve ETV 893 700. 8. Fit the circlip in front of the front bearing. Fit the PTO (Op. E).

C. Changing bearings at upper shaft 1. Remove the PTO (Op. A) and the PTO shaft end (Op. B, 2 ---4). 3. Tap on the rear end of the shaft using for example a soft mallet in order to free the shaft from its bearings. The rear bearing remains in the housing. 4. Remove the gear through the opening in the lower part of the housing.

2. Remove the engaging sleeve (1) and the selector fork (2) at the front of the shaft. Ensure that the ball (3) and the spring (4) are not lost.

5. Remove the front bearing using a puller. Fit a new bearing using sleeve ETV 893 700. Ensure that there is a spacer ring on the shaft behind the bearing.

3. Remove the circlip from in front of the front bearing.

6. Remove the rear bearing using a puller and fit a new one using sleeve ETV 893 700. Change the oil seal before fitting the shaft. Fit a new seal using sleeve ETV 893 700.

494

Model

46. PTO

1. 12. 1986

4. Force out the shaft by for example using a 24 mm key.

205-- 665

Code

462

Page

3

8. Fit the engaging sleeve at the front end of the shaft with the hub pointing forwards and at the same time fit the selector fork on the selector rail. Depress the ball and spring using a screwdriver. 9. Fit the PTO shaft (Op. B, 7 ---8) and the PTO housing (Op. E).

D. Changing selector fork/selector shaft 1. Remove the PTO (Op. A). 2. Pull the selector fork (2) and the engaging sleeve (1) off the selector shaft. At the same time ensure that the ball (3) and the spring (4) are not lost.

5. Remove the bearings from the shaft using a puller.

N.B. It is easier to free the selector fork if, at the same time, the selector arm is turned.

6. Fit new bearings using sleeve ETV 892 350. 7. Tap the shaft into the housing using sleeve ETV 892350. Fit the circlip in front of the front bearing. 3. Unscrew the outer and slacken the inner locking screws for the selector rail. Pull out the selector rail. 4. Push in the new rail. Fit a new O ---ring on the shaft and lubricate it. Push the shaft into position.

495

1. 7. 1989

46. Power take ---off

10. 1. 1992

Model

205-- 665

Code

462

Page

4

5. Turn the shaft so that the groove aligns with the inner locking screw. Tighten the inner locking screw and lock it with the outer locking screw. Apply locking fluid Loctite 222 on the threads of the outer locking screw.

2. Lift the PTO housing into position and at the same time guide it so that the engaging sleeve engages the PTO clutch shaft. On the latest models guide the PTO lubricating oil pipe rear end into its hole on the PTO housing.

N.B. If the selector lever is to be changed, the PTO shaft end must first be removed, before removing the selector lever.

NOTE: Assembly is made easier by turning the PTO shaft end or the selector arm (lever).

6. Fit the selector fork and engaging sleeve at the same time. Also check that the inner selector arm (lever) is located in the hole (socket) in the selector fork. Depress the ball and spring using a screwdriver.

3. Once the PTO is located on the guide pins, the bolts are tightened to 100 Nm (10 pcs, 19 mm) and 195 Nm (M16, 2 pcs) or 380 Nm (M20, 2 pcs). 4. Connect the lower end of the pick ---up hitch control to the locking device. Connect the control rod to the selector lever.

7. Fit the PTO (Op. E).

5. Fit the top link bracket. Fit the lower shaft first. Fit shims of the same thickness as before under the top link bracket spring. Press the top part of the bracket into position and fit the plate on the bolt. N.B. The shims are used to adjust the position of the top link bracket so that the bracket does not move when the impulse transmitter lock is turned down into its locked position. Shims are available in the following thickness: 0,5, 1,0 and 2,0.

E. Fitting PTO 1. Clean contact surfaces on the gearbox housing and PTO housing. Fit a new gasket.

496

1. 12. 1986

46. Power take ---off

1. 7. 1989

Model

205-- 665

Code

462

Page

5

5. Fit a new seal using sleeve ETV 893 700. 6. Fit the protecting ring in front of the seal. Fit the guard plate and tighten to a torque of 195 Nm. Fit the PTO cup guard. 7. Fill the gearbox with oil (23 litres). 220 Nm

G. Special instruction Earlier 305 and 405 models are not equipped with a lubricating oil pipe for the PTO unit, but this can be fitted if required. This involves the fitting of a new oil distribution piece in the gearbox and a lubricating oil pipe between the gearbox and PTO unit. A hole must be drilled through the PTO housing rear wall for the rear end of the pipe.

6. Fit the upper shaft (impulse transmitted lock) with its cup springs in position and fit the tubular pin. Apply locking fluid Loctite 270 to the threads of the screw stud and tighten the nut to 220 Nm.

This modification should be carried out if the tractor is often used on sloping ground, with the front end of the tractor lower than the rear end.

N.B. Check that the top link bracket cannot move when the impulse transmitter lock is turned downwards into its locked position. 7. Fit the PTO shaft end guard plate and tighten the bolts to 195 Nm. Fit the PTO cup guard. 8. Lift up the pick ---up hitch and connect the upper ends of the lifting links. 9. Fill with oil (23 litres). Test---drive the tractor.

F. Changing oil seal at PTO shaft end 1. Drain the oil (23 litres). Remove the PTO shaft end cup guard and guard plate. 2. Remove the protecting ring in front of the seal. Tap a small hole in the seal using a centre punch. 3. Carefully screw in a self ---tapping screw or similar in the hole. Take care not to damage the shaft.

4. Break the seal out of the housing.

497

15. 9. 1995

46. PTO

1. 3. 1997

Model

365-- 865

Code

462

Page

6

Repair instruction of 2---speed PTO (without PTO brake)

A. Removing and fitting PTO housing The 2---speed PTO is removed in the same way as the earlier unit, see page 462/1 instr. A. The PTO is fitted as shown in instr. E on page 462/4. Note! In connection with the 2---speed PTO, there is no ball and needle bearing inside the PTO clutch shaft rear end. The clutch shaft rear end guides into the unit upper shaft front end.

B. Changing PTO shaft seal 3. Tap at the PTO shaft rear end until the shaft releases from its bearings and remove the PTO shaft forwards. The front bearing remains on the shaft and the rear bearing remains in its location on the housing.

See instruction F on page 462/5.

Note! Take care of the possible spacer ring and shims behind the PTO shaft front ball bearing, see note on page 460/5.

C. Dismantling PTO 1. Remove the PTO housing, see Op. A.

4. Take the large gear (Z63) out of the housing.

2.Unscrew three ball bearing fixing bolts on the front face of the PTO unit.

498

15. 4. 1994

46. PTO

1. 9. 2001

Model

365-- 900

Code

462

Page

7

5. Remove the smaller gear wheel from the housing. Note! The PTO selector fork and its lever can be removed without removing the PTO shaft as described above. 6. Unscrew the selector fork rail locking screw on the RH side of the housing. 7. Push the selector fork rail rearwards and take it out of its location at which time also the selector fork locking ball and spring release.

11. Insert an impact puller inside the upper shaft and tap the shaft forwards until it releases. Note! The front bearing of the shaft remains on the shaft and also the front gear wheel (Z18). 12. Take the coupling sleeve and the bigger gear wheel out of the housing. 13. If the shaft rear bearings have to be changed, remove them with an impact puller and fit new bearings by using sleeve ETV 893 700 or use a suitable drift. Note! The upper shaft rear ball bearing is fitted so that the bearing protective plate is turned forwards (towards the PTO).

8. Turn the selector fork so that the shifter lever ball---shaped end releases from the fork hole. Remove the fork. 9. Pull the shifter lever outwards and remove it.

14. If you change the shaft front bearings, pull them out with an extractor and fit new bearings. Note! Before fitting the upper shaft front bearing, ensure that the front gear (Z 18) is placed on the shaft. Important! If the upper shaft must be replaced, always fit a latest spare shaft, which have three axially machined flat surfaces for lubrication.

10. Remove the circlip inside the upper shaft front end.

499

15. 4. 1994

46. PTO

1. 3. 1997

Model

365-- 865

Code

462

Page

8

B. Assembling PTO unit 1. Fit the front gear (Z18) onto the upper shaft and fit the front bearing fully home, if removed. 2. Push the upper shaft into its location through the front bearing hole and fit inside the housing the coupling sleeve and the rear gear onto the shaft. 3. Push the shaft in place and tap at its front end until the shaft rear end is bushed into the rear bearing and the front bearing into its location.

7. Push in the selector fork rail from the rear so that the rail hole more chamfered side is turned towards the rail locking screw hole. Note! The selector fork rail forces the tool ETV 894 080 out and the locking ball remains under the selector fork rail. ETV 894080

4. Fit the circlip inside the shaft.

8. Take the tool ET 894080 out of the housing. 10. Apply locking fluid Loctite 572 to the threads of the rail locking screw. Ensure that the rail hole is at the locking screw hole and screw in the screw. 11. Fit the ball bearing onto the front end of the PTO shaft using sleeve ETV 893 700 (if removed). 5. When the upper shaft is in place, place the selector fork onto the coupling sleeve. Pass the shifter lever into place and fit its round ---shaped end into the hole on the selector fork.

Note! Make sure that the PTO shaft rear bearing is in its location fully home. Tap, if necessary, using sleeve ETV 893 700.

Note! Check/change, if necessary, the shifter lever o---ring and grease it before fitting the lever. 5. Position the spring into the drilling in the fork. 6. Place the ball onto the spring and push tool ET 894 080 from the rear into the fork so that the tool chamfered side presses the ball into place and the tool remains on the ball.

500

15. 9. 1995

46. PTO

1. 3. 1997

12. Fit the PTO shaft smaller gear into the housing with the hub longer side turned forwards and then, in front of the smaller gear, the larger gear (Z63) with the longer hub side turned rearwards.

Model

365-- 865

Code

462

Page

9

2. Remove spring (4). Unscrew the three fixing bolts for the bearings. The upper bolt fixes the pivot pin (5) of the brake shoe (1). Remove the pin (5). 3. Remove the PTO shaft and its gearwheels, selector fork rail and the fork, see instr. C on page 462/6 paragraphs 3---9. Take care of the steel balls. Remove the upper shaft and the brake shoe, see paragraphs 10---14 on page 462/7.

13. Push the PTO shaft from the front through the gears and tap the shaft into place (ETV 893 700), until it is pushed into the rear bearing and the front bearing into its location.

B. Assembling

Note! Observe the possible spacer ring and shims behind the front bearing, see note on page 460/5.

1. Place the foremost gearwheel (Z18) onto the upper shaft and fit the ball bearing in front of the gear fully home (if removed). 2. Push the upper shaft into place and place (inside the housing) the brake shoe, sliding coupler and the rear gearwheel onto the shaft. 3. Push the upper shaft into place and tap at its front end until the shaft rear end is pushed through the rear bearing and the foremost bearing is pushed into its location. 4. Fit the selector fork and its rail, see page 462/8 paragraphs 5---10. Turn the brake shoe into a correct position. 5. Put the PTO shaft gears into the housing. The brake shoe notch must engage with the big gearwheel. Fit the PTO shaft, see page 462/8 paragraphs 11---13.

14. Fit the bearing locking bolts and their washers and tighten the bolts to 80 Nm. 15. Engage the PTO with the selector fork and rotate the PTO shaft and ensure that the shafts can be rotated easily. 16. Refit the PTO housing according to instruction A.

3. PTO brake

3

Note! Compared with the brakeless PTO unit, the PTO unit with the brake has a new gearwheel Z63 and a new selector fork rail. In addition, to the brake. Also the casting of the PTO housing has been modified.The brake can be retro---fitted onto the earlier tractors, which have a 2---speed PTO unit (fitting kit number is 31972900).

6. Fit the pin (5) so that it engages with the brake shoe hole. Fit the bearing fixing bolts (3 off) together with washers. The washer of the upper bolt must engage with a groove on the pin (5). 7. Fit the steel ball (3) into the selector fork drilling and fit the brake shoe in place so that the shoe notch is engaged with the big gearwheel and the ball (3) remains under the shoe. Fit the spring (4) (lower end first). Fit the PTO unit.

A. Disassembling 1. Remove the PTO unit, see instr. A on page 462/6

501

Model

46. PTO

1. 3. 1997

C. Modifikation of PTO brake

With effect from tractor serial number G04305 the function of the brake has been made more precise by adding an adjustment for the brake shoe. Adjust the position of the brake shoe so that the gearwheel rotates without dragging.

502

205-- 865

Code

Page

462

10

51. Service brakes

50. Brake system

52. Parking brake

503

504

1. 5. 1996

51. Brakes

Model

1. 1. 1998

205-- 900

Code

510

Page

1

Contents General (Op. no. 510) Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Brake system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Repair instructions Service brakes (Op. no. 511)

1. Reconditioning service brakes: A. Changing brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Adjusting brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 C. Changing brake mounting and brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Parking brake (Op. no. 512)

A. Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Technical data Brake type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical control disc brake running in oil Number of friction discs per brake: --- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 pcs --- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 pcs Number of intermediate steel discs per brake: --- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 pcs (660938---; 3 pcs) --- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 pcs Friction area, total: --- 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2316 cm2 --- 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2950 cm2 Brake disc, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 mm (8.82 in) Depth of oil grooves in new friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 mm (0.012 in) Number of balls per brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 pcs Brake pedal free travel, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 mm (2 in) Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuates the foot brake mechanically Note! 205---665: With effect from tractor serial number 660938 the brake discs have been changed to the organic type. At the same time one steel disc has been added (innermost), since the friction area of the organic discs is greater. The organic discs require smooth steel discs. The organic brake discs cannot be fitted on the earlier tractors due to lack of space. The application plate, support plate and the return spring pins have been changed from tractor ser. no. 667467 incl. The new return spring pins must be fitted in connection with repairs also onto the earlier manufactured tractors (allow greater space for the springs). Note! The organic brake discs can be fitted in place of the ceramic ones, but the braking surface of the innermost disc is not entirely in use (if not an additional plate is fitted, which requires machining etc.).

