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)

Catalog: 
Price: US$ 59.00

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

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