agroplus 60-70-80 repair manual

8/19/2019 AGROPLUS 60-70-80 Repair manual

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introduction

This publication is intended for the trained technician who must operate on our tractors.

It contains all general information relating to our tractor range, and in particular it highlights the inspection, overhaulingand adjustment procedures as well as the main instructions for dismantling and reassembling operations.

The workshop manual is a natural summary for the mechanic who has attended the vocational training and specializa-tion courses, which are held every year at our Service School, to permit him to perform a precise and qualified work ontractor.

Its contents are therefore an exhaustive reference book for the experienced mechanic who desires to refresh his me-mory on the sequence of the operations to be done. It is then good practice for every authorized dealer mechanic tohave at his disposal this publication, so that it may be consulted quickly when necessary.

We wish to thank in advance for the cooperation all thos people, who will let us have their suggestions in order to makethis publication more complete.

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WORKSHOP MANUAL


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List of contents

Tractor configurations AGROPLUS 60 - 70 - 80 ......................................................................................................6Dimensions and weights...........................................................................................................................................7Prescribed lubricants and capacities ........................................................................................................................8Conversion tables.....................................................................................................................................................9Parts .......................................................................................................................................................................10

1 - ENGINE

................................................................................................................................................................................11

2 - CLUTCHGearshift clutch.......................................................................................................................................................12General specifications ............................................................................................................................................12Cecking clutch ........................................................................................................................................................16Adjusting clutch control pedal.................................................................................................................................16Bleeding air from the hydraulic circuit.....................................................................................................................16Stripping the slave cylinder.....................................................................................................................................17Stripping the master cylinder ..................................................................................................................................18Diagnosing malfunctions ........................................................................................................................................20POWERSHIFT unit, general specifications ............................................................................................................21POWERSHIFT unit detach from the gear box ........................................................................................................24Assembly of POWERSHIFT unit ...........................................................................................................................35Re-assembly of the POWERSHIFT unit. ...............................................................................................................37Fitting the oil manifolds of the POWERSHIFT unit ................................................................................................39Diagnosing malfunctions ........................................................................................................................................44

3 - TRANSMISSIONGeneral specifications ............................................................................................................................................45Technical specifications..........................................................................................................................................45Speed change configurations .................................................................................................................................47Section through transmission .................................................................................................................................51Section through transmission with POWERSHIFT unit ..........................................................................................52

Separating the front gearbox from the engine ........................................................................................................61Dismantling the gearbox.........................................................................................................................................62Removal of the gearbox input and P.T.O. shafts....................................................................................................62Separating the POWERSHIFT unit from the gearbox ...........................................................................................62Removal of the gear train positioned in the front gearbox......................................................................................63Disassembly of the inversor control rods and forks................................................................................................64Dismantling of the gearchange rod and fork assembly ..........................................................................................65Dismantling of the gearchange selector rods and forks assembly .........................................................................66Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive ..........................67Removal of the range gear shaft ........................................................................................................................... 67Examining parts removed.......................................................................................................................................68Adjusting play of the gearbox shafts by means of the thrust plates on the mini/inversorshaft and the secondary shaft ...............................................................................................................................69Warnigns related to assembly of the gears of the P.T.O. unit, the range reduction unit and synchronisedP.T.O. shaft ............................................................................................................................................................73

Assembly of the P.T.O...........................................................................................................................................73Installation of the range reduction unit, the gear for the front-wheel drive shaftand the parking brake discs...................................................................................................................................73Points where sealant is to be used.........................................................................................................................75Tightening torques..................................................................................................................................................78Bevel drive adjustment ...........................................................................................................................................81Servicing operations ...............................................................................................................................................82Rear power take-off ................................................................................................................................................83P.T.O. clutch...........................................................................................................................................................88Technical specifications..........................................................................................................................................89Correct positions of P.T.O. sensors and cables .....................................................................................................89Clutch inspection ....................................................................................................................................................91Checking clutch hydraulic pressures ......................................................................................................................92Checking the end-play of the front shaft of the P.T.O. clutch.................................................................................93Renewal of the rear P.T.O. clutch ..........................................................................................................................94Main operations for removal of the rear P.T.O. unit ...............................................................................................95Diagnosing malfunctions ......................................................................................................................................100

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4 - AXLESRear axle ..............................................................................................................................................................101Installing the rear half-shafts ...............................................................................................................................102Removal and disassembly of the epicyclic reduction unit.........................................................................................104Fitting lateral stub axles of the wheel ...................................................................................................................1052WD extendible axle.............................................................................................................................................106Removing the axle from the front support ............................................................................................................108Centre steering lever ............................................................................................................................................111Wheel hub ............................................................................................................................................................112End float adjustment.............................................................................................................................................114

Front-wheel drive..................................................................................................................................................115Specifications .......................................................................................................................................................115Epicyclic reduction unit .........................................................................................................................................119Side hubs..............................................................................................................................................................121Tightening torques................................................................................................................................................122Adjusting bevel gears ...........................................................................................................................................124Adjustment of the internal control of the mechanical differential lock...................................................................125Installing the differential assembly into the drive axle ..........................................................................................125Diagnosing malfunctions ......................................................................................................................................126

5 - VEHICLEBrakes - General information................................................................................................................................127Hydraulic pump.....................................................................................................................................................128

Assembly of brake master cylinder ......................................................................................................................130Checking the front brake disks on 2WD and 4WD front axles and the rear brake disks......................................131Adjusting service brake pedals.............................................................................................................................131Correct installation of inspection cover for parking brake discs............................................................................132Checking parking brake pads ...............................................................................................................................134Bleeding air from the brake hydraulic system.......................................................................................................135“Separate Brakes” valve .......................................................................................................................................136Diagnosing malfunctions ......................................................................................................................................140Hydraulic lift with “load sensing” ...........................................................................................................................141Installing the lift and front cover plate of the gearbox ...........................................................................................142Lift mechanism .....................................................................................................................................................142Checking the safety valves...................................................................................................................................142Checking the protrusion of the non-return valve...................................................................................................143Adjusting the lift ....................................................................................................................................................145Lift hydraulic circuit ...............................................................................................................................................147

Sensing arm assemblyMontaggio dell'organo sensibile .......................................................................................154Power-lift distributor valve spring setting specifications .......................................................................................155Electronic lift .........................................................................................................................................................156Control panel ........................................................................................................................................................157Control level or depth control knob.......................................................................................................................157Mix position/draft control.......................................................................................................................................157Lowering speed control knob................................................................................................................................158Maximum lift height control knob..........................................................................................................................158Up/Down control switch........................................................................................................................................158Up control .............................................................................................................................................................158Control/Float mode ...............................................................................................................................................158Lift status indicator light........................................................................................................................................158Remote pushbuttons for lift operation from ground..............................................................................................159Lift operation.........................................................................................................................................................160List of electronic lift tests ......................................................................................................................................164

