Engine System

Engine System

CONTENTS PAGE

1. INTRODUCTION A-3
2. ASSEMBLING & DISMANTLING OF ENGINE
ROCKER COVER A-5
ROCKER ASSEMBLY A-5
TURBOCHARGER ASSEMBLY A-10
CYLINDER HEAD ASSEMBLY A-12
PISTON AND CONNECTING ROD ASSEMBLY A-20
CRANKSHAFT ASSEMBLY A-27
TIMING GEAR ASSEMBLY A-32
CYLINDER BLOCK A-40
3. LUBRICATION SYSTEM
INTRODUCTION A-41
SPECIFICATIONS A-43
4. COOLING SYSTEM
INTRODUCTION A-44
DISMANTLING A-44
ASSEMBLING A-46
THERMOSTAT A-47
RADIATOR A-47
SPECIFICATION A-48
5. FUEL INJECTION SYSTEM
INTRODUCTION A-49
FUEL INJECTION PUMP A-53
F.I.P. TIMING A-59
FUEL FEED PUMP A-61
ACCESSORIES A-62
GOVERNOR A-63
ADJUSTING & TESTING OF NOZZLE A-68

6. TROUBLE SHOOTING A-70

7. EGR SYSTEM A-77

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A. ENGINE SYSTEM

1. INTRODUCTION Valve guides are replaceable and valve seat

inserts are pressed into the valve port. These
The chapter describes the dismantling and valve seat inserts are also replaceable. Valve
assembling procedure of Farmtrac Tractor guides are provided with oil seals.
Engines.
The cylinder head assembly incorporates
The engine features a cross flow cylinder the valves, valve springs, spring seat,
head with inlet and exhaust manifold on spring retainers and collets.
opposite sides of the cylinder head. The re-
entrant type combustion chamber (Ref Fig. The crankshaft is supported in the cylinder
A1) is formed in the crown of piston. The block by the five main bearings. Thrust
piston has two compression and one rings provided on 5th main bearing cap and
conformable oil control ring, all located in cylinder block to control the crankshaft
above the piston pin boss. Side oil drain is end float.
also provided on all pistons for excess oil Single lip type seals are provided at front and
drainage. double lip at rear of crankshaft for oil sealing.

Fig. A1

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The piston connecting rods are of "I" section

with straight split type. (Ref. Fig. A2)

Fig. A2 Fig. A4
The lubrication of engine is maintained by Oil flows from the filter to main oil gallery, which
gear type oil pump, mounted at the first main runs along the length of the cylinder block.
bearing cap of engine block. The oil pump is
driven from the gear provided on crankshaft The main oil gallery supplies oil to the
and draws oil from the engine sump. crankshaft main bearings and to the
connecting rod bearings through drilled
holes in the crankshaft.
The main oil gallery also supplies oil to
camshaft bushes and from 1st camshaft
bush; oil goes to rocker shaft, and to rocker
arms. Excess oil flows down the push rods
before draining back to sump.
Timing gears are splash lubricated by
escaped oil from 1st main bearing to
intermediate gear bush.
Cylinder walls, pistons and pins are splash
Fig. A3 lubricated by connecting rods and rotating
A spring loaded relief valve in the pump crankshaft. General Information on Engine
body limits the pressure in the system by
directing excess oil to the sump.
Replaceable element assembly is provided
as shown in Fig (A4)

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Specifications
Description Unit FT-7110
Type Turbocharged
Bore mm 98
Stroke mm 122
Displacement CC 3680
Max Torque Nm 351 @ 1400Erpm
Brake Horse Power Hp (88Ps @ 2200 Erpm)
Compression Ratio 17.5:1
Firing Order 1-3-4-2
Idle Speed Rpm 750 + 50
Rated Speed Rpm 2200
Tappet Clearance (Cold) Inlet -mm 0.3
Exh-mm 0.4
Max. No. Load Speed (High Idle) ( rpm ) 2450 + 50

AIR CLEANER
Type Dry Type
Pre-Cleaner Centrifugal type with
Transparent Dust collector
FUEL INJECTION SYSTEM
Fuel Injection Pump MICO Vertical in Line
Injector Type Single point clamp mounting
Nozzle Type P Type
Governor Type Mechanical
Nozzle opening pressure Bar 250 ± 8 Kg / cm2

Injection Timing Single Point Mounting Degree 7° ±1 BTDC

LUBRICATION
Type Full flow Forced feed and Splash
Pump Gear Type
Eng. Oil Sump Capacity Liters. 11

Note: Specifications are subject to change without notice. Kindly update the same as and when the changes are notified.

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2. ASSEMBLING AND DISMAN- B. ROCKER ASSEMBLY

TLING OF ENGINE Removal and Fitting
A. ROCKER COVER 1. Unscrew the rocker shaft bracket nut.
Remove the assembly, and keep it
Removal and Fitting
properly. (ref fig. A7, A8)
1. Unscrew the cylinder head cover
mounting nuts. Disconnect breather
pipe. Remove the cover and check the
rubber gasket. (ref fig. A5)

Fig. A5 Fig. A7

2. Put the rubber gasket on the cylinder

head cover assembly and then place it
on the cylinder head, tighten the nuts
to specified torque (ref fig. A6)

Fig. A6 Fig. A8

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2. Remove the push rods and place

them in order as these are to be
placed in order in which they are
removed because of their wear
pattern. (ref fig. A9, A10)

Fig. A11
Dismantling and Assembling
1. Dismantle the rocker arm assembly
take out lock and remove the rocker
arms from the shaft. (ref fig.A12, A13)

Fig. A9

Fig. A12

Fig. A10
Place the push rods and fit the Rocker shaft
assembly aligning the push rods. Prior to Fig. A13
tightening the bracket nut, ensure that the cut
mark on the rocker shaft is at front bottom for
oil to reach to rocker arms. (ref fig. A11)

