10 General

20 Engine

95
105 30 Electrical
system

115
X100 40 Power
transmission

X110
X120 50 Brake
system

Service Manual Steering sys-

60 tem and Front
axle

70 Frame and
Wheels

80 Cab and
Shields

90 Hydraulics

Valtra Inc.

100
SF---44200 Suolahti, Finland
Tools
Order no 39 214 211
ENGLISH
 11. Layout
10. General

12. Repairs

13. Maintenance
2
To the reader
The Service Manual for the ValtraValmet tractors is intended to be a practical reference source to be
used in workshop. The repair instructions in the manual are based on methods which have been
worked out in practice during normal workshop conditions and which are based on the use of special
tools from the manufacturer when stated in the instructions. The manual also contains descriptions of
the design and function of the components.

Detailed maintenance instructions can be found in Operator's Manual.

The Service Manual will be continually updated with new revised pages which should be inserted in the
manual. Alterations and additions will first appear as service bulletins.

Only genuine Valmet spare parts should be used to ensure the best possible function of the machine.
Certain operations should be carried out with the aid of special tools designed by Valmet.

Valmet Tractors Inc.

Tractor Service

IMPORTANT!
ValtraValmet 95, 105 and 115 tractors are based on ValtraValmet agricultural tractors as follows:
- 95 is based on 6400DW tractor
- 105 is based on 6600 tractor
- 115 is based on 6800 tractor

ValtraValmet X100, 110H and X120 tractors are based on ValtraValmet agricultural tractors as follows:
- X100 is based on 6550Hi tractor
- X110 is based on 6650Hi tractor
- X120 is based on 6850Hi tractor

95- X120 tractors have frame steering (in 95-X120 tractors there is a new middle frame in place of the
fuel tank which is fitted on the corresponding agricultural tractors) and 95-X120 can have special auxĆ
iliary hydraulics (e.g. special, fixed front loader and its control), which are not fitted on correcponding
agricultural tractors. However, other vehicle components are the same as in corresponding agricultural
tractors.

3
4
 Model Code Page
11. General X100-X120 110 0
24. 5. 2004

The following supplements have been published for the Valtra X100-X120 Service Manual:

Ordering number Date Notes

39 261 211 24.5.2004

Supplement no. 39 261 211 (24. 5. 2004)

Includes:
- Agroline-instrument

5
6
 Model Code Page
95, 105, 115
11. Layout X100-X120 110 1
1. 11. 2000

Layout of Service Manual

1. Division into groups

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

Example. 10. General

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

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

Code Page
410 1

50

60

70

80

90

100

2. Division into components or sub-groups

Each group is further divided into components or sub-groups. The number and the name of each component is given in the top
left box on each page (and comprise the two first figures in the code designation).

Example. 41. Clutch

42. Gearbox
44. Quick-shift gear
45. Final drives etc.

7
 Model Code Page
95, 105, 115
11. Layout X100-X120 110 2
1. 11. 2000

3. Code designation

Three-digit code designations are used to distinguish the different document groups for the respective components. The same
code is also used in the Time List as a reference to the text in this Manual. The code designation numbers appear both in the box at
the top of the page and also in the headings.

Example: Code 410:

- Group: Power transmission (4)
- Component: Clutch (41)
- Document group: General (410)

4. Page numbers

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

1. 9. 2000 Model Code Page

41. Clutch 95, 105, 115 410 1
1. 11. 2000

5. Date

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

6. Model

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

7. Additions and amendments of the service manual

New and up-dated pages will be continually added to the service manual. The new pages should be inserted as indicated by the
code: the first digit (also the first digit on the index leaf) indicated the group:
- the two first digits indicate the component or sub-group
- the third digit indicates the document group for the respective components
- the page number indicates the definite position of the page within the service manual

If there are two pages with the same code and page number the page with the later date in the date box (and the old date in the
crossed-over box) is valid (or the current page).

N.B. Fitting instructions for extra equipment are inserted into the service manual at the end of group concerned (E.g. code 39 is
inserted at the end of group 30).

8
 Model Code Page
95, 105, 115
11. Layout X100-X120 110 3
1. 11. 2000

Code designation in the Service Manual

10. General
110 Layout
120 Repairs
130 Maintenance
20 Engine
21. Engine
210 Technical data, tools, description
211 Cylinder block and flywheel housing
212 Cylinder head and valve mechanism
213 Crank mechanism
214 Timing gears
215 Lubrication system and oil sump
216 Induction and exhaust system, turbocharger
219 Removing and fitting engine

22. Fuel system

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

23. Cooling system

230 Technical data, tools, description
231 Thermostat and coolant pump

30. Electrical system

310 Fuses, specifications, wiring diagrams
314 Autocontrol 2.2/2.3
321 ACB power lift
330 Agrodata on board computer
331 AD-instrument
370 Autocontrol 5 / 5.2 (HiTech)
371 Autocontrol 5.2

40. Power transmission

41. Clutch, fluid coupling
410 Technical data, tools, description
411 Clutch assembly and pedal rods
412 Hydraulic coupling

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

44. DPS, reverse shuttle, 4WD clutch

440 DPS, technical data, tools, description
440 Reverse shuttle, technical data, tools, description
440 4WD clutch, technical data, tools, description
442 Reverse shuttle, repair instructions
443 4WD clutch, repair instructions
444 DPS, repair instructions

45. Final drives

450 Technical data, tools, description
451 Final drives, repair instructions

46 Power take-off
460 Technical data, tools, description
461 Power take-off, repair instructions

9
 Model Code Page
95, 105, 115
11. Layout X100-X120 110 4
1. 11. 2000

50. Brakes
510 Technical data, description
511. Service brakes
520 Parking brake

60. Steering system and front axle

61. Steering system

610 Technical data, tools, description
611 Steering valve
612 Priority valve
613 Frame steering cylinders
614 Adjustments

64. Industrial powered front axle Dana (Sige)

640 Technical data, tools, description
641 Front axle housing
643 Hubs
644 Differential
645 Adjustments

65. Industrial powered front axle Carraro

640 Technical data, tools, description
641 Front axle housing
643 Hubs
644 Differential
645 Adjustments

70 Frame and wheels

710 Tractor frame
720 Tyres and wheel discs

80 Cab and shields

810 Cab
820 Shields
830 Air conditioner

90. Working hydraulics

91 Tractor working hydraulics

910 Technical data, tools, description
911 Pump and pipes, pressures
912 Power lift hydraulics
913 Three-point linkage, towing hook

92. Auxiliary working hydraulic, e.g. front loader

100. Special tools

101 Special tools (ETV)
102 Locally prepared tools

Note! Separate fitting instructions for the optional equipments are inserted into the Service Manual. These instructions are posiĆ
tioned to the end of each main group. E.g. code 39 are placed to the end of group 30.

10
 Model Code Page
12. Repairs 95, 105, 115 120 1
1. 11. 2000 X100-X120

General instructions for repairs

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

Sealing compound and glue

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

Tightening torques and setting values

All necessary tightening torques and setting values for each repair operation are given at the beginning of each repair section
under the heading Technical Data. The most important values can also be found in the repair instructions.

Table 1 later gives the tightening torques in order of dimension, quality and surface treatment. The values given in the table should
be used if the tightening torque is not given in the repair instructions.

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

Trouble-shooting

The following procedure, combined with the information contained in the workshop manual will be helpful in tracing faults accuĆ
rately. It consists of following a number of logical steps to locate and correct the problem:

a) Determine the problem

b) List possible causes

c) Differentiate the causes

d) Conduct checks in logical order to determine the exact cause

e) Consider approximate remaining service life against cost of parts and labour..

f) Make any necessary repairs.

g) Recheck the parts and functions for correct operation

11
 Model Code Page
12. Repairs 95, 105, 115
1. 11. 2000 X100-X120 120 2

Handling of heavy components Cleanliness

Unless otherwise specified, all removals should be accomĆ To ensure long life of a machine, it is important to keep dirt and
plished using adjustable lifting equipment. All supporting foreign material out of its vital working components. PrecauĆ
slings must be parallel to each other and as near vertical as tions must be taken to safeguard against this. Enclosed comĆ
possible in relation to the object being lifted. However, where partments, seals and filters have been provided to keep the
slings are of a far greater capacity than the weight of the load supply of air, fuel and lubricant clean. These protective deĆ
to be fitted, a triangular lifting arrangement may be used. vices must not be removed.

Whenever hydraulic, fuel, lubricating oil or lines are disconĆ

nected, clean the point of disconnection and the surrounding
area. As soon as a line has been disconnected, cap, plug or
tape the line or opening to prevent the ingress of foreign maĆ
terial.

The same cleaning and covering precautions should be taken

when access covers or inspection plates are removed.

Oikein Correct Väärin Clean and inspect all parts. Make sure that all passages and
Mauvais
Rätt Teisingai Fel holes are clear. Cover all parts to keep them clean. Make sure
NeteiĆ
Right Wrong singai parts are clean when they are reassembled. Leave new parts
Richtig Falsch in their wrapping until they are actually needed for reassembly
Giusto Sbagliato

When removing a component at an angle, remember that the Assembly

capacity of an eyebolt is reduced when the angle between the
supporting members and the object becomes less than 90°. When reassembling a machine, complete each step in seĆ
quence. never partially assemble one part then start to asĆ
semble another. Make all recommended adjustments. AlĆ
ways check the job on completion to ensure that nothing has
been overlooked. Recheck the various adjustments before
B putting the machine back into service.

Note! Before fitting new parts, remove rust preventative comĆ

pound from all machined surfaces (usually "peel-off subĆ
C stances).

Lubrication
D
Where applicable, fill the compartments of repaired or reĆ
newed components with the quantity, type and grade of clean
lubricant recommended in the routine maintenance section of
the Operator's Manual.
A
Shims

When shims are removed, tie them together and identify their
location. Keep shims clean and take care not to bend them
Forged eyebolt support before refitting them.

A. Load Gaskets
B. Lifting shackle
C. Shackle retaining plate ( 3 mm thick) Make sure that the holes in gaskets line up with lubricating oil
D. Sleeve passages in the mating parts. If gaskets have to be made, use
material of the correct type and thickness. Make sure that
When necessary the forged eyebolt can be supported in the holes are punched in the right places.
way shown in figure above. Sleeve D may or may not be Incorrectly punched gaskets can cause serious damage.
welded to plate.
Lip type rubber seals
Warning! If a part resists removal, check that all nuts and bolts
have been removed and that there is no interference from adĆ Lubricate the lips of lip-type rubber seals with oil before fitĆ
jacent parts. ment. Do not use grease on seals, except for grease seals.

12
 Model Code Page
95, 105, 115
12. Repairs X100-X120 120 3
1. 11. 2000

ÇÇÇÇ
ÉÉÉÉ
4
É
ÇÇÇÇ
ÉÉÉÉ
É
ÉÉÉÉ 5

The main parts of lip-type seal: Correct and incorrect method of fitting and bending locking
1. Case tabs.
2. Sealing element
3. Ring spring

The figure above shows the construction of a simple lip-type Slackening of nuts and bolts is prevented by mechanical
seal. The cross section shows the heel (4) and the toe (5), means such as lockwashers, tab washers and cotter pins, or
used to identify the sides of a single element seal. With a few by Loctite-type locking agents.
exceptions, the toe of a single-lip is located on the lubricant
side. Some seals have a second auxiliary lip which has no Flat retainers must be installed properly to be effective. Bend
spring. one end of the retainer against the edge of the part. Bend the
other end against one of the nut or bolt head.Always fit new
Cables and wires retainers in compartments which house moving parts. When
fitting lockwashers on aluminium housings, place a flat
washer between the lockwasher and the housing.
When removing or disconnecting a group of cables or wires,
label each one to ensure correct refitment. Note!
1) Never fit a lockwasher (Grower, fan, spring, etc.) under a nut
or bolt to which a specified torque has to be applied.
Locking devices
2) Always thoroughly degrease components before applying
Loctite type locking agents.

Bushes and press fits

Do not fit bushes with a hammer alone. Use a suitable fitting
tool and a hammer or, better still, a press if possible..

When using a press, ensure that pressure is applied directly

in line with the bore. If the ring has an oil hole, take care to align
it with the oil hole in the mating part. When press fitting a part
into another part, lubricate the mating surfaces. Tapered parts
should be assembled dry. Before assembly, check that the
tapers are dry and free from burrs.

Fitting bolts in blind holes

Correct and incorrect use of retainers
Use bolts of the correct length. A bolt which is too long may
"bottom" before the head comes into contact with the part it
is to hold: this will cause damage to the threads. If a bolt is too
short, there may not be enough threads engaged to hold the
part securely.

13
 Model Code Page
12. Repairs 95, 105, 115
1. 11. 2000 120 4
X100-X120

Table

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

Tightening torques Nm1)

Dim. Quality, surface treatment, material and so on
8.8 8.8 8.8 10.9 12.9
lubr. tol.± Zne2) tol± Znk3) tol. ± lubr. tol. ± lubr tol. ±
M4 - - - - -
M5 6,4 0,6 5,7 0,5 - 9 1 11 1
M6 11 1 10 1 12 1,2 15 1,5 18 2
M8 25 2 23 2 30 3 35 4 45 5
M10 50 5 45 5 60 5 70 7 90 10
M12 90 10 80 8 100 10 125 10 151 15
M14 140 15 125 10 160 15 200 20 240 20
M16 220 20 195 20 250 25 300 30 370 40
M18 300 30 270 30 350 35 430 40 510 50
M20 430 40 380 40 480 50 600 60 720 70
M22 570 60 500 50 650 65 800 80 970 100
M24 740 70 660 70 830 80 1030 100 1250 120
M27 1100 100 950 100 1200 120 1500 150 1800 180
M30 1500 150 1300 130 1600 160 2040 200 2500 250

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

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

14
 Model Code Page
95, 105, 115
12. Repairs X100-X120 120 5
1. 11. 2000

Conversion table for common units

Quantities and units Conversion factors

Overall and detail dimensions millimetres (mm) 100 mm=3,94 inches

1 inch=25,4 mm

Short distances e.g. turning circles metres (m) 1 m=3,28 ft

1 ft=0,305 m

Travel distances kilometres 1 km=0,62 mile

1 mile=1,61 km

Tractor weights, axle loadings kilograms (kg) 1 kg=2,2 lbs

1 lb=0,454 kg

Travel speed kilometres per h (km/h) 1 km/h=0,62 mph

1 mph=1,61 km/h

Drawbar pull kilonewtons (kN) 1 kN=224,8 lbs

1 lb=4,448 N

Power (identified by such terms as crankshaft power, 1 kW=1,34 hp

pto power, belt power, drawbar power, indicating 1 hp=0,746 kW
the point at which the measurement was taken)
kilowatts (kW)

Engine torque newton metres (Nm) 1 Nm=0,74 ft lb

1 ft lb=1,356 Nm

Fuel consumption by weight (kilograms per hr, kg/h) 1 kg/h=2,2 lb/hr

(by volume) litres per hr (l/h) 1 lb=0,454 kg
1 l/h=0,22 gal/hr
1 gal=4,54 l

Fuel economy (specific fuel consumption) 304 g/kWh=0,5 lb/hp hr

grams per kilowatt hr (g/kWh)

Engine displacement litres (l) 1 l=61,02 m cu in

100 cu in=1,639 l

Hydraulic pump 1 MPa=145 psi

pressure-mecapascal (MPa) 1000 psi=6,9 MPa
delivery-millimetres per sec (ml/s) 100 ml/s=1,32 gpm
1 gpm=75,77 ml/s

Tyre
pressure-kilopascal (kPa) 100 kPa=14,5 psi
1 psi=6,9 kPa

Area acres-hectare To convert multiply by

0,404686

Volume bushel-litre To convert multiply by

39,3687

Quantity pound per acre-kilogram per hectare Multiply by 1,12085

Volume Multiply by
superficial foot-cubic metre 0,002360

15
16
 Model Code Page
13. Maintenance 95, 105, 115
1. 11. 2000 130 1
X100-X120

Maintenance ValtraValmet
95, 105 and 115
X100, X110 and X120 Greasing lubricating points fitted with
grease nipples
N.B. Detailed maintenance instructions, see Operator's
Manual. - Always clean the grease nipples before applying the
grease gun.
- Apply grease through the nipples until clean grease
General oozes out (unless otherwise instructed).
- Wipe away superfluous grease which has been
Correct maintenance at the right time is a basic condition pressed out at the lubricating point.
for reliable operation of the tractor. Maintenance costs are - Preferably carry out lubrication with bearing points
small compared with any repair costs resulting from lack of and joints unloaded and with the bearings in different
maintenance. The most important measures are those positions.
which you carry out yourself and which include lubrication
and various checks and adjustments.
Lubrication and maintenance schedule
The service intervals shown apply for normal operating
conditions but in more severe conditions servicing should
All intervals are counted from zero hours on the hour recorder.
be carried out more frequently.
For example, 1000 hours service is carried out every 1000
(yearly), 2000 hours (every other year) etc. even if the guaranĆ
General instructions concerning oil tee service has been carried out.
checks and oil filling
- Always stop the engine before starting work Example: The 1000 hour service contains all items mentioned
- Apply the parking brake to ensure the tractor cannot under 10 h/Daily, 50 h/once a week, 250 h, 500 h and 1000 h.
move. If the ground is uneven the wheels should be
scotched
- Wash down the tractor first so that the work can be
done more easily and quickly.
- Always observe the utmost cleanliness in all maintenĆ
ance work. Thoroughly wipe off filler caps and plugs as
well as surrounding parts of the tractor before filling up
with fuel or oil.
- Inspect the oil and filters when changing. Large
amounts of dirt (e.g. heavily clogged filters) can point to a
fault which could cause extensive and costly repairs if not
corrected in time.
-When carrying out checks the tractor should stand on
level ground.
- Levels should be checked in the morning when the oil
is cold and has had time to run down to the bottom of the
unit concerned.
- When changing the oil, bear in mind that the oil can
be very hot when it drains from the tractor. Waste oil and
oil filters should be handled carefully and disposed of
properly
- After completion of the service work always replace all
safety covers etc.

17
 Model Code Page
95, 105, 115
13. Maintenance X100-X120 130 2
1. 11. 2000

Maintenance schedule

13
16 5 14 6 14 15 8 13 10 6 1 14 6 13
6

7
4

6
5 6 15 6 14 11 14 6 2 14 13 10 9 2
60A-10,5

Daily/every 10 hours Every 250 hours

1. Check engine oil level
2. Check coolant level and radiator fins 12. Grease door and window hinges and locks
3. Check for leakage 13. Change engine oil and filter
14. Grease the following parts:
- joints of powered front axle (2 nipples)
Weekly/every 50 hours - power transmission shaft of the front axle
(4 nipples)
- shaft between transmission and motor
4. Grease three-point linkage and trailer hitch, option
(4 nipples)
5. Grease brake mechanism (high pressure
15. Check brake fluid level and clutch fluid level (95, 105
grease)
and 115)
6. Grease the following points:
16. Clean cab ventilation air filter
- bearings of front axle mounting (2 nipples)
17. Check wheel nuts and bolts and tyre pressures
- front axle king pins (4 nipples), Carraro axle only
- frame steering bearings (2 nipples)
- steering cylinders bearings (4 nipples)
7. Check oil level in transmission and hydraulics
8. Clean the prefilter of the engine air intake
9. Check belt/belts tightness
10. Check fuel system pre-filter (X100-X120) /check/
empty water trap (95-115)
11. Check electrolyte level in battery

18
 Model Code Page
95, 105, 115
13. Maintenance X100-X120 130 3
1. 11. 2000

25 23 35
24 27 22 30 32a 24 34 26 28 25 34 18 29 21 34 31 33

22

20 27 22 32 19 21a 20 34 37 38 29 21 25 36
32a 23 60A-11,4

Every 500 hours

18. Clean water trap of fuel system, 95-115
19. Check brake pedal free travel
Every 2000 hours/every other year
20. Change pressure filters of transmission and
hydraulics and hydraulics return oil filter or if filter warnĆ 33. Change engine coolant
ing light comes on 34. Change brake fluid and clutch fluid (95-115)
21. Check oil level in front axle differential and hubs 35. Check and clean injectors (when using biodiesel after
21a. Calibrate gas pedal, X100-X120 every 1000 hours)
36. Check alternator
37. Check starter motor
Every 1000 hours/yearly
Every 4000 hours
22. Change oil in transmission/hydraulics and clean sucĆ
tion strainer 38. Check turbocharger (authorised workshop)
23. Change oil in front axle differential and hubs
24. Change cab ventilation air filter and recirculation
filter
25. Change fuel filter and change pre-filter (X100-X120)
26. Change air filter and safety filter
27. Grease rear drive axle bearings, 95-115
28. Grease flywheel ring gear
29. Check/adjust front wheel toe-in
30. Clean fuel tank
31. Adjust valves
32. Change transmission housing breather
32a. Calibrate gas pedal and check function of HiTech
shuttle (X100-X120)
32b. Tighten frame bolts and nuts

19
 Model Code Page
95, 105, 115
13. Maintenance X100-X120 130 4
1. 11. 2000

Recommended fuel and lubricants (all capacities are incl. of filters)

Volume,
Part of machine Valtra grade SAE grade API grade when chanĆ
ging (litre)
Engine, 4-cylinders: Valtra 10W/30: -20°C...+30°C CE
13
-95, 105, 115, X100, X110, X120 Engine 15W-40: -10°C...+40°C CF/CF-4
min 34, max 43
(105, 115,
J02316-:max
45),
extra max 50
Tractor's hydraulic system and Valtra HT 60: -30°C...+30°C GL-4 (105, 115,
transmission Transmission HT 100: -10°C...+40°C (G2-98) J02316-: extra
max 53).
95-X120 *):
min 45, max
55, extra max
65.
Industrial powered front axle:
-differential, 95-115 (Dana) 8
80W 90
80W-90 GL 5 (LS)
GL-5
-differential, X100-X120 (Carraro) Valtra Axle 6
-hub reduction gears 2x1,5
Fuel tank Diesel fuel 135
Engine cooling system
-95, 105 normal/with openable grill 15,5/19,5
water + anti-freeze
anti freeze agent (standard ASTM D3306-86a
D3306 86a or BS
-115 20,5
6580:1985)
- X100 17
- X110, X120 22
Brake fluid reservoir 0,3
Brake fluid SAE J1703
Clutch fluid reservoir (not HiTech) 0,2
Windscreen washer Washer fluid 3
Auxiliary hydraulics oil tank Oil DIN 51524 (HVLP 32) 100
*) Chassis numbers, see page 450/6.

For HiTech transmission/hydraulics is not available suitable bio oil.

Biodiesel fuel
-In the Valmet engines it is accepted to use esterified rape oil as biodiesel fuel - or RME (rape oil esterified with methanol)
without technical modifications on the engine. The requirement for the acceptance is that the biodiesel that is used is very
pure and that it fills the Austria "Ö1190" biodieselnorm demands of pureness. Practically it means that the amount of pure
carbon, hydrogen and oxygen content together in the biodiesel is more than 99 %.
-In the service instructions there is one change: checking cleaning of nozzles every 1000 hours.

Viscosity classes according to ambient temperature

80W/90

10W/30

15W/40 HT100

HT60
'
-30° C -20° C -10° C 0° C +10° C +20° C +30° C +40° C

20
 Model Code Page
95, 105, 115
13. Maintenance X100-X120 130 5
1. 11. 2000

Maintenance of optional fixed front

loader

Maintenance weekly (at least every 50 Note! In service inspection after 100 running hours, the front
loader oil filter must be changed.
hours)
Note! Regularly check the tightening of the bolts and nuts for
1. Grease loader bar pivots (24 nipples). the front axle locking cylinder attachments. Check now and
2. Grease nipples of the front axle locking cylinders in the then that the breathers are open. They can be loosen by unsĆ
lower parts of the cylinders (2 nipples).
rewing.
3. Check hydraulic oil level

Maintenance at every 250 hours

4. Grease the drive shaft of the loader's variable displaceĆ

ment pump (3 nipples)

Maintenance at every 1000 hours (or

yearly)
5. Change hydraulic oil and filter

21
22
 21. Engine

20. Engine
22. Fuel system

23. Cooling system

21
22
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 1

Contents
General (Op. no. 210):

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Repair instructions

Cylinder block and flywheel housing (Op. no. 211):

1. Cylinder block and cylinder liners:

A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Fitting plug at rear end of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H. Fitting cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. Flywheel housing:
A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Changing flywheel starter gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cylinder head and valve mechanism (Op. no. 212):

1. Cylinder head:
A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Changing valve seat inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Crank mechanism (Op. no. 213):

1. Crankshaft:
A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing crankshaft ring gear (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Connecting rods and pistons:

A. Removing piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

23
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 2

D. Connecting rods, weight classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

E. Changing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Checking piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. Fitting piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
H. Fitting piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Balancer unit, 420 ---engines:

A. Removing and dismantling balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Reconditioning balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Fitting balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engine timing gears (Op. no. 214)

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

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

A. Reconditioning oil relief valve for lubrication oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fitting oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inlet and exhaust system, turbocharger (Op. no. 216):

A. Checking air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Checking inlet and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Reconditioning turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

24
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 3

Specifications (see also page 210/17)

Tractor 95 95 (41/00---) 105 115

Designation 420 DW 420DW 420 DS 420 DWI

Turbocharger yes yes yes yes (+interc..)
No of cylinders 4 4 4 4
Displacement (litres) 4,4 4,4 4,4 4,4
Cyl. bore (mm) 108 108 108 108
Stroke (mm) 1120 1120 120 120
Compr. ratio 16,5:1 16,5:1 16,5:1 16,5:1
Output (kW/r/min DIN) 70/2225 73,5/2200 77/2225 85/2225
Torque (Nm/r/min DIN) 390/1550 415/1400 405/1550 440/1550
Moment rise % 31 30 22 21
Low idling (r/min) 750 750 850 850
Compr. press 1) (bar) 24 24 24 24
Max. no-- load revs (r/min) 2425 2400 2425 2425

Tractor X100 X110 X120

Designation 420DWRE 420DWRE 420 DWRIE

Turbocharger yes yes yes, interc.
Number of cylinders 4 4 4
Displacement (litres) 4,4 4,4 4,4
Cyl. bore (mm) 108 108 108
Stroke (mm) 120 120 120
Compr. ratio 16,5:1 16,5:1 16,5:1
Output (kW/r/min DIN) 73,5/2200 81/2200 88/2200
Torque (Nm/r/min DIN) 430/1400 460/1400 490/1400
Moment rise % 35 31 28
Low idling (r/min) 850 850 850
Compr. press. 1) (bar) 24 24 24
Max. no load revs (r/min) 2400 2400 2400

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

Valves, rockers and tappets

With a valve clearance of 1,0 mm:
--- inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0˚±2˚ B.T.D.C
--- inlet valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16˚±2˚ A.B.D.C
--- exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39˚±2˚ B.B.D.C
--- exhaust valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1˚±2˚ A.T.D.C
Valve clearance cold and hot:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
Angle of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚+20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚+20’
Width of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm
Angle of valve face:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚ ---20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚ ---20’
Outside diameter of valve head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 mm
Max valve movement:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,9 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,1 mm
Inlet valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,960...8,975 mm
Exhaust valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,925...8,940 mm
Inlet valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,055 mm
--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm
Exhaust valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,090 mm
--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm

25
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 4

Inside diameter of valve guide before fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000...9,015 mm

Outside diameter of valve guide . . . . . . 16,028...16,039 mm
Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm
Protrusion of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Depth of valve face below cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,8 mm
Spring pressure when spring compressed to a length of:
--- 48,6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327±17 N
--- 37,4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500±23 N
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,959...19,980
Inside diameter of rocker arm bearing bush:
--- (when fitted in position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,990...20,010 mm
Outside diameter of rocker arm bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,035...23,075 mm
Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000...23,021 mm
Max. permissible push rod deflection (when free) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 mm
Free length of rocker arm spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring pressure when spring compressed to a length 58 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . 80...100 N
Outside diameter of tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29,939...29,960 mm
Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,000...30,043 mm
Engines from week 34 1996:
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,970...22,990 mm
Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000...23,021 mm

Camshaft

Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,925...49,950 mm

Diameter of camshaft bearing journals (others that no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,885...49,910 mm
Diameter of camshaft bearing journals nos 2, 3 and 4 (620/634---engines) . . . . . . . . . . . . . . . . 49,865...49,890 mm
Inside diameter of camshaft bearing bushes (when fitted in position) . . . . . . . . . . . . . . . . . . . . . 50,010...50,070 mm
Diameter of camshaft bearing bores (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,000...50,025 mm
Camshaft clearance in bearing bush no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,145 mm
Camshaft clearance in bearing bushes (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,090...0,140 mm
Camshaft clearance in bearing bushes nos 2, 3 and 4 (620/634---engines) . . . . . . . . . . . . . . . . 0,110...0,160 mm
Bearing bush tolerance in block (press fit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,080 mm
Diameter of bearing bush bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,620...55,650 mm
Camshaft end play with 0,5 mm gasket between cylinder block and timing gear
housing and between timing gear housing and front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Cam height (distance between back of cam and tip of cam):
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,180...41,430 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,080...40,330 mm
Cam lift:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,38 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,28 mm
Camshaft max permissible deflection (total indicator reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03 mm

Cylinder liners

Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,030...0,080 mm

Max. permissible height difference between liners (under same head) . . . . . . . . . . . . . . . . . . . . 0,02 mm
Outer diameter of cylinder liner guide:
--- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,475...124,500 mm
--- at lower end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122,961...122,986 mm
Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108,000...108,022 mm
Height of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,03...9,05 mm
Height of cylinder liner flange, 1st oversize, part no 8366 47933 . . . . . . . . . . . . . . . . . . . . . . . . . 9,08...9,10 mm
Height of cylinder liner flange, 2nd oversize, part no 8366 47934 . . . . . . . . . . . . . . . . . . . . . . . . 9,13...9,15 mm
Height of cylinder liner flange, 3rd oversize, part no 8366 47935 . . . . . . . . . . . . . . . . . . . . . . . . . 9,23...9,25 mm
Outer diameter of cylinder liner flange . 131,700...131,800 mm

Piston, rings and gudgeon pin

Minimum distance between piston and cylinder head (measured with a piece
of lead wire thought the injector location hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,900...1,150 mm
Piston diameter:
--- 17 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107,873...107,887 mm

26
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 5

Pin bore in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,003...40,009 mm

Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,991...40,000 mm
Width of ring grooves:
--- 1st groove tapered groove
--- 2nd grove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,520...2,540 mm
--- 3rd groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,040...4,060 mm
Side clearance of piston rings in their grooves:
--- 1st ring, tapered
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,062 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,082 mm
--- reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 mm

Piston ring height (in direction of cylinder):

--- 1st ring tapered
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,478...2,490 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,975...3,990 mm

Piston ring gap (with piston fitted in cylinder)

--- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40...0,55 mm
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,60...0,80 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30...0,60
--- reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 mm

Max. permissible weight difference between pistons in same engine . . . . . . . . . . . . . . . . . . . . . 25 g

Piston to be heated up to 100˚C before fitting gudgeon pin.
Piston position in cylinder: combustion chamber of piston to face towards injector.

Connecting rod

Inside diameter of piston pin bush (with bush pressed into connecting rod) . . . . . . . . . . . . . . . 40,025...40,040 mm
Outside diameter of piston pin bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,082...44,120 mm
Interference fit: connecting rod small end bushing ---connecting rod . . . . . . . . . . . . . . . . . . . . . . 0,057...0,120 mm
Connecting rod small end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025
Connecting rod big end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71,730...71,749 mm

Big end bearing shell thickness:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835...1,842 mm
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,960...1,967 mm
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,085...2,092 mm
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,335...2,342 mm
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,585...2,592 mm
Big ---end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,046...0,098 mm
End float (side clearance) at big ---end on crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,200...0,410 mm
Piston pin bushing location perpendicular to longitudinal axis of connecting
rod to be within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15:100
Piston pin bushing location and big ---end bearing location to be parallel to within . . . . . . . . . . 0,05:100
Weight marking (letter) at lower end.
Max. permissible weight difference between connecting rods in the same engine . . . . . . . . . . 20 g
Position of connecting rod; order no at valve mechanism side
(away from the combustion chamber in the piston)

Crankshaft

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

27
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 6

--- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,981...67,000 mm

--- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,481...66,500 mm
Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000...40,160 mm

Main bearing journal diameter:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,985...85,020 mm
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,735...84,770 mm
--- 2nd undersize 0,50mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,485...84,520 mm
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,985...84,020 mm
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,485...83,520 mm
Main bearing location diameter (in cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm

Main bearing shell thickness:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,955...2,965 mm
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,080...3,090 mm
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,205...3,215 mm
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,455...3,465 mm
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,705...3,715 mm

Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,050...0,127 mm

Length of thrust bearing journal (journal nearest to flywheel):
--- standard (2 standard thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,000...45,080 mm
--- 1st oversize (one std and one 0,1 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . . . . . 45,100...45,180 mm
--- 2nd oversize (one std and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . . . . . 45,200...45,280 mm
--- 3rd oversize (one 0,1 mm and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . . 45,300...45,380 mm
--- 4th oversize (two 0,2 mm overthick thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,400...45,480 mm

Other crankshaft journals may not be ground longer.

Crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,100...0,380 mm

Max. permissible ovality and other deformity of crankpins or journals . . . . . . . . . . . . . . . . . . . . 0,03 mm
Crankshaft unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm Max.
Balancing unit ring gear location, diameter (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150,220...150,260 mm
Balancing unit ring gear I.D. (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150,000...150,040 mm

Flywheel

Flywheel ring gear no. of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 pcs

Interference fit between ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,425...0,600 mm
Before fitting the ring gear, heat up to a temperature of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150...200˚C
Flywheel unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm Max
Max permissible axial wobble of flywheel clutch face, measured at inner edge
of clutch face on diameter 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06:ø200

Timing gears

Tooth backlash:
Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Max. permissible side wobble of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm
Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,951...54,970 mm
Inner diameter of idler gear bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,000...55,030 mm
Inner diameter of Idler gear hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,000...60,030 mm
Camshaft gear hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,025 mm
Camshaft end diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,043...32,059 mm

28
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 7

Timing marks:
Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre between
compression and power strokes.
On crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 dots on tooth
On idler gear:
--- against crankshaft gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 on tooth
--- against camshaft gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on tooth
--- against fuel injection pump gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on notch
On camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on notch
On injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on tooth

Cylinder block

Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,250...13,320 mm

Main bearing location diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm
Main bearing location (with bearings 8361 40950) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92,000...92,025 mm
Cylinder liner location, diameter:
--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,514...124,554 mm
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,000...123,040 mm
Inner diameter of camshaft bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,010...50,070 mm
Cylinder block height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428,170...428,430 mm

Distance between piston and top dead centre at different crank shaft angles

Grad 420 engines Grad 420 engines

mm mm
6˚ 0,423 21˚ 5,100
10˚ 1,173 22˚ 5,587
11˚ 1,418 23˚ 6,095
12˚ 1,686 24˚ 6,624
13˚ 1,976 25˚ 7,173
14˚ 2,289 26˚ 7,742
15˚ 2,625 27˚ 8,331
16˚ 2,983 28˚ 8,939
17˚ 3,363 29˚ 9,567
18˚ 3,765 30˚ 10,213
19˚ 4,188
20˚ 4,633

Cylinder head
Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,800...105,000 mm
Height (min.) of cylinder head after repair grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,000 mm
Cylinder head straigthness:
--- in lateral direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm
--- in longitudinal direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,10 mm
Valve guide inner diameter (not fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000---9,015 mm
Valve guide outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm
Valve guide bore diameter in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm
Height of valve guide upper end from cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Valve head depth from cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm (max. 1,70 mm)
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm (max. 1,60 mm)
Valve sealing surface angles:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚+20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚+20’
Valve sealing surface width:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm
Diameter of exhaust valve seat insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,070...44,132 mm
Diameter of exhaust valve seat insert location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025 mm
Diameter of exhaust valve seat insert (repair part 8366 52269) . . . . . . . . . . . . . . . . . . . . . . . . . . 44,270...44,332 mm
Diameter of exhaust valve seat insert location (repair part 8366 52269) . . . . . . . . . . . . . . . . . . . 44,200...44,225 mm

Diameter of inlet valve seat insert (8366 47936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,570...48,632 mm

Diameter of inlet valve seat insert location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,500...48,525 mm
Diameter of inlet valve seat insert (repair part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,770...48,832 mm
Diameter of inlet valve seat insert location (repair part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . 48,700...48,725 mm

29
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 8

Lubricating system

Oil pressure at normal running temperature:

--- at idling speed (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa (1,0 kp/cm2)
--- at running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250---400 kPa (2,5---4,0 kp/cm2)
Free length of oil pressure valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring pressure when valve spring is compressed to a length of 52 mm . . . . . . . . . . . . . . . . . . 54+5 N (5,4+0,5 kp)
Diameter of oil pressure valve plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,602...19,635 mm
Diameter of oil pressure valve cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,700...19,752 mm
Oil filter by ---pass valve opens at a pressure difference of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2±0,5 kp/cm2

Oil pump (420 engines)

Backlash between gears when crankshaft lies firmly against the lower side of main bearings:
--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,16...0,26 mm
Diameter of drive shafts:
--- at bearings for body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
--- at gear wheel pressed on shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,099...18,109 mm
Diameter of shaft holes on body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000...18,018 mm
Diameter of gear wheel holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,060...18,078 mm
Drive shaft gear (press fit), distance between side gear (thread side) and first shoulder . . . . . 14,80...15,20 mm
Fixed shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,028...18,039 mm
Protrusion of fixed shaft end below pump body face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Thickness of cover gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06...0,08 mm

Outside diameter of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,486...43,525 mm

Housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,650...43,750 mm
Thickness of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,000...24,027 mm
End play of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,11 mm
Depth of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,000...24,043 mm
Number of teeth on drive gear (320 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 pcs
Number of teeth on drive gear (420 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 pcs

30
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 9

Balancing unit (420 engines)

Tooth backlash:
--- crankshaft ring gear ---balancer weight gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,3 mm
--- between the balancer weights gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,250 mm
Balancing weights end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,5 mm
Shaft diameter at bearing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,000...36,016 mm
Bearing bushing inner diameter (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,050...36,075 mm
Diameter of holes in body for shafts, rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,058...36,083 mm
Diameter of holes in body for shafts, front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35,958...35,983 mm
Shim thickness, cylinder block ---balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 mm

Schwitzer S1B (420 DS engines) and S1BG by ---pass turbo (420 DW engines)
Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0,14 mm
Shaft radial clearance1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0,51 mm
Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,1 Nm
By ---pass passage opening pressure (S1BG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,035 bar

1) Measured at nut on end of shaft.

Tightening torques

Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm

Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm+90˚+90˚+60˚
Cylinder head studs to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm + 90˚
Crankshaft nut:
--- 420 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm
Flywheel bolts:
--- 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Nm
--- 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
Flywheel housing bolts:
--- outer ring M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm (8.8), 150 Nm (12.9)
--- inner ring M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (8.8), 90 Nm (12.9)
Idler gear bolts:
--- M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
--- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Compressor V ---belt pulley, nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Balancing weights, 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Inlet manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Delivery valve retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Engine ---oil sump:
--- 320/420 engines M12 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm (8.8), 140 (12.9)
Nut for lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Lubricating oil pump fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm

31
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 10

Special tools
Order no Description
1 9051 73100 Puller for cylinder liner
2 9101 65600 *) Milling cutter for cylinder liner seat
3 9052 46400 Centring tool for flywheel housing
4 9052 46300 Drift for fitting rear crankshaft seal
5 9030 15200 Drift for fitting front crankshaft seal

6 9052 46620 Drift for 40 mm cap plug

7 9052 46650 Drift for 16 mm cap plug
8 9025 87400 Drift for fitting camshaft cup plug
9 9101 66300 *) Press tool for cylinder liner
10 9025 79200 Holder for dial gauge

11 9101 66100 *) T ---handle for valve seat milling cutter

12 9101 71100 *) Milling cutter for facing exhaust valve seat
13 9101 65502 *) Milling cutter for exhaust valve seat
14 9101 65503 *) Inner milling cutter for exhaust valve seat
15. 9101 75800 *) Milling cutter for facing inlet valve seat

16 9101 65505 *) Milling cutter for inlet valve seat

17 9101 65506 *) Inner milling cutter for inlet valve seat
18 9101 66200 *) Lever for compressing valve spring
19 9052 47200 Counter nut for lever above
20 9101 66000 *) Milling tool for injector seat
21 9052 46660 Drift for 36 mm cup plug
22 9101 65800 *) Drift for removing valve guide
23 9101 65900 *) Drift for fitting valve guide
25 9101 65700 *) Spanner for crankshaft nut

26 9052 48800 Puller for crankshaft gears

27 9020 01100 Conical sleeve for fitting pistons
28 9025 98900 Drift for fitting dust cover, crankshaft front seal
29 9025 98800 Drift for fitting tension pin in timing gear casing
30 9025 98700 Drift for fitting tension pins in timing gear casing and flywheel housing
31 8366 62022 Electronical device (TimeTrac) for checking injection timing on E ---engines
*) New tools for 20---series engines. Other tools are the same as for engines on 505---905 tractors.

6 7 8

1 2 4

5
10

32
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 11

11

12 15
18
19

13
16

14 17

21 22
20

26
23 24 25

27 28 29 30

31

33
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 12

Engine, description The lower face of the flywheel housing functions as a sealing
surface for the oil sump gasket. This means that the lower face
of the cylinder block must be level with the flywheel housing.

General When fitting the flywheel housing, its position is determined

by tension pins.
The Valmet 20---series engines (3---, 4---, or 6---cylinders) are
water ---cooled, four stroke, turbocharged, direct---injection
in ---line diesel engines. Technical values, see page 210/3.

The engines have a rigid and ribbed cylinder block. The crank
mechanism is designed for supercharging. The cylinder
liners are wet and supported at the middle, the cylinder head
bolts are high tensile bolts.

Cylinder block

The cylinder block is the main body of the engine, to which

other engine parts are attached. Wet and replaceable cylinder
liners are supported at the middle which reduces vibrations
and directs coolant circulation mainly to the upper part of the
liners.

The seal between the cylinder liner lower part and the cylinder
block is achieved by three o---rings, which are fitted in grooves
in the liner. The upper part is sealed by the cylinder head
gasket.

The camshaft is located in the cylinder block. The camshaft

front bearing location is fitted with a separate bearing sleeve.
The remaining bearing locations are machined directly in the
cylinder block. The drilling for the camshaft rear end is cov-
ered with a plug.

There are spaces on both sides of the rear main bearing for
guide bearing shims (the crankshaft thrust bearings).

Flywheel housing

The flywheel housing is fitted at the rear end of the cylinder

block. The seal for the crankshaft rear end is placed in a bore
in the housing. The starter motor fixing point is fitted in the fly-
wheel housing.

34
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 13

Crank mechanism
The crankshaft is forged from chrome alloy special steel and
is induction hardened at the bearing and sealing surfaces.
This makes it possible to grind bearings four times without a
new heat treatment. Gear wheels are located at the front end
of the crankshaft. They are a press fit, and drive the idler
wheel and oil pump. In addition, the front end of the crank-
shaft has splines for the hub of the V ---belt pulley. An oil deflec-
tor ring is fitted between the hub and gear wheel, and a dust
shield is fitted on the hub in order to protect the seal.

The crankshaft is supported on the cylinder block by main

bearings which are placed on both sides of each cylinder.
Thus there is one main bearing more than cylinders. The
crankshaft thrust washers are placed in both sides of the rear-
most main bearing.

At the rear end of the crankshaft there is fitted a flywheel on

which is a press---fit a starter ring gear. The forged crankshaft
has an I ---section cross---section. The bearing location at the
bottom end of the connecting rod is split, and the bearing cup
is secured by two special bolts and nuts. The upper part has
a wedge ---shaped bearing location, in which the piston pin
bearing bushing is fitted with a press fit.

The piston is made of an eutectic aluminium alloy. In the

Cylinder head upper face of the piston there is a combustion chamber. The
shape of the chamber is intended to maximise the mixture of
air and fuel. The piston has three rings. The upper molyb-
denum ---coated ring has a wedge ---shaped cross---section.
420---engine have one cylinder head. Each cylinder has its On natural aspirated engines and on slight supercharged
own inlet and exhaust ports located on either side of the head. engines the upper ring is right---angled. The middle ring is tap-
Between hot exhaust valves a cool inlet valve is fitted to bal- ered and it fits into its groove. The taper taking up the clear-
ance the thermal load. ance. The oil control ring is spring loaded and it has a two---
stage, chromed scraping edge.
Cylinder head bolts are high tensile bolts which are tightened
up to yield limit using angle tightening principle. Due to the
large stretch the tightening forces are kept constant during the
whole lifetime and retightening is unnecessary. On the turbocharged engines the upper ring location is
formed in a cast iron ring which is cast in the piston. In addi-
The injector locations are machined directly into the cylinder tion, the piston on supercharged engines is graphite coated
head. The inlet and exhaust valve guides are identical and can to ensure correct running ---in.
be interchanged. In addition, the exhaust valves are equipped
with replaceable valve seat inserts.
Four ---cylinder engines (420) are equipped with a balancer
unit. The eccentric weights, which rotate at twice the engine
speed, even out the vibration forces exerted by the movement
Valve mechanism of the pistons and the crank mechanism.

The valve mechanism is operated by the camshaft which is lo-

cated in the cylinder block. The drive is transferred with the
help of tappets and pushrods. The camshaft gear wheel is
fitted with a press fit and fixed with a key. Each bearing is lubri-
cated by the force feed lubrication system through drilled oil-
ways in the motor block.

35
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 14

Timing gears
The timing gear train consists of hardened, helically cut gear
wheels. The gears are encased by the timing gear casing
which is fitted to the front of the engine. The timing gear drives
the camshaft, fuel injection pump and oil pump.

The idler gear is supported with a bearing sleeve on the shaft

on the front face of the cylinder block.

36
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 15

Lubricating system (in 4-- cyl. engines the lubricat-

ing system is similar)

1. Lubricating oil pump

2. Pressure ---relief valve
3. Oil filter
4. Turbocharger
5. Main oil gallery
6. Oil pressure sensor

Lubricating system

The engine has a pressure lubricating system in which the oil

pump (gear pump) is attached to the cylinder block lower The oil pressure relief valve is located under the oil filter on the
face. The oil is sucked up by the pump through a suction left hand side of the engine. The valve regulates the lubricat-
strainer. After the pump the oil is led through an oilway to the ing oil pressure so that it is kept constant, regardless of the
relief valve and to the oil filter. After the filter, the oil is led engine speed. Oil pressure is about 2,5 ---4 bar depending on
through the main oil gallery from which oilways branch out. revs, oil quality and temperature, and at engine idling speed
The oil is led through the oilways in the main bearings and the pressure is min 1,0 bar.
through the crankshaft to the big ---end bearings.
The oil filter is full---flow disposable type and is fitted on the
left---hand side of the engine. A by ---pass valve is located at
The oil is further directed from the main gallery to the injection the base of the filter to ensure safe cold ---starting or to ensure
pump, turbocharger, balancing unit (420) and to a possible adequate lubrication in case the filter becomes blocked. In
compressor. In addition, the idler gear bushing, the camshaft addition, there is a non ---return valve which stops the filter
bearing points and the valve mechanism get their lubrication from being emptied of oil.
oil via the main oil gallery.

37
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 16

Induction and exhaust sys-

tem
The filtering system for the engine inlet air comprises an ejec- An electric service indicator is located in the filter body. This
tor type precleaner, and two paper filter elements, one of sender lights a control lamp on the instrument panel when the
which acts as the main filter and the other is a safety filter in- air filter is blocked. The inlet system also includes the hoses
side the main filter. The incoming air is made to rotate in the between the air cleaner and the turbocharger and the turbo-
filter housing. This causes most of the impurities to collect in charger and the induction manifold.
the lower part of the filter housing and these bigger impurities
are removed from the housing via the ejector pipe through the The exhaust manifold is attached to the cylinder head with
exhaust pipe The paper filter comprises two replaceable filter high tensile bolts without a separate gasket. Retightening of
elements. The paper is corrugated and surrounded by a metal the manifold bolts is unnecessary.
support.
The turbocharger is small and thus it reacts sensitively at low
The impurities in the air collect at the larger filter element engine revs. The turbocharger gets lubricating oil from the
which can be cleaned when necessary. The inner safety filter engine lubricating system.
prevents impurities form entering the engine should the main
filter element break, or be fitted incorrectly.

The air intake covering above the filter has a net, which filters
larger impurities.

The filter elements are accessible after removing the LH side

engine hood plate. There is a wing nut at the end of the filter
housing.

38
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 210 17

Engine designations in ValtraValmet tractors

1. Basic markings: 320, 420, 620 and 634. The first digit indicates the number of cylinders and the two last digits the stroke
(---20=120 mm, ---34=134 mm).

2. Letters after the basic markings:

--- D=diesel engine

--- S=turbocharger (Schwitzer)
--- W=by ---pass turbocharger (Schwitzer S1BG or S2BG)
--- B=Bosch P in ---line pump (1000, 3000 or 7100---series)
--- R=rotary distributor pump (Stanadyne)
--- I=intercooler
--- E=low emission engines (E ---engines)
--- C=emission tested engines (certificated).

Note! R24, E77 and EPA ---homologations has been made for E ---engines.

IMPORTANT! To make it easier to recognize the engines in the tractors with frame steering, the following comparisons can be
made:
--- 95 tractor has the same engine as an agricultural tractor 6400DW.
--- 105 has the same engine as 6600 tractor
--- 115 has the same engine as 6800 tractor
--- X100 has the same engine as 6550Hi tractor
--- 110 Hi has the same tractor as 6650Hi
--- X120 has the same engine as 6850Hi

NOTE! Engine designations of 95, 105, 115 and X100---X120 tractors are shown on page 210/3.

Starter motor Alternator

Position on the engine number on the RH side of the engine.

39
40
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 211 1

Repair instructions
Note! In the pictures the number of the cylinders can vary, but 9051 73100
the repair instructions are the same.

Cylinder block and flywheel housing

(Op no 211)

1. Cylinder block and cylinder liners

A. Measuring cylinder liner wear

Note! Cylinder liner wear can be measured when the engine

is attached to the tractor. Remove only the cylinder head and
crank the engine so that the piston is in the lower position.

1. Using a micrometer set the dial gauge to zero using a new

cylinder liner indicating the initial dimension of the bore:
108,00 mm.

2. Clean the inner surface of the cylinder liner thoroughly

before measurement.
C. Checking cylinder block

1. Clean the cylinder block and all oilways.

2. Check the cooling channels and remove the scale and sedi-
ment to ensure engine cooling.

3. Check the tightness of the cup plugs and threaded plugs

in the cylinder block as well as the condition of the cylinder
block and sealing faces.

4. Measure the wear of the camshaft bearing points (compare

with rating on page 210/4).

Note! If it is necessary to machine the upper face of the cylin-

der block, the pistons must be shortened by the same dimen-
sion. Observe the valve disc spaces on the piston upper face.

D. Changing camshaft bushing

3. Perform the measurement crosswise at the liner top end,
lower end and middle.
1. Extract the bushing with an internal puller, for example
4. Check the gauge reading for maximum wear and ovalness Sykes 854. If the camshaft rear end plug is removed the bush-
(compare with rating on page 210/4). ing can be forced out with a long drift.

2. Clean the bushing location.

B. Removing cylinder liner

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

1. If the cylinder liners are to be used again they should be

marked so that they can be fitted in the same position.

2. Remove the cylinder liners using cylinder liner puller 9051

73100.

41
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 211 2

0,1---0,4 mm

3. Press in a new bushing. Note the position of the oil hole. It

is unnecessary to ream the bushing because it has a correct
inner diameter when it is fitted in place.

5 4 3 2 1

E. Oversize bushings for camshaft

If the location of the camshaft bushing (front bearing) is dam-

aged, a bushing with a 0,4 mm oversize outer diameter can
be fitted. Bushings are available even for other camshaft bear-
ings which do not normally have bushings. Part numbers and
machining dimensions for the bushing locations are shown in
the figure.

Observe the position of the bushing oil holes. It is unnecess-

ary to ream the bushings after fitting.

140 mm 134 mm
6---7 mm

4 3 2 1

42
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 211 3

272 mm 134 mm
6---7 mm

4 3 2 1

Order no Hole diameter

1. 8363 24661 56,02...56,05

2. 8368 52460 55,42...55,45
Camshaft oversize bearing bushings for 420---engines. 3. 8368 52460 55,42...55,45
Numbering begins from the front end of the engine. 4. 8368 52461 55,64...55,67

F. Fitting plug at camshaft rear end

1. Clean the seat for the plug.

2. Apply sealing compound to the contact surface of the plug

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

3. Drive in the plug with fitting drift 9025 87400.

Note! Do not drive in the plug too far because it will affect the
camshaft end float.

43
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 211 4

G. Fitting pipe for oil dipstick

9101 65600
1. Clean the seat for the pipe.

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

3. Tap the pipe in to the correct fitting height with tool 9025
95900.

Note! The position of the pipe affects an oil level in the engine.
0,03---0,08 mm

9025 79200

H. Fitting cylinder liner

1. Clean the cylinder liner and its recess in the cylinder block.
Without o---rings the liner should rotate easily in its recess.

2. Apply a thin layer of marking paint on the underside of the

cylinder liner flange. Fit the cylinder liner without o---rings and
turn it forwards and backwards. Lift out the liner and check
that paint has been deposited on the whole contact surface.
9101 66300
3. If the recess is damaged, or the cylinder liner height (see
point 5) needs to be adjusted, use milling cutter 9101 65600.
If necessary, a light lapping can be executed after milling with
the help of the cylinder liner. Apply lapping paste to the under-
side of the cylinder liner flange, and twist the liner with twisting 5. Fit the cylinder liners and fix each liner with two press tools
tool. Lapping is not suitable for adjusting the cylinder liner 910166300. Measure the cylinder liner height with a dial
height. gauge and holder 9025 79200. Zero the dial gauge against a
flat surface, for example, the cylinder block face. Measure
4. Clean the contact surfaces. each liner in four places. The height of the liner above the cyl-
inder block face should be 0,03 ---0,08 mm. The height differ-
ence between cylinder liners under the same cylinder head
must not exceed 0,02 mm, nor must an intermediate cylinder
liner lie lower than an outer one.

44
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 211 5

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

flange is fitted.

Order no H Marking grooves

pcs
8266 47420 9,03+0,02 --- (norm)
8366 47933 9,08+0,02 1
8366 47934 9,13+0,02 2 9. Press the cylinder liners into the cylinder block. It should be
8366 47935 9,23+0,02 3 easy to press them fully home. Make sure that the liners do not
rise up after fitting.

Cylinder liners with oversize flanges (higher flanges) are

marked with grooves on the outer circumference as follows:

1st oversize, 0,05 mm = 1 marking groove

2nd oversize, 0,10 mm = 2 marking grooves
3rd oversize, 0,20 mm = 3 marking grooves

Note! Recess depth is adjusted with a cylinder liner recess

cutter 9101 65600.

7. If the liner height of a cylinder liner is not the same all the way
round, the cylinder liner flange and the cylinder block recess
depth should be checked. Cylinder liners with warped flanges
should be discarded.

Musta/Black/Svart/Noir
Schwartz/Juodi

Vihreä/Green/Grön/Vert
Grün/Žalias

8. Fit the o---rings into the grooves in the cylinder lower part
and lubricate them with a liquid soap (not with engine oil).

Note! Stretch the o---rings as little as possible when fitting

them. Max allowable stretching is 6 %.

45
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 211 6

2. Flywheel housing 8360 20054

A. Fitting flywheel housing

The flywheel housing is centred on the cylinder block by two
tension pins. Even the flywheel housings which are delivered
as spare parts have ready ---made holes for the pins.

1. Clean the sealing surfaces between the cylinder block and

the flywheel housing.

Note! If the crankshaft is worn at the sealing location, a 2 mm

spacer ring, part no 8360 20054, can be fitted in front of the
crankshaft rear oil seal.

2. Apply silicone sealant as shown in figure above.

3. Lift the flywheel housing into place and fit all the bolts.

4. Centre the housing and fit the tension pins with drift 9025
98700.

5. Tighten the fixing bolts, the inner ring socket head bolts to
60 Nm (8.8) or 90 Nm (12.9) and outer ring hexagonal bolts
to 110 Nm (8.8) or 150 Nm (12.9).

9052 46300

B. Changing crankshaft rear oil seal 5. Lubricate the sealing surfaces on the crankshaft and on the
seal. Place the seal on the crankshaft and drive it in until it bot-
1. Split the tractor at clutch (between frame joint and flywheel toms using drift 9052 46300. Other tools may cause the seal
to be damaged or mounted askew, resulting in leakage.
housing). Remove the clutch assembly/drive plate (and poss-
ible turbine clutch).
Note! The cranckshaft rear oil seal has been changed to a
Teflon type. The spare part seals have a mounting sleeve,
2. Remove the flywheel.
which must not be removed before fitting. The spare part
numbers do not change. When fitting the seal, place the plas-
3. Remove the oil seal. Do not damage the crankshaft.
tic sleeve on the crankshaft and push the seal on the sleeve
into place. Remove the sleeve and fit the seal with the special
4. Clean the seal location and grind off any burrs.
tool. The seal must be fitted dry.

46
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 211 7

C. Changing starter ring gear on flywheel Note! If a flywheel must be changed on the E ---engines, an
injection timing mark must be made on a new flywheel as fol-
If the ring gear is worn, change it with a new one. The ring gear lows:
cannot be turned around because its teeth are chamfered and
hardened on the starter motor side. --- Rotate the crankshaft so that the piston in the first cylinder
is in the top dead centre. Drop a valve down against the piston
1. Split the tractor between the frame joint and the flywheel top. Place a dial gauge stylus against the valve upper end and
housing. Detach the clutch assembly/drive plate (and poss- zero the gauge to the top dead centre. Rotate the crankshaft
ible turbine clutch) and the flywheel. in the running direction until the dial gauge shows value 4,633
mm after the top dead centre.
1. Detach the earlier ring gear by tapping it with a drift. Clean
the ring gear seat on the flywheel with a steel---wire brush. --- Drill the injection timing mark in the flywheel with the aid of
a drill shown below.

7
5 mm drill

8 mm guide

2. Warm the ring gear to the temperature of 150 ---200˚C. Fit

the ring gear with the inner diameter chamfering turned
against the flywheel and the teeth chamfering against the
starter motor.

3. Allow the ring gear to cool freely without using any coolant.

D. Fitting the flywheel

1. Clean the contact surfaces on the crankshaft rear flange

and on the flywheel.

2. Fasten the flywheel to the crankshaft rear end. As a guide

pins can be used studs (M12, 2 pcs) which are screwed in to
the flywheel fixing bolt holes.

Note! On the flywheel there is a fuel injection timing mark. Fit

the flywheel in the right position according to the guide pins.

Note! In the E ---engines there is an injection timing register

mark on the flywheel and the flywheel has been positioned
with a guide sleeve to the crankshaft.

3. Tighten the flywheel fixing bolts evenly to a torque of 140

Nm (10.9) or 160 Nm (12.9).

47
48
 Model Code Page
95-- 115
21. Engine X100-- X120 212 1
1. 11. 2000

Cylinder head and valve 2. Compress the valve springs using lever 9101 66200. Re-
mechanism (Op no 212) move the valve cotters, spring guide and spring. Remove the
valves.

1. Cylinder head
C. Checking cylinder head
A. Removing cylinder head
1. Remove carbon deposits from the exhaust ports, clean the
sealing surfaces and wash the cylinder head.
1. Remove the engine hood plates. Clean the engine exter-
nally and drain the coolant. Disconnect the coolant hoses 2. Check for cracks and other damage.
from the cylinder head and the thermostat housing.

2. Remove the suction hoses between the turbocharger and

the air filter and between the turbocharger and the inlet mani-
fold).

3. Disconnect the turbocharger pressure and return oil pipes.

4. Remove the pipes to the thermostart fuel reservoir.

5. Remove the injector leak ---off fuel pipes and the delivery
pipes. Remove the injectors. Fit blanking ---off caps on all
open connections.

6. Remove the inlet and exhaust manifolds and the thermostat

housing.

Note! It is possible to remove the cylinder head even thought

these parts are attached to the head.

7. Remove the valve cover and the breather hose. 3. Check the flatness of the cylinder head by using a straight
edge. An uneven or warped surface should be surface
8. Remove the rocker arm mechanism and the push rods. ground. The height of the cylinder head, after grinding, should
not be less than 104,00 mm. The valve disc depth from the
9. Loosen all the cylinder head bolts first by a 1/4 turn and then cylinder head surface should be 0,60 mm for the exhaust
remove them. Remove the cylinder head. valves and 0,70 mm for the inlet valves.

B. Removing valves

Ensure that valves which are to be re ---used are marked, so 9101 66000
that they are fitted in their original locations.

9052 47200

1. Thread the counterhold nuts 9052 47200 onto a screw stud

for the rocker arm mechanism. On the 320---, and
620---engines there is not a screw stud at the valves for the
centre cylinder. A bolt of suitable length should be used 4. Straighten and clean the injector location seat in the cylin-
instead. der head with cutter 9101 66000.

49
 Model Code Page
21. Engine 95-- 115
X100-- X120 212 2
1. 11. 2000

9101 65900

5. Measure the clearance between the valve stem and the

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

D. Changing valve guides

9101 65800 3. The guides are the same for the inlet and exhaust valves.
Ensure that the steepest chamfer on the guide, faces the valve
head. Check that the valves do not bind in the guides.

E. Machining valve seat

1. Press or knock out the old guides using drift 9101 65800.
Clean the valve guide locations.

2. Lubricate the outside of the new guides and fit them using
drift 9101 65900, which ensures the correct fitting height (21
mm over the spring face)
Machine the damaged valve seat with milling cutter (see page
210/10). If the width of the seat exceeds 2,3 mm in exhaust
and 3,7 mm in intake, it should be reduced primarily at the
outer edge.

The valve seat angle is 45˚+20’ for exhaust valve and

35˚+20’ for inlet valve.
50
 Model Code Page
21. Engine 95-- 115
X100-- X120 212 3
1. 11. 2000

G. Grinding valves
F. Changing valve seat inserts
In order to ensure that there is a proper seal around the valves,
Exhaust valves are fitted with separate valve seat inserts. If the there is a difference in the sealing surface angles. Thus there
sealing surface is damaged so badly that it cannot be repaired is a very narrow sealing surface which seals effectively even
with machining, the seat inserts should be changed. after prolonged running.

1. Grind the valve head on a discarded valve so that it sits

down in the valve seat. Fit the valve and weld it in place in the
seat. Cool with water.

2. Turn the cylinder head over and knock out the valve and
B
seat.
A
3. Clean the valve seat location. Cool the new seat in liquid ni-
trogen until it stops bubbling, or alternatively place it in dry ice.

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

N.B. Where necessary, standard size seats can be replaced

by inserts with a larger outer diameter. See Specifications.

A B
INLET 35˚ ---20’ 35˚+20’
11±0,1 EXHAUST 45˚ ---20’ 45˚+20’

1. Grind the damaged valve disc with a valve refacer. Adjust

angles to 45˚ ---20’ for exhaust valves and 35˚ ---20’ for inlet
valves.

2. If the edge of the valve head is less than 1,5 mm after it has
been ground, or if the valve stem is bent, the valve should be
discarded.
48,500...48,525
3. If necessary, grind the end of the valve stem.

4. Lap the valves with lapping paste and check the contact
surface with marking paint.

5. Clean the cylinder head and valves of any remaining lap-

ping paste.

The inlet valve seat machined direct on the cylinder head, can
be provided with a separate valve seat insert, order no 8366
47936. Machine the seat insert location on the cylinder head
(see figure above). Fit the insert like a seat of the exhaust
valve.
H. Fitting valves
Note! Engines on tractors 8550 and 8750 have the valve seat
inserts also on the inlet valves. From March 96 these cylinder 1. Check the valve springs for straightness, length and ten-
heads have been marked with letter V, which is stamped on sion using a spring tester. Compare with specifications.
the cylinder head front upper surface on the exhaust side. As
a spare part these heads can be fitted on all engines. The 2. Lubricate the valve stems and fit the valves in the correct
V ---marked cylinder heads are also available for the 4---cylin- order in the cylinder.
der engines.
3. Fit the springs, spring guides and valve keepers with the aid
of a lever for compressing valve springs, 9101 66200.

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

51
 Model Code Page
21. Engine 95-- 115
X100-- X120 212 4
1. 11. 2000

I. Fitting cylinder head

1. Measure the length of the cylinder head bolts. Compare 22 19 12 6 4 11 14 17

21 10 7
with dimensions shown in figure below. Change too long 2 16
bolts.

8 1 9

20 15
18 3 5 13
max. 142
420

4. Picture above show the correct tightening order of the cylin-

der head bolts. The order has also been marked on the cylin-
der heads.
max. 188,5
5. Tighten the cylinder head bolts progressively as follows:

1. First tightening to 80 Nm
2. Tightening of 90˚
3. Tightening of 90˚
4. Adjust valve clearances
5. Warm engine up to normal operating temperature with
light loading (approx. +75˚C)
6. Tightening of 60˚. Adjust valves.
2. Screw the cylinder head stud bolts in to the cylinder block
to a torque of 30 Nm. Fit the valve tappets if removed.

3. Check that the sealing surfaces are clean and fit the cylinder
head gasket(s) and the cylinder head(s). Ensure that on the
six cylinder engines both cylinder heads are parallel by
fastening lighty the exhaust manifold before tightening the
cylinder head bolts (the exhaust manifold can damage, if the
heads are not parallel). Clean and lubricate and fit the bolts.

Note! The cylinder head gasket order number is 8367 64156

(420 engines).

Tighten the exhaust manifold bolts/nuts to 50 Nm. DO NOT OVERTIGHTEN.

52
 Model Code Page
21. Engine 95-- 115
X100-- X120 212 5
1. 11. 2000

2. Valve mechanism 60˚

A. Reconditioning rocker arm mechanism

1. Check the valve tappets, especially the contact surface

against the camshaft. Worn or damaged tappets should be
discarded.

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

B. Changing camshaft/camshaft gear

1. Remove the inlet pipe between the turbocharger and the

2. Check the straightness of the pushrods by rolling them on induction manifold. Remove the valve cover and the breather
a surface table. Check also the spherical surfaces at the ends. pipe. Remove the rocker arm mechanism.

3. Dismantle and clean the rocker arm mechanism. Check the 2. Remove the radiator, cooling fan, alternator and the v ---belt.
shaft for wear and that the oilways are clean.
3. Remove the crankshaft nut. Remove the V ---belt pulley in-
cluding the hub.

4. Remove the timing gear casing cover (engine front cover).

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

bands to prevent them from falling through.

19,990...20,010

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

Note! Do not connect the pushrods too tightly as this might

cause them to bend or snap.

53
 Model Code Page
21. Engine 95-- 115
X100-- X120 212 6
1. 11. 2000

6. Crank the engine until the aligning marks on the idler gear 420 ---engines
and camshaft gear are facing each other. Extract the cam- --- rotate the crankshaft in the running direction until the valves
shaft. in the 4th cylinder are rocking (exhaust closes, inlet opens).
Check the valve clearance of the 1st cylinder
7. Separate the camshaft from the gear wheel using a press --- Rotate the crankshaft by 1/2 of a turn in the running direc-
or suitable drift. tion so that valves in the 3rd cylinder are rocking. Check
valves in the 2nd cylinder
8. Clean the parts which are to be refitted. --- continue according to the order of injection:
9. Fit the key in its groove. Heat the camshaft gear to 200˚C
in an oven and fit it on the shaft.
Injection order 1 2 4 3
10. Lubricate bearing surfaces and lobes and insert the shaft
in the cylinder block. Ensure that the aligning marks on the Valves rock in cyl. no 4 3 1 2
gears agree.

11. Fit the timing gear casing cover and the crankshaft V ---belt
pulley and hub.

12. Free the pushrods and fit the rocker arm mechanism.
Adjust the valves. Fit the valve cover and the breather pipe
and the inlet pipe between the turbocharger and the induction
manifold.

13. Fit the alternator. Fit the fan and the fan belt. Fit the radiator.

C. Adjusting valves
Note! DW tractors with a by ---pass turbo: The adjusting rod
of this turbo should be released before removing the valve
cover. Detach the front end joint of the rod. Do not detach the
rod rear end from the membrane box since then the by ---pass
passage opening pressure changes. Before adjustment, also I P I P I P I P
remove the silencer, fan space protective frame (if fitted),
radiator support iron in the upper part and the boost pipe (if
fitted), after which the valve cover can be removed.

420
I=inlet P=exhaust

Note! With effect from engine serial no. C6828, the support
strips have been added onto the valve covers. These strips
0,35 prevent the gasket from moving inwards. At the same time the
cover manufacturing accurancy has been improved. Spare
part numbers of the covers do not change.

The valve clearance, which can be adjusted on a hot or cold

engine, is 0,35 mm for both inlet and exhaust valves. The
clearance is adjusted when the respective piston is at T.D.C.
in the compression stroke. The valves for the different cylin-
ders are adjusted in the same sequence as the order of injec-
tion.

--- slacken the lock nut of the adjusting screw

--- measure clearance with a feeler gauge. The clearance is
correct when a 0,35 mm feeler gauge is slightly tight---fitted
between the rocker arm and the valve stem end. Adjust clear-
ance by rotating the adjusting screw.
--- tighten the locking nut and check the clearance

54
 Model Code Page
95-- 115
21. Engine X100-- X120 213 1
1. 11. 2000

Crank mechanism (Op. no 3. Refit the bearing caps with new bearing shells and tighten
them to the correct torque. Measure the I.D. with a dial gauge
213) which has been zeroed to the dimensions obtained in point 2.
With this method the indicator shows the actual bearing clear-
ance. Measure in several points in case the worn bearing
housing is not round.
1. Crankshaft

A. Removing crankshaft

1. Split the tractor at the clutch/drive plate, remove the clutch

assembly (and possible turbine clutch) and the flywheel.
Remove the engine (see also page 219/1).

2. Disconnect the balancing unit lubricating oil pipe from the

cylinder block and unscrew the balancing unit fixing bolts.
Remove the balancing unit and the lubricating oil pipe (only
420---engines).

3. Unscrew the lubricating oil pump pressure pipe fixing

screws from the cylinder block. Remove the oil pump and the
suction and pressure pipes.

4. Remove the flywheel housing.

4. If the bearing clearance exceeds 0,18 mm for main bear-
5. Detach the belt pulley/hub from the crankshaft front end
ings or 0,14 mm for connecting rod big ---end bearings with
(see instr. timing gears).
new bearing shells, the bearing journals on the crankshaft
should be ground. Refer to the specifications for the relevant
6. Remove the connecting rod bearing caps and push the
correct undersize and the corresponding bearings. Ensure
connecting rods out of the way of the crankshaft.
that the radii are not changed when grinding.
7. Remove the main bearing caps and lift out the crankshaft.
Note! Main bearings are available, which are 1,0 mm oversize
(outer diameter) and 0,5 mm undersize (inner diameter). The
cylinder block must then be machined to a dimension of
92,000---92,025 mm. The crankshaft must be machined to a
B. Checking crankshaft dimension of 84,485---84,520 mm. The bearing shell with a
hole and an oil groove must be fitted to the cylinder block and
1. Clean the crankshaft. Do not forget the oilways. the other shell to the bearing cap.

C. Changing crankshaft gears

9052 48800

1. Apply puller for the crankshaft gears and pull off both gears.
2. Measure the journal wear in several points. Out---of ---round,
taper or other wear must not exceed 0,03 mm.

55
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 213 2

2. Fit the bearing shells into the cylinder block and the bearing
2. Clean the seat on the crankshaft with, for example, a wire caps. Ensure that the bearing shell clamping claws fit into their
brush. notches and that the shells to be fitted in the cylinder block
have a hole coinciding with the oil port.
3. Heat the new gears to 200˚ C. Tap them onto the shaft with
a suitable sleeve or soft drift. Note the position of the key and 3. Lubricate the bearing surfaces and fit the crankshaft. Fit the
ensure that the aligning marks on the front gear are visible. crankshaft thrust bearings with the lubricating grooves facing
Leave it to cool. the crankshaft.

D. Changing camshaft ring gear

(420---engines only)

20˚

200 Nm

4. Fit the main bearing caps according to their numbering, the

rear with thrust bearings provided with guide lugs. Lubricate
the bolts and tighten them to 200 Nm.

1. Mark the position of the ring gear on the shaft.

2. Heat the ring gear with a welding torch and drive it off using 0,10-- 0,35 mm
a suitable drift.

3. Heat the new ring gear to max. 250˚C. Fit the ring gear with
the chamfer facing the crankshaft flange, and with the teeth
according to markings or according to figure above. Tap the
ring gear down and leave it to cool.

Note! The figure above shows a rear view of the crankshaft

and no 2 cylinder big end bearing journal.

E. Fitting crankshaft

1. Clean the oilways, bearing shells and bearing locations. 5. Check that the crankshaft can rotate without binding.
Check that the crankshaft is clean. Check the end float using a dial gauge. The correct end float
is 0,10 ---0,35 mm. If the end float is too large, oversize thrust
bearings should be fitted.

Note! Bearing shells should never be reamed or machined in

any other way, nor should the sides of the bearing caps be
filed

56
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 213 3

2. Connecting rods and pistons 3. If the piston pin bushing is worn, it should be driven out
using a suitable drift.

A. Removing pistons together with con-

necting rods
5
Note! Pistons and connecting rods can be removed from the
40,025...
engine when the engine is attached to the tractor by removing
the front axle and the oil sump (see page 219/1). 40,040

1. Detach the engine and the lubricating oil pressure and suc-
tion pipes.

2. Detach the cylinder head.

3. Scrape off the carbon edge in the cylinder liner. If the turn-
ing edge is clearly marked, smooth it down carefully with a
scraper.

4. Remove the big ---end bearing caps and bearing shells.

Place the shells in order if they are to be re ---used.

5. Push up the piston and connecting rod with the shaft of a 4. Drive in the new bushing and ensure that the oil hole is in
hammer or similar wooden tool. the correct position. Ream the bushing to 40.025 ---40.040
mm after it is fitted.
6. Remove the piston pin snap rings. Push out the pin.

Note! If the piston pin does not move under thumb pressure
the piston should be heated to 100˚C. C. Checking connecting rod

The connecting rod is checked in a special fixture, intended

for the purpose (e.g. Carl Larsson).
B. Changing connecting rod bearings

1. Clean the connecting rod and bearing shells. Fit them

together and tighten the bolts to 40 Nm+90˚.
208,00

40 Nm+90˚

1. Fit the big ---end bearing caps and tighten the bolts to 40
Nm+90˚.

2. Fit the connecting rod in the fixture and fit the piston pin
which corresponds to that connecting rod.

2. Measure the I.D. using a cylinder gauge which has been

zeroed to the diameter of the respective bearing journal. If the
clearance exceeds 0,14 mm with new bearing shells, the
big ---end journals require grinding. Refer to the specifications
for the correct undersize and the corresponding bearing. En-
sure that the radii at the end of the bearing journals is not al-
tered when grinding.

57
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 213 4

3. Check that the connecting rod is not twisted by positioning 5. Also check the S ---bending of the connecting rod by using
the measuring tool with the horizontally placed measuring sliding calipers to measure the distance between the edge of
points against the face of the fixture. the small---end bearing bushing and the face of the fixture.
turn the connecting rod round so that the other side of the con-
necting rod faces the fixture. Then measure the same dis-
tance. The accepted deviation is 0,6 mm.

max 86,50

6. Measure the length of the connecting rod bolts. The length

should be max 86,50 mm. If the bolt is longer, change it with
a new one. It is recommended that the bolts are always
changed when they are unscrewed.

D. Connecting rod weight classes

The connecting rods are divided into weight classes with in-
tervals of 20 g. The weight class (a letter) is stamped on the
side face of the connecting rod. All the connecting rods in one
engine should be of the same weight class, that is to say the
greatest permissible weight difference is 20 g.

4. Turn the measuring tool round with the vertically placed

measuring points against the face, and check the straight-
ness of the connecting rod

58
 Model Code Page
21. Engine 95-- 115 213 5
1. 11. 2000 X100-- X120

The letters show the weight classes as follows:

Weight Part no
A 2170---2189 g 8366 52104
B 2190---2209 g 8366 52105
C 2210---2229 g 8366 52106
D 2230---2249 g 8366 52107
E 2250---2269 g 8366 52108

H 2270---2289 g 8366 52109

I 2290---2309 g 8366 52110
J 2310---2329 g 8366 52111
K 2330---2349 g 8366 52112
L 2350---2369 g 8366 52113

M 2370---2389 g 8366 52114

N 2390---2409 g 8366 52115
O 2410---2429 g 8366 52116
P 2430---2449 g 8366 52117
R 2450---2469 g 8366 52118

S 2470---2489 g 8366 52119

T 2490---2509 g 8366 52120
U 2510---2529 g 8366 52121

3. Measure the piston ring gap by pushing one piston ring at

a time into the cylinder bore. The piston ring gap must not
exceed 1 mm on 1. and 3. piston rings and 1,5 mm on 2. pis-
E. Changing piston rings ton ring.

4. Fit the piston rings on the piston using the piston ring pliers.
1. Remove the piston rings with piston ring pliers. Do not open Ensure that the rings are fitted in the correct groove and that
the rings more than necessary. If the rings are to be used ”TOP”, or the manufacturer’s designation, faces upwards.
again ensure that they are fitted in the same groove.

2. Clean the piston ring groove and measure the piston ring
clearance, which must not exceed 0,15 mm. Determine
whether too large a clearance is due to worn rings or a worn
groove. Change worn parts.
Note! The uppermost ring is wedge ---shaped on tractors
95---X120.

59
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 213 6

F. Checking pistons
H. Fitting piston together with connecting
Check the condition of the pistons and piston pins. Pay rod.
special attention to possible cracks on the edge of the com-
bustion chamber and on the upper edge of the piston pin 1. Check that the bearing locations are clean and place the
hole. Measure the diameter of the piston at the point shown bearing shells in the connecting rod and bearing cap. Note
in the figure below. Renew a piston if needed. the position of the bearing shells.

2. Lubricate piston, rings and cylinder bore. Ensure that the

piston ring gaps are spread around the piston.

G. Fitting piston pin

1. Place the connecting rod inside the piston and push the pis-
ton pin into place.

3. Fit the piston with the marking on the connecting rod

(weight class) facing the camshaft (an arrow on the piston
must point forward).

4. Lubricate the big ---end bearing journal and bearing shells,

and push the piston down. Fit the bearing cap so that the
notches for the guide lugs are in the same side. Tighten the
connecting rod bolts to 40 Nm+90˚.

5. Check that the connecting rod has sufficient end float on the
big ---end bearing journal.

Note! The combustion chamber and the weight class letter

should be on opposite sides!

2. Fit the piston pin circlips. Ensure the the circlips are pressed
correctly into the grooves. The circlip ends must point
upwards.

60
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 213 7

3. Balancer unit, 420---engines 4. Place the weights in the body, observing the notch mark-
ings. The gear wheel with the punch mark runs against the
crankshaft and should therefore be placed highest. Insert the
A. Removing and dismantling balancer shafts, remembering the thrust bearings. Apply thread lock
fluid Loctite 270 to the locking screws, and lock the shafts.
unit

1. Remove the engine (Note! The balancer unit can also be

detached when the engine is attached to the tractor. In this
case, remove the front axle and the oil sump, see also page
219/1).

2. Disconnect the lubricating oil pipe of the balancer unit.

3. Remove the balancer unit. Take care of any shims.

4. Loosen the locking screws and press out the shafts in the
direction of the locking screws. Remove the counterweights
and thrust washers.

5. Clean all parts.

0,1---0,5 mm
B. Reconditioning balancer unit

Check the shafts, gear wheels and bushings for wear and
damage.

1. If one of the gear wheels is damaged, change both counter

weights as a complete unit. The gear wheels are not available
separately as a spare part.

2. Remove, if necessary, the old bearing bushings with a suit- 4. Check that the tooth backlash is 0,05 ---0,25 mm and that
able drift. Before removing them, mark the position of the the end float is 0,1 ---0,5 mm
bushing oil groove on the counter weigh. Press in new bush-
ings in the correct position. After fitting the bushings should
be reamed to a correct dimension, see Specifications.

1. Synchronization marking (notch)

2. Marking against crankshaft (punch mark)

61
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 213 8

C. Fitting balancer unit

1. Fit the tension pins in the balancer unit body.

2. Turn the crankshaft and weights so that the markings agree,

and lift the unit into place.

3. Tighten the bolts to 60 Nm. Check that the tooth backlash

between the crankshaft and counterweight is 0,1 --- 0,3 mm.
The backlash can be increased by placing shims 0,2 mm thick
(order no 8361 19920) between the cylinder block and ba-
lancer unit body. One shims (0,2 mm) changes tooth back-
lash about 0,07 mm.

4. Fit the lubricating oil pipe, using new seals.

5. Fit the engine.

62
 Model Code Page
95-- 115
21. Engine X100-- X120 214 1
1. 11. 2000

Timing gears (Op no 214) 6. Unscrew the idler gear bolts (17 and 22 mm). Remove the
flange, gear wheel and bearing journal.

7. Extract the camshaft.

A. Removing timing gear casing
Note! If the cylinder head and valve mechanism have not
been removed, the tappets must be prevented from falling
As the timing gear casing forms a seal against the oil sump, down, see Op. 212 2B.
the casing cannot be removed without first removing the front
axle and the oil sump (see page 219/1 for working order). 8. Remove the timing gear casing (13 mm). Ensure that all
sealing surfaces are not damaged.
1. Detach the engine (or the oil sump).
9. Remove the crankshaft front sealing ring from the front cas-
2. Remove the cooling radiator, alternator and the fan belt (if ing and clean all the parts that have been removed.
not removed earlier).

B. Reconditioning idler gear

If the idler gear bushing is changed, press in a new bushing

so that its rear edge is 0,1 ---0,25 mm inside the gear wheel
rear edge (see picture on next page).

1
2

9101 65700

3. Loosen the crankshaft nut (special tool 9101 65700 and

remove the belt pulley/hub.

Note! Warm the nut with a hot---air blower before unscrewing

(locking fluid. Do not damage the seal). The thread is normal
RH thread. Support the key so that it cannot slip (600
Nm/1000 Nm). Rotation of the crank shaft can be prevented
by fastening a support on the hub (remove the belt pulley and
fasten the support to the hub) or you can use an air powered 1. Chuck of lathe
nut opener, and the crankshaft does not rotate. When nee- 2. Roller ø=5 mm
ded, the hub is removed with an extractor.

4. Remove the timing gear casing cover and the oil deflector Machine the idler gear bushing inner diameter to a correct
ring at the front end of the crankshaft. dimension after fitting. Centre the idler gear according to fig-
ure above so that tooth backlash is kept the same.
5. Remove the injection pump.

Note! If the timing gear casing is not to be changed, the injec-

tion pump can remain in place. In which case disconnect all
leads and pipes from the pump.

63
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 214 2

C. Fitting timing gear casing

4. Fit the idler gear with shaft stud and ensure that the mark-
The position of the timing gear casing and cover is deter- ings are in the correct position. Fit the washer and tighten the
mined by two tension pins. Therefore centring should not be bolts to the correct torque.
undertaken in connection with fitting. However, the tooth
backlash between the different gears should be checked.
Casing and covers that are delivered as spare parts also have
holes for the tension pins already machined.

1. Fit the casing with a new gasket against the cylinder block.
Drive in the tension pins with drift 9025 98700. Tighten bolts
and nuts.

2. Fit the injection pump together with gear wheel (if

removed).

3. Lubricate the camshaft bearings and insert the shaft in the

cylinder block. Release the pushrods and tappets if they have
been suspended.

5. Check the tooth backlash which should be 0,05 ---0,25 mm.

64
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 214 3

9025 98700
9025 98800

9025 98900

6. Fit the oil deflector ring on the crankshaft and fit the timing
gear casing cover using a new gasket. Drive in the tension
pins with drifts 9025 98700 and 9025 98800 respectively (the
tubular pin round the screw stud). Tighten bolts and nuts.
8. Fit the dust shield on the crankshaft V ---belt pulley hub, if it
has been removed. Use drift 9025 98900.

9030 15200
600 Nm

7. Fit the protective plate into the seal location and fit the
crankshaft front seal with special tool 9030 15200.
9. Lubricate both the seal and sealing surfaces and fit the
Note! The crankshaft front oil seal can be changed while the crankshaft V ---belt pulley with hub.
engine is attached to the tractor. In this case, remove the cool-
ing radiator and belt pulley/hub at the front end of the crank- 10. Lubricate the crankshaft nut threads. Tighten the nut to
shaft. 600 Nm.

11. Fit the other detached parts.

65
66
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 215 1

Lubricating system (Op no B. Removing and dismantling lubricating

215) oil pump
A. Reconditioning of oil relief valve for
1. Remove the engine (or detach the oil sump, see page
lubricating oil pressure 219/1).

Note! The latest relief valve, see page 215/4. 2. Remove the oil pump suction and pressure pipe.

3. Remove the oil pump together with any shims between the
If the engine lubricating oil pressure is insufficient or if it varies, pump and the cylinder block.
the relief valve should be checked after first checking the oil
level. 4. Remove the pump cover and the gasket. Remove the gear
on the dead axle.

5. Clamp the pump gear across the teeth in a vice fitted with
soft jaws, and loosen the drive gear nut. Knock the gear wheel
off by hitting the end of the shaft with a soft hammer. Pull out
the drive shaft---gear wheel

6. Clean the parts and check for wear and other damage.
Compare with the specifications. Change damaged parts and
all seals.

1. Remove the cover over the valve (13 mm) and spring. Take
care of the washer between the cover and spring. Remove the
valve insert together with the valve cone and ensure that the
o---ring is also removed.

2. Clean the parts and check that the valve cone slides freely
in the insert and that the sealing surface are undamaged. Mi-
nor damage can be adjusted, but in general, damaged parts
should be changed. Scrape off any remains of the gasket.

3. Assemble the valve with a new o---ring and insert it in the

cylinder block. Place the washer and spring in the cover and 60 Nm
fit it with a new gasket.

Note! With effect from engine ser. no. C1328 the engine lubri-
cating oil pump has been changed.
The fitting between gear and shaft has been changed from
cylindrical type with key to a taper without key.
As a spare part the complete new pump is exchangeable with
the earlier pump. The new drive gear and the shaft can be
fitted in pairs on the earlier pump.

4. Note that the relief valve cover is not symmetrical. The

greater distance between the spring housing and bolt should
be turned downwards.

NOTE! The valve cone has been changed for a new one in the
tractor production.

67
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 215 2

C. Assembling and fitting lubricating oil Note! When measuring the tooth backlash, the engine should
be the correct way up as the crankshaft bearing clearance af-
pump fects the tooth backlash.

1. Fit the gear wheels in the pump body. Fit the cover using 5. Connect suction and pressure pipes together with new
a new gasket. Partly tighten the bolts. Rotate the pump shaft seals.
and tap the side of the cover lightly until the position is reached
where the shaft rotates most freely. Tighten the bolts and 6. Fit the engine (or the oil sump).
check that the shaft still rotates freely.

2. Fit the key and drive gear onto the shaft (tapered joint with-
out key on the later pumps). Apply Loctite 242 onto the nut D. Fitting oil sump gasket
threads and tighten the nut to 60 Nm. Remember the washer
under the nut.
IMPORTANT! In 95---115 and X100---X120 tractors the oil
sump gasket is of rubber and it is o---ring type. The oil sump
contact surface has a groove for the rubber seal.

3. Fasten the oil pump in a vice and check the end float be-
tween gear and pump housing. The clearance which should
be 0,03 ---0,11 mm, is adjusted by the number of gaskets be-
tween the cover and body.

4. Fit the pump and check the tooth backlash against the
crankshaft gear. The clearance, which should be 0,05 ---0,25
mm, is adjusted with shims between the pump body and the
cylinder block (shims 0,2 mm, order no 8360 07871). One
shims increases/decreases the backlash about 0,07 mm.

68
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 215 3

E. Lubricating oil quality requirements

1. QUALITY (API ---CLASS)

--- naturally aspirated engines CCMC D2 API CC 1) ACEA E2 ---96

--- turbocharged engines CCMC D4/D5 API CD ACEA E2 ---96/E3 ---96

1) API ---CD can also be used in conventionally aspirated engines.

NOTE! “Valtra Engine” oil 10W30 or 15W40 is recommended for engines (see page 130/4).

TEMPERATURE ˚C
---30 ---20 ---10 0 +10 +20 +30

5W---20

5W---30
5W---40
10W
10W---20
SAE---CLASS

10W---30
10W---40
15W---30
15W---40
20W---20
20W---30
20W---40
30

69
 Modell Kod Sida
21. Engine 95-- 115
215 4
1. 11. 2000 X100-- X120

F. Latest lubricating oil pressure relief val-

ve, J7595---

2 3

Loctite 638 25 Nm

1
4
5
6

1. Valve seat insert

2. Valve head
3. Spring (engines without the piston cooling nozzles, dark
colour, if cooling nozzles, colour shiny)
Note! The spring expanded end towards the valve head. In
autumn 99, the spring end shape will be changed to prevent
wrong mounting of the valve.
4. Gasket
5. Cover
6. Bolt, 2 pcs

Note! As a spare part the earlier complete valve can be repla-

ced with the new valve fitting kit.

70
 Model Code Page
95-- 115
21. Engine X100-- X120 216 1
1. 11. 2000

Inlet and exhaust system, 4. Check that the exhaust manifold is air tight. Tighten the
turbocharger (Op no 216) bolts to 50 Nm and inspect for any damage (cracks, deforma-
tion, corrosion etc.). Check also the connection between the
turbocharger and the exhaust manifold.

An engine that is equipped with a turbocharger is a great deal 5. Remove the manifold if necessary. Clean the sealing sur-
more sensitive to disturbances and impurities in the inlet and faces and remove any carbon deposits. Check that the seal-
exhaust systems than a conventionally aspirated engine. ing surfaces are flat. If the fastening flanges are twisted or
Therefore special attention should be given to the whole inlet there are scratches on the sealing surfaces, machine the
and exhaust system. flanges or renew the exhaust manifold.

6. Ensure that no loose objects or impurities have entered the

exhaust pipe or the silencer. Any such loose objects or impu-
rities can increase the back pressure for the exhaust gases
A. Checking air cleaner from the turbine wheel.

The engine performance and length of service life depend to

a great extent on the state of the air cleaner. A defective air
cleaner allows impurities to pass through, which in time dam- C. Checking turbocharger
age the turbocharger and the engine. A blocked air cleaner
lowers the engine output and also causes oil leakage through
the sealing ring on the turbocharger shaft. If a fault is suspected in the turbocharger it can be located in
the following way:
Note! The safety filter inside the main filter should not be re-
moved unnecessarily, for checking or cleaning. The safety 1. Visually inspect the turbine and compressor wheels. The
filter must not be cleaned, but should be changed once a year vanes must not show any signs of damage, deformation or
or when necessary (see Operator’s Manual) wear caused by foreign objects.

2. Investigate any oil leaks through the sealing rings on the

shaft in the turbine and compressor housing.

N.B! At low idling there is always a certain amount of oil leak-

age on the compressor side. However, this should not cause
B. Checking inlet and exhaust system too much concern unless the oil consumption is too great.

Important! Leaks in the inlet or exhaust system markedly

lower the effect of the turbocharger. Because of the pressure,
even small leaks in the manifold or in the turbine inlet contact
flange quickly increase in size. For this reason all leaks must
be dealt with immediately.

1. Inspect the pipes and sealing surfaces between the air

cleaner and the turbocharger, as well as between the turbo-
charger and the induction manifold. If the induction manifold
is dusty on the inside, there is a leak in either the air cleaner
or the induction pipes. Remedy the leak.

2. Clean the induction manifold sealing surface. Check that

the sealing surface is flat using a straight ruler. If the surface
is not flat or it has scratches, machine or renew the induction
manifold.

3. Fit a new gasket and fasten the induction manifold. Tighten

the manifold fixing screws to a torque of 30 Nm. Fasten the air
pipes carefully..

3. Check the turbine shaft running clearance. Place the stylus

of a dial gauge against the shaft and move the shaft sideways.
refer to the clearance given in the specifications on page
210/9.

71
 Model Code Page
21. Engine 95-- 115
216 2
1. 11. 2000 X100-- X120

4. Check the shaft end float. Place the stylus of the dial gauge
against the end of the shaft and move the shaft axially. Refer
to the clearance given in the specifications on page 210/9.

If any defects or wear are confirmed, the turbocharger should

be reconditioned.

If the engine does not work correctly and the turbocharger is

not defective or too worn, the fault could be traced to one of
the following items:

--- Blocked air filter

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

72
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 216 3

D. Reconditioning turbocharger
(Schwitzer S1A, S1B, S2B)

N.B! The same degree of cleanliness should be observed

when removing the turbocharger as with repairing the fuel
system. Only remove the compressor and turbine covers if
the requisite special tools, e.g. for adjusting the balance, are
not available. In general, when the turbocharger is dam-
aged it is more economical to fit a factory reconditioned
turbocharger.

Dismantling turbocharger
5. Hold the turbine wheel at hub and unscrew the compressor
wheel nut (left---hand thread). Remove the compressor wheel.
1. Mark the compressor housing, turbine housing and the
bearing housing in relation to each other.
6. Remove the turbine wheel/shaft carefully by tapping at the
shaft end with a soft hammer. Do not bend the shaft.
2. Fix the turbocharger by the outlet flange in a vice fitted with
soft jaws.
7. Place the bearing housing on a table so that the turbine side
is against the table. Remove the support flange circlip.
3. Remove the compressor housing circlip and remove the
housing.
8. Remove the support flange and the oil deflector ring by pry-
ing with two screwdriver behind the support flange grooves.
4. Unscrew the turbine housing fixing screws and remove the
Press the deflector ring out of the support ring.
fixing plate. Detach the bearing housing from the turbine
housing. 9. Remove the oil deflector plate, thrust bearing and thrust
sleeve from the bearing housing. Remove the bearing outer
circlips and remove the bearings and the inner circlips.

73
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 216 4

Cleaning parts of the turbocharger Assembling the turbocharger

N.B. Use conventional cleaning agents. Do not clean with cor- It is recommended to use a repair kit when assembling the
rosive substances as parts of the turbocharger may be dam- turbocharger. This kit includes necessary seals and parts
aged. which are exposed to wear.

1. Wash off all dirt with a detergent solution. Use plastic tools 1. Fit the inner circlips into the bearing housing. Lubricate the
or brush when cleaning aluminium parts. bearing points. Push the bearings into place and fit the outer
circlips.
2. Clean all oilways with compressed air. Check that all contact
surfaces are clean and in good condition. 2. Fit a new sealing ring into the groove and push the rear plate
onto the shaft against the turbine wheel.

3. Lubricate the shaft bearing points and the sealing ring.

Push the shaft into the bearing housing. Do not damage the
sealing ring.

4. Place the bearing housing vertically resting on the turbine

housing.
Checking parts of the turbocharger
5. Fit the thrust sleeve into the thrust bearing and place the
1. Bearing housing parts into the bearing housing according to the position of the
--- Inspect the bearing surfaces for damages and wear. guide pins. Place the oil deflector plate onto the thrust bear-
--- make sure that the turbine side sealing surface is undam- ing.
aged.
6. Fit a new o---ring into the groove of the support flange. Fit
2. Compressor wheel a new o---ring onto the deflector ring. Press the deflector ring
--- check for bends, cracking or corrosion and possible wear into the middle of the support flange. Do not damage the seal-
on the wheel rear face. Small faults can be accepted. Change ing ring and its counter surface.
the wheel if damages affect balancing accuracy. Never bend
the vanes. Check the balancing accuracy (S1A, S1B: 0,21 gm 7. Lubricate the o---ring and push the support flange into the
mm. S2B: 0,36 gm mm). bearing housing. Fit the circlip the chamfered side outwards.

3. Shaft and turbine wheel unit 8. Push the compressor wheel onto the shaft. Tighten the shaft
--- check the bearing point wear, min diameter is S1A, S1B: nut to a torque correct torque. Secure the nut with locking fluid
7,615 mm. S2B: 10,15. Loctite 601.
--- check the width of the sealing groove, S1A, S1B: max
1,630 mm. S2B: 1,58 mm. 9. Pass the compressor housing circlip over the bearing hous-
--- measure the shaft ovality, S1A, S1B: max 0,005 mm. S2B: ing the circlip chamfered side towards the turbine housing.
0,007. Fit the o---ring into the groove on the bearing housing. Fit the
--- check balancing accuracy (S1A, S1B: 0,21 gm mm. S2B: compressor housing according to the markings. Fit the circlip
0,36 gm mm), change the part if given values are exceeded. into groove.

4. Compressor and turbine housing 10. Fit the bearing housing and the turbine housing according
--- check if there are damages, cracks or overheating faults to the markings. Fit the fixing plate and tighten the screws to
caused by wheel contact in the housings. Small damage can 22 Nm (S1A/S1B) or 17 Nm (S2B).
be accepted, otherwise change the housing.

5. Turbine side rear plate

--- change the rear plate if it is bent or cracked.

6. Oil deflector ring

--- check the groove width on the sealing ring, S1A, S1B: max
1,226 mm. S2B: 1,58 Check also for other possible damage
and wear. Reject worn part.

7. Support flange
--- Check wear and cracking of the seal ring counter surface.
Only small wear can be accepted. In general, even a small
wear causes sealing problems.

74
 Model Code Page
21. Engine 95-- 115
216 5
1. 11. 2000 X100-- X120

E. Fitting turbocharger F. Adjusting by ---pass turbo (S1BG)

Locate the cause of the defects on the turbocharger. Remedy The by ---pass turbo is fitted on DW engines on 95, 115, X100,
the fault before fitting the new turbocharger. X110 and 120 Hi.
In order for the turbocharger to work satisfactorily, it is import- N.B.: Normally the adjustment is unnecessary.
ant that the engine oil is in good condition. Likewise the oil
should be to the correct quality specification. The air filter and The following equipment are needed:
oil filter should be serviced according to the handbook specifi- --- surface table and fixing device for the turbo
cation. --- dial gauge equipped with magnetic base
--- compressed air and pressure controller
The setting of the injection pump critically affects the function --- pressure gauge, reading accuracy 0,015 bar
of the turbocharger. The injection pump should be adjusted
according to the manufacturers instructions. 1. Fasten the turbocharger on the surface table. Fasten the
regulator rod to the by ---pass hole lever but do not fit the cir-
1. Check the tightness of the induction and exhaust mani- clip.
folds, and that they are securely fastened. Ensure that there
are no loose carbon or rust particles, or other foreign objects 2. Place the dial gauge stylus against the regulator rod end
in the manifolds. and zero the gauge reading (ensure that the by ---pass hole is
closed).
2. Connect the turbocharger to the exhaust manifold and
tighten down using a new gasket. 3. Connect compressed air to the pressure controller.
Increase pressure progressively (avoid sudden pressure rise)
3. Connect the induction pipe and the silencer. until the dial gauge records 0,4 mm movement in the rod.
4. Pour clean engine oil into the bearing housing through the Note! This movement removes clearances and should be
inlet oilway. This is very important in order to ensure that the happened at a pressure of max. 1,035 bar. When pressure
turbocharger is lubricated at the time of starting. further increases, starts the actual opening movement which
opens the by ---pass passage.
5. Connect the pressure and return oil pipes. Use a new seal.
Check that there are no tensions in the pipes when tightening.

6. Before starting, pull out the stop control and crank the en-
gine over with the starter motor so that the oil pressure rises.
Start the engine and check that there are no leaks.

4. Adjust, if necessary, the rod length until the correct pressure

value has been reached.

5. When the adjustment is correct, tighten the rod locking nut.

6. Fit the rod circlip and the boost pressure pipe.

75
 Model Code Page
21. Engine 95-- 115
216 6
1. 11. 2000 X100-- X120

G. Intercooler on 115 and X120

Intercooler cools the engine intake air. Air density is greater

in lower temperatures and more air can be charged into the
engine combustion cambers at which time fuel combustion
happens more effectively.

Engine coolant circulates in the cooling element of the inter-

cooler and engine intake air is blown thought the element at
which time the air, which is in working temperature, cools
even from +150 ˚C down to +95˚C.

1) Intercooler (---F2684 (4---cyl.) 4---cyl. (F2685---)

1a) Filling plug
1b) Draining plug

The intercooler increases engine coolant volume (compared Note! The intercooler has been modified from engine number
with the normal model) by about one litre (4---cyl. engines). F2685 incl. The new intercooler is interchangeable with the
earlier one, if all modified parts are changed (e.g. intake mani-
---F2684 (4---cyl.): When filling the cooling system, the inter- fold and pipes). As a spare part the earlier type intercooler is
cooler should be filled separately via plug 1a. Draining is still delivered.
made via draining plug 1b.

F2685 --- (4---cyl): When filling the cooling system, slacken the
intercooler upper pipe union, so that air can flow out of the
cooler (draining plug 1b. These do not have the filling plug).

76
 Model Code Page
21. Engine 95-- 115
216 7
1. 11. 2000 X100-- X120

H. Pillar exhaust pipe

The pillar exhaust pipe has been drawn up along the cab LH IMPORTANT!
side front pillar. Near the cab there is a protective outer jacket Concerning tractors with the ejector pipe:
round the exhaust pipe. The jacket has been centralised with When a suction apparatur for exhaust gases is used in work
aid of screws. shop, check that its suction effect is high enough and it does
not restrict the upper end of the exhaust pipe. Otherwise at
The pipe is different on tractors which have the by ---pass high revs exhaust gases can flow through the ejector pipe into
turbocharger (DW---engines) compared with tractors with a the air filter housing and damage the filter and the filter hou-
conventional turbocharger (CD ---engines). sing will become sooty.

77
78
 Model Code Page
21. Engine 95-- 115
1. 11. 2000 X100-- X120 219 1

Working orders
D. Lubricating oil pump
A. Crankshaft seals (Lubricating oil pump, see page 215/1)

(Rear seal, see page 211/6).

(Front seal, see page 214/3). --- Drain the engine coolant and the engine oil. Detach the
front weight bracket together with the parts which are fitted on
--- Before changing the crankshaft rear oil seal, split the tractor it (e.g. radiator).
between engine ---middle frame and detach the clutch assem-
bly/drive plate and the flywheel. --- Remove the front axle. Support the engine and tractor
frame and unscrew the oil sump fixing bolts and remove the
--- When changing the crankshaft front seal, drain the coolant oil sump (unbolt only lower bolts at the frame joint between
from the cooling system. Remove the cooling radiator and the engine ---middle frame).
belt pulley/hub at the front end of the crankshaft.
--- The oil pump can now be removed from the lower face of
Note! The cooling radiator can also be detached so that the
entire front weight bracket is detached together with parts the cylinder block.
which are fitted on it.
E. Balancer unit (only 420---engines)
(Balancer unit, see page 213/7)
B. Cylinder head and valve mechanism --- Drain the engine coolant and the engine oil. Detach the
front weight bracket together with parts which are fitted on it
(Cylinder head and valves, see page 212/1) (e.g. radiator).
(Rocker arm mechanism, see page 212/5)
--- Remove the front axle. Support the engine and tractor
--- Before removing the cylinder head, remove the engine frame and unscrew the oil sump fixing bolts and remove the
hood plates, engine coolant and detach all parts which are oil sump (unbolt only lower bolts at the frame joint between
attached to the cylinder head. After that the cylinder head can
engine ---middle frame).
be removed.
c) The balancer unit is now accessible and can be detached
--- Rocker arm mechanism is accessible after removing the from the cylinder block lower face.
valve cover.

--- Pushrods can be removed after removing the valve cover F. Crankshaft
and the rocker arm mechanism.
(Crankshaft, see page 213/1)

--- Split the tractor between engine ---middle frame. Remove

C. Pistons and connecting rods the clutch assembly/drive disc and the flywheel.

(Pistons and connecting rods, see page 213/3) --- Remove the engine coolant and the radiator. Detach the
engine.

If only pistons/connecting rods are to be changed, the

simplest working order is as follows: G. Cylinder liners

--- Drain the engine coolant and the engine oil. Detach the (Cylinder liners, see page 211/1)
front weight bracket together with parts which are fitted on it
(e.g. radiator). --- Drain the engine coolant and the engine oil. Detach the
front weight bracket together with parts which are fitted on it
--- Remove the front axle. Support the engine and tractor (e.g. radiator).
frame and unscrew the oil sump fixing bolts and remove the
oil sump (unbolt only lower bolts at the frame joint between --- Remove the front axle. Support the engine and tractor
engine ---middle frame). frame and unscrew the oil sump fixing bolts and remove the
oil sump (unbolt only lower bolts at the frame joint between ---
--- Remove the cylinder head. engine ---middle frame).

--- Loosen the connecting rod big ---end bearing caps and --- Remove the cylinder head.
push the pistons together with connecting rods upwards and
remove them through the cylinder bore. --- Loosen the connecting rod big ---end bearing caps and
push the pistons together with connecting rods upwards and
remove them through the cylinder bore.

--- Remove the cylinder liners upwards.

79
 Model Code Page
21. Engine 95-- 115
219 2
1. 11. 2000 X100-- X120

H. Timing gears I. Camshaft

(Timing gears, see page 214/1) (Camshaft, see page 212/5)

As the timing gear casing forms a seal against the oil sump, Before removing the camshaft the following steps should be
the casing cannot be removed without first removing the oil taken:
sump. The timing gear casing cover, however, can be
removed without removing the oil sump.
--- Remove the timing gear casing cover (see under previous
--- Remove the oil sump if the timing gear casing is to be heading H Timing gears).
removed. Otherwise remove the cooling radiator only.
--- Remove the idler gear
--- Remove the fan, alternator and the v ---belt.
--- Remove the valve cover and the rocker arm mechanism.
--- Unscrew the crankshaft nut and remove the belt pulley/
hub.
--- Remove the timing gear casing front cover and remove the --- Support the pushrods (at the same time tappets which are
against the camshaft) to the upper position in pairs by using
oil deflector ring at the front end of the crankshaft.
for instance o---rings (see picture on page 212/5).
--- Remove the fuel injection pump if the timing gear casing is
--- Rotate the crankshaft so that the timing markings on the
to be removed. Otherwise disconnect all the pipes from the
fuel injection pump. crankshaft gear and the camshaft gear become opposite
each other (see picture on page 214/2).
--- The timing gears are now accessible.
--- Pull out the camshaft from the cylinder block.

In addition, the following steps should be taken if the entire Note! Take care when fitting the camshaft that the timing
timing gear casing has to be changed: marks align.

--- Unscrew the idler gear fixing bolts and remove the idler
gear.

--- Pull out the camshaft from the cylinder block.

Note! If the cylinder head and valve mechanism have not

been removed, the tappets must be prevented from falling
down when the camshaft is removed, see page 212/5.

--- The timing gear casing can now be removed.

80
 Model Code Page
22. Fuel system 95-- 115
1. 11. 2000 X100-- X120 220 1

Contents
General (Op no 220)
Specifications, Bosch in ---line pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel system, description with Bosch in ---line injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel system, description with Stanadyne rotary distributor pump . . . . . . . . . . . . . . . . . . . . . . . . 10

Repair instructions

Fuel feed pump and fuel filters, Bosch in-- line pump (Op no 222)
A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Bleeding Thermostart system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Checking overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Changing fuel feed pump valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fuel injection pump and injectors, Bosch in-- line pump (Op no 223)
A. Checking fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Removing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fitting injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Checking/changing delivery valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
H. Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
J. Fitting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
K. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
L. Adjusting injection timing on 6800 tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Function of boost control on 6800 tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Stanadyne rotary distributor pump

A. Removing distributor pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B. Fitting pump and adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
D. Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
E. Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
G. Bleeding Themostart---system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
H. Delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
I. Dynamic injection timing checking, E ---engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

81
 Model Code Page
22. Fuel system 95-- 115 220 2
1. 11. 2000

Specifications, Bosch in-- line injection pump

Note! Stanadyne rotary distributuon pump, see page 220/10.

Bosch in-- line fuel injection pump

Type (pump/governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch PES...A/RSV

Injection order:
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---4---3
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Diameter of pump piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,5 mm (p:12 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm (p:11 mm)
Injection advance:
--- 95, 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19˚
--- 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18˚
Oil fillings 1):
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 l

Fuel feed pump

Type:
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch FP/KEG 24 AD 504
Construction: piston pump, separate hand pump
Fuel feed pressure (overflow valve opening pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7---1,2 bar (70---120 kPa)
Pressure from fuel feed pump (without overflow valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7 bar (270 kPa)

Injectors (see also table on page 220/15)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle

95 ---115:
--- Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 bar (23 MPa)
--- Setting pressure 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235+5 bar (23,5 MPa)
95 from week 41/00 (engine output increased from 70 kW to 73,5):
--- Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270+8 bar (27 MPa)
--- Setting pressure 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 bar (27,8 MPa)

Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495

1) When fitting fuel injection pump.

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

Tightening torques

Injection pump gear nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

Delivery valve retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

82
 Model Code Page
22. Fuel system 95-- 115 220 3
1. 11. 2000 X100-- X120

Special tools
9052 47800 *) Pressure gauge for checking delivery valve
9052 48900 *) Puller for injection pump drive gear
9025 99100 *) Locator for timing mark on the flywheel
9052 47600 *) Control pipe for injection timing
9052 99000 *) Sleeve for limiting control rod travel
9051 71300 *) Extractor for injectors
8366 62022 Electronic device (TimeTrac) for checking injection timing (E ---engines)

*) Same tool as for fuel system on 505---905 tractors.

8366 62022

905248900

902599100

15±1

9052 47800 905247600 9025 99000 9051 71300

A B
A

B
33346600
A
33370300
30068700 33370100
33346700
(0---1 bar)
31965400
Measuring equipment for fuel feed pressure:
A
If the pressure is too low in point A, check the pressure
in point B. If further too low, the fault lies in the fuel
feed pump. Otherwise the filter is blocked.

83
 Model Code Page
22. Fuel system 95-- 115 220 4
1. 11. 2000

2 1

1. Fuel tank
2. Water trap
5 3. Fuel feed pump
4. Fuel filter
5. Fuel injection pump (3---cyl. in picture.
Fuel system in 4---cyl. engines is similar)
6. Injector
7. Thermostart fuel reservoir
3 8. Glow plug
9. Overflow valve

Fuel system, description

Fuel tank:
Fuel feed pump (3) draws fuel from tank (1) through water
--- Empty/clean the fuel tank at every 1000 running hours or
trap (2) and forces it through filter (4) to fuel injection pump
yearly.
(5). The fuel injection pump pumps fuel at high pressure
through the delivery pipes to injectors (6) which inject the
Injectors
fuel in the form of a fine mist into the combustion chamber.
--- Reconditioning of the injector should be carried out by
Excess fuel lubricates the nozzle valve (needle) and flows in
an authorised workshop.
return through the thermostart device reservoir (7) and then
on to the fuel tank. When the thermostart is on (glowing)
Symptoms of dirty or faulty injectors are:
fuel runs from reservoir (7) through glow plug (8) and is
--- Knocking is an indication that one of the injectors is
ignited in the induction manifold. Excess fuel returns from
faulty. When a cold engine ticks over a certain amount of
the fuel injection pump through overflow valve (9) to the
knocking is unavoidable. If the engine knocks after it has
fuel tank.
reached normal operating temperature, it is very likely that
one of the injectors is faulty. Air in the fuel system can also
Maintenance cause knocking (which should disappear after the system
has been bled of air).
--- Smoky exhaust gases may indicate impaired perform-
Fuel filter: ance of the injectors. However, this can also be caused by
--- Change the fuel filter at intervals of 1000 running hours or other faults such as a blocked air cleaner.
yearly.
The fuel system should always be bled when the fuel sys-
Water trap: tem has been emptied (e.g. the fuel tank has been emptied
--- Empty/clean the water trap at every 500 running hours. during driving, in connection with maintenance or repair
work or after a long idle period).

84
 Model Code Page
22. Fuel system 95-- 115 220 5
1. 11. 2000

Fuel injection pump 1

8
95---115 tractors have a Bosch ---make injection pump which
is an in ---line pump and its basic construction is similar on
engines with the different number of cylinders.

2
7

Fuel injection pump

1. Oil filling plug

2. Governor control lever
3. Hand pump on fuel feed pump
4. Lubricating oil into injection pump
5. O ---ring
6. Return of lubricating oil to engine
7. Drive gear
8. Type plate 6
9. Boost control, 115 3
10. Forced ---feed solenoid for starting, 115
11. Indicator plug for adjusting injection To intake manifold
timing (115 + latest 5
95 and 105 tractors, which have a new governor)
9

The fuel injection pump is flange mounted and sealed by 10

one o---ring (5) in the timing gear casing. The injection
pump is driven from the crankshaft through an idler gear.
The injection pump is connected to the engine force ---feed
lubrication system through an external pipe (4). Lubricating
oil returns to the engine via the hole (6) at the front end of 11
the injection pump.

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

Note! 115 tractor have a boost control (9), which is con-

nected via a hose to the engine intake manifold. The boost
control adjusts injected fuel amount to the cylinders accord-
ing to the supercharging pressure in the engine intake
manifold. In addition, these tractors have a forced ---feed
solenoid for starting (10) on the fuel injection pump, see
page 223/9. Adjusting injection timing on 115 and on latest
95 and 105 tractors, see page 223/8.

Boost control

85
 Model Code Page
22. Fuel system 95-- 115 220 6
1. 11. 2000

The pump element consists of one plunger and one cylinder

which are a matched pair and because of the fine tolerances
the whole element should be changed as a complete unit.

The cylinder has two passages: inlet passage and release

passage. Both passages allow fuel to enter the pressure
space. The side of the plunger has one vertical groove and
one metering edge which are used for adjusting the amount
of fuel injected into the combustion chamber of the engine.

The top of the plunger is provided with a starting groove

(delay groove) which delays the injection timing by approx.
8˚. (This should be borne in mind when checking the fuel in-
jection timing). This groove improves the cold starting prop-
erties of the engine. It works fully automatically. When the en-
gine has stopped the control rod in the injection pump turns
the plungers so that the starting groove faces towards the re-
lease passage. When the engine has started and when the in-
jection pump has reached a certain speed, the governor pulls
the control rod back into running position.

1
1. Retainer for delivery valve
2. Delivery valve 2
3. Pump element 5
4. Control rod
5. Return spring for pump plunger 3
6. Roller tappet
7. Camshaft 6
4 7
The purpose of the fuel injection pump is to meter out fuel to
the combustion chamber at the correct time. Plunger (3)
which is driven by the pump camshaft (7) via roller tappet (6)
forces the fuel through delivery valve (2) and further through
the delivery pipe to the injector.
Delivery valve
3 4 5
6
2 1. Holder for delivery valve
2. Valve spring
3. Valve cone
4. Valve guide
5. Valve head
1 6. Pressure ---reducing piston
7. Vertical grooves

7 The delivery valve is fitted on top of the pump element and its
purpose is to close the connection between the pump el-
ement and the delivery pipe. This happens when the metering
edge of the plunger passes the lower edge of the release
passage, thus reducing the pressure in the space above the
plunger. Its second purpose is to reduce the pressure in the
A B C delivery pipe. This is important as it enable the nozzle valve
(needle) to close more quickly.
Two---hole pump element (maximum feed) Delivery valve cone contains a pressure ---reducing piston
which, when the valve closes, is first lowered into the guide
A. Bottom dead centre 1. Inlet passage and then closes the connection between the delivery pipe and
B. Fuel injection begins 2. Cylinder the pump element. The valve head is then pressed against its
C. Fuel injection ends 3. Starting groove seat and the fuel in the delivery pipe is given the same space
4. Release passage as the displacement of the pressure ---reducing piston.
5. Plunger
6. Metering edge
7. Vertical groove
86
 Model Code Page
22. Fuel system 95-- 115 220 7
1. 11. 2000

Governor
Fuel injection pump type plate

The injection pump type plate shows one particular letter indi-
cating the user application, see figure below. This letter
should always be quoted when ordering a replacement pump
or when looking for setting values.

The letters for different pumps on 95---115 tractors can be

found in the table on next page.

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

The governor is of the centrifugal type and is fitted at the rear

end of the injection pump. The governor controls the rota-
tional speed of the engine throughout the whole speed range,
and identifies the rotational speed by means of the governor
weights. The position of the governor control and of the gov-
ernor weights is transferred through the governor lever link-
age to the control rod. The governor has one governor spring.
Starter spring, which is attached to the upper end of the con-
trol lever, it pulls the control rod to the starting position when
the engine stops. This means that the amount of fuel injected
when the engine is started automatically becomes greater.