Precautions for electronic equipment ...................................................................................................................173Checking the electronics system..........................................................................................................................173Checking mechanical components.......................................................................................................................173Front hydraulic liftSollevatore idraulico anteriore..................................................................................................174Hydraulic accumulator and antishock valve for front lift .......................................................................................176Front power take-off - General information...........................................................................................................177Section of the P.T.O.............................................................................................................................................178Fitting the "RING-FEEDER" rings.........................................................................................................................182Checking the clutch..............................................................................................................................................183Diagnosing malfuntions ........................................................................................................................................184Spring specifications.............................................................................................................................................184

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6 - CONTROLSHydrostatic steering..............................................................................................................................................185Inspections and checks ........................................................................................................................................186Steering pump ......................................................................................................................................................186Directional control valve .......................................................................................................................................186Check the setting of the pressure relief valve.......................................................................................................186Bleeding the hydraulic circuit ................................................................................................................................186Assembly of orbital pump unit ..............................................................................................................................186Teering wheel shaft and steering cylinders .........................................................................................................187Instructions for the hydrostatic steering distributor assembly...............................................................................189

Diagnosing malfuntions ........................................................................................................................................192Mechanical controls ..............................................................................................................................................196Electro-hydraulic controls .....................................................................................................................................197Front P.T.O. clutch engagement control...............................................................................................................202Rear P.T.O. clutch engagement control ...............................................................................................................202Differential lock engagement control ....................................................................................................................202Front-wheel drive engagement control .................................................................................................................202Rear P.T.O. engagement control..........................................................................................................................202Gearbox ................................................................................................................................................................202Front and rear lift ..................................................................................................................................................202Hydraulic circuit diagram ......................................................................................................................................202Solenoid valve - Specifications.............................................................................................................................207Adjustment of front and rear differential lock control ............................................................................................214

7 - BODYWORKPlatform ................................................................................................................................................................215Cab - General information ....................................................................................................................................216Cab air filter ..........................................................................................................................................................218Screen wash.........................................................................................................................................................218Screen wipers (front and rear) ..............................................................................................................................218Removing the driving platform complete with cab ................................................................................................219Breakage of the top hood release cable...............................................................................................................220High visibility cab roof...........................................................................................................................................222

8 - SYSTEMSVentilation.............................................................................................................................................................223Heating System ....................................................................................................................................................223Air conditioning unit for cabs ................................................................................................................................227Operation and maintenance of the air-conditioning system .................................................................................228Water dripping from the points at which condensate drain lines are connected to the conditioning unit ............229Checking system ..................................................................................................................................................231System safety elements .......................................................................................................................................231Temperature regulation ........................................................................................................................................231Charging the system.............................................................................................................................................232Filling the metering unit ........................................................................................................................................232

Refilling the system with oil ..................................................................................................................................232Verifying operation of the system after recharging...............................................................................................234Directions for tightening air conditioning system pipeline fittings .........................................................................234Diagnosing malfuntions ........................................................................................................................................241Hydraulic system ..................................................................................................................................................242Oil filters................................................................................................................................................................243Hydraulic pumps...................................................................................................................................................243Checking the relief valves of the hydraulic lift system ..........................................................................................243Stripping the hydraulic pump ................................................................................................................................244Auxiliary hydraulic spool valves............................................................................................................................247Checking the pressure relief valve setting ............................................................................................................250Checking the operating pressure..........................................................................................................................250Conversion of auxiliary spool valves from double acting to single acting operation.............................................250Checking the surface of the valve spools .............................................................................................................250Trailer hydraulic braking system...........................................................................................................................251

Use of the tractor with CUNA 341/01 hydraulic trailer braking .............................................................................253Installing the hydraulic braking valve for trailers equipped with “safety brake”( ITALIAN version) ................................................................................................................................................258Electrical system AGROPLUS 60 (up serial number1017) - 70 (up serial number 2773) - 80.............................261Electrical system AGROPLUS 60 (under serial number 1016) - 70 (under serial number 2772) ........................445

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General safety directions......................................................................................................................................446Jump start utilizing another battery.......................................................................................................................447Recharge system..................................................................................................................................................449Heating system.....................................................................................................................................................450Starting system.....................................................................................................................................................450Ignition key ...........................................................................................................................................................452Ventilation control .................................................................................................................................................452Push button control...............................................................................................................................................452Beacon push button..............................................................................................................................................454Work ligths............................................................................................................................................................454

2-Speed windscreen wiper switch........................................................................................................................454Relay ....................................................................................................................................................................455Electronic flasher unit ...........................................................................................................................................455Switch controlling..................................................................................................................................................456Switch controlling: differential lock - P.T.O. clutch - 4RM - 540 1000 rpm/min P.T.O. speed selector -Economy P.T.O. - Live P.t.o. - electric starter system.........................................................................................456Switch for emergency brake .................................................................................................................................456Fuse box...............................................................................................................................................................457Instrument panel with digital display.....................................................................................................................458Operation of the broken belts alarm control unit...................................................................................................460Engine stop operation with a type 2MH engine control unit .................................................................................462Electrical wiring.....................................................................................................................................................465

9 - APPENDIX

Power lift tester version 1.24a ...................................................................................................................................I

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TRACTOR CONFIGURATIONS:

CAB

- ventilation

- ventilation + heating

- ventilation + heating + air conditioning

GEARBOX

Fully synchronised:

20 Forward + 10 Reverse: 5 speeds x 2 ranges (Hair-Tortoise)

+ SYNCHROSPLIT (H/fast-L/slow-R/rearward)

30 Forward + 15 Reverse: 5 speeds x 3 ranges (Hair-Tortoise-Snail)

+ SYNCHROSPLIT (H/fast-L/slow-R/rearward)

45 Forward + 45 Reverse: 5 speeds x 3 ranges (Hair-Tortoise-Snail)

+ shuttle + version POWERSHIFT - -

CONTROLS

- rear P.T.O. clutch with electro-hydraulic control

- 4WD with mechanical control or optional electro-hydraulic control

- electronic engine throttle

MECHANICALLY OPERATED REAR POWER-LIFT

- with supplementary rams

- without supplementary rams

MAIN EQUIPMENT

- front P.T.O.

- front lift

- hydraulic pump capacities increased by 27 l/min (for hydrostatic steering, electro-hydraulic control

unit and gearbox lubrication) and by 47 l/min (for trailer braking, auxiliary control valves and lift).

- hydraulic trailer braking

- 4-way or 6-way control valves with “Flow Divider”

- etc.

