ITL SOLIS 20, Service Manual

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Page 3: ...RECOMMENDED SCHEDULE FOR MAINTENANCE SERVICE IDENTIFICATION OF TRACTOR CLUTCH FLOOR AREA GEAR BOX DISASSEMBLY AND ASSEMBLY OPERATIONS HYDRAULIC CIRCUIT INSTRUCTION MANUAL FRONT AXLE 2WD GENERAL INFOR...

Page 4: ...S E R V I C E M A N U A L INDEX vii I T L...

Page 5: ...T OF POWER LIFT HYDRAULIC CONTROL VALUE PART DETAILS HYDRAULIC CONTROL VALUE PART DETAILS CONTROL LEVER ASSY CLEANING OF HYDRAULIC CONTROL VALUE INSTRUCTION MANUAL TECHNICAL FEATURES OPERATION OF POWE...

Page 6: ...INSTRUCTION FOR O RING KIN RING ROTO GLYD INSTALLATION INSTRUCTIONS FOR LIP SEAL MAX TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS TECHNICAL FEATURES LIMITED SLIP DIFFERENTIAL DISKS SPECIFICATIONS MAIN...

Page 7: ...S E R V I C E M A N U A L x I T L...

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Page 9: ...S E R V I C E M A N U A L A 1 I T L...

Page 10: ...S E R V I C E M A N U A L A 2 I T L...

Page 11: ...S E R V I C E M A N U A L A 3 I T L...

Page 12: ...A 4 S E R V I C E M A N U A L A 5 0 RECOMMENDED SCHEDULE FOR MAINTENANCE SERVICE EVERY 10 50 250 500 750 1000 1250 1500 I T L...

Page 13: ...A 5 S E R V I C E M A N U A L EVERY 10 50 250 500 750 1000 1250 1500 SERVICE ITEM FUEL SEDIMANTOR BRAKE OPERATION PEDAL KING PIN TOE IN D D D D D D D D I T L...

Page 14: ...A 6 S E R V I C E M A N U A L LEGANDS ADJUST GREASE DRAIN D CLEAN TIGHTEN WASHING CHECK REPLACE EVERY 10 50 250 500 750 1000 1250 1500 FUNCTIONING OF OIL GAUGE FUNTIONING OF TEMPERATURE GAUGE I T L...

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Page 44: ...S E R V I C E M A N U A L B 28 LINER PROJECTION I T L...

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Page 52: ...10x1 5 lock it with nut M10 Step 32 Fit HPD shaft assy in crankcase and tighten it with retainer by using three ScrewsM8x14 Step 33 Fit HPD shaft gear in such a manner that Projected side of gear shou...

Page 53: ...x6x20 and slide cam shaft in the respective bore of Crankcase IMP Check free rotation of camshaft Lubricate Cam shaft before fitting in Crankcase Step 37 Tighten cam shaft retainer by using 3 Screws M...

Page 54: ...lean it properly Step 41 Fit External circlip A 35 in front of bearing Step 40 Press radial ball bearing B B 35 62 14 6007 on IPD shaft Step 42 Fit second radial ball bearing 30x62x116 6206 NR and the...

Page 55: ...Lubricate Bearings before Assy Step 45 Fit IPD gear light with lock nut M30x1 5 Step 44 Place the IPD Retainer and Tight three M8x16 Screws along with spring washers Step 46 Fit FIP Timing gear direc...

Page 56: ...tep 47 Lubricate TIG fit in such a way that its timing mark match with cam gear crank gear FIP Timing Gear Step 48 Place lock plate over TIG and tight it with bolts M8x45 Step 49 Fit tube assy from lu...

Page 57: ...The timing or the resetting of the timing can be simply quickly carried out with following instructions With the engine timing correctly set the engine is turned until no 1 piston is at TDC on its com...

Page 58: ...S E R V I C E M A N U A L B 42 GEAR BACKLASH CHECKING Dial Gauge Pointer Set at Zero Check Backlash Timing Gear Back lash of all gears should be 0 05 0 35 WEAR LIMIT 0 9 I T L...

Page 59: ...Step 52 Fit Neck for screw on suction side of oil pump housing Using sealing ring Cu Step 51 Fit the lubrication oil pump assy to Front Brg Cap using bolt M10x130 Use 0 1mm shim to adjust Backlash if...

Page 60: ...IMP Always use new sealing washers Step 56 Tight suction strainer and Sheet metal cover using screws M8x14and spring washer B8 Step 55 Fit other end of delivery pipe to connection IMP Tight all joint...

Page 61: ...5 using sealing washer18x24x1 5 Cu sealent to plug main oil gallery from rear side Step 59 Place Rear cover gasket using sealent Tight rear cover using five screws of M8x25 and 2 screw M8x30 alongwit...

Page 62: ...pins in case of CI front Cover 10 bolts M10 50 1 bolt M10 55 3cap head screw 11 Spring washers B 10 Step 63 Clean front cover properly Place the front cover gasket and front cover on the locating dow...

Page 63: ...al Step 65 Fit Transmission elbow with gasket using two screw of M8x20 and spring washer B 8 Step 67 Fit Engine Belt Pulley carefully aligning Keyway and Key Tighten crank pulley using nut M32x1 5 tor...