87
 Model Code Page
22. Fuel system 95-- 115 220 8
1. 11. 2000

Table of fuel metering 95---115

Test equipment ISO 4008, Fluid ISO 4113
Nozzle ISO 7440 207 bar/0,60 orifice plate
Pipe diam. ø6x2x600 ISO 4093

Engine Tractor Injection Governor Pump timing ˚ Injected RW mm Control Control rod
type pump Max. output r/min amount rod at le- pos. 4 mm
Low idling r/min mm3 / stroke ast 1 mm
rpm
rpm mm3 rpm
420 DW 95 PES 4A 95D RSV 375--- 1125 ˚19˚ 1100 102--- 104 13,0±0,2 1135--- 1210---
70 kW 320 RS 2807 A2C 2178--- 7R 2225 1000 13,2±0,2 1145 1230
/CH 750 900 13,7±0,2
500 13,7±0,2
375 11--- 15 4,2--- 4,5
420 DW 95 PES 4A 95D RSV 375--- 1125 ˚19˚ 1100 101--- 103 12,8±0,2 1120--- 1210---
73,5 kW 320 RS 2807 A2C 2178--- 7R 2200 1040 104--- 106 13,2±0,2 1130 1220
/DL 850 900 109--- 111 13,3±0,2
700 109--- 111 13,3±0,2
425 11--- 13 4,3
420 DS 105 PES 4A 95 D RSV 375--- 1125 19˚ 1100 101--- 103 12,5±0,2 1140--- 1200---
320 RS 2807 A2C 2178--- 7R 2225 1000 ±0,2 1150 1220
/A 750 900 +0,4
800 +0,5
500 ±0,5
375 11--- 15 4,2--- 4,5

Engine Trac- Injection Governor Pump timing ˚ Injected RW mm Boost Control Cont-
tor pump Max. outpur rpm amount control rod at rol rod
Low idling rpm mm3 / stroke pressure least posi-
bar 1 mm tion
rpm mm3 4mm
rpm
rpm
420 DWI 115 PES 4A 95D RSV 375--- 1200 ˚18˚ 1100 113--- 115 13,4±0,2 1,0 1130 1180---
320 RS 2847 A5C 2268 R 2225 1000 13,7±0,2 1,0 1210
/E 850 800 14,0±0,2 1,0
600 14,0±0,2 1,0
Boost control 0,30
500 94--- 96 12,7±0,2 0
375 11--- 15 3,8±0,2 0

Table of fuel equipment parts, 95---115

Engine/Tractor Injection Element Delivery Governor Injector Nozzle Nozzle hol-

pump valve spring compl. der
420 DW 8367 8353 8353 8353 8366 8366 8366
ValtraValmet 95 54552 31161 39126 31163 39956 39957 39971
70 kW
420 DW 8367 8353 8353 8353 8366 8366 8366
ValtraValmet 95 54902 31161 39126 31163 59808 / 358 59902 39971
73,5 kW
420 DS 8367 8353 8353 8353 8366 8366 8366
ValtraValmet 105 40173 31161 39126 31163 39956 39957 39971
420 DWI 8367 8353 8353 8367 8366 8366 8366
ValtraValmet 115 54640 31161 39126 54532 39956 39957 39971

88
89
 Model Code Page
22. Fuel system X100-- X120 220 10
1. 11. 2000

Specifications with Stanadyne rotary distributor pump

Note! X100, X110 and X120 tractors have Stanadyne rotary distributor pump.The pump is equipped with an electric running
solenoid (ignition switch stop) and with an automatic bleeding system. Stanadyne pump internal lubrication happens with aid of
fuel. A separate fuel feed pump is of a membrane type and it is driven by the engine camshaft. The system includes also the Ther-
mostart glow plug.

8
6

7 9
5
Picture. Stanadyne rotary distributor pump

1. Sealing ring 8368 40858

2. Type plate with pump order number (see page 220/14)
3. Timing marks under the cover
4. Fuel inlet
5. Return fuel/overflow valve 1
6. Revolution lever
7. Connector for wire to electric stop solenoid
8. Aneroid (E ---engines) 4
9. Boost pressure (E ---engines)
10. Detector ring for injection timing (E ---engines)

10

Stanadyne distributor pump

2 3
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DB4 (four pressure plungers)

Injection order:
--- 420---engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---4---3
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Injection advance, static (dynamic injection advance, see page 220/14):

--- 100 HI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16˚ B.T.D.C.

--- 110 Hi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16˚ B.T.D.C.
--- 120 Hi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16˚ B.T.D.C.

Tightening torque of pump gear wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

Fuel feed pump

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . membrane pump, separate

hand pump
Fuel feed pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar (48 kPa)
Fuel feed pressure at test point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2---0,5 bar

Injectors (see also page 220/15).

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle

Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 bar
Setting pressure 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235+5 bar
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nro 8999 01495
Injector nozzle sleeve, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

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

90
 Model Code Page
22. Fuel system X100-- X120 220 11
1. 11. 2000

Fuel system with distributor pump

Water trap on X100---X120.
1. Fuel tank
2. Water trap (X100---X120 have different
water trap)
3. Fuel feed pump
4. Fuel filter (in picture double filter.
X100---X120 have a single filter) A
5. Rotary distributor pump
6. Injector D
7a,b,c. Return fuel to tank
8. Thermostart reservoir
9. Glow plug
10a, b. Bleeding screws B
C

In the X100---X120 fuel system, there is a separate fuel feed for hand and the filter is pulled downwards. When fitting a
pump (3) on the RH side of the engine. new filter, rotate the securing band until it locks the filter
(click).
The lower part of the fuel filter housing have a space for
possible impurities and there is a draining tap under filter
housing (in picture above there is a double filter, but four --- Maintenance
cylinder engines have a single filter).
--- Check/empty the water trap weekly/at every 50 running
The fuel feed pump has a washable metal gauze filter. hours.
There is also a tapered metal net filter inside the fuel distri- --- At every 500 running hours, open the tap under the fuel
butor pump in the inlet line before the pump transfer pump. filter housing and allow possible impurities to run out .
--- Clean the fuel tank at every 1000 running hours/yearly
Important! X100 ---X120 tractors have a Stanadyne water and change the fuel filters and also change the water trap
trap (on the RH side of the engine. Different position as in filter.
picture above), which also includes a filter. There is a drai- --- Check/clean injectors at every 2000 running hours/every
ning tap (B) in the bottom of the housing. Before emptying other year. Faulty injectors cause knocking, smoky exhaust
this water trap, slacken the bleeding screw (A) . After emp- gases and loss of engine power.
tying, close the screws and pump fuel with the feed pump
(C) lever, until the water trap is full of fuel. The Stanadyne Note! When the water trap has been emptied, refill it with
water trap filter loosens, when securing band (D) is rotated fuel by pumping with the fuel feed pump (3) lever. After
changing the fuel filter, bleed the fuel system.

91
 Model Code Page
22. Fuel system X100-- X120 220 12
1. 11. 2000

Stanadyne distributor pump

1. Drive shaft
2. Governor weights
3. Governor spring
4. Stop solenoid
5. Overflow valve
6. Metering valve
7. Cam ring rollers
8. Hydraulic head
9. Pressure regulator
valve
10. Transfer pump blades
11. Distributor rotor
12. Delivery valve
13. Cam ring
14. Automatic advance
15. Centrifugal governor
16. Pumping plungers (4
pcs in picture).

Construction
The pump axial force acts against the pressure regulator valve
The main rotating components are the drive shaft, transfer front face.
pump blades, distributor rotor and governor.
The distributor rotor incorporates two charging ports and a
The drive shaft engages the distributor rotor in the hydraulic single axial port (pressure chamber), in which is placed the
head. The drive end of the DB2 rotor incorporates two pump- delivery valve. After the delivery valve, there is one discharge
ing plungers and DB4 four. port to serve all head outlets to the fuel injection pipes.

The plungers are actuated toward each other simultaneously The hydraulic head contains the bore in which the rotor
by an internal cam ring through rollers and shoes which are revolves, the metering valve bore, the charging ports and the
carried in slots at the drive end of the rotor. The numbers of connections to the fuel injection pipes.
cam lobes normally equals the number of cylinders (not
3---cyl. engines). The pump contains a mechanical governor. The centrifugal
force of the weights is transferred to the metering valve via a
The transfer pump at the rear of the rotor is of the positive dis- linkage. The metering valve can be closed electrically with aid
placement vane type and is enclosed in the end cap. The end of the solenoid in the pump housing.
cap also houses the fuel inlet strainer and transfer pump pres-
sure regulator. The face of the regulator assembly is com- The automatic advance is a hydraulic mechanism which
pressed against the distributor rotor and forms an end seal for turns the cam ring and advances or retards the beginning of
the transfer pump. the fuel delivery from the pump.

92
 Model Code Page
22. Fuel system X100-- X120 220 12A
1. 11. 2000

Stanadyne distributor pump

1. Type plate with ordering number

2. Timing marks under the cover
3. Fuel inlet
4. Fuel return flow/overflow valve
5. Revolution lever
6. Connector for wire to electric stop solenoid

Possible equipment on Stanadyne distributor pump (e.g. E-- engines)

A. Interrupted screw (ordering no. 8366 59038) G. Compact cold advance CCA
Electric advancing of the injection during starting and at low
B. Detector for injection timing
engine revs (below 1100 rpm) in order to decrease the cold
C. Fuel limiter FL smoking. In addition to the injection pump solenoid, the
The fuel limiter limits the injected fuel amount nearest at pump has a separate control unit, which follows up the engine
low engine revs,when the air coefficient is too small. revs.
D. Light load advance LLA H. Torque screw TS (inside the housing).
Adjustment of the injection advance according to the en-
gine revs and loading. This is controlled by the fuel feed With this screw the engine specific curves for output and tor-
pressure after the quantity governing valve. que can be canged into desired form.
E. Aneroid control AC
Aneroid control (limitation of acceleration smoke) allows I. Vented metering valve VMV (inside the pump housing).
a full fuel injection during acceleration just when the
boost pressure has risen enough. The valve makes the inner bleeding of the pump better.
F. Boost pressure

93
 Model Code Page
22. Fuel system X100-- X120 220 12B
1. 11. 2000

Fuel pipes in the middle frame

94
 Model Code Page
22. Fuel system X100-- X120 220 13
1. 11. 2000

Stanadyne distributor pump

Housing pressure
Transfer pump pressure Injection pressure
1. Fuel tank 10. Regulator spring
2. Water trap 11. Centrifugal weights
3. Fuel feed pump 12. Overflow valve
4. Fuel filter 13. Hydraulic head connecting passage
5. Transfer pump 14. Metering valve
6. Pressure regulator valve 15. Hydraulic head charging pasage
7. Automatic advance 16. Distributor rotor
8. Air vent passage 17. Delivery valve
9. Stop solenoid 18. Injector

Function
The fuel feed pump draws fuel from the tank via the water trap While the discharge post is opened, the rollers contact the
and the filter into the fuel injection pump. cam lobes forcing the plungers together. Fuel trapped
between the plungers is then pressurised and delivered by
In the pump fuel flows through the inlet filter screen into the the nozzle to the combustion chamber.
vane type fuel transfer pump. Some fuel is bypassed through
the pressure regulator assembly to the suction side. The injection pump is self ---lubricating, and it has not been
connected to the engine lubrication system.
Fuel under transfer pump pressure (1---6 bar) flows through
the center of the transfer pump into the circular groove on the As fuel at transfer pump pressure reaches the charging ports,
rotor. It then flows through a connecting passage in the head slots on the rotor shank allow fuel and any entrapped air to
to the automatic advance and up through a radial passage flow into the pump housing cavity. In addition, an air vent
and then through a connecting passage to the metering passage in the hydraulic head connects the outlet side of the
valve. The metering valve adjusts amount of injected fuel and transfer pump with the pump housing. This allows air and
position of the metering valve is controlled by the governor some fuel to be bled back to the fuel tank via the overflow
(revolution lever) and the stop solenoid. From the metering valve.
valve fuel flows to the radial charging passage and further to
the head charging ports. The fuel thus bypassed fills the housing, lubricates the inter-
nal components, cools and carries off any small air bubbles.
As the rotor revolves, the two rotor inlet passages register The pump operates with the housing completely full of fuel;
with the charging ports in the hydraulic head, allowing fuel to there are no dead air spaces anywhere within the pump.
flow into the pumping chamber. With further rotation, the inlet
passages close and the port to the injectors opens.

95
Stanadyne-- rotary pumps and delivery pipes on X100-- X120

Tractor Engine Distributor pump Static in- Dynamic injection advance (˚/rpm) Extra equipment *) Delivery pi-
jection pe inner
Type Type Ordering no advance Low idling Max revs 1400 rpm 2200 rpm diameter
(full loa- (full loa- **)
22. Fuel system

ding) ding)
±1,0˚ ±1,0˚ ±1,0˚

100 Hi 420 DWRE DB4427---5254/E 8367 54866 16˚ >3,5˚ 10˚ 14,5˚ 16˚ TS, AC ø 1,75 mm
110 Hi 420 DWRE DB4427---5525 8367 54829 16˚ 4˚ 9˚ 15˚ 17˚ TS, AC ø 1,75 mm
120 Hi 420 DB4427---5526 8367 54822 16˚ >10˚ 15˚ 15,5˚ 17˚ TS, LLA, VMV, AC ø 1,75 mm
DWRIE

Note! Adjusting values of Bosch in ---line pumps, see page 220/8.

*) See page 220/12A.

**) Delivery pipe inner diameter

Ø
without notch, Ø 1,5 mm
1 notch, Ø 1,75 mm
2 notches, Ø 2,0 mm
1. 11. 2000
Model

X100-- X120
Code

220
14
Page

96
ValtraValmet-- tractors, Stanadyne injectors
22. Fuel system

Tractor Type of Ordering Ordering no of Nozzle ope- Adjusting pre- Shims no 1,00...2,00 mm Code C
injector no of nozzle ning pres- sure, bar 1)
compl. in- sure, bar
jector
95, 105, 115 S/736 8366 39956 8366 39957 230+10 240 8366 40104...8366 40122 736
X120, 95 from week 41/00. M/358 8366 59808 8366 59902 270+8 278 8368 62000...8368 62020 358
X100, X110 M/446 8368 54831 8368 54832 270+8 278 8368 62000...8368 62020 446

1) Value to be used both with new and used nozzles.

1. 11. 2000
Model

95-- 115
X100-- X120
Code

220
15
Page

97
98
 Model Code Page
22. Fuel system 95-- 115 222 1
1. 11. 2000

Repair instructions B. Bleeding thermostart system

Always remove air from the glow plug fuel pipe when the pipe
Fuel feed pump and fuel filter (Op no 222) or reservoir has been emptied during repair work etc. This
Bosch in ---line pump prevents damages to the glow plug caused by lack of fuel dur-
ing starting.

A. Bleeding fuel system 1. If the reservoir is empty, fill it e.g. with a drip pot through the
breather hole on the reservoir.

2. Open the glow plug pipe connector and drain fuel from the
pipe. Connect the pipe.

C. Measuring fuel feed pressure

Note! Measuring equipment, see page 220/3.

1. Clean the fuel injection pump and the filter and the pipes
between them.

1. Slacken the bleeder screw on the filter head. Pump with the
hand pump until the fuel flowing out at the bleeder screw is
free from air bubbles. Then tighten the bleeder screw.

2. Fit the gauge at the banjo connection on the pump, as

shown above (between filter and injection pump).

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

N.B. If the measured pressure is below the prescribed value,

this may be caused by:

--- faulty overflow valve

--- blocked fuel filter
--- faulty fuel feed pump
--- blocked or leaking fuel pipes or unions

3. Slacken the injection pump overflow valve. Pump with the

hand pump until the fuel flowing out is free from air bubbles.
Tighten the overflow.

4. Wipe off any fuel from the engine.

99
 Model Code Page
22. Fuel system 95-- 115 222 2
1. 11. 2000

D. Checking overflow valve E. Changing fuel feed pump valves

If the fuel feed pressure deviates from the prescribed value, 1. Clean the feed pump. Disconnect fuel pipes to the feed
check the opening pressure of the overflow valve. pump. Remove the feed pump.

1. Connect a pressure gauge to the banjo union in the same

way as in previous instruction C.

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

3. If the recorded opening pressure deviates from the pre-

scribed value, the overflow valve should be changed.

N.B. If the recorded pressure is considerably lower than the

prescribed value, there may be a fault in the hand pump or
the fuel feed pump valves.

2. Secure the pump in a vice provided with soft jaws. Loosen

the tappet body from the pump and remove the piston, seal
rings, suction valve and the spring.

3. Detach from the pump body the outlet side threaded con-
nector, in which is placed the pressure valve.

4. Rinse the valves with clean fuel and check the function and
possible wear.

5. Change the valve if needed and assemble the pump using

new o---rings and gasket

100
 Model Code Page
22. Fuel system 95-- 115 223 1
1. 11. 2000

Fuel injection pump and injectors (Op no

223) (Bosch in ---line pump)
Note! Concerning fuel injection pumps with a new type gov-
ernor, see page 223/8. 9025 99000

A. Checking injection timing

Note! The exact time at which the fuel should be injected into
no. 1 cylinder is marked with a punch mark on the flywheel.
There is an inspection hole in the flywheel housing and a hole
for the locating tool. Due to the excess fuel flowing into the in-
jection pump the control rod must be moved to the drive posi-
tion when checking the injection timing. Otherwise the timing
will be incorrect!

Checking method:

1. Clean the injection pump and its surroundings carefully.

2. Remove the inspection hole rubber plug from the flywheel 5. Remove the protecting cap for the control rod on the injec-
housing. tion pump front face. Fit adjusting tool (sleeve for limiting con-
trol rod travel) 9025 99000. The tool moves the control rod to
the ”running position”.

6. Disconnect the delivery pipe for the number one cylinder in-
jector at the pump.

7. Clean the delivery valve of fuel. Slowly turn the crankshaft

in the correct direction of rotation until the fuel level in the deliv-
ery valve just begins to rise.

8. Check if the mark on the flywheel is at the point of the locator

which has been inserted into the flywheel housing. Repeat the
check procedure. If the injection pump needs to be adjusted,
follow the instructions under heading B.

9. Fit the delivery pipe and the rubber plug in the flywheel
housing. Remove the locator and the sleeve which was used
to limit the control rod travel. Start the engine.

9025 99100

3. Insert the locator (9025 99100) in the hole on the flywheel

housing front face.

B. Adjusting fuel injection timing

Important! Adjusting fuel injection timing on tractors
95 ---115 with effect from engine number G2358, see page
223/8.

If the timing is incorrect, adjust as follows:

1. Loosen the retaining nuts (17 mm) of the injection pump

and remove the delivery pipes (17 mm).

4. Turn the crankshaft to a position where the 1st cylinder pis-

ton reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the timing mark on the fly-
wheel passes the inspection hole.

101
 Model Code Page
22. Fuel system 95-- 115 223 2
1. 11. 2000
9052 48900

5. Use puller 9052 48900 and loosen the gear from the injec-
tion pump camshaft front end.

M 6. Remove the injection pump attaching nuts (17 mm).

2. If the injection timing is retarded, turn the pump anti ---clock- Remove the injection pump.
wise (viewed from the front end of the pump). If the timing is
advanced, turn the pump clockwise. N.B. If the engine is not to be disturbed while the pump is re-
moved, there is no need to secure the pump gear. The gear
3. Check once again the injection timing and set again if rests against the idler gear.
needed.

4. When the timing is correct tighten the retaining nuts of the

pump and fix the delivery pipes. D. Fitting fuel injection pump

1. Check the condition of the o---ring between the pump and

the timing gear casing. Change the o---ring if necessary.

C. Removing fuel injection pump

1. Clean the injection pump and surrounding engine parts

and the pipes and connectors on the injection pump.

2. Disconnect the delivery pipes and the banjo bolts at the

supply and return fuel connections. Disconnect the lubricat-
ing oil line. Plug all connections.

3. Detach the oil filler pipe/cover from the front cover. Unscrew
the pump drive gear nut.

2. Lubricate the o---ring and place the injection pump so that

the key on the pump shaft aligns with the key slot inside the
gear. Tighten the pump attaching nuts.

3. Tighten the gear nut to 90 Nm . Fix the oil filler pipe/cover.

4. Connect the supply and return fuel lines. Connect the lubri-
cating oil line. Use new sealing washers.

102
 Model Code Page
22. Fuel system 95-- 115 223 3
1. 11. 2000

5. Bleed the fuel system (Op no 222 A). E. Checking/changing delivery valve
6. Adjust the injection timing (Op B).
1. Clean the injection pump, injectors and surrounding parts.
7. Fit the delivery pipes. Disconnect the delivery pipes.

9052 47800

8. If the injection pump is changed or if the lubricating oil has

been drained from the pump, fill the pump with lubricating oil
before starting the engine. Open the hexagonal socket plug
on the governor housing and pour in oil.

Filling quantity: 420---engines 0,4 l

Same oil specification as in the engine.

2. Connect the pressure gauge 9052 47800 to the delivery

valve holder which is to be checked.

3. Rotate the engine with the starter motor, until the gauge
reading is about 330 bar.

Note! Pressure rises fast, do not damage the gauge. Get

ready to pull the stop control out as soon as the gauge reading
reaches an adequate pressure value.

4. Let the gauge reading lower at first about 30 bar. When the
gauge shows 300 bar, observe the reading during one min-
ute. During this time the gauge reading must not lower too
much (max 30---50 bar). If the pressure lowers faster than
specified, the delivery valve must be cleaned or replaced.

Note! The delivery valve plunger and guide should always be

replaced in pairs.

5. Open the delivery valve holder locking and holder. Remove

the valve spring, plunger and the guide.

6. Rinse the plunger and guide in clean fuel or test liquid and
at the same time rotate the plunger in its guide and press the
sealing surfaces against each other.

103
 Model Code Page
22. Fuel system 95-- 115 223 4
1. 11. 2000

2. Ensure that the throttle lever is in the idling position and that
the engine is at normal operating temperature.

3. Start the engine and loosen the adjusting screw of the addi-
tional spring so that it does not affect the idling speed.

7. Fit the delivery valve into the fuel injection pump. Place the
4. Adjust the idling speed using the adjusting screw to about
spring in place and tighten the holder.
20 RPM below rated speed and lock the adjusting screw (10
mm).
Note! Renew the sealing ring and o---ring.
5. Run the engine a few times and ensure that the idling speed
8. Tighten the holder as follows:
remains as set.
--- Tighten first to 30 Nm.
6. Tighten the adjusting screw of the additional spring until the
--- Open the holder about 1/2 a turn and tighten to 40 Nm.
idling speed rises to the rated value. Lock the adjusting screw
--- Open the holder about 1/2 a turn and tighten to 45 Nm.
(17 mm) in this position.

7. Fix the safety caps of the adjusting screws.

Note! Other adjustments (output and max. speed) of the in-

F. Adjusting low idling speed jection pump can only be performed by a specially trained
person who has the necessary special tools and gauges avail-
able.
If the idling speed of the engine deviates from the value given
in the specifications or if the engine revs vary at the idling
speed, adjust the idling speed as follows:

1. Unscrew the idling speed adjusting nut cap (1) and the cap
(2) on the idling speed additional spring adjusting screw.

104
 Model Code Page
22. Fuel system 95-- 115 223 5
1. 11. 2000

G. Removing injectors

1. Clean the injectors and the area around them. Disconnect

the delivery pipes and the leak ---off pipes.

9051 71300

2. Secure the injector in a test bench and check the follow-

ing:
--- injector opening pressure
--- the properties of the chattering (creaking) sound and the
form of the spray pattern
--- sealing of nozzle valve against its seat

3. Remove the injector attaching nuts (13 mm) and remove Opening pressure
the injector from the cylinder head. Fit protective plugs to all
connections. If the injector does not rise by hand, use puller Pump a few times to fill the injector. Increase the pressure in
9051 71300. the injector until the chattering (creaking) sound becomes
audible. Read off the opening pressure of the injector. If the
4. Remove the sealing washers from the bottom of the injector opening pressure deviates from the given value (230±5 bar),
location in the cylinder head if they do no come out with the the injector should be taken apart and checked.
injector
Adjustment is achieved by changing the shims. The thickness
of the shims varies from 1.00---1,90 mm and they are available
in increments of 0,05 mm. A thicker shim will raise the opening
pressure while a thinner one lowers it. A difference in shim
thickness of 0,05 mm changes the opening pressure by ap-
prox. 5,0 bar. As the opening pressure of the injector drops
slightly after adjustment, the opening pressure should be set
to approximately 10 bar above the value given in the specifica-
tions. This value applies both to new and used injector.

H. Inspecting injectors
Chattering sound properties
N.B. When pressure testing the injectors, it is important to
Testing with a hand powered pump does not create the same
avoid the nozzle end as the fuel jetting out easily penetrates
circumstances as when the injector is fitted in the engine. Only
the skin. Also bear in mind that the fuel ”mist” is dangerous to
with new nozzles are the test results reliable. With used
inhale.
nozzles, there is no chattering (creaking) sound when the
tester is pumped at a certain rate. This has to do with the de-
sign of the nozzles.
1. Clean the injector with cleaning fluid and a soft brush.
The carbon deposits must not be knocked off or removed in
However, with a rapid pumping on the tester handle, it should
any other way which may damage the nozzle.
be possible to hear the chattering (creaking) sound or/and
see a mist of the fuel jetting out.

105
 Model Code Page
22. Fuel system 95-- 115 223 6
1. 11. 2000

1
Tightness of nozzle

Press down the tester pump lever until the pressure rises to
approx. 20 bar below the adjusting value. Maintain this pres-
sure for approximately 10 seconds and check whether drops
of fuel are formed on the point of the nozzle. If the injector
leaks, it should be cleaned or the nozzle should be changed. 2

I. Reconditioning injectors

1. Secure the injector in a suitable way.

3
2. Unscrew the nozzle cap nut. Remove the nozzle and the
parts inside the holder.
4
3. Clean the nozzle in cleaning fluid both inside and outside.

4. Clean the nozzle holes with a needle (including in cleaning

set 8360 83288).

5. Test the movement of the nozzle valve as follows: 5

Injector

1. Fuel inlet 6. Nozzle body

2. Leak ---off fuel 7. Pressure chamber
3. Shims 8. Nozzle valve
4. Pressure spring 9. Nozzle hole
5. Valve stop spacer

Rinse the parts thoroughly in fuel or testing fluid. Pull the valve 6. Before assembling, all parts should be carefully cleaned in
out of the nozzle body to 1/3rd of its length. If the fit is correct, clean fuel or testing fluid.
the valve should be able to slide down in the nozzle body
under its own weight. Turn the valve slightly and repeat the 7. Put the same number of shims back as were fitted earlier.
test. Should the nozzle valve bind slightly, it should be Note possible adjustment of the opening pressure. Assemble
changed. the rest of the injector. Note the position of the spring guide
and the valve stop spacer.

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

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 Model Code Page
22. Fuel system 95-- 115 223 7
1. 11. 2000

K. Fitting delivery pipes

J. Fitting injector in engine 1. Check the state of the pipes. If there are kinks, damage by
chafing, or if the tapered sealing end is damaged, the pipes
1. Clean the injector sealing surface in the cylinder head. If should be changed.
necessary use a reamer 9101 66000.
2. Fit the pipes without tension and check that they are at right
angles to the union.

3. Fit the clamps for the pipes.

1. Washer
2. Rubber ring
3. Sealing washer

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

washer.

N.B. The spray pattern from the injector is not symmetrical on

purpose. It is therefore important that the injector is fitted cor-
rectly in the cylinder head. The connection for the leak ---off
line should be facing the valve mechanism.

3. Fit the attaching clamp and tighten the nuts (13 mm) evenly
to 15 Nm.

4. Connect the leak ---off line (10 mm) together with new seal-
ing washers and connect the delivery pipes (17 mm).

N.B. The screw studs in the cylinder head for the injectors
should only be finger tight. If tools have to be used the studs
should be tightened only lightly.

Note! Make sure, that the injector is of a correct type. Wrong

injectors cause malfunctions and can damage the engine.

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 Model Code Page
22. Fuel system 95-- 115 223 8
1. 11. 2000

L. Adjusting injection timing on

95---115 from engine no G2358
incl.
Note! On these tractors the injection starting point in the 1st
cylinder has been positioned with aid of an indicator pin in the
pump governor housing.

2. Unscrew the plug on the side of the injection pump. Take

out the indicator pin.

3. Turn the indicator pin and push it into the hole so that the
groove at the end of the pin points towards the pump.

4. If the pin groove fits on the boss on the governor weight

assembly, the injection timing is correct. Otherwise, turn the
pump to a position where the boss and the pin groove align.

Warning! Do not rotate the crankshaft when the groove end

of the pin is inside the pump, since the pin end damages eas-
ily and metal pieces remain in the governor housing.

5. When the adjustment is correct, turn the indicator pin so that

the groove points outwards (running position) and push the
pin into the hole. Refit the plug.

Note! When checking the injection timing, an electric testing

device can also be used, e.g. Bosch KDEP 1601 according
to the instruction manual of the device.

9025 99100

1. Turn the crankshaft to a position where the 1st cylinder pis-

ton reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the timing mark on the fly-
wheel is at the point of locator 9025 99100.

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 Model Code Page
22. Fuel system 115 223 9
1. 11. 2000

Manifold pressure compensator on

115 tractor (Bosch LDA) A

The boost control unit on the governor housing has been 1

connected via a hose to the engine inlet manifold. At low
revs the boost pressure is low and engine tends to smoke.
The boost control limits amount of injected fuel at low revs
so that exhaust gas emissions are below standard R24.
This adjustment starts at a certain, adjusted, boost pres-
sure.

The boost control unit membrane is pre ---tightened and air B

tight. A spring in the unit affects the lower surface of the
membrane; the other end of the spring rests against the
threaded guide sleeve (2). The spring tension can thus be
changed in certain limits (adjusted in factory).

With thread equipped pin (1) is attached to the membrane.

The lower end of the pin transmits movement of the mem-
brane via an angle piece to the injection pump control rod
(3).
3 2
When increased boost pressure presses the membrane
downwards, also the pin moves downwards against the
spring force and allows the control rod to move towards the
greater fuel amount, which is injected into the combustion
chambers. When the boost pressure decreases, the control
rod moves towards the smaller amount of injected fuel.

Important! The boost control unit has been adjusted in the

factory, and adjustments afterwards are not necessary.
Picture 1. Boost control

A. Adjustment screw with which is adjusted fuel amo-

unt, which the injection pump injects at low boost pres-
sure.

B. The operating pressure is adjusted by removing the

plug and by adjusting wheel B with a screwdriver.

Cold start solenoid

1. Forced ---feed solenoid
When the engine is started, the control rod must move to
for starting
the starting position. This can be done by moving the boost
control lever in the direction of the axle, so that the lever
cannot affect any more the injection pump control rod.
The mechanism functions with aid of solenoid and a cross
shaft.

The solenoid is energised, when the ignition switch is

turned in a starting position. The solenoid is energised as
long as the starter motor is on. In the starting position, the
solenoid is magnetic. When the solenoid moves to the start-
ing position, a click sound can be heard from the injection
pump.

Running position Starting position

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22. Fuel system X100-- X120 223 10
1. 11. 2000

2. Stanadyne distributor pump.

A. Removing pump

1. Clean the pump and the surrounding parts carefully.

Remove the delivery pipes, the throttle cable wire from the rev-
olution lever and the stop solenoid wire from the pump. Fit
protective caps on the delivery pipe unions.

2. Remove the cover (+oil filler tube) of the front plastic cover-
ing so that the pump gear wheel becomes accessible.

Note! On some models the safety frame of the fan space

must be removed.

3. Unscrew the gear wheel attaching nut. Detach the gear

wheel by using puller 9052 48900.

Note! If the timing gear casing has not been removed, the
injection pump gear wheel remains in contact with the idler
gear and it is unnecessary to mark the positions of the gears.

4. Detach the injection pump from the timing gear casing.

Clean the sealing surfaces.
2. Remove the small cover plate on the side of the injection
Note! In the E ---engines one injection pump fixing bolt is so pump. Rotate the pump shaft until the timing marks align (see
called interrupted screw (i.e, it cuts off when it is tightened). arrow in picture above).
Open this bolt by striking to the bolt outer edge with a chisel
(strike to the opening direction). 3. Place a new sealing ring on the pump flange. Push the
pump into place so that the key on the shaft engages with the
key slot on the gear wheel.

4. Tighten the pump into position, where the timing marks

B. Fitting injection pump and adjusting align.
injection timing
5. Tighten the gear wheel nut to a torque of 90 Nm. Fit the
small cover onto the side of the pump. Fasten the pump gear
wheel covering (+oil filler tube).

6. Remove the protective caps from the delivery pipe unions

and fit the delivery pipes. Fit the overflow pipe, throttle cable
wire and the stop solenoid wire. Bleed the fuel system (see
instruction C).

Note! Lubrication oil is not needed because fuel in the pump

lubricates the internal parts.

Note! Concerning dynamic adjustment of injection timing on

the E ---engines, see page 223/13.

9025 99100

1. Turn the crankshaft to a position where the 1st cylinder pis-

ton reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the timing mark on the fly-
wheel is at the point of locator 9025 99100. (injection in no. 1
cylinder begins).

Note! Distance between the piston top face and the top dead
center with different crankshaft angles, see page 210/7.

110
 Model Code Page
22. Fuel system X100-- X120 223 11
1. 11. 2000

C. Bleeding fuel system D. Fuel feed pump

Note! This fuel system removes automatically small amounts
For the membrane type fuel feed pump no spare parts are
of air bubbles from the filter and the pump when the engine
is running. However, bleed the system always, when the sys- supplied. The feed pump must be changed for a new one, if
the feed pressure has dropped noticeably (rated feed pres-
tem has been opened or fuel has been exhausted during driv-
sure is 0,2 ---0,5 bar at low idling speed and max 0,2 bar less
ing or a new spare pump has been fitted (to avoid long starting
time). when engine is accelerating) or if the fuel feed pump has
been damaged.

Metal gauze filter Measuring fuel feed pressure

under cover
Measuring equipment, see page 220/3.

Note! If the feed pressure value is below the rated value, poss-
ible reason can be:
--- blocked fuel filter/fuel feed pump metal gauze filter
--- faulty fuel feed pump
--- blocked or leaked fuel pipes or pipe connections

Important! Under the fuel feed pump cover there is a wash-

able metal gauze filter. If much impurities have gathered on
this filter, fuel cannot flow to the feed pump and further to the
injection pump and this causes malfunctions in the fuel sys-
tem. Always when malfunctions appear, the feed pump cover
should be removed and the metal gauze filter must be
checked and cleaned.

1. Pump by hand the fuel feed pump lever. If the pumping Note! From manufacturing week G42 incl. the fuel feed pump
seems to be ineffective, turn the engine a little so that the cam- gasket no. 8366 40335 has been removed and the sealing has
shaft cam is not at the feed pump lifter. been done with sealing glue T61050 (Weicon Lock AN
305---10 or 75), which must also be used in connection with
possible leakages. Run the engine, until the cylinder block
temperature is at least +60˚C. Clean the sealing surfaces well
by using suitable solvent. Apply the sealing glue onto the
pump sealing face and fasten the pump. Let the sealing glue
dry about one hour before the engine is started (if a fuel feed
pump, which has been tightened with the sealing glue, should
be changed, the pump fastening flange must be warmed up
to about +200˚C before removing the pump).

New fuel feed pump

In the tractor production has been started to fit a new fuel feed
pump (420: H7663 ---. 620, 634: H7728 ---), which has an
o---ring seal and four fixing bolts. This pump can be fitted also
on earlier manufactured tractors, although they should have
the earlier, with two bolts attached pump (mounting kit no.
8366 62052). In the cylinder block there are four fixing holes
2. Loosen the bleeding screw (10a) on the filter. Pump with the from the beginning of the year 98. The Spare Part Centre dis-
hand pump until no air bubbles flows out of the bleeding patches only the new pump.
screw hole. Tighten the bleeding screw.
On the next page there is an instruction on, how to fit the new
3. Pump further with the hand pump and loosen the fuel inlet pump.
connection (10b) on the pump, until the fuel coming out is free
from air bubbles. Tighten the connection.

4. Start the engine and assure, that no leaks exist.

Note! When the bleeding is done in this way, fuel flows

immediately into the internal transfer pump when the starter
motor is rotating and the distributor pump housing is filled
quickly with fuel. In the pump housing there is a stop solenoid,
which must not be switched on for longer periods when the
pump housing is empty of fuel.

111
 Model Code Page
22. Fuel system X100-- X120 223 12
1. 11. 2000

Fitting new fuel feed pump F. Adjusting low idling speed

Revolution lever
Max. revs
Low idling speed

--- Remove the old feed pump and fuel pipes The low idling speed can be adjusted with a limiting screw in
--- Clean the sealing surface on the cylinder block front of the revolution lever. The adjusting screw for max. revs
--- Place an o---ring into the groove on the pump has been sealed. This adjustment has been done in the fac-
--- Engines with two fixing bolts: apply sealing compound tory, and adjustment of max. revs afterwards is prohibited.
T61050 (Weicon Lock AN ---305---74) on the cylinder block si-
de of the flange 4 (if four fixing holes the flange is not fitted. Note! The throttle cable is attached to the revolution lever
--- Apply sealing compound also on the threads of the bolts lower hole. To the upper hole is fastened a return spring.
( 2 pcs or 4 pcs) and fasten the pump. Tightening torque is 30
Nm. Other information
--- Bend the pipe between the filter and pump or use a flexible
pipe which incl. in the kit. The injection pump housing upper cover has been sealed to
prevent adjustment of engine output afterwards. Also the stop
Note! If the cylinder block has already four threaded bolt ho- solenoid is fitted under this cover. If the injection pump is dam-
les , remove plugs from points A, and fasten the pump with aged during the warranty period, a replacement pump must
four bolts (sealing compound on the threads of all bolts) wi- be fitted. After the warranty period it is recommended, that all
thout the intermediate flange (4). pump repairs are made by an authorised Stanadyne work-
shop.
Sealing compound (50 ml)......6909 30030
Sealing compound (250 ml).....6909 30016 G. Bleeding Thermostart system

Always remove air from the glow plug fuel pipe when the pipe
or reservoir has been emptied during repair work etc. This
E. Injectors prevents damages to the glow plug caused by lack of fuel dur-
ing starting.
Injectors are checked and serviced according to instructions
1. If the reservoir is empty, fill it e.g. with a drip pot through the
G ---J on pages 223/5 ---7.
breather hole on the reservoir.
The opening pressure of the injectors, see table on page
2. Open the glow plug pipe connector and drain fuel from the
220/15.
pipe. Connect the pipe.
Adjustment is achieved by changing the shims. The thickness
of the shims varies from 1.00---1,90 mm and they are available
in increments of 0,05 mm. A thicker shim will raise the opening
pressure while a thinner one lowers it. A difference in shim
thickness of 0,05 mm changes the opening pressure by ap-
prox. 5,0 bar. As the opening pressure of the injector drops
slightly after adjustment, the opening pressure should be set
to approximately 10 bar above the value given in the specifica-
tions. This value applies both to new and used injector.

112
 Model Code Page
22. Fuel system X100-- X120 223 13
1. 11. 2000

I. Dynamic adjustment of injection ti-

ming

1. Let the engine run to a normal working temperature before

adjustment. Note! Ensure before engine start that the wires do not to-
uch the exhaust manifold or movable parts.
Note! Stop the engine before connecting and disconnecting
the adjusting device. 8. If the revolution reading is correct, press ENTER after
which text ”Calibrating...”. is visible in the display
2. Remove the protective plug on the fly wheel housing on the
LH side of the engine and fit the magnetic sensor A into the Note! If the revs signal disapperas or engine stops , in the
8 mm hole. Press the sensor against the fly wheel . The sensor display flashes text ”Eng. Not running” and the device re-
must not touch the fly wheel so pull it a little out (0,5...1,0 mm) turns to the revs mode. Start again by pressing button
. Connect the sensor connector to the test device plug MP. MAG PROBE (return to point 5).

3. Fit fastener B on the brass ring between the pump and pipe 9. If the engine is running at 850 r/min and the pump ad-
and tighten the screw. Ensure, that the screw end touches the vance is 6˚ btdc, in the display there is visible ”R=850 MP
brass ring. Connect the injection sensor connector to the test + 6.0”. Now the device is ready for adjustment.
device plug SR. Connect th earth wire to the clean metal sur-
face on the engine or fuel system. Note! If the magnetic sensor signal is cut or the sensor is
lacking, in the display there is text ”R=850 No Probe”.
4. Switch on the test device by pushing ON/CLEAR button. When the signal returns, the device shows again the injecti-
In the display is visible ”Time Trac” and ”Model TT 1000” and on advance.
then i ”R= 0”. Now the device can be used as a rpm counter
without other procedures. 10. The injection time is checked at high idling revs [TT
(HI)]. Adjust if necessary. The function of the pump injecti-
5. Press button MAG PROBE. In the display appears ”Trig Le- on advance governor is assured by checking the injection
vel 30%”. Confirm by pushing ENTER. timing at a low idling speed [TT (LI)].

6. In the display is visible ”Offset 20.0˚”. Confirm by pushing Adjusting values, see tables on page 220/14.
ENTER.
See also instructions of the device manufacturer.
7. In the display is visible ”Calibrate?”. Start the engine and
let it run at low idling. Press ENTER so that in the display is visi-
ble ”R=Set RPM”. Compare the revs to the dashboard rev co-
unter reading and specified values, see page 210/3.

113
 Model Code Page
22. Fuel system X100-- X120 223 14
1. 11. 2000

Possible disturbances

If the injection timing deviates much from the specified value,

check the following points:

1. Vibrating delivery pipe, hold to the pipe with one hand.

2. The distance between the magnetic sensor and the flyw-

heel is incorrect, reposition the sensor.

3. Offset or Trig Level value incorrect, reset the values.

4. Disturbing grooves on the flywheel.

5. The mutual position of the flywheel and the crankshaft

incorrect, remove the flywheel and fit it to the correct position
in relation to the crankshaft.

8366 62022 Electronic device for injection timing

114
 Model Code Page
23. Cooling system 95-- 115
1. 11. 2000 X100-- X120 230 1

Contents

General (Op no 230):

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cooling system, description and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Repair instructions (Op no 231):

A. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reconditioning coolant pump , 95---115 (X100---X120, ---K6490) . . . . . . . . . . . . . . . . . . . . . . 1
D. Quality requirements of engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

115
 Model Code Page
23. Cooling system 95-- 115
1. 11. 2000 X100-- X120 230 2

Specifications
Coolant pump 95---115 (X100---X120, ---K6490).

Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,087...38,100 mm

Inside diameter of bearing housing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,058...38,083 mm
Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,910...15,920 mm
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,881...15,899 mm
Diameter of the seal recess in the pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,450...36,489 mm
The impeller is pressed onto the shaft until the distance between the rear face of impeller
and the rear face of the pump body is . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8---2,2 mm
Distance of belt pulley from rear face of body:
---E7054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178,3...178,7 mm
E7055---. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174,4---174,6 mm
Fan guide diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,00...25,20 mm
Balancing precision of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 Ncm max
Max. permissible eccentricity of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0,3 mm
Belt deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15...20 mm

Fan diameter (belt driven)

--- 95---105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483 mm
--- 115, X100---X120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508 mm

Number of fan blades:

--- 95---115, X100---X120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 pcs

Thermostat
Spare part number Type Opening Fully Max stroke
begins at open at mm
8361 15646 ø67/79˚C 79˚±2˚C 94˚C 8
8361 15718 ø67/83˚C 83˚±2˚C 97˚C 8

Tightening torque

Coolant pump belt pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm

Fan attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm

116
 Model Code Page
23. Coolant pump 95-- 115
1. 11. 2000 X100-- X120 230 3

Special tools
Order no Description

9022 03500 *) Puller for coolant pump impeller (earlier no 8360 85499)
9104 27700 Puller for coolant pump impeller, new coolant pump, K6491---, see page 230/7.
9051 40200 *) Drift for fitting coolant pump seal (seal no 8353 31202)
9051 79300 *) Drift for fitting coolant pump seal (seal no 8353 39425)
9051 64900 *) Drift for fitting coolant pump shaft
9052 48900*) Puller for fan hub (see Fuel system)

*) Same tool as for engines on Mezzo tractors.

9022 03500

905140200 905179300 905164900 9052 48900

117
 Model Code Page
23. Cooling system 95-- 115
230 4
1. 11. 2000 X100-- X120

Cooling system

1. Coolant pump
2. Thermostat
3. By ---pass passage
4. Radiator
Caution! Open the radiator cap carefully, if the coolant is hot
as there will be pressure in the system. Carefully turn the radi-
Description ator cap to the first stop. This will allow the pressure to be
released from system.
The belt driven, centrifugal type coolant pump is attached at
the front end of the cylinder block and the thermostat housing N.B! The coolant pump is provided with a drainage hole on
is fitted above the pump. The system has an internal coolant its underside. This hole must not be blocked. If coolant drips
circulation via the by ---pass passage and the circulation is out of the hole, the pump seal is faulty. There may be slight
controlled by a two---way thermostat. With this is achieved an leakage on a new engine before the pump has been run in.
even warming in all conditions.

The coolant pump has separate ball bearings and the pump Freezing point of coolant
shaft and the bearings are built together to form one unit.
Check the freezing point of the coolant at the beginning of the
The thermostat opens at 79˚C. During a cold season, a ther- cold season. If the freezing point is too low, drain off some of
mostat with the opening temperature of 83˚C can be use. the coolant and top up with anti ---freeze. Run the engine for
a while until the anti ---freeze has been mixed in, then re ---
Maintenance check the freezing point of the coolant. Drain the cooling sys-
tem completely every second year and refill with new coolant.
Never use just water as a coolant.
Check the coolant level daily.
The level of the coolant should be slightly above the radiator
core. If the tractor has an expanison tank, see the next page. Clean regularly the radiator externally from insects and other
Check the condition of the fan belt since it drives the coolant impurities.
pump. Stop the engine immediately if the coolant tempera-
ture rises too much.

118
 Model Code Page
23. Cooling system 95-- 115
1. 11. 2000 X100-- X120 230 5

Expansion tank

3
5

Picture 2. Cooling system with all possible expansion tanks The level of hot coolant is upper. Before filling the expansi-
(all 95 ---115 tractors have not an expansion tank). on tank, unscrew the bleeding plug on the RH side of the
thermostat housing, until no air flows out.
1. Expansion tank (volume 4 l). Earlier tractors had metallic
and later plastic expansion tank. Checking the coolant level: The system has enough coo-
2. Breather hose (metallic tank) lant, if the coolant can be seen in the level indicator hose
3. Filling hose (metallic expansion tank) or in the plastic tank the coolant
4. Outlet hose level surface stands at the mark line on the tank.
5. Connection hose to radiator
Note! The front cover has perforations to improve air flow
Emptying the system in connection with repairs: through the radiator.

--- carefully open the expansion tank cap Warning! Do not open the radiator filling cap, if the coolant
--- empty the radiator through the emptying tap (if not the is hot. All maintenance works of the coolant system should
tap, disconnect the lower water hose) be made through the expansion tank filler cap.
--- unscrew the cylinder block emptying plug
--- open the oil cooler emptying plug (if fitted) Important! If the cooling system has been emptied, check
--- open the cab heater adjusting knob the restriction holes in the thermostat housing and in hose
--- empty the intercooler via the plug (if fitted) union A (see picture above) so that they are not blocked.
Clean if needed.
Filling the system in connection with repairs: First fill
the radiator and after that the expansion tank. The coolant
level should be to the height of 1/3 of the level indication
hose length (metallic tank) or in the latest tractors (plastic
tank) the coolant level must stand at the expansion tank
level marking (black arrow in the picture above), when coo-
lant is cold.

119
 Model Code Page
23. Cooling system 95-- 115
1. 11. 2000 X100-- X120 230 6

Temperature sensor, engine coolant temperature:

The sensor is placed on the engine beside the thermostat housing:

Temperature gauge pin

Warning light

Resistance value, temperature

gauge side:
60˚C=134± 13,5 τ
90˚C=51,2± 4,3 τ
19 mm 100˚C=38,5± 3,0 τ

40
M14x1,5
11

40

Order no Alarm temperature

6542 71208 98 ± 3˚C (used on Valtra ---tractors)
8366 40772 106 ± 3˚C (used on Valtra ---tractors)
8366 64017 110 ± 3˚C

120
 Model Code Page
23. Cooling system X110-- X120 230 7
1. 11. 2000

Coolant pump
Valtra Valmet 100Hi--120Hi, from engine no. K6491 incl.

8367 64215

Expansion tank

Note! left hand thread

Heating unit

25 Nm

Oil cooler

Intercooler

25 Nm

121
122
 Model Code Page
23. Coolant system 95-- 115
1. 11. 2000 X100-- X120 231 1

Repair instructions (Op no 231) B. Reconditioning coolant pump, 95---115

(X100---X120, ---K6490)
A. Thermostat
1. Drain the engine coolant. Disconnect the water hoses from
the thermostat housing and from the coolant pump. Remove
the thermostat housing and the by ---pass hose.

2. Slacken the alternator fixing bolts. Remove the fan and the
pump belt pulley. Remove the v ---belt.

3. Detach the coolant pump. Remove the pump rear plate and
clean the sealing surfaces.

9052 48900

4. Remove the fan hub using puller 9052 48900. Remove the
circlip from the pump body.

9022 03500
The thermostat is of a two---way type. Its opening temperature
is 79˚C. In winter a thermostat can be used with an opening
temperature of 83˚C or 86˚C.

Check the function of the thermostat as follows:

--- lower the thermostat into a vessel of boiling water so that the
thermostat does not touch the sides or bottom.
--- opening must begin under 20 seconds.
--- The thermostat must be fully open under 50 seconds.
Stroke, see specifications.

5. Remove the impeller using puller 9022 03500. Press the

shaft out of the pump body in the direction of the fan. Use a
hydraulic press. Support the body so that the shaft bearing
unit has enough space for releasing.

123
 Model Code Page
23. Cooling system 95-- 115
231 2
1. 11. 2000 X100-- X120

6. Tap out the shaft seal in the body using a suitable drift. 178,5 mm
Clean all parts and inspect their condition. Replace damaged 174,5 mm
parts with new ones. 320 DS: E7536---
420 D/DS: E7055---
N.B. If the pump shaft has to be changed, use a recondition-
ing kit. This kit also contains all seals (see Parts Catalogue).

7. Press the shaft into its location in the body using special tool
1,8---2,2 mm
9051 64900 and fit the circlip.

320
420
9051 79300

905140200

D. Quality requirements of coolant

The coolant used must meet the standards ASTM

D3306---86a or BS 6580:1985.

--- Mixing proportion should be 40---60 % of ethyls---glycol

based coolant and the rest water. The best ratio is 50/50 %.

8353 39425 --- In warm climates the 30 % mixture ratio gives enough good
8353 31202 protection against corrosion.

--- Water used should be clean and soft water i.e. that it does
not include metals and their salts.
8. Fit the shaft seal. Use as a ”lubricating liquid” coolant
between the shaft and the seal. Two different seal types are --- Check the coolant frost resistance every now and then.
used. Both these seals are fitted with their own drift (see figure Change the coolant every other year. Never use just water as
above). a coolant.

9. Press the impeller and the hub to the correct depth (see fig-
ure) and support the shaft at the other end. Ensure that the
shaft can rotate freely. Fit the rear plate using a new gasket.

Note! Coolant pumps (and crankshaft belt pulleys) have been

changed with effect from engine numbers mentioned below:
--- 320DS ---engines: E7536---
--- 420D/DS ---engines: E7055---.

This modification should be observed when ordering spare

parts. The adjusting values, see picture above.

124
 Tractor electrical system
31. Autocontrol 2.2 (J05133-)
30. Electrical system Autocontrol 2.3 (K44242-)

32. ACB power lift

33. Agrodata-instrument

Autocontrol 5 (H49112-)
37. (HiTech)
Autocontrol 5.2 (K41107-)

127
128
 Model Code Page
31. Tractor electrical system 95-115
1. 11. 2000 X100-X120 310 1

General
The tractor electrical system, AC 2.2 and AC 2.3 are described in section 31. The tractor is also equipped with an electro-hyĆ
draulically controlled ACB power lift, see section 32. AD-instrument is available as an optional equipment, see section 33.
AC 5/5.2 have been described in section 37. IMPORTANT: Front loader eletrical system is described under code 920.

ValtraValmet 95-115 and X100-X120 have 12 V electrical system (negative earthing). Battery (12 V, 160 Ah) is fitted in the
engine compartment in front of the cab.

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Ah
Alternator:
- 95-105, Magneti Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 A/870 W
- 115, X100-X120, Iskra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 A/1,28 kW
Starter motor:
- Magneti Marelli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 kW or
- Iskra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,1 kW
Safety start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . operated by the clutch pedal
Bulbs:
- headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60/55 W-H4
- side lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5W
- rear lights/brake lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/21 W
- direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 W
- working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 W-H3
- instrument panel and warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 W-1,2 W
- cabin light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2X10W-4 W

Safety precautions for the electrical sysĆ Battery checks and maintenance:
- Check the charge in the battery using a hydrometer (acid
tem: tester). The density of the electrolyte should be at least 1,23.
- Make sure that the fan belt (belts) are always correctly tenĆ
- always connect the battery with the correct polarity sioned.
- disconnect the negative lead of the battery first and connect - Keep the battery clean. It can be washed with lukewarm
it last water after removal from the tractor..
-disconnect the battery leads before removing the alternator - Also clean the pole studs, the cable terminals and the batĆ
tery retainer thoroughly. Wash off oxidized spots with water.
- remove the battery caps during charging to prevent the
Wipe the outside of the battery when it is clean, and coat the
build up of explosive gases in the battery
pole studs and the cable terminals with petroleum jelly.
- Refit the battery.
Important!
The alternator wiring must be disconnected before arc Caution!
welding is carried out on the tractor or an implement It is forbidden to smoke or have a naked
which is attached to it. flame near the battery. The battery gives
Never run the engine with the alternator disconnected. off explosive hydrogen gas!
Do not attempt to connect any additional electrical equipĆ
ment, as this may damage components of the existing Battery electrolyte is corrosive.
electrical system.
IMPORTANT WARNING! Always when the electric weldĆ
ing is done to the tractor, disconnect both battery cables
Alternator (+ and -) and alternator wires. Otherwise the tractor elecĆ
tric system (e.g. CareTel, Agrodata, ACB power lifts,
The tractor has a negative-earthed alternator which can easĆ AC5/5.2 etc.) can be damaged.
ily be damaged if incorrect connections are made in the elecĆ
trical system. For example, connection of the battery with Note! Auxiliary equipment must be fitted according to the
wrong polarity can burn the alternator or rectifier. The chargĆ instructions. Fuse nominal current rating must be checked
ing current circuit must not be broken when the engine is runĆ before fitting. On HiTech models any auxiliary components
ning. must not be fitted to the AC 5/5.2 electric circuit (e.g. F24)
(safety risk).

129
 Model Code Page
31. Tractor electrical system 95-115
1. 11. 2000 310 2
X100-X120

Fuses and relays K24 Relay for Hi Shift, see code 411.
The fuse box is placed under the instrument panel. The fuse K27 Relay for 4WD in AC 2.2/2.3, see code 314
box should always be kept clean. It contains 30 fuses. The K28 Relay for hand brake, see section 50 (in lever console)
nominal current rating of the fuses is 5-25 A. If any of the Note! X1-X7, see wiring diagrams. Fuses and relays are also
fuses blow, the fault must be traced and remedied. Fuses listed in all wiring diagrams in this manual.
must not be replaced with ones of higher a rating, since this
may cause damage to the electrical equipment. There are
space for reserve fuses between the fuses.

Fuses
F1 15 A Hazard warning flashers, water pump
F2 5A Clock, radio, tachograph, CareTel
F3 15 A Main beams
F4 15 A Dipped beams
F5 10 A Parking light, left
F6 10 A Parking light, right
F7 10 A Front working lights
F8 25 A Light switch
F9 15 A Trailer socket/rear fog light
F10 25 A 3 pole current socket
F11 5A Hydraulic power lift (+bat), buzzer (AC2.2/2.3)
F12 10 A Rotating warning light, cab light, radio (HiTech)
F13 10 A Reserve (AC 2.2/2.3, HiTech)
F14 15 A Ignition switch, thermostart
F15 25 A Fan III-speed
F16 10 A Rear working lights, inner
F17 10 A Direction indicators, FieldMaster, Agrodata Position of fuse box
F18 5A Instruments, warning lights, Autocontrol
F19 10 A Windscreen wiper/washer, horn
F20 10 A Rear window wiper/washer
F21 15 A Fan I, II, air conditioning, floor fan
F22 10 A 4WD, PTO, DPS (AC 2.2/2.3), 4WD (AC 5.2)
AC 5 sensors. X2 X3 X4 X5 X6
F23 10 A Rear working lights, outer
F24 10 A Reserve. Seat direction (AC 5/5.2). Hand brake 7 1
(AC 5) X1 K7
F1
F2

F3
F4

F5

F6
X7
9 3
F25 15 A Air suspension seat, seat heating, rear steering
......... prevention
F26 10 A Reverse buzzer, Hi Shift K1 K6
F10
F11
F12

F13
F14
F15
F7
F8

F9

F27 10 A Brake lights, diff. lock

F28 10 A Telephone
F29 10 A Cigarette lighter, 2-pole current socket K2 K5
F16
F17

F18
F19

F20

F21

F30 10 A CareTel
(F51) 15 A Main circuit breaker, in engine compartment
K3 K4
F22
F23

F24

F25
F26

F27
F28
F29
F30

Relays
K 1 relay, front working lights
K 2 relay, rear working lights
K 3 control relay, diff. lock/4WD. 662343-, fog lights
K 4 relay, starter switch Circuit card, fuse box
K 5 relay, starter switch (The fuse diagram is placed under the fuse box)
K 6 relay, fan III-speed With effect from ser. no 662343, frames of relays K3
K 7 reserve. 662343-, relay for four wheel braking (AC II) and K7 change places.
K9 interval wiper relay (in front of the fuse box)
K10 Relay direction indicators (in front of the fuse box) Spare part number of the circuit card 31542320
K14 relay, starter motor (in engine compartment)
Relays K11, K12, K13, K15 and K16, see Autocontrol 2.2/2.3
under code 314. Relay K12 not in AC 2.3.
K18 Control Stop relay

130
 Model Code Page
31. Tractor electrical system 95-115
1. 11. 2000 X100-X120 310 3

Headlight adjustment Standard trailer socket

1. Brake light (red)

2. LH side direction indicator (yellow)
3. Earthing (white)
4. RH side direction indicator (violet)
5. RH side parking light (brown)
6. LH side parking light (black)
7. Continuous current, max. 15 A. Use only main circuit breaĆ
Correct adjustment of the headlights is very important when ker (if fitted) to switch off this current.
running on the public highway.
Headlight adjustment can be carried out quickly and accuĆ
rately by using an optical headlight adjusting unit. If no optical
instrument is available, adjustment can be done as follows:
Check before adjusting the headlight that the tractor loading
is normal and tyre pressures are correct.With dipped-beam
switched on, the cutoff edge of the light pattern should come
at height H when the tractor is at distance L. With full-beam
switched on, the distance between the light points should be
B. Any necessary adjustment is done with the headlamp adĆ
justing screws.

Measurements:
L=5m
B =Distance between headlight centres
H =Height of headlights above ground minus 50 mm

NOTE! If tractor has up lifted full/dipped beam headlights (on

the top part of the cab), the lights have to be adjusted so, that
the light pattern shines on the mark at a distance of 30 m on
even ground.
Lights which can be mountained under the lower part of the
front frame can not be used on general roads.

131
 Model Code Page
31. Tractor electrical system 95-115
310 4
1. 11. 2000 X100-X120

Electrical equipment for engine

Starter motor Magneti Marelli (Lucas) M 127/2,8 12 V
Spare part no 8353 31592

Test values, unloaded:

- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5500-8000 r/min max
- current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 A
- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
Test values, loaded:
- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 r/min
- current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670 A
- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,8 Nm
- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,0 V
Locked rotor:
- speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
- current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1160 A
- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,4 Nm
- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,0 V
Brush spring pressure (new brush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,6-15,5 N
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm
Commutator, min. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 mm

Note! 95-115 tractors which have Bosch in-line fuel injection pump, have a new starter motor ISKRA 12 V 3,1
kW ( F3792-),

Alternator Magneti Marelli (Lucas) A127-65

Spare part no 8366 40128 (6100-6600)
Spare part no 8353 39304 (8000, 8100)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Max. current 6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 A
Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . minus (-)
Max permissible speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15000 r/min
Brush length, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Brush spring pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3-2,7 N
Stator, no of poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Stator, no of phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ohm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9 ohm
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,4 V
Nut for belt pulley, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm

Note! Tractors 115 and X100-X120 have alternator ISKRA 95 A 12 V, 1,28 kW.

132
 Model Code Page
31. Tractor eletrical system 95-115
1. 11. 2000 X100-X120 310 5

Alternator Iskra AAK 5118 14 V 95 A

(Sisu Diesel no. 8366 40927)

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Max. current (test voltage 13 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≥50 A
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≥84 A
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≥94 A
Charging starts at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 r/min
Max. permissible rotation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 000 r/min
Slide ring min. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,3 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...2,97 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,33...036 ohm
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50...70 Nm
2. Connector B+ (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,2...6,0 Nm
3. Connector D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
4. Connector W (M 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm

1 3

415-3

133
 Model Code Page
31. Tractor electrical system 95-115
1. 11. 2000 310 6
X100-X120

Starter motor Iskra AZJ3234 12 V 3,1 kW

(Sisu Diesel no. 8366 40949)

Test values, unloaded:

Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≤1000 r/min
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≤140 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
Test values, locked rotor
Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min (max.)
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≤1660 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,6 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≥45 Nm
Brush length, new brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm
Brush spring pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40...48 N
Commutator, min diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,5 mm
Tightening torque:
Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 Nm
Solenoid bolts (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Solenoid bolts (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,0 Nm
Field coil fixing bolts (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Shift lever pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Solenoid connection screw (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 Nm
Solenoid connectio screw (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm

134
 Position of electrical components on cab, F17107-.
This picture also contains some components for electro-hydraulic power lift (see section 32) AC 2.2/2.3
31. Tractor electrical system

135
1. 11. 2000
Model
95-115
310
Code
9
Page
 Model Code Page
31. Tractor electrical system 95-115 310 10
1. 11. 2000
AC 2.2/2.3

136
 Model Code Page
31. Tractor electrical system X100-X120 310 11
1. 11. 2000

X100- X120

137
 Model Code Page
31. Tractor electrical system X100-X120 310 12
1. 11. 2000

X100- X120

138
 Model Code Page
31. Tractor electrical system 95-115 310 13
1. 11. 2000

Wiring diagram 95-115 (incl. AC 2.2, Sym- Code

bol Component no
-K44241), Diagram no. 31871650A. AC 2.2, see code
314. F20 10A Rear window wiper/washer 48
Sym- Code F21 15A Fan (I, II), air conditioner, floor fan 55
bol Component no F22 10A 4WD, PTO, DPS 65
F23 10A Rear working lights, outer 41
(A2) Radio 2 F24 10A Reserve 98
A3 Electric centre F25 15A Air suspension seat/seat heating, rear steering
(A5) Air suspension seat 94 prevention 94
(A6) Agrodata 95 F26 10A Back buzzer, HiShift 96, 116
(A10)Control unit, DPS 70 F27 10A Braking lights, differential lock 62
(A11)Telephone 99 F28 10A Telephone 99
(A14)Tachograph 93 F29 10A Cigarette lighter, 2-pin current socket 91
(A16)Fieldmaster 155 F30 10A CareTel 120
B1 Sensor, engine temperature 16 G1 Battery 1
B2 Sensor, fuel gauge 17 G2 Alternator 4, 118
(B3) Sensor, gearbox temperature 102
(B6) Velocity sensor, gearbox 81D, 102, 123, 153 H1 Indicator light, direction indicator III 34
(B7) Velocity sensor, PTO 102, 117, 124, 153 H2 Indicator light, direction indicator II 34
(B8) Sender, wheel speed H3 Indicator light, direction indicator I 34
(B9) Sensor, tachograph 93 H4 Indicator light, air filter 7
(B10)Speed radar 81D H5 Indicator light, engine oil pressure 8
H6 Warning light, stop, engine temp. 15
E1 Headlights, right 26 H7 Indicator light, gearbox oil press. 9
E2 Headlights, left 25 (H8) Indicator light, oil filter, gearbox 10
E3 Front direction indicator, right 31 H9 Indicator light, 4WD 65
E4 Front direction indicator, left 28 H10 Indicator light PTO 67
E5 Rear light, right 33 H11 Indicator light, parking brake 12
E6 Rear light, left 32 H12 Indicator light, Thermostart 6
E7 Cab light 46 H14 Indicator light, main beams 27
E9 Rear working light, right outer 42 H15 Indicator light, fuel reserve 14
E10 Rear working right, right inner 42 H16 Indicator light, charging 6
E11 Rear working light, left outer 41 H18 Indicator light, gearb. oil temp. 13
E12 Rear working light, left inner 41 H19 Indicator light DPS I 71
E13 Front working light, right 44 H20 Indicator light, diff. lock 62
E14 Front working light, left 44 H21 Indicator light DPS II 71
E15 Instrument lights 17 H22 Indicator light DPS III 71
E16 Roof console lights 21 H23 Horn 50
(E17)Seat heater 94 (H24)Rotating roof light 47, 148
(E19)Fog light, rear 35 (H27)Reverse Buzzer 96
(E20)Parking light, right, Norway 29 (H28)Indicator light, STOP, rear
(E21)Parking light, left, Norway 30
(E22)Register plate light 32 K1 Relay, front working lights 43
(E23)Upper head light, right 24 K2 Relay, rear working lights 41
(E24)Upper head light, left 23 (K3) Relay, fog light, rear 35
(E25)Parking light, upper, right 22 K4 Auxiliary relay, starter switch 7
(E26)Parking light, upper, left 22 K5 Auxiliary relay, starter switch 9
(E27)Working light, side K6 Relay, fan III 56
(E28)Working light, side K7 Control relay, 4-wheel brake 65
Fuses 0. K9 Relay, interval wiper 53
K10 Direction indicator relay 34
F1 15A Hazard blinkers, water pump 21, 97
K11 Relay, brake lights/differential lock 63
F2 5A Radio, clock, tachograph, CareTel 2, 120
K12 Control relay, differential lock 61
F3 15A High beam 25
K13 Control relay, differential lock 64
F4 15A Low beam 25
K14 Starter motor relay 4
F5 5A Parking lights, left 28
K15 Control relay, 4-wheel drive 65
F6 5A Parking lights, right 30
K16 Relay, PTO-emergency stop 68
F7 10A Front working lights 44
(K18)Relay, control stop 8
F8 25A Light switch 28
(K24)Control relay, HiShift 115
F9 15A Trailer socket/fog light, rear 35
K25 Control relay, upper head lights to working
F10 25A 3-pin current socket 100
lights
F11 5A Autocontrol (+Bat), buzzer 71, 82B, 82D
K26 Control relay, speed limit, HiShift
F12 10A Rot. warning light, cabin light 47
K27 Control relay, 4WD on/off 66, 68
F13 10A Reserve 100
F14 15A Starter switch, thermostart 97
F15 20A Fan III- speed 56
F16 10A Rear working lights, inner 42
F17 10A Direction indicators, Fieldmaster 32, 153
F18 5A Instruments, warning lights, Autocontrol 17
F19 10A Windscreen wiper/washer, horn 51

139
 Model Code Page
31. Tractor electrical system 95-115 310 14
1. 11. 2000

Sym- Code Sym- Code

bol Component no bol Component no

M1 Starter motor 3 V1 Diodes Y1, Y2, Y3, Y4, Y6

M2 Fan 55 V2 Diodes, AC-2
M3 Windscreen wiper 53 V3 Diodes, 4WD 15
M4 Windscreen washer 51 V4 Diodes, Y11, Y12, (Y17)
(M5) Rear window wiper 49 (V5) Diodes, HiShift 115
(M6) Rear window washer 48
M7 Floor fan 57
(M8) Water pump 97
Ground leads
(M9) Roof window wiper GR1 Rear lights, solenoid valves
GR2 Roof
P1 Engine temperature meter 16 GR4 Autocontrol
P2 Fuel gauge 17 GR5 Cable harness, instr. panel
P3 Tachometer 18 GR7 Battery
P4 Running hour meter/AC 19 GR8 Headlights
(P4 Running hour /speed meter (AD instrumentation)) 19 GR9 Cabin
(P5) Clock, PTO-speed, AC, trip, oil temperature (AgrodaĆ GR10 Electrical stop
ta-instrumentation) 101
X1 9 pin, distribution box
Q1 Heat/starter switch 4 X2 9 pin, distribution box
(Q2) Main switch 3 X3 9 pin, distribution box
X4 9 pin, distribution box
R1 Thermostart 5 X5 9 pin, distribution box
R4 Cigarette lighter 91 X6 9 pin, distribution box
X7 9 pin, distribution box
S1 Switch, head lights 28 (X8) 2 pin, power socket 92
S2 Switch, rear working lights 41 X9 9 pin, combination control
S3 Switch, fan 55 X10 9 pin, combination control
S4 Combined switch 25, 34, 52 X11 9 pin, upwards
S5 Switch, front working lights 43 X12 9 pin, rearwards, right
(S6) Switch, rot. warning light 47 X13 37 pin, transmission
S7 Switch, hazard warning flashers 32 X14 9 pin, rearwards, left
(S8) Switch, air conditioner 54 (X15) 3 pin, air cond., diodes 54
S9 Starter safety switch 4, 66 X17 7 pin, trailer socket 32
S10 Switch, braking lights, right 65 (X18) 2 pin, rear window washer 48
S11 Fuel gauge sender unit 17 X19 37 pin, front wall
S12 Pressure drop indicator, air filter 7 X20 9 pin, front direction indicator
S13 Engine oil press. sender unit 8, 118 (X22) 2 pin, rot. roof light 47
S15 Sender unit to parking brake ind. light 12 X23 3 pin, DPS, extra switches 71
S16 Gearbox temperature sender unit 13 X24 9 pin, upwards
S17 Gearbox oil pressure sender unit 9, 119 X26 26 pin, instrument left, white
S18 Engine temperature sender unit (stop) 16 X27 26 pin, instr. right, blue
(S19)Switch, compressor pressure 54 (X29) 2 pin, STOP-alarm (max. 2 W)
S20 Switch braking lights, left 65 X30 9 pin, switches gear levers
S22 Switch, differential lock 61 X31 2 pin, PTO-emerg. stop 68
(S23)Switch, DPS, selector 139, 140 (X32) 1-pin, electric stop 5
(S23)Extra switch, DPS, selector 71 (X33) 3 pin, fog light, rear
S25 Switch, PTO 68, 75 (X35) 9-pin, Sigma supply
(S26)Switch, fog light rear 35 (X36) 3 pin, HiShift, speed-limit+ supply
(S27)Switch, reverse buzzer 96 (X41) 2 pin, front PTO
S28 Switch, PTO 540 68 (X42) 4 pin, front PTO, supply
S29 Switch, PTO 1000/540E 67 (X45) 9 pin, Fieldmaster, extra equipment
S30 Switch, 4WD 66 (X49) 2 pin, seat 94
S31 Switch, floor fan 57 (X50) 3 pin current socket 96
(S32)Switch, rear window wiper and washer 48 (X55) 1 pin, Fieldmaster 95
(S33)Change over switch, head lights up 23
(S34)Switch, water pump 97
(S35)Switch, rear steering prevention 94 Y1 Solenoid valve, diff lock 63
(S36)Switch, control stop 4 Y2 Solenoid valve, PTO 68
(S37)Switch, Agrodata instrumentation, cursor+prog. 103 Y3 Solenoid valve, 4WD 66
(S38)Switch, front-PTO 69 (Y4) Solenoid valve, DPS 69, 133
(S42)Door switch, cab light, RH 46 (Y5) Magnetic switch, compressor, air conditioner 54
(S43)Door switch, cab light, LH 46 (Y6) Solenoid valve, DPS 70, 134
(S44)Indicator light switch, filter 180 bar 11 (Y7) Solenoid valve, rear steering prevention 94
(S45)Switch, HiShift 115, 142 (Y8) Solenoid, engine running 4
(S45.1) Extra switch, HiShift 115 (Y9) Magnetic clutch, front-PTO 69
(S49)Change over switch, rpm/flow sensor (Y14) Solenoid valve, HiShift 115
(S50)Change over switch, speed sensor, tractor/implement (Y15) Solenoid valve, HiShift, slowing 115
(S53)Indicator light switch, filter, return 10 (Y16) Solenoid, cold cranking 3
(S54)Indicator light switch, filter, 18 bar 11
(S59)Switch, roof window washer

140
 Model Code Page
31. Tractor electrical system 95-115 310 15
1. 11. 2000

Sym- Code
bol Component no

CareTel, information collecting system

A1L CareTel, data logger 118

B1L Pressure sensor, CareTel, 18 Bar 117

(B2L)Pressure sensor, CareTel, 190 Bar 116
B3L Sensor, gearbox temperature 117
B4L Temperature sensor, engine 118

H1L Indicator light, CareTel 120

X1L Connector housing, 9 pin, CareTel,

RS-232 117-120
X2L Connector housing, 3-pin, CareTel, CAN 117-120
X3L Connector housing, 9 pin, CareTel,
extra equipment 117-120
X4L Connector housing, 3 pin,CareTel, supply+
NBUS 117-120

ACB-power lift, see code 321

Wire colours
RU = braun
PU= red
KE = yellow
SI = blue
MU = black
VI = green
VA = white
HA = grey
LI = lilac
0.

141
142
 Model Code Page
31. Tractor electrical system 95-115 310 17
1. 11. 2000

31871650A

AC 2.2.1

AC 2.2.2

143
 Model Code Page
31. Tractor electrical system 95-115 310 18
1. 11. 2000

AC 2.2.3

AC 2.2.4

144
 Model Code Page
31. Tractor electrical system 95-115 310 19
1. 11. 2000

AC 2.2.5

AC 2.2.6

145
 Model Code Page
31. Tractor electrical system 95-115 310 20
1. 11. 2000

AC 2.2.7

AC 2.2.8

146
 Model Code Page
31. Tractor electrical system 95-115 310 21
1. 11. 2000

Wiring diagram 95-115 (AC 2.3, Sym- Code

bol Component no
K44242-). Diagram no. 318 716 60A. AC 2.3, see code
314. F17 10A Direction indicators, Fieldmaster 32, 153
F18 5A Instruments, warning lights, Autocontrol 17, 166
Sym- Code F19 10A Windscreen wiper/washer, horn 51
bol Component no F20 10A Rear window wiper/washer 48
(A2) Radio 2 F21 15A Fan (I, II), air conditioner, floor fan 55
A3 Electric centre F22 10A 4WD, PTO, DPS 65
(A5) Air suspension seat 94 F23 10A Rear working lights, outer 41
(A6) Agrodata 95 F24 10A Reserve 98
(A10)Control unit, DPS 70 F25 15A Air suspension seat/seat heating, rear steering
(A11)Telephone 99 prevention 94
(A14)Tachograph 93 F26 10A Back buzzer, HiShift 96, 116
(A16)Fieldmaster 155 F27 10A Braking lights, differential lock 62
(A17)Adapter, Fieldmaster sensor signals 154 F28 10A Telephone 99
F29 10A Cigarette lighter, 2-pin current socket 91
B1 Sensor, engine temperature 16 F30 10A CareTel 120
B2 Sensor, fuel gauge 17 (F51) 15 A, Main switch, control, in engine compartm. 168
(B3) Sensor, gearbox temperature 102
(B6) Velocity sensor, gearbox 81D, 102, 153 G1 Battery 1
(B7) Velocity sensor, PTO 102, 117, 153 G2 Alternator 4, 118
(B8) Sender, wheel speed
(B9) Sensor, tachograph 93 H1 Indicator light, direction indicator III 34
(B10)Speed radar 81D, 157 H2 Indicator light, direction indicator II 34
H3 Indicator light, direction indicator I 34
E1 Headlights, right 26 H4 Indicator light, air filter 7
E2 Headlights, left 25 H5 Indicator light, engine oil pressure 8
E3 Front direction indicator, right 31 H6 Warning light, stop, engine temp. 15
E4 Front direction indicator, left 28 H7 Indicator light, gearbox oil press. 9
E5 Rear light, right 33 (H8) Indicator light, oil filter, gearbox 10
E6 Rear light, left 32 H9 Indicator light, 4WD 65
E7 Cab light 46 H10 Indicator light PTO 67
E9 Rear working light, right outer 42 H11 Indicator light, parking brake 12
E10 Rear working right, right inner 42 H12 Indicator light, Thermostart 6
E11 Rear working light, left outer 41 H14 Indicator light, main beams 27
E12 Rear working light, left inner 41 H15 Indicator light, fuel reserve 16
E13 Front working light, right 44 H16 Indicator light, charging 6
E14 Front working light, left 44 H18 Indicator light, gearb. oil temp. 13
E15 Instrument lights 17 H19 Indicator light DPS I 71
E16 Roof console lights 21 H20 Indicator light, diff. lock 63
(E17)Seat heater 94 H21 Indicator light DPS II 71
(E19)Fog light, rear 35 H22 Indicator light DPS III 71
(E20)Parking light, right, Norway 29 H23 Horn 50
(E21)Parking light, left, Norway 30 (H24)Rotating roof light 47
(E22)Register plate light 32 (H27)Reverse Buzzer 96
(E23)Upper head light, right 24 (H28)Indicator light, STOP, rear
(E24)Upper head light, left 23
(E25)Parking light, upper, right 22 K1 Relay, front working lights 43
(E26)Parking light, upper, left 22 K2 Relay, rear working lights 41
(E27)Working light, side (K3) Relay, fog light, rear 35
(E28)Working light, side K4 Auxiliary relay, starter switch 7
Fuses 0. K5 Auxiliary relay, starter switch 9
K6 Relay, fan III 56
F1 15A Hazard blinkers, water pump 31, 97 K7 Control relay, 4-wheel brake 70
F2 5A Radio, clock, tachograph, CareTel 2, 120 K9 Relay, interval wiper 53
F3 15A High beam 25 K10 Direction indicator relay 34
F4 15A Low beam 25 K11 Relay, brake lights/differential lock 64
F5 5A Parking lights, left 28 K13 Control relay, differential lock 65
F6 5A Parking lights, right 30 K14 Starter motor relay 4
F7 10A Front working lights 44 K15 Control relay, 4-wheel drive 69
F8 25A Light switch 28 K16 Relay, PTO-emergency stop 68
F9 15A Trailer socket/fog light, rear 35, 165 (K18)Relay, control stop 8
F10 25A 3-pin current socket 100 (K24)Control relay, HiShift 115
F11 5A Autocontrol (+Bat), buzzer 71, 82B, 82D K25 Control relay, upper head lights to working
F12 10A Rot. warning light, cabin light 47 lights
F13 10A Reserve 100 K26 Control relay, speed limit, HiShift
F14 15A Starter switch, thermostart 4 K27 Control relay, 4WD on/off 68
F15 25A Fan III- speed 56 (K51)Warning light, main current switch 166
F16 10A Rear working lights, inner 42

147
 Model Code Page
31. Tractor electrical system 95-115 310 22
1. 11. 2000

Sym- Code
Sym- Code bol Component no
bol Component no
V1 Diodes Y1, Y2, Y3, Y4, Y6
M1 Starter motor 3, 167 V2 Diodes, AC-2
M2 Fan 55 (V5) Diodes, HiShift 115
M3 Windscreen wiper 53
M4 Windscreen washer 51
Ground leads
(M5) Rear window wiper 49
(M6) Rear window washer 48 GR1 Rear lights, solenoid valves
M7 Floor fan 57 GR2 Roof
(M8) Water pump 97 GR4 Autocontrol
(M9) Roof window wiper GR5 Cable harness, instr. panel
GR7 Battery
P1 Engine temperature meter 16 GR8 Headlights
P2 Fuel gauge 17 GR9 Cabin
P3 Tachometer 18 GR10 Electrical stop
P4 Running hour meter/AC 19
(P4 Running hour /speed meter (AD instrumentation)) 19 X1 9 pin, distribution box
(P5) Clock, PTO-speed, AC, trip, oil temperature (AgrodaĆ X2 9 pin, distribution box
ta-instrumentation) 101 X3 9 pin, distribution box
X4 9 pin, distribution box
Q1 Heat/starter switch 4 X5 9 pin, distribution box
(Q2) Main switch 3, (167) X6 9 pin, distribution box
X7 9 pin, distribution box
R1 Thermostart 5 (X8) 2 pin, power socket 92
R4 Cigarette lighter 91 X9 9 pin, combination control
S1 Switch, head lights 28 X10 9 pin, combination control
S2 Switch, rear working lights 41 X11 9 pin, upwards
S3 Switch, fan 55 X12 9 pin, rearwards, right
S4 Combined switch 25, 34, 52 X13 37 pin, transmission
S5 Switch, front working lights 43 X14 9 pin, rearwards, left
(S6) Switch, rot. warning light 47 (X15) 3 pin, air cond., diodes 54
S7 Switch, hazard warning flashers 32 X17 7 pin, trailer socket 32
(S8) Switch, air conditioner 54 (X18) 2 pin, rear window washer 48
S9 Starter safety switch 66 X19 37 pin, front wall
S10 Switch, braking lights, right 72 X20 9 pin, front direction indicator
S11 Fuel gauge sender unit 17 (X22) 2 pin, rot. roof light 47
S12 Pressure drop indicator, air filter 7 X23 3 pin, DPS, extra switches 71
S13 Engine oil press. sender unit 8, 118 X24 9 pin, upwards
S15 Sender unit to parking brake ind. light 12 X26 26 pin, instrument left, white
(S15)Reed relay, parking brake (P) 149 X27 26 pin, instr. right, blue
S16 Gearbox temperature sender unit 13 (X29) 2 pin, STOP-alarm (max. 2 W)
S17 Gearbox oil pressure sender unit 9, 119 X30 9 pin, switches gear levers
S18 Engine temperature sender unit (stop) 16 X31 2 pin, PTO-emerg. stop 74
(S19)Switch, compressor pressure 54 (X32) 1-pin, electric stop 5
S20 Switch braking lights, left 73 (X33) 3 pin, fog light, rear
S22 Switch, differential lock 62 (X35) 9-pin, Sigma supply
(S23)Switch, DPS, selector 139, 140 (X36) 3 pin, HiShift, speed-limit+ supply
S24 Switch, DPS disengagement 69 (X41) 2 pin, front PTO
S25 Switch, PTO 75 (X42) 4 pin, front PTO, supply
(S26)Switch, fog light rear 35 (X43) 8 pins, RS-232 canal
(S27)Switch, reverse buzzer 96 (X45) 9 pin, Fieldmaster, extra equipment
S28 Switch, PTO 540 68 (X46) 7 pins, Fieldmaster socket
S29 Switch, PTO 1000/540E 67 (X47) 2 pins, GPS supply, Fieldmaster
S30 Switch, 4WD 68 (X48) 3 pins, radar, Fieldmaster
S31 Switch, floor fan 57 (X49) 2 pin, seat
(S32)Switch, rear window wiper and washer 48 (X50) 3 pin current socket
(S33)Change over switch, head lights up 23 (X55) 1 pin, Fieldmaster
(S34)Switch, water pump 97
(S35)Switch, rear steering prevention 94
(S36)Switch, control stop 4 Y1 Solenoid valve, diff lock 63
(S44)Indicator light switch, filter 180 bar 11 Y2 Solenoid valve, PTO 68
(S45)Switch, HiShift 115, 142 Y3 Solenoid valve, 4WD 66
(S45.1) Extra switch, HiShift 115 (Y4) Solenoid valve, DPS 69
(S49)Change over switch, rpm/flow sensor (Y5) Magnetic switch, compressor, air conditioner 54
(S50)Change over switch, speed sensor, tractor/implement (Y6) Solenoid valve, DPS 70
(S53)Indicator light switch, filter, return 10 (Y7) Solenoid valve, rear steering prevention 94
(S54)Indicator light switch, filter, 18 bar 11 (Y8) Solenoid, engine running 4
(S59)Switch, roof window washer 49 (Y9) Magnetic clutch, front-PTO 164
(S66) Switch, PTO display, front/rear 163 (Y14) Solenoid valve, HiShift 115
S68 Switch, main currect switch control 168 (Y15) Solenoid valve, HiShift, slowing 115
(Y16) Solenoid, cold cranking 3

148
 Model Code Page
31. Tractor electrical system 95-115 310 23
1. 11. 2000

Sym- Code
Sym- Code bole Component no.
bol Component no
S7E Switch, lowering speed 83B
CareTel, information collecting system S8E Switch, transport height 83B
S9E Switch, draft control 83B
A1L CareTel, data logger 118 S10E Autocontrol-Switch, lift/stop/lower 83B
S11E Switch, forced lowering 83B
B1L Pressure sensor, CareTel, 18 Bar 117 S12E Switch, oscillation damping / slip control 83B
(B2L)Pressure sensor, CareTel, 190 Bar 116
B3L Sensor, gearbox temperature 117 X1E Connector, 9 pins, speed sensors (ACD)
B4L Temperature sensor, engine 118 X2E Connector, 15 pins, supply & rear buttons (+impleĆ
ment position sensors)
H1L Indicator light, CareTel 120
Y1E Solenoid valve, lowering 82B
X1L Connector housing, 9 pin, CareTel, Y2E Solenoid valve, lifting 82B
RS-232 117-120
X2L Connector housing, 3-pin, CareTel, CAN 117-120
X3L Connector housing, 9 pin, CareTel,
extra equipment 117-120 Wire colours
X4L Connector housing, 3 pin,CareTel, supply+
NBUS 117-120 RU = braun
PU= red
KE = yellow
SI = blue
MU = black
ACB Autocontrol power lift: VI = green
A1E Autocontrol control unit 82B VA = white
A2E Autocontrol, circuit card 85B HA = grey
LI = lilac
B1E Position sensor 81B 0.
B2E Draft sensor, right 81B
B3E Draft sensor, left 81B

E1E Illumination, circuit card 83B

E2E Illumination, position potentiometer 83B

R1E Potentiometer, position control 83B

S1E Button, rear mudguard, lift, right 81B

S2E Button, rear mudguard, lowering, right 81B
S3E Button, rear mudguard, lift, left 81B
S4E Button, rear mudguard, lowering, left 81B
S5E Switch, in cabin, nift/lower 82B

149
150
 Model Code Page
31. Tractor electrical system 95-115 310 25
1. 11. 2000

31871660A

AC 2.3 1

AC 2.3 2

151
 Model Code Page
31. Tractor electrical system 95-115 310 26
1. 11. 2000

AC 2.3 3

AC 2.3 4

152
 Model Code Page
31. Tractor electrical system 95-115 310 27
1. 11. 2000

AC 2.3 5

AC 2.3 6

153
 Model Code Page
31. Tractor electrical system 95-115 310 28
1. 11. 2000

AC 2.3 7

AC 2.3 8

154
 Model Code Page
31. Tractor electrical system 95-115 310 29
1. 11. 2000

AC 2.3 9

AC 2.3 10

155
 Model Code Page
31. Tractor electrical system 95-115 310 30
1. 11. 2000

AC 2.3 11

156
 Model Code Page
31. Tractor eletrical system X100-X120 310 31
1. 11. 2000

Wiring diagram X100-X120 (AC 5, Sym-

bol Component
Haku
nro
-K41106)
Fuses
Diagram no. 33563500A. E.g. new wire loom 33412510 and
F1 15A Hazard blinkers, water pump 31, 97
TwinTrac. Not AutoTraction function. F2 5A Radio, clock, tachograph, CareTel 2, 120
Sym Code F3 15A High beam 25
bol Component no. F4 15A Low beam 25
F5 5A Parking lights, left 28
(A2) Radio 2 F6 5A Parking lights, right 30
A3 Electric centre F7 10A Front working lights 44
(A5) Air suspension seat 94 F8 25A Light switch 28
(A6) Agrodata, drive computer 95 F9 15A Trailer socket/fog light, rear 35
(A10)Control unit, Delta Power Shift 70 F10 25A 3-pin current socket 96
(A11)Telephone 99 F11 5A Autocontrol (+Bat) 83B, 83D
(A13)Control unit, Sigma 113 F12 10A Rot. warning light, cabin light 47
(A14 Tachograph 93 F13 10A Reserve 100
(A15)Control unit, front PTO 77 F14 15A Starter switch, thermostart 4
(A16)Fieldmaster 155 F15 25A Fan III- speed 56
(A17)Adapter, Fieldmaster sensor signals 154 F16 10A Rear working lights, inner 42
F17 10A Direction indicators, Agrodata drive computer/
B1 Sensor, engine temperature gauge 16 Fieldmaster 32, 154
B2 Sensor, fuel gauge 17 F18 5A Instruments, warning lights, Autocontrol 17
(B3) Temperature sensor, gearbox, AD 102 F19 10A Windscreen wiper/washer, horn 51
(B4) Sensor, Sigma, crankshaft 114 F20 10A Rear window wiper/washer 48
(B5) Sensor, Sigma, PTO 114 F21 15A Fan I, II, air conditioner, floor fan 55
(B6) Velocity sensor, gearbox 81D, 102 F22 10A Sensors (HiTech), 4WD 70
(B7) Velocity sensor, PTO 117, 102 F23 10A Rear working lights, outer 41
(B8) Sender, wheel speed F24 10A AC5, parking brake 67, 126
(B9) Sensor, tachograph 93 F25 15A Air suspension seat/seat heating, rear steering
(B10)Speed radar 81D prevention 94
B11 Velocity sensor, engine 125 F26 10A Back buzzer, Sigma, HiShift 113
B12 Sensor, F/R power shuttle 126 F27 10A Braking lights, differential lock 64
B13 Sensor, F/R 127 F28 10A Telephone 99
B14 Temperature sensor, gearbox 139 F29 10A Cigarette lighter, 2-pin current socket 91
B15 Angle sensor, accelerator pedal 140 F30 10A CareTel 120
B16 Angle sensor, clutch pedal 137
B17 Temperature sensor, outdoors 141

E1 Headlights, right 26 G1 Battery 1

E2 Headlights, left 25 G2 Alternator 4, 118
E3 Front direction indicator, right 31
E4 Front direction indicator, left 28 H1 Indicator light, direction indicator III 34
E5 Rear light, right 33 H2 Indicator light, direction indicator II 34
E6 Rear light, left 32 H3 Indicator light, direction indicator I 34
E7 Cab light 46 H4 Indicator light, air filter 7
E9 Rear working light, right outer 42 H5 Indicator light, engine oil pressure 8
E10 Rear working right, right inner 42 H6 Warning light, stop, engine temperature, parking
E11 Rear working light, left outer 41 brake cable 15
E12 Rear working light, left inner 41 H7 Indicator light, gearbox oil press. 9
E13 Front working light, right 44 H8 Indicator light, gearbox oil filter 10
E14 Front working light, left 44 H9 Indicator light, 4WD 69
E15 Instrument lights 17 H10 Indicator light PTO 67
E16 Roof console lights 21 H11 Indicator light, parking brake 12
E17 Seat heater 94 H12 Indicator light, Thermostart 6
(E19)Fog light, rear 35 H14 Indicator light, main beams 27
(E20)Parking light, right, Norway 29 H15 Indicator light, fuel reserve 16
(E21)Parking light, left, Norway 30 H16 Indicator light, charging 6
(E22)Register plate light 32 H17 Indicator light, Sigma 111
(E23)Upper head light, right 24 H18 Indicator light, gearb. oil temp. 13
(E24)Upper head light, left 23 H20 Indicator light, diff. lock 63
(E25)Parking light, upper, right 22 H23 Horn 50
(E26)Parking light, upper, left 22 (H24)Rotating roof light 47
(E27)Working light, side (H27)Reverse Buzzer 148
(E28)Working light, side (H28)Indicator light, Stop, rear

K1 Relay, front working lights 43

K2 Relay, rear working lights 41
(K3) Relay, fog light, rear 35
K4 Auxiliary relay, starter switch 7

157
 Model Code Page
31. Tractor eletrical system X100-120H 310 32
1. 11. 2000

Sym- Code
Sym- Code bol Component no.
bol Component no.
S31 Switch, floor fan 57
K5 Auxiliary relay, starter switch 9 (S32)Switch, rear window wiper and washer 48
K6 Relay, fan III 56 (S33)Change over switch, head lights up 23
K7 Control relay, 4-wheel brake 70 (S34)Switch, water pump 97
K9 Relay, interval wiper 53 (S35)Switch, rear steering prevention 94
K10 Direction indicator relay 34 (S36)Switch, control stop 4
K11 Relay, brake lights/differential lock 64 S37 Switch, Agrodata instrumentation, cursor+prog. 103
K12 Control relay, differential lock 63 (S38)Switch, front-PTO 76
K13 Control relay, differential lock 65 S40 Reed relay, direction forward (F) 146
K14 Starter motor relay 4 S41 Reed relay, direction reverse (R) 147
K15 Control relay, 4-wheel drive 69 S42 Door switch, cab light, RH 46
K17 Relay, solenoid for engine running (8950Hi) S43 Door switch, cab light, LH 46
(K18)Relay, control stop 8 S44 Indicator light switch, filter 180 bar 11
K25 Control relay, upper head lights to working S45 Switches, HiShift 115, 142
lights 115 S45.1 Extra switch, HiShift 115
K27 Control relay, 4WD on/off 68 S47 Switch, DPS, man./auto 144
K28 Control relay, parking brake 67 (S49)Change over switch, rpm/flow sensor
(K29)Relay, back buzzer 147 (S50)Change over switch, km/h, speed sensor, tractor/imĆ
plement
M1 Starter motor 3 S51 Switch, DPS-preselection 149
M2 Fan 55 S52 Indicator light switch, parking brake cable 14
M3 Windscreen wiper 53 S53 Indicator light switch, filter, return 10
M4 Windscreen washer 51 S54 Indicator light switch, filter, 18 bar 11
(M5) Rear window wiper 49 (S59)Switch, roof window washer 49
(M6) Rear window washer 48 S60 Safety switch, seat 142
(M7) Floor fan 57
(M8) Water pump 97 V1 DiodedY1, Y2, Y3, Y4, Y6
(M9) Roof window wiper V2 Diodes, AC2
V3 Diodes, 4-veto
P1 Engine temperature meter 16 V4 Diodes, Y11, Y12, Y17
P2 Fuel gauge 17
P3 Tachometer 18 Ground leads
P4 Running hour /speed meter (Agrodata instrumentaĆ GR1 Rear lights, solenoid valves
tion) 19 GR2 Roof
(P5) Clock, PTO-speed, AC, trip, oil temperature (AgrodaĆ GR4 Autocontrol
ta instrumentation) 101 GR5 Cable harness, instr. panel
P6 Display, AC5 130 GR7 Battery
GR8 Headlights
Q1 Heat/starter switch 4 GR9 Cabin
(Q2) Main switch 3 GR10 Electric stop

R1 Thermostart 5 X1 9 pin, distribution box

R4 Cigarette lighter 91 X2 9 pin, distribution box
X3 9 pin, distribution box
S1 Switch, head lights 28 X4 9 pin, distribution box
S2 Switch, rear working lights 41 X5 9 pin, distribution box
S3 Switch, fan 55 X6 9 pin, distribution box
S4 Combined switch 25,34, 52 X7 9 pin, distribution box
S5 Switch, front working lights 43 (X8) 2 pin, current socket 92
(S6) Switch, rot. warning light 47 X9 9 pin, combination control
S7 Switch, hazard warning flashers 32 X10 9 pin, combination control
(S8) Switch, air conditioner 54 X11 9 pin, upwards
S9 Starter safety switch 66 X12 9 pin, rearwards, right
S10 Switch, braking lights, right 72 X13 37 pin, transmission
S11 Fuel gauge sender unit 17 X14 9 pin, rearwards, left
S12 Pressure drop indicator, air filter 7 (X15) 3 pin, air cond., diodes 54
S13 Engine oil press. sender unit 8, 118 X17 7 pin, trailer socket 32
S15 Reed relay, parking brake 149 (X18) 2 pin, rear window washer 48
S16 Gearbox temperature sender unit 13, 119 X19 37 pin, engine
S17 Gearbox oil pressure sender unit 9 X20 9 pin, front direction indicator
S18 Engine temperature sender unit (stop) 16 X21 2 pin, number plate light
(S19)Switch, compressor pressure 54 (X22) 2 pin, rot. roof light 47
S20 Switch braking lights, left 72 X23 3 pin, Delta Power Shift, extra switches 71
S22 Switch, differential lock 62 X24 9 pin, upwards
S23 Extra switch, Delta Power Shift, selector 139, 140 X26 26 pin, instrument left, white
S25 Switch, PTO 75 X27 26 pin, instr. right, blue
(S26)Switch, fog light rear 35 X28 9 pin, sensors power shuttle
(S27)Switch, reverse buzzer 96 (X29) 2 pin, STOP-alarm (max. 2 W)
S28 Switch, PTO 540 143 X30 9 pin, switches gear levers
S29 Switch, PTO 1000/540E 144 X31 2 pin, socket, PTO-emerg. stop 74
S30 Switch, 4WD 68

158
 Model Code Page
31. Tractor electrical system X100-X120 310 33
1. 11. 2000

CareTel, information collecting system

Sym- Code
bol Component no.
A1L CareTel, data logger 118

(X32) 1 pin, electric stop 5 B1L Pressure sensor, CareTel, 18 Bar 117
(X33) 3 pin, fog light, rear (B2L)Pressure sensor, 190 Bar 116
(X35) 9 pin, SIGMA supply B3L Sensor, gearbox temperature 117
X39 9 pin, direction lever B4L Temperature sensor, engine 118
(X41) 2 pin, front PTO
(X42) 4 pin, front PTO, supply H1L Indicator light, CareTel 120
X43 8 pin, RS-232 bus
(X45) 9 pin, Fieldmaster, extra equipment X1L Connector housing, 9 pins,
(X46) 7 pin, Fieldmaster, current socket CareTel, RS-232 117-120
(X47) 2 pin, GPS-supply, Fieldmaster X2L Connector housing, 3 pins, CareTel, CAN 117-120
(X48) 3 pin, radar, Fieldmaster X3L Connector housing, 9 pins,
(X49) 2 pin, seat 94 CareTel, extra equipment 117-120
(X50) 3 pin current socket 96 X4L Connector housing, 3 pins,
(X53) Agrodata socket, 7 pin, implement CareTel, supply+NBUS 117-120
(X54) 9 pin, Agrodata sensors, drive computer
(X55) 1 pin, Agrodata, drive computer 95 ACB Power lift, see code 321
Y1 Solenoid valve, differential lock 64
Y2 Solenoid valve, PTO 68
Y3 Solenoid valve, 4WD 71
(Y4) Solenoid valve, Delta Power Shift 69, 133 Wire colours
(Y5) Magnetic clutch, compressor, air conditioner 54 RU = brown
(Y6) Solenoid valve, Delta Power Shift 70, 134 PU = red
(Y7) Solenoid valve, rear steering prevention 94 KE = yellow
(Y8) Solenoid, engine running 4
(Y9) Magnetic clutch, front-PTO 78 SI = blue
Y11 Solenoid, forward 128 MU = black
Y12 Solenoid, reverse 130 VI = green
(Y13) Solenoid valve, Sigma 113 VA = white
(Y16) Solenoid, cold cranking 3 HA = grey
Y17 Solenoid valve, Delta Power Shift 130
LI = lilac
Y18 Solenoid, parking brake 67

AC5 -Control system, HiTech

A1A Control unit, AC5 122-152

(S1A)Switch, PTO rear start, left 74

(S2A)Switch, PTO rear start, right 74

X1A Connector housing, 9 pin, engine sensors 140-141

TwinTrac reverse drive controls

B1W Angle sensor, clutch pedal 166
K1W Control relay, front/rear control 161
K2W Control relay, front/rear sensor 161
S1W Switch, DPS-extra 171
S2W Limit switch, clutch pedal 66
S3W Limit switch, seat direction 161
S4W Programming switch 162
S5W Reed relay, direction front (f), rear 163
S6W Reed relay, direction reverse (r), rear 164
S7W Reed-relay, parking brake, rear 164

X1W Connector housing 12-pin, TwinTrac

X2W Connector housing 1-pin., supply (P1W)
X3W Connector housing 9-pin., direction lever, rear

P1W Rear display, AC5 128

159
160
 Model Code Page
31. Tractor eletrical system X100-X120 310 35
1. 11. 2000

33563500A

ACV I

ACV II

161
 Modell Code Page
31. Tractor electrical system X100-X120 310 36
1. 11. 2000

ACV III

ACV IV

162
 Model Code Page
31. Tractor electrical system X100-X120 310 37
1. 11. 2000

ACV V

ACV VI

163
 Model Code Page
31. Tractor electrical system X100-X120 310 38
1. 11. 2000

ACV VII

ACV VIII

164
 Model Code Page
31. Tractor electrical system X100-X120 310 39
1. 11. 2000

ACV IX

ACV X

165
 Model Code Page
31. Tractor electrical system X100-X120 310 40
1. 11. 2000

ACV XI

166
 Model Code Page
31. Tractor electrical system X100-X120 310 41
1. 11. 2000

Wiring diagram X100-X120 (AC 5.2, Sym-

bole Component
Code
no
K41107-). Diagram no. 33563510C. Incl. e.g. AC 5.2
unit. AutoTraction function. Fuses
F1 15A Hazard blinkers, water pump 31, 97
Sym- Code F2 5A Radio, clock, tachograph, CareTel 2, 120
bole Component no F3 15A High beam 25
F4 15A Low beam 25
(A2) Radio 2 F5 5A Parking lights, left 29
A3 Electric centre F6 5A Parking lights, right 30
(A5) Air suspension seat 94 F7 10A Front working lights 44
(A11)Telephone 99 F8 25A Light switch 28
(A13)Control unit, Sigma 113 F9 15A Trailer socket/fog light, rear 35, 187
(A14 Tachograph 93 F10 25A 3-pin current socket 96
(A15)Control unit, front PTO 181 F11 5A Autocontrol (+Bat) 83B, 83D
(A16)Fieldmaster 155 F12 10A Rot. warning light, cabin light, radio 47
(A17)Adapter, Fieldmaster sensor signals 154 F13 10A Reserve 100
F14 15A Starter switch, thermostart 4
B1 Sensor, engine temperature gauge 16 F15 20A Fan III- speed 56
B2 Sensor, fuel gauge 17 F16 10A Rear working lights, inner 42
(B3) Temperature sensor, gearbox, AD 102 F17 10A Direction indicators, Fieldmaster 32, 154
(B4) Sensor, Sigma, crankshaft 114 F18 5A Instruments, warning lights, Autocontrol 17, 190
(B5) Sensor, Sigma, PTO 114 F19 10A Windscreen wiper/washer, horn 51
B6 Velocity sensor, gearbox 81D, 102, 128, 153 F20 10A Rear window wiper/washer 48
(B7) Velocity sensor, PTO 116, 102, 123 F21 15A Fan I, II, air conditioner, floor fan 55
(B9) Sensor, tachograph 93 F22 10A Sensors (HiTech), 4WD 70, 181
(B10)Speed radar 81D, 157 F23 10A Rear working lights, outer 41
B11 Velocity sensor, engine 127 F24 10A AC5, seat direction 164, 126
B12 Sensor, F/R power shuttle 124 F25 15A Air suspension seat/seat heating, rear steering
B13 Sensor, F/R 125 prevention 94
B14 Temperature sensor, gearbox 139 F26 10A Back buzzer, Sigma, HiShift 113
B15 Angle sensor, accelerator pedal 140 F27 10A Braking lights, differential lock 64
B16 Angle sensor, clutch pedal 137 F28 10A Telephone 99
B17 Temperature sensor, outdoors 141 F29 10A Cigarette lighter, 2-pin current socket 91
B18 Sensor, front PTO speed 182 F30 10A CareTel 120
(F51) Main switch control, in engine compartment 197
E1 Headlights, right 26
E2 Headlights, left 25 G1 Battery 1
E3 Front direction indicator, right 31 G2 Alternator 4, 118
E4 Front direction indicator, left 28
E5 Rear light, right 33 H1 Indicator light, direction indicator III 34
E6 Rear light, left 32 H2 Indicator light, direction indicator II 34
E7 Cab light 46 H3 Indicator light, direction indicator I 34
E9 Rear working light, right outer 42 H4 Indicator light, air filter 7
E10 Rear working right, right inner 42 H5 Indicator light, engine oil pressure 8
E11 Rear working light, left outer 41 H6 Warning light, stop, engine temperature, parking
E12 Rear working light, left inner 41 brake cable 15
E13 Front working light, right 44 H7 Indicator light, gearbox oil press. 9
E14 Front working light, left 44 H8 Indicator light, gearbox oil filter 10
E15 Instrument lights 17 H9 Indicator light, 4WD 69
E16 Roof console lights 21 H10 Indicator light PTO 132
(E17)Seat heater 94 H11 Indicator light, parking brake 12
(E19)Fog light, rear 35 H12 Indicator light, Thermostart 6
(E20)Parking light, right, Norway 29 H14 Indicator light, main beams 27
(E21)Parking light, left, Norway 30 H15 Indicator light, fuel reserve 16
(E22)Register plate light 32 H16 Indicator light, charging 6
(E23)Upper head light, right 24 H17 Indicator light, Sigma 111
(E24)Upper head light, left 23 H18 Indicator light, gearb. oil temp. 13
(E25)Parking light, upper, right 22 H20 Indicator light, diff. lock 63
(E26)Parking light, upper, left 22 H23 Horn 50
(E27)Working light, side (H24)Rotating roof light 47
(E28)Working light, side (H27)Back buzzer 148
(H28)Indicator light, Stop, rear

K1 Relay, front working lights 43

K2 Relay, rear working lights 41
(K3) Relay, fog light, rear 35
K4 Auxiliary relay, starter switch 7
K5 Auxiliary relay, starter switch 9
K6 Relay, fan III 56

167
 Model Code Page
31. Tractor electrical system X100-X120 310 42
1. 11. 2000

Sym- Code
Sym- Code bole Component no
bole Component no
(S33)Change over switch, head lights up 23
K7 Control relay, 4-wheel brake 71 (S34)Switch, water pump 97
K9 Relay, interval wiper 52 (S35)Switch, rear steering prevention 94
K10 Direction indicator relay 34 (S36)Switch, control stop 4
K11 Relay, brake lights/differential lock 64 S37 Switch, Agrodata instrumentation, cursor+prog. 103
K13 Control relay, differential lock 65 (S38)Switch, front-PTO 183
K14 Starter motor relay 4 S40 Reed relay, direction forward (F) 146
K15 Control relay, 4-wheel drive 70 S41 Reed relay, direction reverse (R) 147
(K18)Relay, control stop 8 S42 Door switch, cab light, RH 46
K25 Control relay, upper head lights to working S43 Door switch, cab light, LH 46
lights (S44)Indicator light switch, filter 180 bar 11
K27 Control relay, 4WD on/off 68 S45 Switches, HiShift 142
K28 Control relay, parking brake 66 (S45.1) Extra switch, HiShift
(K29)Relay, back buzzer 147 S47 Switch, DPS, man./auto 144
(K51)Warning flasher, main switch 191 S51 Switch, DPS-preselection 149
K52 Control relay, starting allowed 66 S52 Indicator light switch, parking brake cable 14
(S53)Indicator light switch, filter, return 10
M1 Starter motor 3 S54 Indicator light switch, filter, 18 bar 11
M2 Fan 55 (S59)Switch, roof window washer 49
M3 Windscreen wiper 53 S60 Safety switch, seat 142
M4 Windscreen washer 51 (S66)Switch, PTO display, front/rear 184
(M5) Rear window wiper 49 (S68)Switch, control of main switch 196
(M6) Rear window washer 48 S76 AutoTraction switch, on / off 161
M7 Floor fan 57
(M8) Water pump 97 V1 Diodes Y1, Y2, Y3, Y4, Y6
(M9) Roof window wiper 50
Ground leads
P1 Engine temperature meter 16 GR1 Rear lights, solenoid valves
P2 Fuel gauge 17 GR2 Roof
P3 Tachometer 18 GR4 Autocontrol
P4 Running hour /speed meter (Agrodata instrumentaĆ GR5 Cable harness, instr. panel
tion) 111 GR7 Battery
(P5) Clock, PTO-speed, AC, trip, oil temperature GR8 Headlights
(Agrodata instrumentation) 102 GR9 Cabin
P6 Display, AC5 133 GR10 Electric stop

Q1 Heat/starter switch 4 X1 9 pin, distribution box

(Q2) Main switch 3, 196 X2 9 pin, distribution box
X3 9 pin, distribution box
R1 Thermostart 5 X4 9 pin, distribution box
R4 Cigarette lighter 91 X5 9 pin, distribution box
R7 Potentiometer, front PTO, starting speed 184 X6 9 pin, distribution box
X7 9 pin, distribution box
S1 Switch, head lights 28 (X8) 2 pin, current socket 92
S2 Switch, rear working lights 41 X9 9 pin, combination control
S3 Switch, fan 55 X10 9 pin, combination control
S4 Combined switch 25,34, 52 X11 9 pin, upwards
S5 Switch, front working lights 43 X12 9 pin, rearwards, right
(S6) Switch, rot. warning light 47 X13 37 pin, transmission
S7 Switch, hazard warning flashers 32 X14 9 pin, rearwards, left
(S8) Switch, air conditioner 54 (X15) 3 pin, air cond., diodes 54
S9 Starter safety switch 142 X17 7 pin, trailer socket 32
S10 Switch, braking lights, right 72 (X18) 2 pin, rear window washer 48
S11 Fuel gauge sender unit 17 X19 37 pin, engine
S12 Pressure drop indicator, air filter 7 X20 9 pin, front direction indicator
S13 Engine oil press. sender unit 8, 118 (X22) 2 pin, rot. roof light 47
S15 Reed relay, parking brake 149 X23 3 pin, Delta Power Shift, extra switches
S16 Gearbox temperature sender unit 13 X24 9 pin, upwards
S17 Gearbox oil pressure sender unit 9, 119 X26 26 pin, instrument left, white
S18 Engine temperature sender unit (stop) 16 X27 26 pin, instr. right, blue
(S19)Switch, compressor pressure 54 X28 9 pin, sensors power shuttle
S20 Switch braking lights, left 73 (X29) 2 pin, STOP-alarm (max. 2 W)
S22 Switch, differential lock 61 X30 9 pin, switches gear levers
S23 Extra switch, Delta Power Shift, selector 139, 140 X31 2 pin, socket, PTO-emerg. stop 74
S25 Switch, PTO 75 (X32) 1 pin, electric stop 5
(S26)Switch, fog light rear 35 (X33) 3 pin, fog light, rear
(S27)Switch, reverse buzzer (X35) 9 pin, SIGMA supply
S28 Switch, PTO 540 146 X39 9 pin, direction lever
S29 Switch, PTO 1000/540E 147 (X41) 2 pin, front PTO
S30 Switch, 4WD 68 (X42) 4 pin, front PTO, supply
S31 Switch, floor fan 57
(S32)Switch, rear window wiper and washer 48

168
 Model Code Page
31. Tractor electrical system X100-X120 310 43
1. 11. 2000

Sym- Code
Sym- Code bole Component no.
bole Component no
S7E Switch, lowering speed 85B
X43 8 pin, RS-232 bus 151 S8E Switch, transport height 85B
(X45) 9 pin, Fieldmaster, extra equipment S9E Switch, draft control 85B
(X46) 7 pin, Fieldmaster, current socket 155 S10E Autocontrol-Switch, lift/stop/lower 86B
(X47) 2 pin, GPS-supply, Fieldmaster S11E Switch, forced lowering 85B
(X48) 3 pin, radar, Fieldmaster S12E Switch, oscillation damping / slip control 85B
X49 2 pin, seat 94
X50 3 pin current socket 96 X1E Connector, 9 pins, speed sensors (ACD)
(X55) 1 pin, FieldMaster, drive computer 95 X2E Connector, 15 pins, supply & rear buttons (+impleĆ
ment position sensors)
Y1 Solenoid valve, differential lock 64
Y2 Solenoid valve, PTO 133 Y1E Solenoid valve, lowering 83B
Y3 Solenoid valve, 4WD 71 Y2E Solenoid valve, lifting 83B
Y4 Solenoid valve, Delta Power Shift 133
(Y5) Magnetic clutch, compressor, air conditioner 54 CareTel, information collecting system
Y6 Solenoid valve, Delta Power Shift 134 (A1L) CareTel, data logger 118
(Y7) Solenoid valve, rear steering prevention 94
Y8 Solenoid, engine running 4 (B1L)Pressure sensor, CareTel, 18 Bar 117
(Y9) Magnetic clutch, front-PTO 77 (B2L)Pressure sensor, 190 Bar 116
Y11 Solenoid, forward 131 (B3L)Sensor, gearbox temperature 117
Y12 Solenoid, reverse 132 (B4L)Temperature sensor, engine 118
(Y13) Solenoid valve, Sigma 113
(Y16) Solenoid, cold cranking 3 (H1L)Indicator light, CareTel 120
Y17 Solenoid valve, Delta Power Shift 134
Y18 Solenoid, parking brake 67 (X1L) Connector housing, 9 pins,
CareTel, RS-232 117-120
(X2L) Connector housing, 3 pins, CareTel, CAN 117-120
AC 5.2 Control system, HiTech (X3L) Connector housing, 9 pins,
A1A Control unit, AC5 122-152 CareTel, extra equipment 117-120
(X4L) Connector housing, 3 pins,
S1A Button, PTO rear start, left 74 CareTel, supply+NBUS 117-120
S2A Button, PTO rear start, right 74

X1A Connector, 9 pins, engine sensors 140-141

Wire colours
TwinTrac, reverse drive controls RU = brown
(B1W) Position sensor, clutch pedal 171 PU = red
(S1W) Switch, DPS-extra 173 KE = yellow
(S2W) Limit switch, clutch pedal 162 SI = blue
(S3W) Limit switch, seat direction 163 MU = black
(S4W) Programming switch, DPS 165 VI = green
(S5W) Reed relay, direction forwards (F), rear 166 VA = white
(S6W) Reed relay, direction reverse (R), rear 167 HA = grey
(S7W) Reed-relay, parking brake, rear 168 LI = lilac

(X1W) Connector housing 12-pin, TwinTrac

(X2W) Connector housing 1-pin., supply (P1W)
(X3W) Connector housing 9-pin., direction lever, rear

(P1W) Rear display, AC5 128

ACB Autocontrol power lift:

A1E Autocontrol control unit 82B
A2E Autocontrol, circuit card 85B

B1E Position sensor 81B

B2E Draft sensor, right 81B
B3E Draft sensor, left 81B
E1E Illumination, circuit card 85B
E2E Illumination, position potentiometer 86B

R1E Potentiometer, position control 85B

S1E Button, rear mudguard, lift, right 81B

S2E Button, rear mudguard, lowering, right 81B
S3E Button, rear mudguard, lift, left 81B
S4E Button, rear mudguard, lowering, left 81B
S5E Switch, in cabin, nift/lower 83B

169
170
 Model Code Page
31. Tractor electrical system X100-X120 310 45
1. 11. 2000

33563510C

AC 5.2 1

AC 5.2 2

171
 Model Code Page
31. Trcator electrical system X100-X120 310 46
1. 11. 2000

AC 5.2 3

AC 5.2 4

172
 Model Code Page
31. Tractor electrical system X100-X120 310 47
1. 11. 2000

AC 5.2 5

AC 5.2 6

173
 Model Code Page
31. Tractor electrical system X100-X120 310 48
1. 11. 2000

AC 5.2 7

AC 5.2 8

174
 Model Code Page
31. Tractor electrical system X100-X120 310 49
1. 11. 2000

AC 5.2 9

AC 5.2 10

175
 Model Code Page
31. Tractor electrical system X100-X120 310 50
1. 11. 2000

AC 5.2 11

AC 5.2 12

176
 Model Code Page
31. Tractor electrical system X100-X120 310 51
1. 11. 2000

AC 5.2 13

AC 5.2 14

177
178
 Model Code Page
31. Tractor electrical system X100-X120 310 52
24. 5. 2004

Wiring diagram, HiTech, L18105-. Sym-

bol Component
Code
no
Diagram no. 33563520A. Diagram incl. e.g. Agroline-instruĆ
ment. Diagrams on pages 310/93-100.
Fuses 0.
Sym- Code F1 15A Hazard blinkers, water pump 31, 97
bol Component no F2 5A Radio, clock, tachograph, CareTel 2, 120
F3 15A High beam 25
(A2) Radio 2 F4 15A Low beam 25
A3 Electric centre F5 10A Parking lights, left 29
(A5) Air suspension seat 94 F6 10A Parking lights, right 30
(A6) Agrodata 95 F7 25A Front working lights 44, 201
(A11)Telephone 99 F8 25A Light switch 28
(A13)Control unit, Sigma 113 F9 15A Trailer socket/fog light, rear 35, 187
(A14)Tachograph 93 F10 25A 3-pin current socket 96
(A15)Control unit, front PTO 181 F11 5A Autocontrol 83B, 83D
(A16)Fieldmaster 155 F12 10A Rot. warning light, cabin light, radio 47
(A17)Adapter, Fieldmaster sensor signals 154 F13 10A Reserve 100
F14 15A Starter switch, thermostart 4
B1 Sensor, engine temperature gauge 16 F15 25A Fan III- speed 56
B2 Sensor, fuel gauge 17 F16 10A Rear working lights, inner 42
(B3) Temperature sensor, gearbox 102 F17 10A Direction indicators, Fieldmaster 32, 154
(B4) Sensor, Sigma, crankshaft 114 F18 5A Instruments, warning lights, Autocontrol 17, 190
(B5) Sensor, Sigma, PTO 114 F19 10A Windscreen wiper/washer, horn 51
B6 Velocity sensor, gearbox 81D, 102, 128, 153 F20 10A Rear window wiper/washer, radio 48
(B7) Velocity sensor, PTO 102, 116, 123 F21 15A Fan I, II, air conditioner, floor fan 55
(B9) Sensor, tachograph 93 F22 10A Sensors HiTech, 4WD 70, 181
(B10)Speed radar 81D, 157 F23 10A Rear working lights, outer 41
B11 Velocity sensor, engine 127 F24 10A AC5, seat direction 126, 164
B12 Sensor, F/R power shuttle 124 F25 15A Air suspension seat/seat heating, rear steering
B13 Sensor, F/R 125 prevention 94
B14 Temperature sensor, gearbox 139 F26 10A Back buzzer, Sigma, HiShift 113
B15 Angle sensor, accelerator pedal 140 F27 10A Braking lights, differential lock 64
B16 Angle sensor, clutch pedal 137 F28 10A Telephone, 2A if HF* 99
B17 Temperature sensor, outdoors 141 F29 10A Cigarette lighter, 2-pin current socket 91
B18 Sensor, front PTO -speed 182 F30 10A CareTel, 1A if HF* 120
F50 25A Electric stop solenoid, 8950Hi
E1 Headlights, right 26 (F51) 15A Main switch control, in engine room 197
E2 Headlights, left 25
E3 Front direction indicator, right 31 If Hands Free is fitted
E4 Front direction indicator, left 28
E5 Rear light, right 33 G1 Battery 1
E6 Rear light, left 32 G2 Alternator 4, 118
E7 Cab light 46
E9 Rear working light, right outer 42 H1 Indicator light, direction indicator trailer II 34
E10 Rear working light, right inner 42 H2 Indicator light, direction indicator trailer I 34
E11 Rear working light, left outer 41 H4 Indicator light, air filter 7
E12 Rear working light, left inner 41 H5 Indicator light, engine oil pressure 8
E13 Front working light, right 44 H6 Warning light, stop, engine temperature, parking
E14 Front working light, left 44 brake cable 15
E15 Instrument lights 17 H7 Indicator light, gearbox oil press. 9
E16 Roof console lights 21 H8 Indicator light, gearbox oil filter 10
(E17)Seat heater 94 H9 Indicator light, 4WD 69
(E19)Fog light, rear 35 H10 Indicator light PTO 132
(E20)Parking light, right, Norway 29 H11 Indicator light, parking brake 12
(E21)Parking light, left, Norway 30 H12 Indicator light, Thermostart 6
(E22)Register plate light 32 H14 Indicator light, main beams 27
(E23)Upper head light, right 24 H15 Indicator light, fuel reserve 16
(E24)Upper head light, left 23 H16 Indicator light, charging 6
(E25)Parking light, upper, right 22 H17 Indicator light, Sigma 111
(E26)Parking light, upper, left 22 H18 Indicator light, gearb. oil temp. 13
(E27)Working light, side H20 Indicator light, diff. lock 63
(E28)Working light, side H23 Horn 50
(E45)Step light 46 (H24)Rotating roof light 47
(E46)Trailer hitch light 205 (H27)Reverse Buzzer 148
(E47)Extra front working light, right 201 (H28)Indicator light, Stop, rear
(E48)Extra front working light, left 203 (H31)Indicator light, direction indicator,
left instrumentation 34
(H32)Indicator light, direction indicator, right
instrumentation 34
(H33)Indicator light front PTO, instrumentation 12

179
 Model Code Page
31. Tractor electrical system X100-X120 310 53
24. 5. 2004

Sym- Code
Sym- Code bol Component no
bol Component no
S18 Engine temperature sender unit (stop) 16
K1 Relay, front working lights 43 (S19)Switch, compressor pressure 54
K2 Relay, rear working lights 41 S20 Switch braking lights, left 73
(K3) Relay, fog light, rear 35 S22 Switch, differential lock 61
K4 Auxiliary relay, starter switch 7 S23 Extra switch, Delta Power Shift, selector 139, 140
K5 Auxiliary relay, starter switch 9 S25 Switch, PTO 75
K6 Relay, fan III 56 (S26)Switch, fog light rear 35
K7 Control relay, 4-wheel brake 71 (S27)Switch, reverse buzzer
K9 Relay, interval wiper 52 S28 Switch, PTO 540 146
K10 Direction indicator relay 34 S29 Switch, PTO 1000/540E 147
K11 Relay, brake lights/differential lock 64 S30 Switch, 4WD 68
K13 Control relay, differential lock 65 S31 Switch, floor fan 57
K14 Starter motor relay 4 (S32)Switch, rear window wiper and washer 48
K15 Control relay, 4-wheel drive 70 (S33)Change over switch, head lights up 23
K17 Relay, electric stop solenoid, 8950Hi (S34)Switch, water pump 97
(K18)Relay, control stop 8 (S35)Switch, rear steering prevention 94
K25 Control relay, upper head lights to working lights (S36)Switch, control stop 4
K27 Control relay, 4WD on/off 68 S37 Switch, Agroline instrumentation, cursor+prog. 103
(K29)Relay, back buzzer 147 (S38)Switch, front-PTO 183
(K51)Warning light, main switch 191 S40 Reed relay, direction forward (F) 146
K52 Auxiliary relay, start allowed 66 S41 Reed relay, direction reverse (R) 149
K56 Time-delay relay, cab light 46 S42 Door switch, cab light, RH 46
S43 Door switch, cab light, LH 46
M1 Starter motor 3 (S44)Indicator light switch, filter 180 bar 11
M2 Fan 55 S45 Switches, HiShift 142
M3 Windscreen wiper 53 (S45.1) Extra switch, HiShift
M4 Windscreen washer 51 S47 Switch, DPS, man./auto 144
(M5) Rear window wiper 49 S51 Switch, DPS-preselection 146
(M6) Rear window washer 48 S52 Indicator light switch, parking brake cable 14
M7 Floor fan 57 S53 Indicator light switch, filter, return 10
(M8) Water pump 97 (S54)Indicator light switch, filter, 18 bar 11
(M9) Roof window wiper 50 (S59)Switch, roof window washer 49
S60 Safety switch, seat 142
P1 Engine temperature meter 16 (S68)Switch, main switch control 196
P2 Fuel gauge 17 S76 Traction control on/off 161
P3 Tachometer 18 S80 Switch, instrumentation, display size setting 103
P4 Running hour meter 19, 111 S83 Switch, trailer hitch light 204
P5 Clock, PTO-speed, AC, trip, oil temperature, S84 Switch, extra front working lights 200
speed, (Sigma) (Agroline instrumentation) 102
P6 Display, AC5 133 V1 Diodes Y1, Y2, Y3, Y4, Y6

Q1 Heat/starter switch 4 Ground leads

(Q2) Main switch 3, 196 GR1 Rear lights, solenoid valves
GR2 Roof
R1 Thermostart 5 GR4 Autocontrol
R4 Cigarette lighter 91 GR5 Cable harness, instr. panel
R7 Potentiometer, front PTO, starting speed 184 GR7 Battery
GR8 Headlights
S1 Switch, head lights 28 GR9 Cabin
S2 Switch, rear working lights 41 GR10 Electrical stop
S3 Switch, fan 55
S4 Combined switch 25,34, 52 X1 9 pin, distribution box
S5 Switch, front working lights 43 X2 9 pin, distribution box
(S6) Switch, rot. warning light 47 X3 9 pin, distribution box
S7 Switch, hazard warning flashers 32 X4 9 pin, distribution box
(S8) Switch, air conditioner 54 X5 9 pin, distribution box
S9 Starter safety switch 142 X6 9 pin, distribution box
S10 Switch, braking lights, right 72 X7 9 pin, distribution box
S11 Fuel gauge sender unit 17 (X8) 2 pin, current socket 92
S12 Pressure drop indicator, air filter 7 X9 9 pin, combination control
S13 Engine oil press. sender unit 8, 118 X10 9 pin, combination control
S15 Reed relay, parking brake (P) 149 X11 9 pin, upwards
S16 Gearbox temperature sender unit 13 X12 9 pin, rearwards, right
S17 Gearbox oil pressure sender unit 9, 119 X13 37 pin, transmission
X14 9 pin, rearwards, left
(X15) 3 pin, air cond., diodes 54
X17 7 pin, trailer socket 32

180
 Model Code Page
31. Tractor electrical system X100-X120 310 54
24. 5. 2004

Sym- Code
Sym- Code bol Component no
bol Component no

(X18) 2 pin, rear window washer 48 ACB/ACD Autocontrol power lift:

X19 37 pin, engine A1E Autocontrol electronic unit 82B, 82D
X20 9 pin, front direction indicator A2E Autocontrol, switch panel 85B, 85D
(X22) 2 pin, rot. roof light 47
X23 3 pin, Delta Power Shift, extra switches B1E Position sensor 81B, 81D
X24 9 pin, upwards B2E Draft sensor, r.h 81B, 81D
X26 26 pin, instrument left, white B3E Draft sensor, l.h 81B, 81D
X27 26 pin, instrument right, blue (B4E) Position sensor, implement (ACD) 81D
X28 9 pin, sensors power shuttle
(X29) 2 pin, STOP-alarm (max. 2 W) E1E Lightning switch panel 85B, 85D
X30 9 pin, switches gear levers E2E Lightning, position potentiometer 86B, 86D
X31 2 pin, socket, PTO-emerg. stop 75
(X32) 1 pin, electric stop 5 R1E Potentiometer, pos .control 85B, 85D
(X33) 3 pin, fog light, rear
X35 9 pin, SIGMA supply S1E Switch, rear operation, r.h., lifting 81B, 83D
X39 9 pin, direction lever S2E Switch, rear operation, r.h., lowering 81B, 83D
(X41) 2 pin, front PTO S3E Switch, rear operation, l.h., lifting 81B, 82D
(X42) 4 pin, front PTO, supply S4E Switch, rear drive, l.h., lowering 81B, 82D
X43 8 pin, RS-232 bus 151 S5E Switch, cabin, lifting/lowering 83B, 83D
(X45) 9 pin, Fieldmaster, extra equipment S7E Switch, lowering speed 85B, 85D
(X46) 7 pin, Fieldmaster, current socket 155 S8E Switch, top limit 85B, 85D
(X47) 2 pin, GPS-supply, Fieldmaster S9E Switch, mixing 85B, 85D
(X48) 3 pin, radar, Fieldmaster S10E Switch, lifting/lowering 85B, 86D
X49 2 pin, seat 94 S11E Switch, forced lowering 85B, 85D
(X50) 3 pin current socket 96 S12E Switch, Drive Balance Control/Slip 85B, 85D
(X55) 1 pin, Fieldmaster 95
X64 2-speed., front PTO speed signal 102 X1E Connector housing, 9 pin, speed sensors (ACD)
X2E Connector housing, 15 pin., supply & rear push
Y1 Solenoid valve, differential lock 64 buttons (+implement position sensor)
Y2 Solenoid valve, PTO 133
Y3 Solenoid valve, 4WD 71 Y1E Solenoid valve, lowering 83B, 84D
Y4 Solenoid valve, Delta Power Shift 133 Y2E Solenoid valve, lifting 83B, 84D
(Y5) Magnetic clutch, compressor, air conditioner 54
Y6 Solenoid valve, Delta Power Shift 134 CareTel, information collecting system
(Y7) Solenoid valve, rear steering prevention 94 (A1L) CareTel, data logger 118
Y8 Solenoid, engine running 4
(Y9) Magnetic clutch, front-PTO 77 (B1L)Pressure sensor, CareTel, 18 Bar 117
Y11 Solenoid, forward 131 (B2L)Pressure sensor, CareTel, 190 Bar 116
Y12 Solenoid, reverse 132 (B3L)Sensor, gearbox temperature 117
(Y13) Solenoid valve, Sigma 113 (B4L)Temperature sensor, engine 118
(Y16) Solenoid, cold cranking 3
Y17 Solenoid valve, Delta Power Shift 134 (H1L)Indicator light, CareTel 120
Y18 Solenoid, parking brake 67
(X1L) Connector housing, 9 pins, CareTel,
AC5 -Control system, HiTech RS-232 117-120
A1A Control unit, AC5 122-152 (X2L) Connector housing, 3 pins, CareTel, CAN 117-120
(X3L) Connector housing, 9 pins, CareTel,
S1A Switch, PTO rear start, left 74 extra equipment 117-120
S2A Switch, PTO rear start, right 74 (X4L) Connector housing, 3 pins, CareTel,
supply+NBUS 117-120
X1A Connector housing, 9 pin, engine sensors 140-141
Wire colours
TwinTrac reverse drive controls
RU = brown
(B1W) Angle sensor, clutch pedal 171 PU = red
(S1W) Switch, DPS-extra 173 KE = yellow
(S2W) Limit switch, clutch pedal 162 SI = blue
(S3W) Limit switch, seat direction 163
MU = black
(S4W) Switch, DPS-preselection, rear 165
(S5W) Reed relay, direction front (F), rear 166 VI = green
(S6W) Reed relay, direction reverse (R), rear 167 VA = white
(S7W) Reed-relay, parking brake, rear 168 HA = grey
(S9W) Switch, brake pedal, rear right 169 LI = lilac

(X1W) Connector housing 12-pin, TwinTrac Explanations of the abbreviation

(X2W) Connector housing 1-pin., supply (P1W) F/R = forward/reverse power shuttle
(X3W) Connector housing 9-pin., direction lever, rear PTO = power take off
P1W Rear display, AC5 128
AC = Autocontrol linkage
AC5 = Autocontrol 5 control system
DPS = Delta Power Shift

181
 Model Code Page
31. Tractor electrical system X100-X120 310 56
24. 5. 2004

HiTech, L18105-
33563520A

183
 Model Code Page
31. Tractor electrical system X100-X120 310 57
24. 5. 2004

HiTech, L18105-

184
 Model Code Page
31. Tractor electrical system X100-X120 310 58
24. 5. 2004

HiTech, L18105-

185
 Model Code Page
31. Tractor electrical system X100-X120 310 59
24. 5. 2004

HiTech, L18105-

186
 Model Code Page
31. Tractor electrical system X100-X120 310 60
24. 5. 2004

HiTech, L18105-

187
 Model Code Page
31. Tractor electrical system X100-X120 310 61
24. 5. 2004

HiTech, L18105-

188
 Model Code Page
31. Tractor electrical system X100-X120 310 62
24. 5. 2004
HiTech, L18105-

189
 Model Code Page
31. Tractor electrical system X100-X120 310 63
1. 9. 2002

HiTech, L18105-

190
 Model Code Page
31. Autocontrol 2.2/2.3 95-115 314 1
1. 11. 2000

Autocontrol 2.2 from ser. no. J05133 incl. AC 2.3 replaces AC 2.2. with effect from ser. no. K44242 incl.. Autocontrol 2.2/2.3
include also ACB power lift which is a standard equipment on 95-115, see code 321.

