Massey Ferguson Series Tractors 8210, 8220, 8220 Heavy Duty, 8220 Xtra, 8240, 8240 Xtra, 8245, 8245 Heavy Duty, 8250, 8250 Xtra, 8260, 8260 Xtra, 8270, 8270 Xtra, 8280, 8280 Xtra Repair Service Manual (3378177M1)
Complete service repair manual with Electrical Wiring Diagrams for Massey Ferguson Tractors 210, 8220, 8220 Heavy Duty, 8220 Xtra, 8240, 8240 Xtra, 8245, 8245 Heavy Duty, 8250, 8250 Xtra, 8260, 8260 Xtra, 8270, 8270 Xtra, 8280, 8280 Xtra, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Massey Ferguson 8200 Series Tractors workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,964 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
3378177M1 - Massey Ferguson 8200 Series Tractors Workshop Service Manual (8210, 8220, 8220 Heavy Duty, 8220 Xtra, 8240, 8240 Xtra, 8245, 8245 Heavy Duty, 8250, 8250 Xtra, 8260, 8260 Xtra, 8270, 8270 Xtra, 8280, 8280 Xtra).pdf
MAIN SECTIONS
CONTENTS...1
1 . INTRODUCTION...2
1 A01 Introduction...4
A . Reading the manual...5
B . General specifications...6
C. Safety instructions...22
D . Practical advice...23
E . Instructions for putting the tractor in service...26
F . Conversion tables...27
G . Locking compounds and sealants...35
H . Tightening torques...36
2 . SPLITTING THE TRACTOR...39
2 A01 Splitting the tractor between front frame / Engine...41
General...42
A . Preliminary operations...42
Fig. 2...43
Fig. 3...44
B . Disassembling (Fig. 4)...45
C . Reassembling...45
D . Final operations...45
E. Version with Carraro front axle...47
F. Service tools...51
2 B01 Splitting the tractor betwwen Engine / Gearbox...53
General...55
A . Preliminary operations...55
B . Disassembling (Fig. 4)...57
C . Reassembling...58
D . Final operations...62
E . Service tools...63
2 C01 Splitting the tractor between Gearbox / Intermediate housing...65
General...66
A . Preliminary operations...66
B . Disassembling (Fig. 2)...68
C . Reassembling...69
D . Final operations...70
E . Service tools...71
F . Heavy Duty Version...72
2 D01 Splitting the tractor between Intermediate housing / Centre housing...79
General...80
A . Preliminary operations...80
B . Disassembling...83
C . Reassembling...85
D . Final operations...87
2 E01 Separating PTO housing / Centre housing...89
A . Preliminary operations...90
B . Disassembling (Fig. 4)...91
C . Reassembling (Fig. 4)...91
D . Final operations...92
2 F01 Chassis reinforcements...93
A . General...95
Parts list...95
Fig. 1...95
Fig. 2...96
Fig. 3...96
B . Installing and adjusting the reinforcements (Heavy Duty gearbox) (Fig. 2 - 3)...97
2 G01 Rear wheels / Hubs...99
General...100
A . Presentation of the main assemblies and torque values...101
B . Changing track...109
C . Replacing a wheel stud...113
3 . ENGINE...115
3 A01 General...117
A . Introduction...119
B . Main characteristics...120
C . Viscostatic fan...124
3 B01 Flywheel and dampers...125
A . General...126
Parts list...128
Fig. 1...127
Fig. 2...128
B . Removing and refitting the damper (Figs 1 - 2)...126
C . Removing and refitting the fly-wheel and the bearing...129
D . Replacing the starter ring gear...130
E . Service tools...130
3 C01 Spacer...131
A . Removing and refitting the spacer...132
Fig. 4...133
B . Service tools...136
3 C02 Spacer - Power Shuttle...137
A . Removing and refitting the spacer...138
B . Service tool...142
4 . CLUTCH...143
4 A01 Pressure loaded clutch...145
General...146
Parts list...147
Fig. 1...147
Fig. 1A...148
Fig. 2...149
A . Removing and refitting the clos-ing plate and replacing lip seal (57) and O?ring (1) P...151
B . Removing and refitting the clutch...152
C . Adjusting the clutch...154
D . Disassembling and reassembling the clutch...155
E . Removing and refitting control valve (Fig. 11)...157
F . Service tools...157
5 . GEARBOX...159
5 A01 General - Operation...161
A . General...163
Parts list...164
Fig. 1...165
B . Operation...167
C . Specifications...171
Fig. 6...171
5 A02 General - Operation...173
A . General...174
Parts list...176
Fig. 1...177
B . Operation...179
C . Sp?cifications...181
D . Tightening torques...183
5 B01 Input unit with mechanical reverse shuttle...185
General...186
A . Removing and refitting the unit...186
B . Service tools...188
5 B02 Input unit with power shuttle...191
General...192
A. Preliminary operations...193
B . Removal...195
C . Refitting...196
D . Adjusting of the progressive sensor...196
E . Final operations...197
F . Service tools...197
5 B03 Dynashift...199
General...200
Theory of Operation...200
Parts list...201
Fig. 1...201
Fig. 2...202
A . Preliminary operations...207
B . Removing and disassembling the cover, housing, front clutch and brake...207
C . Removing and separating the planet pinion cage assembly...208
D . Disassembling the rear clutch and brake...208
E . Assembling the planet pinion cages...209
F . Reassembling the rear clutch and brake...209
G . Reassembling the cover, front clutch, brake and housing...210
H . Shimming the planet pinion cage...212
I . Assembling the input unit...213
J . Final operations...214
K . Service tools...214
5 B04 Dynashift...215