Page 64: ...flywheel and let it cool Step 69 Align the Flywheel dowel hole with Dowel of Crankshaft and push in Step 70 Tighten Flywheel using four hex bolts M12x38 and torque it 8 9 kg m Step 71 Place oil pan G...

Page 65: ...6x1 5 cu Step 73 Lubricate rocker arm pin and fit it to rocker arm bracket Fit Rocker Arm pin to Rocker arm bracket Step 74 Lubricate rocker arm and assemble both Rocker Arms Step 75 Fit external circ...

Page 66: ...ly clean cylinder head and press valve guides Step 78 Slide inlet and exhaust valves in their respective valve guides Lap valve seats with fine lapping paste and clean the valves after lapping IMP Lub...

Page 67: ...springs Step 81 Place valve Retainer cap fit valve cotters properly with fixture Step 83 Fit the studs M10 30 in Cyl Head for exhaust flange mounting and place exhaust flange gaskets Step 82 Gently p...

Page 68: ...ective bores Step 86 Tighten cyl head assemblies using Hex Bolts M16x2x128 Torque the bolts 22Kg m IMP Ensure Diagonal sequence of tightening Step 85 Place Cyl Head assy on Crank case properly Step 87...

Page 69: ...ll tappets Step 89 Place rocker arm sub assembly and tighten it to cylinder head using bolt M8x65 and support stud M8 along with spring washer B 8 Step 91 Fit stud M8 for injector fitment for each Cyl...

Page 70: ...l Inlet Manifold Step 93 Fit water return line using M8x35 and M8x55 bolts and spring washers Step 94 Place valve cover along with gasket Place dowty washer special nut and tight to 0 4 0 5 Kg m Torqu...

Page 71: ...s and B10 washer Fit two studs M10 30 in exhaust flange for exhaust elbow mounting Step 98 Place injector along with sealing washer in each cyl head and tighten Injector clamp alongwith conical washer...

Page 72: ...ine tighten hose clamps Properly Step 101 Push gently centering guide along with sealing rings 14x2 in crank case Step103 Fit oil tube assy With banjo bolt B 13 using sealing washer 18x24x1 5 CU from...

Page 73: ...edure of FIP with IPD shaft Place the FIP gaskets on Crankcase Step 106 Place coupling bush on IPD shaft in such a way that larger teeth of coupling bush meshes with respective teeth of IPD shaft Step...

Page 74: ...g Gear and Big tooth of Coupling Bush and push FIP to crankcase Step 109 Gently tight fuel injection pump using three M10 nut plane B10 washer Step 110 Procedure for FIP Timing Remove delivery valve h...

Page 75: ...E R V I C E M A N U A L B 59 Step 112 Tighten delivery valve holder Step 114 o Rotate Flywheel in clockwise direction and bring it to 14 mark ensure that fuel flow stops with continous pressing of pri...

Page 76: ...its place and torque delivery valve holder up to 4 5 kg m Step 117 Tight 3 FIP nuts M10 Firmly and Fit high pressure pipes and fuel pipes Step116 Set FIP inward and outward and adjust when diesel flo...

Page 77: ...r pipes For Comp Housing Engine with M8 14 Screws Step 121 Fit starter motor after placing gasket using M10 30 and spring washer B10 Step 122 Fit alternator Mtg Bracket to Crankcase with 10x20 screws...

Page 78: ...S E R V I C E M A N U A L B 62 Step 124 Fit Alternator strut front to alternator using bolt M10 Step 123 Mount alternator with mounting bracket using M10x70 bolt nylock nut I T L...

Page 79: ...BEARING CAP STUD 28 FLYWHEEL 29 REAR RING GEAR 30 REAR BAR 31 REAR COVER GASKET 32 DRAIN PLUG 33 SHEET METAL COVER 34 THRUST BEARING BOTTOM 1 35 CON ROD BIG END LINER 36 BEARING LINER BOTTOM 37 BEARIN...

Page 80: ...SY 7 ALTERNATOR ASSY 8 SPACER 9 ENGINE BELT PULLEY 10 POWER STEERING PUMP 11 OIL PAN 12 LUB OIL FILTER S NO DESCRIPTION 13 HEAT EXCHANGER 14 CRANKCASE 15 FLYWHEEL 16 HYDRAULIC PUMP 17 SIDE COVER 18 CY...

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Page 82: ...s Worn Cylinder Bores Pitted Valves and Seats Broken Worn or Sticking Piston Ring S Worn Valves Stems and Guids Overfilled Air Cleaner or use of incorrect grade of oil Worn or Damaged Bearings Insuffi...

Page 83: ...Engine Oil TROUBLESHOOTING I T L S E R V I C E M A N U A L B 67 Refer to oil leakage Replenish Replace Replace Replace Repair TROUBLE Oil leakage Low oil pressure POSSIBLE CAUSE Loosely installed par...

Page 84: ...LAYOUT OF LUBRICATION SYSTEM S E R V I C E M A N U A L B 68 I T L...

Page 85: ...S E R V I C E M A N U A L B 69 FLOW CHART OF LUBRICATION SYSTEM Turbo charger T I T L...