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AGROPLUS 60 - 70 - 80 2RM WITH PLATFORM

2RM WITH CAB

4RM WITH PLATFORM

4RM WITH CAB


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DIMENSIONS AND WEIGHTS

AGROPLUS 60 AGROPLUS 70 -80

2 WD 4 WD 2 WD 4 WD

Length max:- without linkage (A) mm 3800 3835 3930 3985- with front and rear linkage (A) mm - 4350 - 4480

Width min./max. (B) mm 1920 -2320 1920-2320 1920-2320 1920-2320

Height:- al telai di sicurezza (C) mm 2420 2420 1490- at cab (standard) (C) mm 2430 2430 1700- at cab (with air conditioning) (D) mm 2595 2595 2360

Ground clearance (E) mm 345 345 365 365

Wheel base (F) mm 2162 2112 2292 2242

Front trackbase (G) mm 1400 1440 1400 1440min./max. 1300-1600 1340-1740 1300-1600 1340-1740

Rear trackbase (H) mm 1500 1500 1500 1500min./max. 1400-1900 1400-1900 1400-1900 1400-1900

Min. turning radius

without brakes (mm) 3500 4050 3700 4300Operating weight(without front lift)- with plataform kg 2355 2705 2555 2905- with cab kg 2550 2900 2750 3100

Max. permissible load- front kg 240 240 240 240- rear kg 200 200 200 200- block kg - 250 - 250

Tyres- front 7.50-16 12.4R 20 7.50-16 11.2R 24- rear 14.9R30 14.9R30 16.9R30 16.9R30

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PRESCRIBED LUBRICANTS AND FUELS

8

P R E S

C R I B E D

L U B R I C A N T S

A N D

F U E L S

A G R O P L U S

6 0 / 7 0 / 8 0

P a r

t t o

b e s u p p

l i e d

L i t

r e s

( U S

g a

l )

P r o

d u c t

S p e c

i f i c

a t i o n s

S D F G

c h

a n g e

h o u r s

E n g

i n e

A G R O P L U S

6 0

9 . 5

* *

( 2 . 5

)

E n g

i n e

A G R O P L U S 7 0 / 8 0

1 1 * *

( 2 . 9

)

A K R O S T U R B

O

1 5 W 4 0

S a e

1 5 w

4 0

A C E A

E 3

- 9 6

A P I

C F

S D F G

O M

- 1 9 9 1

M I L

- L - 2

1 0 4 E

l e v e

l

M B 2 2 8

. 3 l e v e

l

5 0 0 *

G e a r b o

x a

n d

r e a r

a x

l e

4 1

( 1 0

. 8 )

A K R O S M U L

T I

S a e

1 0 w

3 0

S a e

2 0 w

3 0

U T T O

A P I

G L 4

S D F G

O T

- 1 8 9 1

1 2 0 0

C e n

t r a l a x l e

6 ( 6

. 3 )

S i d e

r e d u c

t i o n s

1 . 5

x 2

( 1 . 6

x 2 )

F r o n

t P T O

2

. 5 ( 2

. 6 )

A K R O S M U L

T I

S a e

1 0 w

3 0

S a e

2 0 w

3 0

U T T O

A P I

G L 4

S D F G

O T

- 1 8 9 1

1 2 0 0

B r a

k e s

a n

d c

l u t c h c o n

t r o

l

M A X

A K R O S M A T I C

A T F D E X R O N

I I D

S D F G

O F

- 1 6 9 1

L u

b r i f i c a

t i o n

p o

i n t s

A K R O S G R E A S

E T 2

N L G I

2 -

L I T I O

S D F G

G R

- 1 2 0 2 L

5 0

( * ) 1 °

r e p

l a c e a

f t e r

5 0

h o u r s

( * * )

W i t h

f i l t e r

+ 1

. 5 l i t

r e

s


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CONVERSION TABLE FROM

FROM TO multiply by:

inch cm 2.540

cm inch 0.394

foot m 0.305

m foot 3.281yard m 0.914

m yard 1.094

Eng. miles km 1.609

km Eng. miles 0.622

Sq.in. cm2 6.452

cm2 Sq.ft. 0.155

Sq.ft. m2 0.093

m2 Sq.ft. 10.77

Sq.yard m2 0.835

m2 Sq.yard 1.197

Cu.in. cm3 16.39

cm3 Cu.in. 0.061Cu.ft. Liter 28.36

Liter Cu.ft. 0.035

Cu.yard m3 0.763

m3 Cu.yard 1.311

Imp.gall. Liter 4.547

Liter Imp.gall. 0.220

US gall. Liter 3.785

Liter US gall. 0.264

pint Liter 0.568

Liter pint 1.762

quart Liter 1.137

Liter quart 0.880

oz. kg 0.028

kg oz. 35.25

lb. kg 0.454

kg lb. 2.203

lb.ft. kgm 0.139

kgm lb.ft. 7.233

lb/in. kg/m 17.87

kg/m lb/in. 0.056

lb./sq.in. kg/cm2 0.070

kg/cm2 lb/sq.in. 14.22

lb./Imp.gall. kg/l 0.100

kg/l lb./Imp.gall. 10.00

lb./US gall. kg/l 0.120kg/l lb./US gall. 8.333

lb./cu.ft. kg/m3 16.21

kg/m3 lb./cu.ft. 0.062

cu.ft./lb. m3/kg 0.062

m3/kg cu.ft./lb. 16.21

Nm kgm 0.102

kgm Nm 9.81

kW PS 1.36

PS kW 0.736

bar kg/cm2 1.014

kg/cm2 bar 0.981

dm3 l 1l dm3 1

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HOW TO ORDER SPARE PARTS

To ensure perfect tractor efficiency thus avoiding serious drawbacks, and to optimize your investment and the operatio-nal expenses, the use of “ORIGINAL SPARE PARTS” is recommended.Spare parts orders must specify the following:

Tractor serial number and engine serial number (if the engine is concerned).Spare part name and reference code.

ENGINE TYPE AND TRACTOR FRAME TYPESERIAL NUMBER AND SERIAL NUMBER

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AGROPLUS 60 and AGROPLUS 70 are powered by F3L 913 / F4L 913engines. The workshop manual for these engines cuold be ordered to thefollowing addresse:

DEUTZ-FAHR DEUTSCHLANDGmbH

Abt. LT-ZE

Deutz-Fahr-Straße 1

89415 LauingenTelefax-Nr.: 09072/997-360 or -353

Using the following code:

0297 7293

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ENGINE


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Earshift clutch

General specifications

The clutch, a single stage type, comprises a friction disc, a pressure plate and a diaphragm spring.The hydrostatic control is self-adjusting: a master cylinder operated by the pedal directs oil to the slave cylinder moun-ted to the left hand side of the intermediate housing, which in turn operates the clutch release lever.

Technical specifications Agroplus Agroplus Agroplus60 70-80 60-70-80

(USA) 6 blades

Type of clutch single disc dry single disc dry single disc dryorganic facing organic facing cerametallik facing

Type of operation hydrostatic with automatic take-up of free travel

Disc p/n 009.6913.3 009.6924.3/20 009.9770.3

Disc diameter mm 279,4 310 310

Minimum permissible thickness of disc mm 6 6 9,7

Thickness of friction disc mm 8 5 0 30 3, ,

,

-

+ 8 5 0 30 3, ,

,

-

+ 10-

+

0 2

0 2

.

.

Type of facing material on friction disc TEXTAR T385 TEXTAR T385 UA 330 DX

Type of master cylinder Benditalia 3/4"

Type of oil AKROS MATIC

Fig. 1 - Engine rpm pickup.