Autocontrol 2.2/2.3 controls the transmission as follows:

1. Differential lock
The lock is controlled with a three-position rocker
switch on the driver's right.

A. Rocker switch front edge B. Rocker switch in the midĆ C. Rocker switch rear edge
depressed. dle position depressed (spring returĆ
ned)

- the lock is always engaged - When the switch rear edge is

except when brake pedal/pedals - the differential lock is disengaged
depressed, the lock is engaged
are depressed or when the power but it disengages when the brake
lift is in the transport position (sigĆ pedal/pedals are depressed. After
nal light illuminates however). The that the lock re-engages only if it
lock engages when the brake is done with the switch.
pedal/pedals are released or
when the lift/lower switch is in the
NOTE! The function of the differential lock has
lowering position or in the middle
been changed in the latest tractors (AC 2.3), see
position.
page 314/10. The function is the same also in
the HiTech-tractors.

2. Front wheel drive

The 4WD is controlled with a three-position rocker
switch on the driver's right.

A. Rocker switch front edge B. Rocker switch in the midĆ C. Rocker switch rear edge
depressed dle position depressed

- automatic position in which the - The 4WD is always engaĆ

- The 4WD is disengaged 4WD engages when the diff. lock is ged. Pilot light illuminates
except when braking with both engaged. When disengaging the
brake pedals. If only one brake diff. lock, also the 4WD disengaĆ
pedal is used, the 4WD does not ges, but, however, not when braĆ
engage. king with both brake pedals.

191
 Model Code Page
31. Autocontrol 2.2 / 2.3 95-115 314 2
1. 11. 2000

3. Power take-off
The PTO is controlled with a lever and a three-position
rocker switch on the driver's right.

PTO 540 or 1000 (or 540E) is selected mechanically with the lever at
which time a pilot light comes on in the instrument panel.

The rocker switch front edge The rocker switch in the middle The rocker switch rear edge
depressed (OFF) position (ON) depressed (START) (spring
returned)

- the PTO is disengaged - after starting the PTO is engaged - When the rear edge is
and the PTO shaft rotates as long depressed, the PTO starts. After
as the switch is in the middle posiĆ depressing, the switch is returĆ
tion and the supply line is not switĆ ned to the middle position by a
ched off. spring.

PTO emergency stop

There is an emergency stop socket which has a plug at the rear of the cab. When the plug is removed, the
PTO is disengaged and starts only when the rocker switch rear edge is depressed (the plug must be in the
socket).

After an engine stop the PTO starts only when the rocker switch rear edge is depressed.

4. Delta Powershift (DPS)

The Delta Powershift is controlled with two push buttons in the speed gear
lever knob.

A. The front push button is depressed. B. The rear bush button is depressed.

- With each press the gear ratio is changed - With each press the gear ratio is changed one
one step up. step down.

In the dashboard there are pilot lights, that show which one of the DPS ratios is engaged:
I=slowest ratio
II=middle ratio
III =fastest ratio

Delta Powershift circuit card A10 has a buzzer, which warns parking brake functions and head lights functiĆ
ons.

After
Ainastarting the enginejälkeen
virrankytkemisen the DPS is always on
pikavaihde in the slowest ratio
kytkeytynyt I. Whenvälitykseen,
alentavaan the clutch pedal
jolloinisyksi
depressed, thepalaa.
merkkivalo DPS
ratios are changed which can be verified from the pilot lights.

192
 Model Code Page
31. Autocontrol 2.2 / 2.3 95-115 314 3
1. 11. 2000

S11E
S10E

G
K16 K13

K12
K27
K11
K15

Picture 1. AC 2.2 / 2.3, components

A. Diff. lock rocker switch Relays K11-K13: Diff. lock control relays (relay K12 is not
fitted in AC 2.3).
B. PTO rocker switch Relay K15: 4WD control relay
Relay K16: PTO control relay
C. 4WD rocker switch There is a relay K7 in the fuse box for the four wheel brakĆ
ing.
D. DPS push buttons in the speed gear lever knob Relay K27: 4WD control relay

D1. DPS circuit card (A10, not HiTech) in connection with Note! In the relay bracket there can also be other relays
ACB/ACD power lift switch panel. The circuit card is accessiĆ depending on the tractor equipment (e.g. HiShift-relay
ble after removing the switch panel (see code 321). K24, Control stop relay K18).

D2. Combination instrument, in which there are DPS pilot Note! The wire looms of the AC 2.2/2.3 tractors have been
lights. standardized with the wire looms of HiTech-models. Thus
there is a connector bracket in the lever console. E.g. soleĆ
E. PTO emergency plug at the rear of the tractor noid valve connector X13 is no more placed under the parĆ
king brake console, but X13 is a 37-pole connector in the
F. S10E: Lift/stop/lower-switch (Autocontrol-switch) lever console (as in HiTech-tractors).
S11E: Forced lowering switch

G: Relay bracket in the lever console

193
 Model Code Page
31. Autocontrol 2.2 / 2.3
1. 11. 2000 95-115 314 4

1. Fault tracing
B. Buzzer functions
A. General
The buzzer notifies, when parking, that the parking brake
must be applied (engine stopped) or that a driver does not
Note! In connection with malfunctions fuses F6, F8, F11, drive with applied parking brake (engine running). The buzĆ
F22 and F27 must be checked, which affect the function of zer also alarms if the head lights remain on after the current
the AC 2.2/2.3. is switched off.

Important! If in AC 2.2/2.3 a pilot light (I, II or III) of engaĆ Testing method:

ged DPS ratio starts to flash, this indicates that the wires
between the solenoid valve (Y4 or Y6) in question and the
- start the engine (oil pressure up)
circuit card A10 of DPS have poor contacts or there is a
- apply parking brake. The buzzer alarms at intervals of 5
short circuit in the solenoid valve or in wires. Tractor driving
seconds.
can be continued with a such DPS ratio, which is functioĆ
- switch on the head lights. Stop the engine and switch off
ning i.e. the pilot ligts illuminates without flashing.
current (oil pressure down). The buzzer starts to alarm
about once or twice per second. Switch off the head
If one of the DPS pilot lights is flashing, so:
lights, at which time the buzzer stops to alarm.
- check that the 18-pole connector is correctly fastened to
- release parking brake. The buzzer starts to alarm contiĆ
the DPS circuit card A10 (the circuit card is placed under
nuously
the ACB-power lift switch panel).
- check solenoid valves Y4 and Y6 and their wires and
The buzzer is fitted on the DPS circuit card A10.
connector X13 on the support plate in the lever console
(pins, see wiring diagram).
The buzzer can be tested in the loose circuit card as follows
(see picture on the next page):
Solenoid valves:
- Ground pin 3 and feed voltage of 12 V to pin 11.
Y1: diff. lock (magnetic, when diff. lock is engaged)
- Ground pin 13 and feed voltage of 12 V to pin 4, at which
Y2: PTO (magnetic when PTO engaged)
time the buzzer must give continuous signal. Disconnect
Y3: 4WD (magnetic when 4WD disengaged)
pin 4, after witch the buzzer should alarm about 2 min.
Y4: DPS (magnetism depends on transmission type, see
- Remove ground from pin 13 and ground pin 12 and feed
picture on the next page, +=magnetic)
a voltage of 12 V to pin 4, after which the buzzer should give
Y6: DPS (magnetism depends on transmission type, see
discontinuous sound signal.
picture on the next page, +=magnetic)
- Feed pin 10 with 12 V and disconnect pin 4, after which the
buzzer must give discontinuous alarm signal.
Position of the solenoid valves on the valve block (on the
LH side of the gearbox housing), see e.g. picture 5 on page
Note! If the buzzer is damaged, the whole DPS circuit card
440/13.
A10 must be replaced.
The resistance value of all solenoids is 11-12 ohms. If the
transmission control system has malfunctions, check the
solenoid valves. The reisistance of the valves can be meaĆ
sured on the wire loom connectors (e.g. X13), but if it is
infinite, it must be measured on the valve pins, so that posĆ
sible breaks can be verified.

If the resistance value is OK when measuring on the valve

pins but the resistance is zero when measuring between
pins 3<>1 or 3<>2 of DPS circuit card connector A10,
the diodes are in short circuit and they must be replaced
(solenoid valve diode housing V1, see e.g. picture on page
310/9). Diode housing V3 in AC 2.3 is for solenoid valves.

Supply voltages of DPS circuit card A10:

If the DPS has engaging problems, make sure that the DPS
circuit card gets supply voltages by measuring it on pins of
connector A10 (DPS circuit card):
- pin 3: continuous ground
- pin 4: 12 V via ignition switch
- Pin 6: 12 V via fuse F22 and ignition switch
- pin 11: 12 V continuous voltage via fuse F11
Check also earth points GR1 and GR5)

If no supply voltage exists, check the condition of the batteĆ

ry and check supply wires and various components in theĆ
se circuits.

194
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31. Autocontrol 2.2 / 2.3 95-115 314 5
1. 11. 2000

C. DPS-circuit card A10

Pins 1 and 2: Current to DPS solenoid valves
(Y4, Y6), battery voltage (12 V)
Pin 3: Continuous ground
Pin 4: voltage of 12 V via ignition switch and
fuse F22.
Pin 5: 12 V, when foremost DPS button is deĆ
pressed. Otherwise unenergised.
Pin 6: 12 V via fuse F22 and ignition switch
Pin 10: 12V, when head lights on, otherwise
unenergised
Pin 11: continuous current via fuse F11
(12 V)
Pin 12: when parking brake is applied, pin 12
is earthed.
Pin 13: earthed, when engine is stopped
Pin 14: 12 V, when rearmost DPS button deĆ
pressed. Otherwise unenergised.
Pin 15 and 16: In transmissions 460 and 650
wire is connected to pin 15 and
in transmission 300 to pin 16
(12 V).

ÈÈÈÈÈÈ
Pin 17, 18 and 8: Signals to DPS pilot lights
(12 V).

Position of connectors
Picture 2. Delta Powershift circuit card A10
X1: In fuse box
+=energised (solenoid magnetic) , 0=unenergised
X4: In fuse box
Z= 18-pin connector of the circuit card
X6: In fuse box
Pins 7 and 9 not in use
X11: In cab roof
X23= connector for extra push buttons
X13: on support plate in lever console
GR1= earth point in the rear part of the lever console
X19: Socket on the cab wall on the RH side
GR5= earth point on the cab front wall
X26: White connector on the rear face of the instrument
Note! Position of various components and wiring diagram are
X27: Blue connector on the rear face of the instrument
shown under code 310.
S23: DPS push button connector at the lower end of the
V1=diode housing of solenoid valves
gear lever
V3=diode housing for solenoid valves in AC 2.3
X23: DPS extra push buttons connector at the lower end of
the gear lever

Note! Electric signals into the circuit card A10 can be On pins 1 and 2 can be measured voltage value when
measured from pins of 18-pole connector when the the current is switched on and the connector is fasteĆ
ignition is switched on. Measure voltages with different ned to the circuit card A10. When measuring on the
switch positions (see picture above). If the measured lower pins, be carefully not to short circuit the poles.
value is faulty, check wires, switches and connectors Measure rather on the wire side of the connector.
which affect the circuit in question.
From pins 17, 18 and 8 are sent signals to the DPS
From pins 1 and 2 of the circuit card is sent current to pilot lights (12 V) in the dashboard instrument. When
the DPS solenoid valves Y4 and Y6 (see +/0 diagram in the DPS push buttons are pressed (ignition on) the
the picture above). pilot lights in the instrument must light up in a correct
If no signal is sent to the solenoid valves, although other order. If the pilot lights have malfunctions, check the
parts are OK, the fault lies in the circuit card. lamps and wires from the circuit card to the lamps. If
the lamps and the wires are OK, but malfunctions ocĆ
cur, change the whole circuit card A10.

195
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31. Autocontrol 2.2 / 2.3 95-115 314 6
1. 11. 2000

D. 4WD control

Checking function (engine is runĆ

ning):

- Depress the 4WD rocker switch rear edge,

at which time the 4WD pilot light must light
up.
This shows that:
- the 4WD switch functions
- the 4WD pilot light functions

- Depressd the switch front edge, at which tiĆ

me the pilot light must go out
- Depress separately unlatched brake
pedals. The 4WD ind. light must not come
on.
- Connect the brake pedals together and
depress the pedals at which time the 4WD
engages (ind. light comes on)
- Release the brake pedals and the ind. light
goes out.
- apply parking brake, the 4WD ind. light
must come on
- release parking brake at which time the
4WD ind. light must go out
This shows that:
- brake pedal switches function
- relays K7 and K15 function
- parking brake switch functions

- Drive the tractor at speed of 4 km/h.

- Make a tight turn
- Engage and disengage the 4WD several
times. When the 4WD is engaged, you
should see the front axle skid and feel a jerk
as you engage and disengage.
This shows that:
- solenoid valve functions
- 4WD clutch functions
Picture 2.4WD control. The system gets the supply via
- Turn the 4WD switch to the middle position (automatic the ignition switch and fuse F22.
position, in which the 4WD engages, when the diff. lock
is engaged). Testing of this position is made in connectiĆ F22: fuse
on with checking of the diff. lock, see page 314/8. S30: three-position rocker switch of 4WD
Y3: 4WD solenoid valve
Note! In case of malfunctions always check fuse F22. H9: 4WD pilot light of 4WD
When the 4WD is disengaged, the solenoid valve Y3 is S10 and S20: brake light switches
energised and the nut at the end of the valve is magĆ K7 and K15: relays, which switch on 4WD, when latched toĆ
netic which can be verified e.g. with a screwdriver. gether brake pedals are depressed.
K27: 4WD relay (4WD engages, when the diff. lock is engaĆ
Note! 4WD is always engaged, when the engine is stopĆ ged).
ped (cup springs engage the 4WD). The use of the parĆ GR1: earth point (solenoid valvest) in the rear part of the lever
king brake earths relays K7 and K15 and the 4WD is console
engaged. GR5: earth point under the dashboard on the cab front wall
V1: Solenoid valve diodes (see picture on page 310/9)
V3: 4WD diode housing (see picture on page 310/9). This dioĆ
de housing is for solenoid valves in AC 2.3.

Note! Engagement of the 4WD during braking can be prevenĆ

ted, when relay K7 (in the fuse box) is removed.

196
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31. Autocontrol 2.2 / 2.3 95-115 314 7
1. 11. 2000

E. Differential lock control

É
É
É

Picture 3. Differential lock component

K12: Switches on voltage to the solenoid valve, when the
Y1: Diff. lock solenoid rocker switch rear edge is depressed. Ind. light
K11, K12 (not in AC 2.3) and K13: control relays comes on. When the brake pedals after this are
S10 and S20: brake light switches depressed, relay K11 is closed and current from relay
K12 is cut-off and the relay opens and switches off
The differential lock rocker switch S22 is placed on the current to the solenoid valve and the ind. lights goes
selector panel on the driver's right. In addition, the lift/stop/ out. The diff. lock does not engage after this although
lower switch of the ACB power lift also controls the diff. the brake pedals are released. Note! This relay is not
lock. fitted in AC 2.3.

The relays are placed in the lever console and are accessĆ
ible after removing the console side panel: K13: Switches off voltage to the solenoid valve and the lock
disengages, when the lift/lower switch is in the lifting
position. The lock ind. light , however, illuminates.
K11: Switches off voltage to the diff. lock solenoid valve When the implement is lowered down to the working
and switches on current to the brake lights, when the position, switches on voltage to the solenoid valve
brake pedal/pedals are depressed. Switches on voltĆ and the differential lock is engaged.
age again to the solenoid valve, when the brake
pedal/pedals are released. Ind. light comes on.

197
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31. Autocontrol 2.2 95-115 314 8
1. 11. 2000

Checking function of the differential lock

control (engine at idling speed). Concerning AC 2.3, see
page 314/10).

- Depress the rocker switch front edge at which time the

lock indicator light comes on. If the 4WD switch is in the
middle position, also the 4WD pilot light lights up and the
4WD is engaged.
- Turn the switch to the middle position at which time the
indicator light goes out (also 4WD disengages).
This shows that:
- the rocker switch front and middle positions function
- The lock indicator light functions
- the 4WD automatics function and also relay K27.

- Depress the switch front edge at which time the indicator

light comes on (also the 4WD engages, if the 4WD switch
is in the middle position)
- Disconnect the brake pedals and depress the pedals sepĆ
arately and together. When depressing the pedal/pedals,
the diff. lock ind. light goes out and the brake lights comes
on. When the pedal/pedals are released, the ind. light
comes on and the brake lights goes out. Note! Also 4WD
disengages, when the brake pedals are depressed sepaĆ
rately)
This shows that:
- the brake pedal switches function
- the switches are correctly positioned
- relay K11 functions
- 4WD relay K27 functions

- Depress the switch rear edge at which time the ind. light
should come on (also the 4WD engages, if the 4WD switch
is in the middle position).
- Depress the brake pedal/pedals at which time the ind. Picture 4. Differential lock control.
light goes out (also 4WD disengages, when the brake peĆ The system is supplied via the ignition switch and via the
dals are depressed separately) fuse F27).
- Release the brake pedal/pedals. The diff. lock ind lights
must not come on and the lock must not engage. 4WD reĆ
mains on in the automatic position, when latched together S22: Diff. lock control switch
brake pedals are depressed. K11, K12, K13: diff. lock control relays
This shows that: S10E: Lift/stop/lower-switch of the ACB power lift
- the rocker switch rear position functions H20: Diff. lock pilot light
- relays K11 and K12 function Y1: Diff. lock solenoid valve
- 4WD automatics function S10 and S20: brake light switches
GR1: earth point in the rear part of the lever console
- Depress the switch front edge and the ind. light comes on GR2: earth point in the roof
- Turn the lift/stop/lower switch to the transport position at GR5: earth point under the dashboard on the cab front wall
which time the diff. lock disengages. Ind. light, however, V1: Solenoid valve diode housing (see picture on page 310/9)
remains on. V2: AC 2.2 diode housing (see picture on page 310/9).
- Turn the lift/stop/lower switch to the lowering position or V3: Diode housing for solenoid valves in AC 2.3.
to the middle position and the differential lock engages.
This shows that: Important! Always check the fuse F27, if there is malfuncĆ
- lift/stop/lower switch functions tions in the control system. The diff. lock solenoid valve is fitted
- relay K13 functions on the lower side of the valve block on the LH side of the gearĆ
box. The rearmost valve Y1 is for the diff. lock. When the lock
- Drive the tractor at speed of 4 km/h and engage the lock is on, the solenoid valve is energised. Then the nut on the
by pushing the rocker switch front edge down. Ind. light valve is magnetic which can be verified with e.g. a screwĆ
comes on. driver.
- Make a tight turn, raise and lower the lift with the lift/stop/
lower switch at which time the diff. lock engages and disĆ
engages.
- You should see the rear tyres skid when the differential
lock is engaged and feel a jerk as you engage and disenĆ
gage. The front axle lock functions in the same way, if
fitted (during the test the 4WD should be disengaged).
This shows that:
- solenoid valve functions
- differential lock functions

198
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31. Autocontrol 2.2 / 2.3 95-115 314 9
1. 11. 2000

F. PTO control
1
Checking function:
Make sure that the plug is fitted in the rear emergency socket.
Move the control lever in the middle position. Check that the
PTO rocker switch front edge is depressed (OFF). Switch off
tractor current. Start the engine and let it run at idling speed.

- Move the PTO lever to the foremost position (540) at which

time the indicator light should come on. The PTO shaft
must not rotate. 2
- Move the lever to the middle position at which time the ind.
light goes out
- Move the lever to the rear position (1000 or 540E) and the
ind. light should come on. The PTO shaft must not rotate.
Move the lever back to the middle position and the ind.
light goes out.
This shows that:
- ind. light switches S28 and S29 functions
- indicator light functions

- Move the lever to the front position (540). Ind. light comes
on.
- Turn the PTO rocker switch to the middle position (ON)
- Depress the rocker switch rear edge (START). The PTO
shaft begins rotate and the rocker switch is returned to the
middle position (ON) by the spring.
This shows that:
- PTO control relay K16 functions
- solenoid valve functions

- Depress the rocker switch front edge (OFF)

- PTO shaft stops to rotate
- Turn the switch to the middle position. The shaft must not
rotate. Depress the switch rear edge at which time the
shaft starts to rotate. Picture 5. PTO control. The system is supplied via the ignitiĆ
This shows that: on switch and fuse F22.
- PTO rocker switch functions

- Remove the plug from the rear socket at which time the
shafts stops rotating. Also the indicator light goes out.
- Refit the plug. The shaft must not rotate but the ind. light
comes on. 1. PTO control lever (540-neutral-1000 (540E)
- Depress the switch rear edge and the PTO shaft must start S28: Lever switch
to rotate. S29: Lever switch
This shows that: X31: Emergency stop socket
- PTO emergency stop functions 2. 3-pos. PTO rocker switch
- relay K16 functions V1: Solenoid valve diode housing (see picture on page 310/9)
V2: AC 2.2 diode housing (see picture on page 310/9).
- Stop the engine. V3: Diode housing for solenoid valves in AC 2.3.
- Start the engine. The PTO shaft must not rotate although H10: Pilot light
the lever is in the engaged position Y2: PTO solenoid valve
- Depress the rocker switch rear edge at which time the K16: relay which connects current to the solenoid valve,
shaft begins to rotate. when the rocker switch rear edge is depressed (START). SoleĆ
- Move carefully the lever to the middle position. The ind. noid is energised so far as the rocker switch is in the middle
light goes out and shaft stops. position (ON) and the circuit is not broken with the lever,
- Move the lever to the front position. The shaft must not emergency plug or with the ignition switch.
rotate. GR1: earth point in the rear part of the lever console
- Depress the rocker switch rear edge after which the PTO GR5: earth point under the dashboard on the cab front wall.
shaft starts to rotate.
This shows that: Important! The solenoid valve Y2 is placed under the valve
- The PTO automatic stop functions when the main current block on the LH side of the gearbox (see picture). When the
circuit is cut off. solenoid is energised, pressure oil is directed to the PTO
- relay K16 functions clutch and the shaft can rotate. The nut at the end of the soleĆ
noid is magnetic when the solenoid is energised.

199
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31. Autocontrol 2.3 95-115 314 10
1. 11. 2000

G. The function of the differential lock has been changed in the latest tractors (AC
2.3): (concerns also HiTech models 100Hi-120Hi).
Note! Manufacturing of AC 2.3 is started from ser. no. K44242 incl.. In connection with modification of the differential lock
function, relay K12 has been removed.

1. Control of differential lock

The lock is controlled with a three-position rocker switch on the driver's right.

A. Rocker switch front edge B. Rocker switch in the midĆ C. Rocker switch rear edge
depressed. dle position. depressed.

- the differential lock is disengaĆ - the lock is always engaged - the lock is always engaged
ged. except when brake pedal/pedals except when brake pedal/pedals
are depressed or when the power are depressed. The lock engages
lift is in the transport position. The when the brake pedal/pedals are
lock engages when the brake released.
pedal/pedals are released or when
the lift/stop/lower switch is in the
lowering position or in the middle
position.

C. Differential lock control in AC 2.3

Depress the diff. lock rocker switch front edge. Now the
lock must be disengaged and the pilot light must not be on.
Solenoid valve Y1 must be unenergised.
This shows that:
- rocker switch front position is OK.

Press the rocker switch to the middle position, at which time

the lock must become engaged and the pilot light must
come on. Solenoid valve Y1 must be energised.
This shows that:
- diff. lock pilot light and its wires are OK.
- rocker switch middle position is OK

While the rocker switch is in the middle position, depress

the brake pedal/pedals, at which time the lock must be diĆ
sengaged and the pilot light goes out. When the brake peĆ
dals are released, the lock must be engaged and the pilot
light comes on.
This shows that:
- brake pedal switches S10 and S20 are OK
- relay K11 is OK

While the diff. lock rocker switch is in the middle position,

press the power lift lower/stop/lift" switch S10E into the
transport position. Now the diff. lock must be disengaged.
Press the power lift switch back to the middle or lowering
position and the diff. lock must be engaged.
This shows that:
- switch S10E is functioning properly
- relay K13 is OK

Depress the diff. lock rocker switch rear edge. In this positiĆ
on the lock must be on and also the pilot light.
This shows that:
- diff. lock switch rear position is functioning properly.

While the rocker switch rear edge is down, depress the braĆ
ke pedal/pedals, at which time the lock must be disengaĆ
ged. When the brake pedals are released, the diff. lock is
engaged and the pilot light comes on. The use of the power
lift switch S10E must not affect the function of the lock. Picture 6. Diagram, differential lock, AC 2.3.
This shows that:
- relay K11 is OK

200
 Model Code Page
32. ACB power lift 95-115
1. 11. 2000 321 1
X100-X120

4
6
Fig. 1 ACB power lift system

1. Hydraulic pump
2. Control valve
3. Lifting cylinder
4. Electronic unit
5. Draft sensor
3 6. Position sensor
7. Switch panel

2
5

1. ACB hydraulic lift, function

Note! Hydraulic system of the power lift is described in secĆ This unit determines the differences between the two sets of
tion 90. signals (i.e. from the sensors and switches) and feed the
necessary control signal to the control valve solenoid.
The Valmet Autocontrol ACB is an electrically controlled hyĆ
draulic lift. All mechanical levers have been replaced with The position sensor (6) is in permanent contact with an eccenĆ
knobs and switches. Ideal mixing/sensitivity values for draft tric on the lift shaft. When the lower links are lifted or lowered
control have been pre-programmed and can be controlled the eccentric moves the pin, which sends a signal to the elecĆ
with one switch. tronic unit; thus the hydraulic lift always "knows" the position
of the lower links.
Operation:
The pump (1) draws oil from the oil reservoir and delivers it to The lower links are connected to the draft sensors (5). When
the control valve (2). The control valve directs the oil to the liftĆ the draft force in the lower links increases the loading on the
ing cylinders (3) for the operation of the lifting arms (lifting, draft sensors also increases. This loading is then converted
lowering and holding functions). The values set on the switch into electrical signals by the draft sensors.
panel (7), and the actual values detected by the draft sensors These signals are amplified by an electronic device which is
(5) and position sensor (6), are fed into the electronic unit (4). built into the the draft sensors. The signals are sent to the AuĆ
tocontrol hydraulic lift. If the draft force increases the hydraulic
lift will raise the implement, the draft control sensitivity deĆ
pending on the setting of the switches in the cab.

201
 Model Code Page
32. ACB power lift 95-115
321 2
1. 11. 2000 X100-X120

On tractors 95-X120 there is as standard ACB power lift, which cannot be equipped with slip control and auxiliary sensors. In
addition, in the ACB power lift the engaging speed of the Drive Balance Control (DBC) cannot be adjusted, but it is always
engaged in the transport position, when the tractor is moving (can be switched off with a selector). The ACB power lift has not
an indication light for the draft control mode. ACB power lift can be recognized by letter B on the switch panel.

A. ACB power lift

- ACB power lifts have a digital control unit

- Position sensor is different as in AC power lift.
- ACB power lifts have as standard a Drive Balance Control (DBC), which damps in transport driving oscillation movements
of the tractor caused by a heavy implement which is attached to the three point linkage unit.
- The ACB power lift switch panels have a diagnostic light, which indicates self-testing and locking of the power lift and it
indicates by flashing numbers of fault codes so that possible faults can be localised.
- Lowering speed selector and the draft control selector have more positions than AC power lift.

8 1 2
3 4

6
10
B

Picture 1. ACB power lift switch panel

1. Lowering speed selector (9 positions)

2. Transport height selector (9 position)
3. Position control/Draft control selector (position P is for position control. The draft control has 6 different positions
4. Drive Balance Control/Slip Control
- OFF; Drive Balance Control and slip control are switched off
- Drive Balance Control switched on
6. Indicator light, Drive Balance Control switched on
8. Diagnostic light
9. Indicator light, lifting
10. Indicator light, lowering

Note! The functions of the position control potentiometer, lifting/stop/lowering switch (=Autocontrol switch) and the forced-
lowering switch are the same as in AC power lift. The lift/lower push buttons in the cab have been replaced with one rocker
switch, but the function is the same as earlier. There are bush buttons on the rear mudguards. The draft sensors are the same
as in AC power lift.

202
 Model Code Page
32. ACB power lift 95-115
1. 11. 2000 X100-X120 321 3

B. Position sensor, ACB

ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ

SIGNAL

SUPPLY

Picture 2. Position sensor on ACB power lift

4. Permatex Super 300 to threads

5. Locking nut
6. In-built amplifier
Connector A:
1. Earth wire
2. Signal wire
3. Supply wire
Measuring position sensor supply and signal
Direct current (DC) is fed into the ACB position sensor. voltages
USupply = 9,5±0,3 VDC Sensor voltages can be measured as earlier by using speĆ
USIGNal = 25-75 % x USupply (lower links down-up) cial tool ETV 894 100 and a universal instrument, see page
321/5.
The position sensor connector is fitted at the end of the
sensor. Measuring values
- Supply voltage . . . . . . . . . . . . . . . 9,2-9,8 VDC
Note! The positon sensor cannot be repaired but a defect - Signal, lower links down . . . . . . . 2,3-2,5 VDC
sensor must be changed for a new one. - Signal, lower links up . . . . . . . . . . 6,9-7,4 VDC

Important! Fault code number 22 indicates, that the posiĆ Adjusting position sensor, see page 321/9
tion sensor does not function. Diagnostic light and fault
codes, see the following instr. C.

203
 Model Code Page
32. ACB power lift 95-115
1. 11. 2000 X100-X120 321 4

ÇÇÇ
ÉÉÉ
ÉÉÉ
ÇÇÇ
View A 1
ÇÇÇ
ÉÉÉ
ÇÇÇ
ÇÇÇ
ÉÉÉ
USUPPLY USIGNAL ÇÇÇ
45 Nm

Figure 5. Draft sensor

1. Pressure resistant grease

C. Draft sensors Measuring the draft sensor internal voltĆ

ages
See page 321/5.
The draft sensors act as mounting bolts for the lower links. The
sensors convert draft forces into electrical signals.
Short circuit in draft sensor line
The draft sensors are housed in tubes manufactured from a - Short circuit in the supply line causes deadlock of the whole
special steel. Inside the sensor there is a carrier wave elecĆ system (current breaks also in the selector panel A2E ). If this
tronics unit, a signal amplifier, and a transformer which proĆ short circuit is only momentary, the system starts normally
duces a magnetic field at the measuring point. with the lift/lower switch. If the short circuit is sustained, the
power lift remains locked.
The draft force causes a shearing stress on the sensor and this
changes the magnetic properties of the metal, which causes - Short circuit in the signal line causes the lifting reaction on
a variation in the voltage in the transformer secondary the lower links during the short. The system returns automatiĆ
cally to the normal function after the short circuit ("ghost lifts").
USUPPLY = 9,5-10,5 V (DC)
USIGNAL = 2,5-7,5 V (DC) (draft max. - push max.) - Contact between the supply and signal lines causes the full
(signal voltage is 5 V when the lower links are unloaded). lowering reaction on the lower links during the short circuit.
The draft pins must be changed if they are damaged. If the Note! The draft sensor internal build-up has been changed.
sensor lead is damaged it can be repaired using three pin At the same time, the sensor coverings have been changed.
connectors. The earlier sensor fits with the new coverings. The new sensor
cannot be fitted with the earlier covers but they must be
Note! changed. The new cover can be used inplace with the earlier
Draft sensor 31287410, 40 kN covers after changing the sheet metal cover.
Draft sensor 33303900, 60 kN

204
 Model Code Page
32. ACB power lift 95-115
321 5
1. 11. 2000 X100-X120

D. Measuring internal voltages of position sensor and draft sensors

The condition of the sensors can be checked by measuring
the sensor supply and signal voltages with the aid of a speĆ
cial tool.

Connect the tool into the power lift by opening the position
sensor or one of the two draft sensors connectors and by
fitting the tool between the lead. Switch on current and actiĆ
cate the power lift with lift/lower switch.
Order no The correct values should be:
ETV 894 100
Position sensor:

Voltages when measuring with a normal multimeter:

- Supply voltage . . . . . . . 9,2-9,8 VDC

- Signal, lower links down 2,3-2,5 VDC
- Signal, lower links up . . 6,9-7,4 VDC

The supply voltage is measured between the red and black

connectors and the signal voltage between the blue and
black connectors.

Draft sensors:

Supply voltage = 9,5-10,5 V (DC)

Signal voltage = 2,5-7,5 V DC (max pull-max push)

Note! The signal voltage should be 5 V DC, when lower

links are unloaded.
Blue
The supply voltage is measured between the red and black
connectors and the signal voltage between the blue and
Yellow-green black connectors.

Brown Note! If the sensors do not receive the supply voltage,

check the power lift fuses and the lead connectors. If these
are OK the possible fault may be inside the electronic unit
which should be replaced.

Black (1)
Blue (2) 1 3
Red (3) 2

A
Figure 1. Tool for measuring the sensor voltages

Red = supply voltage=3

Blue = signal voltage=2
Black = earth lead=1

View A

Draft sensor connectors (A) are placed in the lever console in

the cab and are accessible after removing console side panel.
1 3 Position sensor connector is fitted at the end of the position
sensor.
2

205
 Model Code Page
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1. 11. 2000 X100-X120 321 6

Circuit diagram, ACB

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1. 11. 2000 X100-X120 321 7

Connector X2E for supply and for the rear push buttons is
ACB: List of components placed in the lever console. If the ACB does not respond when
the push buttons are used, check then fuse F11. If the fuse is
OK, check connector X2E (pin 1) and connector X4 pin 8 in
A1E ACB control unit 82B the fuse box. Also check the earth point GR4 in the rear part
A2E Control switch circuit card 85B of the lever console.

B1E Position sensor 81B The wires from the LH side push buttons have been drawn via
B2E Draft sensor, right 81B connector X14 (in the lever console) and the wires of the RH
B3E Draft sensor, left 81B side push buttons have been drawn via connector X12 (in the
lever console).
E1E Illumination, switch circuit card 85B
E2E Illumination, position potentiometer 86B If the ACB power lift responds to the push buttons, but does
not activate with the Autocontrol-switch (lift/stop/lower
R1E Potentiometer, position control 85B switch), check the Autocontrol-switch and its wires. If these
are OK, but the ACB does not activate, the fault may lie in the
S1E Push button, mudguard, lifting, right 83B control unit box.
S2E Push button, mudguard, lowering, right 83B
S3E Push button, mudguard, lifting, left 82B
S4E Push button, mudguard, lowering, left 82B
S5E Switch, cabin, lifting/lowering 83B
S7E Selector, lowering speed 85B
S8E Selector, transport height 85B
S9E Selector, position control/draft control 85B
S10E Switch, lift/stop/lowering 86B
S11E Switch, forced lowering 85B
S12E Switch, oscillation damping (DBC) 85B

X2E Connector, 15 pins, supply & rear buttons

Y1E Solenoid valve, lowering 84B

Y2E Solenoid valve, lifting 84B

Wire colours:
Ru = braun
Pu = red
Ke = yellow
Si = blue
Mu = black
Vi = green
Va = white

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1. 11. 2000 X100-X120

ACB Power lift

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E. Checking function of ACB Power

lift
5

1 2 3 4
6 8

11

12
10

Note! The Power lift must function in the way written in this 7. Lift the lower links up step by step (1-9) by using the
instruction. position control potentiometer (10); The lifting intervals are
almost the same and the red light (6) is lit when the links
1. Start the engine. The red diagnostic light (5) comes on. move up. Leave the knob (10) in the max. upper position;
Activate the Power lift with the Autocontrol-switch (11), at the display shows 100 Ac (in AD-instrument 99 Ac).
which time the diagnostic light (5) goes out. Leave the
Autocontrol-switch (11) in the lowering position and adjust 8. Raise the lower links more to the topmost position with
the lower links with the position control potentiometer (10) lift/lower switch in the cab (not in picture above) (correĆ
to the lowest position. sponding the yellow push buttons in the mudguard), diagĆ
nostic light (5) comes on and shows that the Power lift is
2. Set the lowering speed (1) and transport height (2) to the locked. Release the towing hook and lower the lower links
minimum and position control/draft control switch (3) to and towing hook with the yellow push buttons (the buttons
position P. function in all positions of the Autocontrol-switch (11)).

3. Turn the Autocontrol-switch (11) into the transport posiĆ 9. Turn the Autocontrol-switch (11) to the transport position
tion. The standard instrument shows running hours and the and immediately back to the middle position; the lower
decimal point is flashing, when the engine is running (The links start to rise but stop immediately, when the switch is
display of AD-instrument does not change with AutoconĆ turned to the middle position. The standard instrument
trol-switch, but with a switch of its own). shows running hours in the middle and transport position
(display of AD-instrument does not depend on the position
4. Turn step by step the transport height selector (2). The of the switch (11)).
lower links rise with even intervals, the red lifting ind. light
(6) is lit when the lower links move up. Leave the transport 10. Turn switch (11) to the transport position, at which time
height selector (2) to the max. value (pos. 9). the lower links rise up and the towing hook is locked by the
pawl.
5. Turn the draft control switch (3) to the max. value (pos 6)
and press the Autocontrol switch (11) to the lowering posiĆ 11. Switch on the position control mode (P). Push switch
tion. When the lower links go down, turn the lowerin speed (12), at which time the lower links go down. Release the
selctor (1) to the max. value. The lowering speed increases switch, at which time the lower links return to the original
clearly and the green light (6) is lit. Leave the lowering position. Check the position of the lower links in the Ac-
speed in the max. value. display.

6. When the lower links are in the bottom position, the 12. Turn the switch (11) to the transport position, switch on
green light (6) is lit (floating position), the standard instruĆ the DBC with switch (4); lower links lower approximately 4
ment shows between 0-15 and text Ac (in the AD-instruĆ cm. Switch off the DBC, at which time the lower links rise
ment, the Ac-display must be selected in the upper disĆ up to the top position.
play).

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321 10
1. 11. 2000 X100-X120

0.2 MPa

Í
Í
ÈÈ
ÈÈ
ÈÈÈÈ
ÈÈÈÈ
ÈÈÈÈ

Fig. 3. Electro-hydraulic power lift ACB, J05133-.

1. Control valve
2. Draft sensors
3. Lower links
4. Electronic unit (different on ACB and ACD)
5. Position sensor
6. Lift/stop/lower switch
7. Potentiometer for position control
8. Rocker switch
9. Push buttons, rear mudguards
10. Return oil into the gearbox housing
11. Return oil from control valve
12. Switch, forced lowering (not on earlier models)

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F. Function of diagnostic light and fault codes

When the current is switched on with an ignition switch, the diagnostic light is lit for a while (book symbol). This is the self-
testing of the system. After a short time the diagnostic light is lit continuously. This indicates that the power lift is locked. When
the light is on, all functions are locked, but the push buttons function.

The power lift is activated by turning the lift/lower switch first to the lifting and then to the lowering position, at which time the
diagnostic light goes out and the power lift responds to all switches. Immediately after the activating, the ACB limits the supĆ
ply current to the solenoid valves for safety. This limit delays movements of the lower links. The current supply limit disapĆ
pears, when the function limit of the control unit has been achieved or if the lift/lower switch is used anew.

After use of the push buttons the ACB is locked and the diagnostic light is illuminated.

Fault codes

ACB power lift continually monitors possible malfunctions in the system. The faults are divided into three different levels
according to their seriousness as follows:

1. Serious faults:
- the power lift is locked
- relay closes (protects outputs)
- diagnostic light indicates the fault
- Remedy: Repair the fault, start the tractor and activate the power lift.

2. Medium serious faults:

- the power lift is locked.
- diagnostic light indicates the fault
- Remedy: Repair the fault and activate the power lift with the lift/lower switch

3. Minor faults
- the power lift continually functions
- diagnostic light indicates the fault. When the lift/lower switch is turned, the diagnostic light goes out, if the fault has disapĆ
peared.

A possible fault can be localised with the aid of the diagnostic light, which displays by flashing the number of the fault code.
For example, if the signal wire to the draft control selector is damaged or there is poor contacts in connectors (fault code 36),
the diagnostic lights flashes as follows:

- Long pause - three flashes - short pause - six flashes.

During momentary faults, the diagnostic light flashes, until the lift/lower switch is turned, although the fault has already disapĆ
peared.

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Fault codes of ACB power lift

1. Serious fault

Fault code Fault Control Description

number unit conĆ
nector pin
11 Output/lifting 2 Output signal to lifting solenoid faulty or poor contacts in solenoid wire
to pin 6.
12 Output lowering 14 Output signal to lowering solenoid faulty or poor contacts in solenoid
wire to pin 6.
13 Short circuit 6 Measured current in pin 6 too high. Short circuit between pins 2 and 6
or between pins 14 and 6 (solenoid in short circuit)
14 Push button in 10 Signal from push buttons not OK. Push button or its wire damaged.
mudguard, upĆ
wards
15 Push button in 20 Signal from push buttons not OK. Push button or its wire damaged.
mudguard, downĆ
wards
16 Supply 12 Control unit supply not in order.
Supply of 9,5 V and earthing not in order

2. Medium serious fault

Fault code Fault Control Description

number unit conĆ
nector pin
22 Position sensor 19 Signal from sensor faulty
- Poor contact or position sensor disconnected
- Possible short circuit or earthing
- Position sensor faulty adjusted
23 Position control 16 Signal from potentiometer faulty. Poor contacts or wire loose.
potentiometer
24 Transport height 22 Signal from selector faulty. Poor contacts or wire loose.
selector
28 Up/stop/down 8 Signal from switch faulty. Poor contacts or wire loose.
switch

3. Minor faults

Fault code Fault Control Description

numbers unit conĆ
nector pin
31 RH side draft senĆ 18 Signal from sensor faulty:
sor - Poor contact or wire disconnected
- Possible short circuit or earthing
- Sensor overloaded
32 LH side draft senĆ 17 Signal from sensor faulty:
sor - Poor contact or wire disconnected
- Possible short circuit or earthing
- Sensor overloaded
34 Lowering speed 24 Signal from selector faulty. Poor contacts or wire disconnected.
selector
36 Position control/ 4 Signal from selector faulty. Poor contacts or wire disconnected.
draft control selecĆ
tor

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1. 11. 2000 X100-X120 321 13

G. Drive Balance Control (DBC)

The DBC can be switched off with the selector.

Verifying the function of the DBC

When the tractor is driven in transport driving on an uneven

road or field with an heavy implement attached to the
power lift linkage, the shocks caused by the implement
must light the indicator lights for lifting and lowering. This
indicates that the DBC is functioning (the draft sensors
react to shocks from the implement).

When the DBC is activated, the indicator light for the lowerĆ
ing must light for a while, since the lower links lower 4 % to
the intermediate limit position.

When a tractor is driven in transport drive and a heavy

implement is attached to the power lift linkage, this causes
oscillation of the tractor (front wheels tend to jump up from
the ground) . ACB power lift has the Drive Balance Control
(oscillation damping), which functions when the power lift is
in the transport position. Shocks from an implement cause
tensions in the draft sensors, and these tensions alter to
electric signals, which in turn cause that the linkage makes
small lift and lowering movements.

Drive Balance Control is activated, when the folĆ

lowing four terms are valid:

a) Power lift is activated

b) Power lift is in transport position

c) Drive Balance Control is switched on (ind. light lights).

When these four terms are valid, the lower links lower about
4 % from the upper limit position to the intermediate limit posiĆ
tion.
The lower links can lower 4 % from the intermediate limit posiĆ
tion to the lower limit position. Thus the max. distance
between the upper limit position to the lower limit position is
8 %. All percentages are counted from the total movement
range of the lower links (100 %).

Note! Position of the lowering speed selector does not affect

the Drive Balance Control speed.

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H. Checking switch panel A2E

Measurements are done on the tinned terminals on the rear
If lowering speed , transport height, draft control, Drive BalĆ side of the switch panel. Measurements are done without
ance Conrol selector does not function properly and the detaching the connector from the panel.
malfunction cannot be localized with the help of the precedĆ
ing instruction, the switch panel A2E can be checked as I. Removing the switch panel for checkĆ
follows:
ing
N.B.! In the checking, a voltmeter (measuring scale 0-14 V
DC) is needed. The voltmeter measuring heads should 1. Detach the bracket on which the switch panel is fitted by
have sharp ends so that they can be pricked through proĆ unscrewing four crosshead screws.
tective lacquer.
2. Turn the bracket/switch panel so that voltage measureĆ
ments can be done.

3. Turn the current on with the ignition switch and activate

the control system with the lift/stop/lower switch. Do not
detach the connector from the switch panel.

Note! From serial no 668103 incl. (AC 2.2/2.3), there is the

DPS circuit card fitted on the power lift switch panel.
Remove, if necessary, this circuit card before measuring the
power lift voltages.

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J. Checking switch panel of ACB 3. Checking transport height selector S8E

Remove the switch panel from the lever console (do not disĆ
connect the connector). Switch on currrent and activate the
ACB power lift. Measure from the terminals on the rear side of
the circuit card (DC).

1. Measuring supply voltage

Picture c) Measure voltage between pins 8 and 5 with all

selector positions:

Position Pin 5
1 0
2 0,9-1,2 V
3 1,9-2,3 V
Picture a) Measure supply voltage between pins 21 (-) 4 2,9-3,3 V
and 10 (+): Correct value is 9,2-9,8 V (DC). Measure also 5 3,9-4,3 V
voltage between pins 21 and 8. Correct value is about 1,6 6 4,9-5,4 V
V. 7 5,9-6,4 V
8 6,8-7,5 V
Note! If the supply voltage is incorrect, the fault lies in conĆ 9 7,6-8,2 V
nectors/wires.

2. Checking lowering speed selector S7E 4. Draft control selector S9E

Picture b) Measure voltage between pins 8 and 6 with all

selector positions: Picture d) Measure voltage between pins 8 and 3 with all
selector positions:
Position Pin 6
1 0,3-0,5 V Position Pin 3
2 0,7-1,1 V P 7,6-8,2 V
3 1,1-1,5 V 1 4,0-4,4 V
4 1,6-2,0 V 2 3,3-3,6 V
5 2,3-2,9 V 3 2,4-2,9 V
6 3,1-3,7 V 4 1,6-2,6 V
7 4,1-4,7 V 5 0,7-1,0 V
8 5,6-6,0 V 6 0
9 7,6-8,2 V
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1. 11. 2000 X100-X120

5. Checking DBC selector S12E K. Changing switch panel

Note! If the voltage measurements show that the switch panel

is defective the panel must be replaced as a complete unit as
follows:

1. Remove the DPS circuit card support plate and the card
from the ACD switch panel.

1. Detach the switch panel from the bracket by removing seĆ

lector knobs and by unscrewing ring nuts. Remove the dust
seals.

2. Detach the switch panel connector so that the panel can be

removed.

Picture e) Measure voltage between pins 21 and 1 (DBC)

with two selector positions:

Position Pin 1
OFF 4,2-5,0 V
DBC switched on 0

Note! If the measured values in points 2-5 deviate from the

given values, the fault lies in the switch panel circuit card
which should be changed.

6. Checking lift/stop/lowering switch S10E

3. Fit onto new selectors washers with lugs. These washers

limit selector positions. Before fitting the washers turn every
selector anti-clockwise as far as possible to their extreme
positions. After this fit washers so that the lugs engage in the
holes given below:
- lowering speed selector; hole 9.
- transport height selector; hole 9.
- draft control selector; hole 7.
- DBC without slip control; hole 2.
- DBC with slip control; hole 4.

4. Ensure by rotating the selectors, that the lowering speed

and transport height selectors have 9 positions, draft control
selector 7 position and DBC selector 2 (DBC) or 4 (DBC +slip
control) positions.
Picture f. Measure voltage between pins 8 and 9 with all
4. Connect the connector to the new switch panel. Fit the dust
three switch positions:
covers (no 317 204 20) onto the washers and fasten the circuit
card to the switch panel with the ring nuts (under the nuts lockĆ
Position Pin 9
ing washers JE 9423).
Lowering 2,4-2,8 V
Middle position (Stop) 3,5-4,0 V
5. Fit the knobs and fasten the DPS circuit card. Attach the seĆ
Transport position 4,9-5,4 V
lector panel onto the lever console.
Note! If the measured values deviate from the given values,
check the switch connector. If the values are further incorrect,
the fault lies in the circuit card which should be changed.

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L. Checking switch panel indicator lights Lowering speed positions:

ACB
If the ACB/ACD functions properly, but the indicator lights 1 . . . . . . . . . . . . . ~1,25 A
on the switch panel do not function correctly the following 2 . . . . . . . . . . . . . ~1,50 A
steps must be taken: 3 . . . . . . . . . . . . . ~1,65 A
4 . . . . . . . . . . . . . ~1,85 A
- detach the switch panel and move the connector on the 5 . . . . . . . . . . . . . ~2,10 A
panel so that possible poor contacts are eliminated. 6 . . . . . . . . . . . . . ~2,35 A
- if an indicator light is still out of order the voltage 7 . . . . . . . . . . . . . ~2,80 A *)
measurements shown in instruction F must be carried out. 8 . . . . . . . . . . . . . ~3,10 A *)
-If the voltages are between allowable limits but the light is 9 . . . . . . . . . . . . . ~3,20 A *)
still out of order the fault is in the bulb and the whole switch
panel has to be changed as a complete unit. *) Values inaccurate, since lowering speed is so large, that
ampere-meter reading is difficult to read off.

M. Checking control valve and its soleĆ Resistance of solenoids . . . . . . . . . . ~1,6 W

noid valves
Checking the control valve:
If the lifting or lowering speeds do not function correctly, it is
necessary to clear up whether the fault lies in the electric
If the measured values agree with the correct values above,
system or in the control valve (valve spools can get trapped
but malfunctions occur in the lowering and lifting functions,
etc.).
the control valve should be removed and checked (see
page 912/2).
Checking electric system:

Note! Diagnostic lights and fault codes, see instr. C.

N. Adjusting position sensor

Note! When checking ACB power lift, there must be load in Normally the position sensor does not require any adjustĆ
the three-point linkage. ment. If the sensor has been removed, adjustment is
necessary.

1. Apply sealing compound to the sensor threads. Screw

the sensor locking nut to a point where the distance
between the nut front side and the end of the thread is
about 14 mm (rough adjustment)). Screw the sensor into
place until the lock nut touches the PTO housing.

Warning! If the sensor is screwed too deep, the eccentric

on the lifting arm shaft damages the sensor when the shaft
rotates.

2. Start the engine. Raise the lower links to the max. transĆ
port position. By turning the sensor, find a point, where the
Y1E pump relief valve is blowing off *) and screw the sensor
from that point inwards 1/4 of a turn.
A
3. Lower the lower links.

4. Raise the lower links again to the transport position and

Y2E ensure that the relief valve is not blowing off.

Connect an ampere-meter in series with control valve soleĆ 5. Raise the lower links to the max. upper position by using
noids. Y1E lowering (inner) and Y2E lifting (outer). Use ETV the yellow push button. In this position the relief valve is
894 220 when measuring these values. blowing off and the lifting cylinder stroke from the max.
transport height is 3-4 mm.

Lifting (with yellow push button) . . . . . . . . . ~1,60 A 6. After adjustment, tighten the sensor locking nut.
(maximum current when the Autocontrol-rocker switch is
turned into the transport height). *) When the pump is on, the load on the engine can be
heard easily.
Lowering (with yellow push button):
- ACD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~1,50 A
- ACB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~1,40 A

217
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 Model Code Page
95-115
33. Agrodata-instrument X100-X120 331 1
1. 11. 2000

Agrodata-instrument
Note! Agrodata-instrument (=AD-instrument) is a facĆ
tory-mounted option in 95-115. Standard equipment in HiĆ
Tech tractors X100-X120.

Agrodata-instrument has two digital number displays, which

The different functions of the upper display can be changed
is fitted in place of the standard instrument.
by pressing the rear edge (spring returned) of the switch C on
the LH side of the position control potentiometer. The black
Agrodata has a rev. counter, a temperature gauge and a fuel
arrow indicates which function is selected.
gauge as the standard instrument.
Tractors, which have Agrodata, have two rotation speed senĆ
In addition, the lower digital display B shows:
sors. One on the RH side of the reverse shuttle housing (driĆ
1. Running hours, when the tractor is stationary (also when
ving speed, distance travelled) and another at the rear of the
the current is switched of).
tractor for measuring the PTO shaft rotation speed. The senĆ
2. Driving speed, when the tractor is moving (from 0,3 km/h.
sors are the same as on AC IV system or in HiTech tractors.
There is letter L in front of the value, when the driving speed
is slower than 7 km/h).

The upper digital display A shows:

1. Time (allways when ignition is switched off)
2. PTO shaft rotation speed (r/min)
3. Position of lower links (0-99)
4. Distance travelled (up to1000 km, after which is zeroed)
5. Gearbox temperature (from +40°C. LO is shown at lower
temperatures).

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Agrodata-instrument, sensors and wiring

220
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1. 11. 2000 X100-X120

Agrodata-instrument, sensors and wiring Zeroing the travelling distance

(See picture on previous page) - select travelling distance into the display by pressing the
switch rear edge.
1. Agrodata-instrument P5 (upper display) - press the switch front edge until the display is zeroed.
1. Agrodata-instrument P4 (lower display)
2. Clearance 1/4 of a turn
B3: Gearbox temperature sensor Time setting
B6: Gearbox speed sensor - select time into the display by pressing the switch rear
B7: PTO shaft speed sensor edge.
S37: Selector switch for Agrodata upper display - press the switch front edge, until the hours are flashing.
G2: Alternator (engine speed and running hours) - set the hours by pressing the switch rear edge
- press the switch front edge, until the minutes are flashing.
Position of connectors: - set the minutes by pressing the switch rear edge
X2: In fuse box (not illustrated) - when the time has been set, press the front edge, until the
X3: In fuse box (not illustrated) correct time appears into the display (flashing stops).
X13: on fastening plate in lever console (J05133-)
X19: Plug on the cab front wall on the RH side Calibrating the instrument for different tyres, see page
X25: Connector for Agrodata under the instrument panel 331/5.
(-J05132)
X26: Connector on the rear side of the instrument (white)
X27: Connector on the rear side of the instrument (blue)
X34: Sensor connector in the rear part of the lever console
(-J05132)
X1E: ACD power lift sensors (e.g. radar) on fastening plate in
lever console (J05133-).
GR1: Earth point in the lever console rear part
GR5: Earth point on the cab front wall.
GR8: Earth point on the starter motor

Wiring diagrams, see page 331/4.

Current from the ignition switch (12 V) comes to the AgroĆ

data-unit as on the standard instrument via fuse F18. AgroĆ
data-unit is supplied with permanent current (12 V) for the
clock via fuse F2. If the unit does not work at all, check the
fuses. The supply voltage wire to the clock is via plug X19/18
and via connector X2/5. The voltage can be measured betĆ
ween pins 23 (earth) and 24 (supply) of connector X26. VolĆ
tage via ignition switch can be measured on pin 26 of connecĆ
tor X27.

If the Agrodata-unit has an internal fault (e.g. in electronics),

it cannot be repaired separately, but the damaged instrument
section must be replaced as a complete unit.
The rev counter and fuel and temperaure gauges can be
replaced separately and also the smaller circuit card (or bigĆ
ger basis circuit card) which includes the digital displays. WarĆ
ning light bulbs and instrument light bulbs can be changed
separately without opening the instrument unit.

Switch S37 earths pin X26/12, when the rear edge is depresĆ
sed. When depressing the front edge, pin X26/13 gets eartĆ
hed.

221
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1. 11. 2000 X100-X120

Wiring diagrams of AD-instrument

Wiring diagram, AD-instrument, AC 2.2 Wiring diagram, AD-instrument, AC 5.2

Wiring diagram, AD-instrument, AC 2.3

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 Model Code Page
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331 5
1. 11. 2000 X100-X120

1. Sensors
B. PTO speed sensor B7
A. Gearbox speed sensor B6
Note! The sensor resistance should be 1,0-1,10 kW. The
resistance can be measured on the pins shown below. If the
resistance is infinite, it should be measured on the sensor pins
in order to clear up possible breaks:
B7
Pins:
Sensor pins
X34: pins 1 and 2 (-J05132) Engage the PTO and measure the PTO shaft rotation speed
X25: pins 1 and 2 (-J05132) with a separate RPM meter and compare the reading with the
X26: pins 9 and 10 (white connector) display on the Agrodata-unit. Rudely said the diplay can be
X13: pins 6 and 15 (J05133-) checked so that you adjust the engine speed until the rev.
X1E: pins 1 and 2 (if in use) counter indicator is at 540 mark, at which time the display shoĆ
uld show the same value (±100 rpm).

If there is no PTO speed display or it is incorrect, check the

sensor and its wiring (ensure that the emergency plug is
placed in the rear socket):

Note! The sensor resistance should be 1,0-1,10 kW. The

resistance can be measured on the pins shown below. If the
resistance is infinite, it should be measured on the sensor pins
B6 in order to clear up possible breaks in the loom:

Pins:
Sensor pins
Changing the sensor:
X34: pins 5 and 6 (-J05132)
X25: pins 5 and 6 (-J05132)
Note! Before the gearbox speed sensor can be removed, the
X26: pins 21 and 22 (white connector)
tractor frame must be split between gearbox-fuel tank.
X13: pins 19 and 27 (J05133-)
X1E: pins 5 and 6 (if in use)
- Remove the faulty sensor and clean the threads where the
sensor fits.
- Apply Loctite 572 onto the sensor threads and turn it Changing the sensor:
against the gear wheel and then unscrew it 1/4 of a turn. - Remove the faulty sensor and clean the threads where the
- Lock the sensor with the nut and connect wires sensor fits.
- Carry out a test drive and ensure that Agrodata-unit funcĆ - Find with a dial gauge the shortest distance between the
tions. sensor and the impulse disc through the sensor hole.
- Fit the plastic tube onto the sensor wire. Connect the wires - Apply Loctite 572 onto the threads and screw the sensor
to the sensor and protect with grease UC1913 (vaseline by hand until the sensor touches the impulse disc (do not
spray HHS 2000 (Wyrth)). Move the tube onto the sensor screw too hard because the disc can spring). Unscrew the
and warm it until sensor then 1/4 of a turn.
it is pressed tightly round the sensor. - Lock the sensor with a locking nut and connect wires
- Ensure that the display shows the PTO speed.
- Fit a plastic tube onto the sensor leads. Connect the wires
to the sensor and protect with grease UC1913 (vaseline
spray HHS 2000 (Wyrth)). Move the tube onto the sensor
and warm it until it is pressed tightly round the sensor.

- Fold the wire on the sensor and fasten it with a plastic

cable tie.

N.B.: In 50 km/h transmission the sensor locking nut must - Fold the wire on the sensor and fasten it with a plastic
be removed and the sensor is locked with Loctite 572. This cable tie.
must be done since in this transmission, the measuring
gear wheel is smaller and the sensor thread length is
insufficient to fit the lock nut.

Note! If the driving speed display or travelling distance is

clearly faulty, the fault can lie also in the wrong calibration
of the instrument, see page 331/5.

223
 Modell Code Page
33. Agrodata-instrument 95-115 331 6
1. 11. 2000 X100-X120

C. Gearbox temperature sensor B3 2. Calibrating the instrument for difĆ

ferent tyres
1. Remove the switch C by prying it carefully. Do not disconĆ
nect the wires.

2. Switch on current with the ignition switch.

Note! The gearbox oil temperature must be higher than

+40°C, before the display shows the temperature. At the 3. Connect the switch pins 1 and 7 with an auxiliary wire and
lower temperatures the display shows LO. press at the same time the switch front edge for over 3
seconds. "P" appears in the lower display and the valid code
If the Agrodata-unit does not show the gearbox temperature, number (e.g. P243). The first digit is flashing. Remove the
check the sensor and its wiring. wire.

Pins:
Sensor pin
X34 pin 9 (in the rear part of the lever console) (-J05132)
X25 pin 9 (under the instrument panel) (-J05132)
X26 pin 26 (white connector behind the Agrodata-instr.)
X13 pin 20 (on fastening plate in lever console) (J05133-)

If you doubt that the sensor wiring is faulty, switch on the igniĆ
tion. Select the gearbox temperaure into the Agrodata display
(follow the black arrow).
Detach the wire from the sensor (under the servo valve block)
and connect it to the tractor frame. When the wire is earthed,
some temperature values must flash in the display and three
lines must be visible in the display, if the display and the wiring
is OK.
4. Adjust the hundreds by pressing the switch rear edge.
Some sensor resistances:
- 75-90 W (~+90° C) 5. When the hundreds are correctly adjusted, press the switch
- 200-250 W (~+60° C) front edge and tens start to flash.
(resistance value increases when temperature lowers).
6. Adjust the tens by pressing the rear edge and then press
the front edge, at which time single units start to flash.

7. Adjust the ones by pressing the rear edge.

8. Finally press the front edge for over 2 seconds. Calibrating

has been carried out and running hours appear in the lower
Note! There is an other temperature sensor on the front face
display (read the note below). Fit the switch.
of the servo valve block, which lights up the warning light, if
the gearbox oil temperature rises too much. Also the Stop-
Note! In the beginning of the production (the first 20 tractors),
light starts to flash.
the switch pins 1 and 7 must be once again connected with
auxiliary wire and after that the switch front edge is pressed
over 2 seconds.

Note! The code number value can vary between

P100-P299. When pressing the switch rear edge, the code
value changes from a smaller value to greater one. The code
numbers and corresponding tyres are listed in the table on the
next page.

224
 Model Code Page
33. Agrodata-instrument 95-115
X100-X120 331 7
1. 11. 2000

Code numbers with different tyre sizes and transmission types

Rear wheel 40 km/h Rear wheel 40 km/h

13.6-38/8N 216 16.9R-38/8M 201
13.6R-38/8M 216 16.9R-34/8M 214
14.9R-38/8M 209 540/65R-38/M 202
14.9R-38/8N 209 18.4R-34/8M 207
16.9-34/8N 214 600/65R-38/M 192
16.9R-34/8M 214 600/65R-34/M 208
16.9R-34/8N 214 16.9R-38/8N 201
16.9R-38/8M 201 16.9R-38/8GY 201
16.9R-38/8N 201 18.4R-38/8GY 195
18.4-34/8N 207 18.4R-38/14M 195
18.4-34/8N 207 18.4-38/14FOR 195
18.4R-34/8N 207 20.8R-38/M 187
18.4R-34/8M 207 18.4-38/14IND 195
16.9R-38/8M 201 18.4R-38/M 195
18.4-34/14FOR 207 18.4-34/14FOR 207
18.4R-38/8M 195 18.4-34/IND 207
620/75R-30/M 199 18.4-38/FI 195
620/75R-30/M 199 20.8R-38/8M 187
16.9-34/14IND 214 20.8R-38/8M 187
18.4-34/14IND 207 650/65R38M 184
18.4-34/14FOR 207 520/70R-34 203
18.4R-34/8M 207 540/65R-38/M 202
18.4R-34/8GY 207 480/70R-38 198
13.6R-38/8M 216 520/70R-38 191
14.9R-38/8M 209 520/70R-38 191

225
 Model Code Page
33. Agrodata-instrument 95-115
X100-X120 331 8
1. 11. 2000

Note! If a tractor has tyres which are not listed on the previous
page, the code number can passably be calculated as folĆ
lows:
YxV
X= in which
vmax

X= correct code number

Y=actual code number in AD-instrument
V= tractor's constructional speed (30, 40 or 50 km/h)
Vmax=tractor's max driving speed which is shown by AD-instrument

Example:

In AD-instrument there is an actual code number 170

Tractor's constructional speed is 40 km/h
AD-instrument shows the tractor max. driving speed of 38
km/h

170 x 40
X= = 179
38

226
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 1
1. 11. 2000

Contents
Code 370:

1. AC 5, description
A. AC 5 control buttons and levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. Fault tracing
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Self diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Working orders for fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Using test mode to carry out trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. Checking I.D. numbers of various AC 5 programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F. Funktional differences of program versions, comparison, AC 5 only . . . . . . . . . . . . . . . . . . . . 9B

3. Settings and checking of control circuits

A. Activating setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. Calibrating gas pedal position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
C. Calibrating clutch pedal position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
D. Checking reverse shuttle pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
E. Checking DPS quick-shift gear pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
G. Setting prefilling times of shuttle clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
H. Resetting driving speed parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
I. Choosing temperature unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
J. Choosing driving speed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
K. Setting PTO parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19A

4. AC 5 components
A. Control unit A1 and display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
B. Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
C. Proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
D. Rotation speed sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
E. Temperature sensors, AC 5 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F. Clutch pedal position sensor, AC 5 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
G. Gas pedal position sensor, AC 5 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
H. Detection of driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5. Working orders
A. Fitting control unit A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24A
B. Programming control unit A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24B
C. Setting indexes for DPS and shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24D
D. Test-run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24E

6. Others
A. Electric connections of control unit A1, AC 5 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
B. Wiring diagrams, AC 5 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
C. Control diagrams, AC 5 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Code 371:
Note! Under code 371 are shown AC 5.2 system's properties, which differ from AC 5 and which cannot be shown under code
370 due to lack of space. Under code 370 are given necessary references to code 371.

227
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 2
1. 11. 2000

1. AC 5 and 5.2, description

Autocontrol 5 (-K41106) or 5.2 (K41107-) includes:
- Electric engagement control of HiTech shuttle
- Engagement control of DPS and PTO with electro-proportional valves
- Automatic speed change of DPS. AC 5.2: Additionally AutoTraction and Speed Matching functions of DPS.
- Autocontrol 5/5.2 display unit
- AC 5/5.2 control unit (in the lever console) and required sensors and wires.
- Fault diagnostic functions and setting procedures.

Autocontrol 5/5.2 can be fitted on X100-X120 HiTech tractors. In these tractors the separate circuit card A10 for the DPS is
removed (see Autocontrol 2.1 and 2.2).

Autocontrol 5/5.2 system includes a display unit which shows functions of transmission, helps with manual gear change and
shows a fault code if the system has malfunctions. The display is also used, when testings and settings are carried out.

A. AC 5 / 5.2 control buttons and levers

TwinTrac
(option)

3
4 4
1 3

2 5a
6
1

2
1. Reverse shuttle lever/hand brake lever on the LH side of the steering wheel (or alternatively on the RH side). The parking
brake must always be engaged, when the tractor is parked.
2. The button for pre-programming the DPS speed when the tractor driving direction is changed (this button is also used
when testing AC 5 or when carrying out settings).
3. Push buttons for the manual control of DPS (as earlier) (these buttons are also used in the test mode and setting mode).
4. Push buttons for disengaging the reverse shuttle (function as in HiShift, but the clutch pedal is not depressed). The tractor
has also the clutch pedal for the electrical disengagement of the HiTech shuttle and for normal driving with the pedal.
5. Three-position rocker switch for selecting manual or automatical speed change of the DPS (man/auto1/auto2) (as on
AC III).
5a. Switch for AutoTraction function, AC 5.2 only.
6. AC 5/5.2 display unit, see page 4.
228
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 3
1. 11. 2000

S20
S10

Picture 1. Autocontrol 5 / 5.2 components 20. Limit switch

1. Reverse shuttle lever/parking brake lever IMPORTANT! In the reverse drive controls (TwinTrac) there
2. Push buttons in the gear lever knobs for disengaging the is a shuttle/parking brake lever, clutch and gas pedal (and
Shuttle electrically (like HiShift. When the buttons are steering wheel). In AC 5.2 the rear switches have own digiĆ
pressed, the clutch pedal does not move down) tal inputs in the control unit and also clutch pedal sensor
3. Servo valve block of the low pressure circuit. On the inputs (the rear gas pedal has been connected to the front
block there are gearbox oil temperature sensor, pressure pedal with a cable).
accumulator, electro-proportional valve for the PTO, soleĆ
noid valves for the hand brake, 4WD and the diff. lock. The Note! On AC 5 / 5.2 there is a position sensor (8) on the
block is presented on pages 420/20C and on page 440/24. fuel injection pump throttle lever and an engine speed senĆ
4. Valve block on which there are electro-proportional sor (12) on the gearbox, at which time the automatic speed
valves for the forward drive (F), reverse drive (R) and for the change according to the engine loading is possible. The
DPS rearmost clutch C3. The valve block is presented on clutch pedal has a position sensor (7) and a limit switch
page 440/25. (20) to disengage the multi-disc clutches in the shuttle.
5. Valve block on which there are electro-proportional
valves for foremost (C1) and middle (C2) clutches of the There are two speed sensors (10), which indicate the rotaĆ
DPS, see also page 440/25. tion speed and direction of the shuttle output shaft. The
6. Display unit shuttle rotation speed is compared with the engine rpm so
7. Position sensor on the clutch pedal that the AC 5/5.2 can change the driving direction safety
8. Position sensor on the fuel injection pump and progressively. The AC 5 / 5.2 prevents the direction
9. Auto1/Auto2/Man-switch for the DPS change, if the driving speed is over 10 km/h. The gearbox
9a. Switch for AutoTraction function (AC 5.2 only) speed sensor (11) indicates the tractor driving speed.
10. Two rpm sensors on the Shuttle When the driving direction change is happening, the AC
11. Gearbox speed sensor (driving speed) 5/5.2 pressurises the shuttle clutches progressively.
12. Engine speed sensor
13. Push button for the manual control of the DPS (as AC On the servo valve block (3) there is a temperature sensor,
2.1) which steers the shuttle automatics so that the shuttle funcĆ
14. Pressure accumulator tions progressively regardless of the transmission oil temĆ
15. Outdoor temperature sensor perature.
16. Hydraulic ram of the parking brake
17. Control unit of AC 5 / 5.2. There is an outdoor temperature sensor (15) in the front
18. PTO shaft speed sensor part of the tractor. The display unit (6) is shown on the next
19. Drive disc on the flywheel (see page 410/4A) page.

229
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 4
1. 11. 2000

One arrow is blinking, if a driver does Tractor image is visible

B. AC 5 / 5.2 display unit not sit on the seat and driving always, when the current is
direction (F or R) has been selected. switched on
Arrow is visible
when driving forĆ
wards Arrow is visible when
driving rearwards.
DRIVING MODE:
Pre-selected 1) DPS speed in
forward driving (I, II or III). If Pre-selected 1) DPS speed in reverse
not pre-selected speeds, this drive (I, II or III). If not pre-programĆ
I med speeds, this symbol is invisible.
symbol is invisible. Shows also
main modes.
SERVICE MODE: N is visible when the shuttle
- FI fault code memory (AC lever is in the neutral posiĆ
5.2 only) tion or in P-position. Is blinĆ
- FII test mode king, when automatic traction
- FIII setting mode disengagement is on (AC
5.2).

DPS logo Field driving automatics 2)

General automatics (AC 5.2)
II
Engaged DPS speed (1, 2 or
3). Shows also a selected moĆ Road driving automatics 2)
dule in test mode. Flashes, Adjustable automatics (AC 5.2)
when automatics make speed
change 3). Arrow upwards is blinking, if
the automatics ask driver to
change up 4).
Arrow downwards is blinking, if the
automatics ask driver to change
down 4). km/h Driving speed, when
the tractor is in motion
III
Outdoor temperature
gauge symbol is visiĆ
ble always, when the
tractor is stationary and
Visible, when PTO the current is switched
shaft is rotating. Can on
be visible, altought
the PTO is disengaĆ Outdoor temperature when the tractor is Service book is visible,
ged. stationary. Driving speed when the tracĆ when the system has found
malfunctions and shows a
tor is in motion (accuracy one decimal  fault code. See fault codes
15 km/h. No decimal at greater speeds). on page 370/6 (AC 5) or
Numbers show also fault codes. In the 371/5 and 6 (AC 5.2)
test mode is shown a point, which is
tested or reset.

I = Shuttle, II = DPS, III = Diagnosis

1) Pre-selection means the DPS speed, which is automatically switched on when the driving direction is changed and which is
pre-programmed with the button beside the shuttle lever. The pre-programming is carried out so that when one of the driĆ
ving directions is engaged, driver engages the desired DPS speed and then presses the button at least 2 seconds. During the
pre-programming the clutch pedal must be depressed. Thus the selected DPS speed remains in the memory of AC 5 and
engages always when the driving direction in question is selected. If only one direction is pre-programmed, the pre-progĆ
ramming is valid only for this direction. The DPS speed remains the same in the other direction.
The pre-programmin is cancelled by pushing the button at least 2 seconds, when the shuttle is in the neutral.
2) The two DPS automatic modes (Auto1 and Auto2) are selected with the three-position rocker switch on the lever console. The
function is the same as on AC III. The switch has also a manual position.
3) If a driver changes quickly from DPS speed 1 to 3, the speed 3 flashes immediately in the display (although the automatics
changes the speeds also via speed 2) and speed 3 stops to flash just when the gear change is completed.
4) When the DPS is in the automatic mode (AUTO 1 or AUTO 2), it changes automatically down or up and informs with the flasĆ
hing arrow, if the automatics cannot do more and a driver must change up or down manually.

Note! The display has a background light when the current is switched on. Tractor image, DPS-logo and outdoor temperature
(stationary) or driving speed (in motion) are visible always when the current is switched on. There is a connector (RS-232) in the
lever console for connecting e.g. a micro-computer for re-programming the control unit A1.

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 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 5
1. 11. 2000

2. Fault tracing
A. General
AC 5 / 5.2 unit has an in-built function for self-diagnosis. If fault/faults appear in the AC 5 when working with a tractor, the
fault code of the fault in question is shown in the diplay. In this instruction is shown a table in which there are listed all fault
codes and corresponding faults. In this way can be localised the fault and possible repair works can be carried out.
In addition, AC 5 / 5.2 unit has an additional diagnostic mode. By pressing certain tractor switches and buttons in a correct
order (instructions later), the display can be activated into the test mode, in which the diplay shows technical values of variĆ
ous electrical components when components in question are activated. Later in this instruction are shown tables which show
the correct technical values of the components. These values are compared with the actual signals in the display so that
possible incorrect functions can be verified.
In the same way the diplay unit can be activated into the setting mode, in which can be done various settings of the AC 5
components. The setting instructions are shown later in this instruction. In section 4 (components) are given instructions to
measure with a multimeter. With the aid of these instructions the components can be checked and verified a faulty compoĆ
nent.

NOTE! On page 370/7 there are shown working orders för the fault tracing.

B. Self-diagnosis
The self-diagnosis of AC 5 / 5.2 follow up possible faults in the system (when the current is switched on) and show a fault
code, which appears in the lower display block (also a book image is blinking, when the fault code is shown).

FAULT GROUPS: FAULT TYPES:

A: analog input (position and temp. sensors) 1=short circuit or cut
P: proportional output (proportional valves) 2=cut
d: digital input (switches) 3=value not in permissible limits
F: frequency input (rpm sensors) 4=multi-disc clutch is slipping
L: logical fault (slipping clutch)

All fauts are numbered with running numbers (01-99). In addition, fault type is shown with numbers (1-4).

FAULT CODES
The fault code is shown in the display diagnosis block (lower) in four display segments as follows:
- The first segment from the left shows the fault group (A, P, d, F or L).
- The second segment from the left shows the fault type (1-4)
- The two RH side segments show the order number of the fault (01-99).

Note! When the fault code is shown, the symbol of the faulty module is shown in the middle block (A=AC 5 / 5.2)

When the self-diagnosis shows the fault code, the book image is flashing in frequency of 2 Hz. If two or more faults are
found simultaneously, the codes of different faults are shown three seconds by turns. When the current is switched off, the
fault code memory is erased. If a fault code has been found, the driving speed or outdoor temperature cannot be seen in the
lower display block.

Module A=AC 5

Book symbol is shown together

with fault code.

FAULT TYPE: 1=short circuit or cut

FAULT GROUP:
P=proportional output
FAULT CODE:
01= Proportional valve P1 of DPS

IMPORTANT! Escaping from the fault code mode is done by switching off current with the starter switch.

AC 5.2 has a fault code memory, in which there are stored 3 latest fault codes with running hours, see page 371/6.

231
 Model Code Page
37. Autocontrol 5 X100-X120 370 6
1. 11. 2000
Fault codes in AC 5. Note! Fault codes in AC 5.2, see pages 371/5 and 6.
Fault Pins Fault identification Fault Tests Repairs,
code funkĆ settings
tion leĆ
vel
P101 A1A2/12 Proportional valve P1 of DPS takes current which exceeds or goes 3
below the given limits. Short circuit or wire damage (C1).
P103 A1A2/10 Proportional valve P2 of DPS takes current which exceeds or goes 3
below the given limits. Short circuit or wire damage (C2).
See table See instr.
P105 A1A2/8 Proportional valve P3 of DPS takes current which exceeds or goes 3 d) on paĆ C on page
below the given limits. Short circuit or wire damage (C3). ge 370/13 370/21.
g
P107 A1A2/6 Forward drive proportional valve P4 takes current which exceeds or 3
goes below the given limits. Short circuit or wire damage (F).
P109 A1A2/4 Reverse drive proportional valve P5 takes current which exceeds or 3
goes below the given limits. Short circuit or wire damage (R).
A311 A1A3/2 Gearbox oil temperature value (sensor B14) impossible (over 3 See table See instr.
+150°C). Faulty sensor or its wiring b) on paĆ E on page
g
ge 370/11 370/23
370/23.
A312 A1A3/2 Gearbox oil temperature value (sensor B14) impossible (below 3
-50°C). Faulty sensor or its wiring
A313 A1A3/4 Signal from gas pedal position sensor B15 below 1 V (DC) or over 7 V (DC). SenĆ 3 See table See instr.
sor wrongly fitted or sensor/wires damaged. If fault code A313 is visible together b) on paĆ G on page
with fault code A314, there can be a short circuit or earth leak in sensors B15 or B16 ge 370/11 370/24.
(same supply voltage).
A314 A1A3/7 Signal from clutch pedal position sensor B16 below 1 V (DC) or over 3 See table See instr.
7 V (DC). Sensor wrongly fitted or sensor/wires damaged. b) on paĆ F on page
ge 370/11 370/23.
A315 A1A3/7 When the clutch pedal is down (digital input d06 is active), the signal from the clutch 3 See table See instr.
A1A4/4 pedal position sensor B16 is 0,5 V (DC) greater or smaller than it was in the calibraĆ b) on paĆ F on page
ting point (voltage value must be beyond allowable limit over one second). Check ge 370/11 370/23.
the adjustment of the pedal limit switch S9 with the aid of the test mode, adjust if
necessary. Measure and calibrate the position sensor B16. If the fault code appeĆ
ars in connection with the engine start, ensure the correct starting: depress first the
clutch pedal and after that start the engine.
d116 A1A3/9, DPS up-down push buttons (S23) are active simultaneously. Push 1
10 buttons in the lever knobs may be in short circuit.
See table See instr.
instr
d117 A1A4/7, Forward (S40) and reverse drive direction (S41) are active simultaneously. Shuttle 4
a) on paĆ B on page
8 lever switches may be in short circuit.
ge 370/10 370/20.
d118 A1A4/10, Both PTO speeds are engaged simultaneously. PTO lever switches (S28/S29) may 2
11 be in short circuit.
d123 A1A4/14, Hand brake and one or both shuttle directions engaged simultaneoĆ 4 See table See instr.
7, 8 usly. Shuttle lever switches may be in short circuit. a) on paĆ B on page
ge 370/10. 370/20.
d225 A1A3/7 Clutch pedal position is below 2 % (0...1 %) and d06 is not active (d06=clutch pedal 3 See table See instr.
A1A4/4 limit switch). Check the adjustment of the clutch pedal limit switch S9. Check the b) on paĆ F on page
function of the parking brake pilot light H11 (program versions 42-). ge 370/11 370/23.
F320 A1A1/5, Shuttle speed sensors (B12/B13) give different frequency. Difference 3
7 over 30 %. One of the sensor possible faulty. See table See instr D
c) on page on page
F321 A1A1/13 Engine rpm lower than what the shuttle sensors (B12/B13) indicate, when one soleĆ 3
370/12. 370/22.
noid is fully active. Engine rpm sensor B11 may be faulty.
F324 A1A1/5, Driving speed over 10 km/h and direction information in the control 3 See table See instr D
7 unit is changing. Shuttle sensors B12 or B13 may be faulti or wire c) on page on page
problems. 370/12. 370/22
L419 A1A1/3 Full pressure has been connected to the PTO clutch over 3 seconds, but the PTO 2 See table See instr D
shaft rotation speed is lower than it should be. PTO-clutch may slip. It is possible c) on paĆ on page
that the PTO rpm sensor B7 is faulty. Check in the test mode PTO lever switches ge 370/12 370/22 and
S28 and S29 (check in the test mode that not connected the wrong way round). pages
Check that there is a correct parameter file in the control unit. Ensure that the PTO 370/19 and
speed parameters P and L are correctly set (in program version 42-). 370/24B.
L422 A1A1/13, One shuttle direction is engaged and full control has been active over 3 seconds. 4
8, 6 Shuttle rotation speed is lower than engine speed in relation to the DPS ratio. One
multi-disc clutch in the DPS or in the Shuttle can slip or one proportional valve
(Y4,Y6,Y17,Y11,Y12) can be trapped. This fault code also appears, if both shuttle
sensors (B12,B13) do not give a signal, when engine revs are over 1600 rpm (1700
rpm in versions 50, 52. 60, 62). Check fuse F22.

232
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 7
1. 11. 2000

C. Working orders, AC 5 and 5.2

- If the display unit shows a fault code:
Measures:
1. Decode the fault code according to instr. 2B (self-diagnosis)
2. Check the function of the component in the test modet (instr. 2D).
3. Repair the fault.
4. If the control unit A1 or programs have been changed, make necessary settings according to instr. 5A.
5. Carry out all points in the test mode (instr. 2D). This ensures, that the tractor is OK before delivery.
6. Test-run the tractor according to instr. 5D.

- If the display does not show the fault code:

In the table below, there are faults which have not the fault codes:
Component: Possible reason: Measures:
1. AC 5 display unit does not - control unit A1 supply voltage or earth - check fuse F24
function (on the LH side pillar) has malfunctions or the display supply. - voltage measures from control unit A1
- display unit P6 faulty connectors A1A1/1 ć A1A1/2 (=battery volĆ
- control unit connector A1A1 loose tage)
- new display unit, if the system does not
function
- check connections
2. In the dashboard there is lit - shuttle lever switch S15 (P) faulty or - testing in the test mode, point d16 / d22
P" , although the driving directiĆ wrongly fitted. - 1)
on has been selected - check the fitting of switch S15 (page
370-20)
3. Black arrow is blinking, althoĆ - driver has left the seat over 4 (6) seĆ - on the seat, shuttle lever to position P,
ugh the driving direction has conds. AC 5.2: over 30 sec., when the shuttle lever to the driving position
been selected clutch pedal is depressed. - testing in the test mode, point d05, 2)
- detector switch S60 (in the seat) does
not function or wire damage
4. Black arrow does not change, - shuttle lever switch S40 (F) or S41 (R) - testing in the test mode, points
when using the shuttle lever faulty d09, d10 / d18, d19
5. Shuttle, DPS or PTO have - fault, that the control unit A1 has not - carry out all procedures in the test mode
malfunctons (e.g. function is identified (instr. 2C)
slow) - pressure in the low pressure circuit too - low hydraulics pressure measuring, see
low instr no. 911-1
- clutch pre-fillling or initial pressure - check indexes / in the setting mode ,
indexes are wrongly set (instr. 5 C)
6. Engine does not start (starter - no supply to control unit A1. - check fuse F24
motor does not rotate) - Parking brake switch S15 or input sigĆ - testing in test mode, point d16/d22 (if
Tractors J38343-. nal A1A4/14 (AC 5) or A1A8/8 (AC 5.2) necessary, change switch or control unit)
faulty - Check whether the voltage from control
- Control unit output signal A1A2/3 (AC unit A1 is in relay K28 (when necessary,
5) (to relay K28) or A1A3/5 (AC 5.2) faulĆ change the control unit).
ty.
Note! If the fault cannot be found, try to find it by carrying out all tests in the test mode FII.
1) The parking brake can be released with a tool which incl. in the tractor tool set (after this the tractor can be towed).
2) If detector switch S60 does not function, it can temporarily be by-passed by connecting switch wires with an auxiliary wire (connector beside the seat
holder). The switch must be changed and the auxiliary wire removed as soon as possible (safety).

immediately and a driver can activate it after the current is

switched off and on. The tractor can still be driven.
Fault function levels, AC 5 and 5.2
Fault function level 3 ("home driving")
In the fault function leves the different faults cause different
protective functions to the tractor. For instance in the funcĆ The fault code in question in the display. Shuttle automatics
tion level 2 the tractor driving is possible but the use of the are not in function. Driving direction can be engaged only with
PTO is prohibited. In the fault function level 4 the tractor clutch pedal depressed.
driving is prevented until the fault has been repaired. The control unit reads shuttle parameters from the table for
greatest temperatures. Control unit connects all faulty soleĆ
The number of the fault function levels is 4 pcs. Greater noid outputs unenergised. DPS is locked. Before driving the
digit means a great priority and vice versa. The fault funcĆ tractor, the control unit clears up which one of the DPS speeds
tion level is active, until the current is switched off. If two can be engaged so that the faulty solenoid output is unenerĆ
faults with the priority of 3 have been found simultaneously, gised. If the speed in question is not the speed which is now
the fault function level is always 4 (for instance if two DPS engaged, the speed is changed automatically.
proportional valves are in short circuit simultaneously).
Fault function level 4 ("immediate downdrive")
Fault function level 1 ("fault code")
Only a fault code in question in the display. With the tractor The control unit connects all proportional valves unenergised.
can be driven, but DPS can have malfunctions. Only a fault code in the display, not other information. The
tractor cannot be driven, before the fault has been repaired.
Fault function level 2 ("PTO protection") This is for protecting slipping clutches and engine overloadĆ
The fault code in the display. The PTO is disengaged ing.
233
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 8
1. 11. 2000

D. Fault tracing in test mode 2. Fault tracing in the test mode F II.

1. Activating test mode, AC 5 and 5.2 It is possible in the test mode to check the electric function of various comĆ
ponents (control unit input and output signals) by comparing actual values
from the different components with the correct values in the tables which
Note! Before activating the test mode, possible pre-proĆ
are shown in this instruction. Diagram below shows the test mode menu of
gramming of the DPS speeds must be removed. The test
AC 5 , in which can be stepped up or down with the DPS push buttons (1):
mode is activated by pushing certain tractor switches in a
correct order according to picture below:
TEST MODE MENU IN AC 5 (AC 5.2, see page 371/7):
H40432- SWITCH ON *) Engine running

Symbol in Test point

display
OR
START F7 Direction information (rpm) *)
F6 PTO speed (rpm) *)
F5 Shuttle output speed (rpm) *)
F4 Shuttle output speed (rpm) *)
F3 Reserve
Number Funktion mode Symbol of mode
F2 Driving speed *)
1 Fault code meĆ F I (AC 5.2 only)
mory F1 Engine speed *)

2 Test mode F II
3 Setting mode F III A4 Clutch pedal position %
A3 Gas pedal position *) %
A2 Gearbox temperature
A1 Outdoor temperature

1 d16 Parking brake

d15 PTO standby button
d14 Seat direction (only TwinTrac)
Program I.D. no.
2 d13 PTO-speed 2 (lever in rear position)
- step with the DPS push buttons (1) up or down and select d12 PTO-speed 1 (lever in front position)
the main mode symbol FII (test mode).
d11 DPS pre-programming button (under
- after this confirm the selection by pushing the DPS pre-
shuttle lever)
programming button (2)
- now symbol A starts to blink (2 Hz) in the middle display d10 Direction R (rearwards)
block. d09 Direction F (forwards)
- select module A (7 pcs modules. Only A is in use) by stepĆ
ping again with the push buttons (1). d08 DPS auto/man
- confirm the selection by pushing the button (2) after which d07 DPS auto1/auto 2
A remains without blinking in the display.
- the display is now in the test mode and the trouble shooting d06 Clutch pedal limit switch
can be done d05 Driver detection (in seat) 1)
Note! When the desired module is confirmed, the parameter d04 PTO start
file identification number and the program version number d03 HiShift buttons
start to blink in the lower block of the display (START LEVEL
of test mode F II). The identification number can be seen in d02 DPS push button, down
the two LH side segments and the version number in the two d01 DPS push button, up
RH side segments.
e.g. 5142 START LEVEL
With aid of the program identifying no. (see picture above) Program version nummer
can be checked, which program versio or which parameter P1 DPS solenoid 1 (clutch C1) *)
file is fitted on the tractor.
P2 DPS solenoid 2 (clutch C2) *)
Note! In the test mode the DPS speed is always DPS1. The P3 DPS solenoid 3 (clutch C3) *)
shuttle and PTO function normally, but the display functions
P4 F clutch solenoidi (forwards) *)
are not shown. The DPS pre-programming cannot be done
in the test mode. Also the DPS automatic functions are not in P5 R clutch solenoid (rearwards) *)
use.
b Counter functions
IMPORTANT! Escaping from the test mode is done by switĆ 1) See the next page.
ching off the current. Note! From ser. no. J38343 incl. there are 12 pcs counter
symbols in the test mode menu below symbol P5, see paĆ
ge 370/13A.
234
 Model Code Page
37. Autocontrol 5 X100-X120 370 9
1. 11. 2000

1) If detector switch S60 does not function, it can temporariĆ

ly be by-passed by connecting switch wires with an auxiĆ E.g. I.D nummer 5142:
liary wire (connector beside the seat holder). The switch 51 =parameter file I.D. number, 42 =main program version
must be changed and the auxiliary wire removed as soon number.
as possible (safety).

Example: Main program version numbers:

Version Fitted in production, ser. nos.
If e.g. one step up is stepped from the start level by using 38 –H40431 (pre–series)
the push buttons (1) , in the three LH side segments of the 40 H40432– pre–series, (in series H49112–)
lower display symbol d01 starts to blink with frequency of 41 J01401– (about)
two hertz. This symbol indicates which digital input is being
43 J38343–
tested (d01=DPS push button up, see table a on the next
42 J39116–
page).
42 or 60 J45136– *
When the button in question has been selected, it can be *
confirmed for testing by pushing the DPS pre-programĆ 60 J47542–
ming button (2), at which time the symbol stops blinking. In 62 K02116– (used also in service and in spare parts
the RH side segment can be seen the mode of the switch from J38343 incl.
(0 or 1) depending whether the button is depressed or not. 50 Used in service and in spare part units (up to
When the button in question has been tested, move to the tractors -J38342)
other point in the menu by pressing the DPS pre-proĆ 52 used in service and spare part units
gramming button (2), after which the symbol starts to blink (up to tractors –J38342)
and the menu can be moved with the DPS push buttons * The tractor has either version 42 or 60, must be
(1). The selection is confirmed again with the pre-proĆ checked in tractor display in the test mode.
gramming button (2) (symbol does not blink) and the
switch in question can be tested.
Parameter file I.D. numbers:
Symbols in instruction I.D.num- PTO speeds
bers
- d01...d16, A1...A4, F1...F7 are symbols for the AC 5
control unit input signals (from switches, position sensors, 10 1000
temperature sensors and rotation speed sensors). 17 1000 / 540E
- P1...P5 are symbols for the AC 5 control unit output sigĆ 51 540 / 1000
nals (control of the proportional valves). 57 540 / 540E
- A1A1...A1A5 are names of the control unit connectors 71 540E / 1000E (8350Hi)
(on the AC 5 control unit).
For example: A1A3/2 means pin no 2 in the control unit
connector A1A3 (gearbox oil temperature) Additionally, in service and in spare parts units the folĆ
lowing I.D. numbers have been used with effect from
- S28, S29..., B6, B7... are symbols of the switches and program versions 42 (43) incl.. In these versions all
sensors in the wiring diagram. PTO types have not an own parameter file but the PTO
ratios must be installed into the control unit (see page
- Y2, Y4... are symbols of the proportional valves in the 370-19A). The I.D. number increases, when the paĆ
wiring diagram. rameter file is further developed.
E.g. with main program versions 52 and 62 is used a
parameter file, which has I.D. numbers 23 and 33.

E. Checking I.D. number of AC5 progĆ I.D. Tractor model

number
rams
21...29 X100–X120
*
Programs of AC5

Note! Programming instruction of AC5 control unit, see

page 370-24B.
In the tractor production the AC5 control unit A1 is
equipped with a program, which consists of a main proĆ
gram and a parameter file.
Since in the control unit A1 have been used many different
main programs and parameter files, these different proĆ
grams and files have I.D. numbers for identifying.
The I.D. number, which can be seen in the AC5-display (in
test mode FII), shows the main program version and paĆ
rameter file I.D. number. The two first digits show the paĆ
rameter file I.D. number and two last digits the main proĆ
gram version number.

235
 Model Code Page
37. Autocontrol 5 X100-X120 370 9A
1. 11. 2000

I.D. numbers of programs used in ProĆ 51 43 2) PTO 540/1000

duction, in Spare Parts and in Service 57 43 2) PTO 540/540E
71 43 2) PTO 540E/1000E (8350Hi)
(AC 5 only):
Main program no. 50:
Note! Sorted according to the main program version.
Numbers used only by Service and Spare Parts:
Beside the I.D. numbers there is information, with which
These can be replaced with program version 52.
can be concluded whether the tractor has a correct progĆ
These must no more be used in Service.
ram.
22 50 1) X100-X120
Tractor chassis numbers in brackets show how old tractor
the program is and which program can be fitted. I.D. numĆ Main program no. 52:
bers can be seen in the tractor display. In the PC monitor Numbers used only by Service and Spare Parts:
the numbers change places, e.g. 5162 -> 6251. Suit up to ser. no. J38342, if the end of the control unit ser.
no. is at least 00400.
IMPORTANT! Only with an asterisk marked programs can
20 52 1) X100-X120
be used in Service and Spare Parts (versions 52 and 62).
23 52 * X100-X120
Note! If an I.D number of a tractor cannot be found in this
Main program no. 60 (J45136-K02115):
list, ask Tractor Service.
These can be replaced with program version 62.
These must no more be used in Service.
Main program no. 38 (these must not be on field):
10 60 PTO 1000
These must be replaced with program version 52.
17 60 PTO 1000/540E
These must not be used in Service.
51 60 PTO 540/1000
10 38 1) PTO 1000
57 60 PTO 540/540E
17 38 1) PTO 1000/540E
71 60 PTO 540E/1000E (8350Hi)
51 38 1) PTO 540/1000
57 38 1) PTO 540/540E
Numbers used only by Service and Spare Parts:
71 38 1) PTO 540E/1000E (8350Hi)
These can be replaced with program version 62.
These must no more be used in Service.
Main program no. 40 (these must not be on field):
22 60 3) X100-X120
These must be replaced with program version 52.
These must no more be used in Service.
Main program no. 62 (J38343- ):
10 40 1) PTO 1000
10 62 PTO 1000
17 40 1) PTO 1000/540E
17 62 PTO 1000/540E
51 40 1) PTO 540/1000
51 62 PTO 540/1000
57 40 1) PTO 540/540E
57 62 PTO 540/540E
71 40 1) PTO 540E/1000E (8350Hi)
71 62 PTO 540E/1000E (8350Hi)
Main program no. 41 (J01401-J38342):
Numbers used only by Service and Spare Parts:
These can be replaced with program version 52.
Fit on tractors from ser no. J38343 incl.
These must no more be used in Service.
20 62 1) X100-X120
10 41 PTO 1000
23 62 * X100-X120
17 41 PTO 1000/540E
51 41 PTO 540/1000 1) A new program must be input into the control unit in
57 41 PTO 540/540E connection with service (main program version 52).
71 41 PTO 540E/1000E (8350Hi) 2) If a tractor has the reverse drive controls, a new progĆ
ram must be input (main program version 62). Affects
Main program no. 42 (J39116-J47541):
function of the clutch pedal and AutoDPS when the
These can be replaced with program version 62.
seat is turned rearwards.
These must no more be used in Service.
3) A new program must be input (main program version
10 42 2) PTO 1000
62).
17 42 2) PTO 1000/540E
51 42 2) PTO 540/1000 Note! If the clutch pedal has malfunctions, a new program
57 42 2) PTO 540/540E must be input (main program version 52 or 62). ProgramĆ
71 42 2) PTO 540E/1000E (8350Hi) ming instructions on page 370-24B.
Note! If the I.D. number is 5152 or 5162 after programming
Numbers used only by Service and Spare Parts:
or after control unit change, the parameter file has not been
Can be fitted between nos. J38343-J47541.
input. Input correct parameter file according to instr. on
These can be replaced with program version 62.
page 370-24B.
These must no more be used in Service.
21 42 2) . . . . . . . . X100-X120

Main program no. 43 (J38343-J39115):

These can be replaced with program version 62.
Thes must no more be used in Service.
10 43 2) PTO 1000
17 43 2) PTO 1000/540E
236
 Model Code Page
37. Autocontrol 5 X100-X120 370 9B
1. 11. 2000

F. Functional differences of program versions, comparison, AC 5 only

HiTech -PROGRAMS
DIFFERENCES BETWEEN MAIN PROGRAM VERSIONS:

VERSION 41 VERSIONS 42, 43, 50, 52, 60, 62

** GENERAL **
Reverse drive controls can be fitted as an option.
PTO start-/stop push buttons can be fitted in rear mudguards
(option).
Parking brake is not connected to AC5 ćcontrol unit. AC5 ćunit controls the parking brake.

** AC5 -PROGRAMS **
Five different parameter files for all PTO types (in proĆ Five different parameter files in tractor production.
duction and in service). Only two different parameter files are needed in service (PTO ratios
can be set with indexes).

** FUNCTIONS **
PTO rocker switch in the cab. PTO rocker switch in cab and push button in rear mudguards (opĆ
tion). Operating instructions, see Operator's Manual.
Seat indicator delay is 4 seconds. Seat indicator delay is 6 seconds.
Parking brake can be applied under speed of 4 km/h . Parking brake can be applied under speed of 2 km/h (4 km/h in verĆ
sions 50 and 52).

VERSION 41 VERSIONS 42, 43, 50, 52, 60, 62

Pre-programmed DPS-speeds engages: Pre-programmed DPS-speeds engages:

- when driver moves shuttle lever to F- or R- positiĆ
on (without clutch pedal) - when driver moves the shuttle lever to F- or R- position (with
- or when driver presses the HiShift -button (with or or without the clutch pedal)
without shuttle lever) - or when driver moves the shuttle lever to F- or R- position and
simultaneously presses the HiShift-button (the gear is engaged
after the button is released)

The DPS-pre-programming and AutoDPS can be When AutoDPS is in function, the DPS-pre-programmed speeds
engaged simultaneously => unnecessary gear shifts in are by-passed temporarily. The pre-programmed speeds are
the driving direction change. activated, when AutoDPS is disengaged.
When AutoDPS is in function, the use of the DPS push When the tractor is stopped, AutoDPS engages always gear no. 1
buttons can disturb the gear change when stopping although the DPS push buttons are pressed simultaneously.
driving.
AutoDPS gear shift delay has been shortened. Also some points in
gear shift diagrams have been modified.
PTO symbol is visible in AC5 ćdisplay, when the PTO PTO symbol is visible in AC5 ćdisplay, when the PTO shaft rotates
shaft rotates over 45 r/min. over 150 r/min.

237
 Model Code Page
37. Autocontrol 5 X100-X120 370 9C
1. 11. 2000

VERSION 41
VERSIONS 42, 43, 50, 52, 60, 62

** TEST- AND SETTING MODE **

In the service mode there are two modes: In the service mode there are three modes:
- test mode FII (for service man) - test mode FII (for serviceman and driver)
- setting mode FIII (for srvice man) - setting mode FIII (for serviceman)
- driver setting mode FIII > three settings (A: tyre dimension, F:
°C/°F, S: km/h / miles/h)
Setting of DPS initial pressures cannot be seen as a Setting of DPS initial pressures can be seen as a pressure change in
pressure change in the setting mode. However, affects the setting mode.
the function of the DPS.
In the test mode the temperature sensors (A1, A2) show In the test mode the temperature sensors (A1, A2) show LO" (=
L9" (= low), when the temperature is below -9°C. low), when the temperature is below -9°C.
Counters are nor in use. 12 counters, which gather information, how many times and how
many minutes certain functions have been in use:

** FAULT CODES **
Fault code P101 causes fault code F321 => fault functiĆ Program has been developed. Fault code P101 does not cause
on level 4 => tractor stops. other fault codes.
Fault code d225 appears, if the clutch pedal position is below 2%
(0-1%) and pedal limit switch S9 is not yet switched on.

VERSION 41
VERSIONS 42, 43, 50, 52, 60, 62

** INTERNAL FUNCTIONS**
When the PTO is started, pressure rises always accorĆ When the PTO is started, pressure rises always according to a cerĆ
ding to a certain curve (program). tain curve (program), but the PTO acceleration (sensor B7) is folloĆ
wed at certain intervals and when necessary pressure is raised.
Versions 50 and 60:
-Clutch pedal function precised
-Function of DPS automatic gear change (AutoDPS) has been ensuĆ
red when using reverse drive controls (TwinTrac)
Versions 52 and 62:
-Clutch pedal function precised

238
239
 Model Code Page
37. Autocontrol 5 X100-X120 370 10
1. 11. 2000

a) Testing various switches and buttons (d01-d16) in the test mode in AC 5

NOTE! In AC 5.2 there are more test points, see page 371/8.

FII=test
mode F
symbol A
d
P
C

Module A=AC 5

d01=DPS push button

up
1=button depressed
(when the button is up,
here must be 0).

INPUT DESCRIPTION 1 in display 0 in display

d01 (S23), (S1W) 1) DPS-push button up button down button up
d02 (S23), (SiW) 1) DPS-push button down button down button up
d03 (S45) HiShift buttons (2 pcs, try both buttons) button down button up
d04 (S25) (S1A, S2A) PTO start switch Start position switch up
2)
d05 (S60) Detection of driver (in driver's seat) Driver on seat not seat signal
d06 (S9) (S2W) 1) Clutch pedal limit switch pedal down pedal up
d07 (S47) DPS automatic speed change switch Auto-pos. 1 Auto-pos. 2
d08 (S47) DPS auto/manual Auto 1 or auto 2 Manual
d09 (S40) (S40) 1) Direction F Selected not selected
d10 (S41), (S41) 1) Direction R Selected Not selected
d11 (S51) (S51) 1) DPS-pre-programming button (under shuttle lever) button down button up
d12 (S28) PTO-lever in front position selected not selected
d13 (S29) PTO-lever in rear position selected Not selected
d14 (-) (S3W) 1) Driver's seat direction (TwinTrac only ) backwards forwards
d15 (S25) PTO rocking switch Start position Switch up
d16 (S15) (S15) 1) Hand brake applied not applied

- If the value in the display is not 0, althought it should be according to the table above, the switch can be damaged or in short
circuit. Check, change the switch. Check the switch wires.
- If the value in the display is not 1, althought it should be according to the table above, the switch can be damaged/wires broken/
poor contacts in connectors. Change the damaged switch. Check the switch wirings.

NOTE! If a switch (e.g. DPS push button) is damaged, it can be difficult to move into the test mode. AC 5 display shows, however,
fault codes, if certain switches are out of order.

1) The latter switch is for the reverse drive controls (option) (TwinTrac). When checking these switches the seat must be turned
rearwards.
2) The PTO rear push buttons S1A and S2A (option) are placed on the rear mudguards.

240
 Model Code Page
37. Autocontrol 5 X100-X120 370 11
1. 11. 2000

b) Testing temperature sensors and position sensors (A1-A4) in the test mode in AC 5

NOTE! Corresponding tests in AC 5.2, see page 371/9.

F
FII=test
mode A
symbol d
P
C

Module A=AC 5
A3=gas pedal

99%=gas pedal
down (here must
be 2 % or less
when the pedal is
up).