General...216
Parts list (Fig. 1 - 2)...217
Fig. 1...217
Fig. 2...218
Operating principle...216
A . Preliminary operations...223
B . Removing and disassembling the cover, front clutch casing and brake (Fig. 7 - 8)...223
Fig. 8...224
C . Removing and splitting the planet carrier unit...225
D . Disassembling the rear clutch and brake...226
E . Assembling the planet carriers...226
F. Refitting the rear clutch and brake...227
G . Refitting the cover, front clutch, brake and casing...228
H . Shimming the planet carriers...229
I . Assembling the input unit...231
J . Final operations...231
K . Service tools...232
5 B05 Mechanical reverse shuttle...233
General...234
Operation...234
Parts List...234
Fig. 1...235
Fig. 2...236
A . Preliminary operations...237
5 B06 Power Shuttle...243
General...245
Parts list...248
Fig. 2...249
Fig. 3...250
Fig. 4...251
A . Removing and refitting the front clutch...253
B . Disassembling and reassembling the front clutch...254
C . Shimming the front clutch...257
D . Disassembling and reassembling the rear clutch...258
E . Disassembling and reassembling the driving pinion - Shimming the shaft...262
F . Service tools...265
5 C01 Selector cover...267
General...268
Parts list...268
Fig. 1...269
Fig. 2...270
A . Operation...273
B . Removing and refitting the cover...275
C . Replacing the Hare/Tortoise pis-ton seals (Fig. 4)...278
D . Disassembling and reassembling the selector mechanisms...278
E . Installing and adjusting the gear linkage and reverse shuttle control cables (tractors with cab)...280
F . Version for tractors with platforms...284
Fig. 19...285
G . Adjusting the Hare/Tortoise range...288
H . Service tools...289
5 C02 Selector cover...291
General...292
Parts list...292
Fig. 1...293
Fig. 2...294
A . Operation...297
B . Removing and refitting the cover...299
C . Replacing Hare / Tortoise piston seals (Fig. 4)...301
D . Disassembling and reassembling the selector mechanisms...301
E . Fitting and adjusting the gear linkage...303
F . Adjusting the Hare / Tortoise range...305
G . Service tools...306
5 C03 Selector cover - Optimised Hare / Tortoise function...307
General...308
Parts list...308
Fig. 1...309
Fig. 2...310
A . Identification and functions of components - Hare / Tortoise function...313
B . Removing and refitting the cover...315
C . Replacing Hare / Tortoise piston seals (Fig. 4)...318
D . Disassembling and reassembling the selector mechanisms...318
E . Fitting and adjusting the gear linkage...321
F . Adjusting the Hare / Tortoise range...323
G . Service tools...324
5 D01 Selector rails...325
General...326
Parts list...327
Fig. 1...327
Fig. 2...328
A . Disassembling and reassembling selector rails and adjusting forks and gearbox selector...329
B . Disassembling and reassembling selector rail and adjusting input unit fork...331
5 D02 Selector rails...333
General...334
Parts list...335
Fig. 1...335
Fig. 2...336
A . Disassembling and reassembling selector rails and adjusting forks and gearbox selector...337
5 E01 Output shaft...339
General...341
Parts list...341
Fig. 1...342
Fig. 2...343
A . Preliminary operations...344
B . Removing and refitting the selec-tor rails and forks...344
C . Removing, refitting and shimming the shaft...344
Fig. 3...345
Fig. 4...346
Fig. 5...346
D . Final operations...347
5 F01 Mainshaft...349
General...350
Parts list...350
Fig. 1...351
Fig. 2...352
A . Preliminary operations...353
B . Disassembling and reassembling the shaft...353
C . Final operations...355
D . Shimming of the input pinion (Fig. 8)...356
E . Shimming the shaft...357
5 F02 Mainshaft...359
General...360
Parts list...360
Fig. 1...361
Fig. 2...362
A . Preliminary operations...363
B . Disassembling and reassembling the shaft...363
C . Final operations...365
D . Shimming the shaft...366
E . Service tools...367
5 G01 Layshaft...369
General...370
Parts list General...370
Fig. 1...371
Fig. 2...372
A . Preliminary operations...373
B . Removing and disassembling the shaft...373
C . Reassembling and refitting the shaft...374
D . Final operations...375
E . Shimming the pinions (Fig. 7)...376
F . Shimming the bearings...376
G . Service tools...378
5H01 General...379
A . General...380
B . Characteristics...380
C . Transmission (Figs. 2 to 7)...381
Parts list...381
Fig. 2...382
Fig. 3...383
Fig. 4...384
Fig. 5...385
Fig. 6...386
Fig. 7...387
D . Power transmission ? Description...390
E . Vibration damper and coupling shafts (Figs. 15 - 16)...396
Parts list...396
Fig. 15...397
Fig. 16...398
F . Service tools...399
5I01 Transmission hydraulic circuit...403
A . Characteristics - Transmission hydraulic circuit...405
B . General...406
C . Hydraulic circuit diagram...407
Parts list...407
Fig. 1...407
D . Oil filter (Fig. 2)...408
Fig. 2...408
E . Thermostatic valve (Fig. 4)...410
F . Pressure regulating-valve (Fig. 6)...412
G . Proportional solenoid valve (Fig. 7)...413
H . Pump and pressure circuit...414
I . Disassembling the pump...415
J . Pump reassembly...416
K . Clutch circuit...417
L . Lubricating circuit...418
5J01 Transmission - Repair...419