Spring specifications to Belleville washer for theclutch engagement

Load on the pressure plate Nm 11000

CAUTION: In the event thetransmission beingsplit to gain accessto the clutch assembly, the pickup (A, fig. 1) must be removed toavoid its being damaged by the teeth of the engine flywheel.

IIMPORTANT: In the event of the friction disc being removed, care must be taken during refitment to positionthe components correctly, as indicated, since the disc is not symmetrical.

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2 Clutch and transmission

Clutch


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Fig. 2 - Clutch unit for AGROPLUS 60 Fig. 3 - Clutch unit for AGROPLUS 70-80

Cl


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Clutch unit for AGROPLUS 60-70-80 (USA) 6 blades

14

Clutch and transmission

Clutch

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Fig. 4 - Components of clutch assembly

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2Clutch and transmission

Clutch


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Fig. 5 - Checking clutch disk thickness.

Fig. 6 - Clutch assembly hydraulic operating cyl-

inder.

Fig. 7 - Checking operating cylinder inside springefficiency.

Fig. 8 - Bleeding the air from the clutch hydrauliccircuit.

Fig. 9 - Installing clutch assembly through n. 5.9030.256.4/10 equipment.

Cecking clutchCheck the disk lining for signs of chipping and the disk friction facefor scoring which may prevent theclutch from operating properly.

Check that the sliding surface of the engine flywheel is not scored;if signs of scoring are evident, machine the surface.Check the disk thrust plate for scoring or bluish areas caused bytempering and also ensure the diaphragm-type spring has not lostits efficiency; if so the whole clutch assembly shall be replaced.

Besurethe clutchdiskis freeto movein its housing and the frictionlining securing rivets are duly riveted.Should any wear be found on the thrust bearing or the diap -hragm-type spring, an exhaustive check over the spring operating

conditions installed in the disk thrust lever operating cylinder (seeFig. 6) shall be performed; replace if necessary.On reassembly ascertain dimension A (see Fig. 6) between theoperating cylinder fixing face and the push rod contacting the en -gagement lever is 195 mm.

NOTE: To facilitate correct clutch disk assembly the use of no.5.9030.256.4/10 centering tool is recommended.Warning: With engine running, never ride the clutch pedal withyour foot to prevent the clutch disk from being damaged becauseof overheating.Important: The thrust bearing is prelubricated, and must never onany account be cleaned with fuel oil or other solvents as these willrender the prelubrication treatment ineffective.

Adjusting clutch control pedal

Make sure thedistancebetween pump fixingsurface and fork hole

centre is 106 1 (Fig. 15) otherwise loosen nut A and operate adju-sting stay rod B (Fig. 15).

Bleeding air from the hydraulic circuit

Operate the clutch pedal several times, then keeping the clutchpedal in fully depressed position, slightly unscrew and soon after tighten the air bleeding screw valve again (this being located onthrust lever operating cylinder).

This operation should be repeated as many times as the oil flowsout of the bleeding screw valve without air bubbles.

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23


Clutch


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A Bleed screw D Spring G Push rodB Hydraulic pipe fitting E Seal ring H Rubber boot

C Slave cylinder body F Piston

Fig. 10 - Clutch operating cylinder

Stripping the slave cylinder (Fig. 10)

Remove the boot H. Withdraw the piston F carefully fromthe cylinder C, blasting with compressed air at low pressure to assist removal.Remove the spring D from the cylinder and loosen the bleed screwA.Remove the seals E fom the piston F.CAUTION: When cleaning the components of the cylinder, useonly specifically formulated brake and clutch fluids (see page110). Do not use petrol, paraffin or other mineral oils as these willdamage parts in rubber.

Inspections

— Check both internal and external piston surfaces for scratching.Replace if required.

— Make sure the seal ring grooves are duly clean; blow the groo-ves with compressed air if necessary.— Inspect seal ring, dust boot conditions as well as spring effi-

ciency, worn-out parts should be replaced.— Ensure the air bleeding hole is free from impurities.

Notes on refitment

— When reconnecting the transmission housing, check that the clutchfork remains correctlypositionedandfree to rock onitsfulcrum pivot.Thiscan beensuredbyremovingthe sideplug fromthe flangeof theintermediate housing and viewing the fork through the hole. In theevent of the fork pivot being unseated, reposition correctly with theaidof a screwdriverinsertedthrough theholevacated bytheplug.

— Before refitting the slave cylinder, fill with the recommended oilso as to facilitate the subsequent bleeding procedure.

— Once all components arecorrectly and securely in place, bleedthe hydraulic circuit.

A - Control lever B - Dust bootC - PushrodD - UnionE - PistonF - Seal ringG - Cylinder casingH - Spring

Fig. 11 - Clutchoperating cylindercutaway view.

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23


Clutch


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A Hydraulic pump F - Spring M - Spacer ring R - Snap ringB - Delivery pipe union G - Spring holder N - Piston S - Guard bootC - Delivery pipe H - Screw O - Seal ring T - NutD - Clamp I - Shoulder ring P - Rod U - YokeE - Union L - Seal ring Q - Support disk

Fig. 12 - Clutch hydraulic pump parts.

Stripping the master cylinder

Referring to figure 14, remove the protective boot E, dislodge the circlip B and withdraw the rod D together with thedisc C.Remove the piston together with the spacer, the seal, the backup washer and the spring beneath.

Fig. 13 - Clutch pump control positioning.

A - LocknutB - Yoke

Fig. 14 - Pump control seal ring.

A - Pump D - RodB - Snap ring E - Guard bootC - Support disk

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23


Clutch


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Inspections and checks

WARNING: To clean and wash the hydraulic pump components use only the oil type recommended for brakes and

clutch. Never use petrol, kerosene or other mineral oils to prevent damaging the rubber parts.Inspect both internal and external piston sliding surfaces for scratching. Replace if required.Make sure the seal ring grooves are duly clean; blow the grooves with compressed air if necessary.Inspect seal ring, dust boot conditions as well as spring efficiency, worn-out parts should be replaced.Inspect allpump internal compartments, apertures and passagesand make sure these areproperly clean and free fromforeign matters.Check that the spring is neither lazy nor deformed; replace if necessary.

Reassembly

Reassemble the cylinder, repeating the disassembly steps in reverse order and observing the following directions:— Lubricate surfaces engaged in relative sliding contact, using the recommended oil (see page 12).— Verify correct operation of thecylinder, makingcertain that thepiston is able to complete its full strokeunimpeded.In the event that the fork linking the master cylinder with the pedal has been removed, check that with the push rod fully

extended, the distance between the referencesurface of the cylinder and thecentre of thehole in thefork is as indicatedin figure 15.If not (referring to fig 13), remove the boot, loosen the lock nut A and screw or unscrew the fork B to obtain the prescri-bed clearance, then retighten the lock nut and reposition the boot.

Fig. 15 - Section view of clutch master cylinder

Clutch greasing points.