SYMBOL NAME DESCRIPTION

A1 (B17) Outdoor temperature (xx °C or F) Compare the value with the ambient outdoor temperature. If the values
are different or not visible, check the sensor wires and sensor itself, see
instr E on page 370/23. If the temperature is below -9° C, shows the
display in place of temperature L9" (Program versions 38, 40, 41) or
LO" (Versions 42, 43, 50..., 60...)
A2 (B14) Gearbox oil temperaturte (xx °C) Compare the reading with the actual gearbox temperature. If the values
are different or not visible, check the wires and the sensor, see instr. E on
page 370/23. If the temperature is below -9° C, shows the display in
place of temperature L9" (Program versions 38, 40, 41) or LO" (VersiĆ
ons 42, 43, 50..., 60...)
A3 (B15) 1) Accelerator pedal position (xx %) When the pedal is fully up, the value should be smaller than 2. When the
pedal is down, the value should be greater than 95. Check also that the
value changes evenly when the pedal is moved (in the middle of the
pedal stroke, the value should be about 50). If the values deviate from
corret values, see instr. G on page 370/24.
A4 (B16), Clutch pedal position (xx %) When the pedal is fully up, the value should be greater than 97. With the
(B1W) 2) pedal at the bottom, the value should be smaller than 2. Also check, that
the value changes evenly when the pedal is moved (in the middle of the
pedal travel, the value should be about 50). If the values deviate from the
above given values, see instr. F on page 370/23. Check that the display
reading is 3...8 in point, where the pedal limit switch switches on (click).

1)The gas pedal of the reverse drive controls (TwinTrac, option) controls the same position sensor as the front gas pedal. If the
rear gas pedal value is not within the given limits, the rear gas pedal cable must be adjusted so that the fuel injection pump adjusĆ
ting lever can move the whole stroke.

2) The latter switch is for the reverse drive controls (option) (TwinTrac). When checking these switches the seat must be turned
rearwards.

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 Model Code Page
37. Autocontrol 5 X100-X120 370 12
1. 11. 2000

c) Testing RPM-sensors (F1-F7) in the test mode in AC 5

NOTE! Corresponding tests in AC 5.2, see page 371/9A.

Note! If the display shows e.g. F1 51, it means the engine rpm sensor frequency of 5100 Hz (value x100=Hertz number).

Example:
F
FII=test
mode A
symbol d
P
C
Module A=AC 5

12=possible sigĆ
F1=engine
nal value at engiĆ
RPM senĆ
ne speed of 2000
sor
r/min

INPUT NAME VALUES DESCRIPTION

F1 (B11) Engine rpm sensor 1000 r/min=5,7-6,3 Set the engine revs to 1000 r/min and compare the value
1500 r/min=8-10 with the given values in the LH side column. Raise the
2000 r/min=11-13 revs to 1500 and 2000 r/min and compare the reading. If
one of the values is not within the given limits, check the
sensor, see instr. D on page 370/22.
F2 (B6) Gearbox speed 1000 r/min=0,6-0,8 (50 Set the engine revs to 1000 r/min, engage gear M1 and
sensor km/h) drive the tractor forwards. Compare the reading with the
1500 r/min=1,1-1,3 (50 given value. Test also at 1500 and 2000 rpm engine revs.
km/h) If the values differ, see instr. D sivulla 370/22.
2000 r/min=1,4-1,8 (50
km/h)

1000 r/min=0,5-0,7 (40

km/h)
1500 r/min=0,8-1,1 (40
km/h)
2000 r/min=1,1-1,5 (40
km/h)
F3 Reserve
F4 (B12) Shuttle output Set the gears in neutral. Set the engine revs to 1000
speed (upper senĆ 1000 r/min=1,8-2,1 (F) r/min. Engage forward direction (F) and compare the
sor) 1500 r/min=2,9-3,1 (F) value with the given value. Make the same check also in
2000 r/min=3,8-4,2
/ , , (F)
( ) the reverse direction (R).
( ) Raise the engine
g revs to 1500
F5 (B13) Shuttle output and 2000 r/min
/ and measure again in both directions.
speed (lower senĆ 1000 r/min=1,9-2,2 (R) Compare the reading with the given values. If one of the
sor) 1500 r/min=3,0-3,2 (R) values deviates, carry out a comparing measurement,
2000 r/min=3,9-4,3 (R) check the sensor according to instr. D on page 370/22.
F6 (B7) PTO speed sensor 540=1,7-2,0 Engage PTO. Set the engine revs to 1000 r/min. Compare
540E=2,2-2,5 the values with the given values. If the values deviate,
1000=3,0-3,3 check the sensor acording to instr. D on page 370/22.
540E=2,2-2,5 (8350Hi)
1000E=3,7-3,9 (8350Hi)
F7 Direction informaĆ F=1 Set the gears in neutral. Set the engine revs to 800 r/min.
tion R=2 Engage the forward direction (F) and raise slowly the
(B12, B13) engine revs up to max. The reading must be 1 and must
remain the same during the whole test. Engage reverse
direction (R) and repeat the same measurement. The reaĆ
ding must be 2 during the whole measurement. If one of
the direction readings does not function (value is faulty or
it changes when engine revs varie), but F4 and F5 values
are correct, the AC 5/5.2 control unit A1 may be damaged
and should be changed.

NOTE! If the measured values deviate from the above given values, check first the driver detection switch and its wiring in the
seat.
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 Model Code Page
37. Autocontrol 5 X100-X120 370 13
1. 11. 2000

d) Testing proportional valves (P1-P5) in the test mode in AC 5

NOTE! Corresponding tests in AC 5.2, see page 371/9B.

Note! When the proportional valves are tested, all solenoid outputs are connected automatically unenergised. Note! The PTO
proportional valve cannot be tested in the test mode in AC 5, but the solenoid is checked by measuring the resistance value.

Hint! E.g. value P4 1.8 means, that the forward direction proportional valve takes max. current of 1,8 A (in the test mode).

Example:

FII=test
mode F
symbol
A
d
Module A=AC 5 P
C
P1=DPS
proportional
valve no 1
(C1)
1.2=value within given
limits (1,2 A)

OUTPUT NAME VALUE (activated) DESCRIPTION

P1 (Y4) DPS-solenoid Y4 (C1). Activate the test mode and start the engine. Set the
engine speed to about 1000 rpm.
P2 (Y6) DPS-solenoid Y6 (C2).

P3 (Y17) DPS-solenoid Y17 (C3). 11 19

1,1-1,9 P ti l valve
Proportional l iis activated
ti t d b t i th
by stepping the d i d
desired
solenoid and by pushing the pre-programming butĆ
ton The display reading should be 1,1-1,9.
ton. 11 19
P4 (Y11) Forwards solenoid Y11.
- If HI=short circuit or valve takes too high current.
current
P5 (Y12) Rearwards solenoid Y12. - If LO=wire damage

P6 (Y2) PTO solenoid Y2 In AC 5: Cannot be tested in test mode. Measure reĆ

sistance, see page 370/21.

- If one of the values in the diplay deviates from the given values, measure the solenoid resistance on the connector X13 pins
or direct on the valve pins. Measure so that the pins do not slacken (see instr. C on page 370/21). If the resistance is correct,
but the display reading is faulty, the fault lies in the wires.
Measure also the supply voltage of the control unit while the engine is running (1500 rpm). Correct value is 12 V-14,8 V.
- If the solenoid resistance was faulty, the solenoid is damaged and should be changed. When the proportional valve or the
solenoid is changed, the valve indexes must be checked (see page 370-24D).

If above mentioned points are OK, faulty current value can be caused by a defect AC5 / 5.2 control unit A1.

Note! Resistance measures and diode checks, see instr. 4C on page 370/21.

Important! Be careful not to mix up the proportional valves and normal solenoid valves during repair work.

WARNING! The proportional valves have a pin for a manual use, which MUST NOT be manipulated: the tractor may suddenĆ
ly start to move, or the pin can become trapped and can cause later damage to e.g. multi-disc clutches. That is why it must
always be checked after the repair work (before engine start), that the proportional valve spools are in the outer positions i.e.
almost flush with the valve body (if not, remove the valve and press the spool so that the manual pins" rises).

243
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 Model Code Page
37. Autocontrol 5 X100-X120 370 13A
1. 11. 2000

e) Counter functions, J38343-, (program versions 42-), AC 5

NOTE! Corresponding tests in AC 5.2, see page 371/9C.

With effect from ser. no. J38343 there are 12 pcs counters in the test mode menu (see page 370/8). The counter symbols are
placed below the symbols for the proportional valves, see table below:

F
A Note! The counters has not been connected in all control units, since
d the function has been under testing. Due to this the counters do not
increase in all tractors. This is not a fault, and does not cause a chanĆ
ge of the control unit if the control unit does not have another fault.
P
C

Symbole in Test point The readings of the counters are shown shortened as follows:
display - the LH side display segment shows the counter symbol
- the two intermediate segments show the two first significant
b Number of engagements of F-clutch digits of the reading
F Time in minutes how long time the - the RH side segment shows the number of zeroes.
F-clutch has been engaged (pressurised)
E.g. b 23 3 means that driving direction forwards has been
Number of engagements of R-clutch
(r) engaged 23000 times.
A Time in minutes how long time the R-
Last Number of
clutch has been engaged (pressurised)
digit zeroes
C Number of engagements of DPS1 ratio 0 -
U Time in minutes how long time the DPS 1 1 0
clutch has been engaged (pressurised) 2 00
3 000 (thousands)
J Number of engagements of DPS2 ratio 4 0000
P Time in minutes how long time the DPS 2 5 00000
clutch has been engaged (pressurised) 6 000000 (millions)
Time recorder readings (F, A, U, P, d, L) are also shown in the
E Number of engagements of DPS3 ratio same way.
d Time in minutes how long time the DPS 3
clutch has been engaged (pressurised) Example:
H Number of engine starts
L Time in hours how long time the ACV
control unit has been active. Test mode
symbol
The counters are accessible after activating the test mode
and by stepping in the menu with the aid of the DPS push
buttons.

Note! When the current is switced on with the ignition

switch, the default ratio is DPS1. The value in counter H Module
increases with one digit every time the engine revs rise over
400 r/min. Counter L shows the total running hours of the
control unit. If the counter reading is smaller than tractor
running hours, a new control unit has been fitted later on 35=number of
the tractor. engine starts,
two first digits
Note! Reading counters is happened without a separate
confirmation. The counters cannot be zeroed in service. If
the control unit is reprogrammed, the counter values reĆ
main in the control unit memory. In the spare part control
unit the counters have been zeroed.

The greatest value of the hour recorders is 9999 after which 2 = Number of zeroes
the counters are zeroed. Counters are switched on always H= number of engiĆ
when current is switched on in the control unit. ne starts

i.e. H = 3500 times.

Note! The counters can be used in connection with mainteĆ
nance or repair works, when e.g. estimating life time of varioĆ
us components or clutch wear etc.

245
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 14
1. 11. 2000

Menu of setting mode F III in AC 5 (AC 5.2: see page

3. Settings 371/10):
IMPORTANT! Always before settings, the AC 5 / 5.2 must Symbol Description
be tested in the test mode and it must be sure that the tracĆ
tor electrical system (battery, fuses etc) and low pressure L PTO ratio 2 (lever in rear position) (in program
version 42-)
circuit of the hydraulic system are in order. When carrying
out settings the gearbox oil must be in the normal operating P PTO ratio 1 (lever in front position), (in progĆ
temperature (+30...+60 °C) and the engine in the normal ram version 42-).
operating temperature. Otherwice the calibrations do not S Driving speed unit selection: km/h or miles/h
succeed. Remove possible DPS pre-programmed speeds.
Before changing the setting values, note down the original F Outdoor temp. unit selection: °C or °F.
values). A Setting driving speed parameters 3)

A. Activating setting mode, AC 5 and AC 5.2 9 DPS3 (clutch C3) initial pressure setting. 1) *)
8 DPS2 (clutch C2) initial pressure setting. 1) *)
Note! The setting mode is activated by using certain tractor
7 DPS1 (clutch C1) initial pressure setting. 1) *)
buttons in a correct order as folĆ
lows: 6 Initial pressure setting mode of R clutch. 2) *)
H40432- SWITCH ON
5 Initial pressure setting mode of F clutch. 2) *)

4 Resetting of the prefilling time of R clutch.

OR
START 3 Resetting of the prefilling time of F clutch.
2 Clutch pedal calibrating mode.
1 Gas pedal calibrating mode. *)

1) Change of initial pressure is not visible in pressure value

(but it affects the function of the DPS) (in program version
Number Main mode Symbol of main 42-).
mode 2) Before the initial pressure settings the resetting of the
1 Fault code memory F I (AC 5.2 only) prefilling times must be done.
3) Same as for AD-instrument, see page 331/6.
2 Test mode F II
*) Engine must be in running.
3 Setting mode F III
Note! In the setting mode menu stepping can be done with
the DPS push buttons (1) up and down (symbol is blinking)
and the selection is confirmed with the DPS pre-programĆ
ming button (2) (symbole stops to blink or index numbers
1 are visible and blinking). After that the setting/calibrating
procedure can be done. Moving to the other point is done
by pushing the DPS pre-programming button (2), after
which the symbols start again to blink and a new point can
be stepped in the setting mode menu. The confirmation is
then carried out again with the pre-programming button
etc.

Note! Escaping from the setting mode is done by switching

off the current.
Note! After the setting mode has been activated, all soleĆ
noid outputs are unenergised.
2
- step with DPS push buttons (1) up or down and select the
main mode symbol FIII (setting mode).
FIII=setĆ
- after this confirm the selection by pushing the DPS pre- ting mode
programming button (2) symbol
- now symbol A starts to blink (2 Hz) in the middle display
block.
- select module A (7 pcs modules. A only in use) by stepping
again with push buttons (1). Module A=AC 5/5.2
- confirm the selection by pushing button (2) after which A
stops blinking in the display.
- the diplay is now in the setting mode and various settings
can be done
Blinking 1=
NOTE! When the module A was confirmed, number 1 (calibĆ gas pedal
rating of gas pedal) started to blink in the LH side of the lower calibrating
display block in AC5. 1 is the first point in the setting mode meĆ mode
nu. In AC 5.2 text CAL starts to blink. If you think that the gas and clutch pedal calibrations are
not OK, correct them first.
246
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 15
1. 11. 2000

B. Gas pedal calibration in AC 5 and 5.2 IMPORTANT! Escape from this mode by switching off curĆ
Gas pedal is calibrated, if: rent.
- DPS has malfunctions
- Test mode indicated (table b on page 370/10), that the
gas pedal function is not within the given limits C. Calibrating clutch pedal, AC 5 and 5.2
- Fault code A313 appeared in the display.
- Fuel injection pump position sensor has been changed The clutch pedal is calibrated if:
- According to the maintenance program (also check that - test mode indicated that the pedal function is not within the
change in links between pump and sensor does not affect given limits
the function of the system). - Fault code A314, A315 or d225 (front controls) or A351,
- fuel injection pump has been changed or adjusted
A128 or d254 (reverse drive controls) appeared in the display.
Important! Before calibration, check the pedal sensor voltĆ - pedal position sensor has been changed.
ages in AC 5, see page 370/24. Before activating the gas
pedal calibration, the engine revs must be at the low idling IMPORTANT! Before calibration, check the pedal sensor voltĆ
speed and in the normal operating temperature (over +30 ages in AC 5, see page 370/23. When selecting the clutch
°C). Also the transmission must be in the normal operating pedal calibration, the pedal must be in the upper position.
temperature.

1. Activate the setting mode according to instr. A on page 1. Activate the setting mode according to instr. A on page
370/14. 370/14.

2. Select in the setting mode menu number 1 with the DPS 2. Select in the setting mode menu number 2 with the DPS
push buttons (in the speed gear lever knob) and confirm it push buttons (in the speed gear lever knob) and confirm it
with the DPS pre-programming button (see page 370/14)
with the DPS pre-programming button (see page 370/14)

FIII=setĆ FIII=setĆ
ting mode ting moĆ
symbol de symĆ
bol

1=gas pedal caĆ

librating mode 2=clutch
pedal caĆ
librating
mode
Blinking 00=
calibration can be done Blinking 00=
calibration can be
done.

3. After the clutch pedal calibration has been selected and

3. When the gas pedal calibration has been selected and confirmed (2 is visible in the LH side segment), two digits 00
confirmed (1 is visible in the LH side segment), start to blink in the two RH side segments (2 Hz). This indiĆ
digits 00 start to blink in the two RH side segments (2 Hz). cates that the calibration can be done.
This indicates that the calibrating can be done.
4. Depress the clutch pedal gently and evenly to the bottom
4. Set the mechanical gears in neutral (engine at low idling). and keep the pedal in bottom for a while, at which time the
Raise the engine revs evenly and gently with the throttle control unit reads values in the calibrating points and saves
lever up to max. revs during about 10 seconds, however all
the time the revs must go up. When the max. revs have them in memory. After the successfully calibration digits 01
been reached, wait about 3 seconds and press the HiShift appear in the two RH side digits.
button. Lower to the low idling speed, at which time the
control unit reads values in the calibrating points and saves Note! If the calibration failed (01 did not appear), the values
them in a memory. After the successful calibration digits 01 are not saved. Old values remain in the memory and the caĆ
appear in the two RH side segments. Raise once again the libration must be repeated.
revs slower during 12-15 seconds with the hand gas lever

Note! If the calibration failed (00 without blinking in the two If the calibration failed, so:
RH side segments), the values are not saved and the earlier - check the clutch pedal potentiometer, see instr. F on page
values remain in power. In this case the calibration must be 370/23.
repated. The calibrating mode is left by switching off curĆ - check the pedal limit switch function and adjustment.
rent. - Check the wires of these components
If the calibration failed, so: - If these are OK, the fault may lie in the control unit.
- check the pump position sensor, see instr. G on page
370/24 (AC 5) or on page 371/14 (AC 5.2). IMPORTANT! Escape from this mode by switching off curĆ
- check the position sensor wires rent.
- If the sensor and its wires are OK, the fault may lie in the
control unit and it must be changed. NOTE! Calibrate in the same way the rear clutch pedal of the
- check engine speeds: low idling speed must be under
1000 rpm and max speed over 1800 rpm. optional reverse drive control (TwinTrac).

247
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 16
1. 11. 2000

6. Press again the pre-programming button, at which time

D. Checking pressures in shuttle the index digit stops blinking and read off the pressure
clutches in AC 5 and 5.2 gauge reading, which should be 1,8-2,8 bar (AC 5) or
about 3,5 bar (AC 5.2).
See also the setting orders in instr. 370-24D.
Note! The pressure value can be read after about ten secĆ
Note! If the shuttle has malfunctions or if the shuttle has onds, during which the pressure becomes even (in the
been repaired or the proportional valves have been beginning possible pressure peak is not observed).
changed, the function of the control system must be
checked. These tests ensure, that the pressure in the tractor 7. If the measured pressure value is different, change the
low pressure circuit is high enough and that the F/R proporĆ index. This is carried out so that after the pressure
tional valves are functioning. measurement the blinking (5) is activated again with the
DPS pre-selection button, and the blinking index digit is
Note! Ensure that the transmission oil temperature is changed by stepping with the DPS push buttons.
between +30°C...+60°C before work.
8. After the index has been changed, press again the DPS
33743900 pre-selection button and read off again the pressure
31965400 gauge reading.

Note! If the pressure is too low, increase the index one step
at a time and vice versa and check the pressure again. If
the index is smaller than -4 or greater than +4, the folĆ
lowing points must be checked:
- Low pressure circuit of the tractor (instr. 911-1)
- Condition of the valve coil, see page 370/13.
- Cleanliness of the valve
- Valve seals. Change the valve if necessary.

FIII=setĆ
ting mode
symbol
1. Measure pressure in the tractor low pressure circuit acĆ
cording to instr. 911.
initial
2. Connect a pressure gauge of 25 bar onto the F-direcĆ
pressure
tion pressure-test point (second point from the right, see
calibrating
also picture on page 440/25). mode of
R-clutch
3. Activate the setting mode according to instr. A on page
370/14.
Index digit
4. Step with the DPS push buttons (in the speed gear lever
knob) and select point 5 in the setting mode menu (see
page 370/14 (AC 5) or page 371/10 (AC 5.2)) (F-clutch
initial pressure calibration) (blinking). 9. Repeate the same also with the R-direction pressure-
test point (the LH side test-point on the valve block). In this
case the function number 6 of the setting mode menu
must be activated (R-clutch initial pressure calibration).
FIII=setting
mode symĆ 10. Escape from the setting mode by switching off current.
bol
11. Engage a mechanical gear and range gear lever in the
neutral. Start the engine and engage the forward-driving
Initial presĆ direction (F). See the pressure rise of the F-clutch in the
sure calibraĆ pressure gauge. The pressure must stay in level, which is
ting mode of max. 0,05 MPa (0,5 bar) below the pressure in the low presĆ
F-clutch sure circuit. e.g. 18,0 bar -> 17,5 bar (measured in point
1). If the pressure is lower, it is possible that there is a leakĆ
age in the system (e.g. o-ring damaged).

12. Measure the reverse-drive direction (R) in the same

Index digit way.

13. Check the DPS-pressures in the same way (instr. 3E).

5. Press the DPS pre-programming button, at which time 14. Set the indexes according to instr. 370/24D.
certain initial pressure index (between -9...+9) starts to
blink in the three RH side segments. 15. Test-run the tractor according to instr. on page
370/24E.
Note! The factory setting of the index is normally -3...+3.

248
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 17
1. 11. 2000

E. Checking DPS clutch pressures in AC

5 and 5.2 33743900
31965400

See also the setting orders on page 370/24D.

Note! If the DPS has malfunctions or if the DPS has been

repaired or the proportional valves have been changed, the
function of the control system must be checked. These
tests ensure, that the pressure in the tractor low pressure C1
circuit is high enough and that the DPS proportional valves
C1/C2/C3 are functioning.

Note! Ensure that the transmission oil temperature is

between +30°C...+60°C before work.

Note! The change of initial pressure index is not visible in

the pressure value (but affect the function of the DPS) (in
program versions 38, 40, 41). (Can be seen in other verĆ
sions) C2

1. Measure pressure in the tractor low pressure circuit acĆ 5. Connect a pressure gauge of 25 bar onto the C1 clutch
cording to instr. 911. pressure-test point (in the right), press again the DPS
pre-programming button (index stops to blink) and read
2. Activate the setting mode (see page 340/14). off the pressure gauge reading, which should be 1,8-2,8
bar.
3. Step with the DPS push buttons (in the speed gear lever
knob) and select no 7 (DPS1, clutch C1) (AC 5.2: no 10) in Note! The pressure value can be read after ten seconds,
the setting mode menu and confirm this selection with the during which the pressure becomes even (in the beginning
DPS pre-programming button. possible pressure peak is not observed).

6. When the C1 clutch pressure has been checked, repeat

the same procedures also with the C2 and C3 clutches. At
FIII=setting this time the blinking 7 is changed with the DPS push butĆ
mode symbol tons to 8 (and 9) and confirmed with the preprogramming
button.
7=initial pressure
calibration of DPS - 8 (AC 5.2: 11) (DPS2, clutch C2). Initial pressure value
clutch C1 1,8-2,8 bar.
8= clutch C2 - 9 (AC 5.2: 12) (DPS3, clutch C3). Initial pressure value
9=clutch C3 1,8-2,8 bar (AC 5) and little higher in AC 5.2.
10=C1 (AC 5.2)
11=C2 (AC 5.2) Note! It is important that all DPS three proportional valves
12=C3 (AC 5.2) are checked.

7. Escape from this mode by switching off current.

8. Move the speed gear and range gear levers to the neuĆ
tral. Start the engine and change the DPS-speed with the
push buttons. See the pressure rise in the pressure gauge.
The pressure must remain in the level, which is max. 0,05
Index digit
MPa (0,5 bar) below the pressure in the low pressure cirĆ
cuit, e.g. 18,0 bar ->17,5 bar (measured in point 1). If the
presure is lower, there can be a leakage in the system (e.g.
o-ring damaged).
4. When the initial pressure calibrating mode has been seĆ
9. Check the DPS-pressures in the same way (instr.
lected and confirmed, number 7 (AC 5.2: 10) can be seen
370/3D).
in the left and index digit is blinking in the right.
10. Set the indexes according to instructions on page
370/24D.

11. Test-run the tractor according to instruction on page

370/24E.

249
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 18
1. 11. 2000

G. Resetting prefilling time of shuttle

H. Resetting driving speed parameters,
clutches, AC 5 and 5.2
AC 5 and 5.2
See also working orders in instr. 370/24D)
Note! Driving speed parameter means the pulse parameter
Note! This resetting must always be done before the caĆ (pulses/m) of sensor F2 (gearbox speed sensor).
libration of the initial pressures. Adjust the initial pressure
index of the F- and R-clutches to smaller than -3 (see By changing this parameter value the driving speed display
instr. D) before resetting the prefilling times. can be adjusted so that it shows the correct value accorĆ
ding to the tractor tyres and transmission type. This proceĆ
Note! The resetting is done by changing the prefilling dure is made in the factory for all new tractors. If tyres of
index. As a procedure this is done like the initial pressure different dimensions are fitted later on the tractor, the paraĆ
calibration by stepping with DPS push buttons and by conĆ meters can be reset according to this instruction.
firming with the DPS pre-selection button.
1. Activate the test mode according to instr. A on page
NOTE! If the shuttle engagement causes so called "double 370/14 (if not activated eralier).
jerk" in the beginning of the engagement and the function
has a great delay, so: 2. Select symbol A (blinking) in the test mode menu by
- decreasing the index reduces the jerk and increases the stepping with DPS push buttons (in the speed gear lever
delay knob), and confirm the selection by pushing the DPS preĆ
- increasing the index increases the jerk and reduces the programming button, at which time symbol A stops blinĆ
delay. king and the present parameter value is visible (blinking) in
the three RH side segments.
Testdrive the tractor and carry out, if needed, the resetting
procedure (note down the original index value). Test-run
the tractor after resetting.

1. Check that the transmission oil temperature is

+30°C...+60°C. Activate the setting mode (see page
340/14).
FIII=setting
mode symbol
2. Step with the DPS push buttons (in the speed gear lever
knob) and select no 3 in the setting mode menu and conĆ
firm this selection with the DPS pre-programming button.
A= symbol for driĆ
ving speed paraĆ
FIII=setĆ
meter setting.
ting moĆ
de symĆ
bol

3=Resetting prefilĆ
ling time of F
clutch
4= R-clutch. Value of driving
speed parameĆ
ter.
Index digit

3. The blinking parameter value can be changed by using

the DPS push buttons in the speed gear lever knob.
3. When this mode has been selected and confirmed ,
number 3 is shown (not blinking) in the left and the index Note! The parameters according to the tyres and transmisĆ
digit is blinking in the right. The factory setting is 0. sion types are the same as for AD-instrument, see table on
page 331/6.
4. Change the prefilling index (when it is blinking) one step
at a time with the DPS push buttons and confirm it with the 4. When the desired parameter value is in the display, it is
preprogramming button (blinking stops). After this, test the confirmed by pushing the DPS preprogramming button.
engagement of the shuttle many times. Change the index
when necessary. 5. If the confirmation succeeds, the parameter value in
question remains in the display without blinking.
5. Carry out this same also for the R-clutch. Now number 4
is selected in the setting mode menu. Note! Escape from the setting mode by switching off the
current with the ignition switch.
Note! If the index for the F- or R-clutches must be over
+4 or smaller than -4, it is possible, that the clutch in
question is worn-out or the clutch piston or valve is stuck.

250
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 19
1. 11. 2000

I. Changing temperature unit of outdoor J. Changing driving speed unit, AC 5 and

temperature display, AC 5 and 5.2 5.2
The outdoor temperature unit can be changed between F° The driving speed unit can be either km/h or miles/h.
or °C.
1. Activate the setting mode according to instr. A on page
1. Activate the setting mode according to instr. A on page 370/14).
370/14).

FIII=setting
FIII=setting mode symbol
mode symbol

S=driving speed
selection mode
F= outdoor temp. symbol (in AC
selection mode 5.2 H)
symbol.

Symbol of unit:
1=Celsius Symbol of unit:
2=Fahrenheit 1= km/h
2=miles/h

2. Step with the DPS push buttons (in the speed gear lever
2. Step with the DPS push buttons (in the speed gear lever knob) in the setting mode menu and select symbol S,
knob) in the setting mode menu and select symbol F, which is blinking (choosing driving speed unit), and conĆ
which is blinking (choosing temperature unit), and confirm firm the selection by pushing the DPS preprogramming
the selection by pushing the DPS preprogramming button, button, at which time the symbol S stops to blink and preĆ
at which time the symbol F stops to blink and present unit sent unit symbol (1 or 2) can be seen in the diplay:
symbol (1 or 2) can be seen in the diplay:
1=km/h.
1=°C. 2=miles/h.
2=°F.
The factory setting is km/h units.
The factory setting is Celsius units.
3. Select the desired speed unit by pushing the DPS push
3. Select the desired temperature unit by pushing the DPS buttons and confirm the selection by pushing the DPS preĆ
push buttons and confirm the selection by pushing the DPS programming button. After this the driving speed is shown
preprogramming button. After this the outdoor temperature either in km/h or miles/h.
is shown either in Celsius or Fahrenheit units.
Note! 1 km/h=0,6214 miles/h
Note! With the formula below the Celsius-units can be
changed into Fahrenheit-units. Note! If the selected driving speed unit is miles/h, symbol
km/h is not shown at all in the diplay.
tF = 9 x tC + 32
5

251
252
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 19A
1. 11. 2000

K. Setting PTO parameters (ratios), in program versions 42-, AC 5 and 5.2

L
P

AVO

347
Index value = PTO ratio x 100

285
Speed 1 Speed 2 Index P Index L

208 1000 - 208 1) 208 1)

1000 540E 208 285
540 1000 347 208
175 540 540E 347 285
1000E 540E 175 2)3) 285 2)

1) These are base values in spare control units and in files on the program diskette (versions 52, 62).
2) These are base values for PTO 1000E/540E. They are also the final values.
3) In program versions from no. 82 incl. the base values are: P=175, L=175.

PTO index values shall always be checked and set after programming or assembling the control unit.

PTO speed 1 PTO speed 2

(front pos. of lever) (rear pos. of lever)

253
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 20
1. 11. 2000

B. Switches:
4. Checking AC 5 / 5.2 components
Note! The switches and their wires can be checked in the
A. Control unit and display: test mode FII, see table a on page 370/10 (AC 5) or page
371/8 (AC 5.2). Then the switch in question is activated
If the control unit is damaged, the conditions of other comĆ and in the diplay can be seen the mode (0/1) of the switch,
ponents do not affect the function of AC 5. In case of fault at which time the condition of the switch and its wires can
check that the unit connectors have not poor contacts by be verified.
disconnecting them and reconnecting. If needed, the faulty switch is changed and wires are
checked/repaired.
Note! If the control unit must be changed, the tractor model
and ser. no. must be told to the factory. Also must be told, if The fault codes can show faults in different switches. Fault
the tractor has a turbine clutch (HiTrol). Fitting the control codes, see page 370/6 (AC 5) or page 371/5 and 6 (AC
unit to tractor, see page 370/24A. 5.2).

The control unit has not a battery, but its memory is so deĆ Note! If the switches and wires seem to be OK, but a malĆ
signed that the programs remain in it, although should the function exists, the fault may lie in the control unit.
tractor battery be removed. If necessary, voltage measureĆ
ments can be done on the sides of the unit connectors Note! The shuttle lever/hand brake lever is a special switch.
(without detaching the connectors). Three different units When the lever is moved, the magnet in the inner end of the
have been used (33373000 and 33373010 in AC 5 and lever moves onto the corresponding reed relay and the
33373020 in AC 5.2. desired function is engaged. The DPS pre-programming
button is similar to the DPS and HiShift push buttons. The
The diplay unit cannot be repaired but it is changed as a reverse drive controls (TwinTrac) have the corresponding
complete unit. If the diplay does not function, check first switches).
that the connector is correctly connected to the diplay unit.
If the display has malfunctions, check that connector A1A2 Note! Check the function of the lever with a multi-meter or
of the control unit is correctly in place and that there is in the test-mode FII in connection with repairs.
nothing extra between the connector parts. Check also the
display unit supply voltage, fuse 24 (tractors J38343-)

Connection points of reed-relays

ÉÉÉÉ
Picture 2. Shuttle lever / hand brake
Make a marking on Note! Spring must not touch the reĆ
the relays before fitĆ lays. Parking brake reed-relay must
ting. not touch the magnet.

É ÉÉ
É ÉÉ
É
É ÇÇ É
É ÇÇ É F=1 and 4

É É P=2 and 5

É É
R=3 and 6
Lock relays with DPS=7 and 8

É É
Loctite 495.

Magnet must be placed in = Direction of text on reed relay

point shown in picture above.

254
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 21
1. 11. 2000

5 Nm Note! The end

of the spool
20 Nm must be near
flush with the
valve body

P4 (Y11)
P3 (Y17) Note! Before removing valve
P5 (Y12) Y2 (P6), the temperature
switch S17 must be removed
P1 (Y4) (beside the valve).

P6 (Y2)
P2 (Y6)
C. Proportional valves, AC 5 and 5.2
- P5 is energised when reverse drive is engaged
Note! The unit self-diagnostics show a fault code, if one of - P6 is energised when the PTO is engaged.
the proportional valves is faulty, see table on page 370/6
(AC 5) or page 371/5 (AC 5.2) (PTO proportional valve is 3. The resistance of the proportional valves is measured
not diagnosed in AC 5). After this the valve can be tested in from connector X13 pins. Correct value is 7-9 ohms
the test mode. FII, see table d on page 370/13. (+10°C...+30°C).

4. If the resistance is incorrect, the valve solenoid is

1. All six proportional valves are similar: changed. After this the valve indexes must be set, see instr.
- P1=DPS foremost clutch C1 prop. valve Y4 on page 370/24D.
- P2=DPS middle clutch C2 prop. valve Y6
- P3=DPS rearmost clutch C3 prop. valve Y17 5. If the resistance is correct, but in the circuit there are malĆ
- P4=forward drive (F) proportional valve Y11 functions, check the valve wires and connectos. If these are
- P5=reverse dirve (R) proportional valve Y12 OK, perform the calibration of the initial pressure. Also the
- P6=PTO proportional valve (not diagnosted in AC 5) Y2 diodes must be checked in AC 5 according to table below
(in AC 5.2 the diodes are placed in the control unit A1).
2. When the proportional valve is energised, it is magnetic
and clutch in question is pressurised. Note! One possible and common fault is impurities in the
- P1 is energised,when DPS speeds I or II are selected valves. This can cause faults which are very difficult to find.
- P2 is energised, when DPS speeds I or III are selected If you doubt this fault, change the proportional valve or try
- P3 is energised, when DPS speeds II or III are selected to clean it.
- P4 is energised when forward drive is engaged
6. If the valve and its wires seem to be OK, but malfuncĆ
tions exist, the fault can lie in the control unit.
PINS (X13) SOLENOID RESISTANCE Note! During repair check (before engine start) that the
(+10...+30 °C) valve spool end is nearly flush with the valve body.
2<>5 Y2 (PTO) 7-9 ohms
Diode test with multimeter, AC 5 only.
4<>5 Y4 (C1)
7<>5 Y6 (C2)
11<>5 Y17 (C3) SOLENOID DIODE HOUĆ PINS (V1, V4)
12<>5 Y11 (F) SING (V1, V4)
13<>5 Y12 (R) Y2 V1 2<>5
Y4 V1 9<>8
X13 Y6 V1 7<>8
Y17 V4 9<>8
Y11 V4 7<>8
Y12 V4 3<>6

V1, V4 3 2 1

6 5 4
9 8 7
255
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 22
1. 11. 2000

F1 B11

F4 B12
F6 B7

F5 B13

F2 B6

2. The resistance of the shuttle sensors F4 and F5 cannot

be measured. These sensors are tested in the test mode
FII. Check first sensor fuse (F22, AC 5 only) and measure
D. Rotation speed sensors, AC 5 and 5.2 sensor supply voltage (=battery voltage) in connector X28
(see table below)
Note! If you doubt that one speed sensor is faulty, carry out
the checking of frequency outputs, see table c on page Note! The gearbox speed sensor is accessible after splitĆ
370/12. ting the tractor frame. The other sensors are accessible
without splitting the tractor. The engine speed sensor is
The fault codes can show possible faults in the rotation situating under the cab on the gearbox. The shuttle speed
speed sensors. Fault code list, see page 370/6 (AC 5) or sensors are accessible from under the cab on the RH side
pages 371/5 and 6 (AC 5.2). of the tractor when a cover is removed.

F1=engine speed sensor B11 3. If the sensor resistance is correct, check the sensor wires
F2=gearbox speed sensor B6 and connectors. If the resistance was incorrect, the sensor
F4=shuttle speed sensor B12 (upper), order no on wire. is changed.
F5=shuttle speed sensor B13 (lower), not order no.
F6=PTO speed sensor B7 4. Fitting and adjustment of sensors F1, F2 and F6 is done
in the same way as for corresponding sensors on the AC IV
1. If in the test mode one sensor functioned faulty, measure unit, see pages 351/2-3.
the resistance of the sensor. The resistance can be
measured from the wire loom connector X13. If the resisĆ 5. The shuttle sensors F4 and F5 cannot be adjusted, but
tance is infinitive, it should be measured from the sensor they are pushed into place and locked with a locking plate.
pins so that possible breaks can be verified. Note! The sensors must be fitted correctly: F4 up (marked),
and F5 down. Check the sensors in the test mode, point F7.

6. If the wires and sensors are OK, but malfunctions exist, it

is possible that the control unit is faulty.

RESISTANCE MEASUREMENTS

PINS (X13) SENSOR RESISTANCE

X13 +10-+30°C
14<>6 B11 1000-1100 ohms
15<>6 B6
X28 19<>6 B7
Supply voltage measurements (B12, B13)
Pins (X28) Sensor Voltage
3<>1 B12 Battery voltage
9><7 B13 -"-

256
 Model Code Page
37. Autocontrol 5 X100-X120 370 23
1. 11. 2000

E. Temperature sensors in AC 5 (AC 5.2, see F. Clutch pedal position sensor B16 in
page 371/13). AC 5 (AC 5.2, see page 371/13).
1. Gearbox oil temperature sensor B14

A Punch
mark

X13, X19 Note! The position sensor informs the control unit the posiĆ
tion of the clutch pedal, so that the control unit can control
Note! The sensor is situating on the servo valve block on the clutches.
the LH side of the gearbox. If the position sensor has malfunctions, the self-diagnosis
shows the following fault codes:
1. If this sensor or its wires have malfunctions, the self- - fault code A314 (signal not within given limits).
diagnostics show the following codes: - fault code A315 (pedal calibration faulty or pedal limit
- A311 (value over+150°C, unpossible). switch S9 wrongly adjusted) (switch S2W in the reverse
- A312 (value below - 50°C, unpossible). drive controls (option)).
2. Check the sensor in the test mode FII, see table b on 1. Check the function of the position sensor in the test
page 370/11. Compare the reading with the actual oil temĆ mode (table b on page 370/11). If the function is not within
perature. the given limits, check the sensor mounting and wires.
Check also the fitting of the lever on the sensor spindle.
3. If the tempearture reading is incorrect or it is lacking,
then check the sensor and its wires. Measure the resistance 2. Check the adjustment of the limit switch S9 in the test
of the sensor from connector X13 pins 10 and 6: mode: in the switch-on point the display must show
03...08 (when lifting the pedal). When needed, adjust the
Resistance values (±1 %): position of the limit switch so that it switches on (click) just a
- 1600 W (± 0°C) little before the pedal extreme position. Recheck in the test
- 2000 W (+25°C) mode.
- 3300 W (+100°C)
3. Measure, if necessary, the position sensor voltages.
4. Change the faulty sensor. Check the voltages always before calibrating the pedal.
Connect ETV 894 100 between the sensor and its conĆ
Note! If this sensor is faulty, malfunctions can occur in the nector (see picture on the next page). If ETV is not availĆ
transmission multi-disc clutches (delays or jerks). able, measure the supply voltage in the wire loom conĆ
nector (see picture on the next page). Signal voltage can be
Note! If the temperature sensor seems to be OK, but malĆ measured from control unit A1 connector A1A3/7-A1A3/8
functions occur, the control unit can be faulty. (see page 370/25).

2. Outdoor temperature sensor B17. - measure the supply voltage (+7,7...8,3 V) between pins
1 and 3.
This sensor is similar as the gearbox oil temperature sensor - measure signal voltage between pins 1 (ground) and 2
and it is placed in the front part of the tractor on the bracket (signal). Ensure that the voltage value changes evenly
for signal horn. when moving the position sensor lever. Adjust the sensor
position if needed. If the position sensor is faulty, fit a new
1. If the outdoor temperature reading is faulty or is lacking, one and carry out the pedal calibration. Adjust the position
check the sensor in the test mode FII, see table b on page of the sensor.
370/11.
Clutch pedal Pedal up Pedal in bottom
2. Compare the test reading with the ambient outdoor temĆ Signal voltage 1,5 -3,0 V 5,3-6,0 V
perature. If no outdoor temperature value is visible, check
the sensor and its wires . Note! When necessary, the gas pedal sensor B15 can be
temporarily used as a spare part (similar sensor, remove
3. If the reading is incorrect, check the sensor fitting and the lever). After that the DPS automatic gear change does
measure its resistancefrom connector X19 pins 26 and 37. not function. Try to adjust the pedal bottom" value to
Replace the faulty sensor. 5,7-5,8 V and then check that the upper" position value is
within given limits.
Resistance values:
- 1600 W (± 0°C) 4. Carry out the pedal calibration according to instruction C
- 2000 W (+25°C) on page 370/15.
- 3300 W (+100°C)
Note! If the sensor and its wires seem to be OK, but malĆ
Note! The function of this temperaure sensor does not functions occur, the fault may lie in the control unit A1. SeĆ
affect the technical function of AC 5. cure the screw, which fasten the arm to the sensor spindle
with Loctite 222.

257
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 24
1. 11. 2000
G. Gas pedal (fuel injection pump) posiĆ
tion sensor B15 in AC 5 (AC 5.2, see page H. Detection of driver in AC 5 and 5.2
371/14).

Note! If this sensor is faulty, there occur malfunctions in the Purpose of the switch S60
DPS automatic speed change (auto1, auto2). Also a faulty
engine speed sensor can cause this kind of malfunctions. In AC 5 / 5.2 is used for safety reasons so called driver
detection system. The detection switch prevents unintentioĆ
If the position sensor has malfunctions, the self-diagnosis nal engagement of the PowerShuttle in the situations, in
shows the fault code A313.
which the driver does not sit on the seat.
1. Check in the test mode FII (table b on page 370/11),
whether the pedal values are between the given limits. If the Function
function is incorrect, check the position sensor bearings (no
clearance) fitting and wires and wear of the pump pin. Also The switch in question has been connected to AC 5/5.2
check the sensor. Also check the connector X1A (in engine
compartment). control unit pin d05. When the driver is sitting on the seat
(weight must be over 30 kg), the switch contacts are cloĆ
2. Measure, if needed, the position sensor voltages. Check sed and d05 is activated (GND control). The function of the
the voltages always before calibrating the pedal. Connect switch can be seen in table a on page 370/10 (AC 5) or on
ETV 894 100 between the sensor and its connector (see page 371/8 (AC 5.2). When the driver leaves the seat, the
picture below). If ETV is not available, measure the supply switch contacts open (delay 6 seconds. 4 sec. in program
voltage in the wire loom connector (see picture on the next
page). Signal voltage can be measured from control unit A1 versions 38, 40, 41 and in AC 5.2 30 sec. if the clutch pedal
connector A1A3/4-A1A3/5 (see page 370/25). The voltĆ is depressed).
ages can also be measured in connector X1A.
Function in different situations
- measure the supply voltage (7,7...8,3 V) between pins 1
and 3.
- measure signal voltage between pins 1 (ground) and 2 When the driver engages the PowerShuttle direction, the
(signal). Ensure that the voltage value changes evenly AC 5 control unit checks the signal from the seat. If there is
when moving the position sensor lever. Adjust the sensor not a signal (driver does not sit on the seat) , the direction
position if necessary. If the position sensor is faulty, fit a arrow in the AC 5 display starts to blink and the direction is
new one in the correct way (punch mark on shaft towards not engaged. After this the direction can be engaged just
lever) and perform the calibration of the pedal. Adjust the when the shuttle lever is moved to the parking brake posiĆ
position of the sensor. Fasten the sensor in point, in which tion, the seat signal is activated (driver sits on the seat) and
the sensor shaft is in the same line with the pump lever
shaft (see point A in picture below). the direction is re-engaged.

If the direction has been engaged (or is being engaged)

Gas pedal Pedal up Pedal in bottom and the seat signal disapperas (e.g. driver stands up from
Signal voltage 5,7-5,8 V 1,5-4,0 V the seat), a counter is started. The counter damps possible
disturbing information, which can appear e.g. when driving
Adjust the pedal upper" value and check then that the on an uneven ground. If the seat signal remains floating
pedal bottom" position value is within the given limits. SeĆ (driver does not sit on the seat) over 6 seconds (4 sec. in
cure the screw, which fasten the arm to the sensor spindle program versions 38, 40, 41 and in AC 5.2 30 sec. if the
with Loctite 222. clutch pedal is depressed), the Shuttle is disengaged and
the direction arrow starts to blink. After this the direction can
3. Perform the pedal calibration according to instr. B on be engaged just when the shuttle lever is moved into the
page 370/15. parking brake position, the seat signal is activated and the
Shuttle direction is engaged again.
Note! The calibration of the gas pedal must be done acĆ
cording to the periodical maintenance program. Checking function of the sensor
- in the test mode FII (digital input d05)
B15, B16 - with ohmmeter in the wire loom connector (beside the
ETV 894 100 seat base). The switch is normally open, but closes, when
driver sits on the seat

Changing the sensor

- remove the seat upholstery
A - detach the sensor from its holder by pulling it
A
- remove the sensor together with wire
- pass a new sensor wire and press the sensor into its holĆ
der.
- refit the upholstery. Connect the connector. Check the
function.

A Brown
wire

3 Red, +7,7...+8,3 V

2 Blue, signal 1 Blue

3 (+7,7...8,3 V) 2 (signal) wire
1 Black, earth

258
 Modell Code Page
37. Autocontrol 5 / 5.2 6250-8950 370 24A
1. 11. 2000

5. Working orders, AC 5 and 5.2

A. Fitting AC 5 / 5.2 control unit on the tractor

A B

READY-PROGRAMMED UNPROGRAMMED UNIT

1.1 AC 5 CONTROL UNIT
1.1

FIT THE UNIT ON THE

FIT THE UNIT ON THE 1.2
1.2 TRACTOR
TRACTOR

INPUT MAIN PROGRAM

1.3 INPUT PARAMETER FILE
(AC 5: see instruction on page 370-24B
AC 5.2: see instr. on page 371-26)

CALIBRATE CLUTCH PEDAL SENSOR

CALIBRATE REAR CLUTCH PEDAL SENSOR (in reverse drive controls only), INDEX 2
turn the seat at rear position before calibration
2 SETĆ
TING SET DRIVING SPEED PARAMETER (tyres & transmission) INDEX A
MODE SET OUTDOOR TEMPERATURE UNIT (°C / °F) INDEX F
FIII SET DRIVING SPEED UNIT (km/h / miles/h) INDEX S/H

SET PTO RATIO 1 (LEVER IN FRONT POSITION), in program version 42- INDEX P
SET PTO RATIO 2 (LEVER IN REAR POSITION), in program version 42- INDEX L

WARM THE TRACTOR +30°...60°C

3 (transmission oil temperature)

SETĆ
4 TING
CALIBRATE GAS PEDAL SENSOR INDEX 1
MODE
FIII

TEST MOĆ
5 DE CHECK THROUGH THE WHOLE TEST MODE FII. ALL MUST BE OK
FII

SET THE SHUTTLE, DPS AND PTO INITIAL PRESSURES AND PRE-
SETTING FILLING INDEXES (see page 370/24D (manual setting) or automatic
6 MODE FIII setting in AC 5.2 on page 371/11. Manual setting of PTO clutch, see
page 371/12 (AC 5.2).

TEST-RUN
7 (see instruction 370-24E)

259
 Model Code Page
37. Autocontrol 5 X100-X120 370 24B
1. 11. 2000

B. Programming the control unit A1 in AC 5

The program disk part no is 340 422 50. The PC used must have HYPERTERMINAL" -terminal program. Installing can be done
with MS-WINDOWS-program disk. If You want to read instructions in the disk (Servive Manual pages), the PC must have progĆ
ram Adobe Acrobat reader 4.0 or later version. If needed, contact Your program supplier.
TABLE 1: Control unit part numbers and file names, versions 52 and 62. In Service and in Spare Parts are used these
parameter files and check codes.

Suitability, For tractors no. Control unit Program file Parameter file Check code Check code 2
tractor moĆ part no. name 3) name 3) 1 1) 2)
dels
-- -- 333 730 10 Not programĆ Not programmed -- --
med
X100-X120 J38342-K41106 340 272 20 sc12_52.s19 65P01_5262_23 52 23 1) 23 52 2)

1)Check code 1 is visible in the PC display by typing command PROC_VER?

2)Check code 2 is visible in the tractor display (in the test mode FII)
3)The files can be copied into the control units which have number 333 73 010 and the ser. no. end is 00400 or greater.
CONNECTIONS earlier it is not necessary to perform stage no. 6 (the control
A. Unfixed control unit (see picture 1): unit performs it by itself and goes to stage no.7).

1. Connect the cable of the programming unit (part no. 340 Deleting old program in control unit:
425 00) to the PC's serial communication port COM 1 (or to
6. Write REM_MEM (Caps Lock" off, use shift" key) >
COM 2).
enter
2. Connect an AC5 control unit A1 to the connections of the 7. Appears: FLASH ERASE. * * * * * * (the memory of
programming unit. control unit is cleared) > after a few seconds appears: * *
OK * * SEND DOWNLOAD FILE.
3. Connect the power supply. Switch power off (on/off
switch) 7a (only tractors J38343-). Switch off the tractor current
with the ignition switch and switch on again >display is
B. Control unit that has been assembled to tracĆ emptied.
tor (see picture 2):
Sending program file to the control unit:
1. Switch power of the tractor off. 8. Choose "Transfer" > "Send text file"

2. Connect a programming cable (part no. 337 006 00 or 9. Go to point Files of type" > choose "All files (*.*)" > go
to point Look in" > choose directory Programs" or OhjelĆ
337 006 10) to the PC's serial communication port COM 1
mat" > choose with double click a suitable program verĆ
(or to COM2). sion (see table 1) > transferring data begins (wait 2...3 minĆ
utes, the process can't be seen in PC's display) > when the
3. Connect the cable to the connector X43 (at the right side process is ready text RESET appears (and AC5 display in
panel). tractor begins to work) (=OK)

COPYING PROGRAM FILE TO THE CONTROL 10. Choose Call" > Disconnect" > Call" > connect"
UNIT
COPYING PARAMETER FILE TO THE CONTROL
4. Turn PC's power on and start Windows 95. Insert an AC5 UNIT
programming diskette (part no. 340 422 50) to PC's disk If necessary a parameter file can be deleted and copied
drive A: > choose "My computer" > choose "3½ floppy separately without deleting the program file.
(A:)" > choose file "VALT_TRM95_COM1" or
VALT_RM95_COM 2" depending on which COM-port of Deleting old parameter file in control unit:
the computer the cable is connected to (double click) >
program Hyper Terminal" starts > wait until the program 11. Switch programming unit power off (or switch tractor
has started. power off) > switch power on > appears text: RESET
(=OK)
5. Switch the programming unit power on (or tractor power
on) => text RESET appears, it means that communication 12. Write LOAD_PAR (Caps Lock" off, use Shift" key) >
is OK. In case of malfuntion try once more (switch off > enter > OK (old parameters are cleared in memory):
switch on).

REMARK. If the transmission between the computer and

the control unit fails text RESET begins to appear continuĆ
ously. Press the button s (small one) many times until a text
Software download, Enter password ?" appears > press

The backspace button (<-) ten times > write the passĆ
word 5533710 > press Enter > the control unit start to wait
loading a file Send download file" > send the program file
(see position 8).
Remark ! If the control unit has not been programmed

260
 Model Code Page
37. Autocontrol 5 X100-X120 370 24C
1. 11. 2000

Inputting parameter file:

13. Choose Transfer" > Send text file"

14. Go to point Files of type" > choose All files" > go to

point Look in" > choose directory 3½-levyke A:" >
choose directory Parameters",

15. Choose a parameter file by means of table 1 (double

click) > appears text: RESET (=OK).

NOTE! If text parameters are cleared!!!! card will not work

until set!!!" appears when inputting parameter file, carry out
again procedures shown in paragraphs 12-15 (type
LOAD_PAR>enter...).

Inspection:
16. Write PROC_VER? > enter > a number with four
marks appears in PC's display (e.g. 52 23), this clarifies
what files are situated in control unit (program file and paraĆ
meter file, see table 1). Check that two last marks (e.g. 51)
correspond to part no. and tractor type. If necessary copy
parameters once more (stages 11...16).

17. Choose Call" > disconnect"

Picture A. Check code in AC 5 display
18. Switch programming unit power off
(or switch tractor power off).

19. Disconnect the programming cable

from the control unit (or from tractor).

20. Fill in an adhesive label (part no and

Part no of programmed unit
file names,
see table 1) > fasten it 52= Program version no (52, 62)
on the control unit in right position
(see picture 1).

21. Exit from the Hyper Terminal" 23= I.D. no of parameter file
(23, 33)
program, if you are not going to program
more control units.
Date
Settings after programming
(unit fixed in tractor) Signature of programmer

22. Carry out settings according

to the table on page 370/24A.

23. Test-run the tractor according

to instr. D on page 24E.

or COM2
340 422 50

33700600, L=1,5 m or or COM2

33700610, L=8,0 m
340 422 50
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 Model Code Page
37. Autocontrol 5 X100-X120 370 24D
1. 11. 2000

C. Manual setting of indexes for DPS and shuttle in AC 5

IMPORTANT! In AC 5.2 the indexes can be set automatically, see page 371/11. Manual setting of PTO clutch indexes only in
AC 5.2.

1. Drive the tractor warm, transmission temperature +30°C...+65°C.

2. Shuttle in P-position, gear H1, with accelerator lever 1200-1500 r/min.

Note! It is unnecessary to stop the engine after the index setting. Enough is that the tractor current is switched off and then immeĆ
diately on, so that the tractor can be driven. In the same way not to stop the engine it can be moved to the setting mode FIII. In
this case must simultanious be pressed switches, which activate the test mode.

3. Shuttle pre-filling time indexes

Set the F-clutch initial pressure index to: -6 Index 5
Setting
g mode FIII Set the R-clutch initial pressure index to: -6 Index 6
H1
Set the F-clutch pre-filling time index to: -3 Index 3
1200-1500 r/min
Set the R-clutch pre-filling time index to: -3 Index 4
Make starting drivings forwards with the shuttle lever. Increase pre-filĆ Index 3
ling index one step by turns (-3, -2, -1, 0, +1, +2, +3, +4...) until
the jerk is disturbing. Diminish the index 1-2 steps. Check that in the
starting driving there is a clear but small jerk.
Set the R-clutch pre-filling index in the same way Index 4

4. Shuttle initial pressure indexes

Increase F-direction initial pressure index one step by turns (-4, -3, Index 5
Setting mode FIII -2, -1, 0, +1, +2, +3, +4...) and make starting drivings with the
H1 shuttle lever. Index is suitable, when the tractor accelerates evenly and
1200-1500 r/min there is not delay or break in the traction.
Set the R-direction
R direction initial press
pressure
re inde
index in the same way
a Inde 6
Index
Test mode FII Start the engine and activate the test mode FII and find point A4.
H1 Depress the clutch pedal and switch on the forward driving (F). Raise
1200-1500 1/min the pedal slowly and watch the display and observe in which pedal
position the tractor starts to move (%-value).
Switch on the R-direction. When starting driving rearwards the %-vaĆ
lue must be about 10 %-units greater that when starting driving forĆ
wards. E.g. in forward driving 20/rearward driving 30. If the forward
driving value is the same or greater that the rearward driving value,
recheck the initial pressure indexes.

5. DPS initial pressure indexes

Check the function of the DPS in different situations: different driving
Setting mode FIII speeds, in traction, without traction, in engine braking.
H1 - If the traction breaks when engaging the speed, increase the index.
1200-1500 r/min - If the engagement is too sharp, decrease the index
Clutch C1, affects between DPS speeds 3->2
3 >2 Index 7
Clutch C2, affects between DPS speeds 2->3,
2 3, 2->1
2 1 Index 8
Clutch C3, affects between DPS speeds 1->2 Index 9

6. Carry out a test-run (see instruction 370-24E)

262
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 24E
1. 11. 2000

D. Test-run, AC 5 and 5.2 Function of HiShift

-Start driving (several times) by using the HiShift button,
the tractor must start to move with even acceleration (not
HiTech -tractors shall be test-run always after repair works jerks or long delay)
and, when necessary, also in connection with fault tracing: - Drive ahead over 10 km/h, change gears 1-2-3-4 by
using HiShift buttons (without clutch pedal); traction must
Before the test-run: again continue when the HiShift button is released.

– If the tractor has been repaired, carry out all points in the Function of the clutch pedal:
test mode; all functions must be OK before the test-run. - Start driving slowly with the clutch pedal: traction must
– If the fuel injection pump or its linkage has been repaired engage evenly without a sharp jerk
or adjusted, calibrate the gas pedal position sensor B15 - Start driving faster with the clutch pedal : the tractor must
– If one of the DPS or shuttle proportional valves has been start to move without delay.
changed, the resetting of the shuttle and the DPS pre-fillĆ - Start to move by allowing the pedal rise fast to the top
position (slip foot to one side on the pedal). In this case the
ing time and initial pressure indexes must be done.
automatics take care of a smooth start.
– If a new AC 5 / 5.2 control unit (A1) has been fitted or it is
reprogrammed, carry out the following settings in the setĆ
Function of the reverse shuttle:
ting mode FIII:
- When the engine is running (shuttle lever in pos. P) enĆ
- driving speed parameter, temperature and driving speed gage gear H1
units - Move the lever to pos. N ; the shuttle must further be in
- calibration of the clutch pedal and gas pedal sensors neutral
- resetting of the pre-filling times and initial pressure inĆ - Start driving forwards by moving lever to pos. F (without
dexes of shuttle, DPS and PTO. clutch pedal); repeat many times
- Start driving rearwards by moving lever to pos. R, repeat
Test-run, general: many times
- test-run the tractor on a safe place, not IN TRAFFIC - Compare starts with the shuttle lever and the HiShift-
- observe the display unit during the test-run; if a fault button. They must function with the same speed.
code appears, repair the fault and carry out a new test-run - Drive below 10 km/h forwards, move then the lever to
- if a minor fault appears during the test-run, the control R-position (hand gas lever 1200…1500 rpm); the driving
unit shows a fault code in the display; often driving can be direction change must start immediately (shuttle brakes)
continued but clutch pedal must be used when starting and the R-direction must engage smoothly but fast, when
driving and when the driving direction is changed. the tractor is almost stopped
- Drive over 10 km/h forwards, move then the lever to R-
- If a serious fault appears during the test-run, the control
position (hand gas lever 1200…1500 rpm); the driving
unit prevents driving or using PTO to protect the transĆ
direction change must start at a speed of about 10 km/h.
mission against break-downs
- Check, that the HiTech display shows near the same
Function of DPS, manual mode:
driving speed as the AD-instrumentFunction of the safety - Turn the DPS -rocker switch to "man" ćposition (front
systems: edge depressed), change during driving DPS speeds with
buttons in the gear lever knobs, use also engine revs beĆ
Safety system tween 1700…2000 rpm; the speeds should engage without
sharp jerks and without any long delay
- Start prevention: try to start the engine with shuttle lever - Change quickly with double-click 1=>3 and 3=>1;
in positions F-R-N-P (clutch pedal depressed); the enĆ although the display does not show the speed 2 , the DPS
gine is allowed to start only in P-position (parking brake speed must change via speed 2.
applied), and the engine is not allowed to start, if the clutch - Turn the DPS rocker switch to pos. "Auto1" (AUTO 1 in
pedal is in the upper position display); test by driving in M-range that the DPS changes
- Driver detection (in the seat): stand up from the seat, speed when the loading varies (use an implement if
after 7…10 seconds engage direction F (speed gear enĆ necessary), Auto1 ćprogram tries to keep the engine revs
gaged, clutch pedal up); The tractor is not allowed to move, high
and the direction arrow in the display starts to blink, (to conĆ - Turn the DPS-switch to pos. "Auto2" (AUTO 2 in disĆ
tinue driving: sit on the seat, move the shuttle lever to pos. play); drive with range gear H and ensure that the DPS
P and engage after that the driving direction). AC 5.2: the changes speed when the driving speed varies, Auto 2 alĆ
delay of the seat switch is 30 sec, if the clutch pedal has lows larger engine rev variations than Auto1. In AC 5.2 the
been depressed. AUTO 2 functions with fixed revs and is adjustable, see
- Emergency brake system: switch off current with the page 371/4.
- Turn the DPS-switch to pos. "man", pre-program the
ignition switch (driving speed max. 2 km/h for the safety);
DPS speeds F II / R III, carry out driving direction changes
the parking brake must engage after a while. (without the clutch pedal); the correct, pre-programmed
DPS speed should engage in both driving directions.
Function of the parking brake (HiBrake):

- Drive below 4 km/h (below 2 km/h in program versions

42, 43, 60, 62), apply parking brake: parking brake must
engage after a while
- Drive at a speed of 5…6 km/h, apply parking brake; the
parking brake must engage just when the driving speed
has dropped below 4 km/h (below 2 km/h in program verĆ
sions 42, 43, 60 and 62).
- The parking brake must disengage (engine running) in
the shuttle lever positions N-F-R Function of HiShift funcĆ
tion:

263
 Model Code Page
37. Autocontrol 5 / 5.2 X100-X120 370 24F
1. 11. 2000

Function of PTO (use implement, if needed, as a load):

- Select with the lever PTO speed 1 (front position of the

lever), start the PTO, PTO symbol must light up in the disĆ
play, keep engine revs at about 1800 rpm for about 30 secĆ
onds.
Note the changed PTO starting custom in program version
42- (starting at least 3 seconds). Also check possible rear
push buttons for PTO (option)
- Try the same with PTO speed 2 (lever in the rear position)
NOTE! In AC 5.2 there are as option the PTO start/stop
buttons on the rear mudguards, which have 3 sec. engagĆ
ing delay.

4WD automatics (AC 5.2 only)

The automatics are activated, if the value of index U (in the
setting mode menu) is 1 (=factory value).

- turn the 4WD rocker switch into OFF position (left side
down). When starting driving and when changing driving
direction the 4WD must be engaged for a while. The 4WD
must be engaged also when using HiShift buttons, if the
driving speed is below 10 km/h. The 4WD must be disengaĆ
ged at least when the driving speed exceeds 10 km/h.

Automatic traction control (AC 5.2 only)

- let the engine idle and switch on the AutoTraction control
with the Nauto" switch (right edge down).
Symbol N starts to flash in the display. Engage gear H1 and
switch on the driving direction.
Raise the engine revs with the gas pedal over 1020 r/min, at
which time the tractor must start to move softly (do not use
the clutch pedal). The traction must be disengaged, when
the brakes are depressed while the driving speed is below
10 km/h, the traction must also be disengaged, if the gas
pedal is released and the engine speed lowers under 970
r/min.
The traction control is switched off by stopping the tractor
and by moving the shuttle lever into position P.

Checking fault code memory (AC 5.2only)

Check after the test-run if there are fault codes in the meĆ
mory . If so, repair the faults and empty the fault code meĆ
mory by pushing the DPS pre-programming button over 4
seconds (see page 371/6)

264
 Model Code Page
37. Autocontrol 5 X100-X120 370 25
1. 11. 2000

6. Others
A. Connector pins of AC 5 control unit Data transfer channels

*(CAN 2 GND)

*(CAN 1 GND)

RS-232 GND
NOTE! Connectors of AC 5.2, see page 371/15.

*(CAN 2 LO)

*(CAN 1 LO)

RS-232 RX
RS-232 TX
*(CAN 2 HI)

*(CAN 1 HI)
*) CAN 1 and CAN 2 data transfer
channels are not in use

4
5
6
1
2
3
1
2
3
INPUT
Hand brake d16 (S15) A1A5
14
INPUT
PTO stand-by d15 (S25) 13

Seat direction d14 (S35) 1 Supply +12 V

12
2 GND
PTO speed 2 d13 (S29) 11 (only TwinTrac)
3 F6 PTO-speed (B7)
PTO speed 1 d12 (S28) 10 4 GND, sensors
DPS pre-selection d11 (S51) 5 F5 Shuttle sign. (B13)
9
6
Direction R d10 (S41) 8 A1A4 F4 Shuttle sign., (B12)
A1A1 7
8
Direction F d09 (S40) 7
9 Reserve
DPS auto/manual d08 (S47) 6 10
VALTRA
DPS auto1/auto 2 d07 (S47) 5 AC-5 11 F2 Gearbox speed, (B6)
Transmission control 12
Clutch pedal limit d06 (S9) 4
Driver detection d05 (S60) 3 13 F1 Engine speed, (B11)
PTO start d04 (S25) 2 14

HiShift d03 (S45) 1

DPS down d02 (S23) 10
DPS up d01 (S23) 9
A4 GND (B16) 8 +7,7-8,3 V
Clutch pedal sign. A4 (B16) 7
Clutch pedal supply A4 (B16) 6 A1A3
GND A3 (B15) 5 +7,7-8,3 V
Gas pedal sign A3 (B15) 4
Gas pedal supply A3 (B15) 3
Oil temp. A2 (B14) 2
Out temp. A1 (B17) 1
14
13
12
11
10

3
7

2
1
5
4
6
9

A1A2
GND
GND LCD-display
P1 DPS-solenoid (Y4)
DO 1 LCD display
P2 DPS-solenoid 2 (Y6)
DO 2 LCD display
P3 DPS-solenoid 3 (Y17)
DO 3 LCD display
P4 F-solenoid (Y11)
DO 4 LCD display
P5 R-solenoid (Y12
DO 5 Hand brake relay (-J38342, LCD display)
P6 PTO-solenoid (Y2)
DO 6 PTO pilot light

OUTPUT

d=digital input (on/off)

A=analog input (changing) DO=digital output
F=frequency input (speed) P6 to display
P=output to proportional valves

265
 Model Code Page
37. Autocontrol 5 X100-X120 370 26
1. 11. 2000

Wiring diagram AC5 1

-J38342 (AC 5).

Current must not be taken

from circuit of fuse F24 Note! Supply voltages of
(safety risk) sensors B12 and B13 via
fuse F22.

Wiring diagram AC5 2

266
 Model Code Page
37. Autocontrol 5 X100-X120 370 26A
1. 11. 2000

Wiring diagram AC5 1 J38343-K41106 (AC 5)

Note! Supply
Current must voltages of
not be taken sensors B12
from circuit of and B13 via
fuse F24 (safeĆ fuse F22.
ty risk)

Wiring diagram AC5 2

267
268
 Model Code Page
37. Autocontrol 5 X100-X120 370 27
1. 11. 2000

B. Wiring diagrams AC5

(The diagrams also under code 310). Position of connecĆ C. Control unit connector A1A3
tors, see pages 310/6C och 6D.
B16: Clutch pedal position sensor
A. Control unit A1 connector A1A1 B14: Gearbox temperature sensor
B15: Gas pedal pisition sensor
F24: AC5 fuse in the fuse box B17: Outdoor temperature sensor

B6: Gearbox speed sensor S23: DPS push buttons up/down

B7: PTO speed sensor
B11: Engine speed sensor Position of connectors:
B12: Shuttle speed sensor
B13: Shuttle speed sensor X13: Connector for transmission (37 pins) on the support plate
in the lever console.
Position of connectors: X19: Connector (37 pins) on the cab front wall on the RH side.
X1A: Connector (9 pins) for the engine sensors in the front part
X13: Connector for transmission (37 pins) on the support of the engine compartment near the thermostat housing.
plate in the lever console. X23: Connector for DPS push buttons in the lower part of the
X28: Connector for shuttle sensors (9 pins) in the lever conĆ gear levers
sole X30: Connector (9 pins) for gear lever push buttons in the loĆ
X26: White connector (26 pins) in the rear face of the comĆ wer end of the levers.
bination instrument.
X1E: Connector (9 pins) for ACD power lift speed sensors GR1: earth point in the rear part of the lever console
on the support plate in the lever console (also connector
X2E).
D. Control unit connnectors A1A4 and A1A5
GR1: earth point in the rear part of the lever console
S45: HiShift push buttons in the gear lever knobs
S28: PTO switch at the PTO lever (540)
B. Control unit connector A1A2 S29: PTO switch at the PTO lever (1000, 540E)
S47: Auto1/Auto2//Man switch for the DPS
P6: AC5 display unit S40: Reed relay, forward driving (F) (in the shuttle lever)
H10: PTO ind. light S41: Reed relay, rearward driving (R) (in the shuttle lever)
S51: DPS pre-programming button
Y11: Proportional valve, forward driving (F) S60: Seat safety switch (detection of driver)
Y17: DPS proportional valve (C3) H27: Back buzzer
Y12: Proportional valve, rearward driving (R) K29: Relay for the back buzzer
Y2: PTO proportional valve (PTO)
Y4: DPS proportional valve (C1) Position of connectors:
Y6: DPS proportional valve (C2)
X30: Connector (9 pins) for the gear lever push buttons in the
Position of connectors: lower end of the levers.
X39: Connector (9 pins) for the shuttle lever at the steering
X13: Connector for transmission (37 pins) on the support wheel under the dashboard.
plate in the lever console. X43: RS-232 connector on the lever console
X27: Blue connector (26 pins) in the rear face of the combiĆ
nation instrument. GR1: earth point in the rear part of the lever console
V1: diode box for solenoid valves Y1, Y2, Y3, Y4 and Y6 on GR5: earth point in the cab front wall
the support plate in the lever console.
V4: diode box for solenoid valves Y11, Y12 and Y17 on the
support plate in the lever console.

GR1: earth point in the rear part of the lever console

GR5: earth poin in the cab front wall

269
 Model Code Page
37. Autocontrol 5 X100-X120 370 28
1. 11. 2000

C. Control diagrams, AC 5. Note! Control diagrams of AC 5.2, see page 371/18-22.

DPS control

X13

V1, V4
3 2 1

6 5 4
9 8 7

270
 Model Code Page
37. Autocontrol 5 X100-X120 370 29
1. 11. 2000

Control of shuttle, AC 5

X13

V1, V4
3 2 1

6 5 4
9 8 7

271
 Model Code Page
37. Autocontrol 5 X100-X120 370 30
1. 11. 2000

Control of PTO, AC 5

X13

V1, V4
3 2 1

6 5 4
9 8 7

272
 Model Code Page
37. Autocontrol 5 X100-X120 370 31
1. 11. 2000

Control of parking brake and engine starting, -J38342, AC 5

273
 Model Code Page
37. Autocontrol 5 X100-X120 370 32
1. 11. 2000

Control of parking brake and engine starting, J38343-K41106, AC 5

274
 Model Code Page
37. Autocontrol 5 X100-X120 370 33
1. 11. 2000

Reverse drive controls, AC 5 HiTech

275
276
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 1
1. 11. 2000

Contents
Note! Under code 371 are shown only AC 5.2 instructions, which differ much from AC 5.
Under code 370 are given necessary references to this code.

1. General:

A. New functions of AC 5.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

B. AutoTraction on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. DPS-gear, new automatic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Fault codes in AC 5.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. Fault code memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F. Working orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A
G. Checking ID number of program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B

2. Tests:

A. Test mode menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

B. Table to check different switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. Table to check temperature sensors and pedal position sensors . . . . . . . . . . . . . . . . . . . . . . 9
D. Table to check revolution speed sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A
E. Table to check proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B
F. Counter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C

3. Settings:

A. Setting mode menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B. Setting clutch pedal ratio index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C. Automatic setting of shuttle, DPS and PTO clutch indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
D. Manual setting of PTO clutch indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
E. Setting 4WD automatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F. Setting pre-filling indexes of DPS clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A

4. Components:

A. Reconditioning temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Reconditioning clutch pedal position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. Reconditioning clutch pedal limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
D. Reconditioning gas pedal position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5. Others:

A. Connectors of AC 5.2 control unit A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Wiring diagrams of AC 5.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
C. Control diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6. Programming AC 5.2 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

277
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 2
1. 11. 2000

1. Autocontrol 5.2, general

g) Reverse drive controls (TwinTrac)
Note! AC 5.2 replaces the AC 5 system in 100-X120 tracĆ
tors from ser. no. K41107 incl. The reverse drive controls have separate digital inputs in
the control unit A1. The position of the seat (d14) determiĆ
nes which one of digital inputs the control unit uses.
A. Additional functions in AC 5.2
h) Seat switch
a) Automatic traction control (Autotraction ON/
OFF) The activating delay is normally 6 seconds, but 30 seĆ
conds, if the clutch pedal has been depressed, see page
See page 371/3. 370/24.
b) Fault codes i) PTO start
Fault codes have a fault code memory (in fault code mode The PTO start push buttons in the mudguards (option) have
FI), in which can be checked and deleted from display. The separate digital inputs in the control unit. The PTO rocker
memory stores three latest fault codes and running hours of switch in the cab functions without delay and the push butĆ
the codes (control unit running hours). ton in the mudguard has delay of 3 sec.
New fault codes have been added in the system, see paĆ
j) Zero-point offset of the shuttle outputs
ges 371/5 and 6.
Into the shuttle clutch, which is unpressurised, is fed from
c) Automatic speed change of DPS time to time an oil pressure of 0,1...0,5 bar, so that no air
can enter into the oil passages. This happens if either of the
AutoDPS Auto2 function has been changes so that it functiĆ driving directions is engaged.
ons in fixed speed change revs and driver can set easily the
revs, see page 371/4. Note! The pistons in the shuttle have been made smaller
and the spring force has been increased. The emptying
d) Speed Matching valve has been removed from the piston for reverse driving,
see page 440/19A. In connection with this shuttle the AC
When using the HiShift button the control unit adapts the 5.2 programs must always be used.
DPS speed so that it is suitable for driving situation when
the mechanical gear has been changed, see page 371/4 or NOTE! Initial pressures of the shuttle clutches have been
when traction is disengaged and re-engaged with clutch raised up to about 3,5 bar (earlier about 2 bar).
pedal, with HiShift or with the shuttle lever.
k) Other modifications

e) Automatic calibrations With the aid of output P7 the control unit switches on and
off the auxiliary relay K52 of the starter.
The automatic calibration is activated in setting mode FIII,
and it calibrates the initial pressures and pre-filling times of Control unit output P8 controls the 4WD automatics (relay
the shuttle clutches, for DPS and PTO clutches only the K27).
initial pressures, see page 371/11. The calibrations can
also be done manually, see page 370/24D. Manual calibraĆ The control unit changes no more DPS speed in driving
tion of PTO clutch, see page 371/12. speed of 64 km/h but gives only a fault code.

NOTE! AC 5.2 has a new control unit, which can be used

f. Calibrations of clutch and gas pedals and peĆ also in the earlier manufactured tractors with AC 5, but a
dal position sensors different programs must be used.

The activating point of the clutch pedal limit switch has In the DPS-gear the spring force of clutch C3 has been
been changed to zero point of the pedal position. Now the increased. Also oil way modifications have been done, see
activating point of the switch is not necessary to adjust so page 440/12.
excatly as earlier.
Parking brake! A non-return valve (47/00-) has been
The pedal calibrations have been changed so that the contĆ fitted in the low pressure circuit, which together with progĆ
rol unit accepts more unaccurate signal voltages for the ram modification retards the pressure drop in cases, in
position sensors. Calibrations, see page 370/15. which engine stops during running ( e.g. fuel runs out). In
this case the parking brake cylinder starts to brake after
The position sensors are different and they have been fasĆ 15-30 seconds. A modification has been made in AC 5.2
tened so that no adjustment is needed, see pages 371/13 program, which disengages all multi-disc clutches if tracĆ
and 14. tor's engine stops when the driving speed is over 5 km/h.

With the aid of the clutch pedal ratio index the pedal engaĆ The function of output DO5 has been changed inverse.
ging point can be adjusted separately in F- and R-directiĆ Earlier this output was parking brake on. Now parking braĆ
ons in the setting mode FIII, see page 371/10. ke off. The control unit controls direct the valve and no moĆ
re via an auxiliary relay.

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37. Autocontrol 5.2 (K41107-) X100-X120 371 3
1. 11. 2000

B. Automatic traction control

3. Automatic traction engagement happens,
An extra rocker switch (Autotraction ON/OFF) has been when:
fitted in the cab. This switch switches on/off an automatic
function, in which either driving directions (traction) (F, R) - function is activated and either driving directions (F or R)
can be engaged and disengaged automatically by using is engaged
the gas pedal or the brake pedals depending on the engine - brake pedals are not depressed
revs and driving speed. - engine revs greater than 1020 r/min
- the gas pedal is depressed sufficiently.

The following items affect the autotraction control :

- position of rocker switch (Autotraction on/off), d23

- engine revs, F1.
- gearbox speed (driving speed), F2
- brake pedal switches, S10, S20, d24
- gas pedal position, A3.
- clutch pedal position (front/rear), A5/A7.
- position of shuttle lever (front/rear), d9, d10/d18, d19.
- direction (F, R), F4 and F5.
1. The function can be switched on, when: - parking brake (front/rear), d16/d22

- tractor is stationary (i.e. gerabox speed is zero)

- engine revs lower than 1000 rpm. Note! If the traction control is switced off with the rocker
- rocker switch is turned into position ON switch during driving, the selected driving direction is disenĆ
- gas pedal calibration has been done correctly gaged into the neutral position and symbol N in the display
is blinking. After this the control unit does engage neither
Note! After engine stop the function must be restarted with direction until the parking brake is activated (driving speed
the rocker switch. below 2 km/h) and the driving direction is reselected.

When the function has been switched on and the shuttle FAULT TRACING:
lever is in the neutral position, the system is in the stand-
by mode and symbol N is blinking in the display. The seat - If the AutoTraction has malfunctions, check in the test
switch functions normally during the autotraction control. mode FII the sensors and switches and wires which affect
the function of the system. Also check the calibration of the
2. Automatic traction disengagement happens, gas pedal.
when:
- check the gas pedal signal voltage in the test mode FII,
specially when the pedal is up (page 371/9).
A. the function is switched on, driving direction F or R is
Calibrate the gas pedal and check in the test mode, that the
engaged and the tractor is driven with. Now the automatics
position % is zero when the pedal is up.
observe signal from brake switches (S10, S20). When the
- check the gas pedal position sensor lever and its fasteĆ
brake pedal/pedals are depressed and the driving speed is
ning on the spindle.
below 10 km/h, the traction is disengaged automaticallly,
- check, that the engine revs drop clearly below 950 rpm,
when the gas cable is released.
or
NOTE! When driving with the reverse drive controls (Twin/
B. the function is switched on, driving direction F or R is
Trac), the use of the brake pedal does not disengage the
engaged and when the engine revs drop below 970 rpm. If
traction but the traction must be disengaged otherwise (the
the gas pedal is almost in the upper position, the selected
rear brake pedal has not a brake light switch, so the control
driving direction is disengaged automatically.
unit cannot get information, when the pedal is depressed.
If the above given terms (A or B) come true, the selected
driving direction is disengaged automatically and symbol N
is blinking in the display.

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37. Autocontrol 5.2 (K41107-) X100-X120 371 4
1. 11. 2000

C. Automatic speed change of DPS (AuĆ

toDPS) 2. Speed Matching of DPS

1. Auto2 -function The Speed Matching is one part of the AutoDPS function.
With the aid of the speed matching the DPS speed is chanĆ
AutoDPS Auto2 function has been changed so that the ged automatically to a best suitable speed in connection
automatic gear change occurs at adjusted engine revs. The with the mechanical gear change.
limit revs can be adjusted as follows:
The function is active, when:
- ensure that the shuttle lever is in the neutral position - AutoDPS is switched on (auto1 or auto2) and
- switch on Auto2 with the rocker switch - tractor is in motion and
- press for one second DPS-preprogramming button - either driving directions is on.

After this the present change-down limit revs are blinking When these terms come true, the speed matching is actiĆ
in the display and the black arrow downwards is blinking. vated and it remains on until one of the following terms coĆ
mes thrue:
The blinking revs can be stepped with DPS push buttons at
intervals of 50 rpm in both directions. The limit revs for the - AutoDPS is switched off (Man position) or
change-down can be altered between 900-2300 rpm. - tractor is stopped

After the change-down limit revs are correctly set, press When the speed matching is activated, the control unit obĆ
the DPS-preprogramming button after which the limit revs serves whether one of the following terms comes thrue:
for change-up starts to blink in the display and the black
arrow upwards is flashing. Also these revs can be stepped - HiShift-button is pressed or
at intervals of 50 rpm. - clutch pedal is depressed or
- selected driving direction (F or R) is switched off
The limit revs for change-up can be adjusted between
1000-2400 rpm and it must be at least 100 rpm bigger If one of the above given terms comes thrue, the control
than the change-down revs. unit measures immediately the input frenquency from senĆ
sors F4/F5 (F4 in the beginning), and with the aid of these inputs
When the change-up limit revs are correctly set, press the the control unit calculates the comparison values.
DPS-preprogramming button after which the set revs funcĆ
tion as limit revs in the Auto2 function. When the driving direction is switched on again (HIShift
button is released, clutch pedal is released or driving direcĆ
The adjusted limit revs remain in the memory although the tion is reselected), the control unit measures the frequency
current is switched off. Factory values of the limit revs are from sensors F4/F5 at this moment (F4 in the end).
1400 and 2100 in normal tractors and 1100 and 1700 in low This measured frequency is compared with the comparison
rev tractors. values and the control unit is carried out an automatic DPS
speed change (the automatic speed change can be one or
Note! While the limit revs setting mode is activated, the two step up or down), if the measured frequency is above
control unit does engage neither driving direction (R or F). If or below the calculated limit values.
the driving direction is tried to engage during setting, the
indication arrow of the direction in question is flashing, but The control unit changes first the DPS speed and after this
the direction is not engaged. After this the direction can not engages the traction (shuttle). If there is no need to change
be engaged until the setting is completed and the parking the DPS speed, the traction engages immediately.
brake is engaged. After the parking brake has been engaĆ
ged, the control unit is in the normal function. Note! During the automatic speed change can happen that
it is not possible to change two steps up or down (e.g DPS
speed II is selected and the speed matching should be two
The following digital inputs affect the function: steps upwards). In this case the speed matching is one
d01=DPS-push button up step up.
d02=DPS-push button down
d07=AutoDPS rocker switch Auto1 and Auto 2 The following digital inputs affect the function:
d08=DPS auto/manual d03=HiShift-button
d09=Direction F (forward driving selected) d06=Clutch pedal limit switch
d10=Direction R (rearwards driving selected) d07=AutoDPS rocker switch Auto1 and Auto 2
d11=DPS-preprogramming button d08=DPS auto/manual
d16=parking brake d09=Direction F (forward driving selected)
d10=Direction R (rearward driving selected)
The following frequency input:
F1=engine rotation speed sensor The following frequency inputs:
F2=gearbox speed (driving speed)
The switches and sensors can be checked in the test mode F4=reverse shuttle speed (upper sensor)
FII. F5=reverse shuttle speed (lower sensor)

If the input signals are OK, but malfunctions appear, the The switches and sensors can be checked in the test mode
fault can lie in the control unit of AC 5.2. FII.

If the input signals are OK, but malfunctions appear, the

fault could be in the control unit of AC 5.2.

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 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 5
1. 11. 2000

D. Fault codes in AC 5.2

Note! Concerning AC 5.2 fault code structure, see page 370/5 (AC 5).
Note! Concerning AC 5.2 fault function levels, see page 370/7 (AC 5).

Fault coĆ Control Fault identification Fault Tests Repairs,

de unit pin functiĆ settings
on leĆ
vel
P101 A1A4/6 Proportional valve P1 (Y4) of DPS takes current which exceeds 3
or goes below the given limits. Short circuit or wire damage
(C1).
P103 A1A4/4 Proportional valve P2 (Y6) of DPS takes current which 3
See table See instr.
exceeds or goes below the given limits. Short circuit or wire E on paĆ C on paĆ
damage (C2). ge ge
P105 A1A4/2 Proportional valve P3 (Y17) of DPS takes current which 3 371/9B. 370/21.
exceeds or goes below the given limits. Short circuit or wire
damage (C3).
P107 A1A3/8 Forward drive proportional valve P4 (Y11) takes current which 3
exceeds or goes below the given limits. Short circuit or wire
damage (F).
P109 A1A3/6 Reverse drive proportional valve P5 (Y12) takes current which 3
exceeds or goes below the given limits. Short circuit or wire
damage (R).
P125 A1A3/4 PTO proportional valve P6 (Y2) takes current which exceeds or 2
goes below the given limits. Short circuit or wire damage
P131 A1A3/2 Proportional output P7, which controls the starter interlock relay K52, 1
takes current which exceeds or goes below the given limits.
Short circuit or wire damage. Check the alternator.
P132 A1A3/1 Proportional output P8, which controls the 4WD relay K27, takes 1
current which exceeds or goes below the given limits. Short
circuit or wire damage (FET status error).

A128 A1A5/3 Supply voltage of clutch and gas pedal position sensors is not within 3
A1A5/6 given limits (4,5…5,5 VDC). Probably wires in short citrcuit.
A311 A1A5/2 Gearbox oil temperature value (sensor B14) impossible (over 3
+150°C). Faulty sensor or its wiring See instr.
See ttable
S bl A and B
A312 A1A5/2 Gearbox oil temperature value (sensor B14) impossible (beĆ 3
on page
low -50°C). Faulty sensor or its wiring. C on paĆ
ge 371/9.
371/9 371/13
A313 A1A5/4 Signal from gas pedal position sensor B15 below 0,4 VDC or over 4,4 3 and instr.
VDC. Sensor wrongly fitted or wire damages. D on ppaĆ
A314 A1A5/7 Signal from front clutch pedal position sensor B16 below 0,3 VDC or 3 ge
over 4,7 VDC. Sensor wrongly fitted or wire damages. 371/14
A326 A1A1/1 Control unit supply voltage not within limits 10,5…17,0 VDC. Battery 3
A1A1/2 damaged or poor contacts or short circuit in wires. Check the alternaĆ
tor.
A351 A1A7/1 Signal from rear clutch pedal position sensor B1W below 0,3 VDC or 3 See table See instr.
over 4,7 VDC. Sensor wrongly fitted or sensor/wire damages. This C on paĆ B on paĆ
fault code appears only when the seat is turned backwards. ge 371/9. ge
371/13.

d116 A1A5/9 DPS up-down push buttons (S23) are active simultaneously. Push buttons in 1
A1A5/10 the lever knobs may be in short circuit. The fault code can also appear,
when the service modes (FI-FIII) are activated.
d117 A1A8/1 Forward (S40) and reverse drive direction (S41) are active simultaneously. 4
A1A8/2 Shuttle lever switches may be in short circuit.
d118 A1A8/4 Both PTO speeds are engaged simultaneously. PTO lever switches 2
A1A8/5 (S28/S29) may be in short circuit.
d123 A1A8/8 Front parking brake and one or both shuttle directions engaĆ 4
A1A8/1 ged simultaneously. Shuttle lever switches may be in short See table See table
A1A8/2 B on paĆ B on paĆ
circuit. No function, if the seat has been turned rearwards.
ge 371/8.
371/8 ge
d127 A1A8/8 Digital output, which controls the parking brake solenoid (Y18), is not 3 370/20.
within given limits. Probably solenoid in short circuit or wire damages.
d129 A1A8/3 DPS-pre-programming buttons S51 and S4W in front and reverse 1
A1A2/5 drive controls active simultaneously. Front and rear push buttons in
short circuit or buttons have been stuck.
d130 A1A7/4 PTO start switches (S25, S1A, S2A) in the cab and in the rear mudguard are simulĆ 2
A1A2/9 taneously active. Probably short circuit or switches have been stuck.
d152 A1A2/8 In the reverse drive controls F and R directions active simultaniously. 4
A1A2/7 Shuttle lever switches probably in short circuit. This fault code appeĆ
ars only when the seat is turned backwards.
d133 A1A7/6 Front and rear clutch pedal limit switches S9 and S2W active simultaneously . ProĆ 3
A1A2/6 bably short circuit in the switches or switches have been stuck.
281
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37. Autocontrol 5.2 (K41107-) X100-X120 371 6
1. 11. 2000

Fault coĆ Control Fault identification Fault Tests Repairs,

de unit pin functiĆ settings
on leĆ
vel
d153 A1A2/3 In the reverse drive controls parking brake and one direction (F or R) 4
A1A2/8 active simultaniously. Rear shuttle lever switches probably in short
A1A2/7 circuit. This fault code appears only when the seat is turned backĆ
wards. See table See instr.
d215 A1A7/6 Front clutch pedal position > 50 % and d06 is active (d06=pedal limit 4 B on paĆ B on paĆ
A1A5/7 switch S9). Check the limit switch and its adjustment. ge 371/8. ge
d254 A1A2/6 Rear clutch pedal position > 50 % and d20 is active (d20=pedal limit 4 370/20
370/20.
A1A7/1 switch S2W). Check the limit switch and its adjustment. This fault
code appears only when the seat is turned backwards.

F320 A1A1/7 Shuttle speed sensors (B12/B13) give different frequency. DifĆ 3
A1A1/5 ference over 30 %. One of the sensor possible faulty.
See table
F321 A1A2/4 Engine rpm lower than what the shuttle sensors (B12/B13) indicate, when 3
D on paĆ See instr.
one solenoid is fully active. Engine rpm sensor B11 may be faulty. ge D on paĆ
F324 A1A1/7 Driving speed over 10 km/h and direction information in the 1 371/9A ge
A1A1/5 control unit is changing. Shuttle sensors B12 or B13 may be 370/22
faulti or wire problems.

L419 A1A1/3 Full pressure has been connected to the PTO clutch over 3 seconds, but the 2
PTO shaft rotation speed is lower than it should be. PTO-clutch may slip. It See table See instr.
is possible that the PTO rpm sensor B7 is faulty. Check in the test mode PTO D on paĆ D on paĆ
lever switches S28 and S29. Check that the switches have not been faulty ge ge
371/9A. 370/22.
connected (can be seen in the test mode). Ensure that the PTO speed paraĆ
See table
meters P and L are correctly set. B on paĆ See instr.
ge 371/8. B on paĆ
ge
370/20.

L422 A1A1/7 One shuttle direction is engaged and full control has been active over 3 4 See instr.
A1A1/5 seconds. Shuttle rotation speed is lower than engine speed in relation to the C on paĆ
A1A2/4 DPS ratio. One multi-disc clutch in the DPS or in the Shuttle can slip or one See table ge
proportional valve (Y4,Y6,Y17,Y11,Y12) can be trapped. This fault code E on paĆ 370/21.
ge
also appears, if both shuttle sensors (B12,B13) do not give a signal, when
371/9B. See instr.
engine revs are over 1600 rpm. This fault code is activated at engine speeds D on paĆ
over 1000 rpm and in HiTrol tractors at engine speeds over 1800 rpm. This ge
fault code can also appear, if the turbine clutch has too much slip (e.g. too 370/22
little oil in the turbine clutch).
L334 A1A2/2 Driving speed over 65 km/h measured by gearbox speed sensor B6 1
frequency input. 4WD propeller shaft can be damaged.
L335 A1A2/4 Engine revs over 2800 rpm, measured by sensor B11 frequency inĆ 1
put.

E. Fault code memory (AC 5.2 only)

This fault code is visible two seconds and after this is shown
the running hours of the code. The running hours are shown
The fault code memory functions in all tractors, which have
also two seconds.
main program version 81 or later. In version 80 the fault code
memory has malfunctions.
If there are many codes in the memory, a line is shown one seĆ
cond between each codes. Then the next code and the runĆ
For fault codes have been made a memory where can be
ning hours are shown. When all codes and running hours haĆ
checked and removed appeared fault codes. The memory
ve been shown, the first code appears again in the display.
stores three latest fault codes and their running hours (accorĆ
The codes are shown until the current is switched off or the
ding to the control unit hour counter L", not an exact value).
DPS pre-programming button is pressed over 4 seconds.
The fault code memory FI can be activated in the same way
- if there is no codes in the memory, the line is blinking in the
as the test mode FII, see page 370/8.
lower part of the display.
Number Mode Mode symbol - the fault code memory can be emptied by pressing the DPS
pre-programming button over 4 seconds, after which the coĆ
1 Fault code memory FI des disappear and the line starts to blink.
(AC 5.2)
2 Test mode F II
3 Setting mode F III

When the fault code memory has been activated, the display
shows in the lower part of the display the fault codes stored
in the memory. The fault codes are visible in a correct order so
that after the activation there is an oldest code in the display.
282
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 6A
1. 11. 2000

F. Working order
Setting indexes of transmission (AC 5.2)
1. Warm the transmission up to +30°C0+60°C

Note! If the tractor has HiTrol turbine clutch, carry out stall-test before automatic calibrations (see pagr 411-7).

2. AutoCalibration of shuttle clutches and PTO clutch:

-Calibrate the forward clutch F CAL 1
Setting mode FIII -Calibrate the reverse clutch R CAL 2
M4 (40 kph) -Calibrate the PTO clutch CAL 6
M3 (50 kph,
kph 8350Hi)
(Autocalibration sets the initial pressure and pre-filling time indexes
1700-1800 rpm
for the shuttle, initial pressure index for the PTO)

3. Make a test-drive

4. If the shuttle does not function properly make the AutoCalibration once more
Setting mode FIII -Calibrate the clutch that does not function properly
M4 (40 kph) -Check that you have the right main gear selected
M3 (50 kph, 8350Hi) -Check that the tractor stays at a flat surface
1700-1800 rpm
- Make a test drive (the shuttle)
- If the function is not good enough set the indexes manually (you
can start from the indexes that the AutoCalibration has saved into
memory)

5. Make a test-drive
-Test the function of DPS (shift DPS speeds 1-2-3-2-1 at different situations like accelerating and motor braking)

6. If the DPS does not function properly make the AutoCalibration of DPS clutches:
Set the indexes no. 7, 8, 9 and 12 to zero, since the AutoCalibration
does not set the DPS pre-filling time indexes 7, 8 and 9 and the DPS
clutch C3 initial pressure index 12.
Setting mode FIII - calibrate DPS clutch C1 CAL 3
M4 (40 kph) - calibrate DPS clutch C2 CAL 4
M3 (50 kph, 8350Hi) -The clutch C3 can't be calibrated automatically
1700-1800 rpm
- Make a test drive (the DPS)
- If the DPS does not function properly set the indexes manually

Problems when shifting 1 > 2, Set indexes of the clutch C3 1) Indexes 9, 12

Problems when shifting 2 > 3, Set indexes of the clutch C2 1) Indexes 8, 11
Problems in shifting 3 > 2, Set indexes of the clutch C1 1) Indexes 7, 10
Problems in shifting 2 > 1, Set indexes of the clutch C2 1) Indexes 8, 11

7. Test the start of PTO (with an implement if possible).

- If the PTO start is not good enough set the PTO indexes manually

1) Set first the pre-filling index to zero, since the correct index value is normally near zero. In addition, the effect of the pre-
filling index is not very big, since the piston free movement is short. After that is changed clutch initial pressure index upĆ
wards or downwards:
- if traction disengages for a while during speed change, increase initial pressure index.
- if there is a double jerk" in the beginning of engagement, reduce the initial pressure index.

NOTE! The effect of the index change can be verified, when the speed change upwards is done in heavy loading.

283
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37. Autocontrol 5.2 (K41107-) X100-X120 371 6B
1. 11. 2000

G. Checking ID number of program, AC Note. If the ID number in the tractor display cannot
5.2: be found in this list, contact Valtra Tractor Service.
In some tractors there can be special programs.
PROGRAMS OF AC 5.2
Main program version 80.
Note! Programming instruction for AC5.2, see page These must be replaced with main program version
371-26. 83.
In tractor production a program has input in the These must not be used in Service.
control unit A1, which consists of a main program 1)
and a parameter file. 11 80 X100-X120
Both the main programs and the parameter files are
of different types, and that is why they have ID Main program version 81
numbers. Can be fitted from ser. no. K41107 ->
In the tractor display (in the test mode FII) can be These must be replaced with version 83.
seen the program ID number, which shows the These must not be used in Service.
main program version and the parameter file ID
number. The two first digits mean the parameter file 11 81 1) X100-X120
ID number and the two last digits the main program
version number. Main program version 82:
Can be fitted from. K41107 ->
E.g. ID number 3181: These must be replaced with version 83.
31 = parameter file number, 81 = main program These must not be used in Service.
version number.
11 82 1) X100-X120
Main program version number:
Main program version 83:
Version Used in production Can be fitted from K41107 ->
80 1) K41107 - K42439 These must be used in service
81 2) K42440 -K45217 These programs are in disk 344 046 10.
82 K45218-K50336
83 K50337-> 11 83 * X100-X120

1) Version 80 has also be used in the pre-series,

tractors K25332, K25414, K26316, K26440, In Service and In Spare Parts can be used only
K34507, K35307. with asterisk marked programs (version 83).
2) Version 81 has been input in factory in some
tractors before no. K42440. 1) A new program must be input in the control unit
(main program version 83). In version 83 the
Parameter file ID numbers: faults which are found in versions 80-82, have
been corrected and the function has been imĆ
The parameter files have not been divided accorĆ proved.
ding to the PTO type as in AC 5, but according to
the tractor model. The PTO ratios must be set in the
setting mode FIII, see page 370-19A.
For all main program versions have been done own
parameter files. If the parameter files are develoĆ
ped, the ID number increases one digit, e.g. 11 =>
12. In this way different generations can be distinĆ
guished.

ID number Used in tractor models:

11 X100 - X120

ID NUMBERS USED IN PRODUCTION, IN SPARE

PARTS AND IN SERVICE:

Divided according to the main program version.

Beside the ID number there is information, which
shows whether the tractor has a correct program.

284
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 7
1. 11. 2000

2. Tests
Note! The correct electric signals from sensors and switĆ
ches have been shown in the tables on pages 371/8-9C.
d04 PTO-start switch in cab
A. Test mode FII menu in AC 5.2
d03 HiShift-buttons
Note! Activating the test mode, see page 370/8. d02 DPS-button, down

F7 Shuttle rotation direction *) d01 DPS-button, up

F6 PTO revs *) 99 99 Parameter number and program numĆ

ber. Start level.
F5 Shuttle rotation speed (lower sensor) *)
P1 DPS-prop. valve 1 (clutch C1) current *)
F4 Shuttle rotation speed (upper sensor) *)
P2 DPS-prop. valve 2 ( C2) ottama virta *)
F3 Reserve
P3 DPS-propo 3 (kytkin C3) ottama virta*)
F2 Driving speed *)
P4 Shuttle prop. valve (forwards) current *)
F1 Engine revs *)
P5 Shuttle prop. valve (rearwards) current*)
P6 PTO prop. valve current *)
A8 Rear clutch pedal pos. sensor signal, V
A7 Rear clutch pedal position %
b Counter: informs how many times F-diĆ
A6 Front clutch pedal pos. sensor signal, V rection has been engaged.
A5 Front clutch pedal position % F Counter: informs how many hours F-diĆ
rection has been engaged.
A4 Gas pedal pos. sensor signal, V *)
r Counter: informs how many times R-diĆ
A3 Gas pedal positon % *)
rection has been engaged.
A2 Gearbox oil temperature A Counter: informs how many hours R-diĆ
A1 Outdoor temperature rection has been engaged.
C Counter: informs how many times DPS1
(C1) has been engaged.
d24 Brake pedal position (brake light switches)
U Counter: informs how many hours DPS1
d23 AutoTraction switch (N-Auto) (C1) has been engaged.
d22 Parking brake, reverse drive controls J Counter: informs how many times DPS2
d21 DPS pre-programmming button, reverse (C2) has been engaged.
drive controls P Counter: informs how many hours DPS2
d20 Clutch pedal limit switch, reverse drive (C2) has been engaged.
controls E Counter: informs how many times DPS3
d19 Direction R, lever , reverse drive controls (C3) has been engaged.

d18 Direction F , lever, reverse drive controls d Counter: informs how many hours DPS3
(C3) has been engaged.
d17 PTO-start, button on rear mudguard
H Counter: informs how many times the engiĆ
d16 Parking brake, front controls ne has been started.
d15 PTO stand-by switch L Counter: informs how many hours AC 5.2
control unit has been energised.
d14 Seat direction (TwinTrac only)
d13 PTO-speed 2 (lever in rear position)
*) Engine must be run
d12 PTO-speed 1 (lever in front position)
d11 DPS pre-programming button, front contĆ 1) If detector switch S60 does not function, it can temporarily
rols be by-passed by connecting switch wires with an auxiliary
wire (connector beside the seat holder). The switch must be
d10 Direction R, lever, front controls changed and the auxiliary wire removed as soon as possible
d09 Direction F, lever, front controls (safety).
d08 DPS auto/man
d07 DPS auto1/auto2
d06 Clutch pedal limit switch, front controls
d05 Seat switch 1)

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 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 8
1. 11. 2000

B. Table to check various switches (d01-d24) in the test mode in AC 5.2

Activate the test mode FII (see page 370/8) and select with the DPS bush buttons the correct test point and confirm the selecĆ
tion with the DPS push button, after which the selected point can be checked. When the checking has been done, press
again the DPS pre-programming button, after which a new test point can be selected with DPS push buttons etc.

F
A
d
P
C

DIGITAL INPUT NAME IN DISPLAY 1 IN DISPLAY 0

d01 (S23) DPS push buttons, up Button depressed Button up
d02 (S23) DPS push buttons, down Button depressed Button up
d03 (S45) HiShift button (test both buttons) Button depressed Button up
d04 (S25) PTO-start, in cab PTO switch in START- Disengaged
position
d05 (S60) Seat switch Driver sits on the seat No signal
d06 (S9) Front clutch pedal limit switch Pedal in bottom Pedal up
d07 (S47) DPS automatic gear change switch Auto-position 1 Auto-position 2
d08 (S47) DPS auto/manual Auto 1 or 2 on DPS manual mode (man)
d09 (S40) Direction F, front controls F-direction selected Direction disengaged
d10 (S41) Direction R, front controls R-direction selected Direction disengaged
d11 (S51) DPS pre-programming button (under shutĆ Button depressed. VisiĆ Button up
tle lever), front controls ble only for a while.
d12 (S28) PTO-speed 1 (lever in front position) Speed selected Speed disengaged
d13 (S29) PTO-speed 2 (lever in rear position) Speed selected Speed disengaged
d14 (S3W) Seat direction (TwinTrac only) Seat rearwards Seat forwards
d15 (S25) PTO rocker switch On, PTO-start Disengaged
d16 (S15) Parking brake, front controls Parking brake applied Parking brake disengaged
d17 (S1A, S2A) PTO-start button on rear mudguard Button depressed Button up
d18 (S40) Direction F, reverse drive controls (TwinTĆ F-direction selected Direction disengaged
rac only) *)
d19 (S41) Direction R, reverse drive controls (TwinTĆ R-direction selected Direction disengaged
rac only) *)
d20 (S2W) Rear clutch pedal limit switch (TwinTrac) *) Pedal in bottom Pedal up
d21 (S51) DPS pre-programming button (TwinTrac) Button depressed. VisiĆ Button up
*) bly only for a while.
d22 (S15) Parking brake, rear (TwinTrac) *) Parking brake applied Parking brake disengaged
d23 (S76) AutoTraction switch AutoTraction on AutoTraction off
d24 (S10, S20) Brake pedal position (brake light switches). Pedal in bottom Pedal up
Check both front pedals separately. PossiĆ
ble rear brake pedal has not the switch.

*) Seat must be turned rearwards.

- If the value in the display is not 0, althought it should be according to the table above, the switch can be damaged or in short
circuit. Check, change the switch. Check the switch wires.

- If the value in the display is not 1, althought it should be according to the table above, the switch can be damaged/wires broken/
poor contacts in connectors. Change the damaged switch. Check the switch wirings.

286
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37. Autocontrol 5.2 (K41107-) X100-X120 371 9
1. 11. 2000

C. Table to check the temperature sensors and position sensors (A1-A8) in the test mode
in AC 5.2
Activate the test mode FII (see page 370/8) and select with the DPS push buttons a wanted test point and confirm the selection
with the DPS pre-programming button, after which the required point can be checked. When the test has been done, press again
the DPS pre-programming button, after which can be selected an other test point with DPS push buttons etc.

Example:

FII=test F
mode A
symbol d
P
C

Module symbol A=AC 5.2

A3=gas pedal

99=gas pedal in bottom

(the value must be smaller
than 2 when the pedal is
up).

DIGITAL NAME DESCRIPTION

INPUT
A1 (B17) Outdoor temperature (xx °C or Compare the value with the ambient outdoor temperature. If the values
are different or not visible, check the sensor wires and sensor itself, see
xx°F)
instr A on page 371/13. If the temperature is below -9° C, the display
shows LO".
A2 (B14) Gearbox oil temperature (xx °C) Compare the reading with the actual gearbox temperature. If the values
are different or not visible, check the wires and the sensor, see instr. A on
page 371/13. If the temperature is below -9° C, the display shows LO".
A3 (B15) 1) Gas pedal position (xx %) *) When the pedal is fully up, the value should be smaller than 2. When the
pedal is in bottom, the value should be greater than 99. Check also that
the value changes evenly when the pedal is moved (in the middle of the
pedal stroke, the value should be about 50). If the values deviate from
corret values, see instr. D on page 371/14.

A4 (B15) 1) Gas pedal pos. sensor signal, Gas pedal fully up, signal between 2,5...4,4 V V. Pedal in bottom, signal
Volts. between 0,4-2,4 V.
A5 (B16) Front clutch pedal position (xx %) When the pedal is fully up, the value should be greater than 97. With the
*) pedal at the bottom, the value should be smaller than 2. Also check, that
the value changes evenly when the pedal is moved (in the middle of the
pedal travel, the value should be about 50). If the values deviate from the
above given values, see instr. B on page 371/13. Check that the display
reading is 3...8 in point, where the pedal limit switch switches on (click).
A6 (B16) Front clutch pedal pos. sensor Clutch pedal in bottom, signal between 2,5-4,7 V. Front clutch pedal
signal, Volts. fully up, signal between 0,3-2,4 V.
A7 (B1W) Rear clutch pedal position (xx %) When the pedal is fully up, the value should be greater than 97. With the
*) pedal at the bottom, the value should be smaller than 2. Also check, that
the value changes evenly when the pedal is moved (in the middle of the
pedal travel, the value should be about 50). If the values deviate from the
above given values, see instr. B on page 371/13. Check that the display
reading is 3...8 in point, where the pedal limit switch switches on (click).
A8 (B1W) Rear clutch pedal pos. sensor Clutch pedal in bottom, signal between 2,5-4,7 V. Rear clutch pedal
signal, Volts. fully up, signal between 0,3-2,4 V.
Note! Compare signals from the temperature sensors and position sensors with values in the table above. If the signal from one
sensor is not correct, carry out the required repairs, see e.g. pages 371/13 and 14.

1) The gas pedal of reverse drive controls (TwinTrac, option) affect the same sensor as the front pedal. If the rear pedal signal
value is not within given limits, the rear pedal wire must be adjusted so that the fuel injection adjusting lever moves the hole stroke.

*) The pedal position sensor must be calibrated before checking %-values.

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37. Autocontrol 5.2 (K41107-) X100-X120 371 9A
1. 11. 2000

D. Testing RPM-sensors (F1-F7) in the test mode in AC 5.2

Note! If the display shows e.g. F1 51, it means the engine rpm sensor frequency of 5100 Hz (value x100=Hertz number).

Example:
F
FII=test
mode A
symbol d
P
C
Module A=AC 5.2

12=possible sigĆ
F1=engine
nal value at engiĆ
RPM senĆ
ne speed of 2000
sor
r/min

INPUT NAME VALUES DESCRIPTION

F1 (B11) Engine rpm sensor 1000 r/min=5,7-6,3 Set the engine revs to 1000 r/min and compare the value
1500 r/min=8-10 with the given values in the LH side column. Raise the
2000 r/min=11-13 revs to 1500 and 2000 r/min and compare the reading. If
one of the values is not within the given limits, check the
sensor, see instr. D on page 370/22.
F2 (B6) Gearbox speed 1000 r/min=0,6-0,8 (50 Set the engine revs to 1000 r/min, engage gear M1 and
sensor km/h) drive the tractor forwards. Compare the reading with the
1500 r/min=1,1-1,3 (50 given value. Test also at 1500 and 2000 rpm engine revs.
km/h) If the values differ, see instr. D sivulla 370/22.
2000 r/min=1,4-1,8 (50
km/h)

1000 r/min=0,5-0,7 (40

km/h)
1500 r/min=0,8-1,1 (40
km/h)
2000 r/min=1,1-1,5 (40
km/h)
F3 Reserve
F4 (B12) Shuttle output Set the gears in neutral. Set the engine revs to 1000
speed (upper senĆ 1000 r/min=1,8-2,1 (F) r/min. Engage forward direction (F) and compare the
sor) 1500 r/min=2,9-3,1 (F) value with the given value. Make the same check also in
2000 r/min=3,8-4,2
/ , , (F)
( ) the reverse direction (R).
( ) Raise the engine
g revs to 1500
F5 (B13) Shuttle output and 2000 r/min
/ and measure again in both directions.
speed (lower senĆ 1000 r/min=1,9-2,2 (R) Compare the reading with the given values. If one of the
sor) 1500 r/min=3,0-3,2 (R) values deviates, carry out a comparing measurement,
2000 r/min=3,9-4,3 (R) check the sensor according to instr. D on page 370/22.
F6 (B7) PTO speed sensor 540=1,7-2,0 Engage PTO. Set the engine revs to 1000 r/min. Compare
540E=2,2-2,5 the values with the given values. If the values deviate,
1000=3,0-3,3 check the sensor acording to instr. D on page 370/22.
540E=2,2-2,5 (8350Hi)
1000E=3,7-3,9 (8350Hi)
F7 Direction informaĆ F=1 Set the gears in neutral. Set the engine revs to 800 r/min.
tion R=2 Engage the forward direction (F) and raise slowly the
(B12, B13) engine revs up to max. The reading must be 1 and must
remain the same during the whole test. Engage reverse
direction (R) and repeat the same measurement. The reaĆ
ding must be 2 during the whole measurement. If one of
the direction readings does not function (value is faulty or
it changes when engine revs varie), but F4 and F5 values
are correct, the AC 5/5.2 control unit A1 may be damaged
and should be changed.

NOTE! If the measured values deviate from the above given values, check first the driver detection switch and its wiring in the
seat.

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 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 9B
1. 11. 2000

E. Testing proportional valves (P1-P5) in the test mode in AC 5.2

Note! When the proportional valves are tested, all solenoid outputs are connected automatically unenergised.

Hint! E.g. value P4 1.8 means, that the forward direction proportional valve takes max. current of 1,8 A (in the test mode).

Example:

FII=test
mode F
symbol
A
d
Module A=AC 5.2 P
C
P1=DPS
proportional
valve no 1
(C1)
1.2=value within given
limits (1,2 A)

OUTPUT NAME VALUE (activated) DESCRIPTION

P1 (Y4) DPS-solenoid Y4 (C1). Activate the test mode and start the engine. Set the
engine speed to about 1000 rpm.
rpm
P2 (Y6) DPS-solenoid Y6 (C2).

P3 (Y17) DPS-solenoid Y17 (C3). 1,1-1,9 Proportional

p valve is activated by
y stepping
pp g the desired
solenoid and by
b pushing
p shing the pre-programming
pre programming b butĆ
t
P4 (Y11) Forwards solenoid Y11.
ton. The display reading should be 1,11,1-1,9.
1,9.
P5 (Y12) Rearwards solenoid Y12.
- If HI=short circuit or valve takes too high current.
P6 (Y2) PTO solenoid Y2 - If LO=wire damage

- If one of the values in the diplay deviates from the given values, measure the solenoid resistance on the connector X13 pins
or direct on the valve pins. Check that the pins are not loose (see instr. C on page 370/21). If the resistance is correct, but the
display reading is faulty, the fault lies in the wires.
Measure also the supply voltage of the control unit while the engine is running (1500 rpm). Correct value is 12 V-14,8 V.
- If the solenoid resistance was faulty, the solenoid is damaged and should be changed. When the proportional valve or the
solenoid is changed, the valve indexes must be checked (see page 370-24D).

If above mentioned points are OK, faulty current value can be caused by a defect AC5.2 control unit A1.

Note! Resistance measures and diode checks, see instr. 4C on page 370/21.

Important! Be careful not to mix up the proportional valves and normal solenoid valves during repair work.

WARNING! The proportional valves have a pin for a manual use, which MUST NOT be manipulated: the tractor may suddenĆ
ly start to move, or the pin can become trapped and can cause later damage to e.g. multi-disc clutches. That is why it must
always be checked after the repair work (before engine start), that the proportional valve spools are in the outer positions i.e.
almost flush with the valve body (if not, remove the valve and press the spool so that the manual pins" rises).

289
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 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 9C
1. 11. 2000

F. Counter functions in AC 5.2

There are 12 pcs counters in the test mode menu (see page 371/7). The counter symbols are placed below the symbols for
the proportional valves, see table below:

F The counters are in use from the main

program version no. 81 incl.
A In version 80 the counters were in test
d use,so the values in the memory can
differ from the right values.
P
C

Symbole in Test point The readings of the counters are shown shortened as follows:
display - the LH side display segment shows the counter symbol
- the two intermediate segments show the two first significant
b Number of engagements of F-clutch digits of the reading
F Time in hours how long time the F-clutch - the RH side segment shows the number of zeroes.
has been engaged (pressurised)
E.g. b 23 3 means that driving direction forwards has been
Number of engagements of R-clutch
(r) engaged 23000 times.
A Time in hours how long time the R-
Last Number of
clutch has been engaged (pressurised)
digit zeroes
C Number of engagements of DPS1 ratio 0 -
U Time in hours how long time the DPS 1 1 0
clutch has been engaged (pressurised) 2 00
3 000 (thousands)
J Number of engagements of DPS2 ratio 4 0000
P Time in hours how long time the DPS 2 5 00000
clutch has been engaged (pressurised) 6 000000 (millions)
Time recorder readings (F, A, U, P, d, L) are also shown in the
E Number of engagements of DPS3 ratio same way.
d Time in hours how long time the DPS 3
clutch has been engaged (pressurised) Example:
H Number of engine starts
L Time in hours how long time the ACV
control unit has been active. Test mode
symbol
The counters are accessible after activating the test mode
and by stepping in the menu with the aid of the DPS push
buttons.

Note! When the current is switced on with the ignition

switch, the default ratio is DPS1. The value in counter H Module
increases with one digit every time the engine revs rise over
400 r/min. Counter L shows the total running hours of the
control unit. If the counter reading is smaller than tractor
running hours, a new control unit has been fitted later on 35=number of
the tractor. engine starts,
two first digits
Note! Reading counters is happened without a separate
confirmation. The counters cannot be zeroed in service. If
the control unit is reprogrammed, the counter values reĆ
main in the control unit memory. In the spare part control
unit the counters have been zeroed.

The greatest value of the hour recorders is 9999 after which 2 = Number of zeroes
the counters are zeroed. Counters are switched on always H= number of engiĆ
when current is switched on in the control unit. ne starts

i.e. H = 3500 times.

Note! The counters can be used in connection with mainteĆ
nance or repair works, when e.g. estimating life time of varioĆ
us components or clutch wear etc.

291
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 10
1. 11. 2000

3. Settings
Note! Different setting procedures have been shown on CAL 5 Automatic calibration of DPS clutch C3
pages 370/15-19A. If the settings of AC 5 and 5.2 differ (Y17) (not in use).
from each others, the settings of AC 5.2 have been shown CAL 6 PTO automatic calibration
under code 371.
1) Before setting the initial pressures, the pre-filling times
A. Setting mode FIII menu in AC 5.2 must be set.
2) Parameters are the same as codes for AD-instrument, see
Note! Activating the setting mode menu, see page 370/14. page 331/6.
3) Normally the pre-filling indexes 7, 8 and 9 can be zero, sinĆ
ce their effect is minor due to the piston short free movement.
L PTO ratio 2 (lever in rear position)
P PTO ratio 1 (lever in front position)
B. Setting clutch pedal ratio index
H Choocing speed unit, km/h or miles/h
F Choocing temperature unit °C or °F Note! This setting procedure is only in AC 5.2. With this setĆ
A Setting driving speed parameters 2) ting the clutch pedal can be adjusted so that it engages exact
in the same point in forward and rearward direction. IncreaĆ
U 4WD automatics (on/off), on=1, off=0 sing the index one step increases all clutch pedal control valuĆ
16 Clutch pedal ratio index, rearards es one percent and vice versa. I.e. when increasing the index
the clutch pedal engages deeper and vice versa. The factory
15 Clutch pedal ratio index, forwards
sets the indexes to 0. When both indexes are 0, the clutch
14 Manual setting of PTO clutch initial pressuĆ slips and engages little earlier when driving rearwards.
re 1)
1. Activate the setting mode, see page 370/14. Step in the meĆ
13 Manual setting of PTO clutch pre-filling
time nu with DPS push buttons and select either point 15 (ratio inĆ
dex forwards) or 16 (rearwards).
12 Manual setting of DPS3 (clutch C3) initial
pressure 1)
11 Manual setting of DPS2 (clutch C2) initial FIII=setting
pressure 1) mode symbol

10 Manual setting of DPS1 (clutch C1) initial Module A=AC 5

pressure 1)
E.g.
9 (Manual setting of DPS3 (clutch C3) pre-
15=clutch peĆ
filling time) 3)
dal ratio index
8 (Manual setting of DPS2 (clutch C2) pre- forwards.
filling time) 3)
7 (Manual setting of DPS1 (clutch C1) pre- Valid ratio inĆ
filling time) 3) dex -3.