Tightening torques Gearbox ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear wheel nuts, 205---665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear wheel nuts, 865, 600---900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check link ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower link bracket---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake mounting ---rear axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

505

230 Nm (170 lbf ft) 220 Nm (162 lbf ft) 330 Nm (243 lbf ft) 550 Nm 80 Nm (59 lbf ft) 380 Nm (280 lbf ft) 80 Nm (59 lbf ft)

Model

51. Brakes

1. 12. 1986

205-- 865

Code

510

Page

2

Brake system, description The brakes are multi ---disc brakes running in oil and are fitted in the final drive housing between the planetary gear and the differential. The brakes are mechanically controlled by the brake pedals. The brake pedals can be used latched together for when transport driving, or individually as steering brakes. The parking brake actuates the service brakes mechanically.

Fig. 1. Construction of brakes

The brake mechanism consists of six balls which are housed in the gearbox, application plate, friction discs, intermediate discs and support plate nearest to the final drive. There are grooves in the application plate for the six balls. When the brake is applied, the application plate is turned and the six balls force the application plate to compress the brake discs. The brake discs are fitted onto splines on the inner drive shaft. The intermediate discs are secured to the final drive housing with the aid of the support plate. When the brake is not applied, the coil springs between the application plate and the support plate provide a sufficient clearance between the brake discs.

1. Oil supply for the final drive and the wet---type brakes 2. Ball (6 pcs) 3. Application plate 4. Friction discs (3 pcs) 5. Intermediate discs (2 pcs) 6. Support plate 7. Brake levers 8. Transmission housing 9. Final drive housing

506

1. 12. 1986

51. Brakes

1. 7. 1989

Fig. 2. Brake controls 1. Brake light switch 2. The parking brake switch prevents the connection of the brake lights when the parking brake is applied 3. Note the position of the pin 4. Adjusting nut for service brakes 5. Adjusting nut for barking brake NOTE: With effect from ser. no. 610312 a new type RH side brake rod is fitted. At the same time a new brake mounting has been fitted onto the RH side rear axle. These modifications have been made necessary by the new differential lock control mechanism which has been fitted on the RH side of the gearbox.

507

Model

205-- 865

Code

510

Page

3

1. 7. 1989

51. Brakes

15. 9. 1995

Fig 3. Trailer brake valve from ser. no. 610312 incl. (without priority valve) 1. Brake pedal 2. RH side brake rod 3. Brake cylinder with a bleeding nipple 4. Control pressure to brake valve 5. Brake valve 6. Quick couplings 7. Trailer brake cylinder 8. Hydraulic pump 9. Valve blocks+power lift 10. Hand brake 11. Brake rod

508

Model

205-- 865

Code

510

Page

4

15. 9. 1995

51. Brakes

1. 9. 2001

Fig. 4. Trailer brake valve (with priority valve) 1. Brake pedal 2. Brake rod 3. Brake cylinder with bleeding nipple 4. Control pressure to brake valve 5. Brake valve 6. Quick couplings 7. Trailer brake cylinder 8. Hydraulic pump 9. Valve blocks+power lift 10. Hand brake 11. Brake rod 12. Priority valve

509

Model

205-- 865

Code

510

Page

5

1. 11. 1996

51. Brakes

1. 9. 2001

Model

865, 600-- 900

Code

510

Page

6

Brakes on 865---tractor and 600---900

Picture 5. Brake mechanism on 865.

Brake pedals are adjusted in the same way as earlier, see instr. B on page 511/2.

1. Brake pedals. Can be latched together. 2. Pedal rod 3. Brake rods 4. Brake lever 5. Outer brake application ring 6. Inner brake ball ring (new part). 7a. Friction disc, 4 pcs 7b. Intermediate disc, 3 pcs 8. Spring support pin 9) Brake support 10. Foot brake adjusting screw 11. Hand brake adjusting screw

Adjusting hand brake, see page 512/2. Since the brake mechanism on 865---tractor has been changed, the rear axle housing should be removed and fitted according to instruction A on page 451/6 when changing the brake discs. Otherwise the brake discs are changed in the same manner as shown on page 511/1. The brake discs on 865---tractors are the same as on Mezzo--tractors.

510

Model

51. Brake system

15. 4. 1999

Pressure air brakes for trailer (option)

Picture 6. Components of pressure air brakes 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Compressor Deicer Pressure regulator (incl. filter and relief valve). Pressure gauge Pressure air reservoir Drain cock Trailer brake control valve Trailer brake control valve Two ---line system; reservoir line (red) One ---line coupling (black) Two ---line system; brake line (yellow)

Note! Valve (7) controls combined two---line and one ---line trailer brake system according to the pilot pressure from the tractor brake pedal. The valve has additionally a lever, which has been connected to the hand brake mechanism. When the hand brake lever is pulled up, the valve lever turns and causes braking effect in the trailer brakes. Note! Valve (8) is intended to control the one ---line system. The valve is controlled by pilot pressure from valve 7. Valve (8) also limits pressure to the trailer brakes to 5,2 bar. During braking the valve (8) lowers (in one ---line system) the trailer brake pressure. When the braking is stopped air can flow via valve (8) to refill the air reservoir of the trailer brake.

511

600-- 900

Code

510

Page

7

Model

51. Brake system

15. 4. 1999

600-- 900

Code

510

Page

8

Pressure air brakes for trailer (option)

A

A

1: Compressor 3: Pressure regulator 4: Pressure gauge 5: Pressure air reservoir 7: Control valve (one and two line system) 8: Control valve (one line system)

B General The trailer is connected in the two---line system to two couplings. The couplings (9, 10, 11) have been marked as follows: --- Reservoir line --- red protecting cover --- Brake line --- yellow protecting cover

If the outdoor temperature is below +5°C, eythol alcohol or methanol must be used in the deicer (2) . Antifreeze agent flow valve lever (B) must then be open (position 1). Reservoir (5) and lever (B) are placed in front of the cab on the LH side.

--- In the one ---line system the trailer is connected to the black (brake line) coupling (in certain marketing areas).

NOTE! In the system there must be full pressure, about 7---8 bar, before driving the tractor. Pressure gauge (4) is placed in the cab beside the dashboard.

By turning connection (A) on the pressure regulator (3) to the bottom, compressed air can be taken off for auxiliary purposes (pressure about 8 bar, e.g. for tyre inflation). Through this connection the system can also be filled with auxiliary compressed air, e.g. if the tractor compressor does not function. In this case the connection (A) need not be screwed fully into the bottom.

When connecting in the two---line system trailer to tractor, connect first the trailer yellow coupling (without pressure). When disconnecting the trailer, disconnect first the red coupling (reservoir line).

When the trailer brake quick couplings (9, 10, 11) are not in use, the protective caps must be correctly placed on the couplings.

512

1. 12. 1986

51. Brakes

15. 9. 1995

Model

205-- 865

Code

Page

511

1

Repair instructions Service brakes (Op. no. 511) 1. Reconditioning brakes There are grooves on the ceramic friction surfaces of the brake discs. The depth of these grooves is 0,3 mm (0.012 in) when the ceramic discs are new. When these grooves become shallow, the oil cannot pass through the friction discs and this results in impaired brake action. If the brake discs are worn they should be changed.

A. Changing brakes

3. Pull the friction and intermediate discs off the shaft. 4. Check the surfaces of the support plate and the application plate and remove dirt and uneven spots using an emery cloth. 5. Fit new friction and intermediate discs alternately (friction discs first and last). Important! See note on page 510/1. 6. Fit the springs onto the application plate attaching lugs and fit the plate onto the springs.

1. Remove the final drive (Op. no. 451 1A). 2. Remove the circlips and washers from the application plate attaching lugs and pull out the application plate. Remove the springs from the lugs.

7. Push the application plate against the discs and fit the washers and circlips on the lugs. 8. Fit the final drive (Op. no. 451 1E) and adjust the brakes (Op. B). N.B. The brake application balls, (6 pcs) which are positioned in both sides of the differential housing, can be removed from their drillings with the aid of compressed air. Seats are fitted behind the application balls.

513

Model

51. Brakes

1. 12. 1986

B. Adjusting brakes 1. The brake pedal free travel should be 50 mm (2 in) when the pedals are latched together. 2. Raise the rear end of the tractor off the ground and adjust both brakes separately by turning the adjustment nut until the wheel can no longer be rotated (see Fig. 2). 3. Then slacken the nut one turn and check that the wheel again rotates freely. Check the pedal free travel and if necessary adjust using the nuts. 4. Check for even brake action by driving with the pedals latched together and then applying the brakes. Again check the brake pedal free travel and adjust the parking brake (Op. no. 512 A).

C. Changing brake mounting and brake lever 1. Change the rubber protections by disconnecting the brake rods from the levers (19 mm) and the protections from the retainers (13 mm). Tightening torque 23 Nm (17 lbf ft).

2. When changing the brake mountings, the mounting attaching bolts must be removed. When changing the RH side mounting, the differential lock control must be disconnected on the earlier tractors and when assembling the control must be adjusted (see Op. no. 424 1 D). N.B. When fitting the brake lever, check that the brake lever engages the groove of the mounting and that the stud of the application plate engages the hole on the lever. 3. Adjust the brakes (Op. 1 B).

514

205-- 865

Code

511

Page

2

Model

51. Brake system

15. 4. 1999

600-- 900

Code

511

Page

3

2. Pressure air brakes for trailer (option)

A

1: Compressor 3: Pressure regulator 4: Pressure gauge 5: Pressure air reservoir 7: Control valve (one and two line system) 8: Control valve (one line system)

B

A. Maintenance

Weekly maintenance

General

Check the mounting of the compressor. Check/adjust the compressor belt tightness by adjusting the tension pulley.

The pressure reservoir must not be welded or drilled.

Maintenance at intervals of 250 running hours

In the system there is a filter, which is placed in the pressure regulator. The filter must be cleaned/changed periodically (depending on use). The filter can be removed by removing the tyre filling connection (A) on the pressure regulator (3).

Grease the quick coupling rubber surfaces (9, 10, 11). Check the tightness of the system. The system must be so tight that the pressure drop after the engine stop is max. 0,15 bar during 10 minutes (2%).

The pressure regulator has an in ---built relief valve, which blows off, when the pressure in the reservoir exceeds 12---14 bar. This can be caused by e.g. faulty relief valve, icing or blocking filter.

Others If the hoses or hose unions have leakages, new parts are available as a spare part. Other components of the pressure air system must be changed as a complete unit since no separate spare parts are available.

Daily maintenance Condensed water must be drained from the system daily by pressing or pulling the pin of the draining tap (6) under the air reservoir.

515

Model

51. Brake system

15. 4. 1999

B. Compressor for pressure air brakes

600-- 900

Code

511

Page

4

C. Pressure regulator

Air from compressor flows in through port 1. Air flows then via strainer 2, opens one ---way valve 3, and flows through port 4 into reservoir.

Picture 1 Compressor 1. Compressor draws air from the engine air intake system 2. Compressor 3. Pressure air into pressure regulator 4. Tension pulley 5. Compressor requires extra belt pulley (+hub piece) 6. Lubricating oil from engine 7. Return oil into engine 8. Preessure plates 9. Suction plate Compressor . . . . . . . . . . . . . . . . . . . Knorr LK1311 Displacement . . . . . . . . . . . . . . . . . . 110 cm3 Output (2300 1/min, with 7 bar counter pressure) . . . . . . . . . . . . . . 220 l/min Power consum. (2300 1/min, 7 bar) 1,8 kW Lubrication . . . . . . . . . . . . . . . . . . . . Engine lub. circuit Cooling . . . . . . . . . . . . . . . . . . . . . . . Air cooling Note! On 3--- and 4---cylinder engines (without air conditioning/electric stop) the compressor is fitted on the LH side of the engine. If the tractor is retrofitted with the air conditioning/electric stop, the compressor is fitted on the RH side of the engine. If fitted with pressure air brakes+air conditioning the compressor is driven by two belts.

As soon as pressure in the reservoir is greater than spring force 11 (ca. 8 bar), membrane 5 distorts and piston 6 moves upwards. At the same time rubber collar round the piston closes port in the piston and opens a passage to the upper part of piston 7. Pressure moves piston 7 downwards against spring 9, and air from compressor to port 1 blows off via port 8 to atmosphere. Note! It is possible to adjust the working pressure with the adjusting screw of spring 11. When the screw is turned outwards, working pressure lowers and vice versa.

516

Model

51. Brake system

15. 4. 1999

D. Control valve of one ---line system

600-- 900

Code

511

Page

5

E. Control valve for trailer brakes (One --- and two---line systems)

The valve controls the trailer braking. Depressing the brake pedals or using the parking brake causes the valve body to turn which causes the braking effect in the trailer brakes.

A

Function:

A

Fig. A (not braking) Spring 5 holds membrane+sleeve 6 up. Upper end of valve spindle 8 has opened passage from inlet port 1 to trailer brake port 2. Pressure air flows from tractor reservoir via ports 1 and 2 to the trailer brakes. Simultaneously in port 2 pressure acts on the underside of piston 1.