A . Disassembling the gearbox...420
B . Removing the front housing...421
C . Removing clutches and trans-mission shafts...422
D . Replacing the input shaft seal...424
E . Inspecting and repairing the hous-ing...425
F . Reassembling the gearbox...426
G . Overhauling a speed clutch train...428
Parts list...433
Fig. 38...432
Parts list...435
Fig. 39...434
Parts list...437
Fig. 40...436
H . Input shaft - 1 st stage shaft (Fig. 50)...441
I . Repairing the range clutch shaft...442
Parts list...447
Fig. 64...446
Parts list...449
Fig. 65...448
Parts list...451
Fig. 66...450
5 K01 Creeper unit...457
General...458
Operation (Fig. 2)...459
Parts list...460
Fig. 3...461
Fig. 4...462
A . Removing and remounting the unit...463
B . Disassembling, reassembling and adjusting the selector...465
C . Disassembling and reassembling the epicyclical reducer...468
D . Control adjustment...469
6 . REAR AXLE...471
6A01 Description...473
A . General...474
Parts list...474
Fig. 1...475
Fig. 2...476
B . Layout of the main components (Fig. 1 and 2)...474
6B01 Standard trumpets...477
General...478
Parts list...478
Fig. 1...479
Fig. 2...480
A . Removing and refitting the trumpet housing assembly...481
B . Removing and refitting the brake plate and crownwheel assembly...483
C . Removing and disassembling the planetary carrier...484
D . Reassembling and refitting the planetary carrier...485
E . Replacing the axle shaft bearings...486
F . Shimming the axle shaft bearings...488
G . Replacing a wheel stud on the axle flange...489
6B02 Trumpets with sealed compartment...491
General...492
Parts list...492
Fig. 1...493
Fig. 2...494
A . Removing and refitting the trumpet assembly...495
B . Removing and refitting the com-partment and crownwheel assem-bly...497
C . Replacing compartment seals...498
D . Removing and refitting the planetary carrier...499
E . Reassembling and refitting the planetary carrier...499
F . Replacing the axle shaft bearings...500
G . Shimming the axle shaft bearings...502
H . Service tools...504
6B03 Trumpets with composite drive unit...505
General...507
Parts list...508
Fig. 1...509
Fig. 2...510
Fig. 3...510
A . Removing and refitting the trum-pet assembly...511
B . Removal and refitting the spacer and crownwheel assembly...515
C . Replacing the spacer seals...516
D . Replacing the cassette seal...517
E . Removing and dissassembling of the planetary carrier...518
F . Reassembling and refitting the planetary carrier...519
G . Shimming the planetary gear...520
H . Replacing the axle shaft bearings...521
I . Shimming the axle shaft bearings...522
J . Service tools...524
6B04 Trumpets with double reduction...527
General...529
Parts list...530
Fig. 2...531
Fig. 3...532
A . Removing and refitting the trumpet assembly...533
B . Removing and refitting brake plate, crownwheels, spacer and epicyclic reducer gears (Fig. 12)...537
C . Replacing the cassette seal...540
D . Disassembling and reassembling the planetary gears...541
E . Replacing the axle shaft bearings...542
F . Shimming the axle shaft bearings...543
G . Service tools...545
6C01 Handbrake unit and control link...547
General...548
Operation...548
Parts list...548
Fig. 1...549
Fig. 2...550
A . Disassembling and reassembling the handbrake unit...551
B . Disassembling, reassembling and adjusting the controls...553
C . Disassembling, reassembling the lever and replacing the cable...555
6D01 Differential with standard bevel gear and hydromechanical lock...557
General...558
Parts list...559
Fig. 1...559
Fig. 2...559
Fig. 3...560
A . Removing and refitting the left-hand differential lock carrier, disas-sembling and reassembling the lock assembly...561
B . Removing and refitting the right-hand differential lock carrier...564
C . Removing and refitting the differ-ential unit assembly...565
D . Removing and refitting the plan-etary gears and sun gears and dis-assembling and reassembling the crownwheel...567
E . Adjusting and checking the back-lash...569
F . Shimming the differential unit...571
G . Removing and refitting the drive pinion...574
H . Removing and refitting the drive pinion...577
I . Service tools...581
6D02 Differential with standard bevel gear and multidisc lock...583
General...584
Parts list...585
Fig. 1...585
Fig. 2...585
Fig. 3...586
A . Removing and refitting the car-riers...587
B . Removal and refitting the diffe-rential unit assembly...589
C . Removing and refitting the multi-disc lock...592
D . Removing and refitting the plane-tary gears and sun gears and disassemblying and reassembling the crownwheel...594
E . Adjusting and checking the back-lash...596
F . Shimming the differential unit...598
G . Removing and refitting the drive pinion...600
H . Adjusting and shimming the drive pinion...603
I . Service tools...606
6D03 Differential with hypoid bevel gear and multidisc lock...607
General...608
Parts list...609
Fig. 1...609
Fig. 2...609
Fig. 3...610
A . Removing and refitting the car-riers...611
B . Removing and refitting the diffe-rential unit assembly...613
C . Removing and refitting the multi-disc lock...616