6 Manual setting of R-clutch initial pressure

1).
5 Manual setting of F-clutch initial pressure 2. When the selection has been done, press the DPS pre-
1). programming button, after which the selected point is shown
without blinking and the valid and blinking ratio index can be
4 Manual setting of R-clutch pre-filling tiĆ
seen in the right.
me.
3 Manual setting of F-clutch pre-filling tiĆ 3. The blinking index can be increased or decreased with the
me. DPS push buttons in the speed gear lever knob.
2 Clutch pedal calibration.
4. The index can be between -3....+3. When there is a corĆ
1 Gas pedal calibration. rect index value in the display, press the DPS pre-programĆ
CAL START LEVEL ming button. After a successful setting the correct index value
(without blinking) is shown in the display.
CAL 1 Automatic calibration of F-direction (Y11).
CAL 2 Automatic calibration of R-direction (Y12). 5. The setting mode can be left by switching off current.
CAL 3 Automatic calibration of DPS clutch C1 6. Check the function of the clutch pedal by making startings
(Y4). forwards and rearwards with slipping. Change the index
CAL 4 Automatic calibration of DPS clutch C2 when necessary.
(Y6).

292
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 11
1. 11. 2000

C. Automatic calibrations of shuttle, DPS Note! The calibration can be interrupted by depressing
the clutch pedal (or by getting up from the seat). The caĆ
and PTO clutches librating mode can be left by switching off current.
Shuttle: setting pre-filling and initial pressure indexes. Note! With an aid of the interruption code the control unit inĆ
DPS and PTO: - only setting of initial pressure indexes)
forms that the calibration has failed and the reason for that.
Note! The automatic calibrations only in AC 5.2. These clutĆ
Interruption codes:
ches can also be calibrated manually:
- manual calibration of shuttle and DPS clutches, see page C 00 The seat switch does not recognize a driver or
370/24D clutch pedal has been depressed during calibratiĆ
- manual calibration of PTO clutch, see page 371/12. on.

Note! Implement or trailer must not be connected to the tracĆ C 02 Parking brake applied, engine revs wrong, gearĆ
tor during the automatic calibration. box temperatute wrong, mechanical gear is not
engaged or tractor on a slanting ground.
1. Before calibration the following points must be observed C 03 Initial pressure calibration does not find a correct
(the gas pedal calibration must be done): value in spite of many attempts. The tractor starts
- Warm the engine up to a normal running temperature and to move too sharply. Ensure, that the tractor is on
warm the gearbox oil to an operating temperature the level ground and that the correct mechanical
(+30...+60° C). Check temperature in the test mode FII, point gear has been engaged.
A2 (AD-instrument shows shows only temperatures over
C 04 Clutch which is calibrated does not transmit enoĆ
+40 C). ugh higt torque. E.g. piston or valve trapped,
- If the tractor has a turbine clutch (HiTrol) , check the Stall pressure of low pressure circuit is too low, leaks
revs before the calibrations (page 411/7). etc.
- Remove possible pre-programmings of the DPS speeds
by pressing the pre-programming button over 2 seconds C 05 Calculated initial pressure index is not within giĆ
when the shuttle lever is in the neutral position N. ven limits (limits -9...+9).
- Drive the tractor on a level ground, preferably on asphalt, C 06 Calculated pre-filling index is not within given
on tarmac or on hard gravel, where is space forwards and reĆ limits (e.g. clutch piston does not move freely or
arwards some meters (during calibration the tractor moves clutch worn out) (limits -9...+9)..
some centimeters forwards and rearwards and stops itself).
The calibration fails on field. The calibration must not done inĆ C 07 The pre-filling time calibration does not find a
correct value in spite of many attempts.
doors or on slanting ground
- Move the shuttle lever to the neutral position N.
- Engage a mechanical gear: In 40 km/h models gear M4 Note! If the automatic calibration does not succeed, try to caĆ
and in 50 km/h-models and in 8350Hi gear M3. librate the clutch manually. If a very small or large index must
- Disengage the differential lock, 4WD and PTO be used (below -6 or over +6), the fault can lie in mechanical
- Check that the working hydraulics is in the free circulation parts or in hydraulics.
phase. Turn the front wheel straight ahead.
- Adjust the engine revs with the hand gas to 1700-1800 In the automatic calibration is calibrated the whole control liĆ
r/min. ne:
- if you calibrate the PTO clutch, move the PTO lever to the - Multi-disc clutch
front position. The PTO calibration must be done without load - Proportional valve
in the PTO shaft. - Control unit output

4. Activate the setting mode FIII, see page 370/14. Step with The calibration can also fail, if the fault lies in:
the DPS push buttons in the menu from starting level (CAL, - Control unit
blinking) upwards and select desired calibration: - Wire looms
- Battery (voltage too low)
CAL 1=Calibration of F-clutch (Y11). - Proportional valves
CAL 2=Calibration of R-clutch (Y12) - Low pressure circuit of hydraulics (18 bar)
CAL 3=Calibration of DPS-clutch C1 (Y4) - Mechanical parts (clutc pack etc)
CAL 4=Calibration of DPS-clutch C2 (Y6) - Clutch return springs faulty or wrong number of springs.
CAL 5=Calibration of DPS-clutch C3 (Y17), not in use.
CAL 6=Calibration of PTO clutch (Y2).

4. Confirm desired blinking calibration point with DPS pre-

programming button, after which there is text CAL without
blinking in the display lower row (during the whole calibratiĆ
on). After this the calibration proceeds automatically and
stops either to an interruption code or to an successful calibĆ
ration. When the calibration has been successfully compleĆ
ted, e.g. text CAL1 starts to blink in the display (the calibration
symbol of the clutch, which has been calibrated is blinking).
After this can be stepped to another calibration point etc.

Note! Wait during the whole calibration procedure and do not

touch the controls. During the automatic calibration DPS
speed 1 is engaged automatically. A calibration of a clutch taĆ
kes about 1...1,5 minutes.

293
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 12
1. 11. 2000

D. Manual calibration of PTO clutch (=inĆ

dex settings)

The PTO clutch indexes can be changed if you want to afĆ

Confirm the selection with
fect the PTO engagement phase e.g. due to excessive deĆ
DPS pre-programming butĆ
lay. ton.
Note! In the setting mode menu point 13=manual setting Step in the setting mode menu
of PTO clutch pre-filling time and point 14= manual setĆ with DPS push buttons.
ting of PTO initial pressure. The indexes can be altered betĆ
ween -9...+9.
FIII=setting
Important! The PTO indexes are set in the same way as mode symbol
the shuttle indexes (e.g. 3 and 5 for F-clutch) and they
affect similar: Module A=AC 5
- setting pre-filling times of the shuttle, see page 370/24D
and 370/18. E.g. 14=setĆ
- setting initial pressures of the shuttle, see page 370/24D ting PTO
and 370/16. clutch initial
presure index.
First is set index 13 and then 14. The effect of the indexes
cannot be seen, if an implement is not connected to the Valid initial
PTO. In addition, rotational torque of an implement affects pressure index
the PTO engagement. -3.

Big implement (e.g. a big baler):

- index values can be altered much, affects slowly when 7. First set the PTO initial pressure index to -3 (point 14)
observing visually. and then the pre-filling index to -6 (point 13). Increase the
Small implement (e.g. hay turner): pre-filling index 13 on step at a time (-6, -5, -4, -3,
- index change small, affects quickly when observing visuĆ -2, -1, 0, 1, 2, 3, 4, 5, 6), and test the PTO engagement
ally. after every index change until a clear jerk can be seen in
the beginning of the engagement. Decrease then the index
1. Connect an implement to the PTO. two steps.

2. Warm the engine to a normal running temperature and 8. Again check that the jerk disappeared in the beginning of
gearbox oil to an operating temperature (+30°...+60° C). the engagement.
Apply parking brake.
Note! If the pre-filling index must be set below -6 or over
3. Adjust engine revs to about 1200 r/min. +6, the PTO clutch is worn out or the piston does not move
freely.
4. Move the PTO lever to the engaging position.
9. Increase then the initial pressure index 14 one step at a
5. Check how the PTO engagement happens with the preĆ time (-3, -2, -1, 0, 1, 2, 3) and test the engagement after
sent index values. Start/stop of the PTO can be done with every index change until the implement acceleration occurs
the rocker switch in the cab. Change the enagement proceĆ in the correct way during engagement.
dure as follows:
10. The setting mode can be left by switching off current
6. Activate the setting mode (see page 330/14). with the ignition switch.

E. Setting 4WD automatics (AC 5.2 only)

In the setting mode there is point U, in which can be selecĆ
ted either automatic function on or off (on=1, off=0).

When the 4WD automatics is on (on=1), the 4WD is engaĆ

ged for a moment in the drive direction change/start, which
reduces wheel slip on a slippery ground. After the drive
direction change/start the 4WD is disengaged automaticalĆ
ly.

This function can be switched off by selecting 0 in the setĆ

ting mode menu in point U (0=off). Selection is made norĆ
mally with the DPS push buttons and the selection is confirĆ
med with the DPS pre-programming button.

294
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 12A
1. 11. 2000

F. Resetting pre-filling indexes for DPS

clutches
If in connection with DPS gear change there occurs a
double jerk" or traction disengages for a while, check/set
the DPS clutch pre-filling indexes.

However, first must be set automatically initial pressure inĆ

dexes for DPS clutches C1 and C2 (see page 371/11).

Set all DPS pre-filling indexes first to 0 (index nos 7, 8 and

9). Also set clutch C3 initial pressure index to 0 (index no.
12), since the automatic calibration does not do this.

Check the function of the DPS.

- If in the beginning of the gear change there is the douĆ

ble jerk", decrease the pre-filling index of the clutch in
question to -2 and check the function after that. Decrease
the index value more, if needed. Particularly in the gear
change between speeds 1 > 2 there can easily be a douĆ
ble jerk, if the indexes are incorrectly set.

- If the traction disengages for a while during speed chanĆ

ge, increase the pre-filling index of the clutch in question
to e.g. +2 and check the function. Increase more, if necesĆ
sary. Sometimes the initial pressure indexes must be adjusĆ
ted.

- If speed change between 1 > 2 is bad, set clutch C3

indexes.
- If speed change between 2 > 3 is bad, set clutch C2
indexes.
- If speed change between 3 > 2 is bad, set clutch C1
indexes.
- If speed change between 2 > 1 is bad, set clutch C2
indexes.

295
296
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 13
1. 11. 2000

4. Components 3. Check the sensor mounting. Check the sensor resistance

by measuring it in connector X19 pins 26 and 37. If the
A. Reconditioning temperature sensors resistance was infinite, check connector X1A pins 2 and 5.
Change faulty temperature sensor.

1. Gearbox oil temperature sensor B14 Resistance values of the sensor (±1 %):
- 1600 W (± 0°C)
- 2000 W (+25°C)
- 3300 W (+100°C)

Note! The outdoor temperature sensor does not affect the

function of the AC 5.2 unit.
A

B. Clutch pedal position sensor B16

and B1W (TwinTrac), reconditioning
X13, X19
Note! In the AC 5.2 the clutch pedal position sensor has
been fastened so that its position cannot be adjusted.
Note! Sensor B14 (A) is placed on the servo valve block on Note! In the reverse drive controls (TwinTrac, option) there
the LH side of the gearbox (see also page 440/24). is similar clutch pedal position sensor B1W, which should
be tested and calibrated separately.
1. If this sensor has problems, the self diagnosis shows the
following fault codes: 1. If the position sensors have problems, the self diagnosis
- A311 (temperature over +150°C, impossible). can show the following fault codes:
- A312 (temperature below - 50°C, impossible).
- fault code A128: Reference voltage of clutch pedal (and
2. Check then the sensor in the test mode, see table C on gas pedal) sensor is not within given limits (4,5-5,5 VDC).
page 371/9. Compare the temperature in display to the Eventually short circuit in wires
actual temperature in the gearbox. - fault code A314: Signal from the front clutch pedal senĆ
sor B16 is not within given limits. Sensor faulty fastened or
3. If the temperature reading in the display is clearly wrong sensor/wires defective. Battery voltage too low.
or it missis, check the sensor and its wiring. When needed, - fault code A351: Signal from rear clutch pedal sensor
measure the sensor resistance in connector X13 pins 10 B1W faulty. Sensor faulty fastened or sensor/wires defectiĆ
and 6. If the resistance was infinite, check the resistance in ve. This fault code appears only when the seat is turned
the sensor pins: rearwards. Battery voltage too low.
Resistance values of the sensor (±1 %): 2. Check the function of the sensors in the test mode (see
- 1600 W (± 0°C) table C on page 371/9). If the function is not within given
- 2000 W (+25°C) limit values, check the mounting of the position sensor and
- 3300 W (+100°C) its wires. Also check the sensor lever fitting on the sensor
spindle. If the signal voltage is missing or it is not in limits
4. Change a faulty sensor. Fix wirings. check the supply voltage (4,75-5,25 V) and signal voltage
by means of measuring cable ETV 894510 (see picture on
Note! If this sensor is defective, it can cause engaging proĆ page 371-14).
blems in various multi-disc clutches (delays and jerks).
Clutch pedal, Up In bottom
Note! If the sensor and its wires seem to be OK, but malĆ front / rear
functions exist, the fault can lie in the control unit of the A
Signal voltage 0,3-2,4 V 2,5-4,7 V
5.2.
3. If You doubt poor contacts in wires/connectors, disconnect
2. Outdoor temperature B17 and then reconnect the front sensor B16 connector and make
the same to the control unit connector A1A5.
This sensor is placed in the front part of the tractor behind
the front grille on the signal horn bracket. 4. In the same way, check the rear pedal sensor B1W connecĆ
tor and connector S1W pins 7 and 9 and connector A1A5 on
1. If you doubt, that the sensor is damaged, test it in the test the control unit.
mode, see table C on page 371/9.
Note! If the wires are be OK, but malfunctions occur, the senĆ
2. Compare the diplay reading to the ambient temperature. sor can be damaged or the fault can lie in the control unit A1
If the outdoor temperature does not appear at all or it is of AC 5.2. Defective sensor or control unit must be changed.
clearly wrong, check the sensor and its wires.
4. When the fault has been repaired, calibrate the clutch pedal
sensors, see page 370/15 instr. C. The both pedals are calibĆ
rated in the same way but when calibrating the rear pedal, the
drive's seat must be turned rearwards.

297
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 14
1. 11. 2000

C. Front clutch pedal limit switch S9 and Note! The rear gas pedal (TwinTrac) has been connected
rear pedal switch S2W, reconditioning with a cable to the front gas pedal. When necessary, the
cable must be adjusted.
Note! The limit switches' activating point has been chanĆ
ged into zero point of the clutch pedal posiiton in AC 5.2. The self diagnosis shows the following fault codes, when
That is why the switch activating point is not necessary to the gas pedal position sensor has malfunctions:
adjust accurately.
- A128: Reference voltage of the gas pedal (and clutch
1. If the limit switches have malfunctions, the self diagnosis pedal) position sensor is not within given limits (4,5-5,5
shows the following fault codes: VDC)). Eventually wires in short circuit.
- A313: Signal from the gas pedal sensor under 0,4 or
- d133: The front and rear pedal limit switches active siĆ over 4,4 VDC. Sensor wrongly fastened or wire damages.
multaneouly. Switches possible damaged or short circuit in Battery voltage can be too low.
wires.
- d215: The front pedal position greater than 50 % and 1. Check in the test mode (table C on page 371/9), whether
kimit switch S9 active simultaneously. Switch damaged or the sensor values are within the given limits (point A4 in the
short circuit in wires. table). If the function is defective, check the sensor fitting
- d254: Rear pedal position greater than 50 % and limit and wires. Also check the sensor pin bearings (no clearanĆ
switch S2W active simultaneously. Switch damaged or ce) and pin wear (and fuel injection pump pin wear).
short circuit in wires (this fault code appears only when the If the signal voltage is missing or it is not in limits, check the
seat is turned rearwards). supply voltage (4,75-5,25 V) and signal voltage by means
of measuring cable ETV 894510.
2. Then check the limit switch position and wires. The limit
switch function can be checked in the test mode, see table
B on page 371/8. The end of the locĆ
king screw is pusĆ
3. If You doubt poor contacts, check the wire connections hed a little inside
the spindle hole.
on the switch S9. Also check the control unit connector
Lock the screw with
A1A7 and earth point GR5.
Loctite 222.
4. Check the rear pedal switch S2W wires on it. Check earth
point GR1 and connector A1A2 of the control unit. Direction A
A
Note! If the wires seem to be OK, and the switch functions
when testing it with finger, but still malfunctions occur, the
switch can be defective or control unit of AC 5.2 can be 1=4,75-5,25 V
damaged. Then change the components in question. 2= ground ETV 894 510
4=signal

D. Gas pedal (fuel injection pump) positiĆ

Accelerator peĆ Up In bottom
on sensor B15, reconditioning dal

Note! In AC 5.2 system the gas pedal position sensor is Signal voltage 2,5-4,4 V 0,4-2,4 V
fastened so that its position cannot be adjusted.
2. If You think poor contacts, check the sensor connector and
Note! If the gas pedal position sensor has malfunctions, it
wires. Check connector X1A pins 1, 2 and 3 and connector
affects the automatic or manual functions of DPS (auto1,
X19 pins 28, 29 and 37. Also check the control unit connector
auto2, Speed Matching, AutoTraction etc). Defective engine
A1A5.
rotation speed sensor can also cause these malfunctions in
DPS.
3. If the sensor fitting and its wires seem to be OK, but still malĆ
functions appear, the sensor itself can be damaged or the
control unit A1. Change a damaged part.

4. After the fault has been repaired, carry out gas pedal calibĆ
ration according to instr. B on page 370/15. If the rear clutch
pedal has malfunctions, adjust the pedal cable.

Note! The gas pedal position sensor must be calibrated after

the first 500 running hours and later at intervals of 1000 runĆ
ning hours.

298
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 15
1. 11. 2000

5. Others
A. AC 5.2 control unit, connectors:
Vref (+5 V)=supply to pedal pos.

DO 6

DO 5

DO 4

DO 3

DO 2

DO 1

GND
GND
P8
P7

P6

P5

P4

P3

P2

P1
sensors.

d17 A1
d18 A2
d19 Vref (+5 V)
d20 A3
d21 GND
F1 Vref (+5 V)
d22 A4
F2 GND
d23 d01
F3 d02
d24 CAN 1 HI
F4 CAN 1 LO
GND CAN SHIELD
F5 CAN 2 HI
GND CAN 2 LO
F6 CAN SHIELD
GND GND
Supply
+12 V GND
Rx
(Programming)
Tx
d16
d15
d14
d13
d12
d11
d10
d09
d08
d07
d06
d05
d04
d03
A6
A5

DIGITAL INPUTS: ANALOG INPUTS: OUTPUTS TO PROPORTIONAL VALVES:

d01=DPS up (S23) P1=DPS solenoid 1 (Y4)
d02=DPS down (S23) A1=outdoor temp (B17)
d03=HiShift (S45) A2=oil temp (B14) P2=DPS solenoid 2 (Y6)
d04=PTO start in cab (S25) A3=Gas pedal, signal (B15) P3=DPS solenoid 3 (Y17)
d05=seat switch (S60) A4=front clutch pedal, signal (B16) P4=F-solenoid (Y11)
d06=clutch pedal, front (S9) A5=rear clutch pedal, signal (B1W) P5=R-solenoid (Y12)
d07= DPS Auto1/Auto2 (S47) A6=reserve P6=PTO-solenoid (Y2)
d08= DPS auto/manual (S47) FREQUENCY INPUTS: P7=starter interlock (K52)
d09 = Forwards F, front (S40) F1=engine speed (B11) P8=4WD automatics
d10=Rearwards R, rear (S41) F2=gearbox speed (B6)
d11=DPS pre-progr., front (S51) DATA TRANSFERRING CHANNELS:
d12=PTO speed 1 (S28) F3=reserve CAN 1 HI *)
d13=PTO speed 2 (S29) F4=shuttle speed 1 (B12) CAN 1 LO *)
d14=direction of seat (S3W) F5=shuttle speed 2 (B13) CAN SHIELD *)
d15=PTO standby (S25) F6=PTO speed (B7) CAN 2 HI *)
d16=hand brake, front (S15) CAN 2 LO *)
d17= PTO start, mudguard (S1A, S2A) DIGITAL OUTPUTS: CAN SHIELD *)
d18= Forwards F, rear DO 1=LCD display
d19= Rearwards R, rear GND
DO 2=LCD display Rx RS-232
d20=Clutch pedal, rear (S2W) DO 3=LCD display
d21=DPS pre-progr., rear Tx
d22=handbrake, rear DO 4=LCD display
d23=traction control (S76) DO 5=parking brake *) CAN transferring channels are not in use
d24=Brake pedal switches DO 6=PTO pilot light (H10) for the present.

299
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 16
1. 11. 2000

B. AC 5.2, Wiring diagram

AC 5.2 1

Current must
not be taken
from circuit of
fuse F24 (safeĆ
ty risk)

AC 5.2 2

300
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 17
1. 11. 2000

Wiring diagram AC 5.2 Position of connectors:

X13: Connector for transmission (37 pins) on the support plate
(The diagrams also under code 310). Position of connecĆ in the lever console.
tors, see pages 310/6C och 6D.

A. Control unit connector A1A1 E. Control unit connector A1A5

B14: Gearbox temperature sensor
F24: AC5.2 fuse in the fuse box
B15: Gas pedal pisition sensor
GR1: earth point in the rear part of the lever console
B16: Clutch pedal position sensor
B7: PTO speed sensor
B17: Outdoor temperature sensor
B12: Shuttle speed sensor, upper
S23: DPS push buttons up/down
B13: Shuttle speed sensor, lower
GR1: earth point in the rear part of the lever console
Position of connectors:
Position of connectors:
X13: Connector for transmission (37 pins) on the support
X13: Connector for transmission (37 pins) on the support plate
plate in the lever console.
in the lever console.
X28: Connector for shuttle sensors (9 pins) in the lever conĆ
X19: Connector (37 pins) on the cab front wall on the RH side.
sole
X1A: Connector (9 pins) for the engine sensors in the front part
X26: White connector (26 pins) in the rear face of the comĆ
of the engine compartment near the thermostat housing.
bination instrument.
X23: Connector for DPS push buttons in the lower part of the
X1E: Connector (9 pins) for ACD power lift speed sensors
gear levers
on the support plate in the lever console (also connector
X30: Connector (9 pins) for gear lever push buttons in the loĆ
X2E).
wer end of the levers.
X3: Connector in fuse box

F. Control unit connector A1A6

B. Control unit connector A1A2
X43: RS-232 connector on the lever console
B6: Gearbox speed sensor
B11: Engine speed sensor
G. Control unit connector A1A7
Position of connectors:
X13: Connector for transmission (37 pins) on the support S9: Starter interlock switch at clutch pedal
plate in the lever console. S60: Safety switch in driver's seat
X26: White connector (26 pins) in the rear face of the comĆ S47: Switch, DPS, man/auto
bination instrument. S45: Switches for HiShift
X1E: Connector (9 pins) for ACD power lift speed sensors GR1: earth point in the rear part of the lever console
on the support plate in the lever console (also connector GR5: earth poin in the cab front wall
X2E). Position of connectors:
X30: Connector (9 pins) for the gear lever push buttons in the
C. Control unit connector A1A3 lower end of the levers.

Y11: Proportional valve, forward driving (F)

Y12: Proportional valve, rearward driving (R) H. Control unit connector A1A8
Y2: PTO proportional valve (PTO)
H10: PTO ind. light S40: Reed relay, forward driving (F).
GR1: earth point in the rear part of the lever console S41: Reed relay, reverse driving (R).
GR5: earth poin in the cab front wall S51: Push button, DPS, pre-programming
P6: AC 5.2 diplay, front controls S15: Reed relay, parking brake (P)
(P1W): AC 5.2 display, reverse drive controls (TwinTrac) S28: Switch, PTO 540.
S29: Switch, PTO 1000/540E
Position of connectors: H27: Back buzzer
X13: Connector for transmission (37 pins) on the support K29: Relay, back buzzer
plate in the lever console. GR5: earth poin in the cab front wall
X27: Blue connector (26 pins) in the rear face of the combiĆ Position of connectors:
nation instrument. X39: Connector (9 pins) for the shuttle lever at the steering
wheel under the dashboard.

D. Control unit connector A1A4

Y4: DPS proportional valve (C1)
Y6: DPS proportional valve (C2)
Y17: DPS proportional valve (C3)
P6: AC 5.2 display, front controls
(P1W): AC 5.2 display, reverse drive controls (TwinTrac)

301
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 18
1. 11. 2000

C. Control diagrams

Control of DPS, AC 5.2

X13
V1, V4
3 2 1

6 5 4
9 8 7

302
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 19
1. 11. 2000

Control of HiTech shuttle, AC 5.2

X13

303
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 20
1. 11. 2000

Control of PTO, AC 5.2

X13
V1, V4
3 2 1

6 5 4
9 8 7

304
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 21
1. 11. 2000

Control of parking brake, AC 5.2

305
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 22
1. 11. 2000

Starting control, AC 5.2

306
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 23
1. 11. 2000

Control of 4WD, AC 5.2

HiTech

307
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 24
1. 11. 2000

TwinTrac, AC 5.2

HiTech

308
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 25
1. 11. 2000

AutoTraction

309
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 26
1. 11. 2000

6. Programming the control unit A1 in AC 5.2

The program disk part no is 344 046 10. The PC used must have HYPERTERMINAL" -terminal program. Installing can be done
with MS-WINDOWS-program disk. If You want to read instructions in the disk (Servive Manual pages), the PC must have progĆ
ram Adobe Acrobat reader 4.0 or later version. If needed, contact Your program supplier.
TABLE 1: Control unit part numbers and file names, version 83. In Service, in Spare Parts and in production are used
these parameter files and check codes.

Suitability, For tractors no. Control unit Program file Parameter file Check code Check code 2
tractor models part no. name 3) name 3) 1 1) 2)

– K41107- 333 73 020 Not progr. Not progr. - -

X100-X120 K41107- 344 03 810 ac5v83a.s19 6250_6850_83 8311 1183

1)
Check code 1 is visible in the PC display by typing command PROC_VER?
2)
Check code 2 is visible in the tractor display (in the test mode FII)
3)
The files can be copied into the control units which have number 333 73 020.
earlier it is not necessary to perform stage no. 6 (the control
unit performs it by itself and goes to stage no.7).
CONNECTIONS
A. Unfixed control unit (see picture 1): Deleting old program in control unit:
1. Connect the cable of the programming unit (part no. 340 6. Write REM_MEM (Caps Lock" off, use shift" key) >
425 00) to the PC's serial communication port COM 1 (or to enter
COM 2).
7. Appears: FLASH ERASE. * * * * * * (the memory of
2. Connect an AC5 control unit A1 to the connections of the control unit is cleared) > after a few seconds appears: * *
programming unit. OK * * SEND DOWNLOAD FILE.

3. Connect the power supply. Switch power off (on/off 7a Switch off the tractor current with the ignition switch and
switch) switch on again >tractors display is emptied.

Sending program file to the control unit:

B. Control unit that has been assembled to tracĆ
8. Choose "Transfer" > "Send text file"
tor (see picture 2):
9. Go to point Files of type" > choose "All files (*.*)" > go
1. Switch power of the tractor off. to point Look in" > choose directory Programs" >
choose with double click a suitable program version (see
2. Connect a programming cable (part no. 337 006 00 or table 1) > transferring data begins (wait 3...4½ minutes, the
337 006 10) to the PC's serial communication port COM 1 process can't be seen in PC's display) > when the process
(or to COM2). is ready text Loader v0.4 4Mb" appears (and AC5 display
in tractor begins to work) (=OK)
3. Connect the cable to the connector X43 (at the right side
panel). 10. Choose Call" > Disconnect" > Call" > connect"

COPYING PROGRAM FILE TO THE CONTROL COPYING PARAMETER FILE TO THE CONTROL
UNIT UNIT
If necessary a parameter file can be deleted and copied
4. Turn PC's power on and start Windows 95. Insert an AC5 separately without deleting the program file.
programming diskette (part no. 344 04 610) to PC's disk
drive A: > choose "My computer" > choose "3½ floppy Deleting old parameter file in control unit:
(A:)" > choose file "VALT_TRM95_COM1" or
VALT_RM95_COM 2" depending on which COM-port of 11. Switch programming unit power off (or switch tractor
the computer the cable is connected to (double click) > power off) > switch power on > appears text: RESET
program Hyper Terminal" starts > wait until the program (=OK)
has started.
12. Write LOAD_PAR (Caps Lock" off, use Shift" key) >
5. Switch the programming unit power on (or tractor power enter > OK (old parameters are cleared in memory):
on) => text Loader v0.4 4Mb" appears, it means that
communication is OK. In case of malfuntion try once more
(switch off > switch on).

REMARK. If the transmission between the computer and

the control unit fails text RESET begins to appear continuĆ
ously. Press the button s (lower case) many times until a
text Software download, Enter password ?" appears >
press

The backspace button (<-) ten times > write the passĆ
word 5533710 > press Enter > the control unit start to wait
loading a file Send download file" > send the program file
(see position 8).
Remark ! If the control unit has not been programmed

310
 Model Code Page
37. Autocontrol 5.2 (K41107-) X100-X120 371 27
1. 11. 2000

Inputting parameter file:

13. Choose Transfer" > Send text file"

14. Go to point Files of type" > choose All files" > go to

point Look in" > choose directory 3½-levyke A:" >
choose directory Parameters",

15. Choose a parameter file by means of table 1 (double

click) > appears text: OK Loader v0.4 4Mb" (=OK).

NOTE! If in connection with inputting parameter file the

following information appears parameters are cleared!!!!
card will not work until set!!!", carry out again points 12...15
(type LOAD_PAR>enter...).

Inspection:
16. Write PROC_VER? > enter > a number with four
marks appears in PC's display (e.g. 8321), this clarifies
what files are situated in control unit (program file and paraĆ
meter file, see table 1). Check that two last marks (e.g. 21)
correspond to part no. and tractor type. If necessary copy
parameters once more (stages 11...16).

17. Choose Call" > disconnect"

Picture A. Check code in AC 5.2 display
18. Switch programming unit power off (or switch tractor
power off).

19. Disconnect the programming cable from the control unit

(or from tractor).
A1A6
20. Fill in an adhesive label (part no and file
names and tractor model, A1A5
see table 1) > fasten it 9
on the control unit in right position 10
(see picture 1).

21. Exit from the Hyper Terminal"

program, if you are not going to program Date/Name
Tractor model

more control units. Parameter Version

Software Version
Part. no.

Settings after programming Unit AC -5.2

Transmission Control
(unit fixed in tractor)

22. Carry out settings according

to the table on page 370/24A.

23. Test-run the tractor according

341 12 310
to instr. D on page 24E.

Label (no 341 12 310)

Transmission Control Unit AC -5.2

Part. no. ........... or COM2

Software Version . . . . . . . .
Parameter Version . . . . . . 344 04 610
Tractor model . . . . . . . . . .
Date/Name . . . . . . . . . . . .

Part. no.=part no. of programmed control unit

Software Version=program version number, e,g, 83
Parameter Version=parameter file I.D. number, e.g. 21
Tractor model=tractor model
Date/Name=date/signature

33700600, L=1,5 m tai

33700610, L=8,0 m

or COM2

344 04 610
311
312
 Clutch
41.
40. Power transmission HiShift

42. Gearbox

Quick ---shift gear, DPS

44. Reverse shuttle
4WD clutch

45. Final drives

46. Power take ---off

299
300
 Model Code Page
41. Clutch 95-- 115
1. 11. 2000 X100-- X120 410 1

Contents
General (Op. no. 410):
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Single dry ---disc clutch in 95---115, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic type release mechanism in 95---115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HiShift for 95---115 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Repair instructions (Op. no. 411)

1. Splitting/assembling tractor frame, 95 ---X120:

A. Splitting between engine and middle frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Assembling between engine and middle frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Changing disc/release bearing, 95 ---115 only:

A. Changing clutch/disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Changing release bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Checking the clutch disc and clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. Adjusting and repair instruction for hydraulic type release mechanism, 95 ---115 . . . . 6

4. HiShift, 95 ---115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Technical data
Tractors 95---115 have a single dry ---disc clutch of cup spring type on the flywheel and it is hydraulically operated with an aid of
the clutch pedal. The clutch pedal has a mechanical power assistance in these tractors.Tractors X100---X120 have not a clutch
assemby, but only a drive disc attached on the flywheel.

Dry ---disc clutch, manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F&S

Clutch disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 mm
Linings on 95---115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . organic (asbestos---free)
Releasing force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 2950 N
Clutch pressure against flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . about 11200 N

Tightening torques
Clutch ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Drive flange ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm

301
 Model Code Page
41. Clutch 95-- 115
1. 11. 2000 X100-- X120 410 2

Special tools
A
Part no Description
ETV 893790 Centring tool for clutch disc (not X100---X120)
ETV 894 320 Fitting tool for HiShift hydraulic block piston seal KH 3714 (not X100---X120) (not illustrated)
Locally prepared tools
ET 893470 Support roller to split tractor frame
ET 893480 Support plate (2 pcs) to prevent front axle oscillation

ETV 893790

ET 893470

ET 893480

302
 Model Code Page
41. Clutch 95-- 115 410 3
1. 11. 2000

Dry---disc clutch on flywheel in The clutch transmits power from the flywheel through a drive
shaft to the input shaft of the DPS, and further to the gearbox.
95---115, description The drive shaft front end is supported with a bearing. The drive
shaft front end splines are engaged with the clutch disc hub
Models 95---115 are provided with a single dry ---disc clutch of splines.
the cup spring type. The clutch is operated hydraulically. The
disc is provided with damping springs. Clutch disc diameter
is 330 mm and it has organic linings (asbestos---free).

NOTE! On HiTech tractors X100---X120, which have a Powershift Shuttle , there is not a clutch assembly on the
flywheel, but only a drive disc, see page 410/5.

303
 Model Code Page
41. Clutch 95-- 115 410 4
1. 11. 2000

3 23 Nm

Figure 2. Clutch assembly and release mechanism in

95 ---115 without the turbine clutch.

1. Clutch release bearing

2. Drive shaft
3. Clutch disc
4. Flywheel
Note!. Pressure ---resistant grease on drive shaft splines

304
 Model Code Page
41. Clutch X100-- X120 410 5
1. 11. 2000

X100-- X120

Picture 2A. Drive disc on flywheel on HiTech tractors.

1. Flywheel (different on HiTech tractors)

2. Disc damping springs
3. Plates which increase mass
4. Closed drive shaft (earlier a hollow clutch shafti)
8. EP grease on splines

Picture 2B. Drive shaft between drive disc and DPS input shaft on X100 ---X120
See also page 410/11.

305
 Model Code Page
41. Clutch 95-- 115 410 6
1. 11. 2000

Clutch pedal power assistance in trac-

tors 95---115 (see also page 410/9)
The clutch pedal power assistance reduces pedal force
by about 40 percent. The clutch spedal power assist-
ance is standard equipment on 95---115 tractors.

Figure 3. Clutch servo, see also page 410/9.

1. Measurement X = 4 ---6 mm. After adjustment, make sure

that the pedal returns freely to the upper position.
3. The spring is locked with a pin when assembling. Fit the pin
3 split side downwards.

4. All sliding and bearing surfaces must be greased with uni-

versal grease when fitting the clutch servo.

306
 Model Code Page
41. Clutch 95-- 115 410 7
1. 11. 2000

Hydraulic type clutch release mechanism in 95---115

Picture 7. Clutch release mechanism

1. Reservoir (volume 2 dm3). Brake fluid SAE 6. Universal grease

J1703. 7. Adjusting value of clutch pedal power assistance
2. Master cylinder.
3. Release bearing ---slave cylinder (F&S). Note! From tractor ser. no. F39513 incl. the switch S24 has been
4. Bleeding nipple. The system can also be filled removed and the safety switch S9 has been moved to the sup-
through this hose port lower hole.
5. Clutch shaft. The shaft is thinner at the slave
cylinder

307
 Model Code Page
41. Clutch 95-- 115 410 8
1. 11. 2000

Picture 8. Master and slave cylinder

1. Fluid reservoir (Brake fluid SAE J1703)
2. Cross section of master cylinder
2a. Drilling, master cylinder --- reservoir
2b. Rubber valve
2c. Drilling, valve --- rear side of piston
3. Release bearing/slave cylinder (F&S) (stroke 10
mm)
3a. Release bearing. The bearing can move a little
radially (self ---centring)
3b. Ring piston
3c. Guide sleeve
4. Bleeding nipple
5. Clutch shaft

308
 Model Code Page
41. Clutch 95-- 115 410 9
1. 11. 2000

HiShift, description, 95---115 only

Repair instructions, see pages 411/12 ---14.

HiShift (option) in 95---115 tractors controls the clutch pedal

electro---hydraulically and it is unnecessary to depress the
clutch pedal with the foot. HiShift includes a hydraulic block
attached to the cab front wall with aid of the bracket, a new
clutch pedal, a new clutch fluid reservoir and electric parts.

F
E C
D
A

Picture 9. HiShift assembly

Function of the hydraulic part

The working cylinder piston (A) pushes the clutch pedal When the working cylinder piston (A) releases the clutch, it
down (working pressure from the low pressure circuit). The pulls the damping cylinder piston (C) mechanically out by
working pressure is controlled with the solenoid valve (B, the pin and the damping cylinder is filled with clutch fluid
Y14), which in turn is controlled with aid of the push buttons via the filling valve.
(F) in the gear lever knobs.
When the working cylinder solenoid valve is unenergised
When the solenoid valve (B) is energised (one of the but- (push button is released), the working cylinder piston
tons is depressed), the hydraulic pressure pushes the (pedal) rises first quickly the extent of the oblong hole in the
pedal down. When the button is released (solenoid unener- damping piston and then slower, because the return flow of
gised), the permanent hydraulic pressure on the piston rod the clutch fluid into the reservoir is restricted.
side forces the piston to move inwards and the clutch pedal
returns to the upper position. The damping cylinder restriction can be changed by the
solenoid valve (D, Y15) so that when the driving speed is
less than 4 km/h, the solenoid is energised and the clutch
pedal rises up slower. With speeds over 4 km/h the sole-
Function of the damping part noid is unenergised and the pedal rises faster. When the
shuttle lever button is used, the pedal always rises slower
The damping cylinder has been connected to the clutch regardless of the tractor driving speed.
fluid reservoir (E) by a hose.

309
 Model Code Page
41. Clutch 95-- 115 410 10
1. 11. 2000

Picture 10. HiShift hydraulic block and clutch pedal 12. All sliding and bearing surfaces should be greased with
universal grease in connection with repair works.
1. HiShift hydraulic block
2. Adjustable restriction for clutch pedal rising speed Others
3. Adjustable restriction for clutch pedal rising speed
4. Adjusting screw for adjusting position of knee point Normal foot control of the pedal is always possible, also
(knee point is a point, where clutch starts to slip and simultaneously. The clutch pedal has a hinge for safety.
engage when it rises from lowest position upwards)
5. Damping piston The clutch master cylinder and the clutch release mechan-
6. Main hydraulic piston ism are the same as earlier.
7. Damping cylinder filling valve
8. Clutch master cylinder Note! HiShift can be retrofitted also on earlier manufac-
9. Clutch pedal tured tractors, although they do not have the Agrodata ---
10. In the upper position the pedal should rest against the instrument.
stop and working cylinder piston (6) push rod must be free.
Push rod clearance to the piston hole edges should be at HiShift hydraulic block fixing bolts are tightened to 23 Nm.
least 1 mm in the whole pedal travel. The bolts must not be tightened too hard.
11. When piston (6) is fully pushed out, clearance to the
stopper should be 0,2 ---2 mm.

310
 Model Code Page
41. Clutch X100-- X120 410 11
1. 11. 2000

Repair instructions, see code 425.

1) Upper shaft front part

2) Propeller shaft between engine --- transmission
Maintenance at every 250 running hours: 4 pcs nipples. Bearings are greased at point B.
3) PTO drive shaft
4) Propeller shaft, 4WD
Maintenance at every 250 running hours: front grease points are greased through holes in the botton shield. 4 nipples.
Bearing is greased at point A.
5) Lower shaft
6) Universal grease on splines
7) Nipple is removed when lower shaft is fitted so that air can flow out. Grease through the nipple.
8) Bearings are pressed together against the inner ring. Shaft nut is tightened to 40 Nm and is secured with snap ring.

311
312
 Model Code Page
41. Clutch 95-- 115
1. 11. 2000 X100-- X120 411 1

1. Splitting/assembling tractor
B. Assembling tractor frame between en-
frame gine and middle frame
A. Splitting tractor between engine and Note! The frame joint assembling is done in the reverse
middle frame order but the following must be observed.

Note Splitting the tractor frame at the middle frame joint, 1. The frame joints bolts tightening torques are the same
see page 710/2. as in corresponding agricultural tractors, see page 710/3.

Note! On 95---X120 tractors the tractor frame can be split 2. When pushing the frame parts together, the clutch shaft
between the engine and the middle frame without releasing must be guided into the splines in the clutch disc or in the
the middle joint. In factory the machine is assembled so drive plate.
that the complete middle frame unit is fastened to the trac-
tor front and rear part. 3. Reconnect all oil hoses, electric connectors, cables, fuel
lines etc. If oil has drained out of the system, top up
Note! In this instruction is assumed that a front loader is not necessary amount of oil.
fitted on a tractor.
4. Remove all supports and remove the locking bar of the
IMPORTANT! The middle frame joint must be moved to a frame joint. Test---drive the tractor and check that no leaks
position in which it is when driving straight ahead and it exist and that the electrical system and the steering system
must be checked that no tensions exist in the frame. are functioning properly.
Then lock the front and rear frames with a mechanical
locking bar. Generally, when carrying out splitting
work, it must be very carefully. Under the supported
tractor parts must not be worked if it is not absolute
necessary.

1. Before splitting the frame the front axle oscillation must

be prevented with wedges or with ET 893 480.

2. Disconnect all oil hoses, wire connectors and possible

fuel lines and cables which prevent splitting. Note that
there can be pressurised oil in the hoses.

3. Disconnect 4WD propeller shaft front end flange joint. Put

an axle stand equipped with castors under the rear part of
the engine. When necessary, place a support under the
front piece of the engine so that the front part is in balance.

4. Put another axle stand under the middle frame.

5. Unscrew the bolted joint between engine ---middle frame

and open also bolts on the side of the front frame. Use a
long extension bar in the spanner when you open one bolt
which is in the lower part of the frame joint.

6. Push the engine section apart from the middle frame.

Now the clutch assembly (95---115), drive disc
(X100---X120), fly wheel, crank shaft rear oil seal etc. are
accessible. Also the engine removal is easier, when the
frame is split in this point.

IMPORTANT! If the tractor is equipped with an air conditio-

ning, its hoses can be opened only by a specialist who has
special equipment.

It is possible to carry out the frame splitting so that the air

conditioning system is not opened but only its different
parts are released.

313
 Model Code Page
41. Clutch 95-- 115 411 2
1. 11. 2000

2. Changing clutch disc

A. Changing clutch/disc

1. Split the tractor at the clutch (see instr. 1A).

ETV 893790

4. Fit centring tool ETV 893 790 and place the disc onto the
centring tool (disc hub longer side rearwards).

2. Unscrew the clutch fixing bolts evenly and remove the

clutch assembly/disc.

3. Check the condition of the clutch shaft front end bearing. 23 Nm

Check also splines on the pump drive flange on the flywheel.

Note! On the hydraulic coupling models the coupling must be

detached before checking the pump drive flange.

5. Fit the clutch assembly and tighten it evenly to a torque of

23 Nm. Remove the centring tool.

6. Assemble the tractor (see instr 1B).

B. Changing release bearing

See page 411/6 instr. D.

314
 Model Code Page
41. Clutch 95-- 115 411 3
1. 11. 2000

C. Checking clutch disc and clutch as-

sembly, 95---115

MAX. 0,5 MM

Clutch disc splines

Coat the splines in the centre of the clutch disc with pressure ---
Checking axial throw of clutch disc resistant grease to safeguard the axial movement of the disc
on the clutch shaft.
Mount the disc between the chuck and tailstock on a lathe.
Rotate the disc and measure the axial throw at its outer edge.
Also measure the taper (”dishing”) of the disc. If the throw or
taper is greater than 0,5 mm, change the disc.

10,0---11,1 mm

Clutch disc rivets

Rivets have a small hole for free air flow. If these holes become
clogged (e.g. dust), it can cause sticking of the disc.

0,4---0,8 mm

Organic linings are made by winding asbestos---free band.

For that reason radial grooves must not be made on the lin-
ings because thus bands can cut off. This can cause the lin-
Checking thickness of clutch disc ings to loosen.

Thickness, new disc (unloaded) 10,0---11,1 mm. Friction surfaces must be clean. A small amount of grease on
Axial resilience 0,4---0,8 mm the linings can cause vibrations and the disc can stick.

315
 Model Code Page
41. Clutch 95-- 115 411 4
1. 11. 2000

Checking movement of pressure plate

1. Place the clutch in fixture ETV 892 570 with 10 mm spacers.

Secure with at least four bolts.

max. 0,8 mm

min 1,9 mm
10 mm

2. Apply the clutch 3---4 times so that the cup spring ”beds
down”.

3. Check the height difference between the fingers of the cup

spring: this must not exceed 0,8 mm. If it is greater, the clutch
must be changed.

4. Press the cup spring fingers down by 10 mm and measure

the distance between the spacers and pressure plate. The
clearance must be at least 1, 90 mm. Check at several points.
If the clearance is lower the clutch must be changed.

316
 Model Code Page
41. Clutch
1. 11. 2000 95-- 115 411 5
10 mm

0,01 mm

Checking concavity of pressure plate

A new pressure plate is flat to slightly concave, max. 0,01/10

mm: convexity, i.e. the reverse state, must not occur. The rea-
son for the concave surface is to allow engagement to start at
the outer edge of the lining where the disc is least sensitive to
slipping. A grooved or otherwise deformed clutch must be
changed.

max. 2 mm (4 mm)

Important! When machining the flywheel, it is important to

observe that the clutch surface and the flywheel fixing surface
are parallel.

Measurement A on a new flywheel is 6±0,3 mm, and max

allowable value is 10±0,3 mm.

Machining flywheel

The flywheel can be machined 2 mm without any further ac-

tion. For additional machining the holes for the clutch attach-
ing bolts must also be deepened. The maximum machining
of the flywheel is 4 mm.

317
 Model Code Page
41. Hydraulic coupling 95-- 115 411 6
1. 11. 2000

C. Master cylinder
3. Clutch release mechanism of hy-
draulic type in 95---115
A. Bleeding the clutch circuit
Note! The bleeding hose/nipple is placed on the LH side of
the tractor frame.

This release mechansim does not normally require any

adjustments. The clutch pedal free travel cannot be felt, since
the release bearing is in the continuous contact with the
clutch. If the clutch does not release, the system must be bled.
Note! Check that the reservoir is full of brake fluid before blee- A
ding. Pump with the clutch pedal a few times, so that the sys- The master cylinder is attached with two bolts onto the cab
tem is under pressure. front wall.
A seal kit is available for the cylinder. The seals, piston and the
--- Depress the clutch pedal and at the same time open the spring can be removed from the cylinder by removing the cir-
bleeding nipple. clip A and the intermediate ring behind the circlip. Lubricate
--- When the pedal is down, close the nipple and allow the new seals with brake fluid. The seals must not be lubricated
pedal to rise up. with oil, because oil damages them.
--- Continue in this way until no air bubbles come out of the
nipple
--- Check again liquid level in the reservoir and top up if
necessary
D. Slave cylinder/release bearing
Note! The tractor frame is split at the clutch as before accor-
Note! Do not allow the liquid to contact the tractor frame,
ding to instruction A on page 411/1. Assemble the tractor
since the brake fluid can damage the paint.
frame according to instr. D on page 411/3.

2 3
B. Adjusting the pedal free travel
4
The free travel cannot be felt, since the release bearing tou-
ches the clutch release fingers all the time. Normally the pedal 5
does not need any adjustment.

Adjust the distance between the master cylinder piston and

the pedal push rod to 0,5 ---2,0 mm, when the pedal is in the
upper position.
1. The slave cylinder unit is attached with three bolts onto the
tractor frame. The pressure hose and the bleeding hose have
This clearance can be adjusted by slackening the clevis lock
different threads.
nut and by rotating the clevis.
2. The release bearing can be removed by releasing circlip
1. Before removing the bearing, the locking sleeve 2 claws
should be released from the flange.

3. The plastic covering 3 cannot be removed separately. The

guide sleeve 5 loosens, when you remove the circlip 4.

Important! The slave cylinder seals must not be lubricated

with mineral oil. The seals are lubricated with brake fluid.
Note! When the clutch disc linings are worn, the slave cylinder
shrinks correspondingly and the stroke of the cylinder
remains the same (about 10 mm).

318
 Model Code Page
41. Clutch 95-- 115 411 7
1. 11. 2000

4. HiShift
A. Adjustment

Note! Adjustment has been done in the factory and HiShift Restriction spindles Knee point
does not normally require any adjustment. In connection adjusting
with repair works the adjustment can be done according to screw
this instruction.

Note! There is an access hole on the side of the steering

wheel console, through which the adjusting screw can be
turned.
Pedal movement

6. If necessary, adjust the position of the knee point

(adjusting screw at the end of the damping piston). Screw
Time outwards=point rises and vice versa.
1. Pedal up 4. Driving speed < 4 km/h
2. Pedal down 5. Driving speed > 4 km/h 7. When the knee point has been adjusted, close the cab
3. Knee point 6. Clutch slips and engages side restriction and then open it 1+1/4 turns. The foremost
restriction should be open 2 turns (factory setting). Lock the
restriction spindles.
1. Check the clutch fluid level. Raise the tractor on axle
stands. Start the engine and use the HiShift several times 8. In a test---drive with driving speeds under 4 km/h the
so that air is removed from the system. pedal rises up slower (4) (restriction 1+1/4). With speeds
over 4 km/h the pedal rises up faster (restriction
2. Close the cab side restriction spindle. The foremost (1+1/4)+(2)). When the shuttle lever button is used , the
restriction spindle should be open 2 turns. pedal always rises slower regardless of the driving speed.

3. Depress the clutch pedal by using the push button. Note! Tractor driver can adjust the Hi Shift between certain
Select e.g. gear F/M/1. Adjust engine revs to 800---1000 limits according to his own choice. However, the cab side
r/min (greater than 1500 r/min if the tractor has a fluid cou- restriction must always be open at least 1 turn, to prevent
pling, i.e. Hi ---Trol models). excess wear of the clutch disc.

4. Release the button at which time the pedal rises up to the 9. Check the function of the clutch. Drive under and over 4
knee point (3), in which the working cylinder piston rests km/h and check that the engagement occurs softly. Ensure,
against the damping piston. Tractor wheels must not rotate. that the pedal hinge functions. Check for leaks.

5. Open the cab side restriction a little, at which time the Fault tracing.
pedal starts to rise slowly. The wheels must start to rotate If the clutch pedal in paragraph 4 rises direct to the upper
before the pedal has risen 10 mm (ideal value 5 mm) from position:
the knee point. --- the cab side restriction spindle leaks.
--- solenoid valve Y15 does not function or leaks.
Note! On account of possible small leakage of the restric- --- damping cylinder filling valve leaks.
tion spindle the pedal can start to rise slowly before the
restriction spindle is opened. The knee point (3) can,
however, be observed from change of rising speed of the
pedal.

319
 Model Code Page
41. Clutch 95-- 115 411 8
1. 11. 2000

B. HiShift hydraulic block

The restriction spindles have o---rings (4), which can be
Oil continuously circulates in the HiShift block from the changed. Do not screw in the spindles too hard, otherwise
tractor low pressure circuit and its pressure releases and the spindle tapered surfaces can damage. The restriction
engages the clutch. If the low pressure circuit has malfunc- spindles have securing nuts.
tions, it affects the Hi Shift.
Important! The seal rings of the damping cylinder solenoid
The damping part is not connected to the tractor hydraulic valve Y15 are of different material to the seal rings of the
system, but its own circuit uses clutch fluid (=brake fluid). solenoid valve Y14, and they must not be interchanged.
In connection with malfunctions, check the clutch fluid level Note! Before fitting the solenoid, make sure that the circuit
in the reservoir, when the pedal is in the upper position. in question is brake fluid circuit. Remove o---rings on the
new solenoid valve, wipe off oil on the new solenoid and
Leaking piston seals can be changed after unscrewing seal lubricate new o---rings, which are delivered with the repair
flanges (3). The filling valve spring and ball can be kit, with brake fluid and fit them (do not lubricate the o---
removed by unscrewing plug (5) between the restrictions (1 rings with oil).
and 2). In connection with repair works the solenoid valve Y15 seal
rings must not lubricate with oil but, if needed, with clutch
fluid.

In connection with repairs, tighten the joint between the

hydraulic block and the cab front wall to make watertight
(e.g.Silicone 2650 black).

320
 Model Code Page
41. Clutch 95-- 115 411 9
1. 11. 2000

C. HiShift electric system

AC 2.2 / 2.3

Note! When the buttons are pushed, the solenoid valve

Y14 is grounded and it becomes energised and the clutch --- If the pedal rises never slower when using all three but-
pedal is depressed. AD ---instrument grounds via relay K24 tons, the relay K24 is faulty.
the solenoid valve Y15, when driving speed is under 4
km/h, and the pedal rises up slower. When the shuttle lever If the pedal does not always rise slower when using the
button is used, the valve Y15 is always grounded regard- shuttle lever button
less of the driving speed. --- check function of other buttons. If with the other buttons
the Hi Shift functions correct, but not with the reverse
---If the HiShift does not function: shuttle lever button, the fault lies in the diodes.
--- check fuse F26. If the fuse blows repeatedly, the fault
can lie in diodes. Valve Y15 has been connected to the speed sensor B6 of
--- check the resistance of the solenoid valves which should the AD ---instrument. If the instrument shows correct speed
be 11 ---12 ohms. and travelling distance, the sensor B6 is in order. Otherwise
--- when 12 V is fed to the valve pins, the valves must the sensor should be checked/changed, see page 331/4.
become magnetic and the spindle must move (click).
Diode housing V5 is placed in the steering wheel console.
If the fuse and the solenoid valves are OK, but the Hi Shift In case of diode damages the whole housing should be
has malfunctions: changed.
--- measure whether there is a voltage of 12 V in the con-
nector pins of Y14 when the buttons are depressed. If not, Earthing point GR5 is under the dash board (cab wire
the fault can lie in the valve wires or in the push buttons. loom).
Check/ /correct.
If the pedal rising speed has malfunctions: Relay K24 is situated in the lever console beside the relays
--- measure whether there is a voltage of 12 V in the con- for the AC II.
nector pins of valve Y15 when the driving speed is under 4
km/h or the tractor is stationary. If not, the fault lies in relay Note! The push button wires have been soldered to the
K24 or in valve wires. buttons. As a spare part is dispatched wires together with
--- when driving speed is over 4 km/h, the valve Y15 should the buttons. The wire lower ends have connectors
be unenergised and the pedal rises up faster.

321
 Model Code Page
41. Clutch 95-- 115 411 10
1. 11. 2000

Positions of electrical components for HiShift.

322
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 420 1

Contents

General (Op. no. 420)

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gearbox, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear shift lever system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power transmission, servo and lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Repair instructions

Selector forks (Op. no 421)

1. Adjusting selector forks:

A. Removing gearbox side cover (selector cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Fitting gearbox side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Changing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Reconditioning gearbox (Op. no. 423)

1. Splitting tractor between gearbox ---middle frame:

A. Splitting tractor between gearbox ---middle frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Assembling tractor between gearbox ---middle frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Disassembling gearbox:
A. Removing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Removing side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Removing hydraulic pump, if fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Removing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Removing shafts from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Checking gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. Assembling gearbox:
A. Fitting shafts into the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Fitting and adjusting selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
C. Fitting 4WD clutch drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
D. Fitting side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E. Fitting pump and suction pipes, if fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F. Fitting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Reconditioning differential (Op. no. 424)

1. Changing/reconditioning differential:
A. Changing differential gears/diff. lock friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

323
 Model Code Page
42. Gearbox 95-- 115
420 2
1. 11. 2000 X100-- X120

Technical data
Number of gears:
--- forwards (with 3---step. Delta Powershift DPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
--- reverse (with 3---step. Delta Powershift DPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Oil in transmission housing:

Common oil to transmission and hydraulics. Note! Auxiliary front loader hydraulics has an own oil tank.
Viscosity and quality grade and oil volume: see page 130/4.

Warning lights for gearbox oil pressure and temperature as standard. Oil cooler as standard.
Pressure lubrication for input shaft and bevel pinion shaft.
Lubricating oil pressure ---relief valve, opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 MPa
Suction strainer, degree of separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 m
Pressure filters, filtration capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . β10=75

Tightening torques
Gearbox
Bevel pinion shaft ring nuts (+transmission shaft ring nut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Nm
Input shaft front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21---25 Nm
Layshaft front end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21---25 Nm
Gearbox side cover screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Differential
Crown wheel fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
Differential bearing cover screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40---50 Nm
Frame joints
Gearbox ---middle frame:
--- upper studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270---330 Nm
--- lower hexagonal socket---head screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm
Gearbox ---reverse shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21---25 Nm
Gearbox ---power take ---off:
--- upper studs (8 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270---330 Nm
--- lower studs (6 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72---88 Nm
--- lower studs M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Gearbox ---brake housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270---330 Nm

Settings
Gearbox
Pinion shaft rolling resistance measured with torsion meter at front end of shaft
(without differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,7---2,3 Nm
Input shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025---0,075 mm
Layshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025---0,075 mm
Differential
Differential bearing preload measured with torsion meter at front end of bevel pinion shaft
=pinion shaft rolling resistance+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+0,6---1,7 Nm (Z7/40, Z8/42)
+0,8---2,2 Nm (Z9/38)
+1,0---2,8 Nm (Z11/37)
Tooth backlash, pinion/crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,175---0,325 mm

Sealing compounds and locking fluids used

Reverse shuttle ---gearbox, sealing Hylosil RTV Grade 102 Black
Power take ---off ---gearbox, sealing Hylosil RTV Grade 102 Black
Brake housings---gearbox, sealing Hylosil RTV Grade 102 Black
Side cover ---gearbox, sealing Hylosil RTV Grade 102 Black
Threads on selector fork rails (+transmission shaft ring nut), Loctite 242
Crown wheel fixing bolts, Loctite 273

324
 Model Code Page
42. Gearbox 95 420 2A
1. 11. 2000

Markings of gearboxes
The gearboxes have been marked with letter codes. The purpose is to make recognizing of the gearboxes easier in connection
with tyre changing, repair works and when fitting parts for the ground speed PTO. Concerning PTO unit markings, see page
460/2A. The gearboxes listed below are fitted on tractors which have a Delta Power Shift or which can be fitted with DPS.

Transmission 300: tractor 95 (---K41105).

(DPS 300, gearbox 300, rear axles 300, PTO 300 (---G18213), PTO 450 (G18214---).
Note! Transmission 550 replaces transmission 300 from week 41/00 incl.

Letter Type Number of Ratio Part no Z Z 4WD

gears front/rear
A 40 km/h DPS 36 1,332 32825210 Z8/42 Z32/37
30 km/h DPS 33 1,332 32825210 Z8/42 Z32/37

B 40 km/h DPS, AVO 36 1,332 32825310 Z8/42 Z32/37

30 km/h DPS, AVO 33 1,332 32825310 Z8/42 Z32/37

C 40 km/h 12 1,334 32825410 Z9/38 Z42/39

30 km/h 11 1,334 32825410 Z9/38 Z42/39

D 40 km/h AVO 12 1,334 32825510 Z9/38 Z42/39

30 km/h AVO 11 1,334 32825510 Z9/38 Z42/39
J 40 km/h DPS 36 1,391 32825200 Z7/40 Z34/41
30 km/h DPS 33 1,391 32825200 Z7/40 Z34/41
K 40 km/h DPS, AVO 36 1,391 32825300 Z7/40 Z34/41
30 km/h DPS, AVO 33 1,391 32825300 Z7/40 Z34/41
L 40 km/h 12 1,381 32825400 Z9/38 Z39/35
30 km/h 11 1,381 32825400 Z9/38 Z39/35
M 40 km/h AVO 12 1,381 32825500 Z9/38 Z39/35
30 km/h AVO 11 1,381 32825500 Z9/38 Z39/35

DPS=Delta Power Shift

AVO=Ground speed PTO
Ratio front/rear=ratio between the front and rear axle. E.g. Front wheels rotate 1,332 turns/1 rear wheel turn.
Z=number of teeth on pinion/crown wheel.
Z 4WD=number of teeth on the 4WD gear wheels in the gearbox.
Part no=spare part number of the complete gearbox.

The max. speed is limited with a mechanical blocking device in the gearbox. The bloc-
king device prevents engagement of the highest gear H4 in transmission 30 km/h.

The letter has been stamped on the LH side of the gearbox.

A ---M

325
 Model Code Page
42. Gearbox 95-- 115
X100-- X120 420 2B
1. 11. 2000

Transmission 650: 105, 115, X100 up to no K36111, X110---X120

Transmission 550: 95 (K41106---) and X100 (K36112---)
(DPS 650, gearbox 650/550, rear axles 450/650, PTO 650).

Note! Transmission 550 is the same as 650, but 550 has only two differential pinions, 650 has four and 4WD ratio
is different in these transmission types.

T 40 km/h DPS, AVO 36 1,309 33086100 Z8/42 Z29/45

U 40 km/h DPS 36 1,309 33086200 Z8/42 Z29/45

V 50 km/h DPS, AVO 36 1,315 33086300 Z9/38 Z33/41

Y 50 km/h DPS 36 1,315 33086400 Z9/38 Z33/41

EA 40 km/h DPS, AVO 36 1,309 33511900 Z8/42 Z29/45

FA 40 km/h DPS 36 1,309 33512000 Z8/42 Z29/45

GA 50 km/h DPS, AVO 36 1,315 33512100 Z9/38 Z33/41

HA 50 km/h DPS 36 1,315 33512200 Z9/38 Z33/41

IA 40 km/h DPS, AVO 36 1,209 33673200 Z9/38 Z33/41

JA 40 km/h DPS 36 1,209 33673300 Z9/38 Z33/41

KA (550) 40 km/h DPS, AVO 36 1,339 33757600 Z8/42 Z29/44

LA (550) 40 km/h DPS 36 1,339 33757700 Z8/42 Z29/44

MA (550) 40 km/h DPS, AVO 36 1,339 34257500 Z8/42 Z29/44

NA (550) 40 km/h DPS 36 1,339 34257600 Z8/42 Z29/44

OA (550) 40 km/h AVO 12 1,337 4257700 Z11/37 Z38/37

PA (550) 40 km/h 12 1,337 34257800 Z11/37 Z38/37

DPS=Delta Power Shift

AVO=Ground speed PTO
Ratio front/rear=ratio between the front and rear axle. E.g. Front wheels rotate 1,332 turns/1 rear wheel turn.
Z=number of teeth on pinion/crown wheel.
Z 4WD=number of teeth on the 4WD gear wheels in the gearbox.
Part no=spare part number of the complete gearbox.

The letter has been stamped on the LH side of the gearbox.

The max. speed is limited with a mechanical blocking device in the gearbox. The bloc-
T ---PA
king device prevents engagement of the highest gear H4 in transmission 30 km/h.

326
 Model Code Page
42. Gearbox 95-- 115 420 3
1. 11. 2000 X100-- X120

Special tools
Order no Description
ETV 890 220 Universal handle
ETV 891 870 Plate for fitting thrust bearing for differential side of gear (Gearbox 505---905)
ETV 892 230 Socket spanner for bevel pinion shaft ring nut (Gearbox 305---555)
ETV 894 190 Socket spanner for 4WD clutch drum nut
ETV 892 370 Sleeve for fitting input shaft front end bearing (Front axle 505---905)
Sleeve for fitting bevel pinion shaft front end bearing
ETV 892 380 Sleeve for fitting input shaft rear end bearing (Gearbox 505---905)
ETV 893 300 Puller for differential bearings (Gearbox 505---905)
ETV 893 340 Plate for fitting bearing race, pinion shaft rear bearing (Gearbox 505---905)
ETV 893 400 Plate for fitting differential bearings (Gearbox 505---905)
ETV 894 050 Drift for fitting locking pins for selector forks
ETV 894 080 Drift for fitting selector fork rail for LL ---range
ETV 894 120 Counter hold for puller ETV 893300.
Locally prepared tools
ET 894 060 Press tool for adjusting selector forks

ETV 890220
ETV 891870 ETV 892 230

ETV 892 370

ETV 894 190

ETV 893340

ETV 894120

ETV 893302
ETV 892380
ETV 893 300 ETV 893400

327
 Model Code Page
42 Gearbox 95-- 115 420 4
1. 11. 2000 X100-- X120

ETV 894 050

ET 894 060 ETV 894 080

ETV 894 120

328
 Model Code Page
42 Gearbox 95-- 115
420 5
1. 11. 2000 X100-- X120

Gearbox, description
Position of the gearbox is shown in the figure below. Reverse The Delta Powershift gear triplicates the number of speeds.
shuttle and quick ---shift gear (DPS) are attached to the front
of the gearbox. Power take ---off is attached to the rear end. The gearbox is fully synchronized (except LL ---range). Gear
Rear axles are attached to the both sides of the gearbox. Dif- wheels have helically cut teeth. Pressure lubrication. Separate
ferential is fitted in the rear part of the gearbox housing. reverse shuttle.

The gearbox is operated mechanically with a speed gear lever

and range gear lever on the right hand side of the driver’s seat.
Gearbox has three ranges (LL ---M ---H) and four speed gears.
The reverse shuttle is operated with a separate lever.

Figure 1. Power transmission

1. Gearbox
2. Gear levers
3. Servo valve block

329
 Model Code Page
42 Gearbox 95-- 115
1. 11. 2000 X100-- X120 420 6

Gearbox has four shafts (or five if ground speed PTO) Input shaft (P), layshaft (S) and pinion shaft (M) are supported
--- input shaft (P) in taper roller bearings, ground speed PTO shaft (AVO) and
--- layshaft (S) transmission shaft (U) in ball bearings.
--- bevel pinion shaft (M)
--- transmission shaft (U) Input shaft and pinion shaft have pressure lubrication. Other
--- ground speed PTO shaft (AVO), optional shafts are lubricated through splash lubrication.

In the lower part of the gearbox there is fitted a transmission In the rear end of the input shaft there is a pump driving mech-
shaft (U), which transmits LL ---range to the pinion shaft and anism (not 95---115) which is powered by a long drive shaft.
power to the ground speed PTO shaft (optional). There is a Input shaft front end splines engage to the reverse shuttle
4WD gear and 4WD clutch drum fitted in the front end of the gear splines.
transmission shaft. Power to the 4WD clutch drum is trans-
mitted from the gear at the front end of the pinion shaft. End float for the input shaft and layshaft is adjusted with
shims in the front end of the shafts. Pinion shaft bearing pre-
Selector fork for the ground speed PTO is fitted on the pinion load is adjusted with spacer rings (2 pcs) at the front end of
shaft (M). The ground speed PTO fork is operated with the the shaft. Position of the pinion shaft is adjusted with shims
PTO control lever. under the shaft rear bearing outer race.

90---110 Nm

Oil level
extra
max
1
max
min

Gearbox front side

4

7
40---50 Nm 2
5 40---50 Nm

Figure 2. Gearbox

P=input shaft
1
S=layshaft
M=bevel pinion shaft
U=transmission shaft
AVO=ground speed PTO shaft (optional)

1. Sealing Hylosil RTV Grade 102 Black

2. Gasket
3. Locking fluid Loctite270
4. Draining plug (oil change and suction strainer
cleaning at intervals of 1000 running hours).
5. . Differential
6. Selector cover
7 . Servo valve block

3 270---330 Nm
1

330
 Model Code Page
42 Gearbox 95-- 115
420 7
1. 11. 2000 X100-- X120

Power routes in gearbox

Gearbox shafts

R
R

P
PTO 1 2 3 4 PTO 1 2 3 4
S
M H
LL
M
4WD
U 4WD
AVO
AVO
AVO
Figure 3. Power route in ranges H and M Figure 4. Power route in range LL

B4C

Figure 5. Input shaft (P), ---H42415 A (transmission 550/650). Thickness of

spacer:
1. Bearing end float is adjusted with shims 3,50 mm (without dot)
2. Bushing is locked with Loctite 601 3,65 mm (1 dot)
3. Engine speed sensor, HiTech 3,80 mm (2 dots)
4. Sensor threads are locked with Loctite 542 3,95 mm (3 dots)
5. Lubricating oil to the input shaft 4,10 mm (4 dots)
6. Splash oiling from crown wheel
7.Lubricating oil to pump drive shaft splines, HiTech
Note! In the 550/650 transmission the input shaft rearmost bearing is larger. Also the input shaft is different in the trans-
missions 300 due to the thicker pump drive shaft of the 550/650. In addition, gearwheel Z21 has been made broader.
Spacer ring A has been added between gears Z26 ---Z31. Adjust the clearance beween circlip (8) and synchro hub to zero
or as small as possible.
331
 Model Code Page
42 Gearbox 95-- 115 420 7A
1. 11. 2000

B4C

--- H38215 H38216---

Picture 5A. Input shaft in transmission 550/650 from ser.

no. H42416 incl. (not HiTech).

1. Bearing end float is adjusted with shims

2. Bushing is locked with Loctite 601
3. Engine speed sensor (if fitted)
4. Sensor threads are locked with Loctite 542
5. Lubricating oil to the input shaft
5a. Lubricating oil onto the input shaft front bearing
6. Splash oiling from crown wheel
7. Lubricating oil to pump drive shaft splines
8. Circlip. Play between circlip and synchronizing unit hub
is adjusted to 0,05 ---0,20 mm with a spacer between gears
Z26 and Z31.

332
 Model Code Page
42 Gearbox X100-- X120 420 7B
1. 11. 2000

Kuva 5B. Input shaft in HiTech models (transmission

550/650).

1. Bearing end float is adjusted with shims

2. Bushing is locked with Loctite 601
3. Engine speed sensor, HiTech
4. Sensor threads are locked with Loctite 542
5. Lubricating oil to the input shaft
5a. Lubricating oil onto the input shaft front bearing
6. Splash oiling from crown wheel
7. Lubricating oil to pump drive shaft splines
8. Circlip. Play between circlip and synchronizing unit hub is
adjusted to 0,05 ---0,20 mm with a spacer between gears Z26
and Z31.

333
 Model Code Page
42 Gearbox 95-- 115
420 8
1. 11. 2000 X100-- X120

21---25 Nm

s=0,10
0,15 1
0,025...0,075 mm 1 0,50
Figure 6. Layshaft (S)

1. Bearing end float is adjusted with shims

2. Note the position of the bearing cover
Layshaft gearwheels Z16 and Z38 have been made broader

AVO

Figure 7. Bevel pinion shaft (M)

1. Shims for adjusting position of the bevel pinion shaft

Note! On latest shafts there is a needle bearing
2. Bearing preload is adjusted with spacer rings
fitted inside gear Z39 (for range H). This must
3. Gear Z28 and AVO coupling only on tractors with ground speed PTO
be observed during possible repair works.
4. If coupling sleeve LL and gear Z53 removed, there is a sleeve in place.
Note! Figures in brackets = transmission 50 km/h.

334
 Model Code Page
42 Gearbox 95-- 115 420 9
1. 11. 2000 X100-- X120

Figure 8. Transmission shaft (U)

1. 4WD clutch drum

2, Shaft nut (270 Nm)
Note! Gear Z34 only on tractors with ground speed PTO.
Figures in brackets = transmission 50 km/h.

Figure 9. Ground speed PTO shaft (AVO) (optional)

Note! Gear wheel Z19 has been made wider on the latest shafts.

335
 Model Code Page
42 Gearbox 95-- 115
1. 11. 2000 X100-- X120 420 10

Synchronization
Synchronizing cones
On input shaft (couplers for gears 1---2 and 3---4): ø82 mm,
steel
On bevel pinion shaft (coupler for ranges M and H): ø90 mm,
steel

The synchromesh units can be fitted either way. The synchro-

mesh units on the input shaft are interchangeable and can be
fitted either way. Measuring synchronizing cone wear and as-
sembling the unit, see page 423/7.

A D

B
E
F
C A. Sliding coupler
B. Synchronizing cone (2 pcs)
C. Coupler (2 pcs)
D. Ball (3 pcs)
E. Shoe (3 pcs)
F. Spring (3 pcs)

Figure 10. Synchromesh unit

Engagement
The axial movement of the sliding coupler (A) presses the syn-
Once, the speeds have been synchronized, the sliding
chronizing cone (B) against the male taper on the coupler (C)
coupler (A) continues to exert pressure against the synchro-
by means of the balls (D) and shoes (E). The different speeds
nizing cone (B) and pushes it backwards until the teeth in
of the components to be coupled together produces stagger-
coupler (A) are opposite gaps between the teeth on the syn-
ing of their relative positions, limited by stops, which in turn
chronizing cone (B). At this point the resistance, which had so
causes the chamfered teeth on the synchronizing cone (B) to
far prevented the sliding coupler (A) from moving, is over-
press against the sliding coupler (A), thereby preventing any
come and the sliding coupler (A) engages silently with the
relative movement of this coupler. The pressure exerted by
teeth in the coupler (C)
the sliding coupler (A) and the staggered position of the syn-
chronizing cone (B) creates axial pressure between the tap-
Neutral position
ered friction surfaces on the synchronizing cone (B) and the
The sliding coupler (A) is in the middle position. Balls (D) are
coupler (C) by means of the chamfers on the teeth. This axial
pushed into the V shaped groove in the sliding coupler (A) by
pressure gradually reduces the difference in speeds in order
springs (F). The gears can turn freely on the shaft. The sliding
to achieve synchronization.
coupler (A) is locked in this position by three balls (D) held by
springs (F).

336
 Model Code Page
42 Gearbox 95-- 115
420 11
1. 11. 2000 X100-- X120

Differential
Differential lock

The crown wheel and differential case are mounted in the The differential lock is an electro---hydraulically controlled
gearbox housing on taper roller bearings. Bearing preload multi ---disc clutch. The solenoid valve for the lock is placed
and tooth backlash between the pinion and the crown on the servo valve block on the left hand side of the gear-
wheel are adjusted with threaded flanges. box.

In transmissions 300 and 550, the differential has two differ- The low pressure pump supplies oil to the servo valve block
ential pinions. Transmission 650 has four differential pinions via an external oil hose. A pressure ---limiting valve on the
in the differential. The side bevel gears and pinions in the servo valve block limits the diff. lock oil pressure to 1,8 MPa.
differential case have plain bearings. Pressurised oil from the servo valve block to the diff. lock is
conducted through a pipe inside the gearbox housing.

In the differential case cover there is a piston which presses

the clutch discs together, thus connecting the differential
bevel side gear to the differential casing.

The diff. lock can be engaged while driving. The differential

lock disengages automatically, if the brake pedals (or one
pedal) are pressed.

3 300

(30) & 40 km/h 40---50 Nm

4
1 390
460
Figure 11. Cross ---section of differential 650

1. Loctite 270 on the crown wheel bolt threads

2. Note the position of the tension pin
3. In transmissions 300 and 550, the differential pinion
shaft is locked with a tension pin (2) (1 pc).
4. In transmission 650 the shorter diff. pinion shafts are
locked with tension pins (two pins are needed). Note! On the earlier tractors the differential lock has 5 fric-
5. Oil hole for lubricating oil from the PTO unit lubricating tion discs and 4 steel discs. On the latest tractors there are
oil pipe hole. 5 friction discs and 6 steel discs, which are thinner, since
6. Pressurised oil to the differential lock the disc location is the same. The new discs pack can be
7. Threaded flanges for adjusting differential bearing pre- fitted into the earlier tractors without modifications. Max.
load and tooth backlash between pinion / crown wheel thickness of the disc pack is 21,5 mm.

337
 Model Code Page
42 Gearbox 95-- 115
420 12
1. 11. 2000 X100-- X120

Gear levers In the same way the other ranges are engaged. The range
gear lever is first moved towards the driver’ seat whereat the
selector lever on the side cover is pushed inwards and the
The range gear lever (2) selects ranges LL, M or H. When se- lever inner end engages with a groove on the selector fork for
lecting e.g. LL, the lever is moved first outwards and then for- ranges M and H (fork in foremost position=M. Fork in rear-
wards. The lever lower end first moves inwards and pushes most position=H).
via a cable the selector lever on the side cover outwards and
it engages with a groove on the LL ---range selector fork. When The speed gear lever (1) engages gears 1---4. When selecting
the range gear lever is then moved forwards, the lower part e.g. gear 1, the gear lever first is moved towards the driver’s
moves backwards and via shifter rods it turns the selector seat and then forwards. When moving towards the seat the
lever so that the LL ---range engages. selector lever on the side cover is moved inwards (by the
cable) and it engages with a groove on the fork for gears 1---2.
When the gear lever is then moved forwards, the selector
lever is turned (by the shifter rod) so that gear 1 engages.

Figure 12. Gear levers

1. Speed gear lever (1 ---4)

2. Range gear lever (LL ---M ---H)
3. Reverse shuttle lever (R ---F), not HiTech
D. Support shaft (see next page)
E.Shifter rods and cable wires (see next page)

Note! In the speed gear lever knob there are

push buttons for Delta Power Shift. If a tractor
is equipped with HiShift, there are clutch
release push buttons in the gear lever knobs.

D
E

Cable wires (2 pcs ) Shifter rods (3 pcs)

338
 Model Code Page
42 Gearbox 95-- 115
X100-- X120 420 13
1. 11. 2000

LOCTITE 542

0,3...0,7 mm
5

Figure 13. Gear lever support shaft (point D in figure 12)

Note! Rubber joints allow side movement for the speed and range gear levers

4. Force at the end of the reverse shuttle lever is adjusted to 10 ---20 Nm by tightening the shaft
5. Adjust distance to 0,3 ---0,7 mm by turning the pin
6. Universal grease

446---448 mm
E
LL

M--- H

386---388 mm
241 mm

4--- 3

2--- 1

R--- F

Adjust shifter rods and cable wires

to dimensions shown in figure.Ad-
justment can be done through a ac-
cess hole on the RH side mud-
271---273 mm guard.

266---268 mm (---657167)

Figure 14. Shifter rods and cable wires for inwards/outwards movement of the selector levers (point E in figure 12).
The gear lever must stand in the neutral position when adjusting measurement 241.

339
 Model Code Page
42 Gearbox 95-- 115
420 14
1. 11. 2000 X100-- X120

Selector levers and side cover Selector levers, which move the selector forks, are led into the
gearbox through the side cover on the right side of the gear-
box. Selector levers for speed and range gears can move also
in --- and outwards on the cover.

On the side cover there are fitted blocking pieces which pre-
vent simultaneous engagement of two gears. At the outer end
of the selector levers there are fitted shifter levers. Shifter rods
and cable are attached to the shifter levers.

Also the selector lever for the ground speed PTO (optional) is
led into the gearbox through the side cover (see section 46
Power take ---off). Note! Reverse shuttle selector lever is
placed in front of the side cover (see section 44).

1
1

2
3 4

5
1

H ---M ---LL
1---2
3---4

Figure 15. Selector levers and side cover

1. Shifter levers
2. Lead ---in rubber
3. Sealing rings
4. Side cover (on the RH side of the gearbox)
5. Selector levers AVO
6. Blocking pieces

Note! The side cover together with the selector levers can
be removed from the tractor after the gearbox oil is drained.

340
 Model Code Page
42 Gearbox 95-- 115 420 15
1. 11. 2000 X100-- X120

Selector forks and selector fork rails

When the gears are in neutral, the grooves on forks M ---H and
Each selector fork for gears M ---H, 1---2 and 3---4 are fitted on LL should be opposite each other. In the same way in neutral
their own rail. The forks are attached to the rails with a locking position, the grooves on forks 1---2 and 3---4 should be oppo-
pin. The selector lever round ---shaped end engages with the site each other. This must be noted when adjusting the forks.
groove on the selector fork.
The rail for fork LL (and for the ground speed PTO fork) is at-
There is an adjusting piece at the rear end of the rails. There tached to the gearbox housing with threads.
are also locking balls and springs which engage with the ad-
justing piece grooves (3 pcs).

45---55 Nm

23---27 Nm

Figure 16. Selector forks and rails

2. Long pins into the two upper hole and short pin into the lowest hole
3. Universal grease
4. Hylosil sealing compound (UK 0067) between cover and gearbox
5. Loctite 242 (UK 0126).

341
 Model Code Page
42 Gearbox 95-- 115
420 16
1. 11. 2000 X100-- X120

Figure 17. Blocking device for gear H4

Function:
1. The tension pin must be fitted with the split side either up-
wards or downwards. If the speed gear 4 has been engaged, and then the range ge-
(N.B. The bore does not reach through the blocking device). ar lever is moved to the H position, the blocking device pushes
2. Gearbox RH side cover (by means of a washer on the selector fork rail) the speed gear
4 out of mesh.
If, in turn, the range gear lever is in H --- position, and the
On tractors intended for certain markets, the gearbox (type 40 speed gear lever is moved to position 4, the device disenga-
km/h) is equipped with a blocking device for gear H4. The ma- ges the range H.
ximum speed is then about 30 km/h.

342
 Model Code Page
42 Gearbox 95-- 115 420 17
1. 11. 2000

11. Oil to gearbox lubricating system

13a. Pressure oil to gear clutch C1 (see section 44).
13b. Pressure oil to gear clutch C2 (see section 44).
13c. Pressure oil to gear clutch C3 (see section 44).
14. Oil cooler.
Picture 18 B. Servo valve block with effect from ser. no. 15. Connection to return side of working hydraulics.
660071 on tractors which have Delta Powershift (3 ---step 16. Plug (readiness for front axle diff. lock)
quick ---shift gear) and the mechanical shuttle. 17. Restriction ø 2 mm ( ---661797) or ø 1,2 mm
(661798 ---) eliminates pressure drop when engaging
1 . Servo valve block PTO clutch or diff. lock. On the later valve blocks
2. Oil supply from pump (665536 ---) there is a separate passage from the pump
3. Pressure ---limiting valve, 1,8 ---1,9 MPa (18 ---19 bar) pressure side to the diff. lock solenoid valve. There is res-
4. Safety valve 0,4 MPa (4 bar). Protects oil cooler when triction ø2 mm in this passage. In this way are separated
hydraulic oil is cold and thick. functions of the diff. lock and the PTO.
5. Tank passage from solenoid valves 18. Piston, PTO cushioning valve
6. Pressure ---test point (Valmet HPR, thread M16) 19. Valve ball, PTO cushioning valve
7. Pressure oil to differential lock. 20. Restriction Ø 2mm eliminates pressure drop when
8. PTO cushioning valve, incl. parts 18, 19, 21. engaging 4WD or quick ---shift gear (Delta Powershift)
9. Pressure oil to PTO clutch 21. Valve ball, PTO cushioning valve
10. Pressure oil to 4WD clutch 22.Valve spool for engaging gear clutch C3.
23. End plug of valve spool (position marked with a
punch mark).
343
 Model Code Page
42 Gearbox 95-- 115 420 18
1. 11. 2000

Servo valve block on tractors which have

3---step quick ---shift gear (Delta Powershift),
660071 --

To the quick-
shift gear

To the quick-
shift gear

Picture 21. Servo valve block on tractors which have Delta

Powershift, 660071 ---, and the mechanical shuttle.
The servo valve block above has parts which are needed for
Y1=Solenoid valve for diff. lock 3---step quick ---shift gear (Delta Powershift). Otherwise the
Y2=Solenoid valve for PTO construction of this servo valve block corresponds to the valve
Y3=solenoid valve for 4WD block presented in picture 20 on previous page.
Y4=Solenoid valve for reduction gear
Y6=Solenoid valve for overdrive Important! If repair work concerns the 3---step quick ---shift
S16=Transmission oil temperature sensor (warning light) gear (Delta Powershift), see section 44 page 440/7.
S17=Transmission oil pressure sensor (warning light)
Note! Sensor S17 in the picture above is fitted on the valve Also this valve has the cushioning valve for the PTO clutch,
block up to ser. no. 670581. From ser. no. 670582 incl. there see also section 46.
is a new sensor , which has two wires (earth and supply) and
the pressure values are 10 ---50 kPa. Apply Loctite 542 to the Important! If the valve block should be removed, push with
threads of the sensor. a large screwdriver the lubricating oil pipe (see picture 23
P=Oil supply from low pressure pump point 2 on page 420/22) towards the gearbox. Push the screw-
1=Valve spool for direct ratio of Delta Powershift driver through the oil cooler lower pipe connector. Otherwise
2= Pipe connector for connecting return oil side of working the lubricating oil pipe lower end can loosen from the distribu-
hydraulics tion pipe.

In this servo valve block the pressure ---limiting valve (section Note! With effect from tractor ser. no. 665536 the valve block
A ---A) is the same as shown in figure 20 on previous page. The has been changed. The modified valve block can be fitted in
oil cooler safety valve (section B---B) is the same as shown in place of the earlier block. When fitting the latest valve block,
picture 20 on previous page. thicker ”O” ---rings (KH 4070) must be fitted between the gear-
box and the valve block.

Note! The threaded plug (1) has been removed and has been
replaced with a lockin plate which is fastened on the valve
block with a screw. In this case the valve spool does not need
any adjustment, but it is in the correct position when the loc-
king plate is fitted.

344
 Model Code Page
42 Gearbox 95-- 115 420 19
1. 11. 2000

13c. Pressure oil to gear clutch C3 (see section 44).

14. Oil cooler (oil cooler must not be plugged. In possible
malfunctions, the cooler must be passed with hose)
15. Connection to return side of working hydraulics.
Picture 21A. Servo valve block from ser. no 668103 incl on 16. Plug (readiness for front axle diff. lock)
tractors which have a mechanical shuttle and DPS. 17. Restriction ø 1,2 mm (661798 ---) eliminates pressure
drop when engaging PTO clutch.
18. Piston, PTO cushioning valve
1 . Servo valve block
19. Valve ball, PTO cushioning valve
2. Oil supply from pump
20. Restriction Ø 2mm eliminates pressure drop when
3. Pressure ---limiting valve, 1,8 ---1,9 MPa (18 ---19 bar)
engaging 4WD or quick ---shift gear (Delta Powershift)
4. Safety valve 0,4 MPa (4 bar). Protects oil cooler when
21. Valve ball, PTO cushioning valve
hydraulic oil is cold.
22.Valve spool for engaging gear clutch C3.
5. Tank passage from solenoid valves
23. End plug of valve spool (position marked with a
6. Pressure ---test point (Valmet HPR, thread M16)
punch mark).
7. Pressure oil to differential lock.
24. Ø 2 mm restriction eliminates pressure drop when
8. PTO cushioning valve, incl. parts 18, 19, 21.
using differential lock.
9. Pressure oil to PTO clutch
25. Temperature sensor for Agrodata ---instrument
10. Pressure oil to 4WD clutch
(option)
11. Oil to gearbox lubricating system
26. Change ---over restriction ø2 mm. Prevents pressure
13a. Pressure oil to gear clutch C1 (see section 44).
drop in DPS clutches, when 4WD is disengaged (4WD
13b. Pressure oil to gear clutch C2 (see section 44).
clutch becomes pressurised) e.g. when braking.

345
 Model Code Page
42 Gearbox 95-- 115 420 20
1. 11. 2000

CLUTCH ENGAGED
CLUTCH DISENGAGED

Picture 21B. Lock valve of Delta Powershift on tractors which ratio is changed from the intermediate ratio (II) to the highest
have a mechanical shuttle and transmission 550/650. ratio III and vice versa.

1. Lock valve Testing the valve

1a,e) Non ---return valve, 0,7 bar
1b,d) Non ---return valve Select H ---range gear and start to drive with revs of over 2000
1f,g) Change ---over restriction (ø1,6 mm) rpm. Drive and depress brake pedals until the engine revs
1c) Lock valve piston lower to about 1700---1800 rpm. Change DPS ratio from II to
III and vice versa and follow the rev. counter reading. If engine
In transmissions 550 and 650 (not HiTech) the tractors have revs rises much during gear change, the lock valve must be
the above shown valve. The valve is fitted between the DPS changed as a complete unit.
clutches C1 and C2 and the servo valve block.
If engine overloads strongly during gear ratio change (from II
The valve synchronises the engagement of clutches C1 and to III or vice versa), the lock valve is faulty and should be chan-
C2 so that pressure in one clutch drops just, when the other ged. This overloading damages the DPS clutches.
clutch is fully pressurised. The valve functions, when the DPS
346
 Model Code Page
42 Gearbox X100-- X120 420 21
1. 11. 2000

1,2 MPa

Picture 21C. Servo valve block on HiTech tractors (on the

LH side of the gearbox)
Note! See also picture on page 440/24.
--- Valves Y2 and Y1 have been connected with an oil chan-
HiTech Shuttle has caused the following modifications in nel. Oil cooler by ---pass valve has been added. Safety
the servo valve block: valve limits max. pressure before the oil cooler to 0,7
MPa (was 0.4 MPa).
--- PTO cushioning valve has been removed (PTO solenoid
valve Y2 is proportional). Pressure ---limiting valve in the suction strainer housing is of
--- The valve spindle of the DPS clutch C3 has been remo- 0,4 MPa (was 0,2 MPa).
ved and C3 has its own proportional valve Y17 (is placed
on a separate valve block on the gearbox). By increasing the lubricating oil pressure and with a new
--- Valve Y4 (DPS clutch C1) and valve Y6 (DPS clutch C2) by ---pass of the oil cooler the oil amount, which flows direct
have been changed to proportional valves, and they are into the tank, has been tried to minimized.
placed on the DPS housing. Hand brake solenoid valve
Y18 (+valve 17a) has been added. Pressure sensor S17 has been placed under the block and
--- DPS restrictions have been removed. A pressure accu- it measures actual pressure after the oil cooler.
mulator has been fitted on the valve block (not in pictu-
re), which eliminates pressure drops during engaging/di- Behind plug A there is diff. lock clutch pressure.
sengaging the multi ---disc clutches.

347
 Model Code Page
42 Gearbox X100-- X120 420 22
1. 11. 2000

Note! The end of the

spindle must be almost flush with the valve body.
If necessary, the valve must be removed and the
spindle must be pressed to the outer position.

Picture 21D. Valve block of HiTech ---shuttle on the gear- --- Permatex Super 300 No 83 onto the threads
box housing 13. Proportional valve
14. Lubricating oil flow into the shuttle has been reduced with
1. Valve block
a restriction (diam. 5 mm). This restriction eliminates gear
2. Pressure oil, 1,8 MPa (18 bar), into the valve
change problems (lubricating oil does no more revolve the
3. Pressure oil into DPS clutches C1 and C2.
multi ---disc clutches). In connection with this modification the
4. Pressure oil into the HiTech shuttle (rearward driving)
DPS and shuttle lubr. oil pressure has been improved.
5. Tank passage (into the gearbox and shuttle housings).
6. Pressure oil into DPS clutch C3. 15. A non ---return valve has been fitted to prevent oil pressure
7. Pressure oil into the shuttle (forward driving) escape from pressure accumulator into the hydraulic pump
8. Lubricating oil into the shuttle housing and the brake valve.
9. Lubricating oil from filter distribution block This ensures that the parking brake is not engaged too fast af-
10. Lubricating oil into DPS ter engine stop. Note! This happens only in case that the engi-
11. Tank passage from hand brake ram (leaks) ne stops itself (e.g. fuel runs out) when the driving speed is
12. Tightening torque 15 Nm. over 5 km/h. Does not affect the normal function of the par-
king brake.

348
 Model Code Page
42 Gearbox 95---115 420 23
1. 11. 2000

Picture 23. Lubricating system of power transmission on

tractors which have 3 ---step quick ---shift gear (Delta Powers-
hift), 660071 ---, and the mechanical shuttle.

1. Servo valve block, 660071 ---

2. Lubricating oil supply pipe
3. Distribution piece inside the reverse shuttle housing
4. Lubricatin oil of reverse shuttle
5. Lubricating oil of Delta Powershift
6. Lubricating oil to bevel pinion shaft
7. Lubricating oil to gearbox input shaft
8. Lubricating oil of pump drive mechanism
9. Lubricating oil to power take ---off

349
Working order
In the table below is shown the working orders for certain gearbox repair work. Reconditioning selector forks, see code 421.
Removing, reconditioning and fitting gearbox, see code 423.
42. Gearbox

Drain trans- Remove Raise cab Remove Raise cab Remove Remove Remove dif- Remove se- Remove Remove
mission oil side cover front side PTO unit rear side DPS and re- final drives/ ferential lector forks ground bevel pinion
and split and split verse shuttle brake hous- speed PTO shaft and
tractor be- tractor be- housing ings shaft (op- trans-
tween gear- tween gear- tional) mission
box ---middle box ---middle shaft
frame. frame.
Adjusting selector 1 2
forks for gears
1---2, 3---4 and M ---
H
Adjusting selector 1 2 3 4
forks for range LL
and PTO (op-
tional)
Changing selector 1 2 3 4
forks
Changing selector 1 2
levers

Reconditioning 1 2 3 raise the 4 5

differential cab rear
end.
1. 11. 2000

Changing bevel 1 7 2 3 4 5 6 8 9
pinion shaft/
crown wheel
Model

Changing syn- 1 7 2 3 4 5 6 8 9 10
chronizing rings
95-- 115

on input shaft
X100-- X120
Code

420
24
Page

350
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 421 1

Selector forks (Op. no. 421)

B. Adjusting selector forks

1. Adjusting selector forks
5. Fit the locking balls, springs and pins into their holes.
Note! If the gear change mechanism does not function
properly (e.g. if selected gear does not stay in the engaged Note! The longer pins into the two upper holes and the
position), the selector forks can be adjusted as follows: shortest pin into the lowest hole.

A. Removing side cover

ET 894 060

1. Drain the oil from the gearbox. Remove the RH side rear
wheel. Move the gear levers to the neutral position.

2464
5. Press the upper pin (for gears 1---2) into its drilling with tool
ET 894 060.

Sliding coupling in middle pos.

Synchronizing
cone
2. Disconnect oil hoses from the hydraulic power lift control
valve. Disconnect the return oil hose from the side cover.

3. Disconnect the shifter rod rear ends and the cable wires
from the shifter levers on the side cover.
Cone
Note! There is an access hole on the RH side mudguard.

6. Move the selector fork (and rail) for gears 1---2 to the middle
position. Adjust the fork to the middle position by screwing the
adjusting piece at the rear end of the selector fork rail.

2433

4. Unscrew the side cover bolts and remove the cover. At the
same time the selector fork rail locking pins (3 pcs) are re-
leased.

2439
7. When the fork (and the sliding coupling) is in the middle
position, push the selector rail/fork to the rear position (it is
locked by the ball) and tighten the adjusting piece nut (pre-
vent rotation of the adjusting piece while tightening).

355
 Model Code Page
42 Gearbox 95-- 115
421 2
1. 11. 2000 X100-- X120

8. Take the hold of the rail and move it. It must move loosely. 21. Pour the oil into the gearbox.Test---drive the tractor and
check that the gear change mechanism functions properly.
9. Then push the rail (together with the fork) to the front posi-
tion. Move the rail again. It must move loosely.
2. Changing selector forks
10. Adjust if necessary and finally tighten the adjusting piece Note! See also the following instructions:
nut.
--- instr. 423 2D (removing the selector forks)
--- instr. 423 4B (fitting and adjusting the selector forks)
11. In the same way adjust the selector fork for gears 3---4.
1. Drain the oil from the gearbox.
Note! Selector fork for gears 3---4 is easiest to adjust by mov-
ing the fork so that the groove on it is opposite the groove on
2. Split the tractor between the gearbox and the fuel tank; see
the fork for gears 1---2 when the gears are in neutral position. instr. 441 1A (cab attached to the rear frame) or instr. 423 1A
(cab attached to the front frame).
12. Check the adjustment in the extreme positions, so that the
rail/fork for gears 3---4 moves loosely in these positions.
3. Remove the quick ---shift gear (see instr. 441 1B) and the
reverse shuttle (see instr. 442 1A) from the gearbox front
13. Adjust the selector fork for range gears (H ---M) in the
side.
middle position and check the adjustment in the extreme
positions as above.
4. Remove the gearbox side cover.
14. Move the fork for range LL (and fork for ground speed
5. Remove the selector fork locking pins. Pull out the rails for-
PTO, if fitted) to the neutral position and make sure that the
wards and remove the forks through the side opening in the
groove on the M ---H fork is exactly opposite the groove on the following order:
fork for range LL (gears in neutral).
--- fork for ranges M ---H (remove first the LL/PTO ---rail)
Note! If the LL ---fork has to be adjusted, the tractor frame must
--- fork for ground speed PTO (if fitted)
be split between the gearbox and fuel tank and the reverse
--- fork for gears 3---4
shuttle housing must be detached. Thus the nut at the front
--- fork for range LL
end of the LL ---fork rail can be opened and the rail can be
--- fork for gears 1---2
turned.
6. Fit the forks in the reverse order.

C. Fitting the side cover Note! The rail, fork and the locking pin for gears 1---2 must be
fitted before other parts are fitted into the gearbox. In addition,
15. Make sure that the selector fork rail locking pins are in their the fork for ranges M ---H must be fitted onto the sliding coup-
ling before fitting the rail for range LL (and ground speed PTO
holes.
(if fitted))
16. Move all selector forks to the neutral position. Apply seal-
ing compound (e.g. Silastic) to the contact surface between Sliding pieces on the selector forks
the cover and the gearbox. Clean mating surfaces if necess- (see picture 16 on page 420/15).
ary.
With effect from tractor ser. no. 661937, the selector forks and
the plastic sliding pieces have been changed. In connection
with possible repair works, new forks and sliding pieces must
be fitted.
Note! In connection with repairs the earlier forks and sliding
pieces must be changed into new ones in spite of the condi-
tion of the earlier parts.

Forks 1---2, 3---4, M ---H and F ---R have each 4 pcs sliding
pieces and they are all similar (spare part number 32888200,
16 pcs).
Fasten the sliding pieces on the forks with a little grease dur-
ing fitting.

Also the later AVO and LL forks have sliding pieces.

2433 Note! The reverse shuttle fork F ---R is different on tractors

which have a 2---speed quick ---shift gear or the Delta Power-
17. Fit the side cover (upper end first). shift. Changing the shuttle fork, see under code 442.

18 Tighten the bolts to 50 Nm.

19. Connect the oil hoses to the cover and to the control valve.

20. Connect the cables and the shifter rods to the shifter levers
on the cover

356
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 1

Reconditioning gearbox (Op. no. 423) 8. Now, if the repair concerns DPS unit, shuttle unit or 4WD
clutch, they are accessible after removing them from the front
1. Splitting/assembling tractor bet- face of the gearbox.
ween gearbox and middle frame 1
6
A. Splitting 5
1
Note! In this instruction the transmission unit is pushed
rearwards on the rear wheels and under the front edge of 2
the gearbox there is placed an axle stand equipped with
castors.

1. This splitting is easier to do, if the cab is removed. Howe-

ver, it’s enough that the cab attachments are opened and
the cab is lifted a little upwards so that the rear wheels can
rotate from under the rear mudguards.

Note! If the rear wheel are removed before splitting, it is 3

4
enough that the cab rear attachments are opened and the
cab rear side is supported with suitable bars placed in front 1. Rear axle housings/brake housings
of both rear axle housings. In this case, however, the trans- 2. Delta Powershift (DPS) unit
mission unit is more difficult to support. 3. Shuttle unit housing
4. 4WD clutch in the lower part of the shuttle housing
1. Adjust the middle frame joint position so that it correc- 5. Mechanical gearbox
ponds driving straight ahead. Check that the frame has no 6. PTO unit removed in this picture.
tensions.

2. Lock the middle frame joint with a mechanical locking 9. If the mechanical gearbox must be disassembled, the rear
bar. Prevent the front axle oscillation with wedges or use ET axles must be removed from the transmission unit. Also the
893 480 support plates. If the tractor is equipped with a quick ---shift gear (DPS), shuttle unit/4WD clutchhousing must
fixed front loader, lower it against a ground. be removed from the front face of the gearbox.

3. Drain out oil in the tractor transmission. --- Removing the DPS unit from the front face of the gearbox,
see page 444/5.
4. Remove the PTO unit and pull out the long PTO shaft, --- Removing the HiTech ---shuttle unit, see page 442/4.
see page 462/1. --- Removing the shuttle housing/4WD clutch housing, see
page 442/1.
Note! The PTO unit is not necessary to remove if the repair --- Removing the rear axle housings, see page 451/1.
work concerns only the quick ---shift gear (DPS), reverse --- Removing the brake housings, see page 511/3.
shuttle or the 4WD clutch. If the mechanical gearbox must --- Removing the PTO unit, see page 462/7.
be repaired/disassembled the PTO unit must be removed.
IMPORTANT! If the tractor is equipped with an air conditio-
5. Put an axle stand equipped with castors under the gear ning, its hoses can be opened only by a specialist who has
box front edge. Place another axle stand under the middle special equipment.
frame. Check the balance of the tractor rear part. It is possi-
ble that the transmission unit is rear ---weight i.e. another It is possible to carry out the frame splitting so that the air con-
support must be fitted under the gearbox rear edge. ditioning system is not opened but only its different parts are
released.
Note! It is better if the axle stands are equipped with height
adjustment. It should be better if the axle stand under the
gearbox front edge can be fastened to the gearbox.

Note! If the rear wheels are removed before splitting, it is

more difficult to support the transmission unit. In this case it
is possible that first are removed the rear wheels and the
rear axle housings and the mechanical gearbox are suppor-
ted in a suitable way.

6. Disconnect all oil hoses, wire connectors, possible ca-

bles, linkages and drive shaft flanges (flanges in the rear
frame side) etc. which prevent splitting procedure.

7. Unscrew the bolted join between middle frame ---gear-

box. Push the transmission unit rearwards so that it moves
on the rear wheels and castors of the axle stand.

357
 Model Code Page
42. Gearbox 95-- 115
423 2
1. 11. 2000 X100-- X120

B. Assembling the tractor frame between

5. Tighten the bolted joint between the gearbox ---middle
middle frame and gearbox frame to a correct torque, see page 710/3. The bolts are the
same as in agricultural tractors.
Note! In this instruction the assembled transmission unit
together with the rear wheels are pushed against the mid- 6. Connect all oil hoses, wire connectors, linkages and ca-
dle frame. An axle stand with castors are placed under the bles. Connect the drive shaft flange joints.
front edge of the gearbox so that the unit can be moved on
these wheels. 7. Fit the cab, tighten the cab attaching bolts to a torque of
200 Nm. Connect all hoses, wires and linkages to the cab.
1. Asemble the transmission unit:
8. Remove the parts which prevented the front axle oscillati-
1 on. Remove the safety bar, which locked the middle frame
6 joint.
5
1 9. Fill the transmission with oil. Test---run the tractor. Check
for leaks. Tets the function of the steering system and hy-
2 draulic system. Check the function of the elcrical system.

10. Check that the transmission is functioning properly.

3
4
1. Rear axle housings/brake housings
2. Delta Powershift (DPS) unit
3. Shuttle unit housing
4. 4WD clutch in the lower part of the shuttle housing
5. Mechanical gearbox
6. PTO unit removed in this picture.

Fitting the brake housings, see page 511/3

Fitting the final drives, see page 451/4
Fitting the PTO unit, see page 462/7 (can be fitted after the
transmission is in place).
Fitting the shuttle housing, see page 442/3
Fitting the HiTech shuttle, see page 442/5
Fitting the Delta Powershift, see page 444/11.

2. Fit the rear wheels an put an axle stand equipped with

castors under the gearbox front edge. Position the trans-
mission unit in the rear of the tractor so that it can be pus-
hed into place against the middle frame.

Note! If you fit the tranmission unit without rear wheel, sup-
port the unit in the suitable way. Note that in this case the
cab is not necessary to lift away.

3. Connect all parts and hoses which can be connected

before the unit is pushed into place for easier work.

4. Push the transmission unit into place against the middle

frame flange and guide all tractor elements into correct pla-
ces.

358
 Model Code Page
42. Gearbox 95-- 115
423 3
1. 11. 2000 X100-- X120

2. Disassembling gearbox
In this instruction the gearbox has been removed from the
tractor (see previous instr. 1A) and external pipes have been
removed and also the following components:

--- final drives together with brake housings

--- 3---speed DPS
--- reverse shuttle housing

1. Place the gearbox in the fitting stand. Instruction below is

shown in the correct working order. In addition, the gearbox ETV 893 300
below has been equipped with parts for optional ground
speed PTO. 2431

A. Removing differential
5. Remove the LH side bearing by using puller ETV 893300
Note! Before removing, mark the position of the differential with a counter hold ETV 894120 and claws ETV 893302.
bearing flanges for easier assembling, See also instr. 424 1A.
Note! Make sure that the claws grip around the bearing race
1. Detach the diff. lock pressure oil pipe from the LH side bea- at diametrically opposed points.
ring flange and bend the pipe to one side.

2432

6. Remove the RH side bearing flange and the bearing outer

2430 race. Move the differential to the right and remove the differen-
2. Remove the LH side bearing flange. tial from the gearbox housing (left side first).

3. Press the differential to the left until the LH side bearing is 7. Reconditioning differential, see Op. 424 1A.
pushed out from its location.

4. Fit a wooden wedge under the differential and place an

other wedge between the gearbox housing and the differen-
tial so that it presses the differential to the right against the RH
side bearing. B. Removing side cover.
Note! The side cover can also be detached from the tractor
without removing the gearbox. Only the oil need to be drained
from the gearbox.

359
 Model Code Page
42. Gearbox 95-- 115
423 4
1. 11. 2000 X100-- X120

2433
2435

1. Set all gears to neutral position. Unscrew the side cover

bolts and remove. At the same time selector fork rail locking 4. Unscrew pump fixing bolts and remove the pump.
pins are released.

D. Removing selector forks

Note! If only selector forks have to be removed, then split the

tractor between the gearbox and fuel tank and remove the
C. Removing hydraulic pump, if fitted reverse shuttle housing. Now the selector fork rails can be
removed forwards and the forks can be removed through the
Note! The pump can also be detached from the tractor after side opening (see instr. on page 421/2).
removing the PTO unit (see section 90. Hydraulics).
1. Remove the selector fork rails as follows:

2434

2438
1. Loosen the suction pipe clip (hexagonal socket head screw,
5 mm).
--- remove pins, springs and balls (3 pcs) from their locations.
2. Detach the suction strainer housing on the gearbox and
remove the long suction pipe and the curve pipe.

3. Remove also the pressure pipe connections on the gearbox

(pipes have threads).

360
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 5

2439
2442
--- loosen the rail locking nuts
3. Remove the forks for gears 1---2 and 3---4 on the input shaft
and remove also the sliding pieces.

4. Remove the forks for gears M ---H, AVO and LL on the bevel
pinion shaft. Remove also the sliding pieces on the M ---H fork.
Also the latest AVO and LL forks have sliding pieces.

2440

--- engage gear 1. Tap out the locking pins for the forks for
gears 1---2, 3---4 and M ---H.

2441

--- unscrew the rails from their adjusting pieces at the rear
ends and pull out the rails forwards.

2. Remove the circlip on the rail for gears AVO/LL (ground

speed PTO/LL ---range). Open the nut at the front end of the
rail and remove the rail by turning it.

Note! Take care of the released balls and springs.

361
 Model Code Page
42. Gearbox 95-- 115
423 6
1. 11. 2000 X100-- X120

E. Removing AVO---shaft, bevel pinion

shaft, transmission shaft and input shaft

ETV 892 230

2444

5. Remove the AVO ---shaft through the side opening.

2436

1. Bend aside the tab washer and unscrew the bevel pinion
shaft nuts with ETV 892230. Remove the 4WD output gear at
the front end of the bevel pinion shaft.

2445

6. Remove the bevel pinion shaft rearwards. Remove the

2437 gears and synchronizing units through the side opening.
Remove the bearings.
2. Unscrew the 4WD clutch drum nut with ETV 894190 and
remove the drum. 7. Remove the rear circlip on the transmission shaft and tap
at the shaft rear end until the shaft loosens from its bearings.
3. Remove the circlip on the AVO ---shaft (ground speed PTO
shaft, option). 8. Release the gear wheel circlip through the side opening.

2446

--- pull out the transmission shaft forwards.

2443 --- remove gears, circlips, spacer rings and needle bearings
4. Tap the AVO ---shaft forwards and remove the front bearing through the side opening.
with a puller. Remove the rear bearing with a suitable drift.
9. Remove front bearing covers at the front end of the layshaft
and the input shaft. Pull the input shaft forwards until the front
bearing outer race is detached.

362
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 7

13. Remove the pump drive mechanism, if needed. Fixing

screws are inside the gearbox housing.

Note! Before detaching the pump drive mechanism, the suc-

tion strainer housing and the suction pipes have to be remo-
ved. Also the input shaft lubricating pipe must be removed.

14. Remove bearing outer races from their locations.

3. Checking disassembled gearbox

1. Check the condition of all gear wheels and bearings.

2447 Replace damaged parts with new ones. Lubricate all parts
with oil.
10. Remove the input shaft front end bearing. Support the
shaft so that it is kept horizontal. 2. Clean the gearbox housing and the lubricating pipes if
necessary. Check the bearing locations.

3. Check the condition of the synchronizing units. The input

shaft synchronizing units can be detached by removing the
rear bearing with a puller.

Input shaft in transmission 550/650:

In transmission 650 there is a circlip behind the input shaft

rearmost synchronizer. This circlip must be removed before
removing the input shaft foremost parts (see picture 5 on page
420/7).
Also a spacer has been added between the input shaft gears
Z31 and Z26, with which is adjusted the clearance between
the circlip and the synchronizer hub to zero or as small as pos-
2448 sible. The spacer has marking dots, which indicate the thick-
ness of the spacer, see picture 5 on page 420/7.

11. Remove first the layshaft from the housing. Checking synchronizing ring wear:
--- Place the coupler gear on a flat surface (tapered part
upwards).
--- Place the synchronizing ring correctly on the tapered part
of the coupler and measure the clearance between the ring
and the gear (i.e. how deep the ring is pressed).

Correct clearances:
Input shaft (1---2, 3---4) synchronizing rings (ø 82)
--- new 1,750---1,850 mm (min allowable clearance 0,7 mm)
Pinion shaft synchronizing rings (M ---H) (ø90 mm)
--- new 1,700---2,250 mm (min allowable clearance 1,0 mm).

Assembling synchronizing units

--- place the sliding coupler on a flat surface.
2449 --- put the springs and shoes onto the hub, press them
inwards and place the hub into the sliding coupler so that the
springs and shoes are kept in place.
12. Then remove the input shaft. --- fit three balls (separately) onto the springs and press the
ball inwards and push the parts inside the sliding coupler so
Important! Before removing the layshaft and the input shaft, that they are kept in place.
unscrew the lowest screw for the pump drive mechanism --- when all three balls are in place, push the hub into the sli-
inside the gearbox housing. Also remove the servo valve ding coupler.
block on the LH side of the gearbox, so that the S ---shaped
lubricating oil pipe is released. Note! The bevel pinion shaft and the crown wheel are repla-
ced in pairs because they have been matched together.

363
 Model Code Page
42. Gearbox 95-- 115 423 8
1. 11. 2000 X100-- X120

4. Assembling gearbox
Note! In this instruction, assembling work is done in the cor-
rect working order. Before assembling, the lubricating oil
pipes must be fitted.

A. Fitting layshaft, input shaft, transmis-

sion shaft, bevel pinion shaft and AVO---
shaft

Note! Lubricate all parts with oil before fitting.

1. If the layshaft bearings are changed, warm up new bea-

C
rings before fitting them onto the shaft or use a suitable fitting
sleeve.

2. Fit the pump drive mechanism, if detached. Do not fit the

lowest fixing screw. Fit the input shaft lubricating oil pipe. --- Measure the thickness C of the rear bearing (e.g. 33,75)
(rotate the bearing at least 20 times before measuring).
3. Fit the layshaft rear bearing outer race into the location.
Then fit the spacer ring (3 mm) and the circlip behind the race.

4. Fit the reverse shuttle selector lever (if removed) so that the
round ---shaped end points downwards. Grease the lever
o---ring and fit it. D
Adjusting position of bevel pinion shaft

The purpose of this adjustment is to determine the number of

shims under the rear bearing outer race

--- Read value D stamped into the rear end of the pinion shaft
(e.g. 159,70)

95

X C D
E

Decimal for value E

X = required shim thickness --- Read decimals stamped on the RH side of the gearbox. The
C = thickness of rear bearing shims thickness can be determined by using the following for-
D = measurement stamped into the end surface of the pinion mula:
shaft (the distance from the rear surface of the bearing to the
centre of the differential bearing locations) X=E ---(C+D)
E = the distance from the bottom of the rear pinion bearing
location to the centre of the differential bearing locations. E.G. X=193,95 ---(33,75+159,70)=0,5 mm.

Note! E = 193 mm + decimals stamped on the RH side of

the gearbox housing (e.g. 95). However, if this decimals is bet-
ween 0,00---0,20, then E=194 mm.

364
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 9

s=0,05 2448
0,10
0,30
0,50
8. Fit the layshaft (the bearings are fitted on the shaft). Raise
the input shaft for more space for layshaft.

--- Set the required thickness (X) of shims into the bearing 9. Connect the S ---shaped lubricating oil feed pipe to the distri-
location. butor pipe on the bottom of the gearbox and connect the other
end to the hole on the gearbox wall (note o---ring). Fit the servo
Note! First fit the shims with three lugs (0,30 mm, order no valve block.
30486400).
10. Fit the input shaft front bearing with ETV 892370. Fit the
--- drive in the outer bearing race against the shims using ETV bearing outer race.
893340.

5. Fit the transmisson shaft rear ball bearing with its circlip into
its location.

46 Nm 2451

11. Fit shims in front of the input shaft front bearing (select
2449 shims so that the bearings have a definite clearance). Tighten
the bearing cover.
6. Place the assembled input shaft into the gearbox through
the side opening. Note! Try shims which were there before disassembling. Turn
the input shaft 20---30 revolutions, in order to bed in the bea-
Note! The input shaft front bearing is fitted after the input shaft rings.
and the layshaft are in place.

7. Fit the pump drive mechanism lowest bolt and tighten it to

a correct torque. Fit the S ---shaped lubricating oil pipe.

365
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 10

0,025 ---0,075

2452 2454

12. Measure the input shaft end float. It should be --- Through the front bearing hole are fitted the bushing for the
0,025 ---0,075 mm. Increase or decrease the shim thickness foremost gear, end plate and the earlier spacer rings (2 pcs).
as necessary.

13. In the same way adjust the end float of the layshaft. End
float should be 0,025 ---0,075 mm.

Note! Turn the layshaft 20---30 revolutions in order to bed in

the bearings before measuring. Fit the layshaft front end
cover in the right way (the thin side up).

ETV 892 230

2455

19. Fit the front bearing outer race into its location. Fit the front
bearing with sleeve ETV 892370, fit the 4WD output gear and
tighten the nut to a torque of 270 Nm (ETV 892230).

2446

14. Fit the transmission shaft into the gearbox through the
1,7 ---2,3 Nm
front bearing hole. Note! There must be the wide gear circlip,
the spacer and needle bearings on the shaft.

15. Fit onto the shaft first the broad gear wheel, spacer ring,
circlip and the narrow gear wheel.

16. Fit the circlips into their places. Tap at the shaft front end
until the shaft is in place.

Note! It may be easier (lack of space) to fit first the bevel pinion
shaft and after that the transmission shaft.

17. Fit the bevel pinion shaft rear bearing onto the shaft if
2456
removed (warm up the bearing before fitting).

18. Fit the pinion shaft gears and synchronizing units into the 20. Measure the rolling resistance of the pinion shaft bearings
gearbox as follows: with a torsion meter. Correct value is 1,7 ---2,3 Nm. Increase
--- fit first the foremost gear and the rearmost gear or decrease the spacer ring thickness as necessary.
--- then fit other parts using the pinion shaft as a support. Cou-
plers for AVO and LL are kept in place by hand and the shaft Note! 13 different thickness of spacer rings are available
is pushed through them. (thickness between 5,03---5,93 mm). Make sure that the shaft
can rotate freely. Rotate the shaft 20---30 revolutions before
measurement.

21. After adjustment, tighten the shaft nut to a correct torque

and lock it with locking washer tabs.

366
 Model Code Page
42. Gearbox 95-- 115
X100-- X120 423 11
1. 11. 2000

B. Fitting selector forks

2444

22. Fit the AVO ---shaft into the gearbox through the side ope- 2442
ning and carry out the following steps:
1. Fasten the sliding pieces on the forks with a little grease. Fit
the forks for gears 1---2 and 3---4 onto the input shaft and sup-
--- Fit the front circlip of the rear bearing into its groove.
port the forks in the upper position with a selector fork rail.
--- Fit the rear bearing into place against the circlip.
--- Fit the rear circlip of the rear bearing.
2. Fit the sliding pieces on the M ---H fork and fit the fork onto
--- Tap at the shaft front end until the shaft is fully home.
the bevel pinion shaft.
--- Fit the front bearing.