C

Picture A. Neutral position, brakes are not used: The trailer brake line from port ”A” is connected to atmosphere via the internal part of valve 2 and via air exhaust valve 4. Valve 2 prevents pressure air from flowing from reservoir ”V” into the trailer brakes.

B

Function, fig. C (when braking): When depressing the brake pedal pilot pressure from the trailer control valve port 4. Pressure affects the upper part of membrane 7, and moves the membrane and sleeve 6 downwards against spring 5. Passage from port 2 to sleeve 6 internal hole opens. Pressure flows from port 2 via sleeve 6 and cover hole 3 to atmosphere to give quick pressure drop for trailer pre ---braking. The pressure drop causes an action of trailer brake valve in one ---line system.

Picture B. When depressing the brake pedals, the valve body is turned anti ---clockwise (lever 5 moves down). Push rod 6 moves downwards and guide piece 1 closes passage through the valve (2) into atmosphere. When further depressing the brake pedals valve (2) moves downwards and opens passage from port ”V” to port ”A” to the trailer brakes.

NOTE! During braking replacing air does not flow into the trailer brake system. --- The one ---line system working pressure (5,2 bar) is lower than that in the two---line system. Control valve lowers the system pressure from 7 bar to 5 bar. Contrary to the two--line system coupling (yellow), the black coupling of the one ---line system is under pressure when not braking. The control valve does not require maintenance.

517

Model

51. Brake system

600-- 900

15. 4. 1999

Code

511

Page

6

C

Picture C. Increasing pressure in port ”A” loads piston 7, which moves downwards against the spring force and closes port to connection ”V” so that pressure air cannot flow forwards. The control valve is now in the final position. When braking force is still increased, the full reservoir pressure flows into the trailer brakes. --- When the brakes are released, the push rod 6 moves upwards and opens passage from port ”A” to atmosphere 4. The pressure drops in the trailer brake line: When pressure lowers in port ”A” , piston 7 rises up to the starting position. --- Relative weak force activates the control valve. That is why the trailer brakes function a little earlier that tractor brakes. This function order prevents trailer pushing and turning during braking. 7a) The spring protects the valve, when it is turning. Adjusting pre ---braking: spring (7a) in the upper hole (longer movement) = trailer brakes faster. Spring in the lowest hole (shorter movement) = the trailer brakes slower than the tractor.

Checking the pressure air system: Not braking with pedals or hand brake lever

Full braking with pedals or hand brake lever

Reservoir line (red)

6,0 --- 8,0 bar

6,0 --- 8,0 bar

Brake line (black)

4,8 --- 5,6 bar

0

Brake line (yellow)

0

6,2 --- 7,5 bar

518

1. 12. 1986

51. Brakes

1. 5. 1996

Parking brake (Op. no. 512) A. Adjusting parking brake on 205---665

1. Adjusting nut 2. The parking brake switch prevents the connection of the brake lights when the parking brake is applied 1. When the parking brake is not applied, the clearance between the lever and the adjusting nut should be 5 ---10 mm. Adjust the clearance with the adjusting nut.

519

Model

205-- 665

Code

512

Page

1

1. 3. 1997

51. Brakes

15. 4. 1999

B. Adjusting parking brake on 865 and 600---900 tractors

Picture 6. Brake system on 865 and 600---900 tractors 1. Brake light switch S13 2. Hand brake switch S18 3. Tension pin 4. Brake pedal adjusting nut (on both sides) 5. Hand brake adjusting nut 1. Before adjustment, release the parking brake by pushing the hand level to the lowest position. 2. Adjust the distance between the support iron and the adjusting screw (5) to 3---7 mm. Secure the adjusting nut with the locking nut. Note! The brake pedal adjustment affect the hand brake adjustment. Before the hand brake adjustment it is recommended, that the brake pedals are adjusted.

520

Model

865, 600-- 900

Code

512

Page

2

60. Front axle and steering system

61. Steering system

62. Front axle, 2WD

63. Front axles, industrial tractors

64 Powered front axle ZF

64. Powered front axle Sige

521

522

1. 5. 1996

61. Steering system

Model

1. 9. 2001

205 -- 900

Code

610

Page

1

Contents General (Op. no. 610) Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment for checking oil pressure in steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering system, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering cylinders, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering valve, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 3 4 5 7

Repair instructions Steering valve (Op. no. 611)

1. Reconditioning steering valve: A. Removing steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Fitting steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Checking pressure ---limiting valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Checking shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Changing/cleaning pressure ---limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Adjusting shock valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Cleaning/changing shock valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 2 3 3 3

Steering cylinders (Op. no. 613)

1. Reconditioning steering cylinder, powered front axle: A. Changing seals in steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Measuring clearance between cylinder barrel and end pieces . . . . . . . . . . . . . . . . . . . . . . . . 3 C. Assembling steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2. Reconditioning steering cylinder, non ---powered front axle: A. Dismantling steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 B. Assembling steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Technical data Note! From ser. no. K26106 the Sauer pump (13+10) has been changed into Bosch ---pump (11+11) (with priority valve) or from ser. no. K47331 (without priority valve) Sauer 16+12---pump has been changed to Bosch 16+14 pump. Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering valve up to cab no 54623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering valve from cab no 54624 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering cylinder, non ---powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering cylinder, powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic ZF ---Servostat 2 Orbitrol OSPC---100 Double ---acting special cylinder Double ---acting plunger piston type Steering system oil pump (Sauer or Bosch pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump Pump capacity/revolution, ---K47330 without priority valve// with priority valve combined capacity , ---K26105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 cm3/r // 23 cm3/r Pump capacity/revolution, K47331--- without priority valve // with priority valve combined capacity , K26106--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 cm3/r // 22 cm3/r Pump capacity per minute: --- without priority valve, ---K47330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 litres / 2350 r/min --- without priority valve, K47331--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 litres / 2270 r/min --- with priority valve combined capacity, ---K26105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 litres / 2350 r/min --- with priority valve combined capacity, K26105--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 litres / 2270 r/min Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MPa Pressure ---limiting valve, opening pressure at 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---10 MPa Shock valve, opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---17 MPa Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washable metal gauze filter Suction filter, degree of filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 μm Number of steering wheel revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,6 revolutions

Oil (The oil is common to both steering and working hydraulics) Oil capacity, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 litres Capacity when changing oil, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 litres Viscosity and quality, see page 120/4

Tightening torques

Non ---powered front axle: Clamping bolt, steering arm ---piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm Front axle member ---steering cylinder: --- cone nut M12, 1 pc (---600704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm

523

1. 9. 1992

61. Steering system

15. 9. 1995

Model

205-- 865

--- screw M12, 2 pcs (---600704) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- screw M16, 3 pcs (600705---) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder ends---cylinder frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil hoses to steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code

Page

610

2

80 Nm 195 Nm 65 Nm 50 Nm

Powered front axle ZF: End piece ---cylinder frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm Oil hoses to steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm Stop for steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm Steering valve ZF (up to cab no 54623): Steering valve attaching bolts, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering valve bolts, housing halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure ---limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Nm 32 Nm 12 Nm 30 Nm

Unions on right---hand side of engine for steering hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose union at oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose union at steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil hose at pump for steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 Nm 11 Nm 100 Nm 45 Nm

Equipment for checking oil pressure in steering system

1. Checking opening pressure of pressure ---limiting valve (9---10 MPa). Pressure test kit 31965000 includes these parts.

2. Checking opening pressure, shock valve (15---17 MPa). Pressure test kit 31965000 includes these parts (not hand pump).

524

1. 12. 1986

61. Steering system

15. 9. 1995

Model

205-- 865

Code

610

Special tools Steering cylinder B (non ---powered front axle) Part no. ETV 892 380 (ETV 893 630)

Description Sleeve for removing bearing sleeve and seal from steering cylinder (Gearbox 505---905) Plate for fitting scraper seal, seal and bearing sleeve in steering cylinder (see Gearbox)

ETV 893 630

ETV 892 380

525

Page

3

1. 12. 1986

61. Steering system

1. 7. 1989

Steering system, general The tractor is fitted with a hydrostatic steering system which means that the steering wheel movements are transmitted to the front wheels by oil under pressure. This provides a steering system which is easy to handle. Should the oil pressure fail for some reason, e.g. when the engine stops, the tractor can still be steered. The steering valve then acts as a pump, but a considerably greater effort is required for turning the steering wheel.

Fig. 1. Steering system on the 305---455 tractors (a non ---powered front axle is shown) 1. Gear ---type oil pump 2. Suction pipe from hydraulic housing 3. Steering valve 4. Steering cylinder 5. Steering system return oil pipe to hydraulic housing 6. Suction strainer

526

Model

205-- 865

Code

610

Page

4

1. 12. 1986

61. Steering system

1. 7. 1989

The gear ---type pump on the right---hand side of the engine (front pump for working hydraulics, rear pump for steering hydraulics) draws oil from the hydraulic housing via the suction strainer (6) through the suction pipes (2). The gear ---type pump (1) for the steering hydraulics supplies the oil to the steering valve (3).

Model

205-- 865

Code

610

Page

5

turned, the steering valve allows the oil to circulate back to the hydraulic housing. The return oil from the steering cylinder is conducted through the steering valve (3) and through the return pipe back to the hydraulic housing. If the tractor is provided with an extra lifting cylinder, the hose from the piston rod end of the lifting cylinder has been connected to the rear connection on the return oil pipe. This means that the return oil flow aids the hydraulic lift when lowering.

The steering valve directs the oil flow to either end of the steering cylinder (4) depending on the direction in which the steering wheel is turned. If the steering wheel is not

Steering cylinders, description Non-- powered front axle

The steering cylinder is a double ---acting special cylinder. The piston rod acts as a piston and there are only seals round the piston rod. The steering arm is secured to the centre of the piston rod. The track rods, in their turn, are secured to the steering arm. This design provides for an ample steering force even close to the full steering lock positions.

The steering cylinder is secured to the front axle member with a tapered nut and two bolts. The front bolts are provided with lock washers.

Fig. 2. Steering cylinder for non ---powered front axle 1. Screw studs secured with Loctite 222 2. The bearing sleeve is provided with a groove which should be facing upwards. 3. Check that there is a clearance between the bearing sleeve and the seal 4. Cylinder frame 5. Cylinder ends 6. Piston (=piston rod) 7. Steering arm

527

1. 12. 1986

61. Steering system

15. 9. 1995

Model

305-- 665

Code

610

Page

6

Steering cylinder, ZF ---axle The distance between the mating surfaces on the cylinder barrel and the end pieces are adjusted with shims in order to be able to adjust the clearance to zero. (Shims are available in thicknesses between 0.9 ---1.8 mm (0,035 ---0.071 in), Fig. 3).

The steering cylinder is fitted at the back of the front axle member where it is protected from external damage. The piston is fitted at the centre of the piston rod which runs through both ends of the cylinder. There are seals on the piston against the cylinder barrel and in both end pieces against the piston rod. The tie ---rods are connected directly to the piston rod ends. In this way steering movements are transmitted symmetrically via the tie rods to the steering arms and there is an ample steering force even close to the full---lock positions.

The steering lock can be adjusted with stops fitted at the piston rod ends. The steering lock stops, which are fitted as standard, are set to give a steering lock of 50˚. By turning the stops the steering lock can be limited to 45˚, as extra equipment, the front axle can be fitted with stops which further reduce the steering lock to 37˚.

Fig. 3. Steering cylinder on powered front axle ZF 1. The tie rods are secured by upsetting the edge 2. Secured by applying Loctite 242 to the threads 3. End piece 4. Piston 5. Piston rod 6. Cylinder barrel NOTE! Steering cylinder on Sige ---axle, see page 640A/7 and pages 613/7 ---9.

528

Model

61. Steering system

15. 4. 1994

205-- 865

Code

Page

610

6A

Hydraulic system with priority valve

3

1

2 Picture 3a. Alternative hydraulic system.

Priority valve is the same as on 6000---8400 tractors, Danfoss OLS 80.

1. Twin pump with combined output. 2. Oil cooler. 3. Priority valve.

Tractors, which have a priority valve, the steering valve is different. The steering valve has then five hose connectors. The 5th connector is for the LS line (Load Sensing) to the priroty valve. The steering valve revolution volume, however, is the same as earlier.

In this alternative hydraulic system the twin pump outputs have been combined and the total pump output is then 55 dm3/min at engine speed of 2350 r/min (pump revolution volume is 12,8+10,3 cm3/r). The working pressures are the same as earlier. The priority valve ensures that there is always enough oil for the steering system even if the working hydraulics are used at the same time. Auxiliary hydraulics must not be connected before the priority valve, because the steering system does not function when this auxiliary hydraulics are used.

529

Model

61. Steering system

1

205-- 865

15. 4. 1994

Code

Page

610

6B

2 6

5

4 3

EF

CF

LS EF

P

CF LS P

Picture 3b. Priority valve 1. Plug 2. Sealing ring 3. Connector nut 4. Sealing ring 5. Spring 6. Valve spool

--- The priority valve is located on the RH side of the tractor beside the pressure filter. The priority valve directs oil both to the steering system (port CF) and to the working hydraulics (port EF). The valve gives a priority to the steering system. This means that there is always enough oil supply to the steering system regardless of loading of the hydraulic power lift or the auxiliary hydraulic. When the steering wheel is not turned, the whole combined pump output is available for the working hydraulics.