D . Removing and refitting the plane-tary gears and sun gears and disassembling and reassembling the crownwheel...617
E . Adjusting and checking the multi-disc...619
F . Shimming the differential unit...621
G . Removing and refitting the drive pinion...623
H . Adjusting the position and shim-ming the drive pinion...627
I . Service tools...631
6E01 Brake pistons and seals...633
General...634
Parts list...634
Fig. 1...635
Fig. 2...635
Fig. 3...636
Fig. 4...636
Fig. 5...637
A . Disassembly...638
B . Reassembly...640
C . Service tools...643
6F01 Park lock...645
General...646
Parts list...647
Fig. 1...647
Fig. 2...648
A . Unlocking the system and posi-tioning the special bolt...649
B . Removing and refitting the sleeve...650
C . Disassembling the control...651
D . Reassembling the control...652
6G01 Lift cylinder supports...653
General...655
Parts list...656
Fig. 2...657
Fig. 3...658
A . Cylinder attaching points...659
Parts list...659
Fig. 4...659
B . Preliminary operations...660
C . Removing and refitting the shaft (7)...661
D . Disassembling and reassembling the supports (2) (16)...662
E . Final operations...662
F . Service tools...663
6H01 Creeper...665
General...666
Parts list...667
Fig. 2...667
Fig. 3...667
Fig. 4...668
A . Removing and refitting the unit...669
B . Disassembling, reassembling and adjusting the selection mechanism...671
C . Disassembling and reassembling the epicyclical reducer gear (Fig. 7)...675
D . Adjusting the control...676
6I01 Brackets and automatic hook...677
General...678
Fig. 1...679
Fig. 2...680
Fig. 3...680
A . Identifying the brackets, yokes, swinging drawbars and automatic hook (Fig. 1)...678
B . Adjusting the rods and automatic hook control...680
C . Operating principle of the Dromone retractable hook...682
6J01 Rear hitch mechanism...685
A . General...686
Parts list...686
Fig. 1...687
Fig. 2...687
Fig. 3...687
Fig. 4...687
Fig. 5...687
Fig. 6...687
B . Description of the hitch mecha-nism...686
C . Disassembling and reassembling a lift cylinder...689
7 . POWER TAKE-OFF...691
7A01 Description of the Power Take-off...693
A . General...694
B . Overall views...696
7B01 Driving pinions - Bearings - Layshaft...699
General...700
Parts list...700
Fig. 1...701
Fig. 2...702
A . Removing and refitting the driving pinion, bearings and layshaft...703
B . Shimming...705
7C01 Removable shaft...707
General...708
Part list...708
Fig. 1...709
Fig. 2...710
A . Disassembling and reassembling pinions 540 - 1000 rpm or 750 - 1000 rpm...711
B . Disassembling and reassembling the front bearing block (1)...711
C . Disassembling and reassembling the bearings...712
D . Removing and refitting the shaft and replacing the oil seal...713
E . Shimming (Fig. 3 - 4)...714
F . Service Tools...715
7D01 Shiftable PTO shaft...717
General...718
Parts list...718
Fig. 1...719
Fig. 2...720
A . Disassembling and reassembling 540 - 1000 rpm or 750 - 1000 rpm pinions, fork and bearing (24)...721
B . Removing, refitting and disassembling, reassembling the rear bearing block, oil seal and shaft bearings...722
C . Shimming (Fig. 4 ? 5)...723
D . Long shaft version...723
E . Adjusting the control...724
F . Service tools...725
7E01 1000 rpm power take-off shaft...727
General...728
Parts list...728
Fig. 1...729
Fig. 2...730
A . Disassembling and reassem-blying 1000 rpm pinion and bearing (24)...731
B . Removing, refitting and disassembling, reassembling the rear bearing block, oil seal and shaft bearings...732
C . Shimming (Figs. 4 - 5)...733
D . Long shaft version...733
E . Service tools...734
7F01 Clutch and brake...735
A . General...737
Parts list...738
Fig. 2...739
Fig. 3...739
B . Removing and refitting the clutch...741
C . Disassembling and reassembling the clutch...743
D . Service tools...745
8 . FRONT AXLE...747
8A01 Generality - Carraro front axle...749
A. General description...750
Parts list...750
Fig. 1...751
B. Safety instructions...762
8B01 Dana final drive units...765
General...766
Parts list...766
Fig. 1...767
Fig. 2...767
Fig. 3...768
A . Layout of main components...769
B . Removing and disassembling the planetary carrier, sun gear and crownwheel...771
C . Reassembling and refitting the planetary carrier, crownwheel and sun gear...773
D . Disassembling and reassembling the wheel hub...774
E . Replacing a wheel stud...776
F . Disassembling, reassembling and shimming the swivel housing...776
G . Removing and refitting the universal drive shaft...779
H . Service tools...781
8 B02 ZF final drive units...783
General...784
Parts list...784
Fig. 1...785
A . Removing and refitting the pla-netary carrier, sun gear, crownwheel and wheel hub...787
B . Disassembling and reassembling the planetary carrier...789
C . Replacing the lip seal and wheel hub bearings...790
D . Adjusting the rotational torque of the wheel hub...791
E . Shimming the planetary carrier...792
F . Disassembling and reassembling the swivel housing...793
G . Replacing the seal and transmis-sion bushes...796
H . Removing and refitting - disassembling and reassembling the universal drive shaft...797