Apply Molikote Gn-plus at all the points indicated in the figurewith letter A.Fit part B with Loctite 270.Fit pin C with Loctite 601.

Fitting the P.T.O. shaft oil seal

Before fitting the oil seal 2.1529.517.0 apply Loctite 222 tothe outer face A indicated in the figure.

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Clutch


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clutch slips

clutch jerks

clutch fails to disenga-ge

clutch noisy when di-sengaged

lubricant in clutchhousing

clutch worn

thrust bearing stic-

king

clutch disk surfa-ces dirty

clutch disk warped

difficulty in enga-ging gears whenengine running

worn parts in clutchengagement me-

chanism

renew the front ge-arbox oil seal andthe rear engine oilseal

check condition of clutch disk

clean surfaces and

apply grease

clean the frictionsurfaces

clutch disk surfa-ces dirty

clutch disk worn

plate seals loose

clutch disk warped

hydraulic pumpinefficient

clutch disk stuck toflywheel

replace parts

clean oil seal con-tact surfaces withpetrol

check condition of the spring disk

replace thrust bea-

ring

replace clutch disk

replace clutch disk

replace clutch disk

replace disk

check the stroke of the clutch controlpiston and replaceany worn parts

clean contact sur -faces with a wirebrush and petrol

replace disk

fit new clutch as-sembly

clean or replace the

disk

20


Diagnosing malfunctions


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POWERSHIFT unit

The POWERSHIFT unit is composed of an epicyclic speed reducer and three oil-immersed multiple disc clutches

(LOW - MED - HIGH).The unit is located between the clutch-coupled shaft and the gearbox.The speed reducer is engaged and disengaged selectively by way of the three clutches, which are a push button

and mounted to the knob of the shift lever.

Selecting the control, the MED clutch releases as the force of the belleville discs is overcome by hydraulic pressu-re; at the same time, the HIGH clutch engages, locking the planet carrier of the epicyclic train to the relative housing sothat drive is transmitted to the range input shaft with no speed reduction whatever.

Selecting the control, the MED clutch releases as the force of the belleville discs is overcome by hydraulic pressu-re; at the sametime, the LOW clutch engages, and the shaft carrying the sun wheel is locked to the structure of the tran-smission housing. As a result, theplanet carrier is made to rotate as onewith the epicyclic housing and drive is transmit-

ted to the layshaft at a speed reduction of 0.687 (the ratio between the annulus and the sun wheel gear teeth).Selecting the control, the POWERSHIFT unit is isolated from hydraulic pressure altogether and the bellevillediscs are able to engage the MED clutch, with the result that the shaft in mesh with the larger planet wheel is locked tothe transmission housing. This gives a reduction of 0.825, by reason of the compound ratio between the planet wheelsand the flange of the speed reducer in mesh with the range input shaft.

Technical specifications

Clutch

maker SAME DEUTZ - FAHR

number of friction discs 7 4 2

diameter of friction discs 129,5 129,5 129,5overall thickness of assembled friction

discs complete the intermediate discs mm 25,2 ÷ 25,4 17,50 ÷ 17,60 11,70 ÷ 12,14

number of intermediate discs 3+1 2+1 2+1

disc lubrication pressure bar 5 5 5

maximum pressure bar 16 16 16

piston thrust Kg 1986 1986 1986

Nm 19463 19463 19463

Epicyclic speed reducer

- LOW 1 + (30/66) = 1,4545

- MEDIUM 1 + (21x18) : (66x27) = 1,2121- HIGH 1

SLOW MEAN FAST

Fig. 1 - Range selection indicators mounted to the instrument panel. Fig. 2 - Plate indicating selection of electro-

hydraulic control.

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27


POWERSHIFT


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Fig. 3 - Diagram illustrating operation of the POWERSHIFT system.

Parts in movement Parts locked to transmission housing In rotation (idling)

Fig. 4 - Diagram showing engagement of POWERSHIFT with MED range selected.

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27


POWERSHIFT


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Parts locked to transmission housing

Parts in movement Oil circuit for operation of clutches In rotation (idling)

Fig. 5 - Diagram showing engagement of POWERSHIFT with LOW range selected.

Parts locked to transmission housing

Parts locked to epicyclic Oil circuit for operation of clutches In rotation (idling)

Fig. 6 - Diagram showing engagement of POWERSHIFT with HIGH range selected.

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27


POWERSHIFT


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POWERSHIFT UNIT DETACH FROM THE GEAR BOX

Fig. 7 - Detach the driving platform (or the cab, if fitted) fromthe tractor.

Fig. 9 - Detach the front gearbox from the rear gearbox.

Fig. 11 - Remove the internal clutch control from the frontgearbox.

Fig. 8 - Detach the front part of the tractor complete with en-gine from the gearbox.

Fig. 10 - Remove the upper cover from the front gearbox.

Fig. 12 - Remove the solenoid valve block from the frontright-hand side.

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27


POWERSHIFT


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Fig. 13 - The POWERSHIFT solenoid valve block is removedby pulling it outwards after having disconnected the pipesand removed the retaining screws.

Fig. 15 - Disconnect the delivery line from the POWERSHIFTunit by unscrewing the union.

Fig. 17- Removethe POWERSHIFTunitfromthe front end of the gearbox.

Fig. 14 - Remove the hydraulic lubrication pipe of thePOWERSHIFT unit by first disconnecting the part on the out-side of the gearbox.

Fig. 16 - Using a drift as shown in the figure, drive thePOWERSHIFT unit out of the front of the gearbox.

Fig. 18 - After having removed the POWERSHIFT unit, pro -ceed with its disassembly, if necessary. Then remove theepicyclic reduction unit.

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27


POWERSHIFT


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Fig. 19 - Remove the planet carrier flange from the epicyclicreduction unit.

Fig. 21 - The play adjustment shim for the POWERSHIFTshafts is located between the housing and the epicyclic reduc-tion unit.

Fig. 23 - Removethe circlip indicated in the figure using a pair of bent nose pliers.

Fig. 20 - Remove the circlip and the thrust washer. Onre-assembly,the thrustwasher must be fitted with the lubrica-tion channels facinginwards towards theplanetcarrier flange

Fig. 22 - To dismantle the POWERSHIFT unit, remove thecirclip indicated in the figure.

Fig. 24 - Remove the thrust washer.

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27


POWERSHIFT


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Fig. 25 - Unscrew the screws securing the LOW clutch hous-ing to the POWERSHIFT unit.

Fig. 27 - It is advisable to mark the relative positions of theparts prior to disassembly.

Fig. 29 - Remove the LOW clutch disc pack (7+7).

Fig. 26 - Remove the retaining screws.

Fig. 28 - Using a screwdriver, separate the housing from theunit.

Fig. 30 - Inspect the clutch discs for wear.

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27


POWERSHIFT


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Fig. 31 - Remove the circlip securing the hub of the LOWclutch.

Fig. 33 - Remove the circlip located behind the hub of theLOW clutch.

Fig. 35 - Using a drift, separate the MEDIUM-LOW housingfrom the rest of the unit.