2463 2457

3. Fasten the rail to the LL ---range fork if detached. Note! The

--- Fit the front and rear bearing circlip into the grooves on the groove on the shaft upwards. The locking pin is fitted with the
shaft. split end to one side.
ETV 894 080

2458

4. Fit the spring, ball and tool ETV 894080 into the LL ---range
fork. The tool holds the ball and spring in place. Fit the LL ---
range fork with its rail into the gearbox (latest LL forks have
also the sliding pieces).

367
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 12

5. Move the sliding coupling for the ground speed PTO to the
rear position and the LL ---range sliding coupler together with ETV 894 050
the fork to the front position. Fit the PTO ---fork with the sliding
pieces onto the sliding coupling beside the LL ---fork.

2462

11. Engage gear 1 and fit the locking pin for fork for gears 1---2
(use tool ETV 894 050 when fitting the pins).
2460
12. Similarly fit the locking pins for forks for gears 3---4 and
M ---H.
6. Push the PTO/LL ---rail into the gearbox. Push the rail first
through the LL ---fork while the tool is pushed out.
Note! The split side of the pins to one side.
7. Then fit the spring and ball into the PTO ---fork and the tool
Adjusting selector forks
will press them into place. When the rail has pushed through
both forks, remove the tool.
13. Fit the balls, springs and the pins into their holes at the rail
adjusting pieces.

Note! The shortest pin into the lowest hole.

ET 894 060

2461

8. Turn the PTO/LL ---rail until it is in place and fit the circlip onto
the rail. Tighten the rail front end nut. Adjusting position of the
rail, see instruction later.
2464
Note! Loctite 242 onto the selector fork rail threads.

9. Put the adjusting pieces for rails (1---2), (3---4) and (M ---H)
into their places in the gearbox rear wall (all three adjusting 14. Use tool ET 894060 to press the pins separately into their
pieces are similar). borings when adjusting the forks.

10. Push the rails through the forks and turn the rails so that
their rear ends engage with the threads on the adjusting pie-
ces (the longest rail is for M ---H fork. The two upper rails are
similar).

Note! Fit locking nuts onto the rails before turning their rear
ends into the adjusting pieces.

368
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 13

18. In the same way adjust the fork for gears 3---4.
Sliding coupler in middle position
Note! Adjustment is easier to carry out when the fork for gears
3---4 is adjusted so that the groove on it is opposite the groove
Ring
on the fork 1---2 (adjusted earlier) when the gears are in neu-
Ring tral.

19. In the same way, adjust the fork for ranges H ---M, first in
the middle position and then check the adjustment in both
extreme positions.

20. Move the forks for PTO and range LL to the neutral posi-
tion. Turn the rail so that the groove on the LL ---fork shaft is
opposite the groove on the fork for ranges M ---H (M ---H fork
in the middle position).

21. Check then that the forks for PRO and range LL move loo-
sely when they are in the engaged position.

22. Make sure that the rail locking balls, springs and pins are
in their borings.

15. Move the sliding coupling for gears 1---2 to the neutral
(middle position). Turn the rail rear end into or out of the adjus-
ting piece until the sliding coupling is in the middle position. C. Fitting 4WD clutch drum

2437
2439
1. Fit the clutch drum and its bearings onto the front end of the
16. When the fork is in the middle position, move the rail to the transmission shaft according to the figure 8 on page 420/9.
rear position (the ball locks the rail) and tighten the adjusting
nut (prevent rotating of the rail or the adjusting piece). 2. Apply Loctite 242 to the shaft nut threads.

17. Take hold of the rail and move it. It must move loosely. 3. Tighten the nut with ETV 894190 to a torque of 270 Nm.
Then move the rail to the front position and again move the
rail. It must move loosely. Now the adjustment is correct.

369
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 14

D. Fitting side cover E. Fitting pump (if fitted) , suction pipes

and suction strainer housing
1. Move first all the gears (forks) to the neutral position. Apply
sealing compound (e.g. Silastic) to the contact surface bet- Note! Oil pump and suction pipes can be fitted although the
ween the cover and the gearbox. Clean contact surfaces if differential is in place.
needed.
Note! The input shaft lubricating pipe must be fitted before fit-
ting the differential.

1. Fit the long suction pipe and the curved suction pipe thro-
ugh the holes on the gearbox housing and fasten the suction
strainer housing onto the gearbox.

2. Place the hose clip onto the curved suction pipe (screw
upwards.

2433

2. Turn a guide pin into one lower fixing bolt hole. Fit the cover
with the upper side first.

3. Tighten the fixing bolts to a torque of 50 Nm.

4. Check the engagement of different gears while rotating the

input shaft.
2435
Note! Fit the splined sleeve onto the input shaft front end spli-
nes and attach a crank to the sleeve for easier rotating. 3. Fit the pump and turn it clockwise and tighten the fixing
bolts to a correct torque (40 ---50 Nm).

2434

4. Tighten the hose clip to the correct torque (~ 6 Nm).

5. After the pump has been fitted, place the pressure pipes
into their holes on the gearbox and screw them into the thre-
ads on the pump. Note also the sealing pieces, which have
sealing rings.

Note! Apply Hylosil sealing compound between the gearbox

and pressure pipe sealing pieces. Apply Loctite 542 to the
sealing piece fixing bolts.

370
 Model Code Page
42. Gearbox 95-- 115
X100-- X120 423 15
1. 11. 2000

F. Fitting differential 6. Adjust the backlash between the crown wheel and the
pinion by moving the differential sideways by means of the
adjusting flanges. Ensure that there is no play in the bearings
1. Fit the differential RH side bearing onto the differential hou- during the adjustment by turning both nuts equally in the
sing (if removed) (use tool ETV 893400). Place the differential same direction.
case into the gearbox housing right side first.

2. Support the differential to the height of the bearing holes

and fit the RH side bearing outer race and the bearing flange
together with the threaded adjusting flange according to the
marks. Fit then a wooden wedge so that it presses the diffe-
rential to the right against the RH side bearing.

0,175 ---0,325

2468

7. Measure the tooth backlash with a dial gauge with the stylus
at right angles to the side of the tooth. The backlash should be
0,175 ---0,325 mm.
ETV 893400
2466 Note! Try to adjust the backlash to the middle of the tolerance
range or preferably near the min. value.
3. Fit the LH side bearing with tool ETV 893400.

4. Fit the bearing outer race.

Note! Tap the outer race as deep as possible for good cent-
ring. Nm

2456

8. When the backlash is correct, tighten carefully the RH side

adjusting flange until the differential bearing rolling resistance
is correct. The rolling resistance is measured at the front end
2467 of the bevel pinion shaft. Thus the correct value is the bevel
pinion shaft rolling resistance +:
+0,6 ---1,7 Nm (Z7/40, Z8/42) or
5. Fit the LH side bearing flange/adjusting flange according
+0,8 ---2,2 Nm (Z9/38) or
to the marks.
+1,0 ---2,8 Nm (Z11/37)
Note! The adjusting flange can be tightened with a piece of
In parentheses there is given the number of teeth of the
flat iron and with an adjustable spanner as shown in figure
pinion/crown wheel. Concerning different gearboxes, see
above.
pages 420/2 and 420/2A.

371
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 423 16

2470

9. When the bearing preload is correct, lock the adjusting flan-

ges with locking plates. Tighten the bearing flange screws.

10. Bend and connect the differential lock pipe on the LH side.

Note! The LH side adjusting flange can be in such a position

that the diff. lock pipe connection is not at the pressure pipe.
Then remove the bearing flange screws and turn the bearing
and adjusting flanges together, until the connection is oppo-
site the pressure pipe and can be connected. Then the bea-
ring preload does not change.

372
 Model Code Page
42. Gearbox 95-- 115 424 1
1. 11. 2000 X100-- X120

1. Reconditioning differential (Op. no. 3. Change the bearing for the differential side gear. Remove
the bearing using a drift and fit the new bearing using ETV
424) 891870.

Note! If reconditioning the differential only, then remove: 4. Lubricate the o---rings on the piston and push the piston into
--- PTO unit (see Op. no. 462 1A) place.
--- final drives/brake housings
--- differential (see Op. no. 423 2A) 5. Lift off the crown wheel. Remove the friction and steel discs
and lift out the differential side gear.
Note! For detaching the brake housings, raise the cab or split
the tractor between the gearbox and fuel tank according to
Op. 423 1A.

A. Changing the differential side bevel

gear bearings and the differential lock
discs

6. Drive out the tubular pin (8 mm) locking the differential

pinion shaft and tap out the shaft. Lift out the differential pinion
and the right differential side gear.

Note! In the tractors which have higher engine outputs there

are four differential pinions in the differential, at which time the
short pinion shafts have been secured with tension pins.

1. Remove the crown wheel attaching screws and remove the

differential cover.

7. Remove the right side differential side gear using a hammer

and a drift. Fit a new bearing using ETV 891870.
2. Press the piston for the differential lock out of the casing half
using compressed air but be careful. Change the o---rings on
8. Lubricate the bearing and fit the right---hand side differential
the piston.
side gear in position. Lubricate the differential pinions and
place them in the differential casing. Drive the shaft for the dif-
ferential pinions into place.

9. Fix the shaft in position with the tubular pin.

Note! On models 6600---6900 and 8050---8750 the shorter

pinion shafts are locked with two tension pins.

373
 Model Code Page
42. Gearbox 95-- 115
1. 11. 2000 X100-- X120 424 2

10. Position the crown wheel and the left hand side differential
side gear. Position the friction and steel discs (An earlier disc
pack: the first and the last disc of the disc pack is friction disc.
Latest disc pack: the first and the last disc of the disc pack is
a steel disc).

Note! Earlier there were five friction discs and four steel discs
in the differential lock. In the latest differential lock there are
five friction discs (internal splines) and six steel discs (lugs on
outer circumference). New, thinner discs can be fitted into the
older tractors without modifications. When changing the
discs, change simultaneously the whole disc pack.

11. Position the left differential casing half. Apply locking fluid
to the threads of the crown wheel attaching bolts and tighten
the screws to a torque of 110 Nm.

12. Fit the differential (see Op. 423 4F).

13. Fit final drives/brake housings.

14. Fit the PTO unit (see Op. 462 1G).

374
 Model Code Page
42. Transmission shafts X100-- X120 425 1
1. 11. 2000

Transmission shafts (code no. 425)

1) Upper shaft front part

2) Propeller shaft between engine --- transmission
Maintenance at every 250 running hours: 4 pcs nipples. Bearings are greased at point B.
3) PTO drive shaft
4) Propeller shaft, 4WD
Maintenance at every 250 running hours: front grease points are greased through holes in the botton shield. 4 nipples. Bearing
is greased at point A.
5) Lower shaft
6) Universal grease on splines
7) Nipple is removed when lower shaft is fitted so that air can flow out. Grease through the nipple. Open plug (7) when greasing
through nipple.
8) Bearings are pressed together against the inner ring. Shaft nut is tightened to 40 Nm and is secured with locking washer.

375
 Model Code Page
42. Transmission shafts X100-- X120 425 2
1. 11. 2000

A. Disassembling 5. Apply little grease on the flange sleeve and the seal lips.

The tapered roller bearing unit has been fastened with 6. Place the intermediate ring between the bearings. The
locking pieces. Before disassembling the bolts are opened ring inner circumference has a light press---fit on the flange
and the whole bearing unit can be removed. sleeve.

7. Put the rearmost bearing against its outer race.

B. Assembling tapered roller bearings
8. Knock the flange sleeve in first with a suitable sleeve and
then with a hydraulic press fully home.
Note! The bearings have small pre ---load. The intermediate
ring between the bearings have very accuracy dimensions, 9. Grease the o---ring and put it on the flange sleeve
which give a correct pre ---load to the bearings. The bea- against the rearmost bearing inner race.
rings rotate little stiffly when the nut is tightened to 40 Nm.
10. Fit the spacer ring with chamfered edge turned agains
1. Push the bearing outer races into the housing against the the o---ring.
sholder. The housing has an air groove, which must be
open, so that air can flow out when greasing the bearings 11. Apply locking fluid on the rearmost seal outer face. Tap
the seal in flush with the housing.
2. Fit the foremost bearing inner race against its outer race.
Put the spacer ring against the outer race with groove and 12. Fit the locking washer and tighten the nut to approx. 40
chamfer turned towards the bearing. Nm. Secure the nut with the locking washer.
3. Apply locking fluid onto the foremost seal outer face. Tap 13. Grease the bearings through the nipple. Press grease in
the seal into the housing flush with the housing and its lip with a grease gun. First greasing 40 g. Then 20 g at inter-
inside. vals of 250 running hours.
4. Cool the flange sleeve down to ---20˚C or colder.

376
 Model Code Page
42. Transmission shafts X100-- X120 425 3
1. 11. 2000

C. Disassembling
The front circlip is removed after which the shaft and the 7. Press the shaft assembly with bolts through the flange
straight into place. Do not damage the o---ring. Fit the front
bearing can be removed.
cover circlip.

D. Assembling roller bearing (in picture 4WD Note! Shims (s= 0,5 mm)is fitted between the rear bearing
transmission shaft bearing) cover and the circlip, if the bearing assembly axial play is
greater than 0,50 mm (play must be between 0---0,5 mm).
1. Tap the seals into the sealing covers against the shoul-
ders.
E. Propeller shafts
2. Grease seal lips. Place o---rings into the sealing cover
grooves and grease them. Place the front cover together The 4WD propeller shaft can be removed without removing
with circlip on the shaft . The front cover is narrower. the front axle or without splitting the tractor frame.

3. Press the bearing on the shaft against the shoulder. The transmission shaft between the engine and the trans-
mission can be removed by turning the tractor middle fra-
4. Place the nut locking washer on the shaft and tighten the me joint to its either extreme position after which the trans-
nut to a torque of 35 Nm. Loch the nut. mission shaft can be removed.

5. Grease the bearing and the seal lips. Fit the rear cover
into the housing against the circlip. Do not damage the
o---ring. F. Assembling universal joint
6. Place the shaft together with the front cover and its circlip --- the cross pin is cooled before assembling, at which time
into place. it is easy to press into place. The pin must not be tap into
place.
--- locking fluid on the fixing bolts.
--- use universal greasi when assembling the joint.

377
378
 Model Code Side
44. DPS, reverse shuttle 95-- 115
and 4WD clutch 1. 11. 2000 X100-- X120 440 1

Contents
General (Op. no 440)
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3---step quick ---shift gear Delta Powershift, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mechanical reverse shuttle, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HiTech Shuttle, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4WD clutch, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Servo valve blocks on the gearbox LH side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Working orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Reconditioning reverse shuttle (Op. no. 442)

1. Mechanical reverse shuttle:

A. Removing reverse shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing reverse shuttle synchronizing unit/bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Fitting reverse shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. HiTech Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Reconditioning 4WD clutch (Op. no. 443)

A. Changing 4WD clutch friction discs/seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. Changing 4WD output shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Reconditioning DPS (Op. no. 444)

3. Reconditioning Delta Powershift (DPS) in transmission 300:

A. Reconditioning planetary gear and its multi ---disc clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Reconditioning multi ---disc clutches for reduction ratio and overdrive . . . . . . . . . . . . . . . . . . 4

4. Needle bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. Changing seals in Delta Powershift:

A. Changing oil rings of piston ring type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Changing front oil seal of Delta Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. Changing oil seal and needle bearing inside the input shaft front end . . . . . . . . . . . . . . . . . . 8

6. DPS in transmissions 550/650, modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

379
 Model Code Page
44. Quick ---shift gear, reverse shuttle
95-- 115 440 2
and 4WD clutch 1. 11. 2000 X100-- X120

Technical data
3---step quick ---shift gear Delta Powershift (=DPS)

Gear ratios, transmission 300:

--- reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=1,233
--- direct ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=1,0
--- overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=0,803
Gear ratios, transmissions 550 and 650:
--- direct ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=1
--- overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=0,811
--- overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=0,651
Powershift clutch pressures (from low pressure pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8 MPa
Multi ---disc clutches:
Foremost clutc C1:
--- number of friction discs, transmission 300/550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/9 pcs
--- number of steel discs, transmission 300/550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/9 pcs
Intermediate clutch C2:
--- number of friction discs, transmission 300/550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/7 pcs
--- number of steel discs, transmission 300/550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/7 pcs
Clutch C3 for planetary gear when mechanical shuttle:
--- number of friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 pcs
--- number of steel discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 pcs
Clutch C3 for planetary gear when HiTech Shuttle:
--- number of friction discs/steel discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6/6 pcs
Cup springs (2 pcs) in planetary gear clutch, convexity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7±0,15 mm
Cup springs (6 pcs) in clutch for reduction ratio, convexity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 mm
Cup springs (4 pcs) in clutch for overdrive, convexity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,5 mm

Tightening torques

Gearbox housing ---reverse shuttle housing, 4 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm

Planetary gear fastening flange ---reverse shuttle, 6 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Oil seal housing ---gear housing, 3 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Bolted joint between gearbox ---middle frame:
--- hexagonal socket---head screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm
--- nuts on studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270---330 Nm
Cab attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Seal retainer on quick ---shift gear input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Planet carrier screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Oil hoses to the steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Front axle attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm

380
 Model Code Page
44. Quick ---shift gear, reverse shuttle 95-- 115
and 4WD clutch 1. 11. 2000 X100-- X120 440 3

Mechanical reverse shuttle, 95---115

Gear ratio:
--- forwards 1:1
--- backwards 2,5 % faster
Synchronizing ring diam. ø 114 mm

Tightening torques
Reverse shuttle housing ---gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm

Sealing compound used:

On contact surface between reverse shuttle ---gearbox, Hylosil RTV Silicone Grade 102 black

HiTech shuttle, X100---X120

Number of friction discs/steel discs/ring springs in both clutches . . . . . . . . . . . . . . . . . . . . . . . . 9/9/9 pcs
Axial play of input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2---0,6 mm
Tightening torque of all shuttle bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm

4WD clutch
Number of friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 pcs
Number of steel discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 pcs
Cup springs (4 pcs), convexity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 mm
Clutch pressure (from low pressure circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8 MPa

Settings
Clutch pack clearance is adjusted by first tightening the output shaft nut and then unscrewing it one and a half turn.
Tighten the outer locking shaft nut to 270 Nm.

381
 Model Code Page
44. Quick ---shift gear, reverse shuttle 95-- 115
and 4WD clutch 1. 11. 2000 X100-- X120 440 4

Special tools
3---step quick ---shift gear Delta Powershift

Part no Description
A
ETV 892 180 Drift for fitting oil seal and needle bearing inside input shaft front end (transmission 300)
ETV 893720 Plate for fitting quick ---shift gear front oil seal
ET 893 480 Support plate for front end frame, 2 pcs
ETV 894 200 Drift for fitting oil seal and needle bearing inside DPS input shaft front end (transmission 550/650)
B
ETV 893700 Sleeve for fitting oil seal inside the middle sun gear
ETV 894030 Sleeve for fitting planetary carrier ball bearing

ETV 892 180 ETV 893 720

ETV 893 700

ETV 894 200

ETV 894 030

Mechanical reverse shuttle

A
ETV 892 180 Drift for fitting needle bearing/sealing ring on input shaft (transmission 300)).
ETV 894 200 Drift for fitting needle bearing/sealing ring inside reverse shuttle input shaft front end (transmission 550/650)

ETV 892 180 ETV 894 200

382
 Model Code Page
44. Quick ---shift gear, reverse shuttle 95-- 115
and 4WD clutch 1. 11. 2000 440 5
X100-- X120

4WD clutch/4WD output shaft

ETV 894 170 2) Socket spanner for 4WD output shaft nut

2) Tractors with 3---step quick ---shift gear Delta Powershift. The nut is the same as the nut at the front end of
the bevel pinon shaft
on 505---905 tractors. For this nut spanner ETV 893 440 is used. Spanner ETV 894 170 can be replaced by welding a sleeve onto
the tool ETV 893 440.

ETV 894 170

HiTech Shuttle

ETV 894 350 Compressing tool for F ---clutch large coil spring

ETV 894 350

383
 Model Code Page
44. Quick ---shift gear, reverse shuttle 95-- 115
and 4WD clutch 1. 11. 2000 X100-- X120 440 6

3---step quick---shift gear (Delta

Powershift), description When the push buttons are operated the solenoid valves open
or close and send pressure to the multi disc clutches.

The 3---step quick ---shift gear (1) is fitted in front of the reverse The clutch pressure pipes are external pipes and they run
shuttle. from the valve block to the gear housing connectors.

The different speeds are engaged/disengaged electro--- When parking the tractor and the current is switched off, the
hydraulically with push buttons (3) in the speed gear lever parking brake must always be applied, since the engaged
knob. All speeds can be engaged/disengaged during driving speed gear does not keep the tractor stationary.
without using the clutch pedal. The solenoid valves are fitted
on the servo valve block (2) or on the valve blocks on the gear-
box (HiTech).

Clutch pressures are directed to the gear from the servo valve
blocks The low pressure pump supplies oil to the valve block
which has an in ---built pressure ---limiting valve with opening
pessure of 1,8 MPa.

Picture 4. 3---step quick ---shift gear (in picture

the tractor has a mechanical shuttle)

1. Delta Powershift.
2. Servo valve block.
3. Quick shift gear push buttons

384
 Model Code Page
44. Quick ---shift gear, reverse shuttle
and 4WD clutch 1. 11. 2000 95---115 440 7

Servo valve block with Delta Powershift and with mechanical shuttle (valve blocks with HiTech
Shuttle, see page 440/24)

C2

C1

C3

Pressure ---limiting valve, low pressure circuit Safety valve for oil cooler
Picture 5. Valve block (on the LH side of the gearbox)
Y1=Solenoid valve of diff. lock. When the solenoid valve Y4 is energized, pressure oil affects
Y2=Solenoid valve for PTO the quick ---shift gear foremost clutch C1.
Y3=Solenoid valve of front wheel drive
Y4=Solenoid valve for quick ---shift gear foremost clutch When both solenoid valves Y4 and Y6 are energized. Pressure
(lowest ratio) oil affects in all three multi disc clutches. When pressure oil
Y6=Solenoid valve for quick ---shift gear middle clutch (inter- does not affect the planetary carrier multi disc clutch, the pla-
mediate ratio) netary gear is locked by the clutch Belleville springs.
S16=Transmission oil temperature sensor (warning light)
S17=Transmission oil pressure sensor (warning light). Modi-
fied, 670582 ---, see page 420/20. When the solenoid Y6 is energized, pressure oil affects the
P=Pressure oil inlet from the low pressure pump quick ---shift gear clutch C2

1. Pressure ---test point (Valmet HPR) Note! When the solenoid valve is energized, the nut at the end
2. Oil inlet from the working hydraulic return oil of the valve becomes magnetic which can be verified with e.g.
3. If plug 3 is to be removed, note its position by counting ope- a screwdriver. Concerning electric system of DPS, see sec-
ning turns or measure the plug depth from the valve surface tion 31 code 310 (wiring diagrams), and code 314 (AC
before removing the plug. Ensure that the punch mark is at the 2.2/2.3).
plug groove. A valve spool behing the plug (3) directs pres-
sure oil to the planetary gear multi ---disc clutch when both Important! Concerning removal of the valve block, see page
solenoid valves Y4 and Y6 are energized. Apply Loctite 242 420/18. Concerning DPS in transmissions 550/650, see
onto the plug (3) threads. The plug (3) has been removed pages 440/10 ---13.
on the latest models and a locking plate has been fitted in
place, see page 420/18.

The different ratios are engaged with push buttons in the

speed gear lever knob:

385
 Model Code Page
44. Quick ---shift gear, reverse shuttle
95 440 8
and 4WD clutch 1. 11. 2000

Picture 6. 3---step quick ---shift gear Delta Powershift in transmission 300

386
 Model Code Page
44. Quick ---shift gear, reverse shuttle
and 4WD clutch 95 440 9
1. 11. 2000

3---step quick---shift gear (Delta Important! Apply locking fluid Loctite 243 to the threads of
the planetary gear carrier bolts (6) in connection with repair
Powershift), transmission 300 works.
Tightening torque of the bolts (6):
--- 8.8, 23 Nm (earlier)
Note! See picture 6 on previous page.
--- 10.9, 35 Nm (latest)
Tighten the bolts progressively. Picture below shows the
Delta Powershift is a 3---step quick ---shift gear and it is of a
correct tightening order.
planetary gear type. It has three multi ---disc clutches, one
for reduction ratio, one for overdrive ratio and one for the
planetary gear carrier for a direct ratio. All clutches are cont-
rolled with aid of pressure oil from the low pressure pump.
Solenoid valves are fitted on the servo valve block on the
LH side of the gewarbox.

Gear ratios, transmission 300:

--- reduction ratio 1:1,233
--- overdrive 1:0,803
--- direct ratio 1:1

Gear ratios, transmissions 550 and 650

--- direct ratio 1:1
--- overdrive 1:0,811
--- overdrive 1:0,651
7. Planet gears are divided into classes (A ---E). The letter
When all three clutches are unpressurised (e.g. if current is
marking is stamped on the side of each planet gear. The all
switched off with the starter switch or if the clutch pedal is
three planet gears should have the same letter. Spare part
depressed), the unit is in the neutral position.
planet gears are delivered as a ready ---made kit which
includes three planet gears with same letter markings.
1a) Pressure oil to multi ---disc clutch C1.
1b) Pressure oil to multi ---disc clutch C2.
8. The planet gear letter markings must point towards the
1c) Pressure oil to multi ---disc clutch C3.
sun gear midpoint when assembling the planetary gear.
2. Lubricating oil.
9. The two push buttons of the 3---step quick ---shift gear are
fitted in the speed gear lever knob.
3. Return of lubricating oil and leak oil into the gearbox hou-
sing
10. When the planetary carrier is locked, lubricating oil is
allowed to flow through the tension pins into the planet gear
4. Needle bearing number side (hardened side) outwards.
shafts and further into the planet gears.
5. To be filled with universal grease when assembling.
Note! The tension pins must be knocked a little deeper
than the planetary carrier surface to facilitate free flow of
6. When unscrewing planetary gear carrier attaching bolts,
lubricating oil.
the planet gears can be in such a position that they prevent
unbolting. In this case, pump up pressure with a hand
11. There is a piano wire under the intermediate ring loc-
pump into the clutch C3 after which the planetary gear
king ring. See repair instructions for more detail.
carrier can be rotated to the other position.
12. Lock valve, see page 420/20.

13 Springs (6 off)

14. Holes must align.

387
 Model Code Page
44. Delta power shift 95, 105, 115 440 10
1. 11. 2000

Picture 6A. DPS in transmissions 550/650 with mechanical shuttle

388
 Model Code Page
44. Delta Power Shift 95, 105, 115 440 11
1. 11. 2000

DPS in transmissions 550/650 when

mechanical shuttle
In the 550/650 transmission with the mechanical shuttle the
DPS has been reinforced and some dimensions have been
changed. Basic construction and function is similar to the DPS
in transmissions 300 and 460. The number of friction discs in
the clutches have been increased in transmissions 550/650,
see page 440/2.

In the 550/650 transmissions the pump drive shaft diameter

(inside the gearbox input shaft and the hollow clutch shaft)
has been increased due to the greater transmitted torque.
This means that the needle bearing and the seal ring inside
the shafts are also larger. In the 550/650 transmissions these
parts can be fitted with a new tool ETV 894 200.

Repair instructions, see pages 444/13 ---14.

11. There is a piano wire under the securing ring between

clutches C1 and C 2 with effect from ser. no. F32509. The
securing ring can be squeezed via holes in the clutch drum.

Note! Other reference numbers (in the picture on the previous

page) are the same as in transmission 300 on page 440/9.

Important! Apply locking fluid Loctite 243 to the threads of

the planetary gear carrier bolts (6) in connection with repair
works. Tightening torque of the bolts:
--- 8.8, 23 Nm (earlier)
--- 10.9, 35 Nm (latest)
Tighten the bolts progressively. Tightening order, see picture
on page 440/9.

389
 HiTech
44. DPS

390
1. 11. 2000
Model

X100-- X120
440
Code
12
Page

Picture 6C, DPS on tractors with HiTech Shuttle

 Model Code Page
44. DPS 440 13
1. 11. 2000 X100-- X120

DPS on tractors with HiTech Shuttle

1a) Pressure oil (0---1,8 MPa) to multi ---disc clutch C1.

See picture 6C. 1b) Pressure oil (0---1,8 MPa) to multi ---disc clutch C2.

(HiTech: ---K41106. HiTech 2.0: K41107---). 1c) Pressure oil (0---1,8 MPa) to multi ---disc clutch C3.

1. The rearmost planetary gear clutch (C3) of DPS has been 2. Lubricating oil.
modified so that pressure engages the clutch and it has an
own solenoid valve. In connection with the mechanical 3. Return of lubricating oil and leak oil into the gearbox
shuttle clutch C3 has cup springs and pressure releases the housing.
disc pack. In addition, the number of the discs in the rear-
most clutch is 6+6 pcs (HiTech Shuttle), or 4+5 pcs 3a. Plug for manufacturing of DPS.
(mechanical shuttle).
4. Clutch C3 return springs (6 pcs / 9 pcs) for piston.
2. In connection with HiTech Shuttle all three DPS clutches
have their own solenoid valve and they are proportionally 5. To be filled with universal grease when assembling.
controlled for a progressive engagement. The proportional
solenoid valves have been placed on two valve blocks on 6. Clutch housing fixing bolts (46 Nm). Loctite 243 on the
the tractor frame, see page 440/25. threads.
3. The number of the cup springs in clutches C1 and C2
7. Planet gears are divided into classes (A ---E). The letter
has been increased. Also coil springs have been fitted on
marking is stamped on the side of each planet gear. All
the pistons of these two clutches of DPS.
three planet gears should have the same letter. Spare part
planet gears are delivered as a ready ---made kit which in-
Note! The electrical control of the DPS clutches and the
cludes three planet gears with same letter markings.
calibration of clutch pressures have been described under
code 370 (Autocontrol 5/5.2).
8. The planet gear letter markings must point towards the
sun gear midpoint when assembling the planetary gear.
Modifications, HiTech 2.0 (K41107-- ):
9. The two push buttons of the 3---step quick ---shift gear are
The number of springs (4) was 6 / is 9. The lubrication dril-
fitted in the speed gear lever knob.
lings at the clutch C3 have been reduced and drillings (3
off) to the planet gears have been added. Planet carrier
10. When the planetary carrier is locked, lubricating oil is
front end (in front of gear wheel Z20) has been shaped so
allowed to flow through the tension pins into the planet gear
that it gathers oil and it is connected with aid of lubrication
drillings to the planet gear axles. The clutches are delivered shafts and further into the planet gears.
as a complete unit with correct thickness. Due to the manu- Note! The tension pins must be knocked a little deeper
facturing reasons the splines of the long PTO shaft has than the planetary carrier surface to facilitate free flow of
been moved into the DPS input shaft (NOTE! Different lubricating oil.
lengths of the shafts).
11. There is a piano wire under the intermediate ring lock-
Note! The long PTO shaft cannot be removed forwards ing ring. See repair instructions for more details.
when the DPS is in place due to modifications in the front
end of the shaft. 12. Distribution piece.

13 Springs (à 18 pcs) in the piston bores. The springs

cushion the function of the clutches.

14. Holes must align (pressure line of clutch C2).

391
 Model Code Page
44. Quick ---shift gear, reverse shuttle
and 4WD clutch 95, 105, 115 440 14
1. 11. 2000

Lubricating system of DPS and mechani-

cal shuttle

3
1c
7

10 4

5 2

9
6

1b
1a

Picture 7. Lubricating and pressure oil pipes on tractors with

Delta Powershift and with mechanical shuttle.

1a. Pressure oil pipe to multi ---disc clutch for reduction ratio
1b. Pressure oil pipe to multi ---disc clutch for overdrive ratio.
1c. Pressure oil pipe to multi ---disc clutch for planetary carrier.
2. Feed pipe for lubricating oil
3. Lubricating oil to gearbox input shaft
4. Lubricating oil to PTO unit
5. Lubricating oil to the distribution piece inside the reverse
shuttle housing
6. Distribution piece
7. Lubricating oil from distribution piece to reverse shuttle and
quick ---shift gear.
8. Lubricating oil to quick ---shift gear
9. Pressure oil to 4WD clutch in the lower part of the reverse
shuttle housing.
10. Lubricating oil to bevel pinion shaft
Y4 = Solenoid valve for reduction ratio
Y6 = Solenoid valve for overdrive ratio

392
 Malli Koodi Sivu
44. DPS, shuttle and 4WD clutch X100-- X120 440 15
1. 11. 2000

Lubricating and low pressure piping on HiTech tractors

Picture 7A. Low pressure pipes on HiTech tractors.

1. Servo valve block (see pages 420/20C and 440/24): 11b. Pressure oil to DPS clutch C3.
--- on the valve block there are solenoid valves for diff. lock, 12a. Pressure oil to shuttle F ---clutch
4WD, PTO (proportional) and hand brake. 12b. Pressure oil to shuttle R ---clutch
--- oil cooler by ---pass valve (0,05 MPa) and oil cooler safety 13. Pressure oil to PTO clutch
valve (1,2 MPa) 14. Test point, PTO clutch pressure (threads M14x1,5)
--- pressure limiting valve of 1,8 MPa (clutch pressures). 15. Test point (HPR), lubr. pressure.
2. Lubricating oil to gearbox. 16. Pressure oil to diff. lock
3. Distribution piece (in which there is ø 2mm restriction for the 17. Pressure oil to 4WD clutch
bevel pinion shaft lubrication). 18. Pressure ---limiting valve (0,4 MPa) determines the lubri-
4. Lubricating oil to shuttle cation pressure (0,25 MPa, K41107---).
5. Lubricating oil to DPS 19. Pressure filter of low pressure hydraulics
6. Lubricating oil to bevel pinion shaft 20. Return oil filter
7. Lubricating oil to input shaft 21. Pressure oil from pump via filter into the valve block 1.
8. Lubricating oil to pump drive mechanism 22. Pressure oil to hand brake ram
9. Lubricating oil to PTO clutch (+PTO) 23. Valve block
10. Lubricating oil to PTO shaft (in the pipe there is ø 1,5 mm 24. Restriction, diam 5 mm
hole for differential lubrication) 25. Non ---return valve, 0,05 MPa (47/00---)
11a. Pressure oil to DPS solenoid valves P1/P2.

393
 Model Code Page
44. DPS, shuttle, 4WD clutch X100-- X120 440 16
1. 11. 2000

HiTech

Picture 7B. Lubricating system in HiTech tractors 2b. Return oil connection for front loader.

1. Distribution piece 3. Return oil filter.

1a. Valve 0,25 MPa (2,5 bar), ealier 0,4 MPa, determines the 4. Return oil connection for auxiliary hydraulics.
lubr. oil pressure. The pressure was earlier 0,4 MPa
(---K41106). This modification improves the lubr. oil pressure. 5. Lubr. oil to DPS and shuttle. Oil flow into the shuttle has
This pressure drop has been made so that the valve spool (1a) been reduced with a restriction (diam. 5 mm) (K41107---)
has been lenghtened about 4 mm. Valve spring is the same as
in valve 2a 6. In the servo valve block, in the gearbox lubr. oil pipe, there
is a valve of 0,05 MPa, which ensures lubr. oil to DPS and
1b. Fixing nut of the distribution piece. shuttle, if pressure drops below 0,05 MPa:n.
Observe, that the o---ring must remain in the thinned part of
the distribution piece (not between threads). 7. Oil from control valve (Bosch)
1c) Test point, lubr. oil pressure. Fittend on the rearmost pres- 8. Oil from valve blocks
sure filter, J26434---. 9. Pressure filtre in low pressure circuit
2. Valve body 10. Lubr. oil pipe to the PTO clutch (J26434---).
2a. Pressure limiting valve 0,3 MPa (3 bar) determines the
max. pressure in return oil circuit.
394
 Model Code Page
44. Quick ---shift gear, reverse shuttle
and 4WD clutch 1. 11. 2000 95, 105, 115 440 17

Mechanical reverse shuttle, de-

scription

Figure 4. Power transmission

1. Reverse shuttle
2. Reverse shuttle lever
3. 4WD output shaft

The reverse shuttle housing is attached to the gearbox front In the reverse shuttle housing lower part there is the 4WD
end. The reverse shuttle is controlled mechanically with a clutch and 4WD output shaft. On E ---models, there are two
lever. In the reverse shuttle there is fitted a synchromesh unit. speed sensors on the reverse shuttle front end.

When changing driving direction, the tractor must be station- Important!

ary and the clutch pedal must be pressed. The picture above shows a transmission which has a 2---step
quick ---shift gear. If the tractor has a 3---step quick ---shift gear
The selector fork rail rear end is led into the gearbox through (Delta Powershift), the reverse shuttle housing has a little dif-
the gearbox front wall. The reverse shuttle lever lower end has ferent casting and additionally the input shaft length is differ-
been connected to the shifter lever, which turns the selector ent (see picture on page 440/19). In addition, in the reverse
lever and the selector fork on the synchromesh unit moves. shuttle housing there is no impulse disc for E ---models. The
4WD clutch and the 4WD output shaft have been reinforced
The reverse shuttle has pressure lubrication (see figures on in connection with the Delta Powershift (see picture on page
pages 440/10 and 440/16). 440/21). Also the selector fork rail has been reinforced. Other-
wise the reverse shuttle is the same as earlier.

395
 Model Code Page
44. Quick ---shift gear, reverse shuttle
and 4WD clutch 1. 11. 2000 95, 15, 115 440 18

Figure 9 Cross section of mechanical reverse

21---25 Nm
shuttle
4
1. Cover only on tractors without quick ---shift
gear
2. Lubricating oil bore
3. Reversing shaft
4. Sealing compound Hylosil RTV Grade 102
black
5. Gearbox input shaft
7 6. Reverse shuttle input shaft
7. Reverse shuttle layshaft
8. On later tractors there is a loose metal ring
between bearings. The ring has been fastened
8 with locking fluid.

5 1

2
6

Reversing
Forward driving
The synchromesh unit is in the rear position (R). Power is
The synchromesh unit is in the front position (F). Gear Z31 has transmitted from the input shaft (6) via reversing shaft (3) to
been engaged to the gearbox input shaft (5), and power is the layshaft (7). The layshaft rear gear (Z24) rotates the gear
transmitted direct to the gearbox (transmission ratio 1:1). Z33 which has been engaged to the gearbox input shaft (5).
(transmission ratio 2,5 % faster than in driving forward).

396
 Model Code Page
44. Quick ---shift gear, reverse shuttle
and 4WD clutch 1. 11. 2000 95, 105, 115 440 19

Utan DPS
Without DPS

Picture 10. Mechanical reverse shuttle and 4WD clutch on Note! On tractors with Delta Powershift, the revese shuttle
tractors which have a 3---step quick ---shift gear (Delta Powers- layshaft and reversing shaft are the same as earlier, see pre-
hift). vious page. Between the reverse shuttle input shaft bearings
there is a loose metal ring and the ball bearing of the input
1. Reverse shuttle input shaft shaft has circlips on both sides of the bearing.
2. Lubricating oil inlet
3. Lubricating oil distribution piece Note! This shuttle and 4WD clutch is also on latest tractors
4. Lubricating oil to reverse shuttle and quick ---shift gear which have not the Delta Power Shift. In this case, the shuttle
5. Bevel pinion shaft front end input shaft is tightened with a flange which has an oil seal. Also
6. 4WD multi ---disc clutch (see also page 440/21) inside the input shaft, there is a needle bearing and a seal for
7. Gearbox input shaft the pump (PTO) drive shaft.

397
 Model Code Page
44. HiTech shuttle X100-- X120 440 20
1. 11. 2000

HiTech shuttle (HiTech: ---K41106. HiTech 2.0: K41107---).

HiTech

Kuva 10A. HiTech shuttle

398
 Model Code Page
44. HiTech Shuttle X100-- X120 440 21
1. 11. 2000

HiTech

2
11
6
2

8
7
3

10

3
12

The change of the driving direction can be done without

Picture 10B. HiTech Shuttle components using the clutch pedal or push buttons and the tractor has
not the conventional propulsion clutch on the flywheel.
1. Shuttle lever / hand brake Automatics control the driving direction change and it is
2. In the gear lever knobs, there are push buttons for electri- prevented if the driving speed exceeds 10 km/h.
cal disengagement of the Shuttle (comprare HiShift).
3. Pressure oil (1,8 MPa) from tractor low pressure circuit The following modifications have been done on the tractors
to the valve block on the LH side of the gearbox (see which are equipped with the HiTech Shuttle:
pages 420/21 and 440/24) --- casting modifications on the housings of the DPS and
4. Valve block on which there are proportional solenoid Shuttle.
valves for F --- and R ---clutches of the shuttle, see page --- since the DPS is fastened to the shuttle, modifications
440/25. have been done in the rear part of the DPS.
5. DPS valve block, see page 440/25. --- Main gearbox input shaft front end has modifications
6. Display unit, see code 370 (Autoconrol V) page 370/4. --- The shaft between flywheel---DPS modified.
7. The shuttle can also be disengaged electrically with the --- The pressure and lubricating oil pipes and the various
clutch pedal. The pedal has a position sensor. valve blocks have been arranged in the new way.
8. Shuttle rpm sensors (+rotation direction information) --- New electrical control of the DPS and Shuttle, see code
9. Gearbox speed sensor (driving speed) 370 (Autocontrol V).
10. Pressure accumulator --- Drive plate in place of the propulsion clutch, see page
11. Control unit 410/4A.
12. Hand brake ram
Note! Repair instruction of the HiTech Shuttle, see pages
The construction of the HiTech shuttle is of a planetary type. 442/4 ---11. The electric control of the DPS and Shuttle is
Both F --- and R ---clutch disc packs are similar. When one of described under codes 370/371. Various valve blocks in
the clutches is under pressure (proportional valve in ques- connection with the HiTech Shuttle, see pages 440/24 and
tion energised), the direction in question is engaged. Power 25 and pages 420/21 and 22.
routes in the Shuttle, see picture 10A (R=reverse drive,
F=forward drive). In connection with the HiTech Shuttle, the hand brake cont-
rol has been combined with the Shuttle lever (see page
521/2).

399
 Model Code Page
44. Quick ---shift gear, reverse shuttle 95-- 115
and 4WD clutch X100-- X120 440 22
1. 11. 2000

Note! The latest 4WD clutch, see the

next page.

Picture 12. 4WD clutch on tractors which have Delta Powers- The function of the clutch above is the same as earlier (see
hift (reinforced clutch 660071 ---). previous page).

1. Gear wheel for 4WD at the front end of the bevel pinion In this clutch the propeller shaft rear end is connected to the
shaft. Number of teeth on 4WD gear wheels depends on the 4WD output shaft with a sleeve joint. Additionally, in the clutch
transmission type (30 km/h, 40 km/h or 50 km/h). there are more clutch discs and also the cup springs are rein-
forced.
2. 4WD clutch drum.
The 4WD clutch above is equipped with a separate seal/bea-
3. Pressure oil space for disengaging the 4WD. ring housing which is bolted to the lower part of the reverse
shuttle.
4.Cup springs which keep the clutch in engaged position
when pressure oil does not act in space 3.

5. Pressure oil inlet from the servo valve block (valve block,
see page 440/13).

6. The multi ---disc clutch is adjusted by tightening the shaft

nut first fully home and then unscrewing the nut one and a half
turn.

7. Place for rotation speed sensor on E ---models (AC IV). The

sensor must be removed before the reverse shuttle housing is
detached.

400
 Model Code Page
44. Quick ---shift gear, reverse shuttle 95-- 115
and 4WD clutch 440 23
1. 11. 2000 X100-- X120

Picture 14. Mechanical shuttle (not HiTech) and 4WD

clutch (also HiTech), latest modifications.

1.Gear wheel in the front end of the bevel pinion shaft 7a, b. Speed sensors of gearbox anf front axle
2. Clutch drum 7c.Tachograph (option)
3. Pressure cylinder 8. EP grease on splines..
4. Cup springs 9. Universal grease
5. Pressure oil inlet port
6.Tighten the inner nut fully home and open it then 1,5 turn. Detail B: The shape of the flanges have been changed.
Outer nut is tightened to 270 Nm against the inner nut. With earlier shape the pressure flange could drop between
Loctite 270 on the threads. Note! Prevent inner nut from the shaft and the flange result from the casting faults.
rotating when tightening the outer nut.

401
 Model Code Page
44. DPS, Shuttle, 4WD clutch X100-- X120 440 24
1. 11. 2000

HiTech 2

5
11 9
9

5 10
8
3
3
8 6 7
4
Note! Before removing valve 4 (Y2
(B6)), the pilot light switch 7 must be
7 removed. 4

Note! The end of the spindle must be almost flush

with the valve body. If necessary, the valve must be
removed and the spindle must be pressed to the
outer position.

Picture 15. Servo valve block on HiTech tractors (on the LH side of the gearbox)

NOTE! Cross section of the valve, see page 420/21.

1. Solenoid valve of hand brake (energised, when the hand brake is disengaged, see page 521/2).
2. 4WD solenoid valve (engaging logic, see code 314).
3. Solenoid valve of differentiallock (engaging logic, see code 314)
4. Proportional valve of PTO (see codes 370/371, Autocontrol 5/5.2. Engaging logic, see code 314).
5. Temperature sensor of Autocontrol 5/5.2 (see codes 370/371, AC 5/5.2).
6. Pressure test point. low pressure circuit (1,8 ---1,9 MPa)
7. Indicator light sensor (S17), gearbox oil pressure
8. Indicator light sensor (S16), gearbox oil temperature
9. Oil temperature sensor (B3), AD ---instrument
10. CareTel oil temperature sensor B3L.
11. Connection for pressure accumulator (not ill.).

402
 Model Code Page
44. DPS, Power Shuttle 4WD clutch X100-- X120 440 25
1. 11. 2000

Lubricating oil
pressure test
5 Nm Note! The end of the
point. *)
valve spindle must
20 Nm be almost flush with
the valve body.

P4 (Y11)
P3 (Y17)

P5 (Y12)

B
P1 (Y4)

*) From ser. no. J26434 incl. the

pressure test point is placed on
the bracket of the rearmost
pressure filter and a lubricating
oil pipe has been fitted between P6 (Y2)
the PTO and distributor piece.
P2 (Y6)

Picture 16. Valve blocks in connection with HiTech Shuttle

A. DPS valve block P4=proportional solenoid valve for forward clutch (F).
B. Shuttle valve block Energised when the forward driving has been connected.
C. Renewed servo valve block, see pages 440/24 and The pressure test point is the RH side test point on the
420/21. block.

P5=proportional solenoid valve for reverse clutch (R). Ener-

Valve block A: gised when the reverse driving has been connected. The
pressure test point is the LH side point on the block.
P1=Proportional solenoid valve of DPS foremost clutch C1
This valve is energised, when DPS ratios I or II have been P6=proportional solenoid valve for PTO.
connected (transmission 650). The pressure test point of
this clutch is the LH side point on the block. Note! Concerning pressure tests and pressure calibrations,
see under code 370 (Autocontrol V).
P2=Proportional solenoid valve of DPS middle clutch C2
This valve is energised, when DPS ratios I or III have been Note! The lubricating oil pressure can be measured in test
connected (transmission 650). The pressure test point of point (HPR) on the rear part of the suction strainer housing.
this clutch is the RH side point on the block. Valve block B is also shown on page 420/22.

Valve block B

P3=Proportional solenoid valve of DPS rearmost clutch

C3 This valve is energised, when DPS ratios II or III have
been connected (transmission 650). The middle pressure
test point is for this clutch.

403
 Model Code Page
44. Quick ---shift gear, reverse shuttle 95-- 115
and 4WD clutch 1. 11. 2000 X100-- X120 440 26

Working order
Table below shows working orders for certain repair work. Detailed repair instructions can be found in instructions which start on
next page.

Drain trans- Remove floor Split tractor Remove Remove rever- Disassemble
mission oil hatch between fuel quick---shift se shuttle gearbox
tank---gearbox gear
Changing solenoid Solenoid valves
valves/proportional are placed on
valves for 3---step the separate
quick ---shift gear. valve blocks
and oil draining
is not necessary
Changing 3---step 1 2
quick ---shift gear
front oil seals
Changing oil seal 1 2
inside the quick ---
shift gear input shaft
front end
Changing piston 1 2 (in addition,
ring type oil seals in disconnect oil
3---step quick ---shift pipes from gear
gear housing and
remove the seal
housing in the
front part of the
gear housing.
Reconditioning 1 2 3
quick ---shift gear

Repairing mechani- 1 2 3 4
cal reverse shuttle
synchromesh unit
Changing mechani- 1 2 3 4
cal reverse shuttle
selector fork
Changing mechani- 1 2 3 4 5
cal reverse shuttle
selector lever
Reconditioning Hi- 1 2 3 4
Tech Shuttle multi ---
disc clutches

Reconditioning 1 2 3 4
4WD clutch
Changing 4WD out- 1
put shaft oil seal

Note! The quick ---shift gear/reverse shuttle can be removed in two different ways:
--- split the tractor between gearbox ---fuel tank and roll the front frame away from the gearbox (cab is attached to the rear frame):
see instruction 441 1A
--- split the tractor between gearbox ---fuel tank and roll the rear frame away from the fuel tank (cab attached to the front frame): see
instruction 423 1A.

404
 Model Code Page
442. Mechanical reverse shuttle 95-- 115 442 1
1. 11. 2000

Reconditioning mechanical reverse

shuttle (Op. no. 442).
Note! In the instruction below a tractor is used which has no
quick ---shift gear. On these models, the reverse shuttle has a
flange which is shown in the figures. Casting of the reverse
shuttle housing is a little different on tractors with Delta Power-
shift.

A. Removing reverse shuttle

1. Split the tractor frame between the gearbox and the middle
frame (see instr. on page 423/1).

2. Detach the 3---step quick ---shift gear, see page 444/1

points 1 ---4.

1. Disconnect the oil pipes from the reverse shuttle. 3. Pull out the reverse shuttle selector lever (on the RH side of
the gearbox) until the lever inner end releases from the selec-
tor fork rail groove.

2. 2 ---step quick---shift gear: Detach the oil distributor piece

from the front side of the housing and unscrew the bolt behind
the piece (otherwise the bolt prevents detaching of the hous-
ing)
4. Support the reverse shuttle with a suitable lifting device and
Important! If the tractor has Delta Powershift, the oil distribu- unscrew the reverse shuttle fixing bolts. Pull the housing
tor piece is fitted inside the reverse shuttle housing and it is straight out.
unnecessary to remove it.
Note! Easiest way to remove the reverse shuttle is to use a lift-
3. Remove the gearbox speed sensor on the RH side of the ing device which has a support bar that can be pushed
reverse shuttle housing, if fitted. through the reverse shuttle input shaft as in figure above.

405
 Model Code Page
442. Mechanical reverse shuttle
1. 11. 2000 95-- 115 442 2

B. Changing synchromesh unit/reverse 5. Knock at the input shaft front end and remove all three
shafts from the housing. Remove also the selector fork sliding
shuttle bearings pieces.

1. Unscrew the plug for the selector fork rail locking ball and
spring and remove the spring and ball.

6. Change, if necessary, the layshaft and reversing shaft ball

bearings.

7. If you change the reversing shaft roller bearing, its inner

race can be removed from the shaft by warming it up.

8. Check the condition of the synchromesh unit and change

worn parts.

Note! The synchromesh unit is assembled as follows:

--- place the sliding coupler on a flat surface.

--- fit springs and shoes onto the hub, press them inwards and
place the hub into the sliding coupler, so deep that the parts
are held in place.
--- Fit separately three balls on the springs. Press the ball in-
wards and push the parts inside the sliding coupler so that the
ball is held in place.
3. Tap out the selector fork locking pin. Pull out the selector ---when all balls are in place, finally push the hub into the slid-
fork rail (selector fork remains in place). ing coupler.

Note! Measure the synchronizing ring wear by putting the

ring onto the tapered part of the coupling gear. Then measure,
how deep the ring is pressed. Clearance between the ring and
the gear on the new synchromesh unit is 1,65 ---2,20 mm.
Min. allowable clearance is 1 mm.

9. Remove the circlip of the input shaft front ball bearing and
remove the bearing.

Note! Fit a new bearing after the reverse shuttle housing has
been attached to the gearbox.

Note! The reverse shuttle shafts can be fitted back into the
housing, but the reverse shuttle is easier to fit if the shafts are
fitted first onto the gearbox front side and after that the hous-
ing.

10. If you change the input shaft roller bearing, the inner race
4. Remove the smaller circlip at the input shaft front end. can be removed from the shaft by warming it up. Fit a new
bearing fully home into its location on the housing .

Note! On the latest reverse shuttles, there is a loose metal ring

between the input shaft bearings, see picture on page 440/18
point 8. See also picture on page 440/19.

406
 Model Code Page
442. Mechanical reverse shuttle
1. 11. 2000 95-- 115 442 3

C. Fitting the reverse shuttle

1. Fasten the thrust bearing with universal grease to its place
on the gearbox input shaft front bearing cover.

Note! Before fitting the reverse shuttle, ensure that the gear-
box layshaft front end cover has been fitted in the correct way
(otherwise it prevents the reverse shuttle layshaft from enter-
ing fully home).

8. Fit the selector fork rail locking ball, spring and the plug.
Push the selector lever inwards and check that it has engaged
with the groove on the rail rear end.

9. Fit the input shaft ball bearing and its circlip. Fit the smaller
circlip onto the shaft.

2. Fit the reverse shuttle shafts and the synchromesh unit onto
the gearbox front side (see figure above).

3. Place the selector fork together with sliding pieces (sliding

pieces can be fixed with universal grease on the fork during
mounting) onto the sliding coupler and guide the selector fork
rail through the hole on the gearbox front face. Fasten the fork
to the rail with a locking pin.

Note! Fit the reverse shuttle input shaft roller bearing into its
location on the housing. The foremost ball bearing is fitted
after the housing is in place against the gearbox front side.

4. Make sure that the 4WD output shaft nut has been fully tigh-
tened and then unscrewed one and a half turn (Delta Power-
shift) . Check that the lugs on the 4WD multi ---disc clutch pack
are accurately in line with each other.

5. Apply sealing compound to the contact surface between

the gearbox and the reverse shuttle housing. 11. Connect the external pipes.

6. Push the housing into place and turn the 4WD clutch so that 12. Attach the quick ---shift gear to the reverse shuttle: 3---step
the lugs on the discs engage with the grooves on the clutch quick ---shift gear, see page 444/3
drum.
13. Assemble the tractor frame between gearbox ---middle
6. Push the housing against the gearbox front side and screw frame (see page 423/2).
four guide pins (M8, l= 100 mm) into the holes for housing
bolts.

7. Push the housing fully home (tap carefully with a copper

bar, but do not use too much force). Remove the guide pins
and tighten the reverse shuttle fixing bolts to 23 Nm.

407
 Model Code Page
44. HiTech shuttle X100-- X120 442 4
1. 11. 2000

2. HiTech shuttle

A. Removing shuttle
1. Split the tractor frame between the gearbox and the mid-
dle frame, see page 423/1 (the rear part of the frame is
pushed rearwards and cab is attached to the front frame).

2. Disconnect oil pipes from the DPS housing and the Shut-
tle front flange. Disconnet other parts, which prevent remo-
ving.

5. Wind a lifting rope round the shuttle flange, hold the

shuttle in the horizontal position and pull it straight out of
the housing along the shaft. Take care of the flange large
o---ring.

DPS

Shuttle

3. Unscrew the four DPS housing fixing bolts and pull out
the housing. Take care of the housing large o---ring.

Note! The planetary carrier+rearmost clutch of the DPS

remain on the Shuttle front face. Remove them now or just
when the Shuttle has been removed.

Note! If the reparation work concerns only the frorward

clutch of the shuttle, it is unnecessary to remove the DPS
parts on the shuttle front face.

4. Unscrew two shuttle fixing bolts (M8, socket head). Bolts

are placed in the recesses.

6. Take the shuttle rearmost clutch (F direction) out of the

housing (it remains on the front end of the gearbox input
shaft).

408
 Model Code Page
44. HiTech shuttle X100-- X120 442 5
1. 11. 2000

B. Fitting shuttle
Note! Before fitting the shuttle the DPS planetary car-
rier+rearmost clutch can be fastened onto the shuttle, or
they can be fastened after the shuttle has been placed in 23 Nm (8.8)
the shuttle housing. 35 Nm (10.9)

1. Fit the shuttle large o---ring into its groove. It can be fas-
tened temporarily with a little gearse. Fit the pump/PTO
drive shaft.

6. Fit the DPS ball bearing into the shuttle front face and fit
the small spiral springs into the holes on the piston of the
DPS rearmost clutch . Fasten the DPS planetary car-
rier+clutch pack onto the front face of the shuttle. Use loc-
king fluid Loctite 243 on the bolt threads.

Note! Tightening order of the planetary carrier fixing bolts,

see page 440/15.

2. Wind a lifting rope round the shuttle flange. Position the

shuttle horizontal on the shaft and push it straight into the
housing so that the rearmost sun gear shaft is guided onto
the gearbox input shaft.

Note! Blow, if needed, compressed air through the pres-

sure pipe union into the shuttle foremost clutch so that the
planetary carrier is locked and the rearmost sun gear shaft
can be rotated with the shuttle input shaft, at which time the
splines connect with the gearbox input shaft splines.

3. The final stage of the mounting must be done carefully

so that the metallic sealing rings in the rear end of the shut-
tle are guided into the oil flange. Fit is accurate.

4. When the shuttle is in place, fasten it to the housing with

two bolts (M8, socket head). Tightening torque is 23 Nm.

5. Check, that the shuttle input shaft has an axial play of 7. Place the DPS housing large o---ring into its groove. Fit
0,2 ---0,6. the DPS housing. Tighten the bolts to 23 Nm.

Note! Before fitting the DPS housing, push the foremost

and middle sun gear shafts of the DPS into the clutch drum
in the DPS housing.

8. Reconnect all oil pipes to the shuttle and the DPS hou-
sing. Refit other removed parts.

9. Assemble the tractor frame according to instr. on page

423/2. Check the function of the shuttle and DPS. Check for
leaks.

409
 Model Code Page
44. HiTech shuttle X100-- X120 442 6
1. 11. 2000

C. Reconditioning clutch for forward dri-

ving (rearmost clutch)
1. Split the tractor frame and remove the shuttle according ETV 894 350
to instr. A on page 442/4.

6. If you change the piston seals or the large spiral spring,

screw ETV 894 350 into the threaded holes in the piston.
Tighten the nuts of the ETV at which time the spring is
shrunk (and the piston is pulled out of its location).

2. Take the rearmost clutch out of the housing.

3. Take care of the thrust bearing between the sun gears.

ETV 894 350

7. Remove the clutch drum snap ring.

4. Compress the clutch disc pack and release the snap ring
A and remove the support ring B.

5. Take the friction and steel discs and the spring rings out
of the drum. Remove the small spiral springs in the piston
housing.

Note! Dip the friction discs in oil before fitting and keep
them in oil for a while. Change all small coil springs of the
piston in connection with reparations.

410
 Model Code Page
44. HiTech shuttle X100-- X120 442 7
1. 11. 2000

11. Change, if necessary, the piston large o---ring (arrow)

and lubricate it with oil or grease.

8. Remove the drum (press fit) by pressing it carefully with Note! Check the function of the emptying valve. If the valve
a hydraulic press. is disassembled, the valve circlip damages.

ETV 894 350

9. Unscrew ETV 894 350, at which time the piston loosens.

Check/change the piston small o---ring round the sun gear 12. Place the large spring onto the sun gear shaft. Fit the
shaft (arrow) and lubricate the o---ring with oil or grease. piston and fasten ETV 894 350 and tighten it until the
spring shrinks. Warm the drum a little (+80˚C) and press it
10. Check that the large spring is OK. Ensure, that its length into place and fit the snap ring of the drum.
is within permissible dimensions.
13. Remove ETV 894 350.

411
 Model Code Page
44. HiTech shuttle X100-- X120 442 8
1. 11. 2000

14. Position the small spiral springs into the borings in the
piston.

Note! Change all small coil springs in connection with re-

pair work. Dip all friction discs in oil a little while before fit-
ting.

15. Fit by turns new friction and steel discs and the spring
rings. A steel disc first against the piston springs and
uppermost a friction disc (9 pcs steel discs and 9 pcs fric-
tion discs and 9 pcs spring rings). The spring rings are pla-
ced onto the outer circumference of the friction discs.

18. Place the F ---direction clutch drum on the planetary car-

rier so that the sun gear is guided between the planetary
gears.

Note! Ensure, that there is a thrust bearing between the

sun gears.

19. Fit the shuttle into its housing and assemble the tractor
between the gearbox and the middle frame, see page
423/2.

Note! Before fitting the two last friction discs and a steel
disc, push for instance small screw drivers through holes
on the side of the drum. Compress the disc pack and push
the screw drivers so that they hold the discs pack compres-
sed. Fit then the last three discs.

16. Place the support ring on the disc pack, press down the
disc pack and fit the snap ring (arrow). Remove the screw
drivers.

17. Check/change the metallic seal rings in the rear end of

the sun gear shaft. Ensure, that the ring ends are locked
together.

412
 Model Code Page
44. HiTech shuttle X100-- X120 442 9
1. 11. 2000

D. Reconditionig reverse drive clutch

(foremost clutch)

Disassembling:

1. Split the tractor frame and remove the shuttle according

to instr. A on page 442/4.

2. Remove the DPS planetary carrier+clutch pack on the

front face of the shuttle. Take away small spiral springs in
the borings of the DPS rearmost clutch piston.

5. Lever with two fitting levers (arrows) and remove the pla-
netary carrier of the shuttle.

Rear flange

3. Remove the shuttle input shaft (foremost sun gear shaft).

Take care of the shaft thrust bearing.

6. Unscrew the disc pack rear flange bolts after which the
flange rises upwards with the aid of the springs. Remove
the flange+springs+ball bearing.

7. Take the friction and steel discs and the spring rings out
of the drum. Remove the disc pack hub.
4. Remove the DPS planetary carrier rearmost ball bearing
in front of the oil ring (2) (if not released earlier). Remove 8. Remove the support ring for the piston small spiral
the oil ring (2) and the shuttle planetary carrier snap ring springs. Remove the springs. Remove the ball bearing.
(3).
9. If you change the piston seals, the piston can be forced
out by blowing carefully compressed air through the pres-
sure pipe union.

413
 Model Code Page
44. HiTech shuttle X100-- X120 442 10
1. 11. 2000

10. The planetary gears can be detached by tapping out 12. Fit the ball bearing (picture).
the tension pin (A) and by pushing the gear axles to the left
in the picture above. If you must change the planetary
gears, change all three gears. New gears must be the same
series according to the markings (e.g. A) on the gear teeth.

Assembling

13. Fit the hub (picture). Dip the friction discs in oil a littlew-
hile before fitting.

Emptying valve
14. Fit by turns new friction and steel discs and spring
rings. A steel disc first against the piston springs and
uppermost a friction disc (9 pcs steel discs, 9 pcs friction
11. If you have removed the piston, push it down into its discs and 9 pcs spring rings). The spring rings are placed
location. Place the spiral spring support plate onto the pis- into the outer circumference of the friction discs.
ton and fit the small spiral springs into their borings (pic-
ture). Note! The discs and the spring rings are the same as in the
clutch for the forward driving and a number of the discs is
Important! Position the piston into its location so that the also the same.
emptying valve comes upwards (when the shuttle is fitted in
tractor). Note! Dip all friction discs in oil before fitting.

Note! Ensure, that a spring is not at the emptying valve (a

spring can partly block a hole). Change all springs in con-
nection with repair work.

Note! Emptying valve has been removed in HiTech gen. 2.

tractors (K41107---).

414
 Model Code Page
44. HiTech shuttle 442 11
1. 11. 2000 X100-- X120

15. Before fitting the last steel disc, compress the disc pack
and push ø 3 mm pins (e.g. drills) through the holes on the
sides of the drum so that they hold the disc pack compres-
sed.

23 Nm

18. Turn the planet gears so that the markings on the teeth
(e.g. A) point towards the centre of the sun gears. Fit then
the shuttle input shaft together with its thrust bearing.

16. Fit the last discs and the spring rings. Place the rear
flange together with the spiral springs and the ball bearing
on the disc pack. Screw down the flange a little with two
auxiliary bolts (M8x35) until the flange shoulder is a little
below the edge of the drum. Remove the ø 3 pins and tigh-
ten the flange bolts (M8x25) to a torque of 23 Nm.

Note! When necessary, blow compressed air through the

pressure pipe union into the clutch and check that the
clutch is functioning correct. If everything is OK, the piston
moves and presses the discs against the rear flange.

19. Place the rearmost clutch drum (F direction) on the pla-

netary carrier so that the friction disc teeth engage with the
splines on the hub. Ensure, that there is a thrust bearing
between the sun gears.

20. Fit the shuttle into the housing and reassemble the trac-
tor according to instr. B on page 442/5.

17. Press the planetary carrier into place and fit the snap
ring (1). Fit the oil sleeve and the DPS ball bearing.

415
416
 Model Code Page
443. 4WD clutch 95-- 115
443 1
1. 11. 2000 X100-- X120

A. Reconditioning 4WD clutch on tractors

with 3---step quick ---shift gear (Delta
Powershift)

Changing seals, see Op. B on the next page.

1. Split the tractor frame between gearbox ---middle frame, see 10. Remove the clutch drum/gear wheel on the front face of
page 423/1. the gearbox and place the drum onto the clutch disc pack so
that the steel disc lugs engage with the grooves on the drum.
2. Remove the 3---step quick ---shift gear from the reverse
shuttle front face, see page 444/1. 11. Prevent the 4WD output shaft from rotating by placing a
suitable block between the drum gear (7) and the wall of the
3. Slacken the 4WD output shaft nut (6) using spanner ETV reverse shuttle housing.
894 170 before removing the reverse shuttle.
12. Tighten the shaft nut first fully home and then slacken it
4. Detach the reverse shuttle housing from the gearbox front one and a half turn. The clutch pack has then a correct clea-
side. In HiTech models, remove first the shuttle unit. rance. Tighten the locking nut to 270 Nm (if fitted).

5. Unscrew the 4WD output shaft nut and tap at the shaft front 13. Fit the clutch drum back to the gearbox front end.
end until the clutch/shaft loosen.
13. Attach the reverse shuttle onto the gearbox front face, see
6. Remove the oil sleeve (4) from the shaft. Remove the cup Op. 442 C. In HiTech models fit the shuttle housing and then
springs (3) and the cylinder, piston and the pressure plate. the shuttle unit into the housing.

7. Change the clutch discs as a complete unit: 11 steel discs 14. Attach the 3---step quick ---shift gear (Delta Powershift)
and 12 friction discs. onto the front face of the reverse shuttle, see page 444/3.

8. Assemble the clutch and change the piston seal if neces- 15. Assemble the tractor frame between gearbox ---middle fra-
sary. Push the oil sleeve into its place in the reverse shuttle me, see page 423/2.
housing and fit the cup springs according to the picture
above.

9. Push the shaft/clutch into the housing through the ball bea-
ring.
417
 Model Code Page
443. 4WD clutch 95-- 115
1. 11. 2000 X100-- X120 443 2

B. Changing 4WD output shaft seals on 4. Unscrew the seal housing bolts and pull off the housing.
Remove the oil sleeve on the shaft. On the sleeve there are fit-
tractors which have 3---step quick ---shift ted the seals of piston ring type.
gear (Delta Powershift)
5. Change damaged parts. Apply universal grease to the oil
The oil seal and seals of piston ring type can be changed as seal lips. Carefully push the oil sleeve into the sealing housing
fully home against the ball bearing.
follows:

1. Remove the 4WD propeller shaft undershield. Disconnect 6. Carefully fit the sealing housing. Ensure that the o---ring is
in place. Fit the protective plate and tighten the housing bolts.
the propeller shaft front end flange joint and pull the shaft for-
wards until its rear end releases from the splines on the 4WD
output shaft front end. 7. Place the o---ring onto the shaft and then the wear ring.
Tighten the shaft nut using ETV 894 170 first fully home and
slacken it then one and a half turn. Tighten the locking nut
2. Drain the oil in the gearbox (max. 65 litres).
to 270 Nm (if fitted).

8. Connect the 4WD clutch pressure oil pipe. Fit the 4WD pro-
peller shaft and its undershield. Fill the transmission with oil.

9. Test---run the tractor and make sure that the 4WD clutch
functions and that there are no leaks.

3. Unscrew the 4WD output shaft nut using spanner ETV 894
170. Remove the oil seal wear ring and its o---ring on the shaft.
Disconnect the pressure oil pipe from the output shaft seal
housing.

418
 Model Code Page
44. Quick ---shift gear 95-- 115
1. 11. 2000 X100-- X120 444 1

3---step quick---shift gear, transmis- Note! If one of the planet gears prevents unscrewing of the
sions 300 (Op. no. 444) carrier bolts, the planetary gear cannot be rotated but in this
case, connect a hydraulic hand pump to the pipe connector
on the reverse shuttle housing and pump up pressure into the
1. Reconditioning Delta Powershift clutch until the planetary gear can be rotated.

A. Reconditioning planetary gear and its

multi ---disc clutch

Dismantling:

1. Split the tractor between gearbox ---middle frame, see page

423/1.

2. Disconnect the oil pipes from the DPS gear housing.

5. Remove the foremost and middle sun gears from the plane-
tary gear, if they remained inside the planet gears.

6. Remove the planetary carrier rearmost ball bearing using

two pinch bars. Remove the pressure plate on the clutch disc
pack. Remove the discs and the hub.

7. Remove the foremost ball bearing circlip. Pull out the plane-
tary gear attaching flange together with the bearing.

3. Unscrew four attaching bolts of the housing (see arrows)

and carefully pull off the housing.

Note! The planetary gear and its multi ---disc clutch remain on
the front face of the reverse shuttle. Also the foremost and
middle sun gear may remain inside the planet gears.

8. If the clutch discs are worn so much that the grooves on the
friction discs have disappeared, change the complete disc
pack at the same time.

4. Unscrew the planetary carrier fixing bolts (see arrows) and

remove the planetary gear. At the same time it is releasing the
multi ---disc clutch cup springs (2 pcs)

419
 Model Code Page
44. Delta Powershift 95 444 2
1. 11. 2000

9. If the ring piston seals need to be changed, the piston can

be forced out by using compressed air, but be very carefull. 12. Fit the tension pins so that the split sides come at the car-
rier groove and tap the pins a little deeper that the planetary
carrier surface to facilitate free flow of lubricating oil.

10. Knock the planet gear shaft tension pins into the shafts
and remove the shafts at which time the planet gears and their
needle bearings are releasing. Change damaged parts. 13. When the two planet gears have been fitted, place the rear-
most sun gear so that the letter markings (A ---E) on the planet
gears point towards the sun gear midpoint. Then fit the third
planet gear with the letter marking turned towards the sun
Assembling:
gear midpoint.

Note! All three planet gears should have the same letter mar-
king (either A, B,C, D or E).

14. Grease the piston seals and press the piston into its loca-
tion, if removed.

ETV 894 030

11. Fit the rearmost sun gear into its place (there is a spacer
ring behind the sun gear). Fit first two planet gears together
with the needle bearings and push their shafts into place.

15. Fit the planetary gear foremost ball bearing into the atta-
ching flange against the shoulder (use e.g. ETV 894 030).
Place the attaching flange onto the planetary carrier and fit the
ball bearing circlip.

420
 Model Code Page
44. Delta Powershift 95 444 3
1. 11. 2000

23 Nm (8.8)
35 Nm (10.9)

16. Place the clutch hub into the attaching flange and then fit 21. Raise the cup springs into place using a screwdriver and
alternately 5 steel discs and 4 friction discs in. tighten the planetary gear attaching bolts progressively to a
torque of 23 Nm (8.8), 35 Nm (10.9). Apply Loctite 243 to the
17. Position the pressure ring onto the disc pack so that the threads of the bolts. Tightening order, see pages 440/15.
steel disc lugs fit inside the grooves on the ring. Also the loose
locking pieces must engage with grooves on the pressure Note! Tighten the bolts in order so that when one bolt
ring. becomes stiff to turn, move to the adjacent bolt until the plan-
etary gear attaching flange is tightly against its location on the
reverse shuttle front face. Never use force.

22. After fitting, pump up pressure of 1,7 ---2,0 MPa into the
clutch through the pipe connector. If the clutch does not dis-
engage, the clutch foremost steel disc can be wrongly posi-
tioned. In this case the clutch should be assembled anew. The
connector has thread 9/16 JIC 37˚. The reverse shuttle hous-
ing has thread 14 x 1,5 mm.

23. Place the foremost and middle sun gear into the clutch
drum inside the gear housing fully home.

23 Nm

18. Fit the rearmost ball bearing against the hub (use ETV 894
030, if needed). Support e.g with two screwdrivers (at arrows)
the planetary gear front clutch disc (uppermost disc in picture
above), so that it does not drop.

19. Place the cup springs with concave sides against each
other between the planetary gear and the reverse shuttle.

20. Lift the planetary gear into place and turn it so that the pres-
sure oil bore together with its small o---ring comes at the pipe
connector on the reverse shuttle housing. 24. Grease the large o---ring of the housing and place the
o---ring into its groove. Push the housing into place and
NOTE! Rotate the planetary gear so that the planets do not tighten its four attaching bolts to 23 Nm.
prevent tightening of the planetary gear attaching bolts.
25. Connect the pressure oil pipes to the gear housing.
Assemble the tractor frame, see page 423/2.

26. Let the engine run for a while with the clutch pedal
depressed for proper lubrication. Test---run the tractor and
ensure that the quick ---shift gear functions correctly.

421
 Model Code Page
44. Delta Powershift 95 444 4
1. 11. 2000

B. Reconditioning multi ---disc clutches for

reduction ratio and overdrive

Dismantling:

1. Split the tractor between gearbox ---middle frame, see page

423/1.

2. Disconnect the oil pipes from the gear housing.

5. Remove the front ball bearing circlip. Tap at the shaft front
end until the shaft/clutch drum releases.

3. Unscrew four attaching bolts of the housing (see arrows)

and carefully pull off the housing.

Note! The planetary gear and its multi ---disc clutch remain on
the front face of the reverse shuttle. Also the foremost and
middle sun gear may remain inside the planet gears.

6. Remove the circlip and cup springs of the piston for the
rearmost multi ---disc clutch.

4. Unscrew three fixing bolts of the seal housing and remove

the housing. Remove the oil seals of piston ring type on the
shaft (3 pcs, see arrow).

7. Remove the large circlip of the piston. Remove the piston

carefully using compressed air through the pressure oil hole.
Check and change, if necessary, the piston sealing rings.

422
 Model Code Page
44. Delta Powershift 95 444 5
1. 11. 2000

8. Push the clutch drum inside the casing and remove the cir-
clip which has bevelled ends. Take the drum out of the casing. 10. Remove the circlip of the foremost clutch piston at which
Remove the rearmost disc pack. time the cup springs release. Remove the piston carefully e.g.
with compressed air through the oil port.

Note! If You must change the clutch drum (press fit), remove
it from the shaft e.g. with a hydraulic press and a sleeve. When
fitting the drum, warm it and press it onto the shaft against the
circlip.

Assembling:

11. Ensure that the clutch drum is fully home against the cir-
clip. Tap or press the drum into place, if needed.

9. Remove the piano wire under the locking ring of the inter-
mediate ring between the disc packs. Then squeeze the lock-
ing ring and remove the intermediate ring.
Remove the foremost clutch discs and its hub.

12. Grease the sealing rings of the foremost clutch piston and
press the piston into its location so that the grooves on the pis-
ton come upwards.

423
 Model Code Page
44. Delta Powershift 95 444 6
1. 11. 2000

13. Fit six cup springs with concave sides against each other
on the piston. Open the circlip with pliers and press with two
pinch bars the circlip into its groove according to picture
above.
18. Fit the rearmost clutch pack (6 steel discs and 5 friction
14. Place the foremost clutch hub on the cup springs so that discs). Position the clutch hub together with the sun gear
the internal splines on the hub come upwards. inside the discs.

15. Fit the foremost clutch steel and friction discs (6 steel discs
and 5 friction disc). If the friction discs are worn out, change
the complete disc pack at the same time.

16. Fit the intermediate ring between the two multi ---disc
clutches. Make sure that the locking ring is located in its
groove on the drum.

17. Push piano wire (thickness ø1 mm and length about 450

mm) under the intermediate ring locking ring. Bend the wire
ends outwards about 5 mm so that the wire cannot rotate.

19. Place the clutch casing on the drum and fit the circlip
which has bevelled ends.

Note! When You turn the drum upside down, support the rear-
most clutch hub so that it does not disengage from the disc
pack.

424
 Model Code Page
44. Delta Powershift 95 444 7
1. 11. 2000

23. Fit and grease the gear housing large o---ring. Push the
housing into place until it touches the reverse shuttle front
face. Tighten the four fixing bolts to a torque of 23 Nm .

24. Fit the housing foremost ball bearing. Fit the bearing cir-
clip. Place the seal rings of piston ring type into their grooves
on the shaft. Ensure that the seal ring ends have been cor-
rectly engaged.

25. If you change the oil seal in the sealing housing, remove
the damaged oil seal. Grease the lips of the new seal and fit
the seal using plate ETV 893 720.

20. Grease the sealing rings of the rearmost clutch piston and
press the piston into the casing. Fit the large circlip of the pis-
ton.

26. Fit the sealing housing at the front end of the gear casing.
Grease its o---ring and tighten three attaching bolts (see
arrows) to a torque of 23 Nm.

27. Connect the oil pipes to the gear housing. Assemble the
tractor frame according to instruction on page 423/2.

28. Let the engine run for a while with the clutch pedal depres-
sed for proper lubrication. Test---run the tractor and ensure
21. Fit four cup springs with concave sides against each other that the Delta Powershift functions correctly.
upon the piston. Fit the piston circlip with a sleeve and a heavy
drift. The circlip can also be pressed into its groove between
jaws of a vice.

Note! Do not damage the seal ring grooves on the shaft when
fitting the piston. The function of the multi ---disc clutches can
be tested e.g. with compressed air.

22. Fit the shaft together with the clutch drum onto the plane-
tary gear so that the foremost and middle sun gears are inside
the planet gears and the sun gear front ends are engaged in
the clutch discs. Remove the foremost ball bearing at the gear
housing front end.

425
 Model Code Page
44. Delta Powershift 95 444 8
1. 11. 2000

4. Needle bearings C. Changing oil seal and needle bearing

inside the input shaft front end
The mounting depth of both needle bearings inside the gear
housing is 0,5 mm measured from the end face. This ensures
free flow of lubricating oil. The needle bearing in the sealing 1. Split the tractor frame between gearbox ---fuel tank, see Op.
housing is fitted against the bottom of its location. 441 1A.

5. Changing oil seals of Delta

Powershift
A. Changing oil seals of piston ring type
1. Split the tractor between gearbox ---middle frame, see page
423/1.

2. Diconnect the pressure oil pipes from the gear casing.

3. Unscrew the three fixing bolts of the sealing housing at the

front end of the gear casing and pull out the housing.

Note! Check that sealing ring grooves on the shaft and the
hole in the sealing housing are in perfect condition. Do not
damage the seal ring grooves during repair work since it can 2. Remove the guide ring in front of the seal. Use e.g. an
cause seal ring damages. impact puller.

4. Change three seal rings of piston ring type. When fitting 3. Remove the damaged oil seal inside the input shaft front
new rings, make sure that the ring end lockings engage cor- end. Check/grease the needle bearing behind the oil seal.
rectly.
4. Fit a new oil seal (and needle bearing if changed). The parts
5. Grease and fit the seal housing o---ring. Fit the seal housing can be fitted with tool ETV 892 180.
and tighten the three bolts to a torque of 23 Nm.
Note! Fit the needle bearing and the seal deep enough so that
6. Connect the oil pipes to the gear housing. Assemble the the guide ring can be fitted with its front face level with the
tractor frame according to instruction 441 2B. input shaft front face.

5. Grease the seal lips. Apply Loctite 601 to the guide ring sur-
face and fit the ring in front of the seal.
B. Changing front oil seal of gear housing 8. Assemble the tractor frame between gearbox ---fuel tank,
see page 423/2.
1. Split the tractor frame between gearbox ---fuel tank, see Op.
441 1A.

2. Remove the damaged oil seal and fit a new seal with a suita-
ble sleeve. If you detach the seal housing, the oil seal can be
fitted with plate ETV 893 720.

Note! Do not damage the seal on the input shaft splines.

Apply grease to the lips of the new seal.

3. Assemble the tractor frame according to instr. 441 2B.

426
 Model Code Page
44. Delta power shift 95-- 115 444 9
1. 11. 2000 X100-- X120

6. DPS in transmissions
550/650

A. Changing the planet gears and recondi-

tioning planetary gear multi ---disc clutch
C3

1. Remove the DPS housing and the planetary gear on the 2. Reconditioning the multi ---disc clutch C3 is done in the
front surface of the reverse shuttle and remove bearing (1), same way as on transmissions 300 and 460.
hub (4) and the cup springs and remove the disc pack, see
instr. A paragraphs 1---6 on page 444/1. 3. Changing planet gears, see instr. A points 10---13 on page
444/2.
Note! The steel discs in this clutch (C3) are different com-
pared with the steel discs in clutches C1 and C2. The friction 3. Assembling the planetary gear and fitting the gear and the
discs, however, are the same as in other clutches. DPS housing onto the shuttle front face, see instr. 444 1A
points 19---26 on page 444/3.

427
 Model Code Page
44. Delta power shift 95-- 115
444 10
1. 11. 2000 X100-- X120

.
Note! Remove the piston ring type seal rings B
C D
on the shaft before repair works begin. Do not A
damage the seal ring grooves on the shaft.

G
1

E
F

2
3

B. Changing friction discs in the clutch 8. Assemble the DPS together with its housing to the reverse
drum shuttle front face and assemble the tractor frame, see para-
graphs 21---27 on page 444/7.
1. Remove the DPS housing/clutch drum from the reverse
shuttle front face. C. Changing piston seals of the clutches
2. Remove the sealing housing at the front end of the DPS
housing. Remove the front bearing circlip and tap out the Intermediate clutch:
shaft/clutch drum of the housing, see instr. B paragraphs 4---5
on page 444/4. 1. Carry out procedures according to paragraphs 1---3 in
previous instr. B.
3. Remove the large circlip (A), and remove the outer housing
B by pulling it to the right (in picture above). 2. Remove circlip G and cup springs and blow carefully com-
pressed air into hole 1, until the piston of clutch D comes out.
4. Remove the intermediate disc pack D (7 pcs friction discs Change piston seals.
and 7 intermediate discs). Squeeze the securing ring
between the clutches through holes in the clutch drum C and 3. Carry out procedures according to paragraphs 20---27 on
remove the securing ring and the support ring. page 444/7.

Note! On the latest DPS gears (F32509---), there is a piano

wire under the securing ring.
Front clutch
5. Remove the front disc pack (9 pcs friction discs and 9 inter-
mediate discs). Ensure that the clutch drum is fully home
1. Remove both disc packs according to paragraphs 1---5 in
against the circlip F. Knock or press the drum if necessary.
previous instruction B.
6. When assembling the front disc pack, place first against the
piston an intermediate disc and then by turns friction and 2. Release circlip 3, and remove cup springs. Remove the pis-
intermediate disc. Fit the support ring and its securing ring ton by carefully blowing compressed air through hole 2.
and place the hub E into place.
3. Change the piston seals.
7. Assemble the intermediate disc pack (fit against the sup-
4. Assemble the disc packs and the clutch drum and fit the
port ring a friction disc and then by turns intermediate disc and
friction disc). Fit the outer jacket B and secure it with circlip A. DPS gear onto the tracto.
Fit the disc pack D hub (+front sun gear) and the middle sun
gear shaft.

428
 Model Code Page
45. Final drives 95-- 115
1. 11. 2000 X100-- X120 450 1

Contents
General (Op. no. 450):
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Final drive, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. Reconditioning final drives (Op. no. 451)

A. Removing final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing needle bearings in planetary gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing bearings and seals for outer drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Adjusting outer drive shaft bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Fitting final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technical data
Gear ratio, planetary gears:
--- final drives 300 on 95 (---K41105) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=5,20
--- final drives 450/650 on 95---X120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i=6,86
Rear axle flange distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 mm

Tightening torque
Drive axle housing ---brake housing:
--- M12, 8.8 (transmission 300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
--- M12, 10.9 (transmissions 550/650) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm
Rear wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm
Cab rear attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Draining plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm

Settings
Drive shaft bearing clearance is adjusted by tightening the centre screw to . . . . . . . . . . . . . . . 10 Nm
Distance between brake housing surface ---inner drive shaft end:
--- transmission 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157,50---159,15 mm
--- transmissions 550/650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157,40---159,30 mm

Oil in transmission housing

(The transmission and hydraulic systems use the same oil and same oil reservoir).

Oil quality and oil amount, see page 130/4.

429
 Model Code Page
95-- 115
45. Final drives X100-- X120 450 2
1. 11. 2000

Special tools
B
Part. no. Description
ETV 890 220 Universal handle
ETV 892 260 Final drives 300: Plate for fitting outer drive shaft inner bearing race
ETV 893 690 Fnal drives 450/650: Plate for fitting outer drive shaft inner oil seal
ETV 893 310 Final drives 300: Plate for fitting outer drive shaft inner oil seal
ETV 893 320 Final drives 300: Plate for fitting outer drive shaft bearing race
ETV 894 470 Final drives 650: Tool to fit the cassette seal (rear axle housing with greater oil volume)
ETV 894 480 Final drives 650: Quide sleeve to assemble the final gears (rear axle housing with greater oil volume)
ETV 894 490 Final drives 650: Quide pipe to assemble the final gears (rear axle housing with greater oil volume)
Locally prepared tools
ET 893 410 Support for removing outer drive shaft bearing race

ETV 890220

ETV 892 260

ETV 893 310

ETV 893 690

ETV 893 320 ETV 894 470

ET 893 410 ETV 894 480

ETV 894 490

430
 Model Code Page
95-- 115
45. Final drives X100-- X120 450 3
1. 11. 2000

Final drives, description

The final drives are of the planetary gear type working in The planetary sun gear is machined integral with the inner
conjunction with hydraulically controlled multi ---disc brakes drive shaft. When the inner shaft rotates, it drives the planetary
which run in oil. Final drives have been attached to the gears and the planetary gear retainer, which is connected to
brake housings with 14 bolts. Construction is the same in the outer drive shaft, through splines.
transmission 300. In transmission 550/650 the planetary
gears are of a sturdier construction and a slightly gear ratio, The outer drive shaft is journalled in the drive axle housing in
and the brakes have a greater number of discs. Wheel taper roller bearings. The planetary gears are carried in needle
attaching flanges are identical on all models. bearings on the shaft studs which are fixed to the planetary
retainer.
The power is transmitted from the differential, via the inner
drive shaft, to the planetary gears, and then though the The final drives have not a separate oil space but they have
outer drive shafts to the rear wheels. Planetary gear ratio; common oil with transmission and hydraulic system.
1=5,2 (transmission 300) or i=6,86 (transmission 550/650).

In the final drives in transmission 300 the external splines of

the ring gear has a tight press fit in the rear axle housing. In
transmissions 550/650 the ring gear is fitted between the
rear axle housing and the brake housing and is easy to
remove.

80 Nm
80 Nm

550 Nm 2

Z=23

Z=15

10---20 Nm
3
Z=63

150 Nm
4 5 5

Figure 1. Final drives 300 (95, ---K41105)

1. Grease nipple (grease bearing at intervals of 1000 running hours)

2. Wind the wire ends one to one and a half turns and bend them
3. Bearing clearance is adjusted by tightening the centre bolt to 10 ---20 Nm. Apply Loctite 270 onto bolt threads.
4. Draining plug
5. Sealing compound Hylosil

431
 Model Code Page
45. Final drives 105, 115 450 4
1. 11. 2000

Z=82

Z=33

Z=14

10---20 Nm

Figure 2. Final drives 450 (105, 115, ---J02315)

1. Grease nipple (grease bearing at intervals of 1000 running hours)

2. Wind the wire ends one to one and a half turns and bend them
3. Bearing clearance is adjusted by tightening the centre bolt to 10 ---20 Nm. Apply Loctite 270 onto bolt threads.
4. Speed sensor and impulse disc (only E ---models)
5. Draining plug
6. Sealing compound Hylosil

432
 Model Code Page
45. Final drives X100-- X120 450 5
1. 11. 2000

10---20 Nm

Picture 4. Final drives 650 (X100 ---X120 ( ---K36111), 105 ---115 (J02316 ---K36111)).

1. Grease nipple (greasing at every 1000 running hours)

2. Wind the wire ends one to one and a half turns and bend them
3. Bearing clearance is adjusted by tightening the centre bolt to 10 ---20 Nm. Apply Loctite 270 onto bolt threads.
5. Draining plug
6. Sealing compound Hylosil
7. Plastic ring in front of outer oil seal *)

*) In order to increase the oil volume (cooling advantage), the inner seal has been moved outwards. Axle housing and the oil seal
have different spare part numbers. The plastic ring is a new part.

433
 Model Code Page
95-- 115
45. Final drives X100-- X120 450 6
1. 11. 2000

Picture 5. Final drives 650 with greater oil volume in transmissions 550/650

These final drives in 95 ---X120 tractors:

--- 95, K41106 ---.
--- X100 ---X120 and 115, K36112 ---, *).

1. Hub axle outer oil seal has been changed into a cassette seal (inner oil seal and grease nipple removed).
2. Wind the wire ends one to one and a half turns and bend them.
3. Bearing clearance is adjusted by tightening the centre bolt to 10 ---20 Nm. Apply Loctite 270 onto bolt threads.
4. Axle housing has greater oil volume.
5. Oil draining plug.
6. Sealing compound Hylosil RTV Grade A (UK 0067) onto the ring gear sides.
7. Brake housing.
8. Support bolt.
9. Lower link attachment.

Larger oil volume in transmission:

Dipstick min. mark 45 l
Max. mark 55 l
Extra max. mark 65 l

*) Also K26616, K26440, K25332, K25414, K23241, K23423, K23538, K34139, K34211, K34311, K34443, K34511, K35307.

434
 Model Code Page
45. Final drives 95-- 115
1. 11. 2000 X100-- X120 451 1

B. Changing needle bearings in planetary

1. Reconditioning final drives (Op no gears
451)
1. Remove the lock washer from the centre screw securing the
outer drive shaft to the planetary gear and unscrew the screw.
A. Removing final drives The attaching plate remains inside the planetary retainer.

Note! The brake housing is not removed from the tractor

1. Drain the transmission oil (22 mm, 3 plugs). Disconnect the

check links from the rear axle housings.

2. Slacken the rear wheel nuts. Raise the rear wheel and
remove it. Block up the tractor with an axle stand placed under
the front edge of the brake housing.

3. Unscrew the cab rear attaching bolts. Disconnect the PTO

control cable, pick ---up hitch release control and the joint at
the lower end of the lewelling screw control rod. Remove all
engine hood plates.

4. Raise the cab rear end about 6 cm and support it. 2. Pull the planetary gear off the drive shaft. Cut the locking
wire under the locking spring for the planetary gear shaft
Note! The lifting rope can be attached to the lewelling screw studs. Remove the locking wire.
control rod support on the cab rear wall. Do not damage the
rear window. 3. Compress the locking spring with a pair of pliers and pull
the shaft studs out of the planetary retainer.

4. Remove the planetary gears from the retainer. Push at the

5. Connect a suitable hoist to the rear axle housing. Unscrew wear washers in order to prevent the 2x25 needles in each
the final drive attaching bolts. bearing from falling out. Change the needles. When assem-
bling, fix the needles in position with a little grease.

Note! Note the spacers between the two rows of needles.

6. Pull the housing straight outwards so that it clears the brake

housing.

435
 Model Code Page
45. Final drives 95-- 115
1. 11. 2000 X100-- X120 451 2

5. Press the bearing wear washers against the sides of the pla- 2. Tap at the end of the drive shaft so that it slides out of the
netary gears and press them into the retainer. Compress the bearings. Pull the shaft out of the axle housing.
locking spring and push the shaft studs into position and
make sure the locking spring engages the groove in the studs.

Note! Fit the attaching plate for the planetary gears retainer
before fitting the third planetary gear.

6. Push in (1,5 mm or 2,5 mm) wire under the locking spring

when the planetary shaft studs have been fitted and wind the
wire ends one to one and a half turns and bend them.

7. a) Transmission 300: the ring gear is fitted with a tight press

fit in the rear axle housing. Remove or fitting the gear should
be done using sturdy hydraulic pressing tools.

7. b) Transmissions 550/650: the ring gear can be loosened

with a drift. Before fitting the ring gear apply sealing com-
pound on the sides of the ring gear.

3. Remove the outer drive shaft bearing using a puller. Warm

up a new bearing and fit it onto the shaft fully home.

Note! If the wear ring on the shaft has damaged, change it

before fitting the bearing.

8. Push the planetary gear onto the splines on the outer drive
shaft. Secure the planetary gear by tightening the centre
screw (24 mm).

9. Adjust the bearing clearance of the outer drive shaft (para-

graph D) and fit the assembly to the tractor (paragraph E).

C. Changing bearings and seals for outer 4. Remove the outer seal for the shaft using a puller (fit a suita-
drive shaft ble counter hold inside the rear axle housing).

1. Remove the final drives (instr. A) and detach the planetary

gear (instr. B: 1 ---2).

436
 Model Code Page
45. Final drives 95-- 115
1. 11. 2000 X100-- X120 451 3

11. Grease the bearings before fitting them. Carefully push

the drive shaft into the axle housing. Make sure that the
seals are not damaged.
ET 893 410
Note! The plastic ring on HiTech tractors supports the drive
shaft so that the shaft does not damage the inner seal,
which has been moved outwards.

Note! Rear axle housing with cassette seal: Assemble the

final drives by using special tools ETV 894 480 and ETV
894 490.

12. Fit the inner bearing on the drive shaft. Fit the planetary
gear on the splines on the drive shaft and press the planet-
ary gear home. Fix the planetary gear to the end of the
drive shaft with the attaching plate and the screw.
5. Position counter hold ET 893 410 against the rear axle
housing and pull out the outer bearing race. Fit a new bear- 13. Adjust the drive shaft bearing clearance (instr. D) and
ing race (in transmission 300, use ETV 893 320). fit the final drives (instr. E).

6a. HiTech, ---40/00: Remove the plastic ring in front of the

inner seal. Lever out the seal, if damaged. Grease lips of a
new seal and fit it (e.g. ETV 893 690). Fit the plastic ring in
front of the seal.
6b. HiTech, 41/00 ---: Remove the cassette seal. Fit a new D. Adjusting outer drive shaft bearing
cassette seal with ETV 894 470. clearance
1. Place the drive shaft with the wheel flange on the floor.
7. Fit the race of the outer bearing (transmission 300: ETV Bed in the bearings by rotating the axle housing 20---30
893 320 and universal handle). Tap it fully home turn.
8. Lubricate the outer oil seal and fit it. Use a sturdy plate
for fitting. 10 ---20 Nm
9. Remove the inner bearing race using a puller and sup-
port ET 893 410. Fit a new bearing race using plate ETV
893 320 (transmission 300) or ETV 892 260 (transmissions
550/650).

ETV 893 310

2. Tighten the centre screw to a torque of 10 ---20 Nm. Again

rotate the axle housing and check the torque.
ETV 893 690
Note! After some time of operation the correct bearing clear-
10. Not HiTech: Change the inner oil seal of the outer ance will be established.
drive shaft. Fit a new seal with plate ETV 893 310 (trans-
mission 300) or ETV 893 690 (transmission 550/650). 3. Turn the lock washer for the centre screw so that the notch
on the washer locates in the recess in the planetary retainer.

Note! The lock washer can be fixed with a small amount of

grease before fitting the final drives.

437
 Model Code Page
45. Final drives 95-- 115
1. 11. 2000 X100-- X120 451 4

80 Nm (8.8)
E. Fitting final drive 125 Nm (10.9)

Note! Push the inner drive shaft fully home into the brake
housing so that it is pushed through brake discs and its
splines engage the differential.

1. a) Transmission 300: Place a new o---ring between the rear

axle housing and the brake housing. Fix the o---ring in position
with a little grease. Apply sealing compound Hylosil RTV sili-
cone Grade 102 to the contact surfaces.

b) Transmissions 550/650: Apply sealing compound Hylosil

RTV silicone Grade 102 Black to the ring gear sides and place
the ring gear against the rear axle housing.

Note! Make sure that the bolt holes align.

3. Tighten the bolts to 80 Nm or 125 Nm.

4. Press grease through the nipple to the drive shaft outer

bearing.

5. Connect the check link to its bracket on the rear axle hous-
ing. Fit the rear wheel and tighten the nuts to 550 Nm. Fill the
transmission with oil.

6. Lower the cab rear end and tighten the attaching bolts to
200 Nm.

7. Connect the PTO control cable, pick ---up hitch release con-
trol and the joint at the lower end of the lewelling screw control
rod. Fit the engine hood plates.

2. Lift up the rear axle housing and move it inwards at right 8. Test---drive the tractor and check for leaks.
angles so that the inner drive shaft locates between the planet-
ary gears.

438
 Model Code Page
46. Power take ---off 95-- 115
460 1
1. 11. 2000 X100-- X120

Contents

General (Op. no. 460)

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power take ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
--- PTO 540/1000 r/min and 540/750 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
--- PTO 540/1000 r/min + ground speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
--- Heavy duty PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
--- PTO shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
--- PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
--- engagement of power take ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
--- lubrication system and clutch pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Repair instructions (Op. no. 462)

1. Reconditioning power take-- off:

A. Removing PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Detaching power take ---off clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Reconditioning PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Fitting PTO clutch and adjusting bearing clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Removing selector fork and gearwheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Fitting gearwheels and selector fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. Fitting power take ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. PTO shaft and cushioning valve for engagement:

A. Changing PTO shaft/seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Cushioning valve for engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

439
 Model Code Page
46. Power take ---off 95-- 115
460 2
1. 11. 2000 X100-- X120

Technical data
PTO is controlled with a control lever:
--- engine PTO is engaged at low engine revs.
--- ground speed PTO is engaged while the tractor is stationary
PTO shafts (changeable):
--- ø 35 mm (1 3/8”) ISO 500, as standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---splines
--- ø 35 mm (1 3/8”) ISO 500, option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21---splines
--- ø 45 mm (1 3/4”) ISO 500, option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20---splines
--- ø 45 mm (1 3/4”) ASAE, option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---splines
--- ø 38 mm GOST 3480---58, option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8---splines

At outputs over 50 kW, use 21---splines shaft. In heavy ground speed PTO use is recommended the 20---splines shaft.
Use, if necessary, a torque limiting clutch (1000 Nm)

Engine PTO, ratios:

--- PTO speed 540 r/min at engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1874 r/min
--- PTO speed 540E r/min at engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1539 r/min
--- PTO speed 1000 r/min at engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2080 r/min

PTO multi ---disc clutch:

--- clutch pressure 1,8 MPa (from low pressure circuit of hydraulic system).
--- PTO clutch solenoid valve is fitted on the servo valve block. In the PTO clutch there is fitted a PTO brake. In addition, the system
has a cushioning valve for engagement. Electric control, see codes 314 (AC 2.2/2.3) and 370/371 (AC 5/5.2).
--- friction discs number: transmission 300 6 pcs. Transmissions 550/650 8 pcs.
--- steel discs number: transmission 300 5 pcs. Transmissions 550/650 7 pcs.

Note! In power take ---off units without ground speed PTO, there is not a ground speed PTO shaft (lowest) and a ground speed
PTO gearwheel at the front end of the PTO shaft. Instead of this gearwheel, there is fitted a spacer ring and spacer sleeve. In
addition, the front bearing of the PTO shaft is a ball bearing.

Settings
Clearance of the ground speed PTO shaft bearings . . . . . . . . . . 0,025---0,075 mm
Clearance of the PTO clutch shaft bearings . . . . . . . . . . . . . . . . . 0,025---0,075 mm
Clearance between PTO shaft rear bearing and PTO shaft oil seal is adjusted to zero with shims.

Tightening torques
Frame joint between gearbox ---PTO housing:
--- upper stud nuts (8 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270---330 Nm
--- lower stud nuts (6 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72---88 Nm
--- lower studs M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Front cover of the PTO unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72---88 Nm
Shaft nut on the ground speed PTO shaft . . . . . . . . . . . . . . . . . . . 260---280 Nm
Locking plate for the clutch shaft adjusting nut . . . . . . . . . . . . . . 21---25 Nm
Locking bolt at the front end of the PTO shaft . . . . . . . . . . . . . . . 225 Nm

Locking fluids and sealing compounds used

Sealing compound Hylosil RTV Grade 102 black between gearbox ---PTO unit

440
 Model Code Page
46. Power take ---off 95-- 115
460 2A
1. 11. 2000 X100-- X120

Markings on the PTO units

The PTO units have been marked with number codes. The purpose is to make it easier to recognize different PTO units when
changing tyres, when modifying and repairing the PTO units and in connection with possible repair works.

Transmission 300: tractor 95 ( ---K41105) (DPS ratio, reduction ---direct---overdrivw)

Code Type Z Ratio of AVO

1 540+1000

2 540+1000+AVO Z25/24 A, B/38,62 C, D, L, K/31,06 J,M/42,04

3 540+1000+AVO Z31/22 A, B/28,55 C, D, L, K/22,96 J, M/31,08

4 540+540E

11 540+540E +AVO Z25/24 A, B/38,62 C, D, L, K/31,06 J, M/42,04

12 540+540E+AVO Z31/22 A, B/28,55 C, D, L, K/22,96 J, M/31,08

15 540+1000+AVO Z26/20 A, B/30,95 C, D, L, K/24,89 J, M/33,68

16 540+540E+AVO Z26/20 A, B/30,95 C, D, L, K/24,89 J, M/33,68

AVO=ground speed PTO.

HD=Heavy Duty PTO, see page 460/6.
Z=number of teeth of the gears for the ground speed PTO (in the PTO unit).
Ratio of AVO=E.g. PTO shaft end rotates 38,62 turns/1 turn of the rear wheels.
Letters in front of ratio means different gearbox types, see page 420/2A and 2B.

441
 Model Code Page
46. Power take ---off 95-- 115
460 2B
1. 11. 2000 X100-- X120

Transmission 650: 105-- 115, X100 ( -- K36111), X110-- X120.

Transmission 550: 95 (K41106-- ) and X100 (K36112-- ).

Note! If on HiTech tractors the PTO speeds are changed, the AC 5/5.2 control unit A1 must be reprogrammed,
i.e. the new parameter file must be input, ---J38342 or PTO parameters (ratios) must be set in the setting mode, J38343 ---, see
code 370.

Code Type Z Ratio of AVO

21 540+1000

22 540+540E

23 540+1000+AVO Z26/20 T/40,81 U/40,81 V/32,82 Y/32,82

24 540+540E+AVO Z26/20 T/40,81 U/40,81 V/32,82 Y/32,82

25 HD 1000

26 HD 1000+AVO Z26/20 T/40,81 U/40,81 V/32,82 Y/32,82

27 540+1000+AVO Z31/22 T/37,65 U/37,65 V/30,28 Y/30,28

28 540+540E+AVO Z31/22 T/37,65 U/37,65 V/30,28 Y/30,28

29 HD 1000+AVO Z31/22 T/37,65 U/37,65 V/30,28 Y/30,28

30 540+1000+AVO Z25/24 T/50,93 U/50,93 V/40,96 Y/40,96

31 540+540E+AVO Z25/24 T/50,93 U/50,93 V/40,96 Y/40,96

32 HD 1000+AVO Z25/24 T/50,93 U/50,93 V/40,96 Y/40,96

33 1000+540E

34 1000+540E+AVO Z25/24 T/50,93 U/50,93 V/40,96 Y/40,96

35 1000+540E+AVO Z31/22 T/37,65 U/37,65 V/30,28 Y/30,28

36 1000+540E+AVO Z26/20 T/40,81 U/40,81 V/32,82 Y/32,82

37 540E+1000E

38 540E+1000E+AVO Z25/24 T/50,93 U/50,93 V/40,96 Y/40,96

39 540E+1000E+AVO Z31/22 T/37,65 U/37,65 V/30,28 Y/30,28

40 540E+1000E+AVO Z26/20 T/40,81 U/40,81 V/32,82 Y/32,82

AVO=ground speed PTO.

HD=Heavy Duty PTO, see page 460/6.
Z=number of teeth of the gears for the ground speed PTO (in the PTO unit).
Ratio of AVO=E.g. PTO shaft end rotates 38,62 turns/1 turn of the rear wheels.
Letters in front of ratio means different gearbox types, see page 420/2A and 2B.

1---40
The number code has been stamped on the PTO unit.
442
 Model Code Page
46. Power take ---off 95-- 115
460 2C
1. 11. 2000 X100-- X120

Transmission 550/650 “EKO”, 95-- X120

Note! If on HiTech tractors the PTO speeds are changed, the AC 5/5.2 control unit A1 must be reprogrammed,
i.e. the new parameter file must be input, ---J38342 or PTO parameters (ratios) must be set in the setting mode, J38343 ---, see
code 370.

Code Type Z Ground speed PTO ratio

37 540E+1000E

38 540E+1000E+AVO Z25/24 V, Y/40,9600 T, U/50,9305 GA, HA/40,9600

39 540E+1000E+AVO Z31/22 V, Y/30,2796 T, U/37,6503 GA, HA/30,2796

40 540E+1000E+AVO Z26/20 V, Y/32,8205 T, U/40,8097 GA, HA/32,8205

443
444
 Model Code Page
46. Power take ---off 95-- 115
1. 11. 2000 X100-- X120 460 3

Special tools
A
ETV 890 220 Universal handle
ETV 891 870 Plate for fitting PTO shaft seal (PTO unit with proportional ground speed)
ETV 894 080 Drift for fitting selector fork rail locking ball
ETV 894 420 Ring for fitting PTO shaft new cassette seal (to be used with below listed sleeves)
ETV 894 430 Sleeve (ø 35) for fitting PTO shaft new cassette seal (to be used with above mentioned ring)
ETV 894 440 Sleeve (ø 44,6) for fitting PTO shaft new cassette seal (to be used with above mentioned ring)
B
ET 894 090 Sleeve for fitting PTO clutch circlip

ETV 890220 ETV 891870

ETV 894 080

ET 894 090

ETV 894 430 ETV 894 440

ETV 894 420

445
 Model Code Page
46. Power take ---off 95-- 115
460 4
1. 11. 2000 X100-- X120

Power take---off, description

Z17

1 3

Z59

Z52

Figure 1. PTO 540/1000 r/min and PTO 540/750 r/min. When pressurised oil acts in the PTO clutch, the clutch is en-
gaged (and the brake is released) and power is transmitted
Front end of shaft (1) is connected to the coupling sleeve in to the PTO shaft gearwheels. When sliding coupler (3) is in the
the pump drive mechanism at the rear end of the gearbox front position, 1000 r/min PTO or 750 PTO has been en-
input shaft. Shaft (1) is rotated by the pump drive shaft from gaged. When the coupler is in the rear position, 540 r/min PTO
the engine flywheel. Shaft (1) front end together with the PTO has been engaged.
clutch drum (4) always rotate when the engine is running.
Note! In the picture above the locking flange at the front end
When there is no oil pressure in the PTO clutch, power is not of the PTO shaft (2) is the earlier version. Later version is illus-
transmitted to the PTO shaft (2). Now the PTO brake cup trated on page 460/7. Additionally, the clutch housing has
springs engage the brake which prevents upper shaft gear- been reinforced with a metal ring, see page 460/9.
wheels from rotating

446
 Model Code Page
46. Power take ---off 95-- 115
460 5
1. 11. 2000 X100-- X120

Z25
Z17

(Z31)
Z25
2

Z52
Z59

1
Figure 2. PTO 540/1000 r/min+ground speed PTO
(optional)

On this PTO unit, nominal speeds 540 and 1000 r/min are ob- The ground speed PTO is engaged with the same control
tained in the same way as on a PTO unit without ground speed lever as the engine PTO speeds 540 and 1000 r/min.
PTO (see figure 1)
When the ground speed PTO has been engaged, the PTO
In the figure above shaft (1) is for ground speed PTO. Its front shaft rotates proportional to the rear wheel rotation speed and
end has been connected with a coupling sleeve to the rear power is transmitted from gear (1) to gear (2) on the PTO shaft.
end of the ground speed PTO output shaft in the gearbox.
There is a sliding coupler for the ground speed PTO at the Note! In the picture above the locking flange at the front end
front end of the gearbox bevel pinion shaft. of the PTO shaft is the earlier version. Later version is illus-
trated on page 460/7. Additionally, the clutch housing has
been reinforced with a metal ring, see page 460/9.

447
 Model Code Page
46. Power take ---off 95-- 115
460 6
1. 11. 2000 X100-- X120

Picture 3. Heavy Duty PTO Note! The hardening depth of the clutch shaft has been inc-
reased.
This PTO unit is optional equipment which can be used in very
heavy work.

The heavy duty PTO has an engine PTO 1000 r/min and gro-
und speed PTO which is available in two different ratios (V and
F, see Technical Data).
448
 Model Code Page
46. Power take ---off 95-- 115
460 6A
1. 11. 2000 X100-- X120

Picture 3A. Heavy Duty PTO clutch

1. Cup springs (13 pcs)

2. Pressure plate
3. Brake plate
4. Piston
5. Shaft + drum
6. Gear weheel
7. Pressure oil
8. Lubricating oil
9. Adjustment of bearing clearance
10. Press ---fit
11. Apply Loctite 242 to the threads

449
450
 Model Code Page
46. Power take ---off 95-- 115
1. 11. 2000 X100-- X120 460 7

Figure 4. PTO shaft

1. Clearance is adjusted to zero with shims

2. Universal grease
2a. Cassette seal (H34332 ---). Fitting instruction, see page 462/8A.
2b. Protective cup for cassette seal
3. PTO rotation speed sensor (if fitted)
4. Circlip
5. Unit without ground speed PTO

451
 Model Code Page
46. Power take ---off 95-- 115
460 8
1. 11. 2000 X100-- X120

260---280 Nm

s=0,10 0,025...0,075 mm
0,15
(Nut tightened)

Figure 5. Proportional ground speed PTO shaft (optional)

452
 Model Code Page
46. Power take ---off 95-- 115
460 9
1. 11. 2000 X100-- X120

PTO multi---disc clutch

Pressurised oil to the clutch is conducted from the servo
valve block (on gearbox LH side) via internal piping to the
rear end of the PTO clutch shaft (6) and onwards via dril-
ling to the oil space behind the piston (4)

Figure 6. PTO clutch

1. Cup springs (5 pcs)
2. Pressure plate (modified for spring 14)
3. PTO brake disc
4. Piston
5. Shaft / clutch drum
6. Shaft
7. Pressure oil to clutch
8. Lubricating oil
9. Adjustment of PTO clutch shaft bearing clea-
reance
10. Fastening with Loctite 601
11. Loctite 242 on the threads
12. Support ring (6 friction discs: s=10,25, 7 pcs:
s=7,4 mm, 8 pcs: s=4 mm
13. Hub
14. Cup spring (on latest models)

When there is no oil pressure in the clutch (solenoid valve un- Note! A number of the clutch discs and disc material have
energized), cup springs (1) press plate (2) against brake disc been changed. Number of the discs, see technical data on
(3) causing brake action. page 460/2. Concerning repairs of the earlier clutches, see
page 462/3 and pictures above.
When pressure is connected behind the piston (4), it moves
forwards releasing the brake and engaging via disc pack the Note! From ser. no. F27127 incl. the piston of the HD clutch
clutch drum (5) to shaft (6) and power is transmitted to the and the standard clutch is the same (ø 130 mm). At the same
PTO shaft. time the piston seal was changed into an o---ring. From ser.
On the latest clutches, the clutch housing (5) has been rein- no. H11438 incl. the dimensions and shape of the piston have
forced with a metal ring. been changed. This modification helps to ensure that the PTO
shaft stops when the PTO is disengaging.
453
 Model Code Page
46. Power take ---off 95-- 115 460 10
1. 11. 2000

Picture 8. Engagement of PTO, 95 ---115

1. Control lever
2. PTO switch and engaging logic, see code 314 (AC 2.2 and 2.3)
3. Servo valve block (see codes 420 and 440) with PTO solenoid val-
ve and a cushioning valve.
8. Multi ---disc clutch of PTO

In HiTech models X100---X120 the PTO clutch is controlled with the

aid of the proportional solenoid valve (see codes 370/371).

454
 Model Code Page
46. Power take ---off X100-- X120 460 11
1. 11. 2000

Picture 13. PTO on HiTech tractors

1. Control lever
2. Switch
3. Proportional valve
4. Multi ---disc clutch
5. AC 5/5.2 display
6. PTO rotation speed sensor
7. Pilot light

Note! Electric control of the PTO in X100 ---X120

tractors is described under codes 370 and 371
(AC 5/5.2)

455
 Model Code Page
46. Power take ---off 95-- 115 460 12
1. 11. 2000

Picture 10. Lubricating system and clutch pressure

piping

1. Servo valve block, which has in ---built cushioning

valve for the PTO clutch (see page 462/9). The PTO
solenoid valve is fitted on the valve block lower side.
2. Lubricating oil feed pipe in the gearbox housing
3. PTO clutch pressure
4. Oil distributor piece
5. Lubricating oil to PTO clutch shaft
8
6. Lubricating oil to PTO shaft 9
7. Pressure ---test point
8. Pressure ---test point
9. PTO clutch pressure

IMPORTANT! Lubricating and pressure system of the 7

PTO in X100---X120 tractors have been described un-
der code 440.

4
5

3
1

456
 Model Code Page
46. Power take ---off 95-- 115 460 13
1. 11. 2000

Loctite 542

Picture 12. Cushioning valve

3. PTO solenoid valve under the servo valve block

4. Cushioning valve piston
5. Valve ball of tank passage
6. Upper valve ball
7. Return oil to tank via solenoid valve

Note! On the tractors with the HiTech Shuttle (X100---

X120), the PTO clutch engagement is controlled by a
proportional valve and these tractors do not have the
above shown cushioning valve.

457
 Model Code Page
46. Power take ---off 95-- 115 460 14
1. 11. 2000

PTO clutch cushioning valve

The spring on ball (5) has been changed so that the spring
From tractor ser. no. 660071 the cushioning valve is in ---built wire diameter is now 1,0 mm (earlier 1,1 mm). In addition, the
in the servo valve block on the LH side of the gearbox. The restriction on ball (6) has been changed. The new restriction
cushioning valve end plugs are fitted on the top side of the
has a groove of 0,4 mm (earlier 0,5 mm).
valve block.
These modifications can also be done for the earlier manufac-
When the PTO is engaged, the solenoid valve directs oil to the
tured tractors.
PTO clutch and to the cushioning valve. The cushioning valve The spare part number of the new spring is 30626810.
spring (below piston 4) has its maximum length and raising
The spare part number of the new restriction is 32720410.
pressure in the lower passage opens valve ball 5 and oil can
flow to the tank. At the same time oil flows by valve ball 6 into Note! In order to improve further the engagement of the PTO,
the upper passage.
a new restrictor has been fitted into the servo valve block and
an extra passage has been drilled.
Pressure oil moves piston 4 downwards and spring force
which affects the ball 5 increases. Oil flow to tank decreases
Note! HiTech tractors have not the cushioning valve, but the
and clutch pressure rises slowly to its max. value (1,8 MPa). PTO engagement is controlled by a proportional solenoid
valve which in turn is controlled by the Autocontrol 5/5.2 con-
When the PTO is disengaged, oil returns via solenoid valve to
trol unit (see codes 370/371).
the tank passage 7. Pressure in the lower passage decreases
and oil can flow from the upper passage by ball 6. Piston 4
returns quickly to the original position.

This construction facilitates the function of the valve when the

PTO is engaged quickly again.

458
 Model Code Page
46. Power take ---off 95-- 115
1. 11. 2000 X100-- X120 462 1

1. Reconditioning PTO (Op. no. 462) 5. Disconnect the lifting cylinder upper ends from the lifting
arms. Disconnect the oil hoses from the lifting cylinder and
Note! In the instructions below has been used a PTO unit lower them.
which is equipped with parts for ground speed PTO. The in-
structions are good also for PTO units without the ground
speed PTO.

A. Removing PTO unit

1. Drain the oil from the transmission. Disconnect the PTO

speed sensor wire, if fitted. Remove the position sensor of the
hydraulic power lift.

2. Disconnect the auxiliary hydraulic pipes from the quick ---

action couplings (in front of the bracket for couplings).

3. Disconnect the PTO control cable, pick ---up hitch release

control, if fitted and the locking pin for the levelling screw con-
trol rod joint, if necessary.

Note! Support the lifting arms by pushing an iron bar through

the hole for lifting cylinder pin and further under the return oil
connection for auxiliary hydraulic (the cam on the lifting shaft
can damage if the lifting arms can rotate freely).

6. Unscrew the PTO housing fixing bolts. Disconnect the draft

sensor connectors. Open the leak oil reservoir cap and re-
lease its hoses.

7. Wrap a lifting rope round the PTO housing. Push a tube

onto the PTO shaft end. The unit can be kept in balance with
the tube.

Note! As a suitable tube can be used tool ET 893 550 (tool for
Carraro front axle on Valmet 05---series).

4. Lower the towing hook. Disconnect the lifting links from the
lifting arms. Remove possible special towing devices, if they
prevent removing of the PTO unit.

8. Raise the towing hook,if fitted with a garage jack about 40

cm and pull the PTO unit straight out from place.