I . Replacing a wheel stud...798
J . Service tools...799
8B03 Carraro final drive units...801
General...802
A. Steering cylinder group disassembly...802
B. Epicyclic reduction gear disassembly...803
C. Wheel hub group disassembly...804
D. Axle beam group disassembly...808
E. Axle beam group assembly...809
F. Wheel hub group assembly...810
G. Epicyclic reduction gear assembly...815
H . Toe-in adjustement...816
J. Steering angle adjustment...818
K. Service tools...819
8C01 Dana differential...823
General...824
Parts list...824
Fig. 1...825
Fig. 2...825
Fig. 3...826
A . Splitting front axle / frame...827
B . Removing swivel housings, wheel hub and drive shafts...827
C . Removing the differential housing assembly...827
D . Disassembling the differential...828
E . Removing the differential lock (Fig. 7)...829
F . Removing the crownwheel and drive pinion...829
G . Refitting the drive pinion and crownwheel...831
H . Reassembling the differential lock...834
I . Piston leak test...836
J . Refitting swivel housings, wheel hub and drive shafts...836
K . Refitting swivel housings, wheel hub and drive shafts...836
L . Assembling front axle / frame...836
M . Service tools...837
8C02 ZF differential...839
General...840
Parts list...840
Fig. 1...841
A . Splitting front axle / frame...843
B . Removing the swivel housings...843
C . Removing the axle nose...843
D . Removing and refitting - disas-sembling and reassembling the dif-ferential housing and crownwheel...844
E . Shimming the differential hou-sing and adjusting the backlash...849
F . Removing and refitting the drive pinion, adjusting the bevel gear dis-tance and shimming the bearings...851
G . Refitting the axle nose...857
H . Refitting the swivel housings...857
I . Assembling front axle / frame...857
J . Service tools...858
8 C03 Carraro differential...861
General...862
A. Splitting front axle / frame...862
B. Removing swivel housings, wheel hub and drive shafts...862
C. Disassembling the differential support group...863
D. Pinion group disassembly...866
E. Differential group disassembly...868
F. Pinion group assembly...870
G. Differential group assembly...874
H. Differential carrier group assembly...876
I. Service tools...882
8 D01 2 WD front axle...887
General...888
Parts list...888
Fig. 1...889
Fig. 2...890
A . Removing and refitting the steering arm ball joint...891
B . Removing and refitting the hub, axle spindle and extending arm...891
C . Removing and refitting the stee-ring ram...893
D . Removing and refitting the front axle...894
E . Adjusting the wheel alignment...896
F . Adjusting the wheel track...896
G . Service tools...897
8 E01 Steering column...899
General...900
Parts list...900
Fig. 1...901
Fig. 2...902
Operation...900
A . Removing and refitting the stee-ring column...903
B . Disassembling and reassembling the control lever assembly...903
C . Removing and refitting the not-ched lever and rack...904
D . Removing and refitting the lock-ing mechanism...904
E . Replacing the shafts and bea-rings...905
F . Replacing the guide bushes (26) (27) (30)...905
8 F01 Bearings and transmission shafts (Dana front axles)...907
General...908
Parts list...908
Fig. 1...909
Fig. 2...910
Fig. 3...911
A . Removing and refitting the bea-rings...912
B . Replacing bushes and seal...915
C . 2 WD version...916
8 F02 Bearings and transmission shafts (ZF front axles)...917
General...918
Parts list...920
Fig. 1...919
Fig. 2...920
Fig. 3...921
A . Disassembling and reassembling 4WD transmission shafts and uni-versal joint spiders...922
B . Removing and refitting the bea-rings...924
C . Replacing bushes and seal...926
8 F03 Bearings and transmission shafts (Carraro front axle)...929
General...930
Parts list (Fig.2) ...930
Fig. 1...931
Parts list (Figs. 3 - 4)...932
Fig. 2...932
A . Disassembling and reassembling the 4WD transmission shafts and the universal joint spiders...934
B . Removing and refitting the front bearing support and front axle...936
C . Replacing the friction rings and seal...942
8G01 4 WD clutch...945
General...947
Part list...948
Fig. 1...949
Fig. 2...950
A . Preliminary operations...951
B . Removing, refitting the clutch assembly and shaft...951
C . Disassembling, reassembling and shimming the clutch...953
D . Shimming the shaft...955
E . Final operations...955
8G02 Carraro suspension...957
A. Arms unit disassembly...958
B. Arms unit assembly...961
C. Service tools...970
8I01 Carraro troubleshooting...975
Generality...976
A. Troubleshooting...978
B. Axle problem and diagnosis...980
9 . HYDRAULICS...982
9 A01 Description of the 110 l/min circuit...984
A . General...986
B . Principle...987
C . Centre housing lubricating circuit...987
D . Layout of components in AG 150 - AG 250 Full Powershift and Heavy Duty gearboxes...989
Parts list...989
Fig. 2...990
Fig. 3...991
Parts list...994
Fig. 6...995
Fig. 7...996
Fig. 7A...997
E . Diagrams...1003
Parts list...1003
9A02 Description of the 150 l/min circuit...1012
A . General...1013
B . Principle...1014
C . Centre housing lubricating circuit...1015