Page 86: ...S E R V I C E M A N U A L B 70 COOLING SYSTEM LAYOUT OF COOLING SYSTEM I T L...

Page 87: ...BLE CAUSE Corrosion Overheating Damaged radiator core Coolant leakage from radiator hose Coolant leakage from Thermostat Faulty seal water pump Loose or damaged thermostat cover gasket Loose cylinder...

Page 88: ...removal INSPECTION Check operation and replace if necessary 1 Visually check valve to make sure it is air tight 2 Place thermostat and a thermometer in water 3 Heat water gradually 4 Check initial va...

Page 89: ...following points Does the needle of the pressure gauge continuously point to the same valve Is there excessive swelling in the hose NOTE When removing the tester hot cooling water may blow out The ope...

Page 90: ...Tank for any leakage 2 Check Radiator cap relief valve proper working ensure for damage free rubber seal of radiator cap 3 Check radiator fins for any damage 4 Check radiator tubes are free from rust...

Page 91: ...d check the boost pressure if it is within the specified limit TURBINE WHEEL 1 Allow engine to cool 2 Remove the air hose 3 Verify that the rotor assembly turns smoothly 4 If there is excessive load o...

Page 92: ...Y FUNCTIONING OF TURBO CHARGER DO S Change engine oil and oil filters regularly during service intervals Change clean air filter element at every service Check for oil pressure at engine idling speed...

Page 93: ...n of the object entry correct it Remove restriction or replace damaged parts as required Arrest the leak by replacing gaskets damaged parts or tighten the fasteners as required Remove restriction or r...

Page 94: ...ean primary filter element by blowing air max pressure from inside Safety cartridge not to be removed during cleaning of primary element Safety cartridge to be replaced after every three replacement o...

Page 95: ...0 C 3 0 C 4 0 C 5 0 C 6 0 C 7 0 C 8 0 REF NO INTRODUCTION FUNCTION WORKING SPECIFICATIONS DETAIL OF DOUBLE CLUTCH LINKAGE ASSY PARTS ASSEMBLY PROCESS OF DOUBLE CLUTCH INSPECTION PROCEDURE TROUBLE SHOO...

Page 96: ...ER PRESSURE SPRINGS RELEASE FINGERS RELEASE BEARINGS CLUTCH SHAFT LINKAGES The clutch cover is bolted to the flywheel and the clutch plate is mounted on the splined part of the clutch shaft the front...

Page 97: ...U A L C 2 C 4 0 SPECIFICATAIONS 1 CERAMIC 280 MECH TRACTOR MODE CLUTCH MAKE TYPE DRIVE DISC LINING DIAMETER CONTROL 4 CYL DRY MECH LUK INDIA DRY MECH LUK INDIA DUAL SEPARATE CONTROL 1 ORGANIC 280 MECH...

Page 98: ...G SLEEVE PUSHER BEARING SLEEVE PLUG SLEEVE SUPPORT BOLT M8X25 S NO 1 2 3 4 5 6 7 8 9 DESCRIPTION Qty 1 1 1 1 1 1 1 1 3 S NO DESCRIPTION Qty BEEARING SNAP RING D50 SPLIT PIN 5X14 CLUTCH CONTROL FORK LE...

Page 99: ...with the help of 12 MB screws along with the spring washers with Pneumatic gun having socket of 13mm and torque wrench of 29Nm 3 Check the setting of the fingers Upper main clutch 35 to 36 and lower P...

Page 100: ...rn Clutch disc Note Measure the depth of the rivet head of disc Allowable limit up to 1 6 mm FOR ALL SOLIS III MODELS B CLUTCH COVER CHECKING Fatigue and breakage of the diaphragm spring and breakage...

Page 101: ...Flywheel face run out more Release lever not evenly adjusted Pressure plate assembly misaligned Warped pressure plate or clutch facing Clutch plate nut free on Workest clutch facing PROBABLE CAUSES Lu...

Page 102: ...AREA GEAR BOX CONTENTS D 1A D 1 D 2 D 3 D 4 D 5 REF NO SHEET METAL TIGHTENING TORQUES SEALANTS AND GREASE APPLICATION POWER FLOWS ASSEMBLY TYPICAL DATA FILLING AND CHECKS SERVICE SCHEDULE DESCRIPTION...

Page 103: ...ber pads are Fit on both of the sides ofTrumpets Housing Fit hex bolts M10x1 5x40 and stud mtg with trumpet housing size M16X1 5 And fit all the pins fitted on canopy Disassembling of Fender assembly...

Page 104: ...and bolts of floor assembly on rear housing please connect all the connections Linkages like brake connection gear Levers hydraulic linkage connections the all nuts bolts after that fit fender assembl...

Page 105: ...S O N A L I K A S E R V I C E M A N U A L S E R V I C E M A N U A L D 3 D 1B TRANSMISSION I T L...

Page 106: ...I T L S E R V I C E M A N U A L D 4 Main Dimensions mm LHS View See Main View...

Page 107: ...ealing with possibility of micro moments Strength High Low High High Presence Presence Thread Parts Sealant Adhesive make and type Superbond 321 Superbond 331 Superbond 438 Technical Characteristics L...