CF=to steering valve EF=to working hydraulics P=pressure from pump LS=load sensing line. When the steering wheel is turned, the LS hose is pressurised and the priority valve spool is moved so that oil is directed to the steering valve and vice versa.

530

Model

61. Steering system

1. 1. 1998

Picture 3c. Steering system on 600---900 tractors with priority valve. On 600---900 tractors the pump pressure pipes have been connected together on the pump. In addition, the oil cooler pipes have been bent in a different way (steering valve OSPC 100LS).

531

600-- 900

Code

Page

610

6C

Model

61. Steering system

1. 1. 1998

Picture 3d. Alternative steering system on 600---700 tractors without priority valve (steering valve OSPC 100ON).

532

600-- 700

Code

Page

610

6D

1. 12. 1986

61. Steering system

1. 9. 1992

Model

Code

305-- 455

Steering valve ZF, description (up to cab no 54623)

7 8 9 10

1

11

2

12 3

13

4

5

14

6

15 16 17 18

Fig. 4. Section of ZF steering valve

10. Valve housing 11. Shut---off valve 12. Valve sleeve 13. Steering wheel column 14. Pivoted shaft with centring spring 15. Valve for emergency steering 16. Shock valve 17. Anti ---cavitation valve 18. Steering cylinder

1. Pressure ---limiting valve 2. Metering unit (rotor set) 3. Rotor 4. Pivoted shaft 5. Shock valve 6. anti ---cavitation valve 7. Oil reservoir 8. Oil pump 9. Non ---return valve

533

610

Page

7

1. 12. 1986

61. Steering system

1. 9. 1992

Construction of steering valve ZF

Model

Code

205-- 665

610

Page

8

Valves within the steering valve --- Pressure ---limiting valve (1) limits the working pressure in the steering system.

The metering unit (or rotor set) is a gear ---type rotor pump. A rotor (3) with six external teeth rotates inside the stator (2) which has seven internal teeth. A compression space is formed between these two sets of teeth profiles. The rotor set requires a flow distributor which rotates synchronously with the rotor, as the parting line which separates the suction and the pressure sides rotates with the planetary movement of the rotor.

--- Shock valves (5, 16) takes up any shocks transmitted from the steering cylinder. --- Anti ---cavitation valves (6, 17) are both positioned in separate passages and they counteract cavitation in the steering system.

The flow distribution is achieved with the aid of the turning movement of the sleeve (12) which rotates synchronously with the rotor.

--- Non ---return valve (9) prevents the return flow of oil when the pump is not working. --- Shut---off valve (11) prevents the return of the front wheels when the steering wheel is not actuated.

The measuring unit supplies an amount of oil, delivered by the pump (8), in proportion to the turning of the steering wheel.

--- Valve for emergency steering function (15). Through this valve the rotor can draw oil without the aid of the pump.

The steering valve consists of a housing (10) with drilled passages. The sleeve (12) inside the valve housing can be turned, but it is also axially moveable.

Working principal of steering valve

The outside of the valve sleeve has axial and radial grooves. These correspond to similar grooves on the inside of the valve housing.

When the steering wheel is turned anti ---clockwise the valve sleeve (12) moves to the left allowing oil under pressure from the pump (8) to flow via the flow distributor to the inlet side of the rotor set (2, 3).

The turning movement of the steering wheel is transmitted through the steering column, the pivoted shaft (14) with centering springs and the pivoted shaft (4) to the rotor set (2, 3).

The rotor set directs the oil flow (red), which is proportional to the movement of the steering wheel, through the outlet passage via the flow distributor to the piston rod side (18) of the steering cylinder.

The valve sleeve (12) is on the one hand, connected to the rotor (3) through the upper end of the pivoted shaft (4), and on the other hand it is connected to the steering column (13) and the pivoted shaft (14) through three internal lugs which move in a helically cut groove on the pivoted shaft (14). These lugs cause the valve sleeve (12) to move axially.

The piston in the steering cylinder moves towards the left. The piston side of the steering cylinder is connected to the return line via the grooves on the outside of the valve sleeve. When the steering wheel is released, the valve sleeve (12) is returned to neutral, thus opening the return passages on either side of the delivery passage.

The centering springs allow for a small movement between the steering column and the valve slide. This movement displaces the valve slide axially in the housing. In the figure, the valve slide has been moved to the left from the neutral position. The axial movement of the valve slide affects the working pressure. The radial movement, depending on which way the steering wheel is turned, affects the flow distribution of the rotor set. The rotor set and the valve sleeve are within the same space which is under pump pressure, thus reducing internal leakage. Round the steering column there is a slide ring seal which is under constant pressure. Above this seal there is a space which is connected to the return line. The upper end of this space is sealed by a combined lip and dust seal.

534

Model

61. Steering system

1. 9. 1992

Code

355-- 865

Page

610

9

Steering valve Orbitrol OSPC---100 (from cab no 54624) 6

2

3

5

8 9 7

10

1 4

12

11

Figure 5. Steering valve 1. Shock valve (2 pcs, 19,5 MPa) 2. Non ---return valve 3. Non ---return valve for emergency steering 4. Rotor ring 5. Rotor 6. Valve housing

7. Inner valve spool 8. Outer valve spool 9. Rotor shaft 10. Centring springs 11. Pressure ---limiting valve (14 MPa) 12. Anti ---cavitation valves (2 pcs)

535

Model

61. Steering system

1. 9. 1992

Steering valve, description (Danfoss valve)

Code

355-- 865

610

Page

10

A

See figure 5 on previous page. The steering valve consists of a metering unit (rotor set) and a valve unit. The rotor set consists of a rotor ring (4) with seven internal teeth and a rotor (5) with six external teeth. The valve unit consists of a valve housing (6), outer valve slide (8) and inner valve slide (7). The inner slide (7) is directly actuated by the steering wheel. The outer valve slide (8) is mechanically connected to the rotor (5) by a cross pin and rotor shaft (9). The cross pin which runs through both valve slides permits the inner valve slide to move 8˚ in both directions independent of the outer valve slide. When the steering wheel is in the rest position, centring springs keep the inner and the outer valve slides in neutral (in relation to each other) and the oil flows freely through the steering valve. The passages to the steering cylinder are kept closed and the steering cylinder cannot move. Figure 6. Steering valve lower face A. Anti ---cavitation valves

When the steering wheel is turned, the inner valve slide is turned in relation to the outer valve slide. The neutral---position passages become restricted at the same time the passages down to the measuring unit and on to the steering cylinder gradually open. Simultaneously the return oil from the other side of the steering cylinder flows back via the steering valve. The oil flow from the pump through the valve makes the rotor and the outer valve slide turn in the same direction as the steering wheel and the inner valve slide.

B

When the steering wheel is not turned any further and kept still, the centring springs bring the outer and the inner valve slide back into the neutral position The passages to the steering cylinder close and the oil flows freely again through the steering valve. When the hydraulic pump does not supply any oil, the metering unit of the steering valve acts as a manually powered pump. The oil which is drawn from the steering cylinder and the return line via the non ---return valve (3) is delivered to the other side of the steering cylinder when the steering wheel (and inner valve slide 7) is turned 8˚. The cross pin then also makes the following parts turn: the outer valve slide (8), rotor shaft (9) and rotor (5). Shocks and knocks against the steering wheel are dampened by the two shock valves (1) which are fitted in the steering valve.

C Figure 7. Steering valve upper face B. Shock valves C. Pressure ---limiting valve

The shock valves are combined with anti ---cavitation valves (point A in figure 5) in order to keep the cylinder fully supplied with oil at all times.

536

1. 12. 1986 Model 205 -- 865 1. 9. 1992

61. Steering system

Steering valve

Code

611

Page

1

(Op. no. 611)

Note! This instruction concerns both ZF and Danfoss steering valve. Follow notes in text below.

1. Reconditioning steering valve A. Removing steering valve 1. Remove the knob from the stop/hand throttle control (13 mm) and the rubber grommet for the control (later type models have a stop control in the instrumrnt panel). 5. Remove the steering valve.

B. Fitting steering valve 1. Fit the steering valve attaching bolts, rubber damber and washers (fix the lowermost washers with a quick ---acting glue).

2. Remove the guard plate under the instrument panel (at the same time disconnect the heater hoses from the nozzles).

2. Fit the valve and tighten the bolts (13 mm, 20 Nm (15 lbf ft)) and secure with the tab washer. 3. Connect the oil hoses to the steering valve (22 and 24 mm, 45 Nm (33 lbf ft)). secure the flasher relay if it was removed earlier. 4. Fit the guard plate under the instrument panel and connect the heater hoses to their respective nozzles. 3. Disconnect the oil hoses from the steering valve (delivery and return hoses (22 mm) and the hoses to the steering cylinder (24 mm)).

5. Fit the stop control rubber grommet and the knob (13 mm). 6. Check the oil level in the hydraulic housing and top up with hydraulic oil if necessary. Start the engine and check that the system works.

N.B. If the flasher relay is removed it will be easier to remove the steering valve. 4. Undo the lock washers and remove the steering valve attaching bolts (13 mm). Take care not to damage the electrical leads.

537

1. 12. 1986

61. Steering system

1. 9. 1992

Model

205-- 865

Code

611

Page

2

C. Checking pressure ---limiting valve opening pressure

D. Checking shock valve opening pressure

1. Remove the engine hood upper side plate on the right--hand side.

1. Remove the upper, right engine hood side plate. 2. Disconnect the union on one of the hoses to the steering cylinder. connect the pressure gauge and a hand pump to the hose (measuring equipment, see page 610/2 point 2).

2. Unscrew the hose union (22 mm) on the oil hose to the steering cylinder. 3. Pump up the pressure leading into the steering valve and read off the pressure when the shock valve opens. compare with the opening pressure given in the Technical Data.

3. Fit the gauge using the necessary union and adapters (measuring equipment, see page 610/2 point 1). If the measuring equipment is not used, use a union with 3/4---16 inch thread and a tapered sealing surface equivalent to JIC 37˚.

N.B. The hand pump does not provide an even pressure so that after each pumping movement, the pressure on the gauge drops due to internal leakage in the steering valve. It is better to use a pump that provides a steady pressure.

4. Start the engine and set the hand throttle to approx. 1500 rpm. Turn the steering wheel to full lock and read off the opening pressure. If the reading deviates from the value in the Technical Data, the pressure ---limiting valve must be cleaned or changed (see under heading E (ZF) or H (Danfoss)).

If the measuring equipment is not used, use a union or an adapter which has 3/4---16 inch thread and a tapered sealing surface corresponding to JIC 37˚. Connect a gauge as close to the steering valve as possible to prevent the pressure drop in the hoses from affecting the result of the pressure check.

5. Remove the gauge and connect the steering hose (22 mm, 45 Nm (33 lbf ft)). Fit the engine hood plate.

4. Slacken the hose union on the other oil hose and check the opening pressure of the other shock valve. If the reading deviates from the value given in the Technical Data, the shock valves should be adjusted (see under heading F (ZF) or H (Danfoss)). 5. Remove the measuring equipment and connect the oil hoses (22 mm, 45 Nm (33 lbf ft)). Fit the engine hood plate.

538

1. 12. 1986

61. Steering system

1. 9. 1992

E. Cleaning/changing pressure ---limiting valve (ZF steering valve)

Model

205-- 865

Code

Page

611

3

5. Fit the pressure ---limiting valve (8 mm, socket head, 30 Nm (22 lbf ft)) and secure the steering valve (13 mm, 20 Nm (15 lbf ft)).

1. Loosen the steering valve, but do not disconnect the oil hoses from the valve (see under heading A 1 ---4). Slightly pull the valve out from its place.

6. Check the pressure ---limiting valve opening pressure (see under heading C). If the opening pressure deviates from the value given in the Technical Data, the pressure ---limiting valve must be changed. 7. Fit the steering valve (see under heading B).

F. Adjusting shock valves (ZF steering valve) 1. Loosen the steering valve, but do not disconnect the oil hoses from the valve (see under heading A 1 ---4). Slightly pull the valve out from its place.

2. Unscrew the pressure ---limiting valve (8 mm, socket head).

2. Remove the protective plug by the shock valve adjusting screw and turn the screw (5 mm, socket head) in the desired direction. N.B. A 1/4 of a turn on the screw corresponds to a difference in the opening pressure of approx. 3 MPa (435 psi).

3. Clean the pressure ---limiting valve, using compressed air.

3. Check the opening pressure (see under heading D) and if necessary adjust. fit the protective plug on the adjusting screw. 4. The other shock valve is adjusted in the same way. 5. Fit the steering valve (see under heading B).

G. Cleaning/changing shock valves (ZF steering valve) 1. Remove the steering valve (see under heading A).

4. Remove the oil filter (14 mm) between the oil hoses at the side of the valve. Clean the filter, fit it and tighten to 12 Nm (9 lbf ft).

539

1. 12. 1986

61. Steering system

1. 9. 1992

Model

205-- 865

Code

611

Page

4

3 b) If a new shock valve is fitted: fit the set of springs, valve ball and valve cone in the valve bore (check the o---rings on the valve cone). Screw in the valve until the end of the valve is flush with the face of the valve housing. Carry out the same procedure with the other shock valve. 4. fit the steering valve and connect the oil hoses to the valve (45 Nm (33 lbf ft)). Check the shock valve opening pressure (see under heading D) and if necessary adjust (see under heading F 2 ---4). 5. Fit the steering valve (see under heading B).