D . Layout of components in AG 150 and AG 250 Full Powershift gear-boxes...1016
Parts list...1016
Fig. 4...1017
Fig. 5...1018
E . Diagram...1021
Parts list...1021
Fig. 8...1022
9 B01 Priority blocks with trailer braking...1024
General...1025
A . Identification of ports (Figs. 2 to 4)...1028
B . Operation of spool valves...1029
9 C01 Priority blocks without trailer braking...1032
General...1033
A . Identification of ports (Fig. 2 to 4)...1034
Parts list...1034
Fig. 2...1034
Fig. 3...1035
Fig. 4...1036
B . Operation (Fig. 5)...1037
9 D01 Auxiliary spool valves...1040
General...1041
Operation (Fig. 5 to 7)...1043
A . Different types of spool valves...1046
Fig. 5...1046
Fig. 6-7...1047
Fig. 8...1048
B . Diagram...1049
C . Removing and refitting the spool valves...1050
9 D02 Bosch auxiliary spool valves...1054
General...1055
Operation (Fig. 2 - 3)...1057
A . Layout of components, designation of ports and parts...1057
B . Diagram...1060
C . Removing and refitting the unit - Splitting the spool valves...1061
D . Assembly procedure...1066
E . Assembling and adjusting the control cables (Fig. 19)...1067
9 D03 Electro-hydraulic spool valves...1070
General...1071
Parts list (Fig. 1)...1071
Fig. 1...1072
A . Layout of components and identification of channels and ports...1075
B . Diagram...1078
C . Spool valve assembly...1079
D . Assembly procedure...1082
E . Location of levers on the console and fitting, adjustment of a control cable...1083
9 E01 Lift control spool valve...1086
General...1087
A . Diagrams...1089
B . Removing and refitting the spool valve...1091
C . Neutral position...1093
D . Raise position...1094
E . Lower position...1095
9 F01 Hydrostatic steering...1096
General...1097
Parts list...1097
Fig. 1...1098
A . The principle of Load Sensing...1097
B . Layout of channels and ports (Fig. 3)...1100
C .Diagram...1102
D . Neutral position (engine running) (Fig. 5)...1103
E . Steering lock (engine running) (Fig. 6)...1105
F . Manual steering (engine stopped) (Fig. 7)...1107
G . Disassembling and reassembling the Orbitrol steering unit (Fig. 1)...1109
H . Removing, refitting and disassembling, reassembling the Dana and Carraro steering rams...1111
9 F02 Hydrostatic steering for 4WD front axles - APL5052...1116
General...1118
A . Principle of "Load Sensing"...1119
Parts list...1119
Fig. 1...1120
Fig. 2...1121
B . Neutral position (engine running) (Fig. 3)...1122
C . Wheel steering lock position (engine running) (Fig. 4)...1124
D . Manual steering (engine stopped) (Fig. 5)...1126
E . Disassembling and reassembling the distribution valve (Orbitrol) (Fig. 1 - 2)...1128
F . Removing and refitting ? Disassembling and reassembling a steering ram...1131
G . Layout of channels and ports...1133
9 G01 Right-hand cover 110 l/min Load Sensing...1134
General...1135
Parts list...1137
Fig. 3...1138
3A...1139
Fig. 4...1140
Fig. 5...1141
Fig. 5A...1142
A . Removing and refitting the cover...1146
B . Description and operation of the variable displacement pump...1150
C . Removing and refitting the pump...1153
D . Adjusting the engine speed sen-sor (Heavy Duty version)...1154
E . Removing and refitting ? Disassembly and reassembling the pump bearing...1155
9 G02 150 l/min right-hand cover...1160
General...1162
Parts list...1163
Fig. 9...1170
Fig. 10...1170
A . Removing and refitting the cover...1172
B . Description and operation of the variable displacement pump...1175
C . Removing and refitting the pump...1179
D . Disassembling, reassembling and shimming of the idler pinion...1181
E . Removing and refitting - Disassembling and reassembling the pump bearing block...1184
9 H01 Left-hand cover 110 l/min and 150 l/min Load Sensing...1188
General...1189
Parts list...1191
Fig. 3...1192
Fig. 4...1193
A . Removing and refitting the cover...1195
B . Removing and refitting the boos-ter pump...1197
C . Replacing the pump seals (Fig. 10)...1198
9 I01 Brake and clutch master cylinders circuit and bleeding...1200
General...1202
A . Servicing the master cylinders...1208
B . Brake master cylinders...1208
C . Master cylinder and servobrake assembly...1209
D . Adjusting the servobrake rod (Fig. 10)...1211
E . Adjusting the brake pedals (Fig. 11)...1211
F . Clutch master cylinder...1212
G . Adjusting the clutch pedal (Heavy Duty transmission version)...1213
H . Bleeding the main brake circuit...1214
I . Bleeding the trailer braking circuit...1216
J . Bleeding the clutch control...1217
9 I02 Brake and clutch master cylinders circuit and bleeding...1218
General...1219
A . Servicing the master cylinders and FTE valve...1223
B . Brake master cylinders...1223
Parts list (Fig. 8)...1223
Fig. 8...1224
C. FTE valve (Fig. 9)...1225
D . Adjusting the brake pedals (Fig. 12)...1227
E . Bleeding the main brake circuit...1228
9 J01 Clutch control valve...1231
General...1232
A . Operating phases of the clutch valve...1234
B . Disassembling and reassembling the valve (Fig. 10)...1239
C . Service tools...1241
9 K01 Power Shuttle control unit...1243
General...1244