459
 Model Code Page
46. Power take ---off 95-- 115
462 2
1. 11. 2000 X100-- X120

Note! Prevent the ground speed PTO shaft from rotating e.g.
with pipe tongs. Open the nut with a standard spanner
B. Removing PTO clutch wrench.

1. Remove the PTO unit (see instr. 1 A).

2490
4. Unscrew the front cover bolts. Pry out the cover with a fitting
lever and prevent the selector fork locking ball and spring
2. Remove the external lubricating oil pipes and the oil dis- from springing from their place.
tributor piece.
Note! Easiest way to remove the cover is to pry at the PTO
Important! With effect from tractor searial no. 659787 the oil shaft front end. There is a guide sleeve on two fixing bolts on
pipes have been drawn in the different way. upper and lower corner of the cover.

2484
2485

3. Set the PTO selector lever to the neutral position (middle

5. Remove the PTO clutch and shaft from the housing.
position). Slacken the ground speed PTO shaft nut for easier
removing of the front cover.

Note! On the latest tractors it is unnecessary to slacken the nut

before removing the front cover.

460
 Model Code Page
46. Power take ---off 95-- 115
462 3
1. 11. 2000 X100-- X120

C. Reconditioning PTO clutch

2488

6. Place the friction and steel discs by turns onto the hub (first
friction disc). Number of discs, see page 460/2.
2486
Important! There are 8 friction discs and 7 steel discs in the
1. Remove the oil deflector plate from the PTO clutch hub and PTO clutch.
remove the circlip under the plate and the clutch cup springs
release. 7. Fit then the hub/disc pack onto the plate which has internal
lugs (and on the cup springs) so that the grooves on the hub
2. Remove the clutch discs. Check the condition of the friction engages with the lugs on the plate.
and steel discs and the PTO brake plate. Replace damaged
parts. 8. Fit the circlip into the hub and force the circlip into its groove
by striking with sleeve ET 894 090. Fit the oil deflector plate
Note! The friction discs and steel discs must be renewed as onto the hub.
a complete set. The friction disc must be changed if the Note! Place the clutch shaft on a table and assure that the
grooves on it have disappeared. clutch drum grooves are enough deep. The discs (steel disc)
must not be against the groove bottoms when the shaft is in
3. Remove the piston, if necessary, with compressed air or the working position.
knock the shaft end against the table. Change the piston
seals. Push in the piston

2489

9. Check the clutch shaft rear taper roller bearing and its race
2487 in its location on the housing. Change the parts if necessary.

4. Assemble the clutch by fitting the brake plate on the piston. 10. Check also condition of the piston ring type seals at the
Then place on the brake plate a plate which has internal lugs. rear end of the clutch shaft.

5. Place the cup springs (5 pcs) on the internal lugs. The first 11. Check and change, if necessary, the taper roller bearings
spring concave side against the lugs and then other springs at the front end of the shaft. Fit all bearings fully home.
in pairs the concave sides against each other.

Note! The cup spring convexity is 3 mm.

461
 Model Code Page
46. Power take ---off 95-- 115
462 4
1. 11. 2000 X100-- X120

D. Fitting PTO clutch shaft and adjusting 3. Place the clutch drum/shaft onto the clutch disc pack.
bearing clearances 4. Fit drift ETV 894 080 into the hole for selector fork rail for
holding the locking spring and ball in place.
Adjusting bearing clearance of ground speed PTO shaft
(adjustment is done before fitting the front cover) 5. Fit the front cover and make sure that:
--- the selector fork rail is pushed through the hole on the cover
1. If you have changed the bearings of the ground speed PTO
and that the rail pushes out the drift
shaft (shaft is attached to the front cover), adjust the taper --- the PTO shaft front end bearing is pushed into its location
roller bearing clearance as follows:
on the cover
--- fasten the front cover to a vice
--- the brake plate holes engage with the pins on the cover.
--- fit the old shims between the bearings
--- Fit the spacer ring and tighten the shaft nut to 260 ---280
Nm.
--- Place a dial gauge stylus against the shaft rear end (middle
of the gear)
(Z22)
Z24
260--- 280 Nm
0,025---0,075

s= 0,10 2490
0,15
--- Measure the clearance which should be 0,025 ---0,075. Ro-
tate the shaft and press it to its extreme positions. 6. Tighten the cover bolts to a correct torque. Ensure that the
--- Increase or decrease shims thickness between bearings. selector fork rail locking ball and spring are in place.

Note! Shim thickness of 0,10 and 0,15 mm are available. Note! Two bolts on the upper and lower corner of the cover
Tighten the shaft nut after the front cover has been fitted. have a guide sleeve.

7. When the cover is in place, tighten the ground speed PTO

shaft nut to 260 ---280 Nm and lock it with a locking washer.

2485

2. Fit the PTO clutch shaft into the housing. Do not damage
the piston ring type seals at the rear end of the shaft.

462
 Model Code Page
46. Power take ---off 95-- 115
462 5
1. 11. 2000 X100-- X120

Adjusting clutch shaft bearing clearance E. Removing selector fork and PTO shaft
gears

1. Remove the PTO unit (see instr. 1 A).

2. Carry out measures shown in instruction 1B; 2 ---5.

0,025---0,075

--- Remove the locking plate and turn the adjusting nut on the
2492
shaft until there is no clearance in the clutch shaft taper roller
bearings
--- Place a dial gauge stylus against a hose clip pressed on the
clutch shaft 3. Release the locking washer and unscrew the locking bolt.
--- Unscrew the adjusting nut so that the clearance of Remove the flange and pull out the roller bearing inner race
0,025 ---0,075 mm is obtained for the bearings. Rotate the as above.
shaft and press it to its extreme positions when measuring the
clearance. Note! Tractors without ground speed PTO: Pull out the ball
bearing and remove the spacer sleeve and ring in front of the
gearwheel.
21---25 Nm
4. Remove the small ground speed PTO gearwheel (if fitted)
and the middle gearwheel for engine PTO 1000 r/min.

--- Lock the adjusting nut with a locking plate and tighten its
fixing screw to 21 ---25 Nm. Apply Loctite 242 to threads.

Note! One step of the adjusting nut corresponds to about 0,09

mm alteration on the clearance value. Note that the locking
plate can be fitted in two different way which doubles the 2493
number of steps.
5. Pull the selector fork and its rail out from the housing.
9. Fit the oil pipes and the oil distributor piece. Change, if necessary, the inner selector lever which has a
round ---shaped end. Fit a new fork onto the rail and secure it
10. Fit the PTO unit (see instr. 1 G). with a locking pin.

Note! Fit the locking pin of the outer selector lever so that its
split side points forwards.

6. Remove the larger circlip for the oil seal retainer at the PTO
shaft rear end. Knock at the front end of the hollow shaft round

463
 Model Code Page
46. Power take ---off 95-- 115
462 6
1. 11. 2000 X100-- X120

the PTO shaft and remove the PTO shaft/hollow shaft. Re-
move the big gearwheel from the PTO housing.

7. Check the PTO shaft seal and o---rings and change them
if necessary. Check also the PTO shaft rear ball bearing.

F. Fitting gears and selector fork

2493

3. Fit the sliding coupler onto the fork and place the fork/rail
into the housing so that the sliding coupler engages onto the
teeth on the big gearwheel.

Note! Fit the selector lever round ---shaped end into the hole
on the rail.

4. Fit the middle gearwheel and then the small gearwheel.

1. Push the PTO shaft/hollow shaft/ball bearing as a complete Note! Tractors without the ground speed PTO: fit the spacer
unit into the housing. Place the impulse disc onto the hollow ring and the sleeve in front of the small gearwheel.
shaft splines and fit the spacer ring in front of the disc.
5. Fit the roller bearing inner race onto the shaft in front of the
Note! The impulse disc is fitted only on E ---models. On other small gearwheel and fit the roller bearing onto the race.
models, there are two spacer rings.

2. Fit the big gearwheel onto the shaft before the shaft is fully 190---210 Nm
home. Tap at the PTO shaft rear end until the rear ball bearing
is in its location fully home. Fit the seal retainer and the larger
circlip.

IMPORTANT! On the latest tractors (H34332 ---) there is fitted

a new cassette seal for the PTO shaft, see picture on page 6. Fit the flange and tighten the locking bolt to 225 Nm and
460/7 and fitting instruction of the cassette seal on page lock it with the locking washer. Note that in the picture above
462/8A. there is the earlier attaching flange at the end of the PTO shaft.

Note! There are shims between the seal retainer and the ball Note! Tractors without the ground speed PTO: Fit the ball
bearing. The clearance between these parts is adjusted to bearing and then the locking flange or locking bolt.
zero. Use old shims. If necessary, the clearance can be
measured by placing a dial gauge stylus against the seal re- 6. Carry out measures shown in instruction 1D.
tainer. Available thickness of shims; 0,10 0,15 and 0,50 mm.
7. Fit the PTO unit (see instr. 1 G).

464
 Model Code Page
46. Power take ---off 95-- 115
1. 11. 2000 X100-- X120 462 7

6. Fit the PTO control cable. Connect the pick ---up hitch re-
G. Fitting PTO unit lease control, if fitted. Connect the lower joint of the levelling
screw control rod.

1. Clean contact surfaces between the PTO housing and the

gearbox and apply sealing compound to the surfaces.

7. Connect the lifting link upper ends to the lifting arms. Fit the
top link. Connect the pick ---up hitch lifting links, if fitted.

8. Fit all special towing devices, if they are fitted on the tractor.
2. Push the PTO unit straight into place so that the PTO clutch Fill the transmission with oil.
shaft front end (and ground speed PTO shaft front end) en-
gages with their splines. 9. Fit the position sensor and adjust it, see code 321 (ACB/
ACD Power lifts).
Note! Before fitting the PTO unit, put the ground speed PTO
shaft coupling sleeve onto the rear end of the ground speed Note! Connect the PTO speed sensor wires, if fitted.
PTO output shaft in the gearbox.
Note! On HiTech models, connect the wire of the speed sen-
sor B7. If the PTO speeds have been changed, AC 5/5.2 con-
trol unit must be reprogrammed (parameter files), ---J38342,
or PTO parameters (ratios) must be set in the setting mode,
J38343 ---, see under code 370.

3. Tighten the PTO housing bolts to a correct torque. Connect

the hoses to the lifting cylinders. Connect the lifting cylinder
upper ends with pins to the lifting arms.

4. Connect the draft sensor connectors. Fit the leak oil reser-
voir hoses and the reservoir cap.

5. Connect the pipes to the quick ---action couplings. Slacken,

if necessary, the quick ---action couplings in their bracket for
easier work.

465
 Model Code Page
46. Power take ---off 95-- 115
1. 11. 2000 X100-- X120 462 8

2. PTO shaft seal and cushioning IMPORTANT! Concerning tractors which have a new cas-
sette seal for the PTO shaft (H34332---), see the cassette seal
valve fitting instruction on page 462/8A.

6. Pry out the old oil seal fit a new one with plate ETV 891 870.
A. Changing PTO shaft/seal
7. Grease the seal lips and fit the seal retainer into its location.
1. Drain the oil from the transmission. Remove the PTO shaft Secure the retainer with the circlip behind it.
safety cap.
Note! There are shims between the seal retainer and the ball
bearing. Fit the same shims and fix them, if necessary, with a
little grease.

8. Fill the transmission with oil and check for leaks.

2. Remove the smaller circlip round the shaft and pull out the
PTO shaft. Also a spacer ring releases.

3. Fit a new PTO shaft and check and grease the o---ring on
it. Push the shaft fully home and fit the spacer ring and the cir-
clip.

4. Remove the larger circlip behind the seal retainer and pry
out the retainer by using two screwdrivers.

5. Check/change the seal retainer o---ring in the PTO housing

bore.

466
 Model Code Page
46. Power take ---off 95-- 115
1. 11. 2000 X100-- X120 462 8A

C. Changing cassette seal (H34332---) of

PTO shaft
Note! On the tractors, that have the ground speed PTO, the
PTO shaft seal is of the earlier type. The new cassette seal
can also be fitted on the earlier manufactured tractors,
when the seal retainer is changed.

0,1 KG 2606
0,15 KG 2607
KH4936 0,5 KG 2608
(KG3140)
33418600
KH 1228
(KG4060)
KH4932

ETV 894420

ETV 894430 ø 35

ETV 894440 ø 44,6

33628400

1. Drain the oil from the transmission. Remove the PTO 4. When the seal retainer is in place, fit the cassette seal as
shaft protective tube. Remove the PTO shaft seal retainer follows:
large circlip and pry out the retainer with two large screwdri- --- lubricate the seal inner and outer surfaces with oil
vers. Also the protective cup and the cassette seal are --- tap the seal into place by using ring ETV 894420 and
removed. sleeve ETV 894430 (PTO shaft ø 35 mm) or sleeve ETV
894 440 (PTO shaft ø 44,6 mm)
2. Clean the parts and the housing bore. Change, if neces- --- fit the seal protective cup by using one of the above
sary, the seal retainer o---ring and oil it. mentioned sleeves

3. Fit the seal retainer (use same shims between the retai- Note! It is very important, that the seal is pushed straight
ner and the bearing. When necessary, the play can be mea- into its location. That is why the fitting sleeves and the ring
sured with a dial gauge and new shims can be fitted). Fit must be used.
the seal retainer large circlip.
5. Fill the transmission housing with oil. Start the PTO and
check for leaks.

467
468
 Model Code Page
46. Power take ---off 95-- 115 462 9
1. 11. 2000

PTO clutch cushioning valve, 95---115

The cushioning valve is in ---built in the servo valve block on
the LH side of the gearbox. The cushioning valve end plugs
are fitted on the top side of the valve block, see pictures under
code 420.

Loctite 542

Picture 11. Cushioning valve, 95 ---115

3. PTO solenoid valve on the lower side of valve block

4. Cushioning valve piston
5. Valve ball of tank passage
6. Upper valve ball
7. Return oil to tank via solenoid valve

Function and modifications of this valve, see page 460/15.

The valve can be dismantled by removing the plugs on the
servo valve block.

Note! On HiTech tractors (X100---X120) the PTO engagement

is controlled by a proportional valve (AC 5/5.2), and they have
not the cushioning valve.

469
470
 51. Service brakes
50. Brake system

52. Parking brake

471
472
 Model Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 510 1

Contents

General (Op. no. 510)

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Brake system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Reconditioning brakes (Op. no. 511)

1. Reconditioning service brakes:

A. Changing brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Adjusting brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Changing brake housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Adjusting master cylinder pushrod clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F. Adjusting brakes on tractors which have reverse drive controls (TwinTrac) . . . . . . . . . . . . . . 3

Reconditioning parking brake (Op. no. 521):

A. Adjusting parking brake, 95---115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Parking brake on X100---X120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Technical data
--- number of brake discs per brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 pcs
--- number of balls per brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 pcs
--- friction surface per brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3690 cm2/org (2650 cm2/sint)
--- brake disc, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 224 mm/org. (ø 222/sint)
--- on traffic tractors (50 km/h) the brake dics number is 6 pcs per brake (3+3).
The disc linings are then of sinter type.

Tightening torques
Brake disc attaching flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Brake housing ---final gear housing:
--- 95 (earlier) (8.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
--- 95---115, X100---X120 (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm
Brake housing ---gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270---330 Nm
Rear wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm
Cab attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Brake pipe ---master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm

Settings
Brake pedal free travel (latched together) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70---80 mm
Parking brake free travel (at lever end) (not HiTech) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . about 50 mm
Parking brake cable adjusting value (HiTech) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2 mm

Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE J1703

Brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 litres

473
 Model Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 510 2

Brakes, description

5 S10 S20 8 mm
2
4 1
3

6 7
9

10 8

S15

Figure 1. Brake mechanism

1. Service brakes adjusting nut

2. Parking brake adjusting nut
3. Grease nipple
4. Bleeding nipple
5. Brake fluid reservoir
6. Master cylinders (2 pcs)
7. Brake cylinder (2 pcs)
8. Parking brake cable (not HiTech)
9. Brake mechanism (in rear axle housing)
S10 = switch for RH side brake light
S20 = switch for LH side brake light
S15 = switch for parking brake warning light (not HiTech)

Service brakes are wet multi ---disc brakes fitted in the rear
Parking brake hand lever acts mechanically on the foot
axle housing. Service brakes are controlled hydraulically by
brakes. The brakes can be adjusted by means of the adjust-
means of the brake pedals. When the brake pedals are
ing nuts.
pressed, the 4WD engages causing brake action also on the
front wheels.
As optional equipment, the brake valve for a trailer is avail-
able.
Brake pedals can be used separately as steering brakes or
they can be latched together.

474
 Model Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 510 3

80 Nm
70 Nm
The brake master cylinders and the brake fluid reser-
voir are positioned to the right on the cab front wall. The
brake system has two brake cylinder with in ---built
equalising valves, which ensure even braking action
when the brake pedals are latched together.

The brake discs are fitted on splines on the inner drive

shaft in the brake housing. The brake system and the
gearbox use the same oil.
Z=23

The bleeder nipples are positioned on top of the brake

cylinders
Z=15
During brake application the force from the brake cylin-
ders is transferred, via levers, to the brake discs. The
thrust plates turn in opposite direction and the balls be-
tween the plates force them against the brake discs and
brake action is obtained.
Z=63

Figure 2. Brake housing, earlier 95

80 Nm

Z=82

Z=33

Z=14

125 Nm

Brake cylinder
Master cylinder
Figure 3. Brake housing, 95 ---115, X100 ---X120

475
 Models Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 510 4

1 2

Clearance 1 ---3 mm

Figure 4. Master cylinder

Figure 5. Brake cylinder

The brake fluid flows from the reservoir through pipe (1) into If only one of the brakes is applied, the valve is opened by the
the master cylinder. When the pedals are depressed, the piston, thus pressurising the intermediate pipe (3). This
non ---return valve at the front end of the master cylinder closes causes the valve in the other (not actuated) master cylinder to
preventing oil from returning to the reservoir. The fluid, now close. Oil under pressure now flows from the master cylinder
under pressure in the cylinder, flows through pipe (2) to hole which is being applied to the corresponding brake cylinder.
(4) at the front end of the brake cylinder behind the piston and
forces out the thrust rod. The brake system bleeder nipples (5) are placed on top of the
respective brake cylinders.
The valves and the intermediate pipe (3) in the master cylin-
ders serve as an equalising mechanism, if the mechanical set-
ting of the two brakes differs. When the pedals are depressed,
the pistons actuate the valves so that they open and any pres-
sure differences in the brake circuits are equalised through
the intermediate pipe (3).

476
 Model Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 510 5

70 Nm (M10)
125 Nm (M12)
2

3
80 Nm

1
4 8
5
9
A B
6

Figure 6. Brake mechanism

1. Brake housing
2. Brake cylinder
3. Application plates
4. Brake discs
5. Intermediate discs
6. Brake balls
7. Return spring (4 pcs per brake)
8. Support brake
9. Inner drive shaft
A) Application plates and balls in neutral position
B) Movement of application plates when braking

477
478
 Model Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 511 1

Reconditioning brakes (Op. no. 511) 8. Push the anchor bolt in through the hole in the brake hou-
sing, but do not press it right home. Fit the inner brake discs
on the anchor bolt. Check that the discs remain located in
1. Service brakes front of the inner circlip.

A. Changing brake discs

Note! There are oil grooves on the friction surface of the brake
discs. On new discs the grooves are 0,3 mm deep. If the groo-
ves are worn away, the braking efficiency will be impaired and
the discs should be replaced.

1. Remove the final drives (see Op. 451 1A).

2. Pull out the inner drive shaft. Remove the outer support
plate in front of the discs.

3. Remove the outer brake discs.

9. Insert the application plate into the housing with the upper
edge first locating the lower edge of the plate on the pulled ---
out anchor bolt. Press the bolt and the application plate into
position. Fit the outer circlip on the anchor bolt.

4. Slacken the adjusting nut (see arrow) until the brake

mechanism is loose.

10. Fit the outer brake discs and press the inner drive shaft into
the outermost brake discs. Grip with your fingers behind the
inner brake discs and move them up on to the splines on the
inner drive shaft. Then press the inner drive shaft into position
in the differential.

5. Take out the cotter pin and the link pin at the lower end of
the stay. Pull the stay up until it is free from the application
plate. Remove the application plates by simultaneously pul-
ling out the anchor bolt, fitted under the plate, and loosening
the lower end of the plate from its position.

Note! The removal of the application plates is easier if the

outermost circlip is removed from the anchor bolt.

6. Remove the inner brake discs. 11. Using the link pin connect the brake stay to the link arms
of the application plate and secure with the cotter pin. Tighten
7. Check the friction surfaces in the brake housing and polish the adjusting nut at the upper end of the stay.
with an emery cloth.

479
 Model Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 511 2

Maintenance

Note! Grease brake lever nipples (see arrows) weekly (or

every 50 running hours). It is recommended, that the brake
fluid is changed every other year.

12. Fit the support and tighten it to 80 Nm. C. Bleeding brake system
11. Fit the final drives (see Op. 451 1E) and adjust brakes
(see next instr. B).

B. Adjusting foot brakes

1
1

Note! Both brake cylinders have a bleeding nipple (see

arrow). Bleed both brakes individually (pedals not latched
together).

1. Check thet the brake fluid reservoir is full.

Note! The pedal free travel should be 70 ---80 mm with the 2. Pump several times with the pedal in order to built up the
pedals latched together. Adjust as follows: pressure in the system.

1. Fit blocks in front of the front wheels to prevent the tractor 3. Depress one of the brake pedals and at the same time open
from moving. the bleed nipple on the brake which is being actuated by the
pedal. Close the nipple and slowly let the brake pedal up
2. Raise the rear wheels off the ground and adjust both brakes again.
separately with adjusting nuts (1) until the wheels cannot be
turned by hand any further. 4. Repeat the pumping action with the brake pedal until the
brake fluid which runs out at the bleeding nipple is completely
3. Slacken the adjusting nuts two turns and check that the free of air.
wheels can rotate freely.
5. The procedure for bleeding the brakes is the same on both
4. Check that the brake action is the same on both wheels sides.
while driving with the pedals latched together.

5. Check the pedal free travel.

Tractors with reverse drive controls

On tractors which are fitted with an optional reverse drive cont-

rols, the brake pedal adjustment is done as follows:

--- adjust first the front pedals according to instr. above.

--- adjust then the rear pedal with adjusting nut 2 (see picture
on page 521/1) so that the rear pedal travel becomes 20 mm.

480
 Model Code Page
51. Brake system 95-- 115
1. 11. 2000 X100-- X120 511 3

D. Changing brake housing

The brake housing fixing bolts are difficult to open if the cabin
is fitted in place. For that reason, the cabin must be lifted up
before removing the brake housings (removing the cab, see
section 80) or the tractor frame must be split (see Op. 423
1A).

When fitting the brake housing, apply sealing compound

Hylosil RTV Grade 102 black to the contact surfaces between
gearbox ---brake housing.

Brake housing fixing bolts are tightened to 270 ---330 Nm.

E. Adjusting master cylinder pushrod

clearance

1
2
S20 S10 8 mm

The clearance should be 1 ---3 mm. This adjustment is done

by slackening screw (1) and removing the cotter pin and the
pivot pin and turning the clevis.

Note! Point 2 shows the brake light switch adjusting measure-

ment.

481
482
 Model Code Page
51. Brake system 95-115 521 1
1. 11. 2000

2. Parking brake
Note! Parking brake on X100-X120, see instruction B on
pages 521/2-3.

A. Adjusting parking brake, 95-115

(not HiTech tractors)

Note! The parking brake is controlled mechanically and it is

connected to the foot brake mechanism by a cable. The parĆ
king brake is adjusted in the factory and re-adjustment is not
necessary unless parts of brake mechanism have been chanĆ
ged. The parking brake is affected when the foot brakes are
adjusted (see instr. 1B).

1. Before adjusting the parking brake, adjust foot brakes (see

instr. 1B).

ÉÉÉÉ

2. Adjust the parking brake lever free travel to about 50 mm

(at the lever end) by turning the adjusting nut (2) at the rear
end of the cable.

497
 Model Code Page
51. Brake system X100-- X120 521 2
1. 11. 2000

B. Parking brake on tractors X100---X120

K28

Picture 1. Hand brake mechanism

1. Shuttle lever with hand brake switch

(position P)
2. Valve block on which there is a
hand brake solenoid valve
3. Working ram of hand brake
4. Hand brake cable
5. Sensor
6. Solenoid valve of hand brake.
A. Valve allows oil to flow out of ram
with a little counter pressure

In connection with HiTech Shuttle the hand brake is control-

led electro---hydraulically. When the engine is running and --- If the solenoid is faulty, it should be replaced.
the shuttle lever is moved to position P, hydraulic oil pres- --- If the solenoid is OK, measure whether current comes up
sure from the low pressure circuit is cut off in the ram (3) to the solenoid connector. If not, check the solenoid wires
(solenoid valve (6) becomes unenergised) and the ram and connectors.
spring pulls the hand brake on. --- The condition of the shuttle lever switch can be tested in
the AC 5/5.2 test mode, see code 370/371.
When pressure again is connected to the ram (solenoid --- If the solenoid and its wiring and the hand brake switch
valve energised), pressure compresses the spring and are OK, the fault can lie in the hand brake relay or in the AC
hand brake is released. V control unit.
--- If these are Ok, the fault can lie in the hydraulic system.
When the engine is stopped (pump stops), the hand brake
comes on automatically with an aid of the spring force. Note! If the hand brake engages itself during driving, the
solenoid valve (6) has become unenergised or low pressure
circuit has malfunctions.
If the hand brake does not disengage (engine running)
although the shuttle lever is moved to the N, R or F position Note! If the driving speed exceeds 2 km/h (in the beginning
so: of the production 4 km/h), the hand brake engagement is
prevented by relay K28 (in the lever console).
--- check whether the solenoid valve is energised (magne-
tic), when the hand brake is disengaged. If not, measure
the solenoid resistance, which should be 11 ---12 ohms.

484
 Model Code Page
51. Brake system X100-- X120 521 3
1. 11. 2000

Min. 10 mm

MAX 20

Picture 2. Hand brake ram on HiTech tractors.

1a) Safety switch lights up the STOP light in the dasboard, if e.g. the hand brake cable breaks.
Note! Adjusting dimensions MAX 20 and min. 10 mm must come true when fitting a new cable.

Adjusting hand brake on HiTech tractors

The length of the hand brake cable is adjusted, when neces-

sary, so that when the hand brake is disengaged (=ram pres-
surised), the clearance between the RH side brake cylinder
push rod and the brake mechanism lever is 1 ---2 mm. The
clearance can be adjusted with nuts at the end of the cable
(arrow).

Note! Before adjustment ensure, that the foot brake is cor-

rectly adjusted, see instr. B on page 511/2.

485
486
 61. Steering system
60. Steering system and
front axle
65. Industrial front axle
Sige (Dana)

67. Industrial front axle

Carraro

487
488
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 1

Technical data
Hydrostatic frame steering system. Oil is supplied to the steering system from the high ---pressure pump via the priority valve.
Adjustable telescopic steering wheel column. Two double ---action steering cylinders on both sides of the middle frame joint.

Hydraulic pump, see code 910.

Steering valve, changeable volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OSPQ 125/250---LS
--- capacity per revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,125/0,250 l
--- OSPQ valve has incorporated flow amplification.
Reverse drive controls (TwinTrac, option), steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OSPC 200---LS
--- capacity per revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,200 l
Max. working pressure, pressure limiting valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . 17,0---17,5 MPa
Shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,5---24,0 MPa
Priority valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danfoss OLS 120
Steering speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
over 1,25 rounds/sec. at idling
speed
Steering wheel rotates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,77 turn
Steering capacity ±42˚ with front axle load of 5000 kg on dry asphalt
Pressure filter, degree of separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . β10=75

1.1. Turning circle radius

Tractor X100Hi ---X120Hi
Tyres, with standard track width 14.9---24
Minimum turning circle radius, mm 4530

489
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 2

Special tools

ETV 894 330 Fitting tool for steering valve seal

ETV 894 330

Equipment for measuring steering system working pressure (pressure at test point 17,0 ---17,5 MPa)
Pressure measuring kit 31965000 includes the above shown hose and pressure gauge. These parts can also be ordered sep-
arately.

490
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 3

Hydraulic diagram, steering system

491
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 4

Picture 2. Frame steering components

1. Steering valve (OSPQ 125/250---LS)

2. Steering valveTwinTrac (option) (OSPC 200---LS)
3. Frame steering cylinders (55/32x400)
4. Pressure regulator (TwinTrac, option)
5. Priority valve OLS 120
5a. Pressure spring of 10 bar is changed in place of original 7 bar spring
6. Cross connection nipple

The standard OSPQ steering valve for forward driving is a load sensing steering unit with incorporate flow amplification.
Inside the steering unit the flow through the gearwheel set is amplified with a specified factor.
The amplification factor may vary from 1,2 to 2.
At steering wheel speeds below 1/6 rev/sec., there is no flow amplification. At steering wheel speeds above 1/3 rev/sec., the
flow amplification is fully active.

492
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 5

Picture 3. Steering system

1. Steering valve (OSPQ), standard

2. Steering valve, TwinTrac (OSPC), option
3. Steering cylinders
4. Pressure regulator (TwinTrac, option)
5. Priority valve OLS 120
5a. Pressure spring of 10 bar is changed in place of original spring
6. Cross connection nipple
7. Pump (on 95---115 on the RH side of the engine)
8. Pressure filter
8a. Pressure test point

493
 Model Code Page
61. Steering system 95-- 115 610 6
1. 11. 2000

Reverse drive controls (TwinTrac), 95---115

On certain markets the reverse drive controls are equipped

with a directional control valve 13, which disengages the rear
steering system when driving forwards.
When the seat is turned forwards, the switch S35 under the
seat switches on current to solenoid Y7, and the directional
control valve 13 prevents oil from flowing from the rear steer-
ing valve to the steering cylinder.

Note! Check every now and then fuse F25 (if the fuse is blown,
the valve 13 remains in the open position and the rear drive
controls function despite of the position of the seat).
--- The use of the reverse drive control in the road driving
(transport driving) is prohibited.
--- Valve table + levers (six or eight levers) are available as
optional equipment.

7. Priority valve
8. Non ---return valve
9. Steering valve, forward driving
11. Rear steering valve
12. Shuttle valve
13. Directional control valve

494
 Model Code Page
61. Steering system X100-- X120
610 7
1. 11. 2000

Reverse drive controls (TwinTrac), X100---X120, AC 5 (---K41106)

5
9

8
10 7

2 1

3
4

6080--- 169

1. Rear steering wheel

2. Clutch pedal
3. Brake pedal
4. Gas pedal
5. Shuttle lever/parking brake lever
6. Delta Power Shift pre ---programming button
for driving direction change
7. Lever to adjust steering wheel distance
8. Delta Power Shift switch, three positions
9. Stop (red pilot light, does not flash)
If the stop lamp comes on, the tractor
and the engine must be stopped
immediately. Only in emergency the
driving can be continued little while.
10. Display unit for driving direction change,
for DPS etc.

495
 Model Code Page
61. Steering system X100-- X120 610 8
1. 11. 2000

TwinTrac, AC 5.2 (K41107---)

496
 Model Code Page
61. Steering system 95-- 115
X100-- X120 610 9
1. 8. 2000

Steering wheel column

45 Nm

10 Nm

Lever, steering wheel heigth.

Steering valve

Pedal, steering wheel angle

Locking of joint
pins.

A ---A 50 Nm B---B

Pedal control rod

The steering axle lower end must

be 13 ---14 mm inside the steering
valve.

Steering wheel column is the

same as in agricultural tractors,
but the shaft is little shorter due
to lack of space in 95---X120
tractors.

497
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 10

Steering valve OSPQ

6
2 3

4
10 1

12

11
Figure 4. Steering valve OSPQ
7. Inner valve spool
1. Shock valve (2 pcs) 8. Outer valve spool
2. Non ---return valve 9. Rotor shaft
3. Non ---return valve for emergency steering 10. Centring springs
4. Rotor ring 11. Amplification valve
5. Rotor 12. Anti ---cavitation valves (2 pcs)
6. Valve housing Note! Pressure ---limiting valve not il-
lustrated.

498
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 11

Steering valve OSPQ, description

A
IMPORTANT! OSPQ 125/250---LS valve has a flow ampli-
fication spool (11), which increases the oil flow through the
metering gear set, when a certain steering wheel rotation
speed is exceeded. The flow is amplified by factor between
1,2---2. The flow amplifying is started when steering wheel
rotation speed is over 1/6 rev/sec. and reaches the maxi-
mum flow at rotation speed of 1/3 rev/sec.

The steering valve consists of a metering unit (rotor set)

and a valve unit. The rotor set consists of a rotor ring (4)
with seven internal teeth and a rotor (5) with six external
teeth. The valve unit consists of a valve housing (6), outer
valve slide (8) and inner valve slide (7).

The inner slide (7) is directly actuated by the steering

wheel. The outer valve slide (8) is mechanically connected
to the rotor (5) by a cross pin and rotor shaft (9). The cross
pin which runs through both valve slides permits the inner
valve slide to move 8˚ in both directions independent of the
outer valve slide.

When the steering wheel is in the rest position, centring Figure 5. OSPQ Steering valve lower face
springs keep the inner and the outer valve slides in neutral A. Anti ---cavitation valves
(in relation to each other) and the oil flows freely through
the steering valve. The passages to the steering cylinder
are kept closed and the steering cylinder cannot move. B

When the steering wheel is turned, the inner valve slide is D

turned in relation to the outer valve slide. The neutral---posi-
tion passages become restricted at the same time the pass-
ages down to the measuring unit and on to the steering
cylinder gradually open. Simultaneously the return oil from
the other side of the steering cylinder flows back via the
steering valve.
The oil flow from the pump through the valve makes the
rotor and the outer valve slide turn in the same direction as
the steering wheel and the inner valve slide.

When the steering wheel is not turned any further and kept
still, the centring springs bring the outer and the inner valve
slide back into the neutral position The passages to the
steering cylinder close and the oil flows freely again
through the steering valve.

When the hydraulic pump does not supply any oil, the
metering unit of the steering valve acts as a manually pow-
ered pump. The oil which is drawn from the steering cylin-
der and the return line via the non ---return valve (3) is deliv-
ered to the other side of the steering cylinder when the C
steering wheel (and inner valve slide 7) is turned 8˚. The Figure 6. OSPQ Steering valve upper face
cross pin then also makes the following parts turn: the outer B. Shock valves
valve slide (8), rotor shaft (9) and rotor (5). Shocks and C. Flow amplification valve
knocks against the steering wheel are dampened by the D. Pressure ---limiting valve
two shock valves (1) which are fitted in the steering valve.

The shock valves are combined with anti ---cavitation valves

(point A in figure 5) in order to keep the cylinder fully
supplied with oil at all times.

499
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 12

Fault tracing chart

Before disconnecting the pipes, hoses and hydraulic components it is most important that the units, as well as the adjacent parts,
should be carefully cleaned. Use white spirit or a similar solvent. Also remove paint from the pipe fittings, couplings etc.

Open ports, hose and pipe ends must be plugged immediately after they are exposed, in order to prevent dirt from getting into
the system.

Never use teflon when assembling the system. Traces of teflon can get into the system and cause problems.

Before examining the steering system for particular malfunctions, the fluid level should be checked and the whole system bled
if necessary. Where applicable, check that the fluid system is not blocked. It is also important to make sure that the correct type
of hydraulic fluid is used, see the oil recommendations.

Fault Probable cause Remedy

The steering wheel is hard to turn, 1. No hydraulic pressure. The pump or the Repair the fault
but the steering is otherwise normal pump drive faulty
2. Non ---return valve leaking or ball in wrong Replace the ball or check its position
position.
3. Pressure ---limiting valve jammed in open Repair the pressure ---limiting valve (or
position clean it)

4. Considerable friction in the mechanical parts Lubricate the steering system bearings
of the steering system. and joints, repair if necessary. Check the
steering column clearance
Continual correction of the steering 1. Leaf springs have no force or are broken Change the leaf springs
wheel is necessary. The steering
wheel will not assume a neutral 2. Steering column and steering valve are not in Line up the steering column with the centre
position. line. line of the steering valve

3. Too little play or no play at all between the Adjust the clearance
steering column and the connecting piece.
The steering wheel will not assume 1. Dirt, burrs or swarf between the inner and If possible clean the slides, otherwise
the neutral position, tends to turn it- outer slides. change the complete housing or the whole
self=motor effect) steering valve

2. Jamming between the inner and outer slides Clean the whole steering system
caused by too high fluid pressure
Adjust the pressure ---limiting valve to the
3. Leaf springs broken or have no spring pres- prescribed pressure
sure.
Change the leaf springs
Road wheels turn in the wrong di- 1. Hoses to steering cylinder are reversed Change the hoses round
rection
2. Wrong setting of rotor shaft or rotor set, see Correct the setting
figure
Steering force too low (or only to 1. Steering pressure too low Correct the pump pressure of the pressur-
one side) e ---limiting valve
2. Worn seal on steering cylinder piston
Change the piston seal
3. Too large internal leakage in steering valve
Change or recondition the steering valve
4. Shock valve faulty
Recondition shock valve
5. Abnormal superstructure for use of machine
Compare with machine of standard ver-
sion
Abnormally large ”play” in steering 1. Groove for cross pin worn or broken Change rotor shaft
wheel
2. Play in universal joint on steering column Change the universal joint

3. Leaf springs broken or have no spring force Change the leaf spring

500
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 610 13

Road wheels vibrate 1. Air in the steering cylinder Bleed the steering system

2. Wear in the mechanical connections or wheel Change worn parts

bearings

The steering wheel is subject to se- 1. Faulty setting of rotor shaft and rotor set
vere shocks when steering wheel is
turned or the steering wheel tries to
move the opposite way (=tends to
twist out of the hands)
Shocks from road wheels while 1. Non ---return valve (2 fig. 5) faulty Change steering valve
driving
Steering too slow 1. Too little oil in the system Check oil level and oil pressure flow from
the pump
2. Pipe lines partly clogged
Clean or repair
3. worn steering valve
Change or recondition the steering valve
4. Abnormal superstructure or use of machine
Compare with machine of standard ver-
sion

501
502
 Model Code Page
95-- 115
61. Steering system X100-- X120 611 1
1. 11. 2000

Reconditioning steering system B. Checking shock valve opening pres-

sure
Steering valve (Op. no. 611)
1. General
A. Measuring steering system pressure
(pressure ---limiting valve opening pressure)

1. Start the engine and allow it run until the oil temperature
in the transmission is 30 ---60 ˚C.

Note! Oil warms up faster if the steering wheel is held

against lock.

Pressure test point

1. Disconnect one of the oil lines to the steering cylinders

and connect a hand pump and a pressure gauge to the
disconnected hose (see arrows).

2. Pump up pressure into the steering valve and read off

Pressure the shock valve opening pressure. The correct value is
filter 22,5 ---24,0 MPa (225---240 bar).

3. Completely re ---assemble the system and check the

opening pressure in the other line to the steering cylinder.

Note! If opening pressure is not correct, remove the steer-

ing valve and check and clean the shock valves and adjust
2. Connect a pressure gauge (measuring equipment, see them.
page 610/2) to the pressure test point (Valmet HPR) on the
pressure filter bracket.

3. Run engine at 1500 r/min.

4. Turn the steering wheel to full lock and hold. The correct
pressure gauge reading is 17,0 ---17,5 MPa (170---175 bar).

Note! If the pressure value is not correct, remove the steer-

ing valve and inspect the pressure limiting valve.

503
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 611 2

C. Steering circuit leakage check D. Removing/fitting steering valve

1. Start the engine and allow it run until the oil temperature in
transmission is 30 ---60 ˚C.

2. Run the engine at 1500 r/min.

25 Nm

max. 4 r/min

3. Turn the steering wheel to full lock and apply 25 Nm torque

to the steering wheel.

4. If the steering wheel turns more that 4 rev/min, there is too

much internal leakage in the steering valve and it must be
changed.

5. Check the internal leakage also with a new steering valve.

If the steering wheel still turns too much, the steering cylinder
seals must be checked.

504
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 611 3

2. Reconditioning steering valve 6. Fit the valve ball, washer and the spring.

OSPC 200---LS (TwinTrac, option) 7. Apply a little locking fluid to the threads on the adjusting
screw. Screw in the screw to the depth as measured in para-
graph 3.
A. Cleaning shock valves and pressure ---
limiting valve 8. Fit the sealing ring and the valve plug and tighten to a torque
of 40 ---60 Nm.
1. Remove the steering valve. Secure the valve in a vice with
9. Unscrew the pressure ---limiting valve plug (8 mm socket
soft jaws. head).
Note! There are two shock valves in the steering unit. Both
valves are similar.

2. Remove the plug on the shock valve (6 mm socket head)

and remove the sealing ring of the plug.
10. Remove the pressure ---limiting valve insert by unscrewing
it with a 12 mm Allen key.

11. The pressure ---limiting valve insert can be disassembled

by unscrewing the plug with a 4 mm Allen key. After that the
valve spring, seat and the ball can be removed.

Note! When assembling the valve, screw the plug to the same
depth as it was before disassembling.

12. Clean all parts and the valve bore and lubricate the parts
with oil.

13. Make sure that there is a sealing ring on the pressure ---li-
miting valve insert. Fit the valve insert and tighten it to 40 ---60
Nm.

14. Fit the plug sealing ring and tighten the plug to 40 ---60 Nm.

15. Fit the steering valve and check the steering system pres-
sures.

3. Measure and make a note of the distance between the ad-

justing screw and the upper face of the steering valve to facili-
ate the setting of the opening pressure of the shock valve.

4. Remove the adjusting screw (6 mm socket head). Shake

out a spring, washer and a ball.

5. Clean and check the parts and change faulty ones. Lubri-
cate all parts with oil before assembling. Minor damage to the
seat can be polished with a ball and fine grinding paste.

505
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 611 4

B. Changing seals in steering valve OSPC

(TwinTrac, option)

1. Remove the steering valve.

2. Secure the steering valve in a vice with the cover upwards.

Mark the position of the cover, distributor plate and rotor ring
for easier fitting.

4. Remove the cover, rotor ring and the rotor and the washer
inside the rotor.

3. Unscrew the cover fixing bolts.

5. Remove the rotor shaft and the distributor plate. Check/

change o---rings between the parts.

6. Push up the valve slide and pull them out of the valve hous-
ing. Remove the thrust bearing from the slide bore.
Note! Remember where the bolt with the locating pin was
fitted. If the valve is turned upside down, three valve balls and
two pins will fall out.

506
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 611 5

Note! If the centring springs are changed, they must be fitted

as shown in figure above.

Note! Before removing the springs, mark position of the valve

spindles in ralation to each others e.g. with tusche. Rinse the
spindles with gas oil (also lubricating properties) so that they
can move easily and the centring springs can center them.

9. Fit the ring over the centring springs. Place the thrust bear-
7. Turn the steering valve to a horizontal position and prize out ing assembly onto the valve slide.
the seal from the valve housing. Remove the inner oil seal. Fit
a new outer seal. Apply some grease to the seal and turn the Note! Thick thrust washer first, then bearing and then the thin
valve back to the vertical position. thrust washer. Chamfered side of the thick washer towards the
slide.
8. Fit the inner seal (and the support ring) using tool ETV 894
330 as follows:

ETV 893 100

10. Push the valve slide into the housing fully home

Note! The valve slide together with the thrust bearing is easier
--- lubricate the o---ring. Fit the support ring on the stud of the to fit into the housing when the steering valve is horizontally.
tool and fit the o---ring on the support ring. Push the stud into Turn the slides until the cross pin is parallel to the flat side of
the guide sleeve. the valve housing.

11. Fit a new o---ring and the distributor plate onto the housing
according to the mark. Fit the rotor shaft so that grooves on
it engage the cross pin.

---push the guide sleeve into the valve housing and push the
seal together with the support ring in place using the stud on
the tool. Remove the tool and check that the seal is property
positioned.

507
 Model Code Page
61. Steering cylinder 95-- 115
1. 11. 2000 X100-- X120 611 6

Stepped
splines

Note! In the latest steering valves the rotor shaft and the rotor
have stepped splines at which time the mutual position of the
parts is determined automatically.

13. Then fit a new o---ring and the rotor ring according to the Note! The stepped splines also prevent the rotor shaft from
marks. Fit the rotor according to the figure above. releasing from the cross pin inside the valve. With regard to
possible repair works it is recommended, that a spacer is fitted
14. Fit the washer inside the rotor. at the end of the rotor shaft to ensure the position of the shaft.
The spacers are still available as spare parts.
Note! See also the notes on the next column.

15. Fit the cover according to the marks and tighten the bolts
to a torque of 30 ---35 Nm.

16. Fit the steering valve (see next instruction).

508
 Model Code Page
61. Steering cylinder 95-- 115
1. 11. 2000 X100-- X120 611 7

3. Reconditioning steering valve 4. Remove the adjusting screw (6 mm socket head). Shake
out a spring, washer and a ball.
OSPQ ---LS (as standard)
5. Clean and check the parts and change faulty ones. Lubri-
A. Changing seals in steering valve cate all parts with oil before assembling. Minor damage to the
seat can be polished with a ball and fine grinding paste.
OSPQ
6. Fit the valve ball, washer and the spring.
NOTE! The seals are changed in the same way as in steer-
ing valve OSPC, see instr. B starting on page 611/4.
7. Apply a little locking fluid to the threads on the adjusting
screw. Screw in the screw to the depth as measured in para-
graph 3.
B. Cleaning shock valves, OSPQ
8. Fit the sealing ring and the valve plug and tighten to a torque
of 40 ---60 Nm.
1. Remove the steering valve. Secure the valve in a vice with
soft jaws.

Note! There are two shock valves in the steering unit. Both
C. Cleaning pressure ---limiting valve
valves are similar in OSPC and in OSPQ and they are in the
same places. NOTE! The pressure limiting valve is placed in the different
place in the OSPQ valve and in the OSPC.

1. Measure with a vernier caliper, how deep the pressure ---li-

miting valve setting screw is to make fitting easier.

2. Remove the plug on the shock valve (6 mm socket head)

and remove the sealing ring of the plug.

2. Unscrew with a 5 mm allen key the valve setting screw.

3. Remove the valve spring..

3. Measure and make a note of the distance between the ad-

justing screw and the upper face of the steering valve to facili-
ate the setting of the opening pressure of the shock valve.

509
 Model Code Page
61. Steering cylinder 95-- 115
1. 11. 2000 X100-- X120 611 8

D. Cleaning the amplifier spool

NOTE! The amplifier spool in the OSPQ is placed in the same
place as the pressure ---limiting valve in the OSPC.

4. Remove the valve piston.

5. Clean parts and check them. Change damaged parts.

1. Unscrew the amplifier spool plug with a 8 mm Allen key.

6. Place the piston into the valve bore. Fit the spring.

2. Take out the spring.

7. Check the condition of the setting screw seal. Change the

seal, if necessary. Screw in the setting screw into the same
deep as it was before unscrewing.

3. Take out the spool.

510
 Model Code Page
61. Steering cylinder 95-- 115
1. 11. 2000 X100-- X120 611 9

4. Use a 6 mm Allen key to unscrew the orifice in the bottom 7. Mount the orifice in the bottom of the bore and tighten.
of the bore.

5. Remove the orifice. 8. Mount the spool into the bore. Mount the spring.

9. Check the plug with the o---ring and install in the housing.
6. Disassemble the amplifier spool, if necessary. Clean the Tightening torque 30 Nm.
parts and reassemble the spool.
Make sure that the ball can move freely. Tightening torque 10
Nm.

511
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 611 10

E. Disassembling/reassembling the
check valve (LS)

1. Use a 3 mm Allen key to unscrew the bushing.

2. Shake out the ball.

3. Check and clean parts. Fit in the ball, and mount and
tighten the bushing to a torque of 5 Nm.

512
 Model Code Page
61. Steering system 95-- 115
1. 11. 2000 X100-- X120 612 1

CF EF

LS

P=from pump
EF=surplus oil
CF=max prior. oil flow
LS= load sensing

B. Assembling
Priority valve OLS 120
1. Push the slide (3) into the housing. Fit a new sealing ring on
1. Cleaning priority valve the plug (1).

2. Place the spring (5) into the housing. Fit a new sealing ring
A. Disassembling and the connection (6). Tighten the connection to 40 ---60 Nm.

3. Tighten the plug (1) to 40 ---60 Nm.

1. Detach the priority valve which is fitted beside the pressure
filter under the cab floor on the RH side. 4. Fit the priority valve.
2. Open plug (1) and remove the sealing ring (2).

3. Unscrew the connection (6) and remove the sealing ring (2)
and the spring (5).

4. Push out the valve slide (3) by using e.g. a pencil. Do not
damage contact surfaces on the slide and the housing.

5. Check and clean the parts. Replace the sealing rings with
new ones. Lubricate the parts with oil before fitting.

513
514
 Model Code Page
65. Industrial front axle 95-- 115 650 1
1. 11. 2000

Sige industrial front axle is a standard equipment on earlier 95 ---115 tractors. The industrial front axle has a heavy duty
construction. Later 95 ---120Hi tractors have Carraro industial front axle, see section 67.

Technical data, Sige industrial front axle

Axle type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sige DS17 V SD.01
Flange distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1810 mm
Number of the teeth (crown wheel/pinion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z27/8
Differential ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,375
Ratio of the hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,25
Total ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,72
Number of the differential pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 pcs
Oil volume in hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x1,5 litres
Wheel disc attachment: Hub guides (ø 280,3---280,8), M20x1,5 (10 pcs)
Max. statical carrying capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7700 kg
Max. dynamic carrying capacity 0---8 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6200 kg
Carrying capacity at speed of 40 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3900 kg

Hubs and king pins

Ring gear support bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm Loctite 242

Pre ---load of king pin bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 mm
Rolling resistance of the hub bearings (measured with a spring balance from wheel
attaching bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,6---4,7 kg
King pin covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Nm
Tie rod tapered joint to steering arm (nut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm

Important! This axle has an electro---hydraulically controlled differential lock of a multi ---disc type, which engages simulta-
neously with the rear axle diff. lock.

515
516
 Model Code Page
65. Industrial front axle 95-- 115 651 1
1. 11. 2000

Flange distance 1810 mm

Fig. 1. Industrial front axle Sige DS17V

1. Plug for checking and draining oil in differential housing.

2. Oil filling plug for differential housing.
3. Oil filling and draining plug for hub..
Oil volume in differential housing 8 litres
Oil volume in hubs 2x1,5 litres.

517
 Model Code Page
65. Industrial front axle 95-- 115 651 2
1. 11. 2000

Fig. 2. Industrial front axle hub

1. Adjusting king pin bearing pre ---load

2. Loctite 242
3. Shims for adjusting hub bearing pre ---load
4. Loctite 290
Apply grease between the lips of the seals

518
 Model Code Page
65. Industrial front axle 95-- 115 651 3
1. 11. 2000

Note! Here is presented shortly the repair instructions for Adjusting wheel bearing preload:
the industrial front axle.
--- oil new bearings. Fit the wheel attaching flange and the
bearings into place. Fit the ring gear support and tighten
1. Hubs, drive shafts and king pins the bolts (2) so that the bearings have a small play, so that
(see fig. 2 on previous page) the hub rolling resistance can be measured without bearing
preload. Before measurement, rotate the hub many times
into both directions.

B. Drive shaft seals and double joints --- attach a spring balance wire to the wheel attaching bolt
and measure the hub rolling resistance without preload,
The king pins can be removed with extractor. King pins e.g. F=6,5 kg.
have thread M12. The king pin cover bolt tightening torque --- Then tighten the ring gear support flange bolts to 120
is 190 Nm. Nm and measure again the rolling resistance, e. g. F=11
kg. Subtract this from the previous value:
The outer diameter of the drive shaft outer seal is 95 mm.
11 kg ---6,5 kg=4,5 kg
The ring gear support tightening torque is 120 Nm. When
you remove the ring gear support flange, at the same The preload value should be between 3,6 ---4,7 kg.
release also shims for adjusting the wheel bearing pre ---
load. The shims should be fitted back when reassembling The preload is adjusted with shims which are fitted between
the hub. the ring gear support and the hub.

The inner drive shaft seal seal outer diameter is 80 mm. Note! The same shims can be used often, because the
The seal has also a wear ring. Apply Loctite 290 under the bearings are precision ---machined.
wear ring, if removed.

D. Changing king pin bearings

C. Hubs
Adjust the king pin bearings as follows:
The hub big seal can be fitted with locally prepared tool ET
894 020. --- Ensure that the lower king pin with its bearing and cover
is fitted in place. Tighten the lower pin cover bolts to a cor-
rect torque.

--- Fit the upper king pin together with its bearing into place
and press with a suitable plate and bolt the upper king pin/
bearing into its location until the bearings have no play.

--- Measure with a depth gauge how deep the upper king
pin was pressed, measurement M e.g. 0,8 mm

--- The king pin bearings need a preload of 0,5 mm. The
shim thickness S which must be fitted on the upper pin can
be calculated as follows:

S=M+0,5

E.g. 0,8+0,5 mm=1,3 mm.

519
 Model Code Page
65. Industrial front axle 95-- 115 651 4
1. 11. 2000

Picture 3. Differential and bevel pinion shaft.

Apply grease between the lip seal lips.
Oil felt gasket before fitting.

520
 Model Code Page
65. Industrial front axle 95-- 115 651 5
1. 11. 2000

2. Bevel pinion shaft and differen- --- use a spring balance to measure the force needed to
rotate the pinion shaft (see picture on page 644/4), Ø 60 m
tial (See picture 3 on the previous page)
--- the rolling resistance should be 3 ---5 kg.

A. Bevel pinion shaft seal --- if the rolling resistance is not correct the number of shims
The seal can be changed without removing the front axle. under the nut must be adjusted. If the rolling resistance is
too great, more shims are required and vice versa.

--- when the rolling resistance is correct the seals can be

B. Changing differential friction discs fitted.

It is best to change both disc packs at the same time. The

disc pack thickness should be between 14,51 ---14,69 mm. Adjusting differential bearing preload
The differential has four pinions. and pinion/crown wheel tooth backlash
C. Changing bevel pinion shaft and --- Using a vernier caliper, measure the distance between
crown wheel the differential bearings, see picture on page 644/5,
measurement D e.g. 226,50.
Adjusting bevel pinion shaft position: --- Read off measurement A (larger figure) marked inside
the longer axle housing. This is the distance between the
--- read off value E which is stamped on the end of the pin- bottom of the differential bearing location and the axle
ion shaft (e.g. 114 mm). housing flange surface (e.g. 141,20 mm).
--- see the bigger value marked in the axle housing (inside --- Read off measurement B marked inside the shorter axle
the longer axle section), measurement C (e.g. 152,00) housing. This is the distance between the bottom of the
bearing housing and the axle housing flange surface (e.g.
--- measure the thickness of the inner bearing (larger bear- 87,20 mm).
ing), measurement H (e.g. 36,50)
---The preload (P) of the differential bearings should be
--- calculate the number of shims required for correct pinion 0,05 mm. Calculate the number of shims required as fol-
shaft position: lows:
S=C ---(H+E) S=(A+B) ---D+P
E.g. 152,00---(36,50+114) = 1,5 mm E.g. (141,20+87,20)---226,50+0,05=1,95 mm.
--- put the shims required under the inner bearing outer --- Fit an equal number of shims under each differential
race and fit the outer race against the shims. bearing. Fit the differential into the axle housing and con-
nect the axle sections with several screws (190 Nm).
Adjustment of pinion shaft bearing preload:
--- Measure the pinion/crown wheel tooth backlash using an
--- fit the pinion shaft together with its bearings. indicator gauge stylus against a screw on the drive flange,
see picture on page 644/6.
--- fit the circlip in front of the outer bearing.
--- the correct tooth backlash value is 0,20 ---0,25 mm.
--- fit the drive flange onto the shaft but do not fit yet the
seal. --- If the backlash is not correct transfer shims from one
bearing race to the other.
--- fit the same shims as earlier. Fit a ring in front of the
shims and tighten the shaft nut to 250 Nm. N.B. If the backlash is too small transfer shims from the
shorter axle section side to the longer side and vice versa.

521
 Model Code Page
65. Industrial front axle 95-- 115 651 6
1. 11. 2000

Tapered joint between tie ---rod and steering arm

ø40

ø48
ø32 --- 0,1, --- 0,2
4

Taper 1:10
35---0,20
30---0,13

Material 41CrMo4

ø37 H7/r7

R32

The tie ---rod end has been strengthened. Taper ø 32 mm (was

ø 26 mm), joint ball ø 40 mm (was ø 35 mm). At the same time
the steering arm has been modified in the corresponding way.
The modified steering knuckle and the tie ---rod are in pairs
exchangeable with each others. This modification is in pro-
duction with effect from axle number 0116/94.

The earlier steering knuckle can be rapaired by machining a

space for a body ---fit sleeve (see picture above). The repair
work can be done in the tractor factory, if necessary.

522
 Model Code Page
67. Powered front axle Carraro 95-- 115
670 1
1. 11. 2000 X100-- X120

Contents
General (Code no. 670)
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Axle housing and mounting brackets (Code no. 671):

A. Removing front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing bearing sleeves of central pivot bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Fitting front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Hubs (Code no. 672):

1. Reconditioning hub reduction gear
A. Changing planetary gears/bearing rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing hub cassette seal and wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Changing king pin bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Drive shafts (Code no 673):

1. Changing drive shaft/seals/bearing bushing:
A. Changing inner oil seal and inner bearing bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Changing outer oil seal and outer bearing bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Reconditioning differential/bevel pinion shaft (Code no. 674):

A. Changing bevel pinion shaft cassette seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Removing bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Disassembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. Adjusting position of bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
G. Adjusting bearing preload of bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
H. Fitting differential onto bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
I. Adjusting tooth backlash between bevel pinion and crown wheel
and adjusting preload of differential bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
J. Fitting differential into axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

523
 Model Code Page
67. Powered front axle Carraro 95-- 115
670 2
1. 11. 2000 X100-- X120

Technical Data
Axle type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carraro 20. 29
Electro---hydraulic differential lock (HiLock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . standard
Ratio, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,538
Ratio, hub reduction gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,923
Total ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,570
Ratio, front axle ---rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,320
Steering angle, adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 55˚
Oscillation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±7˚
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6˚
KPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7˚
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5˚
Toe ---in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---2 mm
Flange distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900
Oils:
--- in differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 litres
--- in hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x1,5 litres
--- oil quality (e.g. Valtra Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W/90 GL ---5 (LS)

Setting values
Bevel pinion shaft:
--- bearing pre ---load (measured with a spring balance on the shaft, Ø 34,8 mm) . . . . . . . . . . . 3---5 kg
--- thickness of shims for position adjustment (with increment of 0,1 mm) . . . . . . . . . . . . . . . . . 2,50---3,40 mm

Differential:
--- bearing pre ---load (measured with spring balance on the bevel pinion shaft, Ø 34,8 mm)
is bevel pinion shaft bearing preload+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---9 kg
--- tooth backlash, bevel pinion ---crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,17---0,23 mm
--- thickness of thrust washers for differential side gears (with increment of 0,1 mm ) . . . . . . . 1,45---1,55 mm
--- tooth backlash, differential pinions---differential side gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,13---0,18 mm
--- thickness of steel discs in differential lock (8 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,43---1,57 mm
--- thickness of friction discs in differential lock (7 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,24---2,36 mm
Others:
--- End float of central pivot bearing brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1---1,1 mm

Tightening torques
Hubs:
--- Hub cover (planet gear carrier) bolts (2 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
--- Planet gear fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
--- Ring gear support fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm
--- King pin covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Nm
--- Front wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm
--- Front wheel stud bolts to hub flange (threads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
--- Tie ---rod tapered joint to knuckle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Bevel pinion shaft:
--- Shaft nut is tightened until the bearing pre ---load is correct.
--- Bolts between bevel pinion shaft drive flange ---propeller shaft drive flange . . . . . . . . . . . . . . 70 Nm
--- drive flange attaching bolts on bevel pinion shaft (2 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Differential:
--- Differential bracket bolts to axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Nm
--- Bearing covers of differential bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Nm
--- Crown wheel fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
--- Locking nuts for differential bearing adjusting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm
Others:
--- Front axle central pivot bearing bracket to tractor frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm
--- Tie ---rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm
--- Tie --- rod ball joint locking nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm
--- Locking nut for steering angle limiting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
--- Bolts of steering cylinder end flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
--- Locking bolts for central pivot bearing brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
--- Steering cylinder hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

524
 Model Code Page
67. Powered front axle Carraro 95-- 115
670 3
1. 11. 2000 X100-- X120

Special tools
Ordering no. Description
ETV 893 490 Socket spanner for bevel pinion shaft nut (also Carraro 505---905)
ETV 894 460 Plate to fit hub cassette seal (new)
ETV 893 450 Tool to adjust bevel pinion shaft position, which incl.:
ETV 893 451, Measuring rod (1 pcs) (also Carraro 505---905)
ETV 893 452, Screw M10x100 (1 pcs) (also Carraro 505---905)
ETV 893 453, Compression plate (2 pcs) (also Carraro 505---905)
ETV 893 454, Nut M10 (1 pcs) (also Carraro 505---905)

Note! Various bearings and bearing races can be removed by using a drift and a suitable puller. Fitting can be done with
sleeves or plates of suitable dimensions. Bearings can be warmed or cooled according to the fitting. Drive shaft seals can be
fitted with plates or sleeves of correct dimensions. Some earlier ValtraValmet ETV ---sleeves and --- plates can be used when
repairing this axle.

ETV 893 490 ETV 894 460

ETV 893 452

ETV 893 451

ETV 893 454

ETV 893 453

ETV 893 450

525
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 670 4

Description
Carraro 20.29 axle replaces the earlier used Sige industrial Build ---up of Carraro axle is shown in pictures on the
front axle from week 32/99. The Carraro axle has as stan- following pages.
dard an electro---hydraulically controlled differential lock The maintenance intervals and oil qualities are the same
(HiLock), which functions simultaneously with the rear axle as in Sige ---axle. However, the grease nipples of the
lock. king pins are greased at intervals of 50 running hours/
weekly.
Earlier used front wheel discs cannot be used with this Car-
raro---axle, since the front wheel fixing studs are different.

Picture 1. Carraro front axle

1. Axle housing oil draining plug

2. Filling plug
3. Hub oil draining / filling plug
4. EP ---grease on splines

526
 Model Code Page
67. Powered front axle Carraro 95-- 115
670 5
1. 11. 2000 X100-- X120

Picture 2. Carraro front axle hub

1. Oil draining / filling plug

2. Mounting depth of hub cassette seal
3. King pin grease nipples (at intervals of 50 running hours / weekly)
4. Drive shaft

527
 Model Code Page
67. Powered front axle Carraro 95-- 115
670 6
1. 11. 2000 X100-- X120

Picture 3. Differential, Carraro front axle

1. Compression bushing

528
 Model Code Page
67. Powered front axle Carraro 20.29 95-- 115
670 7
1. 11. 2000 X100-- X120

IMPORTANT! Front axle steering cylinder has been

locked in the middle position with tubes on the
piston rods. The oil hoses are not connected to the
cylinder, since 95 ---X120 tractors have frame stee-
ring.

Picture 4. Steering cylinder

1. Piston rod and piston

1a. Piston seal + piston seal expander
1b. Wear rings
2. Cylinder liner
3. End flange
3a. Scraper
3b. Oil seal

529
 Model Code Page
67. Powered front axle Carraro 20.29 95-- 115
670 8
1. 11. 2000 X100-- X120

Picture 6. Front axle oscillation brake

530
 Model Code Page
67. Powered front axle Carraro 20.29 95-- 115
670 9
1. 11. 2000 X100-- X120

Picture 6. Front axle oscillation brake

1. Support cylinder
1a) Adjustable throttle
1b) Change ---over valve
1c) Suction valves
2. Lifting cylinder
3. Support cylinder
3a,b) Pressure and suction lines
3c) Lower support.
4. Sensitive pressure, lifting cylinder (piston side)
5. Breathing hose to the tank
6. Throttle adjusting screw
---When turning clockwise --- more stiffness)
--- Adjusting with max. 1/4 turns
7. Locking nut
8. Electrical locking valve for the support system

Automatic support of the front axle:

The oscillation of the front axle is automatically made stiff

during working, which stabilizes the tractor.The support
valve functions automatically. The basic adjustment has
been made already by the manufacturer.

Function:

If the tractor moves with loaded bucket, a free oscillation of

the front axle causes unsteadiness of the tractor (support
only on rear axle).

This is why an automatic support system has been devel-

oped. The system consists of support cylinders 3, a sup-
port valve 1 and cross---connected pressure / suction lines
3a and 3b.
However, the automatics don’t make the front axle totally
stiff, but front axle slowly gives in (about 2 degrees / sec.).

The pressure of the lifting cylinder 2 affects on the throttle

1a of the support valve. When the pressure of the lift cylin-
der is small, throttle is open and by inclining front axle oil
can flow free through the throttle. When the bucket is
loaded, the throttle functions and the oscillation movement
has been damped.

If e.g. the roughness of the ground causes pressure rise in

the support cylinder and line 3b, the pressure can get
through change ---over valve 1b and through adjustable
throttle 1a to the tank. By this way the pressure shock
caused by the roughness is damped and the swinging of
the load is prevented.
Through suction valve 1c can oil flow in place of the es-
caped oil to the other side of the pistons in the cylinders 3.

Adjustment:

The automatics has been adjusted right, when turning the

tractor on even ground with loaded bucket (beams in lower
position) the tractor seems to be steady, and the rear wheel
doesn’t rise.
The valve has to be adjusted carefully, because even a 1/4
turns have sufficient affect.

531
 Model Code Page
67. Powered front axle Carraro 20.29 95-- 115
670 10
1. 11. 2000 X100-- X120

Picture 5. Propeller shaft between front axle input shaft---main gearbox output shaft, see also page 410/11.

532
 Model Code Page
67. Powered front axle Carraro 95-- 115
671 1
1. 11. 2000 X100-- X120

Axle housing and attaching

brackets (Op. no. 671)
A. Removing front axle
1. Apply parking brake. Scotch the rear wheels. Discon-
nect, if necessary, battery cables.

2. Drain oil in hubs and axle housing (if necessary for re-
pair).

3. Remove the propeller shaft guard under the tractor. Dis-

connect the propeller shaft front end flange joint.

4. Disconnect oil hoses on the steering cylinder. Disconnect

the differential lock pressure oil pipe on the axle housing.
Raise the tractor front end and put axle stands under the
front frame. Remove front wheels when needed.
5. Slacken the locking bolt and remove the bearing sleeve.
Check sleeve for wear. Change if necessary. Tighten the lock-
5. Fasten lifting ropes to the axle on both sides of the en-
ing bolt.
gine.

6. Unbolt the central pivot bearing bracket bolts. Lower the

6. Check the V ---shaped seal ring on the axle. Change if
axle and remove it.
necessary.

B. Changing central pivot bearing

sleeves.
1. Apply parking brake. Scotch the rear wheels. Discon-
nect the battery cables.

2. Raise the tractor front end and put axle stands under the
tractor.

3. Support the axle so that the bearing brackets can be

unbolted.

7. Remove the rearmost bearing bracket on the axle.

4. Open the bearing bracket bolts. Lower the axle until the
guide sleeves release and remove first the foremost bearing
bracket.

8. Check the condition of the sleeves. Change when necess-

ary. Check also condition of the V ---shaped seal on the axle,
change when necessary.

533
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 671 2

C. Fitting front axle

1. Ensure that the bearing brackets are correctly positioned

on the axle and that their guide sleeves are in place.

2. Lift the axle into place and tighten the bearing brackets to
a torque of 380 Nm.

3. Connect the oil hoses to the steering cylinder. Connect

the differential lock pressure oil pipe. Connect the propeller
shaft front flange joint (70 Nm).

4. Fasten the front wheels, if removed (550 Nm). Remove

the axle stands under the tractor.

5. Fill the differential housing with oil (6 litres) and fill hubs
(2x1,5 litres), if drained (oil quality 80W/90 GL ---5 (LS), e.g.
9. Slacken the bearing sleeve locking bolt and remove the Valtra Axle).
sleeve. Change if needed. Check also condition of the o---
ring. 6. Grease the bearing bracket nipples with universal
grease.
10. Fit the bearing brackets on the axle. Ensure, that the
guide sleeves are in their places. Position the axle under the 7. Test---run the tractor and check that steering and front
tractor and tighten the bearing bracket bolts to 380 Nm. axle function properly. Check for leaks.

11. Grease the bearings sleeves with universal grease

(nipples).

12. Remove the axle stands under the tractor.

13. Test---run the tractor and check that axle functions are OK.

534
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 672 1

Hubs (Op. no. 672)

1. Reconditioning hubs

A. Changing planet gears/bearing rollers

1. Apply parking brake. Place wedges on the both sides of

the rear wheels. Disconnect the battery cables.

2. Raise the tractor front end and support it with sturdy axle
stands. Remove front wheel(s).

7. If the planet gears/bearing rollers must be changed, un-

screw bolts (B) and remove the thrust washers. Take care
of the locking pin (C), if it releases.

3. Turn the hub so that the oil draining/filling plug (3) is in

the rear position. Unscrew the plug and drain the oil into a
suitable vessel (1,5 litres oil in both hubs)

B
8. Remove the planet gears and washers under them.
Do not mix the planet gear bearing rollers. Change, if
necessary, the bearing rollers (28 pcs/gears).

Note! If the stud bolts must be changed, they cannot be

separately removed and changed but the whole planetary
carrier must be changed. The studs have press fits and
they must be pressed into place during fitting.

9. Fit the washer, bearing rollers and planet gears and fit
B the thrust washers and tighten the bolts to 80 Nm. Ensure
that the locking pins remain in their locations.

Note! The bearing rollers can be fastened with a little

4. Unscrew two hexagonal socket head bolts (A) in re-
grease when assembling them.
cesses. B is the hub large o---ring.
10. Check the hub large o---ring, change if necessary.
5. Tap with a soft mallet the planetary carrier (hub cover)
Grease the o---ring.
out and pry it out with two fitting levers.
11. Push the planetary carrier (hub cover) into place and
6. Fasten the planetary carrier e.g. in a vice.
tighten the two socket head bolts to 25 Nm

12. Fill the hub with 1,5 litres oil (80W/90 GL ---5 (LS), e.g.
Valtra Axle.

13. Fit the front wheel(s), remove the supports and test---run
the tractor. Check for leaks.

535
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 672 2

B. Changing hub cassette seal/wheel

bearings
1. Remove the planetary carrier (hub cover) as shown in
instr. 1A stages 1 ---5 on page 672/1.

5. Remove the hub flange with wheel bearings and the cas-
sette seal. Remove the outer wheel bearing.

2. Support the hub with a lifting rope. Remove the drive

shaft snap ring and thrust washers. Observe the positions
of the washers.

6. Remove the inner wheel bearing on the knuckle housing,

if damaged. Removing can be done with a drift and a puller.

3. Unscrew the ring gear support bolts (F). Screw in two

bolts into puller holes (G) and pull out the ring gears.

7. Prise out the hub cassette seal.

4. Remove the ring gear and its support.

536
 Model Code Page
67. Powered front axle Carraro 95-- 115
672 3
1. 11. 2000 X100-- X120

12. If you change the steel sleeves, prefit the sleeves into
8. Remove the wheel bearing outer races in the hub flange ring gear support so that two sleeves protrude some milli-
and fit new ones. Removing can be done e.g. with a drift metres to guide the ring gear support when fitting it.
and a hammer. When fitting new races, they can be cooled.

13. Fasten the ring gear onto support and secure it with the
9. Fit a new cassette seal with plate ETV 894 460. Grease snap ring.
the seal lips.
14. Press the hub flange into place so that the inner bearing
10. Fit a new inner tapered roller bearing on the knuckle outer race fits onto the roller bearing on the knuckle hous-
housing. The bearing can be warmed up to +80˚ C. ing.

15. Push the outer wheel bearing against its outer race in
the flange. The bearing can be warmed up to +80˚ C.

16. Place the ring gear onto the hub. Tap in all steel sleeves
to their boring. Fit and tighten the ring gear support bolts to
230 Nm.

11. Detach, when necessary, the ring gear by releasing

circlip (H) with a suitable pliers. Remove, when necessary,
steel sleeves (I) and fit new ones.

17. Refit the washers in a correct order and secure them

with the circlip.

537
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 672 4

18. Fit the planetary carrier (hub cover) and add oil into the
hub, see instr. 1 A stages 10---13 on page 672/1.

C. Changing king pin bearings

1. Remove the hub cover according to instr. 1A stages
1 ---5. Remove the drive shaft outer end circlip and the
washers.

Note! The above shown stage 1 is not necessary, since the

hub can be removed as a complete unit when the king pin
covers are removed. In this case the drive shaft comes out
with the hub. However, the drive shaft outer seal cannot be
changed.

5. Fasten the lower king pin in a vice and drive out the tap-
ered ring according to the picture above.
A
6. Remove the sleeve from the upper king pin in the same
way.

2. Disconnect the tie ---rod tapered joint from the steering

arm.

3. Support the hub/knuckle housing with a lifting rope and

unscrew the king pin upper and lower covers. Do not mix
the upper and lower tapered rings (different thickness and
shape).
7. Press with a hydraulic press a new tapered ring (lower
pin) and a new sleeve (upper pin) into place.

4. Remove the king pins and remove the nub. Take care of
the washers.

Note! If the drive shaft remains in the axle housing, do not 8. Pull out the lower king pin inner tapered ring and fit a
damage the drive shaft outer seal. If the drive shaft comes new one.
out together with the hub, do not damage the drive shaft
inner seal.

538
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 672 5

12. Support the hub with a lifting rope and push it onto the
9. Remove the upper pin sleeve after removing the tapered axle end and fit the washers and the king pins.
ring.
Note! Do not mix the upper and lower washers (different
thickness and shape). Do not damage the drive shaft outer
seal, if the drive shaft remained in the axle housing

10. Fit a new lower king pin outer bearing cup.

13. Tighten the king pin covers (190 Nm).

14. If you removed the hub cover and the circlip and the
washers at the end of the drive shaft, refit first the washers
and circlip (correct order) at the end of the drive shaft and
fit the planetary carrier (hub cover) as shown in instr. 1A
stages 10 ---13 on page 672/1.

15. Grease the king pin nipples with universal grease.

16. Connect the tie rod tapered joint (220 Nm).

11. Fit the upper pin bearing cup.

539
540
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 673 1

Drive shafts (Code no. 673)

1. Changing drive shaft oil seals / bear-

ing bushings

A. Changing inner seal/bearing bushing

Note! The drive shaft inner oil seal can be changed so that
first are removed the king pins and then the hub is pulled
out together with the drive shaft. In this case is unnecessary
to disassemble the hub.

1. Remove the front wheel. Disconnect the tie ---rod tapered

joint, support the hub with a lifting rope and remove the
king pins, see instr. 1 C stages 2 ---4 on page 672/4. 5. Tap in a new bushing with a suitable fitting tool. Grease
the bushing.
2. Pull out the hub/drive shaft. When necessary, drain the oil
in the axle housing.

1. Puller
2. Oil seal
6. Fit a new inner oil seal into the housing bore (lips turned
3. Prise out or pull out the inner oil seal. to the housing side). Grease the seal lips.

7. Push the hub/drive shaft into the housing. Do not dam-

1. Bushing age the inner oil seal with the drive shaft splines.
2. Puller
3. Impact puller
8. Fit the king pins/washers and tighten the pins to a torque
of 190 Nm. Connect the tie ---rod tapered joint to the steer-
ing arm (220 Nm).

9. Grease the king pin nipples.

10. Add oil into the axle housing, if drained (6 litres,

80W/90 API GL ---5 (LS), e.g. Valtra Axle).

11. Refit the front wheel. Test---run the tractor and ensure
that no leaks exist.

Drive shafts:
4. Check the condition of the drive shaft bearing bushing in Note! Check the condition of the drive shaft splines and the
the axle housing bore. Pull it out, if damaged, with a suit- double joints. The double joints can be disassembled in a
able puller. normal way concerning these joints, see e.g. instr. C on
page 642/3.

If the joints have been damaged, cross pieces, sleeves and

washers are available as a spare part.

541
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 673 2

B. Changing drive shaft outer oil seal /

bearing bushing

12. Drain oil in the hub, remove the planetary carrier (hub
cover), see instr. 1A stages 1 ---5 on page 672/1. When
necessary, drain oil in the axle housing.

16. Drive in a new bushing with a suitable tool.

13. Remove the drive shaft snap ring and the washers (note
the order of the washers).

17. Fit a new outer seal with a suitable tool.

18. Grease the bushing and the seal

19. Wrap a plastic foil round the drive shaft splines (sun
gear) and push the drive shaft into the hub. Remove the
plastic foil, fit the washers (observe order) and fit the snap
ring.
14. Support the hub with a lifting rope. Disconnect the tie ---
rod from the steering arm. Remove the king pins/washers 20. Push the hub/knuckle housing together with the drive
and pull out the hub. shaft into the axle housing (do not damage the drive shaft
inner oil seal).

21. Fit the washers/king pins and tighten the pins to a

1. Knuckle torque of 190 Nm. Reconnect the tie ---rod (220 Nm).
housing
2. Oil seal 22. Grease the king pin nipples.
3. Puller
23. Add oil into the axle housing, if drained (6 litres,
80W/90 API GL ---5 (LS), e.g. Valtra Axle).

24. Fasten the planetary carrier, see instr. 1A stages 10 ---13

on page 672/1.

25. Test---run the tractor and ensure that no leaks exist.

15. Prise out the drive shaft outer oil seal. Check the condi-
tion of the bearing bushing. Pull out the damaged bushing
with a suitable puller or knock it out with a suitable tool.

542
 Model Code Page
67. Powered front axle Carraro 95-- 115
674 1
1. 11. 2000 X100-- X120

Reconditioning differential/bevel B. Removing differential

pinion shaft (Code no. 674)
1. Drain the oil in the axle housing. Remove the steering ram
(see instr. A stages 675/1). Disconnect the diff. lock pressure
A. Changing bevel pinion shaft cassette oil hose.
seal.
2. Remove both hubs together with the drive shafts (see instr.
Note! The seal can be changed from under as follows: 1A stages 1 ---2 on page 673/1)

1. Drain oil in the axle housing.

2. Remove the propeller shaft guard under the tractor.

3. Disconnect the flange joint at the front end of the pro-

peller shaft and lower the shaft to the ground. Remove the
drive flange on the bevel pinion shaft splines.

3. Unscrew the differential bracket bolts (A) and take out the
differential/bevel pinion shaft. In the mating surfaces there are
dowels.

4. Prise out the damaged seal with a suitable lever. Remove

the o---ring, if fitted.

5. Put the o---ring into place and grease it and lips of a new
cassette seal. Fit the new cassette seal with a suitable fitting
tool. Do not damage the seal on the shaft splines.

6. Refit the drive flange onto the bevel pinion shaft (60 Nm).
Reconnect the flange joint (70 Nm). Refit the propeller shaft
guard. Add oil into the axle housing.

7. Test---run the tractor and check for leaks. 4. Place the differential unit in a suitable fitting base.

5. Unscrew bolts (A) and remove lock tabs (B).

543
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 674 2

6. Unscrew and remove the adjusting nuts. 9. Remove the differential unit together with its bearings
and remove oil distributor sleeve, o---ring and the intermedi-
ate ring.

7. Before removing the differential bearing caps, mark their

positions to make refitting easier.
10. Remove the differential bearings, when necessary.

C. Removing bevel pinion shaft:

8. Unscrew the bearing cap bolts (C) and remove the caps.

11. Remove the cassette seal by prising it out (note that the
seal is damaged when it is removed).

544
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 674 3

12. Remove the cassette sea and the o---ring (if fitted). 15. Knock out the shaft with a soft mallet. Take care of the
intermediate rings, compression bushing and the outer
bearing, which are released.

13. Unscrew the bevel pinion shaft nut with spanner ETV
893 490. Prevent shaft from rotating in a suitable way.
16. When necessary, drive out the shaft bearing outer races
in the differential bracket.

14. Remove the nut and the lock washer on the shaft.

17. Remove the inner tapered roller bearing on the shaft

and remove the spacer ring under the bearing.

Note! The chamfered side of the spacer ring must be

turned to the bevel pinion side.

545
 Model Code Page
67. Powered front axle Carraro 95-- 115
674 4
1. 11. 2000 X100-- X120

D. Disassembling differential

2 9
10
11
5
4 25
6
1 7
20

12
16 13
28 14 16
15 17
21
22
23
24
26
8
3 15
13
27
18
19

18. Unscrew bolts (27), at which time the crown wheel is E. Assembling differential
released and the differential housing is split.

19. Remove cover (12) and change o---ring (24). 25. Assembling is done in a reverse order.

20. Remove piston (22) and change o---rings (21) and (23). 26. Lock the differential pinions with pins (5). Fit the disc
pack and the differential side gears (disc pack contains 1
21. Remove the disc pack (9, 10, 11) (note the fitting order. thrust plate, 8 steel discs and friction discs. Steel discs
Steel discs have teeth on the outer circumference) and have teeth on the outer circumference).
check the condition of the discs. If the disc wear can be
found, change all discs at the same time. Thickness of the 27. Refit piston (22) and its o---rings (23) and (21), cover
discs, see page 670/2. (12) and o---ring (24).

22. Remove and check the condition of the differential pin- Note! The differential gears have thrust washers with differ-
ions. Before removing, remove tension pins (5). ent thickness, see technical data. In addition, the differential
gears have a certain tooth backlash, see technical data. If
Note! In connection with damages, change all parts under the thrust washers must be changed, the tooth backlash
pos. no. 25. must be checked with a dial gauge.

23. Check/change seals (23) and o---ring (27).

24. Check the housing wear. Small damages can be re-

paired with fine emery cloth.

546
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 674 5

F. Adjusting position of bevel pinion

shaft

31. Fit both bearing outer races into their locations in the
bracket. Cool, when necessary, the bearing races before
28. Place the crown wheel into place, apply Loctite 270 on fitting.
the bolts (1) and tighten them to 70 Nm.

ETV 893 453

ETV 893 452

ETV 893 454 ETV 893 453

29. Fit the differential bearings onto the housing. When 32. Fit the bevel pinion shaft bearings and fasten them with
necessary, warm the bearings up to +80˚C before fitting. the special tools (plates ETV 893 453 (2 pcs), ETV 893 454
nut M10 and ETV 893 452 screw M10x100) so that the
bearings rotate freely but without clearance. Rotate bear-
ings many times.

ETV 893 451

30. Fit the intermediate plate (25), protector (24) and seal
(23) (if removed). After this the differential can be fastened
onto the support. Observe the o---ring (27) and plate (26).

IMPORTANT! The intermediate plate (25) must be fitted so 33. Place the measuring rod ETV 893 451 on the differential
that the bent side is turned to the bearing side (see picture bearing bores in the middle of them in the lowest position.
on page 670/6).
Note! Bearing caps (in picture) can be removed.

547
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 674 6

ETV 893 451

D

B
36. Fit the correct spacer ring S (chamfered side to the
d bevel pinion side) and the bearing. When needed, warm

Y
the bearing to +80˚C before fitting.

G. Adjusting pre ---load of bevel pinion

D=90 mm shaft bearings
d=25 mm
37. Fit the thrust washer on the shaft, new compression
bushing and other thrust washer.
34. Measure distance Y according to the picture above. Y is
the distance from the bevel pinion shaft bearing surface to
the upper surface of the rod ETV 893 451 (e.g. 99,10 mm).
Place the vernier caliper through the groove in the rod.

34a. The sought measurement B (distance between the

bevel pinion shaft bearing surface to the middle of the dif-
ferential bearing locations) can be calculated as follows:

B = Y ---d+ D/2, e.g.:

B= 99,10 mm ---25 mm + 45 mm = 119,10 mm

116,10
38. Push the shaft into place and fit the other bearing onto
it, locking ring and screw in the shaft nut.

35. Read measurement V (e.g. 116,10) at the end of the

bevel pinion shaft.

Thickness of spacer ring between the bevel pinion and the

bearing can be calculated as follows:

S=B ---V, e.g.

S=119,10 mm---116,10 mm = 3.00 mm

Choice a correct spacer ring S. Available from 2,5 mm to

3,4 mm: (with increments of 0,1 mm).

39. Tighten progressively the nut with tool ETV 893 490
and measure now and then the bearing rolling resistance
with a spring balance. Always after tightening, rotate the
shaft many times.

548
 Model Code Page
67. Powered front axle Carraro 95-- 115
674 7
1. 11. 2000 X100-- X120

40. Wind a rope round the bevel pinion shaft (Ø 34,8 mm) 45. Refit the bearing caps according to the marks and
and connect a spring balance to the rope (shaft without the screw in the fixing bolts and tighten them but not too hard.
cassette seal).

41. Measure the rolling resistance P two, three times. Read

off the value, while the shaft is rotating. In the beginning
more power is needed.

The correct rolling resistance should be 30 N---50 N (3 ---5

kg)

42. Tighten the shaft nut, if necessary.

IMPORTANT! Take a note of the rolling resistance value,

since it is needed when adjusting the differential bearing
rolling resistance.

H. Fitting differential onto bracket 46. Screw the adjusting nuts into place in a suitable way.

I. Adjusting tooth backlash and differen-

tial bearing pre ---load:

43. Fit the o---ring (27) and the washer (26) into the differen-
tial.
47. Place the dial gauge (1) stylus against the crown wheel
Note! Grease the parts to keep them in place during fitting. tooth (measure at least on three teeth). Adjust the tooth
backlash by slackening (if too small backlash) or by
44. Position the differential onto the bracket. Do not move tightening (if too big backlash) the adjusting nut (3) (i.e. by
parts (26) and (27). Ensure, that the bearing outer races moving the differential axially so that the bearing clearance
are in places fully home. is kept as zero or slightly pre ---loaded).

The backlash must be between 0,17 ---0,23 mm.

549
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 674 8

48. When the tooth backlash is correct, ensure that the ad-
justing nuts keep the differential bearings without clearance
or slightly pre ---loaded. If the nuts must further be tightened
(when adjusting preload), the differential must not move
axially.

52. The teeth contact surface can be checked (if necessary)

by using marking colour. The picture above shows the cor-
rect colour spread pattern on the teeth.

49. Wind the spring balance rope round the bevel pinion J. Fitting differential into axle housing
shaft (Ø 34,8 mm).

50. Measure the common rolling resistance of the differen-

tial bearings and the bevel pinion shaft bearings (T) two
three times. Read off the value when the shaft is rotating. In
the beginning more power is required.

The correct value (T), is:

T = (P+60 N)...(P+90 N) i.e. (P+6 kg)... (P+9 kg)

In which:

T= common rolling resistance of the differential bearings

and the bevel pinion shaft bearings
P= rolling resistance of the bevel pinion shaft bearings
(measured earlier))
6 kg ---9 kg (60---90 N) =differential bearing allowable roll-
ing resistance.
53. Tighten the differential bearing caps to a correct torque
51. If the value is not within the given limits, tighten the dif- (270 Nm)
ferential bearing adjusting nut (if resistance is too small)
and vice versa. Always after tightening the nut, rotate the
differential many times.

IMPORTANT! Do not affect the tooth backlash when

tightening the adjusting nuts. After the rolling resistance
adjustment, check once more the tooth backlash.

54. Refit the locking tabs. Turn the nuts, if necessary, so that
the tabs fit into the notches on the nuts. Tighten the screws
to 13 Nm.

550
 Model Code Page
67. Powered front axle Carraro 95-- 115
1. 11. 2000 X100-- X120 674 9

55. Lock the bevel pinion shaft nut with the locking washer.

56. Fit the o---ring (if any), grease and fit the cassette seal
with a suitable sleeve. Do not damage the seal on the shaft
splines.

57. Clean the mating surfaces on the axle housing and on

the differential bracket. Apply Loctite 510 or alt. Loctite 518
and push the differential into the axle housing. There are
dowels in the joint.

58. Tighten progressively the bracket fixing bolts to 170

Nm. Reconnect the diff. lock hose.

59. Fit the bevel pinion shaft drive flange (fixed with two
bolts). Connect the propeller shaft front flange joint (70
Nm).

60. Fit the steering ram, see instr. A on page 675/1.

61. Fit the bottom guard.

62. Fasten the hubs/drive shafts, see instr. 1C stages

12 ---16 on page 672/5.

63. Add oil into the axle housing (6 litres. 80W/90 GL ---5
(LS), e.g. Valtra Axle).

64. Test---run the tractor and check the function of the front
axle and differential lock. Check for leaks and test the steer-
ing system.

551
552
 71. Frame
70. Frame and wheels

72. Wheels

553
554
 Model Code Page
70. Frame and wheels 95-- 115
1. 11. 2000 X100-- X120 710 1

Dimensional drawing for tractor frame

(Hi)

(105---X120)
(95)

555
 Model Code Page
70. Frame and wheels 95-- 115
1. 11. 2000 X100-- X120 710 2

Middle frame with joint

2x

Splitting the middle frame at the joint

Note! First must be disconnected all connectors and hydraulic oil hoses and possible cables which prevent the splitting. Also
fuel lines must be disconnected where necessary. Note that in oil hoses there can be pressurised oil.

--- the front axle oscillation must be prevented with wedges or with ET 893 480
--- support the middle frame under the both sides of the joint (preferably with an axle stands, which have height adjustment).
--- check the position of the front and rear parts of the tractor so that no tensions exist and the joint pins can easily be knocked
out.
--- lift the cab or remove it so that the upper joint pin can be removed upwards.
--- the transmission shaft flange joints in the rear frame side must be released.
--- if the tractor has a front loader, it is not necessary to remove it but it must be lowered and supported so that no risk of accident
exsists.

556
 Model Code Page
70. Frame and wheels 95-- 115
1. 11. 2000 X100-- X120 710 3

Tightening torques for frame joints

Clutch assembly 23 Nm
Drive plate 45 Nm 80 Nm

300 Nm (M16)

PTO upper studs 300Nm (8 pcs)

125 Nm (M12)
DPS, 23Nm PTO lower studs
80Nm (6 pcs)
380 Nm M16: 220 Nm

Shuttle housing, 23 Nm
150 Nm (12.9), 6 pcs
Engine bolts:
30 Nm (M8)
90 Nm (M10) 70 Nm (M10)
110 Nm (8.8), 140 Nm (12.9) (M12) 125 Nm (M12)

300 Nm

557
558
 Model Code Page
70. Frame and wheels 95-- 115 720 1
1. 11. 2000

1. Tyres and track widths, 95---115

Alternative tyre equipment (in pairs)

Rear Front 95 105, 115

18.4---34/8 14.9---24/8 X
18.4---34/14 FOR 14.9---24/14 FOR X
18.4---38/14 FOR 14.9---28/14 FOR X
16.9---34/14 IND 13.6---24/12 IND X
18.4---38/14 IND 16.9---24/14 IND X
18.4R38/8 14.9R28/8 X
18.4---38/14 FOR 14.9---28/14 FOR X
18.4---34/14 IND 14.9---24/14 IND X
20.8---38/14 FOR 16.9---28/14 FOR X
Always contact your dealer to ensure the right ratio is used. When track widths are adjusted or larger tyres fitted, the
turning angles have to be checked/adjusted with max oscillation angle of front axle on both sides.

Tyre pressures

Rear axle Front axle

Tyre Max loading per tyre Pressure Tyre Max loading per tyre Pressure
18.4---34/8 2565 kg 140 kPa 14.9---24/8 1760 kg 180 kPa
18.4R38/8 3000 kg 160 kPa 14.9R28/8 1800 kg 160 kPa
16.9---34/14 IND 3935 kg 290 kPa 13.6---24/12 IND 2585 kg 330 kPa
18.4---34/14 IND 4850 kg 290 kPa 14.9---24/14 IND 3090 kg 330 kPa
18.4---34/14 FOR 2985 kg 260 kPa 14.9---24/14 FOR 1900 kg 300 kPa
18.4---38/14 FOR 3110 kg 260 kPa 14.9---28/14 FOR 2024 kg 300 kPa
18.4---38/14 IND 5055 kg 290 kPa 16.9---24/14 IND 3530 kg 300 kPa
20.8---38/14 FOR 4340 kg 230 kPa 16.9---28/14 FOR 3120 kg 270 kPa
When using twin ---mounted wheels the loading on these two wheels together can be multiplied by 1.76 of the permissible
loading on one wheel.

Track widths
Measured between middle of tyres
Rear Track width Front industrial axle Track width
16.9 - 34/14 IND,
16.9- 14.9R28, 14.9-- 28/14 FOR 1788, 1812
1740 1790
1740,
18.4-- 34/14 IND 14.9-- 24/14 IND, 16.9-- 24/14 IND 1760, 1836
18.4-- 34/14 FOR 1650, 1880 16.9-- 28/14 FOR 1718, 1882
18.4-- 38/14 FOR, 18.4R38
18.4-- 38/14 IND, 20.8R38, 1650, 1875
20.8-- 38/14 FOR
The standard track widths are underlined. When track widths are adjusted or larger tyres fitted, the turning angles have
to be checked/adjusted with max oscillation angle of front axle on both sides. Check also when using chains that the
distance from the cab to the tyres does not go under 80 mm. Check further that the distance from parking lights to
the outer sides of the tyres does not exceed 400 mm.
At the rear, the distance between the mudguards is 1020 mm.

559
 Model Code Page
70. Frame and wheels X100-- X120 720 2
1. 11. 2000

2. Tyres and track widths, X100---X120

Alternative tyre equipment (in pairs)

Rear Front X100- X120
18.4R38 14.9R28 X
520/70R38 420/70R28 X
20.8R38 16.9R28 1) X
580/70R38 480/70R28 X
600/65R38 480/65R28 X
650/65R38 540/65R28 X
16.9R34 IND 14.9R24 IND X
18.4R34 IND 14.9R24 IND X
18.4-- 38 IND 16.9-- 24 IND X
1)
20.8R38 IND 16.9R28 IND X
18.4-- 34 FOR 14.9-- 24/14 FOR X
18.4-- 38 FOR 14.9-- 28/14 FOR X
20.8-- 38 FOR 16.9-- 28/14 FOR X
1)
600/65R38 FOR 500/65R28 FOR X
23.1-- 34 FOR 16.9-- 28 FOR X
1) Wide rear mudguards
Fixed discs
Always contact your dealer to ensure the right ratio is used. When track widths are adjusted or larger tyres fitted, the
turning angles have to be checked/adjusted with max oscillation angle of front axle on both sides.

Tyre pressures
Rear axle Front axle
Tyre Max loading per tyre Pressure Tyre Max loading per tyre Pressure
18.4R38 3000 kg 160 kPa 14.9R28 1800 kg 160 kPa
3875 kg 160 kPa 2060 kg 160 kPa
520/70R38 420/70R28
2185 kg 60 kPa 1160 kg 60 kPa
20,8R38 3650 kg 160 kPa 16.9R28 2240 kg 160 kPa
3875 kg 120 kPa 2500 kg 160 kPa
580/70R38 480/70R28
2185 kg 60 kPa 1410 kg 60 kPa
3075 kg 160 kPa 1850 kg 160 kPa
600/65R38 480/65R28
2150 kg 70 kPa 1300 kg 70 kPa
3350 kg 120 kPa 2070 kg 120 kPa
650/65R38 540/65R28
2510 kg 60 kPa 1540 kg 60 kPa
16.9R34 IND 3925 kg 290 kPa 14.9R24 IND 3090 kg 330 kPa
18.4R34 IND 4850 kg 290 kPa 14.9R24 IND 3090 kg 330 kPa
18.4---38 IND 5055 kg 290 kPa 16.9---24 IND 3530 kg 300 kPa
20.8R38 IND 5640 kg 260 kPa 16.9R28 IND 3765 kg 300 kPa
18.4---34 FOR 3985 kg 260 kPa 14.9---24/14 FOR 2024 kg 300 kPa
18.4---38 FOR 3110 kg 260 kPa 14.9---28/14 FOR 2500 kg 300 kPa
20.8---38 FOR 4340 kg 230 kPa 16.9---28/14 FOR 3120 kg 270 kPa
600/65R38 FOR 4375 kg 240 kPa 500/65R28 FOR 2800 kg 240 kPa
23.1---34 FOR 4470 kg 330 kPa 16.9---28 FOR 2900 kg 270 kPa
When using twin ---mounted wheels note the following:
--- the loading on these two wheels together can be multiplied by 1.76 of the permissible loading on one wheel.
--- using twin ---mounted wheels is for decreasing the surface pressure, not for getting better side support
--- please do not exceed tyre/tire size stated for the model in table J 3. when using dual/extension wheels
--- the track width of the inner wheels has to be adjusted to minimum value.

560
 Model Code Page
70. Frame and wheels 95-- 115
1. 11. 2000 X100-- X120 720 3

Track widths, X100---X120

Rear Track width (mm) Front, Industrial axle Track width (mm)
420/70R28, 480/65R28, 480/70R28, 1530, 1625, 1730, 1830,
1610, 1715, 1810, 1915, 540/65R28 1930, 2025, 2130, 2230
520/70R38 580/70R38,
520/70R38, 580/70R38
2010, 2115 14.9-- 24/14 FOR,14.9R24 IND,
1840, 1915
16.9-- 24/14 IND
1715, 1810, 1915, 2010,
600/65R38, 650/65R38 14.9R28, 16.9R28, 16.9R28/14 IND,
2115
14 9 - 28/14 FOR,
14.9- FOR 16
16.9-
9 - 28/14 FOR,
FOR 1870 1890
1870,
16.9R34 IND, 18.4R34 IND 1740, 1790
500/65R28 FOR
18.4-- 34 FOR 1650, 1880

18.4R38,
18 4R38 18.4-
18 4 - 38/14 FOR,
FOR
18 4 - 38/14 IND,
18.4- IND 2020.8R38,
8R38
1650, 1875
20 8 - 38/14 FOR,
20.8- FOR 20.8R38
20 8R38 IND,
IND
600/65R38 FOR

23.1-- 34 FOR 1865, 1895

Measured between middle of tyres.

The standard track widths are underlined. When track widths are adjusted or larger tyres fitted, the turning angles have
to be checked/adjusted with max oscillation angle of front axle on both sides. Check also when using chains that the
distance from the cab to the tyres does not go under 80 mm. Check further that the distance from parking lights to
the outer sides of the tyres does not exceed 400 mm.

Fixed discs
At the rear, the distance between the mudguards is 1020 mm.
When using the narrow track widths of rear axle, check that the lower links don’t touch the tyres/tires. When needed lock the
side regulators.

Wheel nuts tightening torque, 95---X120

--- Wheel nuts, front 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm

rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 Nm
--- Rim ---wheel disc (front and rear) . . . . . . . . . . . . . . . . . . 310 Nm

561
562
 81 Cabin
80. Cab and shields

82. Shields

83. Air conditioning

563
564
 Model Code Page
95-- 115
80. Cab and shields X100-- X120 810 1
1. 11. 2000

Contents

General (Op. no. 810)

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cab, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Instruments and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cabin heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Repair instructions (Op. no. 811)

1. Removing and fitting cabin:
A. Removing cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Glueing cab windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

565
 Model Code Page
80. Cab and shields 95-- 115
1. 11. 2000 X100-- X120 810 2

Locally prepared tools

ET 894 110 Tool for lifting the cabin

ET 894 110

566
 Model Code Page
80. Cab and shields 95-- 115
810 3
1. 11. 2000 X100-- X120

Cab, general

A
A

B---B A---A
3 4
6

1. Sound ---insulating shield.

2. Access hole (on the RH side mudguard). On the cabin floor there is also an access hole.
3. Floor mat: rubber or polyurethane.
4. Insulating material: foam rubber s=15mm (protected with polyurethane film).
5. The windscreen and door windows have been glued onto the cab frame in the beginning of the tractor production. Later the
glasses have been fastened with butyl rubber and plastic fasteners.
6. The hoses for the air conditioner (optional equipment) are located in the LH side front corner pillar (in the right side there are
the hoses for the cab heater).

567
 Model Code Page
80. Cab and shields 95-- 115 810 4
1. 11. 2000

Instruments and controls

Instrument panel and pedals, 95---115

13 11
17 12

18
16
15 20

14
19
6
21
7

9
8
10

1 4

5
2 6181--- 24

1.Clutch pedal
2.Brake pedals 9.Ignition switch
3.Latch for brake pedals 10. Stop control
4.Accelerator pedal 11.Rev. counter and hour recorder
5.Lock for steering wheel inclination 12.Coolant thermometer
6.Steering wheel 13.Fuel gauge
7.Lever for adjusting steering wheel height 14.Light switch
8.Control for: 15 .Hazard warning flasher switch
--- main/dipped headlights 16.Switch, rear working lights
--- direction indicators 17.Switch, front working lights
--- horn 18.Indicator lights on instrument panel
--- windscreen wiper 19. Places for switches for optional equipment
--- windscreen washer 20. Switch for rotating warnng lights
--- headlight flasher 21. Switch for upper head lights

568
 Model Code Page
80. Cab and shields X100-- X120 810 5
1. 10. 1999

Dashboard on HiTech models

11 9 10
17 5
4

15 16
14
13
7
12

3 6

2
1 68d 1

7. Toggle switch, raised headlights

Shuttle/parking brake lever (3. ) and combination control 8. Ignition switch
(6. ) can be fitted also on the other side of the steering 9. Rev counter/hour recorder/lower link position
wheel. AD ---instrument, see code 331
1. Steering wheel 10. Engine temperature gauge
2. Locking lever, steering wheel height 11. Fuel gauge
3. Shuttle lever/parking brake lever 12. Light switch
4. Delta Power Shift pre ---programming button for driving 13. Switch for hazard warning flashers
direction change 14. Switch, rear working lights
5. Display for transmission functions 15. Switch, front working lights
6. Combination control: 16. Warning ligh panel, see the next page
--- high/dipped beams 17. Switch for rotating warning light
--- direction indicator flashers
--- horn
--- windscreen wiper
--- windscreen washer
--- high beam flash

569
 Model Code Page
80. Cab and shields 95-- 115
1. 11. 2000 X100-- X120 810 6

Indicator and warning lights, 95---X120

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 18 19 20 21 22
50--- 12,1

1.Direction indicator warning light for second trailer (green) 16. Battery charging (red)
18. Gearbox oil temperature (red)
2.Direction indicator warning light for first trailer (green)
19. DPS indicator light
3.Tractor direction indicator warning light (green)
20. Differential lock (yellow)
4.Air cleaner warning light (yellow)
21. DPS ind. light
5.Engine oil pressure (red)
22. DPS ind. light.
6.Engine Stop --- (red)
7.Gearbox oil pressure (red)
The central warning (STOP) lamp is actuated by::
8.Blocked working hydraulics pressure filter, red (option)
--- engine oil pressure
9.Front wheel drive (yellow)
--- gearbox oil pressure
10. Power take ---off (yellow). --- gearbox oil temperature
11. Parking brake (red)
--- engine coolant temperature
12. Thermostart --- glow (yellow)
13.Not used (yellow)
14.Main beams (blue) If the central warning light (stop) comes on when the tractor
has been driven the engine must be stopped immediately
15. Low fuel level (yellow)
and the fault must be repaired before continuing again.

Note! If the STOP---light comes on alone, and engine tem-

Rev. counter and hour recorder perature is not too high, the fault lies in the engine tempera-
ture sensor, which should be changed (temperature gauge
shows, however, a correct value). In this case, the STOP---
light goes temporarily out, when you disconnect the sensor
wire.

The rev. counter shows the engine speed in hundreds of revol- When the lift/lower switch is in the lower position, the display
utions per minute. The revolutions which correspond to the shows the position of the lower links on a scale 0---100
nominal revolutions of PTO are also marked on the rev. (50=middle position).
counter.
Note! The letters Ac after the number mean Autocontrol.
The digital hour recorder shows the total number of hours
worked, when the lift/lower switch of the power lift is in the lift-
ing position.
AD ---instrument, see code 331.

570
 Model Code Page
80. Cab and shields 95-- 115
810 7
1. 11. 2000 X100-- X120

Control on RH side in cab

26
16 17 19
15

6 18
12

5
3 7
27
29
4 10
8

2 22 31 20
4

23
2
28
1
21 25
2.a
9

11
13 14 24
6000A--- 18,6
30

19. Oscillation damper (DBC) switch.

1. Speed gear lever 20. Ind. light, oscillation damper
2. Delta Power Shift push buttons 21. Forced lowering switch
2a.Switch for DPS when driving backwards 22 Switch for AD ---instrument, if fitted
3. Range gear lever 23. Power lift lift/lower rocker switch (correcponding yellow
4. HiShift button push buttons on both rear mudguards.
5. 4WD rocker switch 24 Control levers, auxiliary hydraulics
6. Delta Power Shift Auto/Man switch (HiTech only) 25 Pick ---up hitch release control (option)
7. Diff. lock switch (three positions) 26 Side window opening handle
8. AutoTraction switch (HiTech only) 27. Place for remote controller
9 PTO control lever 28 Rear window wiper+washer (option)
10.PTO rocker switch (3 positions), PTO push buttons on 29 Cigarette lighter (also current socket)
rear mudguard as an option 30 3---pin current socket
11. Hand throttle 31. Hydraulic lock for bucket (front loader models)
12. Diagnosis light (indicated possible faults in power lift)
13 Position control potentiometer
14 Power lift lift/stop/lower switch (Autocontro switch)
15. Draft control selector
16 Lowering speed selector
17 Transport heigth selector
18 Ind. light, lift/lower

571
 Model Code Page
80. Cab and shields 95-- 115
810 8
1. 11. 2000 X100-- X120

Driver’s seat (standard)

12

11

10

7
2

6
6

5
3

4 4A

1. Lock for adjustment for forwards/rearwards

2. Adjustment forward/rearward
3. Lock for turning seat
4. Suspension
4. A. Weight decal
5. Lock for longitudinal suspension
6. Height adjustment, by lifting the seat
7. Seat belt anchor point
8. Seat back inclination
9. Arm rest adjustment
10. Seat heating
11. Place for books
12. Head support height adjustment and removing

572
 Model Code Page
80. Cab and shields 95-- 115
1. 11. 2000 X100-- X120 810 9

Ventilation and heating system

1. Air intake.
2. Cab air filter (cleaning at every 250 running hours). When the grille is closed (the knob on the RH side) it is
3. Heater radiator. The radiator has been made wider in achieved:
connection with modifications. --- Better removal of moisture and prevention of icing
4. Recirculation valve --- Greater pressurisation of the cab (reduced dust ingress)

In the front part of the roof panel there is a steplessly adjus- 5. Warm air into cab (nozzles can be turned 360˚)
table air recirculation grille. When opening the grille, the 6. From floor heater fan
outdoor air intake passage is closed at the same time (the 7. Overpressure valve
passage is reduced to about 15 %). 8. Heater control knob
When the grille is open (fully open when the knob is in the 9. Roof fan (3---speed).
extreme position on the LH side) it is achieved: 10. Floor heater fan switch (2---speed with effect from cab
--- Faster cab heating. no. 2347).
--- Greater heating capacity. 11. Pre ---filter is accessible after removing the grille. Wash
--- Greater cooling effect if the air conditioner is fitted. the filter when necessary.

573
574
 Model Code Page
95-- 115
80. Cab and shields X100-- X120 811 1
1. 11. 2000

2. Glueing cab windows

3. Changing rear window
The cab front windows and the door windows have been fas-
tened with sealing compound (butyl) and plastic fasteners. In 1. Remove the damaged rear window.
connection with possible repair work the windows are fitted as
follows: 2. Check that the handle fits correctly against the window.
Bend the handle, if needed, so that holes on the handle
1. Clean the window contact surfaces from remaining sealant and the window are against each other. Check also that the
and glass. Remove possible grease spots with suitable sol- handle fastening flanges are parallel with the glass surface.
vent. Fasten the handle and note the mounting order of the
fastening parts.
2. Before fastening the window, check that it fits into place.
Ensure that there are not unevenesses on the contact surface 3. Fit the window seal. Fit the window. Bend the hinges, if
(e.g. welding splashes etc). necessary, so that the window fits correctly in position.

3. Place butyl rubber band KH 3708 onto the window contact 4. Adjust counter piece 31607100 so that the glass closes
surface on the door or on the cab frame. with power of 15 kp which corresponds the seal compres-
sion of 2---4 mm in the middle of the seal in the lower edge.
4. Position the window in place and fasten it with the plastic If there is not enough adjusting space, new M6 holes have
fasteners. Check that the glass is in the middle of the opening. to be drilled for counter piece screws HD 9153. Alternatively
sheet iron screws HN 6646 can be used.
5. Varnish the butyl band with protective lacquer UF 3274 so
that dust does not fasten on the sealant (not necessary if the
tractor is not used in dusty conditions immediately after fitting
the windows).

Note! Since in very warm conditions the side exhaust pipe

can raise windscreen temperature near the max. allowable
temperature of the butyl band (+80˚C), the butyl band raw
material has been changed. Temperature resistance of the
new material is +100˚C. In addition, the side movement of
the windscreen has been prevented by filling the space
between the windscreen upper part and the frame with sili-
cone mass.

Order numbers:

--- Butyl band (Ø 8 mm, 6 m, 80˚C): KH3708

--- Butyl band (Ø 10 mm, 6 m, 100˚C): KH6343
--- Silicone (300 ml): UK0067
--- Silicone (80 ml): UK0068
--- Cleaner (250 ml): 32637300

575
576
 Model Code Page
95-- 115
83. Air conditioner X100-- X120 830 1
1. 11. 2000

Contents
Air conditioner (Op no 830):
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance, fault tracing, repairs (Op no 831):

--- Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
--- Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
--- Drier container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Fault tracing without special equipment:
A. Correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Refrigerant filling and moisture in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. Fault tracing with pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. Important information on air conditioner repairs and spare part storage . . . . . . . . . . . . . . . . 8

4. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5. Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

577
 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 830 2

Technical data
Air conditioner:
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134a (SUVA)
--- refrigerant filling in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,4 kg

Compressor Diesel Kiki DKS 15 CH:

--- Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 pcs
--- Cyl diam x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 34 mm x 24 mm
--- Max revs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 r/min
--- Lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZXL 100 PG (DH ---PS)
--- Lubricating oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 cm3 (2,0 dl)
Electro---magnetic clutch:
--- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V (DC)
--- starting torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
--- power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 W (max)
--- clutch clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3---0,6 mm
Drier:
Pressure switch switches off at max pressure, R12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,55±0,2 MPa
Pressure switch switches off at max pressure, R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,40±0,2 MPa
--- switches on again when pressure drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,57±0,2 MPa
Pressure switch switches off at min pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190±20 kPa
--- switches on again when pressure rises up to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200±30 kPa
Thermostatic switch:
--- switch off when evaporator temperature is below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +2...+3 ˚C
--- switch on when evaporator temperature has risen up to (max cooling effect) . . . . . . . . . . . . +6...+7 ˚C
--- switch on when evaporator temperature has risen up to (min cooling effect) . . . . . . . . . . . . about +19 ˚C
High and low pressures at engine revs 1500 r/min between temperatures +20...+25 ˚C:
--- low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50---300 kPa
--- high pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700---1400 kPa

578
 Model Code Page
83. Air conditioner 95-- 115
830 3
1. 11. 2000 X100-- X120

Operating principle The air conditioner functions so that the refrigerant is

continuously circulated in the system at which time it
An air conditioner takes heat from the cab air when outdoor changes from liquid form into gaseous form. This pro-
temperature is high. Refrigerant in the system is exposed cess absorbs heat from the cab when the refrigerant
under different pressures and temperatures and this causes vaporises in the evaporator and emits heat to outdoors
a cooling effect. Refrigerant vaporizes in the evaporator when refrigerant becomes condensed in the condenser.
and evaporation absorbs heat which is taken from the
warm cab air which is blown through the evaporator. Although the process has four parts, it can be divided
into two main parts: high pressure side and low pressure
side according to the figure below.

Low pressure side High pressure side

Expansion valve

Drier

Heat is trans- Heat is trans-

ferred from ferred from
cab to refrige- Evaporator refrigerant to
rant Condenser outdoors

Compressor

Figure 1. Operating principle of air conditioner

579
 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 830 4

Evaporator
High pressure gas

High pressure liquid

Low pressure liquid

Low pressure gas

Expan-
sion
Compressor valve

Condenser Drier

Circulation of the refrigerant begins from the compressor. When the air conditioner is operating the low pressure
The compressor sucks low pressure gas from the evapor- hoses are cold and high pressure hoses are warm.
ator and compresses high pressure gas into the con-
denser. In the condenser gaseous refrigerant becomes Liquid refrigerant from the condenser is filtered and dried in
condensed and emits heat to outdoors. From the con- the drier container. The drier also prevents gaseous freon
denser high pressure liquid flows via a drier to the expan- from entering into the expansion valve. In the drier con-
sion valve in which a part of the liquid vaporizes and the tainer there is a pressure switch which switches off current
refrigerant cools and its pressure drops. Liquid flows from to the compressor if pressure in the high pressure circuit
the expansion valve into the evaporator where cab heat rises too high or becomes too low:
changes liquid into gas. This low pressure gas then flows
into the compressor suction side from where a new circula-
tion begins. The drier has two inspection glasses through which can be
checked the refrigerant filling and moisture in the system
Max. cooling effect corresponds to the situation when the (see page 831/2).
compressor works all the time. In order to achieve a certain
cooling effect, the compressor has to keep a certain pres-
sure in the evaporator outlet side.

An evaporation temperature of f the R134 is ---26˚C. When

pressure increases the evaporation temperature rises and
vice versa.

580
 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 830 5

Figure 3. Air conditioner on 95---X120 tractors

Wiring diagram:
1. Condenser F21 = Air conditioner fuse
2. Compressor F15 = Fan fuse
3. Drier S3 = Fan switch
A=Inspection glass S8 = Temperature switch
B=Moisture indicator S19 = Pressure switch
C. Cooling effect selector Y5 = Electromagnetic clutch
4. Expansion valve M2 = Fan
5. Evaporator K6 = Relay, max speed III of fan
6. Temperature switch
7. Re ---circulation nozzles
8. Air inlet into cab
9. There are valves in the outlet pipes for condensing water.
The valves prevent air from entering into the evaporator
housing. Water becomes condensed in the housing when
the warm cab air flows through the cold evaporator.

Compressor (2) is driven by an extra belt pulley at the front Temperature switch sensor (6) (capillary tube) is pushed
end of the crankshaft. The compressor belt pulley is fitted between the evaporator fins and it senses evaporator tem-
with an electromagnetic clutch, which switches the com- perature in its coldest place. The sensor switches off the
pressor off and on according to the required cooling effect. compressor when the evaporator temperature drops below
The compressor is shown on page 831/9. +2...+3˚C (prevents icing on the evaporator), and switches
on again when the evaporator temperature has risen over
The expansion valve (4) regulates the amount of refrigerant +6...+7˚C (or up to +19˚C when the temperature switch
in the evaporator (5) so that the refrigerant vaporizes in the is in min position).
best possible way. The expansion valve lets only as much
refrigerant flow into the evaporator as the evaporator can
vaporize. The expansion valve is shown on the next page.

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 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 830 6

Expansion valve

5
1
Figure 5. Expansion valve

2 1. Expansion valve
2. Hose from condenser
3. Inlet pipe to evaporator
4. Outlet pipe from evaporator
5. Hose to compressor suction side

Temperature sensor

Diaphragm
When the compressor starts pressure drops in the evap-
orator and the diaphragm pushes the pin downwards and
the ball opens. Refrigerant can now flow via the spring
housing into the evaporator

When the temperature in the evaporator outlet pipe

From evaporator lowers, the temperature sensor pulls the diaphragm
upwards and the valve ball closes preventing refrigerant
from flowing into the evaporator.
To compressor
In this way the expansion valve regulates all the time the
amount of refrigerant in the evaporator.

On the later air conditioner, the expansion valve functions

in a similar way.
To evaporator
Note! The expansion valve and the metal pipes have
From condenser been covered with insulating mass 30794000.

582
 Model Code Page
95-- 115
83. Air conditioner X100-- X120 831 1
1. 11. 2000

Maintenance
Maintenance, fault tracing and --- Before switching on the air conditioner, ensure that win-
repairs dows and doors are properly closed. If for any reason the
cab cannot be completely closed, the air recycling system
must be switched off. If these recommendations are not
Safety precautions observed, there is a risk of blockage at the evaporator and
risk of damage to the compressor.
Important! If the air conditioner system must be opened, --- Check externally the drier, condenser and hoses (if the
this work must be done by an expert who knows refrigerat- evaporator or expansion valve for any reason should be
ing systems. checked, the cab roof and the evaporator housing cover
must be removed). All impurities (and ice on evaporator)
--- The pressure of the refrigerant is always greater than its cause malfunctions. Check also occasionally the tightness
normal boiling point. If piping is split, the refrigerant will of the compressor belts.
evaporate or boil very rapidly.
--- Check regularly through the drier inspection glasses
---Uncontrolled escape of refrigerant must be avoided. The moisture and refrigerant filling in the system (see next
refrigerant R134a is non ---flammable, non ---toxic (except page).
when in contact with a flame) and non ---corrosive (except in
contact with water). --- Always when the system has leaked and it has been
opened and specially if brown or yellow colour can be seen
--- Never attempt to empty the system by loosening a con- in the drier inspection glass or if the moisture indicator has
nection. Slow emptying without danger can only be carried changed its colour, the drier should be changed.
out using a manifold gauge set.
--- From the bottom of the evaporator housing there are
--- You should be very careful when handling refrigerant. It drawn three drain hoses through which the condensing
can freeze the skin or the eyes on direct contact. Never water flows away from the housing. This prevents icing on
handle refrigerant without wearing safety goggles, as well the evaporator.
as gloves.
--- In order to keep the system in good condition, we rec-
--- Do not empty the system in a room where there is a ommend to operate the system for several minutes each
flame. Refrigerant R134a and open flame form poisonous month in order to lubricate all the components, since the
and stimulating compounds (e.g. hydrofluoric acid) compressor oil can get mixed with the refrigerant.