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2. Inspect the rocker arms for surface Check the shaft diameter with
step. If it has a light step or scoring it micrometer. Replace if worn out. (ref
can be ground on grinding stone. If fig. A17)
step is severe, the rocker must be
discarded. (ref fig. A14)

Fig. A17
Check the parent bore diameter of
bracket rocker shaft with the help of
Fig. A14 telescopic gauge and micrometer.
Inspection and Correction Replace the bracket if worn out. (ref
fig. A18)
1. Check the rocker arm bushes with
telescopic gauge and micrometer and
replace them with new one if worn
out.(ref fig. A15)

Fig. A18
Checking and Adjustments
Bring the 1st piston at TDC position in
compression stroke. Ensure that the
Fig. A15 locating pin from the rear side of Flywheel
housing goes inside the 2nd hole on the
2. Check the rocker shaft for seizure and flywheel. Adjust valve tappet clearance of
scoring marks. Place the rocker arm valve 1, 2, 4 and 5. (ref fig. A19) Take out
shaft on magnetic V-blocks and with pin and rotate the crankshaft one turn
a dial gauge measure the run out. If (360°) and bring the 1st piston at TDC in
the run out is observed, correct it with exhaust stroke. (ref fig. A19)
Hydraulic Bench Press and recheck
it. (ref fig. A16)

Fig. A16 Fig. A19

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nd
Ensure the locating pin goes in 2 hole of
the flywheel and then adjust valve tappet 3
and 6. (ref fig. A20)
Inlet: 1, 3 and 5, 7
Exhaust: 2, 4, 6 and 8

Valve Clearance (Cold):

Inlet : 0.3 mm Fig. A20
Exhaust: 0.4 mm

CAMSHAFT ROCKERARM
Engine Model FT-7110 HER
I

Rocker Shaft diameter (mm). 21.959-21.980

Rocker Arm Shaft Bracket diameter (ID) (mm). 22.000 - 22.033
Rocker Arm bush diameter. (ID) (mm). 21.6-21.7
Rocker Arm bush and shaft clearance. (mm). 0.259 - 0.38
Tappet clearance (mm) Inlet: 0.3
Exhaust: 0.4
Torque
Rocker arm Bracket Bolt (N-m) 50+2
Tappet cover bolt (N-m) 25

DRY AIR CLEANER

Servicing procedure
1. Unscrew Wing nut and remove gasket washer and service cover.
2. Remove Primary filter.
3. Use Clean cloth to wipe dust and debris from inside of the housing.
4. Inspect new primary filter for cuts, tear and for proper adhesion.
5. Check for proper seating of gasket with housing.
6. Place new primary filter in position and refasten with wing nut.
7. Refit cover and ensure dust collector is vertically downward then refasten gasket
washer and wing nut.
8. Reset service indicator manually.
9. Do not use any tool to fasten wing nut.(fasten with hand only).

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Warning: Air cleaner servicing should be done only when engine is not running.

Component Action When to service

Primary Filter Replace After 3 cleaning or 1 year which
ever is earlier.
Safety filter Replace After replacing primary filter 3
times.
Air Outlet pipe&hoses Replace if damaged At the time of primary filter
replacement.
Housing &mounting bracket Replace if damaged At the time of primary filter
replacement.
Dust Collector,Gasket,
and rubber parts Replace if damaged At the time of primary filter
replacement.
Service Indicator Check function Once in a year or at the time of
primary filter replacement

Air Cleaner
(Housing)

Safety Filter

Service Cover

Wing Nut

Hex Nut

Primary Filter

Gasket
Gasket Washer

Dust Collector

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C. TURBOCHARGER ASSEMBLY: some exhaust gases back to intake manifold.

A Turbocharger utilizes the exhaust gas A turbocharger is provided with twin filters as
energy to compress the fresh filtered air & a particle more than 30-40 micron can
that compressed air is then directed to the damage the turbocharger.
intake manifold of the engine. Compressed Due to compression the air temperature at
air means we are increasing the density of air intake manifold becomes high, which may
which we are sending into the combustion lead to pre-ignition of fuel. So to avoid this,
chamber which leads to higher power with an INTERCOOLER is provided between the
minimal increase in fuel delivery. So it is turbocharger and intake manifold to control
mainly used for 2 purposes: the air temperature at intake manifold.
1. to reduce the NOx emission,
2. to increase the power output.

Fig.A-22
Air Flow Diagram
Removal of Turbocharger from Engine:
1. The turbocharger need to be removed
Fig.A-21 before removing the exhaust manifold.
A turbocharger assembly consists of an 2. Remove EGR guard.
Impeller, compressor and a shaft 3. Unscrew the EGR pipe at EGR valve
connecting both. and exhaust manifold end.
The impeller takes the power from the 4. Keep EGR on a clean surface.
exhaust gases running out of engine
cylinder and passes it on to the 5. Remove the wire connecting ECU and
compressor, through the shaft. EGR valve.

The compressor then compresses the air 6. Remove two M8 bolts and take EGR
valve out.
coming out of Air cleaner and sends it to
the intake manifold through Intercooler. 7. Unscrew two M4 bolts holding ECU on
ECU pad,remove it and keep in a clean
Along with this, a turbocharger assembly is
place.
provided with 2 oil Filters, Blow By Pipe,
EGR pipe and intercooler. 8. Remove intercooler pipe from
An EGR pipe is provided between Exhaust compressor end of TC and exhaust
manifold and intake manifold. It is basically a connection at impeller end.
constant flow external EGR which works on 9. Unscrew TC from exhaust manifold.
the principle of the pressure difference of the Remove turbocharger and gasket.
exhaust side & the intake side. It helps in 10.Remove oil filters.
controlling the NOX emissions by sending

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It should spin freely and it is normal to

feel some play on wheels.
6. Fit the turbocharger on manifold using the
gasket or joint ring, and then reconnect the
exhaust pipe. Tighten all nuts / bolts.
7. Install EGR pipe,EGR valve,ECU and
then EGR guard.