A . Designation of pipes and components (Fig. 1)...1244
B . Removing and refitting the control unit (1) (Fig.1)...1246
C . Location of ports and identifying proportional solenoid valves...1248
9K02 Hydraulic control unit - Suspended front axle...1249
A. Technical Features...1250
Parts list (Fig. 1 - 2)...1250
Fig. 2...1251
B . Description of the hydraulic circuit...1252
C . Disassembly / Assembly of the hydraulic control unit...1255
D . Disassembly / Assembly of the steering cylinder...1257
9 L01 Dynashift control...1261
General...1262
A . Explanation of ratios...1266
B . Checking piston pressures...1268
9M01 Oil decontamination...1269
A . General...1270
B . Decontamination procedure...1271
C . Diagrams...1275
Parts list...1275
Fig. 3...1275
Parts list...1277
Fig. 4...1277
9 N01 Hydraulic tests...1279
A . General...1280
B . Testing the high pressure 110 l/ min circuit...1281
Fig. 10...1285
Fig. 11...1285
Fig. 13...1286
C . Testing the low pressure 110 l/min circuit...1287
D . Testing the high pressure 150 l/ min circuit...1294
E . Testing the low pressure 150 l/min circuit...1302
F . Low pressure hydraulic functions of the Full Powershift gearbox...1303
10 . ELECTRICAL EQUIPMENT...1313
10 A01 Electrical equipment...1315
A . General...1317
B . Dynashift - Cab accessories and engine equipment (Fig. 1 to 7)...1322
Fig. 1...1323
Parts list...1322
Identification of connectors...1322
Fig. 2...1325
Parts list...1324
Identification of connectors...1324
Fig. 3...1327
Parts list...1326
Identification of connectors...1326
Fig. 4...1329
Parts list...1328
Identification of connectors...1328
Fig. 5...1331
Parts list...1330
Identification of connectors...1330
Fig. 6...1333
Parts list...1332
Identification of connectors...1332
Fig. 7...1335
Parts list...1334
Identification of connectors...1334
C . Full Powershift ? Engine equipment (Fig. 8)...1336
Fig. 8...1337
Parts list...1336
equip-ment Colour codes Identification of connectors...1336
D . Full Powershift - Cab equipment (Fig. 9)...1338
Fig. 9...1339
Parts list...1338
Identification of connectors...1338
E . Lighting layout (except North America) (Fig. 10)...1340
Fig. 10...1341
Parts list...1340
Identification of connectors...1340
F . Direction indicator lamps (except North America) (Fig. 11)...1342
Fig. 11...1343
Parts list...1342
Identification of connectors...1342
G . Work lights and flashing beacons (except North America) (Fig. 12)...1344
Fig. 12...1345
Parts list...1344
Identification of connectors...1344
H . Dynashift - Full lighting system (North America) (Fig. 13) ...1346
Fig. 13...1347
Parts list...1346
Identification of connectors...1346
I . Full lighting system - Full Powershift (North America) (Fig. 14)...1348
Fig. 14...1349
Parts list...1348
Identification of connectors...1348
J . Dynashift ? Fuses (except North America) (Fig. 15)...1350
K . Full Powershift ? Fuses (except North America) (Fig. 16)...1351
L . Dynashift ? Fuses (North America) (Fig. 17)...1352
M . Full Powershift ? Fuses (North America) (Fig. 18)...1353
10 A02 Deutsch electrical equipment...1355
A . General...1357
B . Engine and cab equipment Autotronic 3 (Fig. 2 to 10)...1366
Parts list...1366
Fig. 2...1367
Parts list...1368
Fig. 3...1369
Parts list...1370
Fig. 4...1371
Parts list...1372
Fig. 5...1373
Parts list...1374
Fig. 6...1375
Parts list...1376
Fig. 7...1377
Parts list...1378
Fig. 8...1379
Parts list...1380
Fig. 9...1381
Parts list...1382
Fig. 10...1383
Parts list...1384
Fig. 11...1385
C . Engine and cab equipment...1384
Parts list...1386
Fig. 12...1387
Parts list...1388
Fig. 13...1389
Parts list...1390
Fig. 14...1391
Parts list...1392
Fig. 15...1393
Parts list...1394
Fig. 16...1395
Parts list...1396
Fig. 17...1397
Parts list...1398
Fig. 18...1399
Parts list...1400
Fig. 19...1401
Parts list...1402
Fig. 20...1403
D . Lighting equipment - Europe...1404
Parts list...1404
Fig. 21...1405
Parts list...1406
Fig. 22...1407
Parts list...1408
Fig. 23...1409
E . Lighting equipment - North...1410
Parts list...1410
Fig. 24...1411
Parts list...1412
Fig. 25...1413
Parts list...1414
Fig. 26...1415
F . Location of fuses - Dynashift (Europe) (Fig. 27)...1416
G . Location of fuses - Dynashift (North America) (Fig. 28)...1417
H . Location of fuses - Powershift (Europe) (Fig. 29)...1418
I . Location of fuses - Powershift (North America) (Fig. 30)...1419
11 . ELECTRONICS...1421
11 A01 Description...1423
A . General...1425
B . Flowchart of Autotronic 2 modes...1426
C . Flowchart of functions...1427
D . Diagrams...1432
11 A02 Checks without a tester...1435
A . Test procedure...1436
B . Analysis of possible faults...1440
11 A03 Description...1443
A . General...1444
B . Autotronic 3 status flowcharts...1444
C . Automatic responses of the Autotronic 3...1447
D . Operating principle of the Auto-matic Dynashift...1456
E . Calibration of throttle pedal potentiometer...1460
F . Power Shuttle principles...1461
G . Calibration of the Power Shuttle...1463
H . Power Shuttle error codes...1467
I . Disassembling, reassembling the Power Shuttle lever ...1471
J . Operation of the manoeuvring pedal...1473