Page 108: ...S E R V I C E M A N U A L D 6 Grease Application in Assembly POLYMER 400 MU EP2 Apply on the Indicated Surfaces Fill Apply in Excess 4WD Mechanical Drop Box I T L...

Page 109: ...S E R V I C E M A N U A L D 7 CLUTCH HOUSING 12x12 Synchro Shuttle I T L...

Page 110: ...S E R V I C E M A N U A L D 8 DETAILS 12x12 Synchro Shuttle I T L...

Page 111: ...S E R V I C E M A N U A L D 9 GEAR BOX GROUP I T L...

Page 112: ...S E R V I C E M A N U A L D 10 GEAR BOX DETAILS I T L...

Page 113: ...I T L S E R V I C E M A N U A L D 11 FINAL DRIVE GROUP...

Page 114: ...S E R V I C E M A N U A L D 12 GD TPO AND PTO ASSY 540 540E I T L...

Page 115: ...S E R V I C E M A N U A L D 13 UPPER AND LOWER COVER I T L...

Page 116: ...S E R V I C E M A N U A L D 14 HYDRAULIC CONTROL BRAKE ASSY I T L...

Page 117: ...S E R V I C E M A N U A L D 15 INNER GEAR CONTROL ASSY F H H FOR ALL MODELS I T L...

Page 118: ...S E R V I C E M A N U A L D 16 OUTER GEAR CONTROL ASSY Y Y FOR ALL MODELS I T L...

Page 119: ...S E R V I C E M A N U A L D 17 D 2 POWER FLOWS FRW FIRST SPEED HIGH FOR ALL MODELS I T L...

Page 120: ...S E R V I C E M A N U A L D 18 POWER FLOWS FRW FIRST SPEED MEDIUM FOR ALL MODELS I T L...

Page 121: ...I T L S E R V I C E M A N U A L D 19 J POWER FLOWS FRW FIRST SPEED LOW...

Page 122: ...S E R V I C E M A N U A L D 20 POWER FLOWS FRW REV TRANSMISSION POWER FLOW 12 12 SYNCRHO SHUTTLE AVANTI FRW INDIETRO REV FRIZIONE CLUTCH AVANTI FRW INDIETRO REV FRIZIONE CLUTCH I T L...

Page 123: ...S E R V I C E M A N U A L D 21 D 3 ASSEMBLY TYPCIAL DATA Position 1 Gear Box End float Min 0 20 Max 0 30 mm Shims Range Thickness mm Quantity 0 10 0 15 0 20 0 50 END FLOAT SHIMS I T L...

Page 124: ...S E R V I C E M A N U A L D 22 Position 2 Gear Box End float Min 0 00 Max 0 00 mm Shims Range Thickness mm Quantity 0 10 0 15 0 20 0 50 SHIMS END FLOAT I T L...

Page 125: ...S E R V I C E M A N U A L D 23 Position 3 Gear Box End float Min 0 15 Max 0 25 mm Shims Range Thickness mm Quantity 0 05 0 10 0 30 END FLOAT SHIMS I T L...

Page 126: ...S E R V I C E M A N U A L D 24 Position 4 Gear Box End float Min 0 15 Max 0 25 mm Shims Range Thickness mm Quantity 0 01 0 3 0 5 END FLOAT SHIMS I T L...

Page 127: ...S E R V I C E M A N U A L D 25 Position 5 Gear Box End float Min 0 0 Max 0 1 mm Shims Range Thickness mm Quantity 0 10 0 30 0 50 END FLOAT SHIMS 12 12 SYNCHRO SHUTTLE I T L...

Page 128: ...e maximum level marked on the level dipstick 1 Apply the parking brake Keep the speed control in NEUTRAL range Start the engine by keeping the slow running of 800 1000 rpm until an oil temperature hig...

Page 129: ...S E R V I C E M A N U A L D 27 FILLING AND CHECK POINTS I T L...

Page 130: ...S E R V I C E M A N U A L D 28 12 12 MR SYNCHRO SHUTTLE 4WD MECHANICAL DROP BOX No 3 PLUGS 122187 D38x10 REQUIRED OIL LEVEL SYNCHRO SHUTTLE No 7 PLUGS 138341 D20 35x6 OIL I T L...

Page 131: ...nditions may require more short intervals Tempi previsti Recommended intervals 50 h 400 h 1200 h 800 h Operation Change the transmission hydraulic oil Change the oil suction strainer Change high press...

Page 132: ...GROUP ACTUATOR ASSEMBLY VIEW DETAILS OF BRAKE HOUSING INSIDE PARTS VIEW DETAILS OF BRAKE PADDLES PARTS VIEW DETAILS OF HAND BRAKE LINKAGE ASSEMBLY PARKING BRAKE HOUSING SENSORS ASSY DIFFERENTIAL LOCKI...

Page 133: ...AL S E R V I C E M A N U A L E 1 T1 T2 12 12 MR synchro shuttle 2WD mechanical control brake 12 12 MR synchro shuttle 4WD mechanical T57 drop box and mechanical control brake For models 75 90 Worldtra...