2. Remove the shock valve screw (5 mm, socket head). Remove the valve ball and the set of valve springs from the valve bore.

N.B. If the same shock valve is to be fitted again, the valve screw and valve housing must be marked and the distance between the top of the adjusting screw and the top face of the valve housing must be measured to facilitate assembling.

3 a) If the same shock valve is refitted: clean the valve and fit the spring set, valve ball and valve cone in the valve bore (check the o---rings on the valve cone). Screw in the valve to the same depth as before the valve was removed.

540

1. 9. 1992

61. Steering system

15. 4. 1994

H. Cleaning shock valves and pressure --limiting valve (Danfoss valve)

Model

Code

205-- 865

611

Page

5

6. Fit the valve ball, washer and the spring. 7. Apply a little locking fluid to the threads on the adjusting screw. Screw in the screw to the depth as measured in paragraph 3.

1. Remove the steering valve (see instr D). Secure the valve in a vice with soft jaws.

8. Fit the sealing ring and the valve plug and tighten to a torque of 40 ---60 Nm.

Note! There are two shock valves in the steering unit. Both valves are similar.

9. Unscrew the pressure ---limiting valve plug (8 mm socket head). Measure and make a note of the distance between the adjusting screw and the upper face of the steering valve to facilitate the setting of the operating pressure of the pressure ---limiting valve.

2. Remove the plug on the shock valve (6 mm socket head) and remove the sealing ring of the plug.

10. Unscrew the pressure ---limiting valve adjusting screw with a 6 mm Allen key. 11. Carry out operations shown in paragraphs 4---8. Note! When assembling the valve, screw the plug to the same depth as it was before disassembling. 12. Fit the steering valve (see instr. G) and check the steering system pressures (see instr. A and B).

3. Measure and make a note of the distance between the adjusting screw and the upper face of the steering valve to faciliate the setting of the opening pressure of the shock valve. 4. Remove the adjusting screw (6 mm socket head). Shake out a spring, washer and a ball. 5. Clean and check the parts and change faulty ones. Lubricate all parts with oil before assembling. Minor damage to the seat can be polished with a ball and fine grinding paste.

541

Model

61. Steering system

1. 9. 1992

205-- 865

Code

611

Page

6

I. Changing seals in steering valve (Danfoss valve) 1. Remove the steering valve (see instr. D). 2. Secure the steering valve in a vice with the cover upwards. Mark the position of the cover, distributor plate and rotor ring for easier fitting.

4. Remove the cover, rotor ring and the rotor and the washer inside the rotor.

3. Unscrew the cover fixing bolts.

5. Remove the rotor shaft and the distributor plate. Check/ change o---rings between the parts. 6. Push up the valve slide and pull them out of the valve housing. Remove the thrust bearing from the slide bore. Note! Remember where the bolt with the locating pin was fitted. If the valve is turned upside down, three valve balls and two pins will fall out.

542

15. 9. 1995

61. Steering system

1. 1. 1998

Model

205-- 900

Code

611

Page

7

Note! If the centring springs are changed, they must be fitted as shown in figure above. Note! Before removing the springs, mark position of the valve spindles in ralation to each others e.g. with tusche. Rinse the spindles with gas oil (also lubricating properties) so that they can move easily and the centring springs can center them. 9. Fit the ring over the centring springs. Place the thrust bearing assembly onto the valve slide.

7. Turn the steering valve to a horizontal position and prize out the seal from the valve housing. Remove the inner oil seal. Fit a new outer seal. Apply some grease to the seal and turn the valve back to the vertical position.

Note! Thick thrust washer first, then bearing and then the thin thrust washer. Chamfered side of the thick washer towards the slide.

8. Fit the inner seal (and the support ring) using tool ETV 893 100 as follows: ETV 893 100

10. Push the valve slide into the housing fully home Note! The valve slide together with the thrust bearing is easier to fit into the housing when the steering valve is horizontally. Turn the slides until the cross pin is parallel to the flat side of the valve housing.

--- lubricate the o---ring. Fit the support ring on the stud of the tool and fit the o---ring on the support ring. Push the stud into the guide sleeve.

11. Fit a new o---ring and the distributor plate onto the housing according to the mark. Fit the rotor shaft so that grooves on it engage the cross pin.

---push the guide sleeve into the valve housing and push the seal together with the support ring in place using the stud on the tool. Remove the tool and check that the seal is property positioned. Note! The inner seal has been changed during autumn 96 in all steering valves (fitting tool ETV 894 330).

543

1. 9. 1992

61. Steering system

1. 1. 1998

Model

205-- 900

Code

611

Page

8

Stepped splines Note! In the latest steering valves the rotor shaft and the rotor have stepped splines at which time the mutual position of the parts is determined automatically.

13. Then fit a new o---ring and the rotor ring according to the marks. Fit the rotor according to the figure above.

Note! The stepped splines also prevents the rotor shaft from releasing from the cross pin inside the valve. With regard to possible repair works is recommended, that a spacer is fitted at the end of the rotor shaft to ensure the position of the shaft. The spacers are still available as spare parts.

Note! Concerning the latest steering valves, see picture in the column beside. 14. Fit the washer inside the rotor.

15. Fit the cover according to the marks and tighten the bolts to a torque of 30 ---35 Nm. 16. Fit the steering valve (see next instruction).

544

Model

61. Steering system

1

Code

205-- 865

15. 4. 1994

612

Page

1

2 6

5

4 3

Priority valve (Op. no. 612) 1. Cleaning priority valve A. Dismantling

B. Assembling

1. Detach the priority valve which is fitted beside the pressure filter under the cab floor on the RH side.

1. Push the spool (6) into the housing. Fit a new sealing ring on the plug (1).

2. Open the plug (1) and remove the sealing ring (2).

2. Place the spring (5) into the housing. Fit a new sealing ring and the connection (3). Tighten the connection to 40 ---60 Nm.

3. Unscrew the connection (3) and remove the sealing ring (4) and the spring (5).

3. Tighten the plug (1) to 40 ---60 Nm.

4. Push out the valve spool (6) by using e.g. a pencil. Do not damage contact surfaces on the spool and the housing.

4. Fit the priority valve.

5. Check and clean the parts. Replace the sealing rings with new ones. Lubricate the parts with oil before fitting.

545

546

1. 12. 1986

61. Steering system

15. 9. 1995

Model

205-- 665

Code

613

Page

1

Steering cylinders 1. Reconditioning steering cylinder (4WD, ZF ---axle) A. Changing seals in steering cylinder The seals can be changed without removing the front axle.

3. Disconnect the oil hose (22 mm) from the end piece and remove the end piece (17 mm).

1. Slightly raise the front axle. Remove the steering lock stop (13 mm). Note the position of the stop so that it can be refitted in the same way.

4. Pull the piston rod out of the steering cylinder

2. Disconnect the tie rods from the piston rod ends (27 mm and 46 mm).

5. Pull out the cylinder barrel 6. Push the end piece from the other end of the cylinder into and through the cylinder housing and take it out.

547

Model

61. Steering cylinder

1. 12. 1986

7. Remove the scraper seal, the seal and the o---ring from the end piece and fit new parts (the lip of the seal should be turned inwards and the lip of the scraper seal outwards).

205-- 665

Code

613

Page

2

12. Remove the O ---ring (7) which is fitted in the middle, inside the piston. 13. Remove the piston (8) and locking ring halves (5) from the other side.

8. In the same way change the seal and the scraper seal in the other end piece.

14. If necessary, change the locking ring (3), intermediate ring (4) and spacer ring (6). 15. Fit the locking ring halves (5) in their groove and push the piston (8) onto the piston rod, with the assembled side against the locking ring halves.

Steering cylinder piston (powered front axle). 9. Remove the support rings (1) and seal ring (2) from the piston. 16. Fit the O ---ring (7) and spacer ring (6) in the piston and fit the locking ring halves (5) for the other side in their groove. Fit the intermediate ring (4) and locking ring (3). 17. Fit the sealing ring (2) and support rings (1) on the piston. Turn the support rings so that the places where the rings are split come on opposite sides of the piston. 18. Fit the piston in the steering cylinder (see under headings B and C).

10. Remove the locking ring (3) and intermediate ring (4). 11. Remove the locking ring halves (5) and spacer ring (6) behind them.

548

Model

61. Steering cylinder

1. 12. 1986

B. Measuring clearance between cylinder barrel and end piece

205-- 665

Code

613

Page

3

C. Assembling steering cylinder

Measuring should be carried out if the cylinder barrel or the end piece has been changed.

1. Push the inner end piece into the cylinder housing. 2. Insert the cylinder barrel in the housing with the narrower end first. 3. Lubricate the seals on the piston and in the end piece with oil, and carefully push the piston into the cylinder barrel.

End piece of steering cylinder (powered front axle ZF). 1. Measure the distance A on the end piece between the contact faces for the cylinder barrel and for the cylinder housing (e.g. 27,3 mm).

4. Fit the other end piece (17 mm, 70 Nm). Connect the oil hoses (22 mm) and tighten to 45 Nm.

2. Measure the distance B between the end surface of the cylinder barrel and the end face of the cylinder housing (e.g. 25,80 mm). 3. Shim thickness X =A---B (=1,5 mm, see the table above).

5. Connect the tie rods to the ends of the piston rod (27 and 46 mm) and secure by upsetting the edge. Use for example Loctite 242 on the threads (see Fig. 3 items 1 and 2).

549

Model

61. Steering cylinder

1. 12. 1986

205-- 865

Code

Page

613

4

3. Remove the steering cylinder ends (8 mm, socket head) and remove the o---rings. Remove the cover plate from the steering cylinder frame (10 mm) and move the piston until it is in the centre.

6. Fit the steering lock stop (13 mm, 25 Nm). Make sure the stop is fitted in the same way as before it was removed. N.B. If the piston rod has been changed, check the toe --inand if necessary adjust (see under heading 641 1D), See the Technical Data for the toe ---in measurements. 7. Lower the front axle to the ground and check the level in the hydraulic system. Top up if necessary. Check the function of the steering system.

2. Reconditioning steering cylinder (non --powered front axle) A. Dismantling steering cylinder The steering cylinder ends can be changed without removing the steering cylinder. 1. Disconnect the tie rods from the steering arm (22 mm). Disconnect the hoses (22 mm) from the steering cylinder.

4. Remove the clamping bolts for the steering arm (use the screwdriver to stop the bolt from turning), and remove the bolt together with the bearing. 5. Remove the circlip from the end of the bolt and remove the bearing using a drift. 6. Drive the piston rod (piston) out of the cylinder frame using a soft drift. Remove the steering arm together with the tie rods.

2. Remove the steering cylinder (bolts M16, 3 pcs); One wheel should be turned to full lock.

7. Remove the scraper seals from the cylinder frame.

550

Model

61. Steering cylinder

1. 12. 1986

205-- 865

Code

613

Page

5

3. Position the steering arm together with tie rods in the cylinder housing

ETV 892 380

90 Nm

8. Drive out the bearing sleeve, the seal and intermediate ring from either end of the cylinder frame using ETV 892 380. 4. Tap the piston rod (piston) into the cylinder with a soft hammer (note the groove for the steering arm bolt). Secure the steering arm to the piston rod (19 and 22 mm, 90 Nm).

B. Assembling steering cylinder

5. Fit the bearing to the end of the bolt and secure with the circlip. Fit the cover plate onto the cylinder frame (10 mm).

1. First fit the scraper seal (sealing lip in towards the cylinder frame) using ETV 893 630. Position the intermediate ring at the bottom of the seal housing.

6. Fit the O ---ring onto the bearing sleeve and fit the cylinder ends to the frame (8 mm, socket head 65 Nm). Make sure that the holes for the hoses face forward and upwards. 7. Fit the steering cylinder to the tractor and tighten the bolts (19 mm, 80 Nm, screw stud 85 Nm, w.e. fr. ser. no. 600705, 24 mm, 195 Nm). Apply Loctite 222 or equivalent to the threads on the screw studs. Secure the front bolts with the tab washers (see Fig. 2 on page 610/5).

ETV 893 630

2. Drive the seal in against the intermediate ring using ETV 893 630. Drive in the bearing sleeve until it bottoms, using ETV 893 630, with the groove in the bearing sleeve upwards. The clearance between the seal and the bearing sleeve will then be approx. 1 mm. Points 1 and 2 apply to both ends of the cylinder frame.

551

Model

61. Steering cylinder

1. 12. 1986

50 Nm

120---150 Nm 8. Connect the oil hoses (22 mm, 50 Nm) and secure the tie rods to the steering arms (22 mm, 120 ---150 Nm). 9. Start the engine and turn the steering wheel until the steering cylinder is filled with oil. Check for any leaks. 10. Start the engine and check the oil level in the hydraulic system.

552

205-- 865

Code

613

Page

6

Model

61. Steering cylinder

15. 9. 1995

205-- 865

Code

613

Page

7

Steering cylinder, Sige axle 1. Changing seals in steering cylinder Note! This instruction concerns earlier steering cylinder up to axle number 129/92. Later cylinder, see page 613/9.

A. Removal of steering cylinder N.B. It is not necessary to remove the front axle from tractor when repairing the steering cylinder. In the figures below the front axle is detached. 1. Raise the front end of the tractor and place axle stands behind the front axle. Turn the front wheels to the left against the limiter screw.

6. Remove steering cylinder attaching bolts (on LH side). 7. Pull out the cylinder to the left from the axle housing.

2. Heat up the RH side piston rod end at the joint between the piston rod and tie rod until the locking fluid in the threads melts (apply heat carefully about 30 mm from end, max 200˚ C).