Fig.A-23 NOTE:EGR valve should be connected

with 12V battery supply.
Radial Movement: 0.058-0.096mm
Axial Clearance: 0.027-0.073mm 8. Oil feed and drain lines must be totally
clean and undamaged – oil flow must
Inspection: be unrestricted. Check that any flexible
There are two major things which should be hose liners have not collapsed.
checked to find out whether the
Turbocharger is in good condition or not. NOTE: Damaged oil return line can cause
restriction to oil flow & oil leakage from
1. Use Dial gauge for measuring the
turbocharger.
Radial Movement and Axial Clearance
of the turbocharger. 9. Check that oil feed line not too close to
source of heat.
NOTE: A turbocharger assembly is not to
be operated by the mechanic. It should be 10. Fit oil drain line. Refill the oil inlet hole
sent to Cummins Authorized Service with new clean engine oil and reconnect
Centre, in case any overhauling required. the oil feed line.
11. Fit air hoses and tighten.
It is recommended to clean Turbocharger
and Intercooler system every 2500 hrs for 12. Use new air, oil and fuel filters, refill
better performance, engine with new clean engine oil.
Installing the Turbocharger: 13. If possible prevent the engine from
firing and crank the engine for 10 -
1. Before installing the Turbocharger
15seconds to prime oil feed. Start the
make sure that all the parts are
engine and keep it on idle for 3 to 4
thoroughly cleaned.
minutes before increasing speed.
Like: All air hoses connected to the Check for oil and gas /air leaks.
turbo, air filter and housing etc.
2. Clean engine breather system and
check function.
3. Remove old gasket material from the
exhaust manifold and pipes. Faces
must be undamaged.
4. Remove plastic or foam blanking plugs
from the turbo before fitting.
5. Fill the oil inlet hole of the turbocharger
with new engine oil and spin the
compressor wheel by hand a few times. Fig.A-24

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14. Stop engine and recheck engine oil

level. The oil level should not be above
the point where oil returns from the
turbo to the engine.
D. CYLINDER HEAD ASSEMBLY
DISMANTLING
1. To remove the overflow pipe unscrew
the banjo bolts. (ref fig. A26, A27)

Fig. A28
3. Remove the injector one by one after
unscrewing the nut of clamp nozzle
holder from the stud. (ref fig. A29)

Fig. A26

Fig. A29
NOTE: "P" type injector has integral flange for mounting

Fig. A27
2. Loosen the nuts on the both ends of the
high-pressure pipes and remove all the
pipes from the injectors. (ref fig. A28)

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4. Remove the injectors, check the 6. Loosen the nuts of the intake manifold,
washers and keep the injectors in and remove it from the cylinder head and
proper place (ref fig. A30) place it properly. Discard the loctile.

Fig. A32
7. Loosen bolts and remove the cylinder
head assembly and keep it properly.

Fig. A30

5. Loosen the bolts of EGR pipe(1) from

exhaust manifold (2) and intake manifold
(3)and remove it, remove turbocharger
(4)mounted on the exhaust manifold,
loosen the nuts of the exhaust manifold Fig. A33
and remove it and keep it properly. 8. Remove the cylinder head gasket and
discard the same. (ref fig. A34)

Fig. A34
Valves and Valve Springs
Fig. A31 With the help of valve spring pressing tool press
the spring and remove the collets. Remove
the tool and remove both outer and inner
springs with the retainer then remove the
valves and clean them. (Ref fig. A35)

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3. Check valve springs for cracks and

squareness. Place the spring against the
tri-square and pass the feeler gauge
through the gap. The maximum out of
squareness is 1.5mm (ref fig. A38)

Fig. A35
1. Check valve condition. Burnt, crack
and eroded valves must be discarded.
Slightly pitted valves can be reused.
Place them in order then check each
valve stem diameter with a
micrometer. (ref fig. A36)

Fig. A38
4. Check spring free length with a
vernier caliper.
5. Measure the spring tension with the
help of a spring tester. (ref fig. A39)

Fig. A36
2. The bore can be checked with a
telescopic gauge. Insert the gauge
inside and lock it then measure it with
micrometer. (ref fig. A37)

Fig. A39
Fig. A37

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6. Check valve seat and its angle. If

damaged the seats can be replaced
with new one and cut with a valve
seat cutter to the required angle.
7. Finish by lapping with fine emery paste.
Check valve leakage with kerosene or
petrol after lapping. (ref fig.A40, A41)

Fig. A43
Assembling
1. Fit a new valve guide in the cylinder
head with the help of SST No. E0200.
(ref fig. A44)

Fig. A40

Fig. A41 Fig. A44

2. With the help of SST No. EO 201A press
the valve guide seal on each guide.
(ref fig.A45, A46)

Fig. A42
Inspection and Correction
1. Check cylinder head flatness with
straight edge and feeler gauge on six Fig. A45
sides and two diagonals. NOTE: Lubricate the valve stems with oil
Maximum permissible out of flatness and then insert the same in each guide.
of cylinder head faces is 0.02mm, if Care should be taken that the seal lip does
excessive repair by refacing it. (ref fig. not get damaged while inserting the valves.
A43)

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Specifications

Fig.A46 Valve Assembly With 3 Lip Collet And Oil Seal

1. Valve, Exhaust; 2.Valve, Inlet; 3.Seat, Valve Spring Lower; 4.Spring, Valve Outer; 6.Disc, Valve Spring; 7.Lock, Valve
Spring Disc (Cotter); 8.Seal, Valve Stem.