--- Never weld or clean with steam near a filled system: --- When restarting the compressor, specially if it has not
excess pressure may be created with possible leakage. operated for some time, proceed in the following manner to
ensure lubrication right from the first rotations of the com-
--- If it is necessary to retighten a connection, use two pressor:
spanners for tightening, so as to prevent distortion which
may give rise to leakage. . Switch on the electromagnetic clutch by switching the
fan on and moving the temperature switch to cold.
--- Do not store refrigerant in the sun or close to a source of . Crank over the tractor engine for a few seconds with the
heat. fuel stop button out.
. Then push in the fuel stop button, start the engine and
--- Avoid subjecting the bottle to impact. Do not carry the allow to idle slowly for several minutes.
bottle in the passenger compartment of a vehicle.

A simple functional check:

In the event of an accident, proceed as follows:
a) Start the engine and adjust engine revs to 1500 r/min.
--- If you get refrigerant in your eyes, wash them carefully Turn the fan switch to max speed and select the max cool-
with a solution of mineral oil, and continue to wash them ing effect with the temperature switch (compressor starts).
carefully, with a solution of boric acid and water (1 tea-
spoonful of acid, diluted in a quarter of a cup of water). b) Check temperature of different components:
Contact a doctor immediately.
--- Low pressure hoses, compressor inlet hose should be
Important! Never wash you eyes with pure water because cold when touched by hand.
refrigerant+water causes corrosive acid.
--- Compressor outlet hose, condenser, drier and every high
--- Freezing caused by liquid refrigerant can be treated by pressure hose should be warm when touched by hand
progressively thawing the injured area with cold water and
then applying a dry skin cream. Contact a doctor immedi- Note! Expansion valve and evaporator are accessible only
ately. after removing the cab roof. The thermostatic temperature
switch is accessible after removing the roof panel in the
cab.

583
 Model Code Page
83. Air conditioner 95-- 115
X100-- X120 831 2
1. 11. 2000

Possible faults can be localized easily if pressure gauges are Note! If You have not got enough training for repairing
connected to the compressor service valves. The low pres- refrigerating systems, it is necessary to call an expert if
sure gauge is connected to valve S and the high pressure the system should be opened or if refrigerant must be
gauge to valve D. For instruction on how to carry out these added. The refrigerating system expert has equipment
pressure measurements, see page 831/5. with which repair work can be done in a correct and safe
way.
.
Drier

The drier reservoir (3) is a combined expansion/liquid

reservoir and a drying filter for moisture. The drier
also includes a filter which filters impurities in the
system. There are two inspection glasses on the
drier: A=inspection of refrigerant and its filling,
B=moisture indicator.

The drier reservoir must not be stored with pipe con-

nections open. The drier must be changed if the
system has been opened for maintenance work.
There is a pressure switch S19 which switches off
current to compressor, if the high pressure rises too
much or is too low.

Inspection glass A (1500 r/min and max cooling effect)

Sightglass Description Conclusion and remarks

No bubbles appear at all. POSSIBLE EXCESSIVE REFRIGERANT
(Reduction by bleeding is necessary). The high--- pressure side will be abnormally hot.
(This can also mean that there is no refri- REMEDY: Contact authorized workshop for releasing the excess refrigerant
gerant at all in the system).
The fluid inside is almost transparent. A SUFFICIENT REFRIGERANT.
few bubbles may appear as the engine The high--- pressure side will be hot and the low--- pressure side cold.
speeds up and down.
A few bubbles appear intermittenly, at INSUFFICIENT REFRIGERANT.
intervals of 1 to 2 seconds. The high--- pressure side will be warm, and the low--- pressure side fairly cold.
(Refilling is necessary) REMEDY: Check for refrigerant leakage. Contact authorized workshop.
When bubbles flow continuously, or the VERY LITTLE REFRIGERANT.
flow has changed to a ”mist” flow, the There will be almost no difference in temperature between the high--- pressure
refrigerant is almost exhausted . side and the low--- pressure side.
(Refilling is necessary) REMEDY: Stop the compressor and inspect the entire system. When neces-
sary, contact authorized workshop.

N.B. The refrigerant in the inspection glass should be clear. If it has brown/yellowish colour, the refrigerant and the drier must be
changed.

Inspection glass B

If the moisture indicator colour is blue, the system is in order. If its colour has changed into pink or grey, the drier and the refrigerant
should be changed.

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 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 831 3

1. Fault tracing without special Possible leakages can be found with an electronic leak
detector. If the refrigerant filling is wrong or there is moisture
equipment in the system, contact an expert who knows refrigerating sys-
tems. If everything is OK, see the following instruction C.

Note! This instruction supposes that the outdoor temperature

is high enough so that the temperature switch switches on the C. Electric system
compressor.
30
15

F21

F15
A. Correct function

38LIX24/638LI X5/1
When the air conditioner is functioning properly the com-
pressor runs and stops at regular intervals and cool air flows
38LI
into the cab according to the position of the temperature
switch.
S3
To check for malfunction, carry out the following simple test in 01 2 3
18KE
the shadow by fitting a thermometer sensor into the front ven- 18KE

tilation nozzle on the LH side and by following nozzle tem- 4VI

X24/4
X15
peratures during 5---10 minutes. During this test the windows, 3RU

X7/118KE
doors and re ---circulation nozzles should be closed. Select
the max speed for the fan. Adjust the max cooling effect and
S8
set the engine revs to 1500 RPM. K6

X11/993MU

X7/3
Nozzle temperatures should be according to the curve below 70MU
(±1,0˚C).

93MUX19/893MU

X24/5
70MU
20
18 1 2 3 4
Nozzle temperatures ˚C

S19 2
16 M2
Y5 1
14
12
10
Switch on current to the tractor and turn on the fan S3. If the
fan does not start, check fuse F21. If the fan started, turn the
20 22 24 26 28 30 temperature switch S8 to max cooling effect at which time the
click ---sound must be heard from the compressor magnetic
Outdoor temperature ˚C
clutch. This indicates that the electric system functions.
If measured temperatures agree with the curve above, the air
conditioner is in order. If the click ---sound was not heard, disconnect the wires to the
pressure switch S19 and connect the wire ends (never con-
If the nozzle temperatures are higher, make sure that the nect the + wire to the frame). If the click can now be heard in
heater control knob is closed so that the warm engine coolant the compressor, the electric system is OK, but the fault lies in
does not circulate in the heating element which is placed in the pressure switch or in the system pressures. Call an expert.
front of the evaporator. If the knob is closed, see the following
If the click ---sound cannot be heard when connecting the
instruction B. pressure switch wires, check the supply wire for current to the
pressure switch. If it is there, the fault lies in the compressor
magnetic clutch or in its wiring.

B. Refrigerant filling and moisture Measure the voltage from the pressure switch supply wire
with different fan speeds. If there is no current with some fan
speed, the fault lies in diodes, which should be changed. The
--- Check the amount of refrigerant and moisture in the system
diodes cannot be changed separately but the complete wir-
through the drier inspection glasses (see page 831/2). ing set no 326 107 00 (earlier air conditioner) or no 328 351 00
(later air conditioner) should be changed.
Moisture in the system causes icing in the expansion valve
and in the compressor which in turn causes malfunctions. If there is no current to the pressure switch wire, check con-
Refrigerant+water causes a corrosive compound. nector X19/8 in the cab front wall on the RH side and also con-
nector X11/9 which is placed behind the roof panel in the cab
(on the RH side).

If there is no current to the pressure switch wire, connect the

temperature switch wire ends. If now there is current to the
pressure switch supply wire, the fault lies in the temperature
switch which should be changed.

585
 Model Code Page
95-- 115
83. Air conditioner X100-- X120 831 4
1. 11. 2000

D. Compressor
E. Expansion valve

Note! The expansion valve is accessible after removing the

cab roof and the evaporator housing cover. In addition, the
evaporator is covered by insulating mass.

--- A faulty expansion valve causes a poor cooling effect.

--- If the expansion valve is noisy (continuing whistle), there is

too little refrigerant in the system which causes bubbles to
appear in the inspection glass of the drier.

--- If the expansion valve does not function (stuck fast or frozen
in open or closed position) the cooling effect is insufficient.

--- If the air conditioner blows first cool air, then warm and then
again cool, there is ice in the expansion valve which prevents
refrigerant from flowing into the evaporator.

1. Normal function

--- When the compressor is functioning properly, it starts and

stops regularly. With max cooling effect the compressor runs F. Evaporator
often but not as long as in min cooling. Unusual sound must
not be heard from the compressor. Check the compressor
Note! The evaporator is accessible after removing the cab
belts regularly.
roof and the evaporator housing cover.
2. Continuing running, no cooling
--- If there is icing on the evaporator, the fault lies in the tem-
--- The compressor is faulty and should be changed. Also perature switch or its sensor is wrongly positioned between
icing caused by moisture can cause this kind of malfunction the evaporator fins.
(check the moisture indicator colour). In this case also tem-
perature difference between high and low pressure pipes is Note! Do not use the air conditioner if the outdoor tempera-
diminutive. ture is below +20 ˚C.

3. Continuing running, max cooling --- Make sure that the drain pipes for the condensing water are
open i.e. water can flow away from the evaporator housing
--- The compressor is in order but a fault lies in the temperature bottom. Otherwise icing can appear on the evaporator. If there
switch which does not switch off current to the compressor is water on the evaporator housing bottom, the drain pipes
when the evaporator temperature is under +2...+3 ˚C. Make should be checked e.g. with compressed air.
sure that the temperature switch sensor is correctly fitted
between the evaporator fins. This malfunction causes icing on
the evaporator which lowers the cooling effect.
G. Condenser
4. Irregular running

--- Check the compressor belt tightness.

--- Change for faulty compressor

5. Unusual sound

Compressor engaged:
--- Check the compressor attachment.
--- Electromagnetic clutch slips, faulty bearings or valves in the
compressor can cause an unusual sound.
--- Wrong refrigerant filling in the system can cause unusual
sound.
--- Change faulty compressor

Compressor disengaged:
--- electromagnetic clutch clearance is wrongly adjusted. --- If malfunctions occur, always check and clean externally
the condenser from impurities. Cleaning can be carried out
Note! If the compressor front end is oily and moist, the com- with compressed air. The tractor front covering can be raised
pressor shaft seal can be leaking. If the compressor does not up and the condenser has hinges for easier cleaning.
run at all, the fault is in the electrical system.

586
 Model Code Page
83. Air conditioner 95-- 115
831 5
1. 11. 2000 X100-- X120

2. Trouble shooting with pres-

sure gauges d) An over ---charged system, an expansion valve stuck
open or a clogged condenser will cause excessive pressure
on the low pressure side.
System pressures depend directly on air pressure and
temperature. At outdoor temperature 20˚ ---25˚C and at e) A clogged condenser and an over ---charged system will
engine revs 1500 r/min the low pressure varies between cause excessive pressure on the high pressure side.
50 ---300 kPa and the high pressure between 700 ---1400
kPa. The pressure gauges are connected to the com-
pressor service valves: low pressure gauge to (S) and high Overcharge
pressure gauge to (D).
Note! The correct refrigerant filling is 1,4 kg.
Fault analysis and symptoms
In a correctly charged system the refrigerant discharged
a) Leaks in the system will lead to inadequate cooling and from the compressor in the form of gas looses its excess
low and high gauge readings will be too low. heat, resulting from compression in the first coil of the con-
denser and condenses to a liquid in the subsequent coils.
b) If the system is under ---charged, bubbles will be perma- Before flowing to the reservoir, this liquid is held in the last
nently visible in the dehydrator sight glass and both gauge condenser coil. If the system is over ---charged, the liquid
readings will be low. level builds up in the condenser, leaving fewer coils avail-
able to condense the gas. Both temperature and pressure
c) If the evaporator is dirty or an expansion valve is blocked then build up, causing hoses to burst in some cases.
or frozen up, there will be a partial vacuum on the low pres-
sure side and insufficient pressure on the high pressure
side.

Connecting pressure Stop the engine. Remove the service valve protective caps. Connect the low pres-
gauges: sure gauge to valve S and high pressure gauge to valve D.

Disconnecting gauges: Stop the engine. Unscrew rapidly the low pressure gauge. Run the air conditioner
5---10 min and stop the engine. Unscrew rapidly the high pressure gauge.

Note! Refrigerant in the gauge hoses blows off. Use gloves and goggles when con-
necting and disconnecting gauges. Recap valves.

Possible fault Remedy

Low pressure too low High pressure normal
1. Expansion valve faulty. 1. Change expansion valve.

2. Moisture in system caus- 2. Empty and flush the sys-

ing icing in expansion valve tem. Change the drier and
the expansion valve if
necessary.
3. Expansion valve is
clogged or evaporator dirty, 3. Empty system and
if low pressure gauge change the expansion
shows underpressure. valve and also the evapor-
ator and drier if necessary.
4. Drier blocked (tempera-
ture difference on different 4. Empty system and
sides of blockage causes change the drier.
icing in the drier when air
conditioner is functioning).

S D
587
 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 831 6

Low pressure high High pressure normal

Possible fault Remedy

1. Expansion valve faulty. 1. Empty system and
Valve stuck fast in open change expansion valve.
position.

2. Compressor faulty or its 2. Check compressor belt.

belt slackened. Change damaged com-
pressor.

3. Too little refrigerant in 3. Empty and refill the sys-

system. tem with refrigerant (1,4
kg).

S D

Low pressure high High pressure low

Possible fault Remedy

1. Valves or seals in com- 1. Change compressor.
pressor faulty.

2. Too little refrigerant cau- 2. Empty and refill the sys-

ses the high pressure rea- tem with correct amount of
ding to be too low. refrigerant (1,4 kg).

S D

Low pressure normal High pressure high

Possible fault Remedy

1. Air in system or too 1. Empty system and refill
much refrigerant in system. with refrigerant (1,4 kg).

2. Condenser dirty (insects 2. Clean the condenser.

etc)

3. If bubbles appear in 3. Empty system and

inspection glass fast filling change hose connections.
is OK, the drier hose con- Change the drier. Refill sys-
nections have been con- tem (1,4 kg).
nected faulty and refrige-
rant flows in reverse direc-
tion.

4. If there is bubbles and 4. Empty system and

S D icing in the drier, there is

restriction in the drier inlet
remove blockage and fit a
new drier. Refill system
side. (1,4 kg).

588
 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 831 7

Low pressure high High pressure high

Possible fault Remedy

1. Condenser is dirty 1. Clean condenser
(insects etc.)

2. Too much refrigerant in 2. Empty and refill system

system. with refrigerant (1,4 kg).

S D

Both gauges show same pressure

Possible fault Remedy

1. Compressor magnetic 1. Change compressor
clutch does not function.

2. Compressor is faulty 2. Change compressor

3. Electric system faulty 3. Check electrical system

(temperature switch, pres- (see page 831/3 instr. C).
sure switch, fuse etc.)

S D

589
 Model Code Page
83. Air conditioner 95-- 115
1. 11. 2000 X100-- X120 831 8

Important information on air

conditioner repairs and spare
part storage

Note! Moisture is the worst enemy of any air conditioner.

1. Keep all spare parts sealed and store in a dry place.

2. Immediately make all connections air tight when interrupt-

ing the refrigerant circuit.

3. Before installation purge refrigerant hoses with nitrogen or

refrigerant.

4. When installing parts, do not remove plugs until shortly

before assembly. This is especially important for the drier. A
drier, which is not sealed, quickly becomes saturated and
cannot be used.

5. Do not pump refrigerant from the air conditioner back into

the cylinder.

6. Always keep empty refrigerant cylinders closed.

7. Only buy refrigerant from specialized dealers.

8. Do not carry out repairs outdoors in damp weather.

9. Always replace drier receiver after interrupting the refriger-

ant circuit.

10. The presence of moisture in the refrigerant circuit does not

only lead to a poor cooling output but also to the decomposi-
tion of the solid ---state drier and the decay of the refrigerant
lines due to acid formation. Expensive repairs and down ---
time are the result.

11. Before starting, check oil level of the compressor and

evacuate refrigeration circuit according to instructions given.
Time of evacuation 1---4 hours. Dry refrigeration circuit at least
once by breaking the vacuum with liquid refrigerant.

590
 Model Code Page
83. Air conditioner 95-- 115
X100-- X120 831 9
1. 11. 2000

Compressor

D = Discharge
S = Suction
Y5 = magnetic clutch

Compressor type:
Diesel Kiki model DKS 15 CH.

Specifications

Number of cylinders . . . . . . . . . 6 pcs

Cyl. diam x stroke . . . . . . . . . . . ø34 mm x 24 mm
Max. revs . . . . . . . . . . . . . . . . . . 7000 r/min

Lubricating oil: ZXL 100 PG (DH ---PS).

Oil volume: 200 cm3 (2,0 dl)

Magnetic clutch:
Voltage . . . . . . . . . . . . . . . . . . . . 12 V (DC)
Starting moment . . . . . . . . . . . . 50 Nm
Power consumption . . . . . . . . . 44 W (max)
Clutch clearance value . . . . . . . 0,3---0,6 mm

If the compressor should be changed, contact an expert

who knows refrigerating systems.

A new compressor is filled with 2,0 dl oil in the factory.

Drain the oil in the new compressor. 1,6 dl oil must run
out. Pour the oil back to the compressor and fit the
plug. If the drained oil amount was not 1,6 dl, add or
reduce the oil volume to 1,6 dl (on account of the inter-
nal build ---in, all oil in the compressor does not run out).

Note! If the system is opened and refrigerant changed,

the compressor oil should also be changed. In this
case, fill the compressor with 2,0 dl oil.

Detach the new compressor protective caps very care-

fully so that the threads and connections do not
damage.

Tightening torques:
--- 3/4” connection on pressure side 24,5 ---29,5 Nm.
--- 7/8” connection on suction side 29,5 ---33,5 Nm.

Draining/filling plug for lubricating oil.

Note! Do not open the plug, if the system is filled

with refrigerant. Compressor oil should be stored in a
closed container.

591
 Model Code Page
95-- 115
83. Air conditioner X100-- X120 831 10
1. 11. 2000

Part numbers
Order no
Dryer reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32814800
Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32844300
Pressure switch O ---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32275210
Dryer reservoir hose O ---rings (2 pcs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30414910

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32838600
Service valve S (LH side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32839000
Service valve (S) O ---ring against compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30415110
Service valve D (RH side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32838800
Service valve (D) O ---ring against compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30415010
LH side valve (S) upper end O ---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30415110
RH side valve (D) upper end O ---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30415010

Note! When fitting the compressor, adjust the distance between the support and compressor to 0,1 mm with shims.

Condenser hose O ---rings:

Front hose O ---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30415010
Rear hose O ---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30414910

Expansion valve O ---rings:

Upper hose O ---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30415110
Lower hose O ---ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30414910
O ---rings (2 pcs) on the evaporator side tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30415010

Note! Before changing the expansion valve O ---rings, the insulating mass should be removed. After fitting, cover the valve with
mass no 30794000.

592
 91. Tractor hydraulics,
low and high pressure
90. Hydraulics circuits

92. Front loader

hydraulics

593
594
 Model Code Page
95-- 115
91. Tractor hydraulics X100-- X120 910 1
1. 11. 2000

Contents

General (Op. no. 910)

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic power lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Three ---point linkage and towing hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Valves for auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Oil flow regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Return oil connection for auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Repair instructions

Pump and pipe system (Op. no. 911)

1. Low pressure circuit:

A. Measuring pressure in low pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Measuring diff. lock clutch pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Measuring PTO clutch pressure and lubricating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. DPS clutch pressure, 96---115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. DPS and shuttle clutch pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. High pressure circuit:

A. Measuring free ---circulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Measuring working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Removing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Fitting pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. Pump and pipes, fault tracing:

A.General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Inspecting oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Fault tracing without removing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Internal inspection of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Hydraulic power lift (Op. no. 912)

1. Hydraulic lift control valve:
A. Checking shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Fitting control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Reconditioning control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Lifting cylinders:
A. Changing lifting cylinder seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Three ---point linkage and towing hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Adjusting pick ---up hitch lifting links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checking locking of pick ---up hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

595
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 2

596
 Model Code Page
91. Tractor hydraulics 95-- 115
X100-- X120 910 3
1. 11. 2000

Technical data (concerning front loader hydraulics, see section 92)

The tractor hydraulic system has low and high pressure circuits. Oil is supplied by a twin gear pump.
Both circuits have a common suction strainer. In addition, the high pressure circuit has a pressure filter and also the low pressure
circuit. On X100---X120 tractors there are two pressure filters in the low pressure circuit.

Low pressure circuit (rearmost pump)

--- pump capacity at max. engine revs. l/min, 95 ---115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
--- pump capacity at engine revs of 2200 rpm, l/min, X100 ---X120 . . . . . . . . . . . . . . . . . . . . . . . 30
--- max. pressure (pressure ---limiting valve opening pressure in servo valve block) . . . . . . . . . 1,8 MPa (18 bar)
Supplies oil for the following functions:
--- quick ---shift gear (DPS) engagement
--- HiTech shuttle engagement (X100---X120)
--- 4WD disengagement
--- PTO engagement
--- diff. lock engagement
--- transmission lubrication
--- oil for brake valve for trailer (optional)
--- oil to oil cooler
--- oil to disengage the hand brake on HiTech tractors.

High pressure circuit (foremost pump)

--- pump max.capacity at min. pressure and at engine revs of 2225, (l/min), 95 ---115 . . . . . . 51
--- pump max.capacity at min. pressure and at engine revs of 2220, (l/min), X100 ---X120 . . . 73
--- max. pressure, 95 ---X120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MPa
The capacity of the hydraulic system measured from output with max
power 20 kW, X100---120:
--- pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 MPa
--- capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70,6 l/min
Pump safety valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 MPa
Shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 MPa
Supplies oil for the following functions:
--- steering system (priority valve)
--- hydraulic power lift
--- auxiliary hydraulics (front loader hydraulics have an own pump in the front of the tractor)

Pressures at test points (1500 r/min, 40---65˚C)

Low pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,8---1,9 MPa
High pressure circuit/free circulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,0---19,8 MPa/ca. 1,5 MPa
Hydraulic power lift shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20---21 MPa
Lubricating oil pressure, 95---115/X100---X120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 0,03 MPa/min. 0,12 MPa

Oils:
Common oil for tractor transmission and hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 130/4
Available volumeof oil for auxiliary hydraulics (depending on filling quantity) . . . . . . . . . . . . . . 20---40 litres

Hydraulic power lift

Electro---hydraulic power lift (Autocontrol ACB)
Hydraulic lift control valve
--- type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch EHR 4
--- shock valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 MPa (200 bar)
Two external lifting cylinders:
--- Ø 80 mm (earlier 95)
--- Ø 90 mm (later 95, 105, 115, X100---X120)
--- lifting cylinder working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 18,0 MPa (180 bar)
Three ---point linkage, category 2;
--- telescopic lower links (earlier 95)
--- linkage has quick ---attaching type links (later 95, 105---115, X100---X120.
Hydraulically controlled pick ---up hitch (option). Agricultural drawbar (option). Different kind of towing devices are available.

Valves for auxiliary hydraulics

Two 1/2---action valves as standard, separate levers:

--- First standard valve has a mechanical position locking function.
--- Second standard valve has a floating position.
--- As an extra equipment can be fitted two extra valves+oil flow control valve, which controls the first valve.
--- At the rear of the tractor there are quick ---action couplings.
--- As an option a hydraulic brake valve for trailer is available

597
 Model Code Page
91. Tractor hydraulics 95-- 115
910 4
1. 11. 2000 X100-- X120

Special tools
A
Locally prepared tool
ET 893 530 Sleeve for fitting lifting arm shaft seals (Hydraulic lift 505---905)

B
ETV 893 540 Sleeve for removing/fitting lifting arm shaft bushes
ETV 893 580 Conic sleeve for fitting lifting cylinder piston seal (Lifting cylinder ø 80)
ETV 893 590 Sleeve for crimping lifting cylinder piston seal, (Lifting cylinder ø 80)
ETV 893 600 Drift for fitting lifting cylinder piston seal (Lifting cylinder ø 80)
ETV 894 240 Conic sleeve for fitting lifting cylinder piston seal (Lifting cylinder ø 100)
ETV 894 250 Sleeve for crimping lifting cylinder piston seal (Lifting cylinder ø 100)
ETV 894 260 Drift for fitting lifting cylinder piston seal (Lifting cylinder ø 100)

ETV 893 540

ET 893 530

ETV 893 580 (ø 80) ETV 893 590 (ø 80)

ETV 894 280 (Ø 90) ETV 894 290 (Ø 90)
ETV 894 240 (ø 100) ETV 894 250 (ø 100)

ETV 893 600 (ø 80)

ETV 894 300 (Ø 90)
ETV 894 260 (ø 100)

598
 Model Code Page
91. Tractor hydraulics 95-- 115
910 5
1. 11. 2000 X100-- X120

Pressure measuring equipment

1. Equipment for measuring pressure in low pressure circuit ( 1,8 ---1,9 MPa). On X100---X120 tractors the pressure test point is
placed on the outer face of the servo valve block on the LH side of the gearbox, see page 910/15.
2. Equipment for measuring pressure in high pressure circuit (19,0 ---19,8 MPa).
Pressure measuring kit 31965000 includes the above shown equipment, which can also be ordered separately.

Measuring opening pressure of hydraulic lift shock valve

1. Measuring opening pressure of the hydraulic lift shock valve (opening pressure 20 MPa).
Note! T ---connector GS9276 has thread 3/4---16 for connecting a hand pump. The kit 31965000 does not include the hand pump.

599
 VALVE FOR HYDRAULIC MOTOR (OPT.)

20 MPa

KICK--- OUT VALVE (OPTION)

95---115
91. Tractor hydraulics

Hydraulic diagram,

19. MPA
BREAK VALVE
(OPTION)

FLOW
REGULATOR
(OPTION)

600
19 MPA
23 MPA

20 MPA
i=1,32

14 MPA
1. 11. 2000
Model

20 MPA
95-- 115

Ø 1.5
Code
910

REAR STEERING (OPTION)

6
Page

Figure 1A. Hydraulic diagram

 Model Code Page
91. Tractor hydraulics 95-- 115 910 7
1. 11. 2000

Hydraulic diagram, 95---115

See picture 1A on previous page.

1. Oil reservoir in transmission housing

2. Suction strainer (125 m)
2a. Pressure ---limiting valve 0,2 MPa (lubricating pressure)
3. Twin gear pump on the RH side of the engine
4. Safety valve 23 MPa. (placed in the high pressure pump).
5. Pressure test point (Valmet HPR)
6. Pressure filter (degree of separation: β10=75).
--- by ---pass valve 0,35 MPa.
7. Priority valve OLS 120
9. Steering valve OSPC 125---LS in picture
--- steering system pressure ---limiting valve 17,5 MPa
--- shock valve 22 MPa
10. Steering cylinder, in picture only one steering cylinder
11. Steering valve, reverse drive (optional)
12. Shuttle valve, reverse drive
13. End plate (oil inlet)
--- pressure ---limiting valve 19 MPa (high pressure circuit)
14. Valve for auxiliary hydraulics, 2/1--- action (out---hold ---in)
15. Valve for auxiliary hydraulics, 2/1--- action (float---out---
hold ---in), float position can be locked)
16. End plate (tank side)
17. Valve for auxiliary hydraulics (optional), 2--- action (out---
float---in), out and in positions can be locked)
18. Valve for auxiliary hydraulics (optional), 2---action, kick ---
out function (float---out---hold ---in), float, out and in positions
can be locked)
19. Hydraulic lift control valve (Bosch EHR4)
--- lifting cylinder shock valve 20 MPa
20. Lifting cylinder
21. Breather filter for lifting cylinders and transmission hous-
ing (degree of separation: β10=75).
22. Brake valve for trailer (optional)
23. Servo valve block
--- safety valve for oil cooler 0,4 MPa
--- pressure ---limiting valve for low pressure circuit 1,8 MPa
24. Differential lock
25. Cushioning valve for PTO engagement
26. PTO
27. 4WD clutch
28. 3---step quick ---shift gear (DPS)
29. Reverse shuttle lubrication
30. Lubrication for bevel pinion shaft
32. Lubrication of gearbox input shaft
33. Lubrication of differential gears
34. Lubrication of PTO unit shafts
35. Lubrication of PTO mechanism
36. Return oil connection for auxiliary hydraulics
37. Oil cooler
38). Oil flow regulator valve (Rexroth), (optional)
38a). Intermediate flange for oil flow regulator valve

601
 Malli Koodi Sivu
91. Tractor hydraulics X100-- X120 910 8
1. 11. 2000

Hydraulic diagram, HiTech tractors

10
11
39
12

602
 Model Code Page
91. Tractor hydraulics X100-- X120 910 9
1. 11. 2000

Hydraulic diagram, HiTech tractors 41. Low pressure circuit filter

--- safety valve 22 MPa
42. Valve 0,3 Mpa (3 bar)
1. Oil reservoir in tractor transmission housing
43. Return oil filter
2. Suction strainer (125 m)
44. Hand brake ram
2a. Pressure ---limiting valve, lubr. oil pressure 0,25 MPa
45. Valve block (F, R, C3).
(K41107---), 0,40 MPa (---K41106)
46. R ---clutch of shuttle
3. Twin gear pump
46a. F ---clutch of shuttle
4. Safety valve, 23 MPa, beside the pump
47. Pressure ---test point, PTO clutch
5. Pressure ---test point, high pressure circuit
48. Non ---return valve 0,05 MPa (0,5 bar)
6. Pressure filter (filtration grade: β10=75).
49. Lubricating oil flow into the F ---clutch has been reduced
7. Priority valve (OLS 120)
with a restriction, diam. 5 mm.
8. Pressure ---test point (lubrication pressure)
9. Steering valve, OSPQ 125/250 LS
10. Frame steering rams
11. Steering valve OSPC 125 LS, TwinTrac
12. Non ---return valve, TwinTrac
13. End flange (pump side)
--- pressure ---limiting valve 19 MPa
14. Valve block, 2/1--- action
(out---hold ---in)
15. Valve block, 2/1--- action
(float---out---hold ---in, float pos. locked)
16. End flange (tank side)
17. Valve block, option,
2--- action, actuator (out---
float---in, out---in pos. locked)
18. Valve block, option,
2--- action, kick ---out
(float---out---hold ---in, float---out---in
pos. locked)
19. Power lift control valve (Bosch EHR4)
--- lifting ram safety valve 20 MPa
20. Lifting rams
21. Lifting ram+ transmission
breather filter (filtration grade: β10=75).
22. Brake valve (option)
23. Servo valve block
--- pressure ---limiting valve 1,8 MPa
--- safety valve 1,2 MPa
--- pressure ---test point, low press. circuit
24. Differential lock
25. Pressure accumulator
26. PTO
27. 4WD multi ---disc clutch
28. DPS
29. Shuttle lubrication
30. Bevel pinion shaft lubrication
31. Lubr. of pump drive gears
32. Input shaft lubrication
33. Differential lubrication
34. Lubrication of PTO shafts
35. Lubrication of PTO
36. Return oil connection, auxiliary hydraulics
37. Oil cooler
--- by ---pass valve 0,35 MPa
--- switch, blocked filter
38. Oil flow control valve (Rexroth), (option)
38a. Intermediate flange (see above)
39. Control valve (TwinTrac)
40. Diff. lock, front axle
--- steering, press. ---limiting valve 17,5 MPa

603
 Model Code Page
91. Tractor hydraulics 95-- 115 910 10
1. 11. 2000

Picture 2A. Hydraulic system in 95---115 tractors

604
 Model Code Page
91. Tractor hydraulics 95-- 115 910 11
1. 11. 2000

Hydraulic system, 95---115

See picture 2A on previous page.

1. Oil tank in transmission housing

2. Suction strainer (125 m)
2a. Pressure ---limiting valve 0,2 MPa
3. Double pump on the engine RH side
4. Pump pressure ---limiting valve 23 MPa.
5. Pressure ---test point (Valmet HPR) for steering and work-
ing hydraulic pressure
6. Pressure filter (degree of separation: β10=75).
--- by ---pass valve 0,35 MPa.
6a. Warning light sensor, blocked pressure filter (option)
7. Priority valve OLS120
8. ---
9. Steering valve (OSPQ)
--- pressure ---limiting valve 17,5 MPa
10. Steering cylinder
13. End plate (oil inlet side)
--- pressure ---limiting valve 19 MPa for working hydraulics
19. Hydraulic lift control valve (Bosch)
--- shock valve 20 MPa
20. Lifting cylinder
21. Lifting cylinder+transmission housing breather filter
(degree of separation: β10=75).
23. Servo valve block (safety valve 0,4 MPa + pressure ---li-
miting valve 1,8 MPa for low pressure circuit)
36. Return oil connectio for auxiliary hydraulics.
37. Oil cooler
38. Pressure filter in the low pressure circuit.

Picture 2B. Warning light sensor, blocked pressure filter

(option).

Note! The function of the sensor can be tested by pushing

the sensor pin with power of 13 kp, at which time a bulb
connected to the sensor should light.

Note! On HiTech models X100---X120 there are three pres-

sure filters (one in working hydraulics and two in low pres-
sure side) and all have the indicator lamp switch. By di-
sconnecting the switch wires can be tested, which one of
the filters is blocked.

605
 Model Code Page
91. Tractor hydraulics X100-- X120 910 12
1. 11. 2000

HiTech

Picture 2C. Working hydraulics, HiTech tractors

606
 Model Code Page
91. Tractor hydraulics X100-- X120 910 13
1. 11. 2000

Working hydraulics on HiTech trac-

tors X100---X120
See picture 2C.

1. Oil tank in transmission housing

2. Suction strainer (125 m)
2a. Pressure ---limiting valve, lubr. oil pressure
3. Twin gear pump, 25+11 cm3/r
4. Safety valve 23 MPa.
5. Pressure ---test point (Valmet HPR), high pressure circuit
6. Pressure filter (filtration grade: β25=75).
--- by ---pass valve, 0,40 MPa.
6a. Indicator lamp switch, blocked filter, see page 920/11.
7. Priority valve
8. ---
9. Steering valve (OSPQ).
--- safety valve 17.5 MPa
10. Steering ram
13. End flange (inlet side)
--- pressure ---limiting valve 19 MPa
19. Control valve (Bosch) for hydraulic power lift
--- shock valve 20 MPa
20. Lifting rams
21. Liftin rams+transmission breather (filtration grade:
β10=75).
23. Servo valve block (safety valve 0,4 MPa + pressure ---limi-
ting valve 1,8 MPa + pressure ---test point).
36. Return oil connection, auxiliary hydraulics
37. Oil cooler

607
 Model Code Page
91. Tractor hydraulics 95-- 115 910 14
1. 11. 2000

Servo valve block on 95---115

C2

C1

C3

Pressure ---limiting valve, low pressure circuit Safety valve for oil cooler

Picture 3. Valve block (on the LH side of the gearbox) When both solenoid valves Y4 and Y6 are energized. Pres-
sure oil affects in all three multi disc clutches. When pres-
Y1=Solenoid valve of diff. lock.
sure oil does not affect the planetary carrier multi disc
Y2=Solenoid valve for PTO
Y3=Solenoid valve of front wheel drive clutch, the planetary gear is locked by the clutch Belleville
Y4=Solenoid valve for quick ---shift gear foremost clutch springs.
(lowest ratio)
Y6=Solenoid valve for quick ---shift gear middle clutch When the solenoid Y6 is energized, pressure oil affects the
(intermediate ratio) quick ---shift gear clutch C2
S16=Transmission oil temperature sensor (warning light)
S17=Transmission oil pressure sensor (warning light). Note! When the solenoid valve is energized, the nut at the
P=Pressure oil inlet from the low pressure pump end of the valve becomes magnetic which can be verified
with e.g. a screwdriver. Concerning electric system of DPS,
1. Pressure ---test point (Valmet HPR) see section 31 code 310 (wiring diagrams), and code 314
2. Oil inlet from the working hydraulic return oil (AC 2.2/2.3).
3. The plug (3) has been removed on the latest models
and a locking plate has been fitted in place, see page Important! Concerning removal of the valve block, see
420/18. page 420/18. Concerning DPS in transmissions 550/650,
see pages 440/10 ---13.
The different DPS ratios are engaged with push buttons in
the speed gear lever knob:

When the solenoid valve Y4 is energized, pressure oil

affects the quick ---shift gear foremost clutch C1.

608
 Model Code Page
91. Tractor hydraulics X100-- X120 910 15
1. 11. 2000

Servo valve block on X100---X120

5
11 9
9

5 10
8
3
3
8 6 7
4
Note! Before removing valve 4 (Y2
(B6)), the pilot light switch 7 must be
7 removed. 4

Note! The end of the spindle must be almost flush

with the valve body. If necessary, the valve must be
removed and the spindle must be pressed to the
outer position.

Picture 4. Servo valve block on HiTech tractors X100 ---X120 (on the LH side of the gearbox)

NOTE! Cross section of the valve, see page 420/21.

1. Solenoid valve of hand brake (energised, when the hand brake is disengaged, see page 521/2).
2. 4WD solenoid valve (engaging logic, see code 314).
3. Solenoid valve of differential lock (engaging logic, see code 314)
4. Proportional valve of PTO (see codes 370/371, Autocontrol 5/5.2. Engaging logic, see code 314).
5. Temperature sensor of Autocontrol 5/5.2 (see codes 370/371, AC 5/5.2).
6. Pressure test point, low pressure circuit (1,8 ---1,9 MPa)
7. Indicator light sensor (S17), gearbox oil pressure
8. Indicator light sensor (S16), gearbox oil temperature
9. Oil temperature sensor (B3), AD ---instrument
10. CareTel oil temperature sensor B3L (option).
11. Connection for pressure accumulator (not illustrated).

609
 Model Code Page
91. Tractor hydraulics X100 ---X120 910 16
1. 11. 2000

Hydraulic pump and suction pipes, X110---X120

Picture 4A. Hydraulic pump and suction pipes, X100---X120

610
 Model Code Page
91. Tractor hydraulics X100-- X120 910 17
1. 11. 2000

Hydraulic pump and suction pipes, Important! From ser. no. H18329 incl. the pump pressure
pipe lead ---in plates and their seals have been changed in
X100---X120 transmissions 650, 300 and 390.
From ser. no. H19317 incl. (in transmission 650) there is a
Bosch ---make pump in the hydraulic system.
IMPORTANT! In 95 ---115 trcators the pump is placed on The new Bosch pump is replaceable with the earlier pump,
the RH side of the engine. when the pump connection parts are changed (suction
connection is not necessary to change). A new part is fitted
See picture 4A on previous page. between the pump and the suction connection, and the
pressure connection has been changed. The safety valve
Pump technical values, see Technical Data on page 910/3. body has been changed, the other parts as earlier. In con-
nection with possible repair work new lead ---in plates and
1. Twin gear pump seals must be fitted.
2. Suction strainer housing on the gearbox. The suction
straines should be cleaned according to the maintenance Note! On X100---X120 tractors, the low pressure pump out-
program. put is greater than in earlier 95---115 tractors, which have a
3. Safety valve for high pressure pump. Opening pressure mechanical shuttle.
is 23 MPa.
4. Pressure limiting valve for lubricating oil. Opening pres- Note! From autumn 2000 there is the same hydraulic
sure is 0,2 MPa. pump as in X100---X120 models (25+11 cm3/r) in trans-
5. Sealing plates at pressure pipe lead ---in points. Apply mission 550. Transmission 550 is in tractors 105---115 and
Hylosil---silicone to the lower face of the plates. X100 from ser. no. K36112 incl. (in 95, K41106---).

The pump is removed and fitted according to instruction on

page 911/4.

611
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 18

Figure 5. Pressure filter

1. By ---pass valve (opening pressure 0,35 MPa)
2. Support ring (outermost)
3. Filter insert

All oil to the working hydraulics flow through the pressure filter.
Change pressure filter according to the maintenance program.
--- working temperature ---40...+100˚C
--- degree of separation β10=75
--- max. working pressure 25 MPa
--- pressure loss 0,13---0,17 MPa
Note! From ser. no. F13130 incl. the tractors have a pressure 3
filter also in the low pressure circuit . The pressure filters can
be equipped with a sensor for the warning light, which indi-
cates blocking of the filter. From ser. no. F16407 incl. the pres-
sure filter has been modified. A spring under the filter insert has
been removed and the upper end tightening has been
improved. This new filter is not exchangeable with the earlier
one. X100---X120 have two pressure filters in the low pressure 200 Nm
circuit.

Figure 6. Pressure ---limiting valve, working hydraulics, 19 MPa)

1. Opening pressure stamped on end of valve
2. Opening pressure can be adjusted with shims (S=0,2, 0,5, 1,0 and 2,0 mm)

612
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 19

Hydraulic power lift (Electrical system has been described under code 321 (ACB Power lift))

A
1 2

Figure 7. Hydraulic lift

1. Control valve (Bosch EHR ---4) 5

2. Lifting cylinders (2 pcs)
3. Valves for auxiliary hydraulics
4. Pressure ---limiting valve (lubri-
cating system)
5. Lower links

The hydraulic lift control valve (1) is fitted on the RH side of

the gearbox. Oil flows to the control valve from the high The control valve (1) has an in ---built shock valve (20 MPa)
pressure pump via the priority valve and via the valves for which protect the working hydraulics against pressure
the auxiliary hydraulics (3) (hose P). shocks from the lifting cylinders.

Electrically controlled valve (1) directs oil to the lifting cylin- Working hydraulic pressure is limited by a pressure ---limit-
ders (port A) in the lifting position. In the lowering position, ing valve (19 MPa) which is placed on the underside of the
the oil returns to the oil reservoir (gearbox housing). In the end plate (inlet side) of the auxiliary hydraulic valve block
neutral position, the valve holds pressure in the lifting cylin- (3).
ders and the valve is in the free ---circulation position (hose
N).
The free ---circulating oil (below 0,2 MPa) flows to the trans-
mission lubricating system.

613
 Model Code page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 20

Hydraulic lift control valve Bosch

EHR---4 Lowering valve
Solenoid

The valve is fitted on the RH side of the gearbox.The valve

regulates oil flow regardless of loading in the three ---point
linkage.

There are push buttons on the ends of the both solenoid

valves. Thus it is possible to move the control valve main
spool manually if, for instance, there is a malfunction of the
control valve or if it is suspected that the hydraulic system is
not functioning properly.

Note! Solenoid valves must not be connected direct to the

tractor battery terminals (e.g. for testing purposes) for long
periods (max 10 seconds) since the solenoids cannot with-
stand strong current and will be damaged
Solenoids can be changed separately. In addition, the
shock valve and lowering valve can be cleaned and Solenoid Shock valve (20 MPa)
checked and valve springs can be changed.

Figure 8. Hydraulic lift control valve

614
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 21

Figure 9. Control valve in neutral position

Function (neutral position)

The main spool (2) is held in the middle position by the action
When the tractor is started oil flows from the pump (port ”P”) of the centring springs (left end of spool in fig 9) The pressure
to the left end of the spool (1) through a drilling in the middle. (+spring) keeps the lowering valve (6) closed.
The spool is then pushed to the right against a spring and
opens the unloading circuit between ports P and N (pump --- 1) 3---way oil flow regulating slide
tank) 2) Main spool
3) Pilot pressure limiting valve for lowering valve
Through the drilling in the spool (1) oil flows through the dril- 4) Shock valve
ling at the right end of the slide. The constant oil (Qs) flows 5) Lowering valve pilot piston.
via the main spool (2) to the tank (”port T”). 6) Lowering valve
7) Free circulation oil to the transmission lubricating system

615
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 22

Figure 10. Control valve in the lifting position

Function (lifting position):

The lifting solenoid is controlled so that in the beginning and
In the lifting position the RH solenoid is energized. The in the end of the lifting movement, the solenoid current is cut
magnet presses the main spool (2) to the left against the cen- a period of some milliseconds, so that the movement be-
tring spring. Then it opens the passage from the spool (1) to comes smooth. The actual lifting movement is carried out with
the lifting cylinders by an amount proportional to the strength full current (otherwise as in the lowering position).
of the current supplied to the RH solenoid.
1) 3---way oil flow regulating slide.
The right end of the slide (1) is under lifting cylinder pressure. 2) Main spool.
Pump pressure becomes equal in value to lifting cylinder 3) Pilot pressure limiting valve.
pressure + pilot pressure (=spring). The pressure difference 4) Shock valve.
through the restriction of the main spool (2) is always equal to 5) Lowering valve pilot piston.
pilot pressure so the oil flow depends only on the position of 6) Lowering valve.
the main spool (2) (and oil viscosity). 7) Free circulation oil to the transmission lubricating system.

616
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 23

Figure 11. Control valve in the lowering position

Function (lowering position):

Therefore the return flow does not depend on the pressure
In the lowering position the LH side solenoid is energized. caused by the load on the three point linkage. The rate (lower-
The magnet presses the main spool (2) to the right against the ing speed) of the return flow is proportional to the current
inner spring. The spool opens the passage between the supplied to the solenoid for lowering. The pilot pressure limit-
lowering valve (6) and tank (T). ing valve (3) sets a pressure difference which acts over the
main spool (2) when the load is being lowered.
At the same time the spool (2) also allows oil (Qs) to flow be-
hind the pilot piston (5). The piston moves to the left and The free circulation circuit from the pump (P) to the tank (N)
opens the lowering valve pilot ball. The pressure behind the functions as in the neutral position.
lowering valve decreases (compared with the pressure in the
working line) and the lowering valve opens and allows oil to 1) 3---way oil flow regulating slide
flow from the lifting cylinders to the tank. 2) Main spool
3) Pilot pressure limiting valve
The return oil flow pressure also acts on the front of the piston 4) Shock valve
(5). If this pressure reaches a sufficient level (greater than the 5) Lowering valve pilot piston
force of spring+pressure Qs), the holding valve stops the 6) Lowering valve
flow. 7) Free circulation oil to the transmission lubricating system.
617
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 24

Lifting cylinders

max 185

2
Earlier 95 95 -- 115
X100
d=30 d=40
d D=80 D=90
D

1
X110 --
X120
d=40
D=100

Figure 12. Lifting cylinders

1. Working pressure (max 17,5 MPa)

2. Ventilation
3. Tightening torque 150 Nm. Locking fluid Loctite 270.

Note! The cylinder can be loaded in both direction. Nipples

should be greased weekly/every 50 running hours.

The above shown lifting cylinder is made by Hydroline

Alternative cylinders are made by Ognibene.

618
 Model Code Page
91. Tractor hydraulics 95-- 115
910 25
1. 11. 2000 X100-- X120

Three---point linkage and towing

hook

Figure 13. Lifting force and lifting range Earlier 95

Note! Hydraulic lifting link gear is available as an op- 95---115, X100
tional equipment X100---X120

5
4
438 mm

85 mm
56 mm

1
6---8 mm
Max 10 mm 2

Figure 14. Pick ---up hitch

1. Adjusting pick ---up hitch lifting links

2. Checking locking of pick ---up hitch
3. Grease nipples weekly/every 50 running hours
4. Universal grease
5. Attachment for optional equipment
619
 Model Code Page
91. Tractor hydraulics 95-- 115
910 26
1. 11. 2000 X100-- X120

Valves for auxiliary hydraulics Quick ---action

couplings Valves

95---X120 tractors have as standard two valves for auxiliary

hydraulics, which are controlled separately with two levers.
The valves are fitted on the RH side of the tractor so that the
control levers go straight into the cab.

Both of these valves are adjustable for either single ---acting

or double ---acting function. One of these valves can be
locked mechanically in different positions and the other
valve has a ”floating position”.

Standard quick ---action couplings or Push ---Pull type coup-

lings are available. A leakage oil reservoir is standard.

As an extra equipment can be fitted;

a) two extra valves+brake valve for trailer
or
b) one extra valve equipped with an oil flow control
Figure 15. Valves for auxiliary hydraulics
valve+brake valve for trailer.

For later tractors two extra valves+brake valve for trailer+oil

flow control valve can be fitted.

When repairing or changing the valves, they are accessible

through the hole in the cab RH side mudguard.

Figure 16. Access hole

1. Adjustment between single/double ---action 3

2. Adjustment between single/double ---action
3. Position locking
A
Intermediate plate A and the pump side end plate B have
been attached to the valve bracket (3 pcs bolts). Tightening
torque for the bolts is 45 Nm. 1
Bolts C (4 pcs) through the valve block set must be tigh-
tened evenly and crosswise to 23 Nm. Otherwise the valve
spools can get trapped. When fitting extra valves, bolts C
B
should be changed for longer ones.

Note! When fitting valve blocks, ensure that the o---rings

between the blocks are correctly positioned in their C
grooves.
2
6181--- 64

Figure 17. Control levers for standard valves

620
 Model Code Page
91. Tractor hydraulics 95-- 115
910 27
1. 11. 2000 X100-- X120

23 MPa

Figure 18. Valves for auxiliary hydraulics

A Position locking for the first valve
B. On the end plate underside there is fitted a pressure ---limit-
ing valve for working hydraulics (19 MPa)

621
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 28

4
A N
B
N
C N

1 1 1

A A A

N N N
T P T P T P
2 2 2

B B B

3 P T 3 3

19 MPa
P

Figure 19. Foremost standard valve

C: Pressure position: Slide 1 has been moved upwards.

--- the foremost standard valve (order no 32536400): 1/2 ---ac- Flow ---through channels N are closed and oil flows via port B
tion, 3 positions (out---hold ---in), spring ---return. Out---position to the auxiliary hydraulics. Return oil flows from port A to tank
can be locked mechanically. channel T.

Function:
The change ---over valve 4 is used to give a double ---acting
valve a single ---action function. When single ---acting, the
A: Neutral position. Oil flows from the priority valve through
the flow ---through channels N to the control valve of the hy- equipment hose must be connected to the lower connector B.
draulic lift.
1) Slide
The channels to the auxiliary hydraulics (A, B) and the non ---
return valve 2 are closed.
2) Non ---return valve
B: Pressure position: When the slide 1 has been moved
downwards, the middle part of the slide closes the channels 3) Centring springs
N, and its upper part opens the line to the port A. Pressure in
the channel N and in channel P increases (these channels 4) Change ---over valve
unite in the front end flange).
The non ---return valve 2 opens and oil flows to the auxiliary hy-
draulics via port A.
At the same time the slide opens the return line from port B to
tank channel T.

622
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 29

A N
B N
C N

1 1 1

A A A

N N N
T P T P T P
2 2 2

B B B

3 4 P T 4 3 4
3
19 MPa
P

Figure 20. Rearmost standard valve

C: Floating position: The slide 1 has been moved further up-

--- The rearmost standard valve (order no. 32536500): 1/2 wards. The detent balls lock the sleeve. The sleeve opens the
---action, 4 positions (out---hold ---in ---float), spring ---return. middle channels N and oil flows to the hydraulic lift.
Floating position can be locked. The lines from the pressure channel P to ports A and B are
closed. Both ports A, B are connected to tank channel (and
Function: to each other).

A: Neutral position. Oil flows from the priority valve (and valve --- The change ---over valve 4 is used to give a double ---acting
no 1) through the flow ---through channels N to the control valve a single ---action function. When single ---acting, the
valve of the hydraulic lift. The channels to the auxiliary hy- equipment hose must be connected to the upper connector
draulics (A, B) and the non ---return valve 2 are closed. A.

B: Pressure position: When the slide 1 has been moved up- 1) Slide
wards, the middle part of the slide closes the channels N, and
its lower part opens the line to the port B. Pressure in the chan- 2) Non ---return valve
nel N and in channel P increases (these channels unite in the
front end flange). 3) Centring springs
The non ---return valve 2 opens and oil flows to the auxiliary hy-
draulics via port B. At the same time the slide opens the return 4) Change ---over valve
line from port A to tank channel T.

When the slide has been moved downwards, the port A is

pressurised and return oil flows via port B.

623
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 910 30

Oil flow control valve

0---40

--- The oil flow control valve makes it possible to use simulta- Functions:
neously two hydraulic cylinders, or simultaneous use of po- The valve directs the required priority flow (that can be ste-
wer lift and one auxiliary cylinder. plessly adjusted from 0 to 40 litres per minute) to the spool val-
ve that is mounted between the oil flow control valve and the
With the oil flow control valve the oil flow can be adjusted so intermediate plate.
that it suits the implement, when maximal flow is not needed
for e.g. speed control of hydraulic motors (together with a spe- The rest of the flow is directed through an external pipe to the
cial valve of the motor). next, downstream spool valves.

The oil flow control valve is situated between the pump end X = pressure channel for the regulated oil flow
plate and the valve block. The oil flow is adjusted with a knob Q --- X = the surplus flow to other spool valves
on the side panel in the cab. 1) Oil flow control valve
2) Intermediate plate
Note! Two seal kits are available for repairing the oil flow cont- 3) The spool valve supplied by the regulated flow (the valve
rol valve no. 32599900: kit no. 32449400 (complete) and kit type is a matter of choice)
no. 33643500 (internal seals).
624
 Model Code Page
90. Hydraulic system 95-- 115
1. 11. 2000 X100-- X120 910 31

Oil flow control valve

A) The oil flow is not adjusted. When the throttle spindle 1 is opened, the flow X grows and
the flow Q ---X decreases.
The first spool valve can not be used when the throttle is clo-
sed. The pump flow goes through the channel Qp to the spool If the pressure in channel X varies, the same pressure change
valves after the intermediate plate, and further through the po- is transmitted through the throttle and the balance piston bore
wer lift control valve into the tank. also to the opposite head of the piston, and this means in
practice that the spindle keeps its position and the flow does
Direction of the pressure to one spool valve or to the power lift. not change.

B) The oil flow is adjusted (and the manual control valve The throttle in the piston bore prevents vibration.
is in the active position). --- When the oil flow is adjusted, the pressure of the flow X is
the pump pressure minus the spring load. The pressure of the
The pump flow is divided in proportion to the throttle between flow Q ---P varies from free flow pressure to maximum pressu-
0 and 65 litres per minute among the channels Q ---X and X and re, depending on the use of the other manual control valves
can simultaneously be used for controlling the spool valve X / of the power lift.
(between the pump end plate and the intermediate plate) and
one of the next spool valves, or the spool valve X and the po- 1) Adjusting knob
wer lift. 2) Pressure channel that goes through the valve blocks
3) Adjusted flow to the X spool valve
4) Surplus flow to other spool valves

625
 Model Code Page
90. Hydraulic system 95-- 115
1. 11. 2000 X100-- X120 910 32

Return oil connection for auxiliary

hydraulics

Valmet 6100---8100 tractors have as standard a return oil con-

nection (1), which can be used when low return pressure is
needed.

Counter pressures:

1/2 inch connection, flow 50 l/min, 10˚C max. 9,0 bar

1/2 insc connection, flow 50 l/min, 50˚C . . max. 4,0 bar
1 inch connection, flow 50 l/min, 10˚C . . . max. 5,0 bar
1 inch connection, flow 50 l/min, 50˚C . . . max. 3,0 bar

Push---pull quick couplings

There is a breather hole under the rubber seal ring in the Push ---Pull quick couplings, which hole should point downwards. From
January 2000 oil gathering protectors will be fitted in the quick couplings and the oil gathering hose nipple must also point down-
wards. The parts must not moved in relation to each others during fitting.

If the breather hole does not point downwards, little oil can leak inside the coupling or water can condens, which make it difficult
to connect the couplings.

626
 Model Code Page
90. Hydraulic system 95-- 115
910 33
1. 11. 2000 X100-- X120

Kick ---out valve

--- Extra equipment (32536700): 2---action, 4 positions (float--- Pressure return (kick ---out) to the neutral position happens
out---hold ---in) kick out. Float, out and in ---positions can be when oil pressure pushes ball+needle at the spool lower end
locked. and releases the locking balls (at a pressure of 14---16 MPa).

Function: The spring space is open and allows oil to be returned to pass-
age T. Rest of pressure in the oil space (if greater than 0,2
A: Neutral position: Oil flows from the priority valve (via valve MPa) can cause returning of the spool to the neutral position.
blocks) through passages N and further to the power lift con-
trol valve. Passages to auxiliary hydraulics (A, B) and the D: Floating position: Spool 1 has been moved further
non ---return valve 2 are closed. upwards. The locking balls lock the spool in position. The
middle passages N open and oil flows through them to the
B: Pressure position: When the spool 1 is moved down- power lift control valve. Connection between pressure pas-
wards, the spool middle part closes the passages N and the sage P to ports A and B is closed.
spool upper part opens an oil way to port A. Pressure in pass- Both ports A and B are connected with tank passage T.
age N increases as in passage P (passages joint together in
the front end plate). --- When the valve is used as a single ---acting valve, an imple-
Non ---return valve 2 opens and oil flows via port A to the aux- ment hose should be connected to the upper coupling A. The
iliary hydraulics. return oil flow can be created by moving the spool to the float-
At the same time the spool has opened a return passage from ing position (upwards).
port B to tank passage T. Locking balls lock the spool.
1) Spool
C: When the spool is moved upwards, port B is pressurised 2) Non ---return valve
and oil returns via port A. 3) Centring springs

627
628
 Model Code Page
95-- 115
91. Tractor hydraulics X100-- X120 911 1
1. 11. 2000

Repair instructions

1. Low pressure circuit (Op. no. 911)

A. Measuring pressure

1. Start the engine and run it at 1500 revs/min.

2. Warm up the transmission/hydraulic oil to 30 ---60˚C.

Note! The oil warms up faster if the steering wheel is held

against the stop. Pressure ---test point

3. Disengage as many servo functions as possible (clut-

ches unpressurised in order to eliminate a pressure drop
caused by leakages in clutch piston seals).
Pressure ---limiting valve
Note! When the 4WD is engaged, the clutch is unpressuri-
sed. On HiTech models the shuttle must be in the neutral
position. Two DPS clutches are always pressurised, when 4b. X100 ---X120: Connect a pressure gauge to the test
the engine is running. point on the servo valve block and read the pressure value
The pressure value is 1,8 ---1,9 MPa (18---19 bar). Test
equipment, see page 910/5.
Pressure ---limiting valve
Note! These pressures are maintained by the low pressure
limiting valve and seals at various solenoid valves (and
Pressure ---test point clutch piston seals in pressurised clutches).

Pressure ---limiting valve (1,8 MPa)

5. If the pressure gauge reading deviates much from the

correct value, the fault can lie in the pressure ---limiting valve
or the low ---pressure pump is worn out. Also excessive lea-
kage can cause pressure loss.

6. Then activate each service in turn. The pressure should

4a. 95 ---115: Connect a pressure gauge to the test point on
momentarily drop but quickly re ---stabilise. A constant pres-
the servo valve block and read the pressure value. It sho-
sure drop of about 0,1---0,2 MPa indicates excessive lea-
uld be 1,8 ---1,9 MPa (18---19 bar). Test equipment, see
kage and therefore pressure loss in that service.
page 910/5.
Note! It is available a pressure ---test kit which order no is
31965000. It includes all equipment needed for pressure
measurement. The parts can also be ordered separately.

629
 Model Code Page
91. Tractor hydraulics 95-- 115
911 2
1. 11. 2000 X100-- X120

B. Diff. lock clutch pressure C. Lubricating pressure and PTO clutch

pressure
Note! Engine revs 1500 r/min. Oil temperature 30 ---60 ˚C.
Note! Engine revs 1500 r/min. Oil temperature 30 ---60 ˚C.

Lubricating oil
pressure

A
1a. 95 ---115: The lubricating oil pressure can be measured
by connecting a pressure gauge to the hole on the LH side
of the PTO housing beside the top link bracket. The lubri-
cating oil pressure minimum value is 0,03 MPa.
1a. 95 ---115: The diff. lock clutch pressure can be measu-
red separately by connecting a pressure gauge to the hole
A on the servo valve block. The hole has thread M14X1,5
and connector 30068700 fits into the hole. Pressure value
should be 1.8---1,9 MPa.

1b. X100 ---X120: In HiTech tractors the lubricating pressure

min. value is 0,12 MPa measured at test point (HPR) on
the rearmost pressure filter bracket (point 15b, J26434---.
point 15, ---J26433).
1b. X100.129Hi: The diff. lock clutch pressure can be mea-
sured separately by connecting a pressure gauge to the 2. The PTO clutch pressure is measured by connecting a
hole A on the servo valve block. The hole has thread pressure gauge to the hole on the RH side of the PTO
M14X1,5 and connector 30068700 fits into the hole. Pres- housing beside the top link bracket. The pressure should
sure value should be 1.8---1,9 MPa. be 1,70 ---1,85 MPa (0,05---0,1 MPa lower than pressure
measured at the pressure ---test point on the servo valve
IMPORTANT! In 95---X120 tractors the front axle HiLock block). In HiTech models there is a Valmet HPR test---point
pipe has been connected to point A. Remove the pipe and in the hole.
connect the pressure gauge to point A. If there is leakage
in the front axle diff. lock, excess oil can flow into the front 3. Both holes have thread M14X1,5 and connector
axle housing and oil level rises. 30068700 can be screwed into them.

630
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 911 3

D. DPS clutch pressures in 95---115 E. Pressures in DPS and shuttle

clutches in X100---X120
Note! The pressures are measured at engine revs of 1500
rpm and with an oil temperature of 30 ---60 ˚C.
IMPORTANT! On the X100---X120 tractors, there are fitted
Valmet HPR test points to measure the DPS and HiTech
shuttle clutch pressures.

NOTE! Under codes 370/371 there are also shown calibra-

tions and resettings of DPS clutches (C1, C2, C3) and Hi-
Tech Shuttle clutches (F and R).

The pressures are measured at engine revs of 1500 rpm

and with an oil temperature of 30 ---60 ˚C.

C1=DPS foremost clutch C3

C1

C2
C2= DPS middle clutch Position of pressure test points:
--- C1=DPS foremost clutch
--- C2=DPS middle clutch
--- C3=DPS rearmost clutch in planetary gear
--- R= forward drive clutch of HiTech shuttle
--- F = reverse drive clutch of HiTech shuttle

The pressure values in all clutches should be 1,8 ---1,9 MPa

C3=Clutch in planetary gear (rearmost)

All three pressures should be between 1,8 ---1,9 MPa. Pres-

sure measuring equipment in pictures above are included
in pressure ---test kit 31965000.

NOTE! On tractors which have a lock valve (transmissions

550/650 with a mechanical shuttle, see page 420/20), the
piping deviates from the pictures above.

631
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 911 4

2. High pressure circuit B. Working pressure

A. Measuring free circulation pressure

(0---40 bar)
1. Connect a pressure gauge (pressure measuring equip-
ment, se page 910/5) to the pressure ---test point at the
The free circulation pressure can be measured by connect- pressure filter (foremost filter for hifg ---pressure circuit).
ing a pressure gauge to the pressure ---test point at the
pressure filter bracket (foremost filter for high pressure cir- 2. Adjust engine revs to 1500 r/min. Warm the hydraulic oil
cuit). When measuring this pressure, the steering wheel to 30 ---60˚C.
must not be turned. The auxiliary hydraulic valve levers
should be in the neutral positions. In addition, the power lift 3. Move an auxiliary hydraulic valve lever to the pressure
position control potentiometer must not be in the lowest position and read off the gauge reading which should be
position. 19,0 ---19,8 MPa.

Pressure values at engine revs of 1500 r/min:

--- ~ 1,5 MPa (+50˚...+65˚C)
--- ~ 1,7 MPa (+30˚...+32˚C)
--- ~ 2,0 MPa (+20˚...+25˚C)

Note! Possible extra hydraulic equipment raise the free

circulation pressure value. For instance, on tractor that has
three valve blocks (and a front loader), the pressure value is
about 2,1 MPa (+50...+65˚ C).

Note! Pressure measuring equipment above are included

in the test kit 31965000.
Shims

Pressure ---limiting valve

Note! The pressure is maintained by the pressure limiting

valve on the underside of the front plate of the auxiliary
hydraulic valve set.

4. If the pressure reading deviates much from the correct

value, change pressure limiting valve spring or adjust it with
shims. Shims thickness of 0,2 mm raises the pressure value
about 0,4 MPa.

Note! Possible deviation can also be caused by a dirty or

faulty safety valve (23 MPa) in the hydraulic pump or the
pump can be rundown.

632
 Model Code Page
91. Tractor hydraulics X100-- X120 911 5
1. 11. 2000

C. Removing hydraulic pump,

X100---X120

1. Drain the oil from the transmission.

2435
5. Unscrew the pump fixing bolts and remove the pump
from the gearbox housing.

D. Fitting hydraulic pump

1. Fit the pipe clip (screw upwards) onto the suction pipe.
2. Remove the PTO housing (see Op. 462 1A).
Fit the pump coupling sleeve into the pump drive mechan-
A ism (if removed).

2. Fit a new pump. Turn the pump clockwise and tighten

the fixing bolts to 40 ---50 Nm.

3. Push the pressure pipes through the sealing pieces and

screw the pipes into the pump thread to a torque of 60
Nm.

A 4. Apply sealing compound Hylosil RTV Grade 102 Black

between the gearbox and sealing pieces. Apply Loctite 542
to the sealing piece screws and tighten them.

5. Connect the pressure hoses to the pressure pipes. Fit the

brake cylinder.

3. Remove the RH side brake cylinder. Disconnect the con- 6. Tighten the suction pipe clip to a torque of 2 Nm.
nectors from the pressure pipes. Slacken the sealing pieces
(A) and unscrew the pressure pipes from the pump. 7. Fit the PTO unit (see Op. 462 1G).

8. Fill the transmission with oil and test---drive the tractor.

Make sure that the new pump is functioning by measuring
hydraulic pressures.

Note! For the pump is available a seal kit no. 32664100.

The high pressure pump safety valve (and separate parts)
are available as a spare part. During warranty period the
pump is changed as a complete unit.

E. Hydraulic pump on 95---115 tractors

In these tractors the pump is placed on the RH side of the
engine and the pump is driven by the engine timing gears.
2434
In the warranty period the pump is changed as a complete
4. Slacken the pump suction pipe clip. unit.

Note! The differential can be in place because it does not pre-

vent removal of the pump.

633
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 911 6

2. Pump and pipes, fault tracing

High pressure pump Low pressure pump

Position of pump in X100---X120

Technical data of pump, see page 910/3

A. General B. Fault tracing by inspecting oil:

The condition of the pump can be checked e.g. by measuring 1. Air in oil --- If there is too much air in oil, the result is that oil
pump output at different counter pressures. A worn pump has foams in the tank. In this case, check all seals and connectors
a lowered output and it cannot maintain enough high pres- in the suction side. Also the suction strainer cover seal can be
sure. In this case the hydraulic circuit does not function as it faulty. Check the condition of the pump drive shaft oil seal.
should. Change oil if necessary.

The lowered output causes the hydraulic cylinder movements 2. Water in oil --- Water in oil causes the oil to be milky. The
to be slower than normal. system must be emptied and filled with new oil. In addition,
The lowered pressure means that the hydraulic cylinder can- prevent water from entering into the hydraulic system. Water
not raise heavy loads. E.g. the lifting cylinder cannot raise the causes corrosion to the various parts in the hydraulic circuit.
load even thought its weight is below the max permissible
load. 3. Impurities in oil --- Impurities can be verified by taking a
sample of oil and by pouring it through a filter paper. The suc-
A possible reason can also be a faulty pressure ---limiting valve tion strainer and the pressure filter should be serviced accord-
or shock valve. In addition, oil leaks in various components ing to the maintenance schedule. Impurities can enter into the
and seals can also cause corresponding malfunctions. system from the auxiliary hydraulic cylinders. The hydraulic
oil and the pressure filter must be changed according to the
The pump can be tested e.g. by measuring the pump output instructions.
with a flow meter. Use of a separate loading valve makes it
possible to measure the output at different pressures. The 4. Impaired properties of oil --- Mineral oil loses some lubri-
pump output must not vary much at different counter pres- cating properties in prolonged use. This can appear in
sures. The working hydraulic pump output can be measured change of colour, change of smell or change of viscosity. For
from the quick ---action couplings. The low pressure pump these reasons, it is necessary to change the oil according to
output can be measured by connecting the flow meter on the the maintenance program. Also oil level should be checked
pressure hose between the pump and the servo valve block. regularly.

It is difficult to determine a certain reject limit to the pump. In

a light agricultural use even a worn pump can function satis-
tactorily. Just when a tractor has extra hydraulic equipment
(front loader, timber loader etc.), a worn pump cannot main-
tain the hydraulic circuit and it should be changed.

634
 Model Code Page
91. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 911 7

3. Air in oil --- If air enters into the system via the suction
C. Fault tracing without removing pump side or via the pump drive shaft seal, this causes the same
damages as cavitation. If there is too much air in oil, the oil
If the hydraulic system functions when the oil is cold, but in
in the reservoir foams.
the operating temperature different functions are slow or
powerless, this indicates that the oil pump is worn ---out.
4. Pump drive shaft loading --- If the pump drive shaft has
a strong radial loading caused by the pump drive mechan-
The high pressure pump can be tested by connecting a
ism, this causes damages to the shaft seal and air and oil
pressure gauge to the circuit and by pulling one auxiliary
leaks by the seal and after a prolonged use, the drive shaft
hydraulic valve lever to the pressure position. Now if the
bearings are worn unevenly. For the same reason, the
pressure gauge reading follows clearly the engine revs
pump gears cut the pump housing on one side resulting
alteration, this indicates that the pump is worn.
internal leakages in the pump.
The faulty pump can be noisy which indicates a damage in
the pump. Note that a blocked suction strainer causes a
shrieking sound to the pump. Observe the following when assembling the
pump
A worn pump ”whips” oil and due to the fluid friction the
whole hydraulic system overheats. This can be verified by Assemble the low pressure pump and tighten the end
feeling the temperatures of the pipes and the oil reservoir. cover bolts to a correct torque. Assemble the high pressure
In this case, for instance, the pump pressure pipe can be pump and tighten the end cover bolts only to finger tight.
essentially warmer that other pipes and the oil reservoir. Blow compressed air (~ 5 bar) through the pressure side
hole (suction side hole open) at which time the shafts and
gear wheels are centered and at the same time tighten the
end cover bolts to a correct torque of 61 ---68 Nm.
D. Internal inspection of pump
Note! Without this centering the pump will probably dam-
age after a very short operating time.
Note! Never dismantle the pump if the warranty is valid, but
in this case change a new spare pump.

1. Detach the damaged pump from the tractor. Make sure E. Maintenance
that the pump and a fitting table are clean before dismantl-
ing the pump. 1. Check the hydraulic oil weekly/at every 50 running hours.
Oil quality: see page 130/4.
3. Mark all removed parts in relation to each other for easier
assembling. 2. The pressure filters are changed the first time at 100
hours warranty service. The second change is done at 250
4. Fit always new seals. A seal kit no. is available for the running hours and the third change at 500 running hours.
pump. After that the filter is changed at every 500 running hours.

Note! When the hydraulic system is in a perfect condition, 3. Hydraulic oil should be changed at intervals of 1000
the pump housing surfaces are smooth and shiny as well running hours or yearly which one is reached first. The suc-
as the bearing surfaces. Text below presents how faults in tion strained should be cleaned always when the oil is
the hydraulic system affect the oil pump. changed. The suction strainer should be changed more
often when necessary.
1. Impurities in oil --- Impurities cause clear dragging
Note! If You use continually the auxiliary hydraulics, the
grooves on the pump housing and bearing surfaces in the
hydraulic oil and the pressure filters should be changed
direction of rotation. The most evident damage caused by
more often.
impurities are deep grooves on the gearwheel side sur-
faces. Impurities wear the pump fast resulting lowered out-
4. The high pressure and the low pressure can be
put value.
measured according to instructions. Also different clutch
pressures can be checked. The pressure limiting valve and
2. Cavitation damages --- Mineral oils contain 10 percent
the shock valve can be opened and cleaned. These valves
of air. In the pump suction side if suction is too high, air
can also be adjusted by changing shims.
bubbles are formed, which fasten onto the pump housing.
When pressure in the pressure side rises rapidly, the Important! If the hydraulic power lift or the Delta Powershift
bubbles ”explode” causing deep pits on the pump housing.
or the HiTech shuttle have malfunctions, the pressure filter
In certain cases the cavitation generates sound, which can inserts should be changed immediately.
be heard from the pump.

Possible reasons:
1. Suction pipe or suction strainer blocked.
2. Wrong oil viscosity.
3. Air enters into system.

635
636
 Model Code Page
95-- 115
90. Tractor hydraulics X100-- X120 912 1
1. 11. 2000

Hydraulic power lift

B. Removing control valve
1. Control valve Note! The control valve is fitted on the RH side of the gear-
box housing.
A. Checking shock valve opening pres- 1. Remove the RH side rear wheel. Disconnect the soleno-
sure id valve wires from the control valve.

1. Lower the lower links to the lowest position.

2. Disconnect all oil hoses from the control valve. Unscrew

the control valve fixing bolts (3 pcs) and remove the valve.

Note! There is an oil hole between the control valve and

2. Connect a pressure gauge and a hand pump to one the selector cover. This hole has been sealed with an o---
pressure hose of the lifting cylinder (see arrows). ring, which must be fitted back when the control valve is
refitted.
3. Raise the lower links to the upper position, stop the en-
gine and switch off current.
C. Fitting control valve
4. Pump with the hand pump pressure into the control valve
and read the opening pressure, which should be 20 ---21 1. Make sure that the o---ring is in place between the control
MPa.
valve and the selector cover.

2. Fit the control valve and tighten the fixing bolts evenly to
23 ---27 Nm.

3. Connect the solenoid valve wires and all oil hoses.

4. Test---drive the tractor and check the function of the hy-

draulic power lift.

Shock valve (20 MPa)

Note! The shock valve is accessible without removing the

control valve.

Note! If you want to lower the lower links without starting

the engine (e.g. during repair work), unscrew the shock
valve after which the lower links can be pressed to the
lower position.

637
 Model Code Page
90. Tractor hydraulics 95-- 115
X100-- X120 912 2
1. 11. 2000

D. Reconditioning control valve

Lowering valve
pilot piston

Main spool
Lowering
valve

3---way oil flow regula- Shock valve

ting slide

Lowering valve

If the hydraulic power lift makes many lifting corrections (reac-

tions) per minute when a weight is attached to the three ---point Adjusting pilot pressure:
linkage, a possible fault can be faulty lowering valve (or its Connect a pressure gauge to the pressure filter test point. Ac-
pilot piston). tivate the power lift and adjust the engine revs to 1500 rpm.
Turn the position potentiometer to lowering. Now the free cir-
In this case, the lowering valve can be disassembled and culation pressure must rise 5 bar, e.g.: not activated 20 bar
cleaned as well as the pilot piston. Leaking lowering valve and activated 25 bar.
must be changed. In addition, the valve spring must be
checked and changed. Note! If the lift does not hold the load,
possible fault can also be leaky lifting cylinder piston seal. The tighter the valve is, the greater is the lowering speed (if the
valve is tightened too great, the free flow pressure rises too
Shock valve (20 MPa) much in the lowering movement). If the valve is too loose, the
lower links do not lower at all (lowering valve does not open).
If the lift does not hold the load, the possible fault can also be
leaking shock valve. When the control valve is in neutral posi-
tion, the load rests on the shock valve. Solenoids

In this case, open and clean the shock valve and, if necessary, Solenoid valves are available as a spare part. When fitting a
change the valve spring or adjust it with shims. new solenoid, fit the same shims onto the end of the main
spool spring. Do not tighten the solenoid screws too hard.
3 ---way oil flow regulating valve
Tightening torques
This valve can be opened and cleaned. The valve slide must
move easily in its bore. Shock valve plug . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
Lowering valve plug . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Pilot pressure limiting valve Pilot piston plug . . . . . . . . . . . . . . . . . . . . . . . . . 103 Nm

Note! The new pilot valve has neither a ball nor a spring but Note! When reconditioning the control valve, always fit new
only a tapered valve pin and a locking nut. The valve must not sealing rings. When opening the valve plugs, use good tight
be screwed fully home, it must be opened 1/2---1 turn. Allen keys because the plugs can be very tight. When
slackening the plugs, knock at the Allen keys with a hammer.

638
 Model Code Page
90. Tractor hydraulics 95-- 115
X100-- X120 912 3
1. 11. 2000

2. Lifting cylinders

A. Changing lifting cylinder seals

1. Disconnect the lift cylinder pressure lines and remove the

cylinder.

2. Take out the circlip and backing ring of the cover.

6. Remove the cover from the piston rod and the seals from
the cover.

3. Knock the cover into the cylinder until the o---ring and circlip
of the cover inside the cylinder can be removed.

7. Squeeze the new seal as shown in the figure and press it

into its groove (sealing lip downwards). Fit the piston rod oil
stripper.

8. Change the o---ring and backing ring of the cover.

9. Place the circlip and backing ring on the piston rod. Grease
the inside seals of the cover and push the cover on the piston
rod.

10. Fit the piston on the piston rod. Use locking fluid Loctite
4. Pull the cover and piston out of the cylinder with a sharp 270 on the threads. The piston nut tightening torque is 150
movement. Nm

5. Remove the sealing ring of the piston (cut off with a knife),
the o---ring and guide ring. Remove the piston from the piston
rod.

Note! Removal of the piston is facilitated by heating it up so

that the locking fluid on the threads melts.

639
 Model Code Page
90. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 912 4

13. Roll the two guide rings together as shown in the figure
11.Fit the o---ring on the middle groove of the piston and the and fit them on the piston.
outside sealing ring. Use ETV 893580 (ø 80), ETV 894 280 (Ø
90), ETV 894 240 (ø 100) and ETV 893600 (ø 80), ETV 894 300
(Ø 90), ETV 894 260 (ø 100). Apply grease on the sliding sur-
faces of the tool.

14. Lubricate the sealing surfaces of the piston and cover and
push the unit into the cylinder with a sharp movement. Fit the
circlip inside the cylinder. Pull out the cover against the circlip
and fit the o---ring, backing ring and outer circlip.

15. Fit the lift cylinder. Connect the oil hoses and tighten to 45
Nm.

12. Squeeze the seal into the groove with ETV 893590 (ø 80),
ETV 894 290 (Ø 90), ETV 894 250 (ø 100).

640
 Model Code Page
90. Tractor hydraulics 95-- 115
1. 11. 2000 X100-- X120 912 5

Three---point linkage and towing Adjusting pick ---up hitch lifting links, if
hook fitted

2
6181--- 125

Lower links

If the lower link (1) must be changed, first remove the draft The lifting links should always have a certain amount of clear-
sensor cover (2) and the draft sensor locking piece (3). Now ance when the hydraulic lift is in its upper position. However,
the lower link can be removed after the draft sensor is pulled they must be adjusted in such a way that the pick ---up hitch
out. is securely locked by the pawl, even when the towing hook
is loaded.

Pick-- up hitch, if fitted Before adjusting, raise the hydraulic lift to its upper position
using the position control knob (towing hook unloaded).
When removing the pick ---up hitch the lower links must be de- Check the adjustment by moving the lifting links manually.
tached first. After that drive out the locking pins of the pick --- Adjustment is correct when the link moves loosely and when
up hitch shaft and remove the pick ---up hitch shaft. the lift is lowered the towing hook is locked positively by the
pawl. Make sure that the spring returns the pawl fully home.
Note! Remove the check link bracket from one rear axle hous-
ing. Remove, if necessary one rear wheel, if the pick ---up hitch Adjust the length of the links if necessary by removing the
shaft cannot be pulled out from its place. cotter at the upper end of the links and turning until the correct
length is obtained. Check that both lifting links are the same
The pick ---up hitch loosens when the locking pins at the front length after adjustment.The lifting links may be tightened
end of the hitch is removed. Now the hitch releases from its when lifting with push buttons.
cast iron guide ways under the gearbox housing.
Correctly adjusted lifting links ensure that the hydraulic lift can
Lifting arm shaft be raised to its uppermost position. The pick ---up hitch is
locked when the lift is lowered to the point where the hitch
rests on the pawl, thereby preventing unnecessary loading on
If the lifting arm shaft has to be changed, the PTO housing
the hydraulic pump and overheating of the oil.
must be detached from the tractor. Then remove the PTO unit
front cover and the PTO clutch shaft.

Remove the position sensor cam from the lifting arm shaft Checking locking of pick-- up hitch
through the opening in the upper part of the PTO housing.

Remove the lifting arms and pull out the lifting arm shaft from
6-- 8 mm

its location on the PTO housing.

Note! Do not damage the position sensor when removing the

PTO housing. Remove the position sensor always before de-
taching the PTO housing from the tractor (see section 46).

6181--- 126

Make sure that the spring returns the pawl fully home. When
the pawl is turned upwards the pick ---up hitch should move up
by 6 ---8 mm.

641
642
 Model Code Page
95-- 115
92. Implement hydraulics X100-- X120 920 1
1. 11. 2000

Fixed front loader (optional)

13
11

--
12

7a

7b

6
5
4
10
8b 1

2 3

8a

Picture 1. Front loader and its control

10. Maintenance support (under the loader can be worked
1. Variable displacement pump (130 l/min/2200 r/min) only, when the bar is supported with the maintenance sup-
2. Hydraulic oil tank (100 l) port)
3. Return oil filter 11. Bucket locking position indicator pin for safety.
4. Pressure ---test point on the valve block set (working pres- 12. Mounting plate for implements (3 different plates avail-
sure 21 MPa) able)
5. Four control valve blocks in line, one for loader bucket 13. Loader lowering speed adjustment (by turning to +is
and one for loader bar cylinders, one for extra implement faster lowering speed and --- is to slower lowering speed).
cylinder and one for optional motor spindle. Separate This valve is placed on the floating valve.
blocks for bucket hydraulic lock function (option) and float-
ing function (option) and one block for controlling loader The hydraulic system of the loader is of load sensing type.
control lever pilot pressures. The variable displacement pump (1) is located in front of
6. Front loader control lever the motor. The hydraulic tank (2) is in the tractor’s front
7a. Rocker switch to pre ---select the floating position func- frame.
tion of the bucket (option)
Return filter (3) is located on the right hand side of the hy-
7b. Push button to switch on/off the floating position func-
draulic tank beside the battery. Oil specifications are shown
tion (option)
on page 130/4. Maintenance procedures of the front loader
8a. Rocker switch to pre ---select the hydraulic lock of the
are shown on page 130/5.
bucket
8b. Switch to switch on/off the bucket hydraulic lock func-
IMPORTANT! Front axle oscillation brake, see page 670/9.
tion.
9. Button to lower the front loader in special situations (push
the button and turn it). The button is placed in the cartridge
end of the locking valve block.

643
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 2
1. 11. 2000

Picture 2. Motor spindle fitting, option

This function is double acting in front of the tractor (front

quick couplings B), but single acting at the rear side of the
tractor (rear quick couplings C). The quick couplings are
3/4” at both ends.
Controlling lever (A) is in the front panel on the LH side.
Adjustment is stepless and under the rubber cover of the
lever pivot point there are friction plate tension screw.
The control lever has a locking position in the middle posi-
tion and in the extreme positions.

NOTE: It is very important that the control lever is in the

middle position, when implement is not connected.
When oil couldn’t flow freely, its goes through the pres-
sure controlling valve and heats up.

For that reason, when there is no use of the control lever of

the motorspindle, adjust its friction plate screw so loosely,
that the pivot certainly returns the lever to the middle posi-
tion.

644
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 3
1. 11. 2000

Hydraulic diagram of implement hydraulics

LV
x

Picture 3. Hydraulic diagram of implement hydraulics

9. Front quick couplings 1/2”
1. Control valve blocks for loader 10. Bucket locking cylinder
2. Loader control lever 11. Pilot pressure valve
3. Motor spindel control lever, option 12. Change ---over valve
4. Variable displacement pump 13. Quick couplings 3/4”, motor spindle front
5. Bucket cylinders, 2 pcs 14. Quick couplings 3/4”, motor spindle rear
6. Loader bar lifting cylinders, 2 pcs 15. Return oil flter
7. Bucket floating/locking valve, option 16. Hydraulic oil tank
8. Change ---over valve 19. Resistance non ---return valve
20. Front axle oscillation damping cylinders
21. Oscillation damping control vale
22. Pressure test point

645
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 4
1. 11. 2000

Picture 4. Implement hydraulic diagram

646
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 5
1. 11. 2000

Picture 4. Implement hydraulic diagram

1. Extra implement cylinder (e.g. snow plough)

2. Locking cylinder
3. Locking / Implement valve
4. Bucket cylinder
5. Hydraulic pump for loader hydraulics (max 130 l/ 210 bar)
6. Hydraulic pump, tractor working hydraulics (95---115: in connection with engine timing gears. X100---X120: in gearbox hou-
sing)
7. Loader bar lifting cylinder
8. Floating position / locking valve
9. Restriction/non ---return valve (adjustable)
10. Directional valve (for loader)
11. Return filter of the hydraulic system
12. Control pressure unit
13. Control lever (lift---lower ---bucket). In the lever top there is a switch for implement cylinder.
14. Control lever for motor use (front/back). The lever is friction locked
15. Quick couplings back (1---action)
16. Quick couplings front (2---action)
17. Non ---return valve 0,035
MPa

A
B
C
D

Picture 5. Pump and pipes

1. Pump
2. Suction pipe
3. Pressure hose
4. Control signal
5. Leakage oil to tank
6. Valve
7. Pressure ---test point (21 MPa)
A. Loader bar movements
B. Bucket movements
C. Motor spindle
D. Extra implement cylinder

647
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 6
1. 11. 2000

Front loader electric system

(basic machine wiring diagrams are shown under code 310)

RUSK= brown
SIN=blue
VIHR=gree
KELT=yellow
HARMAA=grey
MUSTA=black

60A--- 18

1. Bucket floating position, electric control 2. Bucket locking position, electric control

Electric components: Electric componens:

--- Switch S102 on the dashboard (pilot light in the switch) Rocker switch S100 on the lever console on the driver’s right
--- Push button S103 in the loader control level knob (spring returned to pos. 0)
--- Relay K102 behind the fuse box circuit card (relay is of Rocker switch S101 in the loader lever knob (spring returned
impulse type i.e. the satus of the relay (0, 1) is changed to middle pos. 0).
every time the button S103 is pressed Solenoid valve Y12 (change ---over valve on the bucket side of
--- Y10 and Y11, solenoid valves in the engine compartment the front loader bar).
--- Diode V102 (prevents voltage F24 from entering into the Solenoid valve Y13 in engine compartment
alternator G2 D+ circuit when relay K102 is energised. Solenoid valve Y14 in engine compartment

Description: Description:
Hold switch S100 in pos. 1, at which time solenoid valve Y12
When switch S102 is in pos. 1 (pilot light illuminates), the is energised and the control of the bucket locking is possible
floating position can be switched off and on with button The locking function is controlled with switch S101 as follows:
S103 in the loader control lever knob. --- left side down=solenoid valve Y14 is energised and the
When pressing button S103, relay K102 is earthed at which bucket is locked
time solenoid valves Y10 and Y11 become energised and --- right side down=solenoid valve Y13 is energised and the
the floating position is switched on. bucket locking is released.
When pressing second time the button the relay is disen-
gaged and the floating function is switched off i.e. the float- Extra equipment: hydraulic cylinder in the front part of the
ing position is on in every other time when the button is loader (e.g. snow plough position) is controlled with switch
pressed. S101 as follows:
The bucket floating function can also be switched off when --- left side down=solenoid valve Y14 is energised and the cyl-
the rocker switch S102 is turned to the 0 position (pilot light inder is functioning.
in the switch goes out). --- right side down=solenoid valve Y13 is energised and the
cylinder is functioning
Note! The control of relay K102 (floating) does not function
when the engine is switched off (control voltage from the Note! Moving directions depend on the connections of the
alternator), hoses

648
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 7
1. 11. 2000

Rocker switch S102 Solenoid valve Y11

Push button S103

Solenoid valve Y10

Picture 6. Position of electric components for bucket floating function (option)

Locking function valve with solenoid

valves Y13 and Y14

8a

8b

8a. Rocker switch S100

8b. Rocker switch S101

Picture 7. Position of electric component for bucket locking (option)

649
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 8
1. 11. 2000

Picture 7A. Position of electrical components

650
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 9
1. 11. 2000

Picture 8. Operating the hydraulic cylinder by the switch

(2) on the top of the loader control lever (option)

Note! Valve 3 gets oil through the same pipe as the func-
tion of bucket hydraulic locking

Hydraulic cylinder (1) is operated by the switch (2) as fol-

lows:
--- pushing right end of the switch moves piston outwards
--- pushing left end of the switch moves piston inwards

This function can be used e.g. when changing the angle of

the snow plough. Operating of the hydraulic cylinder is
done by means of solenoid valve (3) Y12 located in front of
the loader bar.

651
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 10
1. 11. 2000

Control valve block set type SX14, trouble shooting

Note! Before you doubt, that this valve block set has malfunctions, check
first whether the other hydraulic component are OK (e.g. pump)
This valve block set controls the normal working movements of the front
loader and extra implement cylinders and possible motor spindle.

7. Pressure ---test point, 21 MPa.

Note! The below shown trouble shooting table may include equipment, which are not fitted on 95---115 and X100---X120 trac-
tors, since it includes all variations of this type of control block set. In Valtra tractors the valve block spools are moved hy-
draulically by means of pilot pressure to the both ends of the valve spools. The pilot pressure are steered to the spool ends by
means of a “Joy Stick” type single lever in the cab.

Malfunction Probable cause Additional checks Remedy

Lack of force at all actuating 1. LS pressure relief valve Take a pressure measure- Replace LS pressure relief
members defective. ment valve
2. LS pressure relief valve
out of adjustment
Lack of force on one actuat- 1. Secondary pressure relief Reset to original pressure
ing member only valve out of adjustment (refer to block specifica-
2. Secondary pressure relief tions)
valve blocked “open” (return Replace secondary pressure
to tank) relief valve
Lack of speed in the per- SX14 with “open center” on Replace housing+piston as-
formance of a movement or the inlet element (if so sembly
all movements equipped)
--- piston if the “open center”
blocked in position P to-
wards T.
Movement performance slow 1. Spool stroke incorrect Manual control: measure If stroke is incorrect: replace
spool stroke. housing+spool assembly
Direct electrical control: If resistance is incorrect: re-
--- check coil resistance place coil.
(R: 2,5 ohms at 25˚C) Replace housing+pressure
compensator assembly
Lack of load hold 1. Load hold check valve fail- Replace housing+valve as-
ure sembly.
2. Excessive clearance be- Replace housing+spool as-
tween the housing and the sembly.
spool
Steering abnormally hard 1. Flow divider adjustment 1. Adjustment piston sliding Replace control sub ---sys-
problem freely. tem.
2. Adjustment piston Replace housing+control
blocked. system assembly.
Clamp operation malfunction 1. Coil on the outlet element Check coil resistance (R: 7,6 If resistance is incorrect: re-
(SX 14 installed on backhoe defective. ohms at 20˚C place the coil.
loader) 2. Shuttle valve malfunction Replace shuttle valve.
on the outlet element Replace 2---way valve
3. 2---way valve defective
Simultaneous movement 1. Blockage of the individual Remove and clean individual
mafunctions compensator orifice compensator
2. Individual pressure com- Replace the housing+pres-
pensator blocked sure compensator assembly
3. LS line leakage Replace LS flow regulator.
Engine remains under load Flow regulator blocked Replace flow regulator
after spools are returned to
neutral

652
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 11
1. 11. 2000

Spool detent malfunction 1. Mechanism defective Check coil resistance (for Replace mechanical detent.
2. Coil defective electrical detent. R: 16,5 If resistance is incorrect, re-
ohms at 20˚C place coil.
Increase of force on controls Control block assembly tie Check tightening torque Loosen and tighten to 25±2
or return defective rods too tight Nm.
Spool seals obsolente Replace spool seals.
Spool leaking oil Spool seals defective Replace spool seals
Oil leakage at pressure relief Seals defective Remove pressure relief valve
valve and plugs or plug and replace seals.
Oil leakage between el- Seals between elements de- Remove working sections
ements fective and replace joints.

Removal/installation of valve block set: Installation:

General: Clean all contact faces. Check the condition of line con-
nector seals.
Before removing the valve block set from the machine, the Clean the block if it has been in storage for a long period of
block and its surroundings must be throughly cleaned with time.
a high ---pressure cleaner. No impurities must enter the hy- Correctly place and secure the control block onto the ma-
draulic system. Plastic plugs are to be fitted on lines and chine with the mounting screws.
orifices immediately following their removal Connect the lines to the block as per the connecting dia-
gram and tighten to the correct torque.
IMPORTANT! Set all actuating members connected to the Ensure that the hoses are not twisted or rub.
machine in neutral position (on the ground, at lower limit
etc) to avoid accidents which could result from uncontrolled Once correctly installed, the unit can be placed into oper-
movements of the equipment when the hydraulic system is ation:
disconnected.
--- decalibrate the LS pressure relief valve before starting
IMPORTANT! With the engine off, release the pressure the machine
remaining in the system by manipulating all of the distribu- --- maneuver the distribution spools
tion spools. --- adjust the maximum pressure value using the LS pres-
sure relief valve.
Removal:
Control block disassembly/assembly
Disconnect all oil hoses from the valve block set and plug
all oil holes with plastic covers. Valve set assembly nuts 23 ---27 Nm. The load hold check
valve plugs are placed on the side of each valve block.
Unscrew the mounting screw and remove the control block. Check all o---rings between the valve blocks.

Flow regulator
LS pressure relief valve Flow divider control sub ---assembly

Flushing valve
Secondary pressure relief valve Spool movement

653
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 12
1. 11. 2000

29
10

14

42 36

43

Picture 9. Front loader piping

654
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 13
1. 11. 2000

Control valve to reduce the

pilot pressure to approx. 35
bar.

Loader control
valves

Control
lever

Readiness for motor spindle

Divider

Picture 10. Front loader control lever pilot hydraulics, which move the valve spools

The control valve, which reduces the pilot pressure is placed above the bucket floating valve on the LH side of the loader
contol valve set

655
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 14
1. 11. 2000

Picture 11. Control lever of front loader

Picture 12. Parts of the control lever

656
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 15
1. 11. 2000

Variable displacement pump

LS
Pilot valve
--- upper part for flow regulation
--- lower part for pressure regulation

Picture 12. Axial piston variable displacement pump

A spare part pump has been adjusted in the factory, but when fitting a new pump, pump pressure adjustment must be
checked/adjusted according to instruction on page 920/17.

If a new spare part pump is fitted on the tractor, the pump housing must be filled with hydraulic oil before the pump is
taken to use. The housing is filled through the leakage oil hole.

657
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 16
1. 11. 2000

Picture 13. Function of pump pilot valve

658
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 17
1. 11. 2000

FUNCTION OF PUMP PILOT VALVE

Function of pump:
See picture 13 on page 15.
Engine does not run:
The system pressure affect the pilot valve port P. Pressure
Spring of the pump adjusting plate presses the plate into
is conducted via boring in the pistons into the left hand side max. output position.
of the valve spools.
Engine is started (but not hydraulic functions):
Line A goes to the piston which adjust the position of the
pumping elements.
Behind the piston, against the spring, there is pressure from
the flow regulator,which has been adjusted to approx. 30
Line T goes into the pump housing and is connected to the bar:iin (to the flow regulator spool). LS ---port (and spring
tank via the leakage oil line.
cavity) is unpressurised. Pressure presses the pump plate
towatds the 0---angle and pump output is small e.g for oil
Pressure regulator leakages (approx. 4 l/min). Pressure affect the pressure
side.
When pressure increases the lower spool is pushed to the
right against the spring force. When the adjusted max. Engine is running and hydraulic pressure for e.g. front
pressure has been reached, passage between P and A loader cylinder is needed:
opens and the pump is adjusted to the smaller pumping
angle (=smaller output). Stand ---by pressure (30 bar) flows into the LS port and
further into the flow regulator in the spring side and pres-
Flow regulator ses the spool to the left. Connection between P--->A is
closed and connection between A --->T is opened. Pres-
The system pressure affect the left hand end of the upper sure behind the regulator piston is decreased and pump
spool. The LS pressure in passage X affect the spring cavity output becomes larger.
in the right hand end . The possible pressure difference in
the system over the directional valve presses the regulator Pump supply pressure affect the P port and the implement
spool against the spring. If the pressure difference in- cylinder pressure via LS port in the spring side (X) of the
creases, connection from P to A opens and pump is ad- flow regulator. Between P---X there is a pressure differ-
justed to the smaller output. If the pressure difference be- ence, which remains the same regardless of the hydraulic
comes smaller, connection from A to T opens and the load alterations.
pump is adjusted to the greater output.

Stand by status

If passage X is unpressurised, i.e, connected to tank, the

system pressure pushes the flow regulator spool agains the
spring to the right. Connection from port P to port A is
open and the pump is adjusted to zero output and to about
pressure of 20---25 bar.

659
 Model Code Page
92. Implement hydraulics 95-- 115
X100-- X120 920 18
1. 11. 2000

2,5 MPa
Adjustment of pump 25 MPa

NOTE! The spare part pump pressure has been adjusted to

25 MPa in the factory and the flow regulator pressure differ-
ence to 1,4 MPa (stand ---by pressure is then 2,0 MPa).
After fitting a new spare part pump, the pump pressures
must always be checked and, if needed, adjusted.

Pressure adjustment:

1. Ensure, that all control valve blocks are in the neutral

position. Connect a pressure gauge (30 MPa) to the pres-
sure ---test point.

2. Screw both pump adjusting screws fully open (flow re-

gulation and pressure regulation).

3. Start the engine, adjust the engine revs to 1500. Oil tem-
perature must be between 40 ---60 ˚C.

4. Screw the flow regulator screw (upper regulator) fully

closed (then the LS pressure affects the regulator). Pres-
sure in the pressure line must not rise.

5. Adjust the pressure cutter (lower regulator) to 25 MPa

and lock the adjusting screw.

6. Change pressure gauge (4 MPa). Adjust the flow regula-

tor screw to 2,5 MPa, lock the adjusting screw.

7. Change pressure gauge (30 MPa). Check the max. LS

pressure by manipulating the first valve block, pressure
must be between 21 ---22 MPa (ensure, that other valves
are in the neutral position). When necessary, adjust the ad-
justing screw in the lower face end block (see picture). After
the adjustment, check the Stand ---by pressure in the LS line
(when all valve blocks are in the neutral position), which
should be between 2,0 ---2,5 MPa.

660
 101. Special tools
100. Special tools (ETV)

102. Locally prepared

tools (ET)

661
662
 Model Code Page
100. Special tools 95-- 115
X100-- X120 100 1
1. 11. 2000

Contents

1. Special tools (Op. no. 101)

21. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22. Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23. Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
32. Electro---hydraulic power lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
42. Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
44. Quick ---shift gear, reverse shuttle and 4WD clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
45. Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46. Power take ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
61. Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
64. Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
70. Frame and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
91. Hydraulic power lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Locally prepared tools (Op. no. 102)

42. Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
44. Quick ---shift gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45. Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
46. Power take ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70. Frame and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
80. Cab and shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
91. Hydraulic power lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Special tools (ETV)

(can be ordered from the factory)

Class A includes tools needed for service, minor repairs and changing of external seals.

Class B includes tools needed for more extensive jobs.

Locally prepared tools (ET)

(ET tools are not supplied by Valmet).

Simple special tools which can be prepared locally. Drawings for these tools can be found under code 102

Special tools are grouped according to the tractor component concerned. The primary use of a tool is shown in brackets after
the description.

663
664
 Model Code Page
101. Special tools 95-- 115 101 1
1. 11. 2000 X100-- X120

21. Engine
Order no Description
1 9051 73100 Puller for cylinder liner
2 9101 65600 *) Milling cutter for cylinder liner seat
3 9052 46400 Centring tool for flywheel housing
4 9052 46300 Drift for fitting rear crankshaft seal
5 9030 15200 Drift for fitting front crankshaft seal

6 9052 46620 Drift for 40 mm cap plug

7 9052 46650 Drift for 16 mm cap plug
8 9025 87400 Drift for fitting camshaft cup plug
9 9101 66300 *) Press tool for cylinder liner
10 9025 79200 Holder for dial gauge

11 9101 66100 *) T ---handle for valve seat milling cutter

12 9101 71100 *) Milling cutter for facing exhaust valve seat
13 9101 65502 *) Milling cutter for exhaust valve seat
14 9101 65503 *) Inner milling cutter for exhaust valve seat
15. 9101 75800 *) Milling cutter for facing inlet valve seat

16 9101 65505 *) Milling cutter for inlet valve seat

17 9101 65506 *) Inner milling cutter for inlet valve seat
18 9101 66200 *) Lever for compressing valve spring
19 9052 47200 Counter nut for lever above
20 9101 66000 *) Milling tool for injector seat
21 9052 46660 Drift for 36 mm cup plug
22 9101 65800 *) Drift for removing valve guide
23 9101 65900 *) Drift for fitting valve guide
25 9101 65700 *) Spanner for crankshaft nut

26 9052 48800 Puller for crankshaft gears

27 9020 01100 Conical sleeve for fitting pistons
28 9025 98900 Drift for fitting dust cover, crankshaft front seal
29 9025 98800 Drift for fitting tension pin in timing gear casing
30 9025 98700 Drift for fitting tension pins in timing gear casing and flywheel housing
31 8366 62022 Electronical device for checking injection timing on E ---engines
*) New tools for 20---series engines. Other tools are the same as for engines on 505---905 tractors.

6 7 8

1 2 4

5
10

665
 Model Code Page
101. Special tools 95-- 115
X100-- X120 101 2
1. 11. 2000

11

12 15
18
19

13
16

14 17

21 22
20

26
23 25

27 28 29 30

31

666
 Model Code Page
101. Special tools 95-- 115
X100-- X120 101 3
1. 11. 2000

22. Fuel system

9052 47800 Pressure gauge for checking delivery valve
9052 48900 Puller for injection pump drive gear
9025 99100 Locator for timing mark on the flywheel
9052 47600 Control pipe for injection timing
9052 99000 Sleeve for limiting control rod travel
9051 71300 Extractor for injectors
8366 62022 Electronic device (TimeTrac) for checking injection timing (E ---engines), which incl. parts 1---3 below:
1. 836662121 Magnetic detector
2. 836662122 Cable
3. 836662123 Fastening device
Parts 4---10 below are available, but not needed for Valtra ---engines (not illustrated):
4. 836662120 Timing light
5. 836859466 TimeTrac in ---line sensor
6. 836662124 Clamp ---on Transducer, 4,5 mm
7. 836662125 ---” ---, 5,0 mm
8. 836662126 ---” --- ,6,0 mm
9. 836662127 ---” --- ,8,0 mm
10. 836662128 ---” --- ,1/4 inches

8366 62022

905248900

902599100

15±1

9052 47800 905247600 9025 99000 9051 71300

A A B

B
33346600
A
33370300 Measuring equipment for fuel feed pressure:
30068700 33370100
If the pressure is too low in point A, check the pressure
33346700
(0--- 1 bar) in point B. If further too low, the fault lies in the fuel
feed pump. Otherwise the filter is blocked.
31965400
A

667
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 230 4

23. Engine cooling system

Ordering no Description

9022 03500 *) Puller for coolant pump impeller, 320--- and 420---engines (earlier no 8360 85499)
9104 27700 Puller for coolant pump impeller, new coolant pump (420, K6491---), not illustrated.
9051 40200 *) Drift for fitting coolant pump seal (seal no 8353 31202)
9051 79300 *) Drift for fitting coolant pump seal (seal no 8353 39425)
9051 64900 *) Drift for fitting coolant pump shaft, 320--- and 420---engines
9052 48900*) Puller for fan hub (see Fuel system)

*) Same tool as for engines on 505---905 tractors.

9022 03500

905140200 905179300 905164900 9052 48900

668
 Model Code Page
101. Special tools 95-- 115
101 5
1. 11. 2000 X100-- X120

32. Hydraulic power lift (ACB)

A
ETV 894 100 Cable for measuring internal voltages of position and draft sensors (ACB)
ETV 894 220 Cable to check control valve solenoid valves (Y1E, Y2E) (ACB).

Direction A

Y1E,
Y2E
1 3
2
ETV 894 220

ETV 894 100

Blue
Yellow ---Green
Brown

Black (1)

Blue (2)
Red (3) A

37. Autocontrol 5/5.2 (HiTech)

Ordering no. Description

337 00 600 Programming cable, L=1,5 m. To be used when programming AC 5/5,2 control unit, which is fitted on
tractor
337 00610 Programming cable, L=8.0 m. To be used when programming AC 5/5,2 control unit, which is
fitted on tractor.
340 42 500 Programming device for AC 5/5.2. To be used when programming removed control units.
Supply voltage 230 V 50/60 Hz, Euro---socket. In some markets must be used a separate adapter.
340 42 220 Computer disk (parameter file). (3½, Win. 95/98) to program AC 5 control unit (incl. program version
41and parameter file)
344 04 600 Computer disk (parameter file). (3½, Win. 95/98) to program AC 5.2 control unit

669
 Model Code Page
101. Special tools 95-- 115 101 6
1. 11. 2000

41. Clutch
A
Part no Description
ETV 893790 Centring tool for clutch disc, 95---115

Locally prepared tools

ET 893470 Support roller for splitting tractor, also X100---X120
ET 893480 Support plate (2 pcs), also X100---X120

HiShift
ETV 894 320 Fitting tool for HiShift hydraulic block piston seal KH 3714 (not illustrated), 95---115

ETV 893790

ETV 891900

ET 893470

ETV 892380 ET 893480

670
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 7

42. Gearbox
B
Order no Description
ETV 890 220 Universal handle
ETV 891 870 Plate for fitting thrust bearing for differential side gear
ETV 892 230 Socket spanner for bevel pinion shaft ring nut
ETV 894 190 Socket spanner for 4WD clutch drum nut
ETV 892 370 Sleeve for fitting input shaft front end bearing
Sleeve for fitting bevel pinion shaft front end bearing
ETV 892 380 Sleeve for fitting input shaft rear end bearing
ETV 893 300 Puller for differential bearings
ETV 893 340 Plate for fitting bearing race, rear pinion shaft bearing
ETV 893 400 Plate for fitting differential bearings
ETV 894 080 Drift for fitting selector fork rail for LL ---range
ETV 894 050 Drift for fitting locking pins for selector forks
ETV 894 120 Counter hold for puller ETV 893 300

Locally prepared tools

ET 894 060 Press plate for adjusting selector forks

ETV 890220
ETV 891870 ETV 892 230

ETV 892 370

ETV 894 190

ETV 893340

ETV 894 120

ETV 893302
ETV 892380
ETV 893 300 ETV 893400

671
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 8

ETV 894 050

ETV 894 080

ETV 894 120

ET 894 060

672
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 9

44.2 Mechanical reverse shuttle

A
ETV 892 180 Drift for fitting needle bearing/sealing ring inside the reverse shuttle input shaft in transmission 300
These parts only on tractors without the quick ---shift gear or the DPS.
ETV 894 200 Drift for fitting needle bearing/sealing ring inside the reverse shuttle input shaft in transmission 550/650
These parts only on tractors without the DPS gear.

ETV 892 180 ETV 894 200

44.3 4WD clutch/4WD output shaft

A
ETV 893 260 1) Socket spanner for 4WD output shaft nut (Gearbox 505---905)
ETV 894 170 2) Socket spanner for 4WD output shaft nut (new tool)
ETV 891 900 1) Sleeve for fitting 4WD output shaft sealing ring/bearing (Gearbox 505---905)
B
ETV 890 830 1) Sleeve for fitting 4WD clutch piston onto the output shaft (PTO 505---905)

1) Tractors without quick ---shift gear

2) Tractors with 3---step quick ---shift gear Delta Powershift. The nut is the same as the nut at the front end of
the bevel pinon shaft
on 505---905 tractors. For this nut spanner ETV 893 440 is used. Spanner ETV 894 170 can be replaced by welding a sleeve onto
the tool ETV 893 440.

ETV 893 260

ETV 891900 ETV 890 830

ETV 894 170

673
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 10

44.4 3---step quick ---shift gear Delta Powershift

Part no Description
A
ETV 892 180 Drift for fitting oil seal and needle bearing inside input shaft front end (see 2---step quick ---shift gear)
ETV 893720 Plate for fitting quick ---shift gear front oil seal
ETV 894 200 Drift for fitting oil seal and needle bearing inside the DPS input shaft front end in transmission 550/650.
ET 893 480 Support plate for front end frame, 2 pcs
B
ETV 893700 Sleeve for fitting oil seal inside the middle sun gear
ETV 894030 Sleeve for fitting planetary carrier ball bearing

ETV 893 720

ETV 892 180 ETV 894 200

ETV 893 700

ETV 894 030

44.5. HiTech Shuttle

ETV 894 350 Compressing tool for F ---clutch large coil spring

ETV 894 350

674
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 11

45. Final drives

Part. no. Description
ETV 890 220 Universal handle
ETV 892 260 Final drives 300; Plate for fitting outer drive shaft inner bearing race
ETV 893 690 Final drives 450/650; Plate for fitting outer drive shaft inner oil seal (Final drives 305---555)
ETV 893 310 Final drives 300; Plate for fitting outer drive shaft inner oil seal (Final drives 505---905
ETV 893 320 Final drives 300; Plate for fitting outer drive shaft bearing race (Final drives 505---905)
ETV 894 470 Final drives 650: Tool to fit the cassette seal (rear axle housing with greater oil volume)
ETV 894 480 Final drives 650: Guide sleeve to assemble the final gears (rear axle housing with greater oil volume)
ETV 894 490 Final drives 650: Guide pipe to assemble the final gears (rear axle housing with greater oil volume)
Locally prepared tools
ET 893 410 Support for removing outer drive shaft bearing race (Final drives 505---905)

ETV 890220
ETV 892 260

ETV 893 310 ETV 893 320

ETV 893 690

ETV 894 490

ETV 894 470 ETV 894 480
ET 893 410

46. Power take---off

A
ETV 890 220 Universal handle
ETV 891 870 Plate for fitting PTO shaft seal
ETV 894 080 Drift for fitting selector fork rail locking ball
ETV 894 420 Ring for fitting PTO shaft new cassette seal (to be used with below listed sleeves)
ETV 894 430 Sleeve (ø 35) for fitting PTO shaft new cassette seal (to be used with above mentioned ring)
ETV 894 440 Sleeve (ø 44,6) for fitting PTO shaft new cassette seal (to be used with above mentioned ring)
B
ET 894 090 Sleeve for fitting PTO clutch circlip

ETV 890220
ETV 894 080

ETV 891870

ET 894 090

ETV 894 420 ETV 894 440

ETV 894 430

675
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 12

61. Steering system

B
ETV 894 330 Fitting tool for steering valve seal

ETV 894 330

Measuring steering system working pressure (pressure at test point 17,0 ---17,5 MPa).

676
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 13

67. Powered front axle Carraro 20.29 (industrial front axle)

Ordering no. Description
ETV 893 490 Socket spanner for bevel pinion shaft nut
ETV 894 460 Plate to fit hub cassette seal (new)
ETV 893 450 Tool to adjust bevel pinion shaft position, which incl.:
ETV 893 451, Measuring rod (1 pcs)
ETV 893 452, Screw M10x100 (1 pcs)
ETV 893 453, Compression plate (2 pcs)
ETV 893 454, Nut M10 (1 pcs)

ETV 893 490 ETV 894 460

ETV 893 452

ETV 893 451

ETV 893 454

ETV 893 453

ETV 893 450

677
 Model Code Page
101. Special tools 95-- 115
101 14
1. 11. 2000 X100-- X120

70. Main frame and wheels

A
Order no Description
ET 893480 Support plate for front frame, 2 pcs

B
ET 893470 Support roller for splitting tractor

ET 893480

ET 893470

678
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 15

91. Hydraulic power lift

A
Locally prepared tool
ET 893 530 Sleeve for fitting lifting arm shaft seals (Hydraulic lift 505---905)
B
ETV 893 540 Sleeve for removing/fitting lifting arm shaft bushes
ETV 893 580 Conic sleeve for fitting lifting cylinder piston seal (Lifting cylinder ø 80)
ETV 893 590 Sleeve for crimping lifting cylinder piston seal, (Lifting cylinder ø 80)
ETV 893 600 Drift for fitting lifting cylinder piston seal, (Lifting cylinder ø 80)
ETV 894 240 Conic sleeve for fitting lifting cylinder piston seal, (Lifting cylinder ø 100)
ETV 894 250 Sleeve for crimping lifting cylinder piston seal, (Lifting cylinder ø 100)
ETV 894 260 Drift for fitting lifting cylinder piston seal, (Lifting cylinder ø 100)

ETV 893 540

ET 893 530

ETV 893 580 (ø 80) ETV 893590 (ø 80)

ETV 894 280 (Ø 90) ETV 894 290 (Ø 90)
ETV 894 240 (ø 100) ETV 894 250 (ø 100)

ETV 893600 (ø 80)

ETV 894 300 (Ø 90)
ETV 894 260 (ø 100)

679
 Model Code Page
101. Special tools 95-- 115
X100-- X120 101 16
1. 11. 2000

91. Pressure measuring equipment

Note! Measuring equipment are included in the pressure measuring kit 31965000 which can be ordered from Tractor Works.
These equipment can also be ordered separately.

1. Pressure in low pressure circuit 1,8 ---1,9 MPa. In X100---X120 the test---point is in the front face of the valve block, see page
911/1.
2. Pressure in high pressure circuit (pressure at test point 19,0 ---19,8 MPa), see page 911/4.

680
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 17

1. Measuring PTO clutch pressure (pressure at test point 0,05 ---0,1 MPa lower that pressure at pressure test point on the
servo valve block), see page 911/2.

2. Measuring lubricating oil pressure (LUB) (min. pressure in 95---115 tractors is 0,03 MPa). In the HiTech tractors X100---
X120 there is a separate HPR test point in the rear part of the suction strainer housing on the gearbox (---J26433) or on the
rearmost pressure filter bracket (J26434---), see page 911/2. Lubricating pressure value in HiTech tractors min. 0,12 MPa.

681
 Model Code Page
101. Special tools 95-- 115
1. 11. 2000 X100-- X120 101 18

DPS--- PRESSURE, C1
DPS--- PRESSURE, C2

DPS--- PRESSURE, C3

Measuring Delta Powershift clutch pressures on tractors which have the mechanical shuttle unit (95---115) . Pressure in each
clutch should be 1,8 ---1,9 MPa.
C1=foremost clutch.
C2=middle clutch
C3=planetary gear clutch (rearmost clutch).

Note! If the tractor has HiTech Shuttle (X100---X120), all three DPS clutches have their own HPR test point and a pressure
gauge can be connected direct to the test points with measuring hose 31965400, see page 911/3.

Note! On tractors which have the lock valve (95---115 with transmission 550/650), the oil piping deviates from the pictures
above. The lock valve (see page 420/20) is not fitted in the HiTech tractors X100---X120.

682
 Model Code Page
102. Locally prepared tools 95-- 115
X100-- X120 102 1
1. 11. 2000

42. Gearbox
B
ET 894 060 Press plate for adjusting selector forks

8
M10

10,5
20

35
7

55

ET 894 060

683
 Model Code Page
102. Locally prepared tools 95-- 115
1. 11. 2000 X100-- X120 102 2

44. Quick---shift gear

B
ET 893 420 Sleeve for fitting bearings on planet carrier
Sleeve for fitting bearings on front end of cylinder

410
~ 15

ø 82
ø 90
4
ET 893420

45. Final drives

B
ET 893 410 Support plate for removing bearing race, outer drive shaft (Final drives 505---905)

195
30
30

45˚

155

ET 893 410

684
 Model Code Page
102. Locally prepared tools 95-- 115
1. 11. 2000 X100-- X120 102 3

46. Power take off

B
ET 894 000 Tool for loosening the locking flange at the front end of the PTO shaft (see Steering system 6100---8100)
ET 894 090 Sleeve for fitting PTO clutch circlip (new)

10 70
4

ø70
ø60

ET 894 090

685
 Model Code Page
102. Locally prepared tools 95-- 115
102 4
1. 11. 2000 X100-- X120

70. Frame and wheels

A
ET 893480 Support plate for front frame (Frame and wheels 505---905)
B
ET 893470 Support roller for front frame (Frame and wheels 505---905)

62

10

50

150
22

110

ET 893480

590 4
4
ø 36

ø 55

M30

ø 45

40
130 10

Standard roller
4
M30

120

350

500

ET 893470

686
 Model Code Page
102. Locally prepared tools 95-- 115
1. 11. 2000 X100-- X120 102 5

80. Cab and shields

ET 894 110 Lifting tool for cab

774 19
A
3 5 70
(13,5 ast.)
a3 110

180
A a3 110
a5 50
a5 50
665

5 50
2 a5 50
Kumi
Gummi
415

1
Rubber
a3 50

3
25 4

a3 50
175 a3 50
1630

R25

1. 50 x 50 x 5
2. 50 x 50 x 5 a5 97
70

ø12
3. 30 x 30 x 3 a5 97
4. 50 x 25 x 2,5
167

130
Lifting eye ø 12 mm

A ---A

1290

(4,5˚)
93
50 70
30 10

1260

687
 Model Code Page
102. Locally prepared tools 95-- 115
X100-- X120 102 6
1. 11. 2000

91. Hydraulic power lift

A
ET 893 530 Sleeve for fitting lifting arm shaft seal (Hydraulic lift 505---905)

ø 84,5
ø 74,5
ET 893 530

10 80

688
95 95 95
105 105 105
115 115 115
X100 X100 X100
X110 X110 X110
X120 X120 X120
Service Service Service
Manual Manual Manual

95 95 95
105 105 105
115 115 115
X100 X100 X100
X110 X110 X110
X120 X120 X120
Service Service Service
Manual Manual Manual