B. Changing seals in RH side end piece

Important!. the metal must not be allowed to become blue during the heating operation. Do not heat up the ball joint because this can damage the rubber cover on the joint.

1. Remove steering cylinder (instr. A).

2. Secure the cylinder in a vice. Tap a pin (ø 4 mm) in the RH side end piece hole. Push the pin as far as possible. 3. Disconnect the tie rod from the piston rod end. 4. Turn the LH wheel to the right against the limiter screw and disconnect the threaded joint between the LH side piston rod and tie rod in the same way as described above. 5. Disconnect oil hoses from the steering cylinder. Remove the connecting fitting from the RH side end piece. Cover all holes with suitable plugs.

553

Model

61. Steering system

15. 9. 1995

205-- 865

Code

Page

613

8

C. Changing seals in LH side end piece 1. Remove steering cylinder (instr. A). 2. Secure steering cylinder in a vice.

3. Turn the end piece with tool ET 894000 until the locking wire emerges. Remove the end piece from cylinder. Remove the pin from the end piece. 4. Change the o---ring and support ring which sits against the cylinder liner. Grease the o---ring with universal grease (support ring is fitted outermost).

3. Unscrew the locking screw on the LH side end piece.

5. Change scraper seal, support ring and seal which sits against the piston rod. Grease parts with universal grease. Change the innermost support ring when necessary. Note! Scraper seal lip outwards, seal lip inwards.

4. Knock out the end piece using a hammer. Remove the now loose locking ring segments. 5. Change the o---ring on the cylinder liner outer side. Change the scraper seal, sealing ring and two support rings which are fitted on the end piece. Grease parts with universal grease. Important: The lip of the scraper seal should be inwards. 6. Fit the end piece onto the cylinder liner until it lies against the segments of the locking ring. Turn the end piece until the locking screw can be fitted.

6. Push the end piece carefully into the cylinder, hook the safety wire into the hole and rotate the end piece until the whole wire has been correctly positioned in the groove (note direction of rotation).

N.B.! Apply silicon to the locking screw. 7. Fit the steering cylinder into the axle housing (Op. D).

7. Drive the pin into the hole until it is level with the surface of the end piece. N.B. Never use a pin that is too long ( max ø4x8 mm), because it will prevent removal of the end piece in the future.. 8. Apply silicon to the pin, to the locking wire groove and to the joint between cylinder liner and end piece. 9. Fit the steering cylinder into the front axle housing (Op. D).

554

Model

61. Steering system

15. 9. 1995

205-- 865

Code

Page

613

9

2. Later steering cylinder

D. Fitting steering cylinder

The steering cylinder on Sige front axles has been changed from axle number 130/92. The new cylinder is as a complete unit exchangeable with the earlier one. Order number of the new steering cylinder is 31955500.

A. Changing seals 1. Removing the cylinder, see instr. 1A on page 613/7.

190 Nm

1

2

1. Push the steering cylinder into the axle housing. Tighten cylinder attaching screws to 190 Nm.

290 Nm

2. Remove the locking ring (1). Push the end piece a little inwards and remove the securing ring (2). 3. Pull the piston rod/piston out of the cylinder with a rapid movement at which time also the end piece releases. 4. Remove all damaged seals and fit new ones. Note! A seal ring kit no 31797510 is available. Lubricate all seals with oil before assembling the cylinder.

2. Connect the piston rod to the tie rods. Tighten the joint to 290 Nm. Apply locking fluid Loctite 586 to the threads.

5. Assemble the cylinder in the reverse order. Fitting the cylinder into the front axle, see instr. D on this page 613/9.

3. Connect the oil hoses to the steering cylinder. 4. Start the engine and check that the steering system functions properly. Check for possible leaks. Check oil level in hydraulic oil tank.

555

556

1. 12. 1986

62. Non ---powered front axle

Model

10. 1. 1992

205-- 865

Code

620

Contents General (Op. no. 620) Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Non ---powered front axle, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Repair instructions

Front axle with central pivot bearings (Op. no, 621) 1. Reconditioning front axle: A. Changing wheel bearings and hub seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Changing steering knuckle bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Adjusting track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Checking and adjusting toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 3 32.

2. Front axle central pivot bushing: A. Changing axle member and central pivot bearing bushings . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technical Data Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front axle flange distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steel member 2---6 mm ±13˚ 2˚ 8˚ 0˚ 1390---1490---1590 mm

Tyres and track widths (measurement between centres of tyres): Tyres

Track widths

Ground clearance

7.50---16/8 10.00---16/8

1436---1536---1636 mm 1442---1542---1642 mm

460 mm 505 mm

Track widths w. e. fr. ser. no. 600705 1336---1436---1536 1410---1510---1610

Max. permissible axle loads: (with standard track widths 1436 or 1336) With tyres 7.5---16/6 max 3000 kg With tyres 10.00---16/8 max 3000 kg/35 km/h max 3600 kg/8 km/h max 4500 kg/8 km/h with front loader use with short distances ( ACB control valve) has been drawn from out of the hydraulic housing, has been observed the connection of the front loader. If the front loader is connected before the valve blocks (earlier system) , pressure in the front end of the line rises too much so that the front loader safety valve opens before the hydraulic lift own valve (18 MPa). Note! In this construction the opening pressure of the front loader safety valve must not changed (over 18 MPa). In the new construction tractor’s own safety valve determines the max pressure of the pump.

747

Model

92. Autocontrol Power lift

15. 4. 1999

A. Control valve

600-- 900

Code

Seite

920

10

Note! The valve allows lowering function also when the tractor engine is stopped. The lowering function has not a pressure compensation, but the lowering speed varies according to the load. The pressure compensation has been replaced with electronics. If the lowering speed increases too much, the electronics decreases the lowering speed.

See picture 9. The valve is fitted on the LH side of the hydraulic housing as the earlier valve with three fixing bolts (25 ---31 Nm). The valve has pump pressure port P, port A to the lifting cylinder and return oil ports R1 and R2 (between valve and housing) which have been sealed with o---rings.

The valve has not an in ---built shock valve, but the shock valve is located at the lifting cylinder as in the mechanical power lift.

The valve has lifting and lowering module. Both modules have proportional magnets. The function of the pressure balance is cushioned by a restriction. The non ---return valve has a lightening function for oil to/from the cylinder. The pressure balance and the lifting spool are fitted in the same axle. This causes the lifting magnet to open at pump pressure. Oil flow to cylinders is limited to 60 l/min.

The upper solenoid if for lifting and the lower for lowering (I max=3,35 A). The solenoid coils can be changed separately. There are push buttons at the ends of both solenoids.

1,2. Passages (lifting module) 3. Spool (lifting module) 4. Non ---return valve 5. Spring (lifting module) 9. Spool (pressure balance, lifting module) Picture 10. Control valve in neutral position Oil flows from port P via pressure balance 9 to port R2 and back to the tank. The spring side of the pressure balance is connected to port R1, in the other side there is the free --flow pressure.

The standard pressure difference is always in passages 1 and 2, and it is the same in all functions. In passage 1 there is always higher pressure. Passage 2 has been connected to port R1. In order to create the standard pressure difference, the pressure balance moves to the position, where oil flow from P to R2 is restricted with this pressure difference.

Forces against the face of the pressure balance 9 determine its position in relation to body. The sums of forces of both faces are always equal. Then the pressure in the spring side of the pressure balance is always smaller than the spring force in the opposite side. This pressure difference is called a standard pressure difference.

Lowering and lifting functions are closed in the neutral function and both solenoids are unenergised.

748

Model

92. Autocontrol Power lift

15. 4. 1999

1,2. Passages (lifting module) 3. Spool (lifting module) 4. Non ---return valve 5. Spring (lifting module) 9. Spool (pressure balance, lifting module)

Picture 11. Control valve in lifting position Spool 3 has moved to the left, and has connected passages 1 and 2. The springs of the pressure balance push it to the right and restricts oil from port P to port R2. Passage 2 has not connected to the separate return oil port R1. Pressure increases, until the non ---return valve 4 opens. The spring side of the pressure balance is now connected to the load pressure (cylinder pressure). Pressure in passage 1 is standard pressure difference higher. Load pressure+standard pressure difference adjust the pressure balance 9 between P and R2. Oil flows under standard pressure difference to cylinder A. Opening cross---section determines the oil flow. Stroke of spool 3 is determined by magnetic force of the solenoid, against which the spring 5 pushes. Then the oil flow is proportional to the current in solenoid coil. Since the load pressure affects the pressure balance 9, this oil flow does not depend on the load (load sensing). The lowering function is closed.

749

600-- 900

Code

920

Page

11

Model

92. Autocontrol Power lift

15. 4. 1999

600-- 900

Code

920

Page

12

1,2. Passages (lifting module) 3. Spool (lifting module) 4. Non ---return valve 5. Spring (lifting module) 6. Spring (lowering module) 7. Pre ---steering spool and its bore (lowering module) 7a. Pre ---steering seat surface 7b. Pre ---steering groove 8. Main spool 8a. Restriction 9. Spool (pressure balance, lifting module) 10. RH side of the main spool (lowering module)

Picture 12. Control valve in lowering position

Lowering function (only lowering passage open), the lowering solenoid is energised:

The most important parts of the lowering function are pre --steering spool 7 with bores and main spool 8. The pre ---steering spool is locating in the middle of the main spool.

Pressure balance 9 functions as in the neutral position. When the lowering solenoid pushes the pre ---steering spool to the left, first opens the pre ---steering seat surface 7a and after that the pre ---steering groove 7b. Oil flows from space 10 to tank. Then the pressure drops below the load pressure. Oil flows via restriction 8a back to this space.

Spring 6 pulls the pre ---steering spool 7 to the right against the seat 7a. Since the pre ---steering seat is integrate machined in the main spool, also it is pulled to the right against the main seat. The pre ---steering spool is in the balance via passage 7. This situation is not on in the main spool 8. The load pressure affect the radial surface AR and in the closed situation against the face AS on the LH side. Since the surface AS is bigger than AR, pressure forces the main spool into this position.

Intermediate pressure in space 10 depends on the opening surface of the pre ---steering grooves. If the force against surface AS is equal to force of the load pressure against ring surface AR, the main spool follows in this position the pre ---steering spool. This construction creates a large positioning force. Hydraulic load sensing is not arranged as in the lifting position. The load sensing in the lowering position is created electronically.

750

15. 4. 1999

92. AC and ACB power lifts

1. 9. 2001

Model

600-- 900

Code

920

Page

13

Picture 14. Side view of AC and ACB power lifts 1. Sealing compound Hylosil (UK 0067) between hydraulic housing ---cover plate. 2. Dowels (2 pcs) has M10 thread for puller. 3. Dipstick: --- upper mark (35 L) --- lower mark (25 L) --- with max. filling the available oil volume for the auxiliary hydraulics is 24 litres 4. Sealing compound Hylosil (UK 0067) 5. Limiter bolt limits the max. lifting heigth when using the mudguard push buttons. The limiter bolt is adjusted so that the lifting arms does not touch the cabin. Loctite 270 (UK0085) on the limiter bolt threads. The earlier limit switch (S17E) is not needed any more. Note! When using the position potentiometer, the system must stop the lifting movement before the inner lever touch the limiter bolt (adjustment of the position sensor, see pages 320/10A and 321/15). 6. Top link locking bolt does not free the top link (the locking bolt has not the level machining). 7. EHR5: The shock valve limits the cylinder shock pressure to 20 MPa 8. Pressure ---limiting valve limits the working hydraulic pressure to 18 MPa:iin. EHR 5: Boring for control valve pressure oil. 9. Position sensor (B1E) 10. Connecting pipe + breather filter 11. Draft sensor (B2E). EP grease on the sensor.

751

752

101. Special tools (ETV)

100. Special tools

102. Locally prepared tools (ET)

753

754

1. 12. 1986

100. Special tools

Model

1. 9. 2001

205-- 900

Code

100

Page

1

Contents 1. Special tools (Op. no. 101): 21. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23. Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32. Autocontrol hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42. Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. Low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45. Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46. PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61. Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62. Non powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64. Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71. Frame and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91. Hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 4 4 5 5 7 10 11 12 12 13 14 15 16

2. Locally prepared tools (Op. no. 102): 21. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42. Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. Low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45. Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61. Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71. Frame and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91. Hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 3 5 5 6 7 8

Special tools (ETV) The special tools for the tractors are divided into two series: A and B. The A---series: Comprises all tools required for service, minor repairs, repair of clutch and changing external oil seals. The B ---series: Comprises special tools required for more comprehensive repairs.

Locally prepared tools (ET)

(N.B. These tools are not made by the tractor manufacturer). These ET ---tools should be made locally (in your own workshop) according to the drawings shown in Code 102.

General In the following lists the ETV --- and ET ---tools are divided according to the tractor components. As most of the tools are not new, but already in use for earlier tractor models, the type designation of the earlier tractor model is given at the end of the description of the respective tool. If a tool is used for tractors 205---665 only, there is an asterisk after the tool number. If there are brackets around a particular tool number, this indicates that this tool is also used for repairing another component of the 205---665.