VALVE SPECIFICATION

Engine Model FT-7110

Valve stem diameter (mm) Inlet: 7.95 – 7.97
Exhaust: 7.93 –7.95
Valve Head diameter (mm) Inlet: 39.30-39.50
Exhaust: 36.9-37.1
Clearance, valve stem to guide (mm) Inlet: 0.030-0.065
Exhaust: 0.050 - 0.085
Valve guide inner diameter (finished) 8.000 – 8.015
Inlet Valve Opens BTDC (Deg) 8°
Inlet Valve Closes ABDC (Deg) 26°
Exhaust Valve Opens BBDC (Deg) 47°
Exhaust Valve Closes ATDC (Deg) 9°
Valve Springs
SPRING (OUTER) Free Length (mm) 67.3
Spring Primary Deflection (at 14.5 kg) (mm) 44.6
Spring test deflection (at 30.4 kg load) (mm) 34.44
Valve Seat
Valve face angle Inlet: 44°40’-45°00’
Exhaust: 44°40’-45°00’
Valve seat angle Inlet: 45°00’-45°15’
Exhaust: 45°00’-45°-15’
Valve seat run out in relation to valve
guide bore (TIR) (mm) Inlet: 0.03
Exhaust: 0.03
Valve protrusion from cylinder head
face (mm) Inlet: 0.3-0.70
Exhaust 0.3-0.71

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Fig. A50
2. Tappets should not have any surface
cracks, peeling or pits. Replace
tappets, which show excessive wear
ovality, taper or seizure marks.
Fig. A47
Remove minor surface damage by
1. Assemble the valve with inner and using oilstone.
outer springs retainer and collets with
Keep the tappets in sequence as they
the help of a spring pressing tool. (ref
were removed and return to the same
fig. A47, A48) Check valve face depth
bore because of their wear pattern.
and protrusion for cylinder head face
(ref fig. A51)
with a depth gauge.

Fig. A51
Check with micrometer the outer diameter of
the tappet. Check the tappet bore in cylinder
Fig. A48 block with Telescopic gauge and micrometer.

Fig. A49 Fig.A52

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3. Lubricate the tappets and fit them in

cylinder block tappet bore. Check free
fall and movement of tappet in the bore.

Fig. A55
Torque the cylinder head bolts up to the torque
ANGULAR TORQUEING SPECIFICATION:-
50Nm+90Deg+60Deg
STEP 1: TORQUE THE BOLTS TO 50Nm±2Nm AS PER TORQUEING
SEQUENCE.
STEP 2: LOOSEN THE BOLTS AS PER TORQUEING SEQUENCE.
STEP 3: TORQUE THE BOLTS TO 50Nm±2Nm AS PER TORQUEING
SEQUENCE.
STEP 4: TORQUE THE BOLTS TO 90deg±1.5 deg AS PER TORQUEING
SEQUENCE.
STEP 5: TORQUE THE BOLTS TO 60deg±1 deg AS PER TORQUEING
Fig. A53 SEQUENCE .
4. Check all push rods for straightness Cylinder Head Bolt Torqueing Sequence
on a surface plate with a feeler
gauge. Discard the bent push rod.

17

Fig. A56
Fig. A54 6. Fit all the high-pressure pipes
5. Place a cylinder head gasket and the connecting injectors and F.I pump and
cylinder head assembly on the cylinder clamp the pipes properly. Fit the over
block. Tighten the bolts in sequence. flow pipe on the injector with new
Fit all the injectors in cylinder head with copper washer and banjo blots.
new copper washer and tighten the
clamp nut or the flange. Fit intake with
Loctite and exhaust manifold with
gasket, and tighten the nuts to a
specified torque. (ref fig. A55)

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Specifications

Engine Model Unit FT-7110

Cylinder Head Surface

Flatness on cylinder head bottom face. mm 0.2

Non-parallelism between top and bottom faces. mm 0.1
Tappets
Tappet outer diameter mm 15.966-15.984
Parent tappet bore in block mm 16.000-16.018
Permissible tappet wear (on dia) mm 0.15
Permissible tappet guiding portion Cylindricity mm 0.006
Push Rod
Push rod Stem diameter mm 8.4-8.5
Overall length of push rod mm 213.5-214.5
Straightness of stem mm 0.25
Tightening Torque
Cylinder head bolt N-m 50Nm+90Deg+60Deg
Bolt, Rocker arm bracket with cylinder head N-m 50+2
Nut clamp nozzle holder N-m 25+2
Exhaust manifold nut N-m 50+2
Intake manifold nut N-m 45+2

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E. PISTON & CONNECTING

ROD ASSEMBLY
REMOVAL & FITTING
1. Before removing the piston assembly,
remove the ridge formed due to wear at
the top of the cylinder bore with a ridge
cutter. This will help in easy removal of
pistons and will prevent damage to the
Fig. A59
piston rings. (Ref fig. A57)
3. Match the number punched on
connecting rod & the cap. Remove all
the pistons one by one and keep
them in a wooden box to prevent
damage. (Ref fig. A60)

Fig. A57
2. Now turn the engine so that the piston
you are working on is at the bottom of Fig. A60
its stroke. INSPECTION
Loosen the connecting rod bearing cap 1. Check the piston for external damage
bolt. Tap the cap with mallet and lift the and cracks. Hold the piston with
cap with the bearing shell. Turn the connecting rod in a vice with a soft
crankshaft until piston is at the top of its jaws. Remove the rings with ring
stroke. Now carefully push out the expander and clean the ring groove
connecting rod and piston assembly with ring groove cleaner. Do not use
from the cylinder block with the help of wire brush on the ring groove check
a hammer handle. (Ref fig. A58) the land clearance using a new ring
with the help of a feeler gauge. Discard
the piston if clearance is in excess.

Fig. A58
Fig. A61

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Fig. A62
Check the piston diameter at the piston
skirt with a micrometer. Discard the piston
if it is worn out. (Ref fig. A63)

Fig. A65
NOTE: Piston, Pin and Circlips are
serviced in sets only.
3. Check the connecting rod gudgeon
pin bush inside diameter with a
telescope gauge & micrometer.
Replace the bush if worn out.
Fig. A63
Check the piston boss inside diameter with
a telescope gauge & micrometer. Discard
the piston if it is worn out.