Fig. 32 - Remove the hub of the LOW clutch.

Fig. 34 - Proceed with the disassembly of the housing of theMEDIUM-LOW" clutches.

Fig. 36 - Detach the MEDIUM-LOW housing from the unit.

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27


POWERSHIFT


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Fig. 37 - Remove the Belleville springs from the MEDIUMclutch.

Fig. 39 - MEDIUM clutch discs (4 friction discs+3counterdiscs+2 thrust plates).

Fig. 41- Thispistoncan beremoved byremoving the circlip of the piston return spring located on the opposite end of thehousing.

Fig. 38 - Remove the discs from the MEDIUM clutch.

Fig. 40 - The control piston of the LOW clutch may be re-moved from the “MEDIUM-LOW” bell-housing using a pressof the type illustrated below.

Fig. 42 - Remove the LOW clutch shaft.

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27


POWERSHIFT


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Fig. 43 - Check that the oil ways in the shaft are not ob-structed.

Fig. 45 - Thispistoncan beremoved byremovingthe circlip of the piston return spring located on the opposite end of thehousing.

Fig. 47 - Remove the thrust washer of the HIGH clutch.

Fig. 44 - The LOW clutch control piston can be removed fromthe housing using a press of the type illustrated below.

Fig. 46 - Removethe circlip securing theHIGH clutchdiscs.

Fig. 48 - Remove the HIGH clutch disc pack (2 friction discs +2 counterdiscs + 1 thrust plate).

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27


POWERSHIFT


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Fig. 49 - HIGH clutch discs.

Fig. 51 - Separate theHIGH clutchhousing from theMEDIUMclutch housing using a press to compress the springs and re-move the circlip.

Fig. 53 - “ VESPEL” seals of the HIGH clutch housing.

Fig. 50 - HIGH clutch control piston.

Fig. 52 - Remove the MEDIUM clutch hub and then the rela -tive housing.

Fig. 54 - Remove the HIGH clutch housing.

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27


POWERSHIFT


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Fig. 55 - Remove the Belleville return springs of the HIGHclutch control piston from the MEDIUM shaft.

Fig. 57 - If necessary, remove the circlip and remove thebearing from the MEDIUM clutch housing.

Fig. 59 - Examine the condition of the seal ring of the pistonfrom the MEDIUM clutch housing.

Fig. 56 - Examine the condition of the “VESPEL” seals on theHIGH clutch housing.

Fig. 58 - Remove the piston from the MEDIUM clutch hous-ing.

Fig. 60 - Proceed to dismantle the LOW clutch control pistonwith the aid of a press.

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27


POWERSHIFT


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Fig. 61 - Remove the circlip securing the springs.

Fig. 63 - Disassemblysequencefor the5 Bellevillewashers.

Fig. 65 - Groove for O-ring in the LOW clutch housing.

Fig. 62 - Remove the assembly from the press and removethe Belleville springs.

Fig. 64 - Remove the piston.

Fig. 66 - Examine the condition of seal ring of the piston fromthe LOW clutch housing.

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27


POWERSHIFT


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A - Cover I - Seeger T - LOW sun wheelB - LOW clutch L - Clutch hub U - Planet carrier

C - LOW clutch control piston M - Thrust plate V - Thrust washer D - Clutch housing N - Bearing Z - Ring gear

MEDIUM - LOW O - Thrust plate X - Planet gearsE - LOW clutch belleville springs P - MEDIUM clutch control piston J - LOW shaftF - MEDIUM clutch belleville springs Q - HIGH clutch housing Y - MEDIUM shaftG - Actuator disc R - HIGH clutch control piston W - Secondary shaftH - MEDIUM clutch S - HIGH clutch K - Reduction unit shaft

Fig. 67 - POWERSHIFT unit

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27


POWERSHIFT


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Assembly of POWERSHIFT unit

Fig. 68 - Components of POWERSHIFT unit

The POWERSHIFT unit requires that the basic gearbox, with respect top the standard version, is equipped with a se-condary shaft A and a r ange input shaft B, of specific type.

Warning: no special tools are required to re-assemble this unit, just an M8x1.25x30 screw to hold the central shaft C in

position during POWERSHIFT play adjustment.

Assemble the unit as follows:— Fit the input ring gear D to the secondary shaft, securing it with circlip E;

— Separately assemble LOW gear F with the planet carrier flange G . When fitting gear F, the planets must be positio-ned so that their punch marks are aligned with the position reference marks on the carrier flange, (Fig. 69).

Timingreference countermark

Fig. 69 - Timing the epicyclic speed reducer of the POWERSHIFT unit.

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27


POWERSHIFT


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Timing marks on gear teeth of the epicyclic reduction of the POWERSHIFT unit.

Fig. 70 - Pre-assembly of parts on MEDIUM shaft. Fig. Pre-assembly of MEDIUM-LOW clutches.

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27


POWERSHIFT


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RE-ASSEMBLY OF THE POWERSHIFT UNIT.

Fig. 72 - Assemble the HIGH clutch. Fit the bearing with therelative snap rings in the MEDIUM clutch housing; fit the hubsecuring it with the relative circlip and fit the three servicecirclips to the housing. Fit the O-ring seals to the piston , thenfit the piston.

Fig. 74 - Fit the MEDIUM clutch discs.

Fig. 76 - Fit the circlip and check that the shaft has certainamount of play.

Fig. 73 - Fit the LOW shaft, the relative roller bearings, andposition the snap ring.

Fig. 75 - Apply Loctite 510 sealing compound to the housingcontact surfaces as shown in the figure.WARNING: when applying sealing compound take care notto obstruct the oil ways.

Fig. 77 - Fit the MEDIUM clutch thrust washer with outlets ori-ented towards the circlip.

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27


POWERSHIFT


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Fig. 78 - Join the two housings together; the studs will locatein the 3 holes to ensure the correct relative positions of thetwo housings. Rotate the shaft during this operation so as tocentre the clutch discs.

Fig. 80 - Fit the LOW clutch, first positioning the circlip on theshaft as indicated in the figure.

Fig. 82 - Then install the discs of the LOW clutch.

Fig. 79 - Note that a small space will be left between the twohousings; this is to allow preloading of the Belleville springswhen the screws are tightened.

Fig. 81 - Then fit the clutch hub and position the secondcirclip.

Fig. 83 - The disc pack is completed with a final friction disc,the tabs of which do not engage the splines on the hub, andtherefore, when refitting the cover, it is advisable not to rotatethe shaft soas to allow the disctabsto meshcorrectlywiththehub.

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27


POWERSHIFT


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A - pressure regulator valve F - solenoid control valves(operating pressure 16 bar) G - electro-hydraulic control unit

B - gearbox lubrication oil H - anticavitation valve for safety steeringpressure setting valve (setting 5 bar) I - bistable valve

C - anticavitation valve for safety L - safety steering valvesteering (30 l/min.) M1 - pressure gauge with scale 0 - 40 bar

D - oil pump (capacity 10 to 27 l/min.) M2 - pressure gauge with scale 0 - 40 bar

E - suction filter (25 micron) M3 - pressure gauge with scale 0 - 10 bar T - lubrication

Fig. 85 - Hydraulic diagram illustrating operation.