Page 134: ...19 Note the cover is attached with sealant Drain the oil completely from the transmission Unscrew the bolts 23 and remove the group Tap on the shaft end to release the transmission group bearings Note...

Page 135: ...by mean of a pad and a hammer Note this is a destructive operation for the seal ring Push the shaft 3 by mean of a pad and a hammer to extract the bearing 2 from the housing Remove the shaft bearing a...

Page 136: ...ve the clutch sleeve 9 Remove the bearing 12 Remove the snap ring 4 to disassemble the clutch sleeve Danger the washer 5 and spring 8 can be ejected with force Against the operator Remove the washer 5...

Page 137: ...the springs 8 Remove the sleeve 7 from the clutch sleeve 9 Collect the springs 8 Release the lock nut 27 Remove the fastening screws 28 Danger the spring 29 can be ejected with force against the opera...

Page 138: ...the spring 29 and ball 30 Remove the plug 32 Note the plug is attached with sealant Remove the pin 31 Extract the shaft 33 Danger the ball 34 and spring 35 can be ejected with force against the opera...

Page 139: ...Warning collect with care the disassembled parts they are necessary in the assembly operation Note remember the position of the springs 35 and 29 Check the disassembled parts wear condition Collect t...

Page 140: ...S E R V I C E M A N U A L E 9 Remove the lever 26 and the shaft 17 Remove the spring 18 Remove the seal ring 25 Note this is a destructive operation for the seal ring FIG 25 FIG 26 I T L...

Page 141: ...ean with care the housing 15 Check the wear condition of the bearings seats Insert the seal ring 25 into the housing 15 with the special tool CA715619 and a hammer Lubricate the seal ring 25 See sec C...

Page 142: ...into the housing 15 See sec C 4 and sec E 1 4WD mechanical drop box Push with a punch the ball 34 on the spring 35 then insert the special tool CA715620 on the ball 34 Insert the fork shaft 33 in the...

Page 143: ...shaft 17 Note align the pin hole in the shaft 17 to the hole in the lever 26 Lock the shaft 17 in the right position with a punch Assemble the pin 24 Assemble the fork 16 to the clutch shaft 17 in the...

Page 144: ...ert the fastening pin 31 with a punch and a hammer Apply prescribed sealant on the plug thread 32 Assemble the plug 32 and tighten it to the prescribed torque See sec C 4 Insert the bearing 12 into th...

Page 145: ...t springs 8 into the sleeve 7 to assemble the clutch Sleeve group Assemble the sleeve 7 to the clutch sleeve 9 Note check the springs 8 and key 6 position Assemble the washer 5 Assemble the snap ring...

Page 146: ...ial tool CA715623 and a hammer See sec E 1 4WD mechanical drop box Insert the spacer 10 and gear 11 in the housing Assemble the shaft 3 with bearing 2 as shown Insert the bearing 2 and shaft 3 into th...

Page 147: ...7 and tighten it to the prescribed torque See sec C 4 Clean with care the covers 14 and 19 Insert the seal ring 1 into the cover 14 with the special tool CA715621 and a hammer Lubricate the seal ring...

Page 148: ...bed torque See sec C 4 Apply prescribed sealant on the housing contact surface Assemble the housing to the vehicle transmission group with bolts 23 Tighten the bolts to the prescribed torque Fill the...

Page 149: ...16 INCLUDED ON ITEM 6 D 2 FINAL DRIVE For Models 75 90 Worldtrac 75 90 Worldtrac T1 T2 12 12 MR synchro shuttle 2WD mechanical control brake 12 12 MR synchro shuttle 4WD mechanical T57 drop box and me...

Page 150: ...0 Remove pins 8 from trumpet 6 11 Remove O Ring 19 on ring gear 18 Note destructive operation for O Ring 12 Remove snap ring 11 13 Collect bearing cone 10 14 Turn the group upside down 15 Extract the...

Page 151: ...fig 1 and sec E 1 Final drive 4 Assemble studs 2 on wheel axle 1 5 Warm the outlined area at 120 C for 4 5 minutes to allow introduction of the wheel axle 1 See fig 1 6 Assemble wheel axle 1 7 Turn tr...

Page 152: ...ssemble bearing cone 21 on planetary gears carrier 12 pin Assemble gear 22 to gear carrier 12 Assemble bearing cone 23 Assemble pin 24 Assemble washer 25 Apply sealant to screw 17 See sec C 4 Tighten...

Page 153: ...r 14 and screw 15 tighten screw 15 to prescribed torque See fig 3 and sec C 4 SHIMS RANGE Thickness mm 0 05 0 10 0 30 0 50 Quantity 3 Measure preload P of the taper roller bearings with a dynamometer...

Page 154: ...16 5 Insert shaft 20 into the transmission See fig 8 7 Assemble locking screw 7 to the requested torque See sec C 4 8 Assemble greaser 5 and tighten to the prescribed torque See sec C 4 6 Assemble tru...

Page 155: ...E 22 D 3 Upper Covers and Rockshaft T1 T2 12 12 MR synchro shuttle 2WD mechanical control brake 12 12 MR synchro shuttle 4WD mechanical T57 drop box and mechanical control brake For models 75 90 World...