Fig. A64 Fig. A66

2. Check the gudgeon pin diameter in 4. Check the connecting rod alignment
the center with the help of a in the alignment gauge for bend and
micrometer. Replace it if worn out. twist. (Ref fig. A67)

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6. Aligned the arrow mark on the piston

crown with the escorts logo on the
connecting rod. Place the small end
inside piston and Align with its pin
boss. Insert the gudgeon pin in the
boss. (Ref fig. A69, A70)

Fig. A67 Fig. A69

5. Fit the big end bearing shells in the
connecting rod and torque the bolts to
specified torque. Hold the connecting
rod in the vice. Measure the bearing
inside diameter with the help of a bore
gauge. Discard the bearing if worn
out. Also, replace the bearings, which
have signs of scratches, cracks or
metal peeling. Replace the bearings
to next size as per the ground
crankshaft pins. (Ref fig. A68)
Fig. A70
7. Insert circlip in the groove on both side
of the piston pin boss. Rotate the circlip
for ensuring proper seating in the
groove. Ensures that the opening of
the circlip is on the top or bottom side.

Fig. A71
Fig. A68

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8. Check the end float of the connecting

rod small end with respect to piston
boss. (Ref fig. A72)

Fig. A74
10. Hold the piston and connecting rod
assembly in a vice with a soft jaw.
(a)
Ensure the end gap of the Oil ring coil
expander is opposite to the oil ring Butt gap.
Fig. A72 After fitting the oil ring coil expander on the
third oil groove, with the help of a ring
expander fit the oil ring in the same groove.
NOTE: The side float of connecting rod is
checked between crankshaft & connecting
rod where Pre heating of piston is not
required for piston pin fitting.

Fig. A75
(b)
Fit the second compression ring, black in
colour. Take care that the 'TOP'mark is
Fig. A73 towards up. Reverse fitment of ring will
cause engine oil consumption. (Ref fig.76)
9. Before fitting the rings on the piston, check
the Butt gap taking care that a ring is
squarely placed while pushing it with a
piston. Check the Butt gap of each new
piston ring in the respective bores at
unworn area. Keep the rings with their
relevant pistons. (Ref fig.A74)

Fig. A76

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The top ring is a chrome-plated ring and is 12. Loosen and remove the connecting rod
to be fitted in the top groove only. Ensure bolt and the cap. Fit big end bearing
that the "Top" mark is towards up. shell in the connecting rod aligning the
Repeat the ring fitting procedure on the locating lug. (Ref fig. A79)
other remaining pistons.
11. Arrange the butt gap 180 degree apart so
that butt gaps of the rings are not in one
line. Ensure that the crimp on the ring
compressor is facing downwards, to
prevent it from going in the bore, tighten
the ring compression on to the piston to
squeeze the rings for easy fitment in the
cylinder bore. (Ref fig. A77) Fig. A79
13. Fit the three pulley bolts to rotate the
crankshaft and bring the big-end journal
at top dead center (TDC) position.
Lubricate the shell bearings and inside
of the cylinder liner with clean engine
oil. Place the piston assembly on the
cylinder bore. Taking care that dimple
on the connecting rod is facing towards
front of the Engine. Rotate the
crankshaft with handle and keep
pressing the piston with a wooden
Fig. A77 hammer handle until its reach at B.D.C
position.
Note: Butt gaps should not align with
gudgeon pin side. This will lead to oil
consumption and power loss.

Fig. A78 Fig. A80

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14. Ensure that the locating lugs on the 15. Check the piston protrusion above the
bearing shells are on the same side. Fit cylinder block surface by holding the
the connecting rod cap on the crank pin cyl. liner in its place; to take care of the
with the bolt. Tighten the bolt and movement of cyl. Liner. (Ref fig.A82)
torque to required specification. Repeat NOTE: Check protrusion of the piston top
this operation for other piston and with respect to cylinder block face at TDC
connecting rods. (Ref fig.A81) position as per the following.
0.175-.0425 mm

Fig. A81

Fig. A82

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 Engine System

Specifications

PISTON
Engine Model Unit FT-7110
Cylinder liner protrusion above cylinder block
face (at 100 kg. Load) mm 0.06-0.11
Piston protrusion above the cylinder block
surface mm 0.32-0.55

Piston:

Piston diameter (std) mm 97.893+0.007

Piston pin diameter (std.) mm 27.994-28.000
Piston Pin Boss Gap. mm 35-0.005
Piston Combustion Chamber
Smaller Diameter/ Outer Dia mm 55+0.2
Bigger Diameter/ Inner Dia mm 50+0.2
Connecting Rod

Length Between Centers mm 186+0.025

Small End Bushing (ID) mm 35.033-35.020
Clearance between Bushing and Piston Pin mm 0.020-0.039
Maximum Wear Limit mm 0.1
Side Float Gms 0.2-0.45
Difference in weight between connecting rods
of one engine should not exceed Gms 15
Max. Twist (overall length of 100 mm) mm 0.05
Max. Bend (overall length of 100 mm) mm 0.05
Con. rod width (at big end) mm 34.65-34.75

Con. rod width (at small end) mm 25.70-25.90

Torque:

Bolt Crank pulley to crank shaft (N-m) 320+10

Bolt Connecting rods (N-m) 80+3

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Engine System

F. CRANKSHAFT ASSEMBLY 3. Loosen all the main bearing caps bolts.

Remove all the caps and lift the
DISMANTLING Crankshaft.
1. Prior to removal of the flywheel remove
the pilot bearing from the flywheel.