755

756

1. 12. 1986

101. Special tools (ETV)

1. 7. 1989

Model

305-- 555

Code

Page

101

1

21. Engine A (11 -- series) Order no. 1. 8360 97532 2. 8360 97336 3. 8361 97470 4. 8360 97463 5. 8360 86085 6. 8360 97315 7. 9030 15200 8. 8360 85499 9. 8360 13091 10. 9025 58000

Description Lever for compressing valve spring (505---905) Counterhold nut for above (505---905) Milling tool for injector seat (505---905) Drift for fitting injector sleeve (505---905) Extractor for injector sleeve (505---905) Drift for fitting crankshaft rear seal (505---905) Drift for fitting crankshaft front seal (505---905) Puller for coolant pump impeller (505---905) Puller for coolant pump hub (505---905) Cylinder head spanner (505---905): earlier number 8360 97328

21. Engine B (11 -- series) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 26B. 27. 27A. 28.

8360 97337 8360 97457 8360 97434 8360 97435 8360 97436 8360 97437 8361 97468 7314 03506 8360 97327 9025 79200 9025 78100 9025 98900 9051 40200 9025 98800 9025 98700 9051 73100* 8353 39292 9051 72900* 9051 72800 9051 71300*

Drift for removing valve guide (505---905) Drift for fitting valve guide (505---905) T ---handle for valve seat milling cutter (505---905) Milling cutter for facing exhaust and inlet valve seat(505---905) Milling cutter for exhaust and inlet valve seat (505---905) Inner milling cutter for exhaust and inlet valve seat (505---905) Drift for fitting 16 mm cap plug (505---905) Drift for fitting 36 mm cap plug (505---905) Puller for crankshaft gear (505---905) Holder for dial gauge (505---905) Press tool for cylinder liner (505---905) Drift for fitting dust cover, crankshaft front seal (505---905) Drift for fitting coolant pump seal (505---905) Drift for fitting tubular pin in timing gear casing (505---905) Drift for fitting tubular pin in timing gear casing (505---905) Puller for cylinder liner26A. 8365 39293 Puller flange, 305, 405 Puller flange, 455 Milling cutter for fitting cylinder liner, 305---405 Milling cutter for fitting cylinder liner, 455 Puller for injector

Locally prepared tools 29. 30.

9051 64900 ET(893 760)

Drift for fitting coolant pump shaft (505---905) Support between front end and front axle to prevent oscillation

1

2 3

757

4

5

Model

101. Special tools (ETV)

1. 12. 1986

Code

305-- 555

Page

101

2

6

7

11

8

9

10 12 17

14

15

16

18

13

20

19

758

Model

101. Special tools (ETV)

1. 12. 1989

Code

305-- 555

Page

101

3

21

22

23

25

24

26 26A 27

759

28

Model

101. Special tools (ETV)

1. 12. 1989

305-- 555

22. Fuel system A (11---series) Order no. (8360 13091) 8360 97339 9025 99000

Description Puller for injection pump drive gear (see Engine A) Control (calibrating) pipe for injection timing (505---905) Sleeve for limiting control rod travel (505---905)

22. Fuel system B (11---series) Order no. 6541 30600 8360 83288

Description Pressure gauge for checking delivery valve (505---905) Cleaning tools for injectors (505---905)

9025 99000 8360 13091

8360 97339

8360 83288

6541 30600

760

Code

101

Page

4

1. 9. 1992

101. Special tools (ETV)

Model

1. 9. 2001

Code

355-- 900

101

21A. Engine (20-- series, 656316-- ) Order no 1 9051 73100 2 9101 65600 *) 3 9052 46400 4 9052 46300 5 9030 15200

Description Puller for cylinder liner Milling cutter for cylinder liner seat Centring tool for flywheel housing Drift for fitting rear crankshaft seal Drift for fitting front crankshaft seal

6 9052 46620 7 8361 97468 8 9025 87400 9 9101 66300 *) 10 9025 79200

Drift for 40 mm cap plug Drift for 16 mm cap plug Drift for fitting camshaft cup plug Press tool for cylinder liner Holder for dial gauge

11 9101 66100 *) 12 9101 71100 *) 13 9101 65502 *) 14 9101 65503 *) 15. 9101 75800 *)

T ---handle for valve seat milling cutter Milling cutter for facing exhaust valve seat Milling cutter for exhaust valve seat Inner milling cutter for exhaust valve seat Milling cutter for facing inlet valve seat

16 17 18 19 20 21 22 23 25

9101 65505 *) 9101 65506 *) 9101 66200 *) 9052 47200 9101 66000 *) 7314 03506 9101 65800 *) 9101 65900 *) 9101 65700 *)

Milling cutter for inlet valve seat Inner milling cutter for inlet valve seat Lever for compressing valve spring Counter nut for lever above Milling tool for injector seat Drift for 36 mm cup plug Drift for removing valve guide Drift for fitting valve guide Spanner for crankshaft nut

26 27 28 29 30

9052 48800 9020 01100 9025 98900 9025 98800 9025 98700

Puller for crankshaft gears Conical sleeve for fitting pistons Drift for fitting dust cover, crankshaft front seal Drift for fitting tension pin in timing gear casing Drift for fitting tension pins in timing gear casing and flywheel housing

*)

New tools for 20---series engines. Other tools are the same as for engines on 305---405 tractors.

1

3

2

4

5

6

7

8

9

761

10

Page

4A

1. 9. 1992

101 Special tools (ETV)

Model

Code

355-- 900

1. 9. 2001

Page

4B

101

11

18 15

12

13

19

16

14

17

22

21

20

26

25

23

27

29

28

762

30

Model

1. 3. 1997

101. Special tools (ETV)

Code

355-- 900

1. 9. 2001

Page

101

22A. Fuel system (20-- series, 656316-- ) 9052 47800 *) 9052 48900 *) 9052 47600 *) 9052 99000 *) 9051 71300 *) 8366 62022

*)

Pressure gauge for checking delivery valve Puller for injection pump drive gear Control pipe for injection timing Sleeve for limiting control rod travel Extractor for injectors Tester (TimeTrac) to check dynamic injection advance, E ---engines: 1. 836662121 Magnetic detector 2. 836662122 Cable 3. 836662123 Fastening part 4. 836662120 Timing light (not illustrated) 5. 836859466 TimeTrac in ---line sensor (not illustrated) 6. 836662124 Clamp ---on Transducer 4,5 mm (not ill.) 7. 836662125 ---” ---, 5,0 mm (not ill.) 8. 836662126 ---” --- ,6,0 mm (not ill.) 9. 836662127 ---” --- ,8,0 mm (not ill.) 10. 836662128 ---” --- ,1/4 inches (not ill.)

Same tool as for fuel system on 305---405 tractors.

15±1

9025 99000 9051 71300

905248900 3 2

9052 47800 902547600

A

B

A

8366 62022

1

B 33346600

A

33370300 30068700 33370100 33346700

(0---1 bar) 31965400

Measuring equipment for fuel feed pressure:

A

If the pressure is too low in point A, check the pressure in point B. If further too low, the fault lies in the fuel feed pump. Otherwise the filter is blocked.

763

4C

1. 9. 1992

101. Special tools (ETV)

1. 9. 2001

Model

355-- 900

23A. Cooling system (20-- series, 656316-- ) Order no 9022 03500 *) 9104 27700 9051 40200 *) 9051 79300 *) 9051 64900 *) 9052 48900 *) *)

Description Puller for coolant pump impeller, 320--- and 420---engines (earlier no 8360 85499) Puller for coolant pump impeller, latest coolant pump, see page 231/4. Drift for fitting coolant pump seal (seal no 8353 31202) Drift for fitting coolant pump seal (seal no 8353 39425) Drift for fitting coolant pump shaft, 320--- and 420---engines Puller for fan hub (see Fuel System)

Same tool as for engines on 305---405 tractors.

9022 03500

905140200

905179300

905164900 9052 48900

764

Code

101

Page

4D

1. 3. 1997

101. Special tools (ETV)

1. 9. 2001

Model

Code

355-- 900

32. Autocontrol hydraulic power lift Part no. ETV 894 100

Description Cable to check voltages of draft sensor and position sensor

Blue Yellow ---green Brown

View A

1

3 2

Black (1) 1

Blue (2) Red (3)

3

2

A

765

101

Page

4E

Model

101. Special tools (ETV) Part no. ETV 894 220

1. 3. 1997

355-- 900

Code

Page

101

4F

Description Cable to check the control valve solenoids (Y1E, Y2E) on AC power lift (also 6000---8750).

Y1E, Y2E

ETV 894 220

766

1. 9. 1992

101. Special tools (ETV)

Model

205-- 900

1. 9. 2001

Code

Page

101

41. Clutch A Note! Adjusting kit ETV 892 570 below concerns F&S ---clutch. Only some notes are given for LuK ---clutch (on 555---665)

Clutch A

Part no ETV 891 211* ETV 892 570 1. ETV 892 571 2. ETV 892 592 3. ETV 892 575 ETV 892 578 4. ETV 892 570 7. ETV 893 710* 8. Std. 10. ETV 892 582 12. ETV 893 711* ETV 893 712* 13. ETV 892 584 14. ETV 892 585 ETV 892 586 15. ETV 892 58 (ETV 893 650) ETV 894 320

Description Centring drift for PTO clutch disc (not 205) Kit for adjusting clutch (504, 604) containing the following parts: Adjusting fixture Centring sleeve for propulsion clutch disc Press drift D = 150 mm, L = 50 mm Press drift D = 90 mm, L = 40 mm Pressure and turning lever, complete Spacer block 6,5 mm (4 pcs) (Spacer block 7,6 mm for LuK ---clutch) Bolt M8X60, at least 4 pcs Guide pin Spacer sleeve 72 mm, propulsion clutch (Spacer sleeve 68 mm for LuK ---clutch) Spacer sleeve 96 mm, PTO clutch (Spacer sleeve 93 mm for LuK ---clutch) Indicator sleeve, L = 30 mm Long indicator, PTO clutch Short indicator, propulsion clutch Indicator nut Drift for fitting needle bearing and seal inside clutch shaft (see Gearbox) Fitting tool for HiShift hydraulic block piston seal KH 3714 (not illustrated)

Locally prepared tools ET 891 200 ET 893 670* (ET 893 760) ET 893 780* ET 894 130

Handle for removing centring drift ETV 891 211 Lifting handle for clutch Support plate, 2 pcs. Prevents front axle oscillation when splitting tractor Sleeve for removing clutch release bearing for propulsion clutch Centring drift for clutch disc on 205---tractor

Note! (*) = entirely new tools for Valmet tractors.

Clutch A

ETV 891 211 ETV 893 650

8

1 3

4

10

12

13 14 15

D

2

L L

ETV 892 570

7

767

5

1. 12. 1986

101. Special tools (ETV)

Model

10. 1. 1992

205-- 865

Code

Page

101

Locally prepared tools

ET 891200

ET 893670

ET 893760 ET 893780

ET 894 130

768

6

1. 12. 1986

101. Special tools (ETV)

1. 3. 1997

Model

Code

205-- 865

101

Page

7

Gearbox A Part no. ETV 893 260 ETV 893 630 ETV 893 640 ETV 893 650

Description Key for round nut, output shaft front wheel drive (505---905) Plate for fitting seal in bearing cover, input shaft Plate for fitting seal in bearing cover, output shaft front wheel drive Drift for fitting needle bearing/sealing ring in input shaft

Gearbox B ETV 890 220 ETV 890 830 ETV 891 220 ETV 891 870 ETV 891 900 ETV 892 210 ETV 892 230 ETV 892 350 ETV 892 490 ETV 893 660 ETV 893 610

Universal handle Sleeve for fitting front bearing on pinion shaft (PTO 505---905) Sleeve for fitting bearing on counter shaft Sleeve for fitting rear bearing on output shaft, front wheel drive Plate for fitting thrust bearings for differential side gears (Gearbox 505---905) Sleeve for fitting outer bearing race for input shaft front bearing (Gearbox 505---905) Sleeve for fitting bearing race for pinion shaft front bearing (Gearbox 505---905) Key for pinion shaft round nut (Gearbox 702---903) Sleeve for fitting front bearing on output shaft, front wheel drive Sleeve for fitting rear bearing on input shaft (Gearbox 505---905) Plate for fitting pinion shaft rear bearing bearing race (Final drives 702---903) Key for adjusting differential bearings Tool for removing/fitting input shaft and bearings --- ETV 893 611 Spindle --- ETV 893 612 Sleeve for removing shaft --- ETV 893 613 Sleeve for fitting shaft --- ETV 893 614 Drift for removing/fitting shaft --- ETV 893 615 Nut M16

Locally prepared tools ET 893 570

Drift for removing/fitting selector shaft

ET 893 620

Sleeve for fitting rear bearing on pinion shaft Sleeve for fitting counter shaft bearing races Sleeve for fitting rear bearing on input shaft Support for front frame (2 pcs), prevents front axle oscillation when splitting tractor (see Frame and Wheel)

(ET 893 760)

ETV 893260

ETV 893630

ETV 893640

769

ETV 893650

Model

101. Special tools (ETV)

1. 12. 1986

Code

205-- 865

101

ETV 890 220

ETV 890 830

ETV 891 870

ETV 892 210

ETV 891 220

ETV 891 900

ETV 892230

ETV 892 350

ETV 893660 ETV 892 490

770

Page

8

1. 12. 1986

101. Special tools (ETV)

1. 3. 1997

Model

Code

205-- 865

101

ETV 893611 ETV 893612

ETV 893614

ETV 893615

ETV 893613

ETV 893 610

Locally prepared tools

ET 893570

ET 893 620

ET 893 760

771

Page

9

1. 12. 1986

101. Special tools (ETV)

1. 1. 1998

Model

205-- 900

Code

101

Page

10

44. Low gear/Overdrive A Part no. ETV 892 440

Description Plate for fitting front oil seal and removing/fitting all bearings (PT0 702---903)

44. Low gear/Overdrive B Part. no. (ETV 892 350) (ETV 893 650)

Description Sleeve for fitting rear oil seal (see Gearbox) Drift for fitting needle bearings/oil seal in main gearbox input shaft (see Gearbox)

Locally prepared tools ET 893 380 Drift for fitting selector shaft (Gearbox 505---905) (ET 893 760) Support (2 pcs) for front end frame, prevents front axle oscillating when parting tractor (see Frame and Wheels

ETV 892 440

ETV 892 350

ETV 893 650

Locally prepared tools

ET 893 380 ET 893 760

772

1. 12. 1986

101. Special tools (ETV)

1. 1. 1998

Model

Code

205-- 900

101

Page

11

45. Final drives B, 205---665 Order no ETV 891 710 (ETV 892 210) ETV 893 320 ETV 893 690*

Description Sleeve for fitting bearing race för outer drive shaft (Gearbox Valmet 1102---1203) Sleeve for fitting oil seal for outer drive shaft (see Gearbox) Plate for fitting outer shaft seal for outer drive shaft (Final drives 505---905) Plate for fitting bearing race for outer drive shaft

Locally prepared tools ET 893 410 Support bar for removing bearing race, outer drive shaft (Final drives 505---905)

Locally prepared tools

ETV 893 320 ET 893 410

ETV 893 690

ETV 891 710

ETV 892 210

45. Final drives B, 865 and 600---900 Part no. ETV 890 220 ETV 893 310 ETV 893 320 ETV 894 210

Description Universal handle Plate for fitting drive shaft inner oil seal (Mezzo) Plate to fit drive shaft bearing outer races (Mezzo) Centring tool foor outer brake application ring when fitting final drives on 865 and 600---900.