Page 156: ...rews 8 Warning approximate weight of rockshaft case assembly is 82 Kg See fig 1 2 Remove Shield Warning during disassembly procedure do not damage the shield Note for rockshaft disassembly see tractor...

Page 157: ...3 4 Note cover 7 correct assembly See fig 4 Fig 4 5 Assemble screws 6 to the prescribed torque See sec C 4 6 Clean all contact surfaces of the lever assy 3 with care 7 Apply prescribed sealing See se...

Page 158: ...tial housing Apply a coat of Loctite 574 to mating surfaces See fig 5 11 Install rockshaft case 9 using a suitable lifting device Screw up the eight bolts 8 Torque wrench setting 120 Nm 90 lb ft Warni...

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Page 167: ...ring 13 from shaft 12 9 Remove pin 2 10 Remove lever 9 11 Remove pin 5 12 Remove PTO control fork 7 after raising PTO control lever 1 13 Remove ball 3 and spring 4 from fork 7 14 Extract PTO control l...

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Page 170: ...emble pin 2 18 Assemble bearing 13 and inner ring of bearing 11 onto PTO shaft 12 using a pad 19 Insert PTO shaft 12 using a driver and a hammer See fig 12 20 Assemble bearing 23 onto the cover 24 usi...

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Page 183: ...Parts No DESCRIPTION Qty 1 2 3 4 5 6 7 8 No DESCRIPTION Qty 9 10 11 12 13 14 15 PIN D 11 PIN LOCKING SPRING TIE BAR BRAKE MECHANISM BRAKE DISC BRAKE COUNTER PLATE FLANGE BOLT TIE ROD SPRING BALL NUT B...

Page 184: ...10437AE 10010438AD 10010524AB 10080072AC 10080073AC RUBBER PAD BRAKE PEDAL ASSY RIGHT ADJUSTABLE TIE ROAD FOR BRAKE PEDAL CIRCLIP 25 1 2N I S3075 PART 1 WASHER BRAKE PEDAL TENSION SPRING BRAKE ASSY FE...

Page 185: ...Qty 1 2 3 4 5 6 7 No DESCRIPTION Qty 8 9 10 11 12 13 HANDBRAKE LEVER RH ELASTIC RINGH D 8 BRAKE ROD BRAKE ROD PIN D 10X28 NUT BRAKE ROD PIN D 12 5X31 HANDBRAKE NUT ELASTIC RINGH D 9 HANDBRAKE LEVER RH...

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Page 210: ...E M A N U A L E 77 D 15 2 Assembly 1 Assemble forks 3 and 13 See fig 1 FORK 1st 2nd SPEED GEAR SYNCHRONIZER FORK 3rd 4th SPEED GEAR SYNCHRONIZER 4th SPEED GEAR 3rd SPEED GEAR 2nd SPEED GEAR st 1 SPEED...

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Page 246: ...pected load will have a value 40 50 lower than expected for new bearings See fig 1 and 2 2 Disconnect brake control 3 Disassembly screws 1 4 Remove brake 2 5 Remove right flange 4 6 Remove bearing cup...

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Page 250: ...the range available Shims Range Thickness mm Quantity 0 05 0 10 0 30 0 50 See fig 15 16 Adjust shims 11 and 10 remembering that a if the measured backlash is less than given tolerance range increase...

Page 251: ...hose cord is wound on the pinion ring nut with diameter D 80 mm The measured value should be within following range for T1 and T5 models T P 6 3 to P 9 5 N for T2 models T P 7 0 to P 11 0 N for T3 and...

Page 252: ...bevel gear crown backlash value unchanged d if the total preload is greater than given range decrease shims 11 and 10 by same measure keeping pinion bevel gear crown backlash value unchanged See fig 1...

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Page 255: ...S E R V I C E M A N U A L E 122 Fig 1 Fig 2 I T L...

Page 256: ...S E R V I C E M A N U A L E 123 Fig 3 Fig 4 I T L...

Page 257: ...d float is eliminated Install false differential box s3 s4 See fig 5 6 Measure distance X distance between the axis of the differential bearings and the base of pinion head with a depth gauge See fig...

Page 258: ...r 4 collar 3 central clutch 2 and thrust washer 1 Note right position for central clutch 2 See fig 9 Note grease thrust washers 8 and 1 so that they do not fall on the gear box See fig 10 and 11 13 Se...

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Page 261: ...measured on D 80 mm The measured value should be within following range P 40 to 60 N Warning values valid for new bearings See fig 15 If bearings are not new measured valve should be starting value S...

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Page 264: ...I T L S E R V I C E M A N U A L E 131 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6...

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Page 270: ...1 1 1 1 1 1 1 1 1 1 2 1 2 Hydraulic Pump Inlet manifold Assembly HYDRAULIC FILTER Suction pipe From Strainer to hose Strainer Control Valve Sec Pipe from pump to rear cover Lift Housing Gasket DCV Lev...

Page 271: ...S E R V I C E M A N U A L F 2 No Models Reference Description Qty F 2 0 Hydraulic Control Valve Part Details I T L...