Fig. A85
4. Place the Main Bearing caps with
Fig. A83 bearing shells on the block. Re-
Now unlock the flywheel bolts, loosen them torque the cap bolts as specified.
and then remove the flywheel with a special Check main bearing inner diameter
service tool. with the help of a bore gauge in three
directions to ascertain the clearance
between main bearing & journals.
2. Unlock and loose the bolts of the Discard the worn out bearing shells.
flywheel housing and remove the
flywheel housing.

Fig. A84

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 Engine System

3. Fit bearing shell on main bearing and

lubricate the bearing. Ensure that the
locating lug on the bearing shells is on
the same side.

Fig. A86
ASSEMBLING
1. Place the main bearing shell on all four
bearing seats in the cylinder block. Fig. A89
Lubricate and place the crankshaft. In addition, fit thrust ring on both side of
fourth main bearing cap. Install the main
bearing caps, lubricate and tighten the bolts
to specified torque. (Ref fig.A90)

Fig. A87 Fig. A90

2. Insert the bottom half thrust ring in the Tighten the center bolts first and then side
groove & press the same in 4th bolt cross-wise. The crankshaft should
bearing seats. Rotate it with hand to rotate freely when rotated with hand.
ensure proper seating. The oil
grooves on the thrust ring should be 4. Check crankshaft end float with the
on crank side. (Ref fig.A88) help of magnetic stand and dial gauge
as shown in figure.A91

Fig. A88

Fig. A91

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Engine System

5. Fit the Oil Seal in the Flywheel housing.

Fig. A92
Fig. A93

6. Fit the gasket on the Flywheel housing 8. Apply the Loctite on the oil sump then
back face and mount the same on the fit the same on the engine block.
cylinder block. Torque all mounting (Loctite – 5060) D95010830
bolts to specified torque and lock them.
7. Fit the flywheel assembly on the
crankshaft and check the run out with the
help of dial gauge & magnetic stand.

Fig. A94

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 Engine System

INSPECTION
1. Check the removed crankshaft for any
crack with the help of a magnifying
glass. Also, check for journal scoring
or for signs of over heating.
Mount the crankshaft on magnetic 'V'
blocks and measure the run out with a
dial gauge mounted on a stand. Gently
rotate the crankshaft and read the dial Fig. A97
gauge as the crankshaft is turned. (Ref
fig. A95)
NOTE: Maintenance of fillet radius is very
important. The steps formed after the
regrinding will lead to breakage of
crankshaft due to stress concentration.
Refit the main bearing caps with the bearing
shells & torque the bolts to specification.

Fig. A95
2. Measure all the bearing journals with
the help of a micrometer. Measure the
ovality and taper at two cross sections
in the perpendicular planes.
Regrind the journals in the course of
repair to the next under size. The
extent of regrinding depends on the Fig. A98
most worn journal. After regrinding the
journals, check the fillet radius with a
radius gauge. (Ref fig. A96)

Fig. A96

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Engine System

Specifications:

Crankshaft FT-7110
Engine Model Unit
Main journal diameter Std mm 69.981-70.0
Big end journal Diameter Std mm 55.981-56.0
Main Thrust Journal Width mm 33.0-33.1
Main & Big end fillet radii mm 4.0-4.5
Max permissible taper ovality after wear mm 0.06
Main and Big end journal wear limits mm 0.15
Crank shaft end play mm 0.2-0.47
Max permissible crankshaft runout mm 0.04
Crank Shaft Throw mm 54.95+55.05
Rear Oil Seal Journal Diameter mm 75+0.019
Permissible cylindricity of 4 main journal mm 0.007
Main & Big End Bearing:
Main Bearing shell working ID mm 75.019
Main Bearing diametrical clearance mm 0.030-0.090
Big end bearing shell working ID mm 60.013
Big end bearing running clearance mm 0.016-0.064
Flywheel:
No. of Gear Teeth 115
Run out of clutch face mm 0.15
Ring gear run out mm 0.2
Torque:
Main bearing cap bolt torque N-m 250+5
Oil sump mounting bolt to timing gear cover N-m 30+5
Oil sump mounting bolt to cylinder Block N-m 120+5

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 Engine System

G. TIMING GEAR ASSEMBLY F.I. pump gear and then remove the gear.
DISMANTLING Check the gears for any damage and
replace if teeth found chipped or having
1. Unscrew all the three bolts and remove excess backlash.
the pulley.

Fig. A102
Fig. A99
5. Unlock the bolts and then loosen to
2. Unscrew the bolts and remove the remove the intermediate gear.
timing gear housing cover.

Fig. A100
3. Before removing the timing gears, check
the backlash between intermediate gear
to camshaft gear, to crankshaft gear
to F.I. Pump gear and Camshaft gear
to Hydraulic pump gear.( Ref fig.101)
Fig. A103
Intermediate gear bolts
6. Align the thrust plate bolt head with
Cam gear hole and unscrew the bolts.
Remove the camshaft assembly with
gear by rotating and pulling it out from
the bore. Take care that the lobes of
camshaft are not damaged.
Fig. A101
4. Unscrew the three mounting bolts of the

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Engine System

Fig. A104
Fig. A108
7. Remove the four mounting bolts of
the F.I. pump assembly. Take out the ASSEMBLING
F.I. Pump assembly. 1. Apply loctite on timing gear housing gear
housing. Place timing gear housing on
the cylinder block; position. Tighten the
timing gear housing with four bolts and
tab washers.
Torque the bolts to specified torque and
bend the tab washer to lock bolts head.

Fig. A105
8. Unlock the mounting bolts of the
timing gear housing.

Fig. A109
2. Place the thrust flange on the camshaft
on the gear fitment end. Insert the
Fig. A106 woodruff key in its slot and press. Place
9. Remove the engine mounted Hydraulic camshaft gear matching the key slot.
pump by first unscrewing the bolts of
inlet & pressure pipes. Unscrew the
two mounting bolts of the Hydraulic
pump and remove the same.