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27


POWERSHIFT


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Fig. 86 - Electrohydraulic control unit for POWERSHIFT system.

PROCEDURE FOR CHECKING THE H-M-L CONTROL UNIT INLET PRESSUREReferring to Fig. 86:

1 - Connect pressure gauge 5.9030.514.0 (0 ÷ 40 bar) at position M1.

2 - Connect pressure gauge 5.9030.515.0 (0 ÷ 10 bar) at position M2.

Start the engine and throttle up to the revolutions indicated in the table; now verify that the inlet pressures are as prescribed.

NB: Pressure tests should be conducted using oil at a temperature of 80 °C.

A - Test fitting for testing pressure of LOW clutch hydraulic circuitB - Bistable valveC - Valve bodyD - Non-return valveE - Non-return valveF - Oil pressure regulator valveG - Lubrication pressure control valveH - Delivery line to P.T.O.I - Delivery line to differential lockL - P.T.O. lubrication pipeM - P.T.O. disk lubrification manifoldN - Manifold for P.T.O. clutch oil pipeO - Secondary shaft and POWERSHIFT lubrification pipe

P - Pipe from radiator oil to the gearboxQ - Delivery line to front-wheel drive engagement pistonM1 - Pressure gauge with scale 0 - 40 bar M2 - Pressure gauge for P.T.O. lubrication pipeM3 - Pressure gauge with scale 0 - 40 bar for pressure at P.T.O.

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27


POWERSHIFT


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Fig. 88 - Hydraulic control circuit.

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27


POWERSHIFT


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clutch slips

clutch won’tdisengage

check the clutchassembly hydraulicsystem

check piston for free stroke

check the clutch

plates for wear

inspect the controlmechanism

inspect the disks

piston jammed inseat

replace the defecti-ve parts

examine piston andmanifold seal rings

remove any roug-hness preventingpiston from slidingfreely

replace the clutch

disks

replace defectiveparts

burnt disks

relpace the piston

replacedefective parts

replace the disks

jammed disksremove any roug-hness preventingdisks from sliding

freely

44


Diagnosing malfunctions


45/508

General specifications

The basic transmission utilizes 5 speed synchromesh gearbox with 2 or 3 speed ranges.

A shuttle, fitted as standard, makes the tractor easy to handle and manoeuvre.

Options include Creeper, and Underdrive (in place of or in addition), giving a total of:

For tractors equipped with platform or cab20 FWD + 10 REV: 5 gears x 2 ranges (L-V) + mini-reduction + reverser shuttle30 FWD + 15 REV: 5 gears x 3 ranges (SR-L-V) + mini-reduction + reverser shuttle.45 FWD + 45 REV: 5 gears x 3 ranges (SR-L-V) + reverser shuttle + POWERSHIFT

Each version is also available with 30 or 40 km/h top speed.

Technical specifications

number of speeds 20 AV + 10 RM

gearbox ratios

1st gear 19/59 = 1/3,1053

2nd gear 23/50 = 1/2,1739

3rd gear 29/44 = 1/1,5172

4th gear 35/38 = 1/1,08575th gear 41/32 = 1/0,7805

shuttle forward 29/37 = 1/0,7838

reverse 23/19 = 1/0,8261

range ratios low (19/50)x(22/46)= 1/5,5024

high 1

rear axle ratios bevel gear pair 30 km/h 8/39 = 1/4,8750

40 km/h 9/33 = 1/3,6667

epicyclic final drive (12/12+69) = 1/6,7500

overall ratio 30 km/h 1/32,9063

40 kmIh 1/24,7502

backlash between crownwheel

and pinion teeth mm 0,18 - 0,24

Mini-reduction 32/34 = 1/0,9412

Super-reduction (19/50)x(22/46)x(19/50)x(20/48) = 1/34,7520

axial play of the secondary shaft mm 0,09

axial play of the gears of the change,

of the reverser and mini-reduction mm 0,15 ÷ 0,30

reference distance for adjustment

of bevel gear pai rmm 2,5 ± 0,1

45

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3Transmission

Gearbox


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Speed change configurations

DURING TRANSPORT OPERATIONS ON PUBLIC ROADS BOTH BRAKE PEDALS MUST BEOBLIGATORILY COUPLED BY MEANS OF THE SPECIAL LOCKING LATCH. IN ANY CASE,

ALWAYS OBSERVE LAWS AND REGULATIONS IN FORCE.

46

31

3 Transmission

Gearbox

20 + 10

30 +15

45 + 45

Powershiftcontrol

GearshiftingControl

Synchrosplitcontrol

Speed rangeControl

NO. OF SPEED(forward + reverse)


47/508

* see technical characteristics of gearbox on p. 45

** see technical characteristics of 4wd front axle on p. 115

Fig. 2 - Ratios of 5-speed x 2 range transmission with mini-reduction (20 FWD + 10 REV).

47

31

3Transmission

Gearbox


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Ratios of 5-speed x 2 range transmission with mini-reduction and super-reduction (30 FWD + 15 REV).

48

31

3 Transmission

Gearbox


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Fig. 3 - Ratios of transmission with 3 ranges (Super-reduction) + POWERSHIFT (45 FWD + 45 REV).

49

31

3Transmission

Gearbox


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Assemble the front and rear gearboxes and the rear hydraulic lift,after having applied PIANERMETIC 510 to surfaces Aand LOCTITE 636 to bushes B.

Fig. 4 - Front and rear gearbox.

50

31

3 Transmission

Gearbox


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Fig. 5 - Longitudinal section through transmission.


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53/508


54/508

Fig. 8 - Inversor lever ( A -Side view and B -Front view) - C - Range reduction lever. X - Version with Mini-reduction Y - Version without Mini-reduction

54

Transmission

Gearbox

3

31

A

Y

X

B

A


55/508

Fig. 9 - Gear lever. Fig. 10 - Front view of gearbox with FULLDRIVE.


56/508

Fig. 11- Views of the gearbox.

56

Transmission

Gearbox

3

31


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Fig. 12 - Electro - hydraulic control for front-wheel drive engagement/disengagement.

Asse ruota

97080.2

ø

0 . 4

M 1 6 x 1

. 5


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Range selector rods and forks

Fig. 15 - Range selector rod. D - bolt securing hub to rod.

Correct positioning of the gearbox, shuttle and ranFit the gearbox, shuttle and range control levers s

Fig. 16 - Correct positioning of the gearbox, shuttle and ra


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Fig. 18 - Separate the rear gearbox from the front gearbox

Separating the front gearbox from the engine

(this operation is necessary in order to access the POWERSHIFT unit)

— Remove the engine pick-up from the top of the gearbox (in the area of the spacer housing).

— Place wedges under the front axle support.

— Disconnect the fuel delivery pipe in the area between the front gearbox and the engine.