Page 272: ...S E R V I C E M A N U A L F 3 No Models Reference Description Qty F 3 0 Hydraulic Control Valve Part Details I T L...

Page 273: ...S E R V I C E M A N U A L F 4 F 4 0 Control Lever Assy No Models Reference Description Qty I T L...

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Page 281: ...S E R V I C E M A N U A L F 10 Forward to operate the A port Backwards to operate the B port 2 1 I T L...

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Page 284: ...S E R V I C E M A N U A L G 2 CIRCUIT DIAGRAM OF HYDRAULIC LIFTING DEVICE I T L...

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Page 286: ...S E R V I C E M A N U A L G 4 M 4 2 A NEUTRAL PHASE I T L...

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Page 288: ...S E R V I C E M A N U A L G 6 M 4 4 B DELIVERY PHASE I T L...

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Page 290: ...G 8 M 4 6 C DISCHARGE PHASE I T L...

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Page 292: ...S E R V I C E M A N U A L G 10 M 5 2 NEGATIVE STROKE I T L...

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Page 294: ...NEGATIVE STROKE...

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Page 296: ...S E R V I C E M A N U A L G 16 I T L...

Page 297: ...S E R V I C E M A N U A L G 17 I T L...

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Page 300: ...S E R V I C E M A N U A L G 20 M 7 3 I T L...

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Page 309: ...40 58 2 10 PIVOT PIN THRUST WASHER SPRING WASHER B 8 HEX SCREW M8X1 25X30 8 8 SA2JS INTEGRAL FRONT AXLE BRACKET 4 CYL TYRE SIZE 7 50 16 16 9 28 LOCK PIN MTG BRACKET HEX SCREW M8X1 25X30 8 8 SA3NS SPR...

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Page 323: ...SYMBOLS DESCRIPTION...

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Page 330: ...WHEEL HUB GROUPS SUPPORTS GROUP DIFFERENTIAL GROUP AXLE BEAM GROUP...

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Page 337: ...change 50 100 hours 3 150 200 hours 2 150 200 hours 3 150 200 hours 1 Seasonally or every 1500 hours Every oil change 1 Monthly or every 300 400 hours 1 Monthly or every 300 400 hours 1 2 Weekly or ev...

Page 338: ...S E R V I C E M A N U A L J 10 J 8 Grease in Assembly Technolube POLYMER 400 AGIP GR MU EP2 Apply on the indicated surfaces Fill Apply in excess I T L...

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Page 343: ...S E R V I C E M A N U A L K 1 FIG 1 D 1 Steering Cylinder Group I T L...

Page 344: ...S E R V I C E M A N U A L K 2 FIG 2 FIG 3 FIG 1 I T L...

Page 345: ...S E R V I C E M A N U A L K 3 FIG 2 FIG 3 FIG 4 I T L...

Page 346: ...S E R V I C E M A N U A L K 4 FIG 5 FIG 6 FIG 7 I T L...

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Page 399: ...I T L S E R V I C E M A N U A L L T 1 0 T 2 0 T 3 0 REF NO...

Page 400: ...ation front tyre resistance halfshaft breakage Steering is difficult vehicle goes straight while turning No differential action jamming while steering Uneven wear of tyre Friction noise Vibration duri...

Page 401: ...C E M A N U A L L 2 T 2 TROUBLESHOOTING This chapter is a descriptive and explanatory guide to common axle problems This guide suggests the repair correct procedures to be followed PROBLEM CAUSE ACTI...

Page 402: ...S E R V I C E M A N U A L L 3 PROBLEM CAUSE ACTION I T L...

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Page 405: ...ball joint replacement x 1 Steering rod tie rod replacement x 1 Ball joint protection replacement x 1 Tie rod protection replacement x 1 Steering cylinder overhauling 60 30 15 30 15 15 120 Epicyclic R...

Page 406: ...S E R V I C E M A N U A L M 2 Differential Support Group M2 Cod Operation Min B1 B4 Differential replacement Differential housing bearings replacement 150 180 I T L...

Page 407: ...S E R V I C E M A N U A L M 3 D1 D2 D3 D4 Axle beam replacement Spherical bearing replacement x 1 Double U joint seal replacement Double U joint bush replacement 180 45 45 60 I T L...

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Page 409: ...ON PIPE OIL TANK OIL TANK RETURN PIPE STEERING COLUMN CCC STEERING UNIT HIGH PRESSURE PIPE S NO 1 2 3 4 5 6 7 8 9 10 PART NAME Qty 1 1 1 2 1 1 1 1 1 1 S NO PART NAME Qty HIGH PRESSURE L BOW O RING FOR...

Page 410: ...valve Check Valve DESCRIPTION Dust seal ring Housing spool sleeve Ball dia 8 5 mm O ring roto glyd Bearing assembly Ring Cross pin Set of springs Cardon shaft O ring Distributor plate 1 2 3 5 7 10 11...

Page 411: ...ST 3 0 DETAIL VIEW OF HYDROSTATIC STEERING UNIT...

Page 412: ...S E R V I C E M A N U A L N 4 FIG 1 FIG 2 FIG 3 FIG 4 I T L...