Fig. A110

Fig. A107

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 Engine System

3. Press fit the gear on the camshaft

lubricated the camshaft journals and
the cam-bush inside the block. Insert
the camshaft in to the bore. Align the
thrust flange and then tighten the two
bolts and washers on the thrust flange
and torque the same. Camshaft
should rotate freely.

Fig. A113
6. Apply grease on the F.I pump mounting
face and put a gasket on it. Fit the pump
on the timing gear housing with 4 sets of
bolt, nut and washer and tighten them.
Fit FIP drive gear on the F.I pump hub
and match the 'O' mark on F.I pump
gear. Tighten the three bolts with
washers.
Fig. A111
4. Check camshaft end float with dial gauge.
It should be between 0.27-0.445 mm.
Tighten the tacho drive slotted bolt.

Fig. A114
7. Fit oil pump drive gear on the
crankshaft. Ensure that the projection
is towards crank gear side. Check the
backlash with the feeler gauge.
Fig. A112
5. Fit the intermediate gear on its shaft
matching the 'S' marks of camshaft gear
with intermediate gear and the
crankshaft gear with intermediate gear.
This will ensure the position of first
piston at T.D.C. Tighten thrust plate with
two bolts. Check the gear endplay, (0.2
mm) with the feeler gauge or a dial
gauge. Tighten bolt to the required
torque. Fig. A115

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Engine System

8. Fit the oil seal in the Front timing

cover. Apply the Loctite front cover
and assembly the housing with four
bolts and tighten it.
Loctite-5060(D95010830)

Fig. A116

INSPECTION
1. Check with micrometer the out side
diameter of the intermediate gear shaft
and then check bore with a telescope Fig. A118
gauge and micrometer. Replace the
intermediate gear bush for an over size
one when maximum permissible play
between bush and shaft is exceeded.
(Ref fig.A121,A122,A123).
.

Fig. A119
2. The removed camshaft should be,
placed on 2 v-blocks and with the help
Fig. A117 of a dial gauge and magnetic stand,
check the run out. if it exceeds the
specified limit replace it.( Ref fig.A120).

Fig. A120

A –36
 Engine System

3. Check the camshaft lobes for any 4. Check the cam bush bore inside
damage, replace it if found necessary. diameter with the telescopic gauge &
Check the camshaft journal diameter micrometer. Replace the bush if worn
with a micrometer and record the out. (Ref fig. A122)
same. (Ref fig. A121)

Fig. A122
Fig. A121

1 Piston cooling nozzle assembly and disassembly

Process as shown the figure in (122A).

Note: while assembly the piston and disassembly

Need to care about the cooling nozzle.

1A. While interesting the piston inside the bore place the
Nozzle and give the torque as mention in the
Specification.

1B. During dismantle the piston avoid damages of

Piston nozzle. Make the angle of connecting rod
and take out the piston by force.

A –37
Engine System

Specifications

Timing Gear Assembly

Intermediate gear to camshaft gear backlash mm 0.10-0.30
Intermediate gear to crankshaft gear backlash mm 0.10-0.30
Intermediate gears to F.I.Pump gear backlash mm 0.10-0.30
Intermediate Gear Support shaft mm 37.950-37.975
Permissible Coaxiality of shaft 0.01
Idler gear bush inner diameter mm 38.000-38.025
Idler gear shaft clearance mm 0.025-0.075
Maximum permissible clearance(discard limit) mm 0.2
Intermediate Gear end play mm 0.2
Camshaft
Camshaft journal diameter mm 46.944- 47.04
Permissible journal wear mm 0.08
Permissible run out of central journals with
respect to the outer journals mm 0.04
Max. Cam height
Intake: mm 5.023
Exhaust: 4.69
Camshaft end float mm 0.070-0.195
Camshaft Key slot width mm 5.5+0.1-5.042
Cam bush inner diameter
(pre-finished in fitted condition) mm 48.581-48.569
Cam bush outer diameter mm 50.054-50.091
Parent cam bore (with out bush) mm 50.000-50.025
Cam bush journal running clearance mm 0.025-0.096
Max. permissible cylindricity of bush bore mm 0.006
Max. out of coaxiality of cam bush mm 0.02
Torque
Bolt Camshaft N-m 120+5
Bolt timing gear cover to T.G.Housing N-m 25+5
Bolt timing gear housing to block N-m 25+5
Bolt Crank Pulley to crankshaft N-m 320+10

A–38
 Engine System

H. CYLINDER BLOCK 3. Thoroughly clean cylinder block &

INSPECTION measure the parallelism of cylinder block.

1. Clean the cylinder liner bore 4. Check the cylinder block surface for
thoroughly and check wear by means unevenness with the help of straight
edge and a feeler gauge.
of a bore gauge. Set the bore gauge
to zero and then measure the bore in Flatness of top surface should be
four places in two directions parallel checked four places and diagonally.
to the engine and crosswise. Record (Ref fig. A125)
the measurement on the Engine
inspection sheet.

Fig. A125
Fig. A123
2. If the cylinder liner bore is scored or
otherwise damaged and is worn
beyond permissible value, replace it
with new one.
Using special service tool No.EO-2500,
remove all the liners one by one.

Fig. A124

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Engine System

ASSEMBLING
1. Fit two silicon rings on cylinder liner.
Dip the rings in light soap solution
and fit the liner in to cylinder block.