— Disconnect the two front brake pipes and the differential lock control pipe.

— Support the front gearbox on a stand.

— Remove the 10 screws securing the front gearbox to the engine flange, then detach the gearbox.

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31

3Transmission

Gearbox


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Dismantling the gearbox.

— Remove the 8 screws securing the top cover and then remove the cover itself.

— Remove the gearbox clutch control located in the spacer housing as follows:—— Remove the thrust bearing.

— Remove the lock pin and withdraw the control lever.

— Undo the union and remove the oil delivery pipe to the POWERSHIFT unit.

— Unscrew the 2 screws and the 2 nuts securing the POWERSHIFT unit;

— Remove the 2 retaining screws of the POWERSHIFT control valve unit, (one of these screws also secures the fuelprefilter with the relative pipe).

NOTE: one of the screws has an extension with a small plate to support the clutch control lever; these parts are to be re-moved together with the screw.

Removal of the gearbox input and P.T.O. shafts

— Remove the circlip attaching the gearbox input shaft to the inversor shaft coupling sleeve.Withdraw the 2 shafts from the front of the spacer housing (the shafts should be withdrawn together to prevent damageto the seal ring positioned between them).

NOTE: To replace the seal on the gearbox input shaft, it will be necessary to remove the cab or platform to gain accessto the upper cover of the gearbox, from which the seal housing may be accessed.

Separating the POWERSHIFT unit from the gearbox— Using a copper drift, tap the housing of the POWERSHIFTunit in order to extract from the front part of the spacer ho-

using;(if the purpose of this operation is solely to inspect or replace the hydraulic clutches, it will not be necessary to remo-ve the epicyclic reduction unit from the gearbox or to remove the cab/platform).

— If instead the epicyclic reduction unit is to be removed, simply withdraw it from the front of the gearbox, then removethe calibrated thrust washer and the circlip, and then remove the housing complete with the ring gear.

— The POWERSHIFT clutch units are to dismantled on the bench.

NOTE: for instructions on dismantling the POWERSHIFT unit, see page 24.

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31

Transmission

Gearbox

3


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Removal of thegear train positioned in thefront gearbox

WARNING: On tractors equipped with POWERSHIFT, first follow the instructions to remove the POWERSHIFT unitand the gearbox input and P.T.O. shafts.For the following operations the driving platform or cab must be removed in order to gain access to the upper gearboxcover.

Before proceeding with theremoval of thegear train, it is necessary to removethe selector rods andforks. Theseopera-tions are only possible after having separated the rear gearbox from the front; before separating the two gearboxes, re-move D fig. 5 on page 51.Detach thefront gearbox from therear gearbox. To do this, it will be necessary to removethe 5 speed relay hub together with the intermediate support, located on the right-hand side of the rear gearbox. Remove screw A (fig. 14) screws B

(fig. 15) and screw D (fig. 16).

NB: Remove the selector rod detent balls and springs by unscrewing the relative plugs located on the right-hand side of the gearbox. Then proceed with the separation of the two gearboxes.The 3 gearbox shafts (inversor, primary and secondary) and the gear selector and inversor control rods and forks willremainattached to the front gearbox. To removethese rods, it will first be necessary to removethe 3 shafts by removingthe 3 circlips A - B - C fig. 5 on page 51 and then moving all 3 shafts simultaneously backwards to disengage them fromtheir housings; thefirst shaft to be detachedwill be theprimary shaft, followed by thesecondary, and then theinput shaftlocated at theuppermost part of thegearbox is to be withdrawn. Each selector rodwill come away together with its shaft.

Fig. 19 - Oilpipe from thesolenoidcontrol valve to the hydraulicactuatorresponsiblefor engaging/disengaging front-wheel drive.

A Pipe union on solenoid valve end B Pipe union on actuator ende C Connection pipe.D Manifold E Solenoid valve assembly

63

M 1 6 x

1 . 5

A

E

D C B

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3Transmission

Gearbox


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Fig. 20 - Retaining screws of the gear rods to beremoved prior to detaching the front gearbox fromthe rear gearbox.

A retaining screw of the inversor controlrod hub

B retaining screws of the gear controlrod hubs.

C Range gear control rod.

D Gearchange control rod.

E Inversor/minireduction control rod.

Disassembly of the inversor control rods and forks

Disengage the fork from the sleeve and rotate it so that the hole in the fork is aligned with the retaining pin; then, using adrift as shown in figure 23, tap the pin out of the hole.On tractor equipped with a minireduction unit, repeat the above operations to remove the second selector fork.

Fig. 21 - Components of inversor rod and fork assemblye for gearbox with minireduction.

Fig. 23 - Removal of the fork retaining pin.

Fig. 22 - Rod and fork for gearbox without minireduction.

Fig. 24 - Removal of fork from control rod.

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3 Transmission

Gearbox


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Dismantling of the gearchange rod and fork assembly.

Fig. 25 - Detach the rod with forks from the secondary shaftby moving it laterally

Fig. 27 - Disengage the 1st gear selector fork from the sleeveand rotate it to align the hole on the fork with the retaining pin.Then, using a suitable drift, drive the pin out of the hole.Detachthe 2nd and 3rd gear selector forks and sleeves in thesame way.

Fig. 29 - Remove the sleeve located on the rod between se-

lector fork.

Fig. 26 - Remove the screw securing the rod hub and removethe hub from the rod.

Fig. 28 - Withdraw the gearchange control rod.

Fig. 30 - Rotate the 4th and 5th gear the two forks. so that the

hole on the fork is aligned with the retaining pin, then using adrift and a hammer as shown in figure 23, drive the pin out of the hole (the figure shows the components of the selector rodsand forks assembly).

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3Transmission

Gearbox


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Dismantling of the gearchange selector rods and forks assembly

Fig. 31 - Unscrew the 6 retaining screws and remove thecover giving access to the gearchange selector rods andforks assembly. Then using a spanner, unscrew the guidebolt of the super-reduction control fork.

Fig. 33 - Unscrew the guide screw of the L-V selector fork.

Fig. 35 - Remove all the parts mounted on the rod, recoveringthem from the lateral access hole.

Fig. 32 - Unscrew the guide screw of the central sleeve lo-cated between the 2 forks. (NB. Loctite has been applied tothese screws; we recommend that they are heated using anoxyacetylene torch to facilitate removal).

Fig. 34 - Access the front compartment of the gearbox extractthe rod by pulling the hub.

Fig. 36 - Parts comprising the selector rod and forks themfrom the lateral accesshole assembly forthe super-reductionunit and range gears.

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31

3 Transmission

Gearbox


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Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive

Separate the rear gearbox from the front gearbox, (it is first necessary to remove circlip (A fig 37). Unscrew union B ( fig19 page 63) located on the left-hand side of the rear gearbox and remove the front shaft complete with the front-wheeldrive actuator.

IMPORTANT: Only unscrew union B fig. (19 page 63) located on the left-hand side of t

agroplus 60-70-80 repair manual

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