K . Electrical diagram...1474
Parts list...1474
Fig. 8...1475
Parts list...1476
Fig. 9...1477
Parts list...1478
Fig. 10...1479
Parts list...1480
Fig. 11...1481
Parts list...1482
Fig. 12...1483
Parts list...1484
Fig. 13...1485
Parts list...1486
Fig. 14...1487
Parts list...1488
Fig. 15...1489
Parts list...1490
Fig. 16...1491
Parts list...1492
Fig. 17...1493
Parts list...1494
Fig. 18...1495
11 B01 Description and operation...1497
A . Description...1499
B . DCC dashboard...1501
C . Status of DCC switches...1510
D . Characteristics of DCC sensor input signals...1514
E . Transmission Controller (TC)...1517
F . Operation of solenoid valves and test procedures...1531
G . Input signals of TC sensors / swit-ches...1532
H . Operation of the manoeuvring pedal...1537
I . Operation of the armrest gear selector switch assembly...1538
J .Steering wheel gear shift lever...1539
K . Use of the Backup Harness...1541
L . Location of sensors...1542
11B02 Calibration...1547
A. General...1548
B . Level 0...1549
C . Level 1...1551
D . Level 2...1555
E . Level 3...1563
F . Adjust the shifting...1564
G . Diagnostic modes...1565
11B03 Error codes...1575
A . General...1576
B . List of TC and DCC error codes...1576
C . TC and DCC error codes analysis...1581
11 C01 Description of electronic linkage...1597
A . Description...1598
B . Console...1602
C . Diagram...1605
11 C02 Linkage auto-diagnostics...1613
A . Operation...1614
11 D01 Datatronic...1617
A . General...1618
B . Activating the basic data...1623
C . The "Working" key...1625
D . The "Implement Width" key...1626
F .The "Wheel Slip Control" key...1627
G . "Memory" keys...1628
H . Comparative mode...1632
I . Flowmeter fitting...1634
J . Diagram...1640
11 D02 Front Dual Control...1643
A . General...1644
B . Block diagram...1645
C . Description of the Adjustment screen EXT.TEMP...1648
D . Adjustments...1649
E . Use...1650
F . Error codes...1651
G . Assembly of the additional lever...1651
11 D03 Dual Control for Semi-mounted implement...1653
A . General...1654
B . Block diagram...1655
C . Description of the Adjustment screen EXT.TEMP...1658
D . Adjustments...1659
E . Use...1661
F . Error codes...1663
G . Assembly of the additional lever...1663
11 D04 TIC for semi-mounted implements...1665
A . General...1667
B . Block Diagram...1668
C . Description of the screen...1672
D . Settings...1673
E . Using...1676
F . Error codes...1676
G . Lever and electro-hydraulic spool valve assembly...1677
11 F01 Wintest ? General...1687
A . General - Description...1689
B . Installing Wintest on the PC?s hard drive...1690
C . Updating Wintest software...1691
D. Connections...1692
E . Accessing the Wintest main menu...1695
F . Wintest version...1699
11 F02 Autotronic 2 with Wintest...1701
A. Using Autotronic 2 with Wintest...1702
B. Programming and Setting parameters...1703
C. Setting parameters...1719
D . Tests and diagnostics...1731
11 F03 Autotronic 3 with Wintest...1747
A . General...1748
B . Using Autotronic 3 with Wintest ...1749
C . Programming...1750
D . Setting parameters...1753
E . Tests and diagnostics...1761
F . Manual calibration of the power shuttle...1778
G . List of error codes...1783
11 F04 TC and DCC with Wintest...1787
A . General...1788
B . Programming...1789
C . Setting parameters...1794
D . Adjusting the restarting speed...1802
E . Tests and diagnostics...1803
E . List of error codes...1822
11 F05 Electronic linkage with Wintest...1825
A. Using the Electronic linkage control with Wintest...1826
B. Tests and diagnostics...1827
C. Error codes...1831
D . Adjusting the position sensor...1834
E . Setting the parameters...1836
F . Dual Control/TIC...1843
11 F06 Datatronic 2 with Wintest...1847
A . Using the Datatronic 2 with Wintest...1848
B . Tests and diagnostics...1849
11 F07 Joystick with Wintest...1859
A . Using the Joystick...1860
B . Tests and diagnostics...1861
C . Joystick calibration...1864
D . Valve parameters...1866
11 F08 Autotronic 3 to Kit Autotronic...1871
A . Programming Autotronic 3...1872
B . Accessing the Wintest main menu...1876
C . Parameters...1877
11 F09 Kit Autotronic to Autotronic 3...1883
A . General...1884
B . Reprogramming Autotronic 3...1885
11G01 Carraro suspension...1889
General...1890
A. Suspension control system...1890
B . Disassembling and assembling of the sensor...1891
C. Electronic control unit (Fig.14)...1895
D. Service tools...1898
11H01 Description...1899
A . General...1901
B . Description of SMS components...1902
C . Operation and troubleshooting without a tester...1908
D . SMS error codes...1910
E . Disassembly, reassembly of the Joystick...1915
F . Replacement of ON / OFF or Memory switches...1915
G . Electrical diagram...1916
12 . CAB AND EQUIPMENT...1919
13 . ACCESSORIES...1920
14 . SERVICE TOOLS...1921
14 A01 Service tools...1923
Splitting the tractor...1924
Perkins engines...1925
Valmet engines...1930
Clutch...1941
Gearbox...1942
Rear axle...1945
Power take off...1947
Front axle...1948
Hydraulics...1954
Electricity - Electronics...1956
Cab and equipment...1963