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Page 425: ...S E R V I C E M A N U A L N 17 ST 6 0 MAX TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS T Tank L Left port P Pump R Right port Max Tightening Torque N m lbf in Screwed connection I T L...

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Page 428: ...ice Gerotor end up Clamp lightly on edges of port face sides refer fig 1 Use protective material on vice jaws Housing distortion can result if jaws are over tightened Note Here figures are not shown i...

Page 429: ...FIG 4 FIG 5 FIG 6 FIG 7 S E R V I C E M A N U A L N 21 I T L...

Page 430: ...FIG 8 S E R V I C E M A N U A L N 22 I T L...

Page 431: ...FIG 9 FIG 10 FIG 11 FIG 12 S E R V I C E M A N U A L N 23 I T L...

Page 432: ...FIG 13 FIG 14 FIG 15 FIG 16 S E R V I C E M A N U A L N 24 I T L...

Page 433: ...FIG 17 S E R V I C E M A N U A L N 25 I T L...

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Page 439: ...S E R V I C E M A N U A L O 2 I T L...

Page 440: ...S E R V I C E M A N U A L O 3 I T L...

Page 441: ...nstruments and controls Fig 3 9 Dashboard ENLARGED VIEWS Fig 3 10a Mobile charging socket Fig 3 10b Light turn indicator and horn 1 2 3 C Lights off Parking Light Dipped beams Pushed down driving beam...

Page 442: ...S E R V I C E M A N U A L O 5 A A B B I T L...

Page 443: ...S E R V I C E M A N U A L O 6 I T L...

Page 444: ...O 7 S E R V I C E M A N U A L E 3 0 ELECTRICAL WIRING CIRCUIT DIAGRAM TAIL AREA DASHBOARD AREA FRONT AREA FRONT AREA I T L...

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Page 448: ...OF LUBRIANTS GREASES GREASING POINTS ON TRACTOR SPECIAL TOOLS FOR TRANSMISSION FINAL DRIVE 4WD MECHANICAL DROP BOX PTO POWER TAKE OFF CLUTCH HOUSING SYNCRO SHUTTLE HYDROSTATIC STEERING UNIT P 1 P 2 P...

Page 449: ...P 1 S E R V I C E M A N U A L O 1 0 RECOMMENDED GRADE OF LUBRICANTS GREASES O 1 1 HYDROSTATIC STEERING OIL I T L...

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Page 451: ...from Front Pump For removal of bearing from Flywheel For Installing the Rear Oil Seal in the Retainer For Installing of the Timing Case Oil Seal in the Front TimingCase Cover For Installing of the Tim...

Page 452: ...tralizing the Double Clutch Plate Assy For centralizing the Double Clutch Plate Assy For tightening and loosening the Lay Shaft Nuts of Single Clutch Gear Box For tightening and loosening the Lay Shaf...

Page 453: ...emove the Steering Wheel from Steering Assy For give the support to Rear Axle at the time of the repair the Rear Axle and Final Drive For removal of Thrust Pad from king Pin Stub Axle For spliting Gea...

Page 454: ...For give the support to Rear Axle at the time of the repair the Rear Axle and Final Drive S E R V I C E M A N U A L Remove the Steering Wheel Remove the Steering Wheel from Steering Assembly...

Page 455: ...S E R V I C E M A N U A L For pulling of Timing Gears For pulling of Fuel Injector From Engine...

Page 456: ...S E R V I C E M A N U A L P 11 CA716145 1 CA716144 CA715206 I T L...

Page 457: ...CA716145 2 CA715821 CA715830 CA715848 CA715805...

Page 458: ...S E R V I C E M A N U A L P 13 CA716145 3 CA715800 CA715583 CA715810 CA715815 I T L...

Page 459: ...CA716145 4 CA715831 CA715821 CA715808 CA715807...

Page 460: ...S E R V I C E M A N U A L P 15 5 CA716145 CA715843 CA715843 CA715809 CA715093 CA715798 CA715801 CA715798 I T L...

Page 461: ...S E R V I C E M A N U A L P 16 CA716160 1 CA715836 CA715826 CA715827 CA715844 I T L...

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Page 463: ...uttle 2WD mechanical control brake 12 12 MR synchro shuttle 4WD mechanical T57 drop box and mechanical control brake For models 75 90 WorldTrac 75 90 WorldTrac O 7 0 PTO power take off CA716210 1 CA71...

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Page 465: ...12 12 2 CA716138 CA716154 CA716202 CA715842 CA715314 CA716138 CA715314...

Page 466: ...ed with the interchangeable handle CA119033 its use is recommended together with a suitable safety handle in order to protect the hands CA119033 CA119068 CA119097 Handle Handle Driver CA119220 CA71502...

Page 467: ...P 22 CA715643 CA715644 CA715649 Driver Driver Driver CA715651 CA715652 CA715653 Handle False pinion Driver CA715654 CA715656 CA715657 False differential box Tool for prepload measur Driver CA716288 CA...

Page 468: ...S E R V I C E M A N U A L P 23 I T L...

Page 469: ...I T L S E R V I C E M A N U A L P 24 FIG 5 FIG 6 FIG 7...