Locally prepared tools ET 893 410 Support to remove drive shaft bearing outer races (Mezzo)

Locally prepared tools

ETV 890220

ETV 893 310 ET 893 410

ETV 893 320

ETV 894 210

773

15. 4. 1994

101. Special tools (ETV)

1. 3. 1997

Model

205-- 900

Code

101

46. PTO A Order no ETV 893 700*

Description Sleeve for fitting PTO shaft end, bearings or oil seal

46. PTO B (ETV 892 350) ETV 894 080

Sleeve for fitting upper shaft or bearings (see Gearbox) Tool for fitting selector fork locking ball (also PTO 6000---8400)

ETV 893 700

ETV 892 350 (1 ---speed PTO)

ETV 894 080 (2 ---speed PTO)

61. Steering system Order no ETV 893 100

Description Tool for fitting seal in steering valve (from cab no 54624) (see also 505---8100)

ETV 893100

61. Steering cylinder B (2WD) Order no ETV 892 380 (ETV 893 630)

Description Sleeve for removing bearing sleeve and seal from steering cylinder (see Gearbox 505---905) Plate for fitting scraper seal, seal and bearing sleeve in steering cylinder (see Gearbox)

ETV 893 630

ETV 892 380

774

Page

12

Model

Special tools (ETV)

15. 9. 1995

205-- 865

Code

101

Page

12A

Equipment to measure steering system pressures

Equipment to measure steering system working pressure (9 ---10 MPa). Measuring kit no. 31965000 includes these parts. The parts can also be ordered separately.

Equipment to measure shock valve opening pressure (16 MPa). T ---connector GS 9276 has thread 3/4---16 for the hand pump. Measuring kit no. 31965000 does not include the hand pump.

775

776

Model

101. Special tools (ETV)

1. 12. 1986

Code

205-- 865

101

62. Non ---powered front axle B Order no ETV 890 820 ETV 892 390 ETV 892 410 (ETV 892 210) (ETV 892 400) ETV 892 370 (ETV 892 350) ETV 891 230 ETV 892 360

Description Drift for fitting central pivot bearing bushings (front axle Valmet 504---604) Sleeve for fitting wheel hub bearing race (front axle 505---805) Plate for fitting wheel hub bearing race (front axle 505---805) Sleeve for fitting shaft seal in hub (see Gearbox) Sleeve for fitting roller bearing in wheel hub (see Powered front axle ZF) Sleeve for fitting roller bearing on steering knuckle (front axle 505---805) Sleeve for fitting needle bearing race on steering knuckle (see Gearbox) Drift for fitting needle bearing in steering knuckle housing (front axle Valmet 504---604) Plate for fitting roller bearing in steering knuckle housing (front axle 505---805)

ETV 892390

ETV 890820

ETV 892370

ETV 892410

ETV 892210

ETV 892350

ETV 891230

777

ETV 892400

ETV 892 360

Page

13

1. 12. 1986

101. Special tools (ETV)

Model

1. 9. 1992

205-- 665

64. Powered front axle A (ZF axle) Order no ETV 891 840 ETV 892 400

Description Sleeve for fitting oil seal on pinion shaft (see Gearbox 505---905) Sleeve for fitting pinion shaft nut locking sleeve (see Front axle 505---805)

64. Powered front axle B (ZF axle) (ETV 890 820 ETV 891 780 (ETV 892 350) ETV 893 720* ETV 893 730* ETV 893 750* ETV 893 770*

Drift for fitting drive shaft seal and bearing bushings (see Non ---powered front axle) Plate for fitting oil seal in hub (Gearbox 1102---1203) Sleeve for fitting steering knuckle bearing races (see Gearbox) Plate for fitting pinion shaft bearing race Plate for fitting pinion shaft bearing race Plate for fitting bearing races in hub Tool for adjusting pinion shaft bearing preload Tool for adjusting tooth backlash pinion/crown wheel

ETV 891 840 ETV 892 400

ETV 891 780

ETV 892 350

ETV 890 820

778

Code

101

Page

14

15. 9. 1995

101. Special tools (ETV)

Model

205-- 865

1. 3. 1997

ETV 893 730

ETV 893 720

ETV 893 750

ETV 8932 770

64. Powered front axle Sige ETV 892 290 Tool for fitting drive shaft outer oil seal (Sige 6100---8100) ETV 893 600 Tool for fitting pinion shaft seals (Sige 6100---8100) ETV 894 020 Plate for fitting hub seal (Sige 6100---8100) ETV 894 150 Plate for fitting new hub seal (cassette type), 1108/94--Locally prepared tools ET 894 010 Drift to remove/fit drive shaft bearing bushings (Sige 6100---8100)

ETV 893600

ETV 892290

ET894010

ETV 894 020

ETV 894 150

Puller for king pins

779

Code

101

Page

15

1. 12. 1986

101. Special tools (ETV)

1. 7. 1989

Model

Code

205-- 865

101

91. Hydraulic lift B Order no ETV 892 660 ETV 892 670 ETV 892 680

Description Device for checking damping valve (Hydraulic lift 504---604) Device for checking tightness of lifting cylinder and shock valve (Hydraulic lift 504---604) Checking device for control valve (Hydraulic lift 504---604)

ETV 892 660

ETV 892 680 ETV 892 670

The above mentioned tools are included in an earlier used pressure ---testing kit ETV 892 920. Equipment for measuring and testing pressures, see ”Locally prepared tools”, code 102. Order no ETV 893 530 ETV 894 030*

Description Sleeve for fitting lifting arm shaft seals (Hydr. 505---905) Sleeve for fitting lifting arm shaft bushings (610312---)

ETV 894 030

ETV 893 530

780

Page

16

15. 9. 1995

101. Special tools (ETV)

1. 5. 1996

Model

205-- 865

Code

101

Page

17

Measuring equipment, 205---665

Measuring pressure in working hydraulics (18 MPa). Test kit no. 31965000 includes these parts. The parts can also be ordered separately.

Measuring equipment, 865 with extra lifting cylinder

Measuring working pressure in working hydraulics (18 MPa). T ---connector GS 9276 is connected to the lower hose of the extra lifting cylinder. Test kit no. 31965000 includes these parts. The parts can also be ordered separately.

781

1. 3. 1997

Special tools (ETV)

Model

205-- 900

1. 9. 2001

Code

101

Page

18

Hand pump

Measuring opening pressure of shock valve (20 MPa) on 865---tractor. The pressure gauge and hand pump are connected to the extra lifting cylinder lower hose. Pressure test kit no. 31965000 does not include the hand pump.

A

B

C

Measuring working hydraulics working pressure on the latest 65---models and on 600---900. A. Pressure test point on the extra lifting cylinder hose on the LH side. B. Pressure test point beside the AC power lift control valve. C. On tractors without the test point, the pressure can also be measured from the quick couplings of the auxiliary hydraulics.

782

10. 1. 1992

102. Locally prepared tools (ET)

1. 9. 1995

Model

205-- 865

Code

Page

102

1

21. Engine

75

120

ø 30

3x45˚

Locally prepared tools 9051 64900 Drift for fitting coolant pump shaft (505---905) (ET 893 760) Support plate, 2 pcs. Prevents front axle oscillation when splitting tractor (see Frame and Wheels)

R1

25

5

3,2 R2 ø 16+0,1 ø 22,5+0,5 ø 29,8 --- 0,1

905164900

41. Clutch

Locally prepared tools Part no Description ET 891 200 Handle for removing centring drift ETV 891 211 (Clutch 504---604) ET 893 670* Lifting handle for clutch (ET 893 760) Support plate, 2 pcs. Prevents front axle oscillation when parting tractor (see Frame and Wheels) ET 893 780* Sleeve for removing clutch release bearing for propulsion clutch ET 894 130 Centring drift for clutch disc on tractor 205

M12

2000

ET 891 200

783

120

ø 12

25

1. 12. 1986

102. Locally prepared tools (ET)

Model

Code

205-- 865

10. 1. 1992

102

85

110

R10

R10

72

ø8

17

35 ET 893 670

184

ø 48,5

ø 49±0,5

10

190

ø 25

30˚

ø 40,5

ET 893 780

ø 19,9

ø 54 ±0,5

4

16 57 103 183 ET 894 130

784

Page

2

1. 12. 1986

102. Locally prepared tools (ET)

1. 3. 1997

Model

Code

205-- 865

102

Page

3

42. Gearbox Locally prepared tools ET 893 570 ET 893 620

ø 15,9 (---0,1)

(ET 893 760)

Drift for removing/fitting selector shaft Sleeve for fitting rear bearing on pinion shaft Sleeve for fitting counter shaft bearing races Sleeve for fitting rear bearing on input shaft Support for front frame (2 pcs), prevents front axle oscillation when splitting tractor (see Frame and Wheel)

20˚

5 23 ET 893 570

400

ET 893 620

785

20

ø 61,8

ø 60

ø 53,7

390

1. 12. 1986

102. Locally prepared tools (ET)

1. 3. 1997

786

Model

205-- 865

Code

102

Page

4

15. 9. 1995

Locally prepared tools (ET)

1. 5. 1996

Model

205-- 865

Code

Page

102

Locally prepared tools Description Drift for fitting selector shaft (Gearbox 505---905) Support (2 pcs) for front end frame, prevents front axle oscillation when splitting tractor (see Frame and Wheels)

ø 16 h11

Part no. ET 893 380 (ET 893 760)

120 ET 893 380

45. Final drives Description Support bar for removing bearing race, outer drive shaft (Final drives 505---905) Support/centring tool for brake application plate when fitting rear axle housing on 865 tractor 195

30

30

Locally prepared tools Part no. ET 893 410 ET 894 210

45˚

155 ET 893 410

~2 ~6 ~6

Ø6

~ 99 ~ 75

Oil plug GR0225

Ø6,3 Plug is fitted on bolt before shaping the bolt end.

ET 894 210

787

Standard bolt M6x100

5

1. 5. 1996

Locally prepared tools (ET)

1. 3. 1997

788

Model

205-- 865

Code

102

Page

6

15. 9. 1995

102. Locally prepared tools (ET)

1. 3. 1997

Model

Code

205-- 865

64. Powered front axle Sige Order no ET 894 010

Description Drift for removing/fitting drive shaft bearing bushings (also Sige 505---8100)

165±1 15+0,5

30˚

SR 50

30˚

130±1

789

ø 35---0,3

Stamp ET 894 010

ø43,5 ---0,2

ø39,9 ---0,1

1,5

102

Page

6A

790

Model

102. Locally prepared tools (ET)

1. 12. 1989

205-- 865

71. Frame and wheels Locally prepared tools Support plate to prevent front axle oscillation (2 pcs) 100

40

32

40

20

ø 18

90

20

260

ET 893 760

ET 893 760 25

791

8

Code

102

Page

7

1. 12. 1989

102. Locally prepared tools (ET)

15. 9. 1995

Model

205-- 865

Code

Page

102

R1/4

91. Hydraulic power lift

ETV 892 921 (Enerpac P---39) *)

TEMA 2500 (R1/4)

3/4--- 16 UNF

9801---01---04.00

ETV 892 922 *)

ETV 892 660 ETV 892 680

1. Equipment for pressure testing damping valve and control valve

TEMA 2500 (R1/4)

TEMA 2500 (R1/4) 9801---01---04.00

2103---05---01.00

ETV 892 921 (Enerpac P---39) *) 2120---04---02.50

2. Equipment for tracing leakage in neutral position. Checking opening pressure of working hydraulic shock valve. Equipment for pressure ---testing lifting cylinder x) These tools are not supplied by Sisu ---tractors (the tools are included in an earlier pressure ---testing kit ETV 892 920. Part numbers consisting of digits only indicate parts which are generally available on the market. N.B. The measuring range of the pressure gauge is 0---40 MPa (0---5800 psi).

792

8