Fig. A126
2. Check cylinder liner protrusion above
cylinder block face with the help of a
straight edge and feeler gauge. The
protrusion should be checked by
placing two-piston pin pressing the
flange of the liner at 100 kg load.
Alternatively it may be checked with a
dial gauge and a stand (Ref fig. A127)

Fig. A127

A–40
 Engine System

Specifications
CYLINDER BLOCK
Engine Model Unit FT-7110
Flatness of cylinder block top surface mm 0.04
Flatness of cylinder block bottom surface mm 0.1
Flatness of Timing Gear Face – Front mm 0.05
Flatness of Bell housing face – Rear mm 0.05
Maximum permissible cylindricity of main
bearing shell parent bore mm 0.007
Maximum permissible out of coaxiality of main
bearing shell parent bore (w.r.t. central & extreme) mm 0.030-0.090
Maximum permissible cylindricity of tappet bore mm 0.006
Perpendicularity of tappet bore axis w.r.t.
cam bore axis mm 0.04/100
Maximum permissible cylindricity of cam
shaft bore mm 0.006
Maximum permissible out of coaxiality of cam
shaft parent bore in relation to main bearing
shell parent bore mm 0.05
Non-parallelism of cylinder block Top face
w.r.t. crank bore mm 0.05
Maximum permissible non-parallelism of
cylinder block side & gear side face of
flywheel housing(mm) mm 0.2
Cylinder Liner:
Cylinder liner material. Cast iron
Cylinder Liner Arrangement. In line
Taper of the Cyl. Bore (repair limit) mm 0.15
Taper of the Cylinder Bore (wear limit) mm 0.3
Cylinder liner Protrusion above Cylinder
Block face. (at 100 kg. Load) mm 0.06-0.11
Cylinder Bore Diameter (STD) mm 91.00 – 91.025
Maximum permissible cylindricity of liner
bore (On dia) mm 0.015
Piston cylinder working clearance mm 0.101-0.144
FIP Timing
Nozzle holder F002 c70 023(KBAL 80 P 143)
Nozzle (P Type) F002 C40 713 (DSLA 146 P 5509)
Opening pressure 250 – 258 bar

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Engine System

3. LUBRICATION SYSTEM by high-pressure oil fed by the pump. The oil

pump delivers to the main oil gallery through
A. INTRODUCTION
oil filter. After filtration, the oil from main
The purpose of lubrication is to reduce wear gallery goes to the main bearings and Big-
and friction between moving parts. The end bearings through the holes drilled in the
other functions of lubricating oil is: cylinder block and crankshaft. Some of the oil
1. To minimize wear and tear of moving parts. from the front main bearing goes to the timing
gears and camshaft bearings. Through the
2. To reduce the power loss due to friction. first camshaft journal it enters the rocker arm
3. To absorb heat from various moving shaft through a hole drilled in the cylinder
parts by acting as a cooling agent. block and lubricates the rocker arms. The
return oil flows back to the sump. The
4. To form a good seal between piston escaped oil from big end and main bearings
rings and cylinder walls. creates a splash with rotating crankshaft,
In this system the engine, parts are lubricated which lubricates the Liner, Piston and rings.

Rocker Assembly
Push Rod Push Rod Push Rod Push Rod
Tappet No. 1&2 Tappet No. 3&4 Tappet No. 5&6 Tappet No.7&8

No. 1 Camshaft No.2 Camshaft No.3 Camshaft No.4 Camshaft No.5 Camshaft
Bearing Bearing Bearing Bearing Bearing
FIP Live
Lubrication
Drain to the Drain to the Drain to the Drain to the
sump sump sump sump
No. 1 Small No. 2 Small No. 3 Small No. 4 Small
Bore End Bore End Bore End Bore End Full flow
lub oil filter

Timing No. 1 No. 2 No. 3 No. 4

Gears Big End Big End Big End Big End

No. 1 Main No. 2 Main No. 3 Main No. 4 Main No.5 Main
Bearing Bearing Bearing Bearing Bearing

Lub Main Oil gallery

Relief Valve
Oil Pump

Sump Strainer
Unfiltered oil
Filtered oil
Returned oil

A–42
 Engine System

GEAR OIL PUMP REPLACEMENT OF ELEMENT ASSEMBLY

The oil pumps fitted in the Engines are 1. Unscrew the mounting filter of the
gear type. (Ref. Fig. A133) The pump has post assembly. (Ref. Fig. A132)
a pair of gears and as the gears rotates the
space between the gear and casing is filled
with oil due to the suction.
As the gear moves further it carries the oil
and delivers it to the filter. This is a
continuous process.
To keep the oil pump from building up too
much pressure a relief valve is provided in
the pump. The valve is spring loaded plunger
type. When the pressure increases the
plunger is moved against the spring. It opens Fig. A132
a passage through which oil can flow back to 2. Hold the pot shell container with hand
the oil sump. (Ref. Fig. A130, A131). to avoid fall. (Ref. Fig.A133)

Fig. A129
Fig. A133
3. Remove the filter and Replaced with
new one.
4. Replace a new filter with sealing ring.
Fit the pot shell (container) and
tighten the filter as given the
specified torque. (Ref. Fig.A134)
Fig. A130
When Engine Speed is low

Fig. A131
When Engine Speed is High Fig. A134

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Engine System

B. SPECIFICATION
Engine Model Unit FT-7110
Location of pump inlet With strainer in sump
Oil filter type Replaceable filter
Oil filter capacity (litre) 0.5
Oil pump delivery at 1420 – 1460 pump rpm
speed & at oil temperature of 70°C and
pressure of 2.9-3.1 kg/cm² 20 liters/min
Relief valve setting (kg/cm²) 4.2-4.9
Lubricating oil pressure at rated speed (Kg/cm²) 4—5
Oil sump capacity (litres) 11.5
Backlash between drive & driven gear (m.m) 0.09-0.2
Radial clearance between gears & pump body (m.m) 2
End Float of Gears (m.m) 0.15-0.28
Torque
Bolt oil pump to block N-m 65+2

Bolt oil Filter body to block N-m 10

Oil Recommendations
S.No. Item Oil Specification
1. Engine 15W40 CI 4+

A–44
 Engine System

4. COOLING SYSTEM B. DISMANTLING OF WATER

A. INTRODUCTION PUMP (Ref. Fig. 139)

The satisfactory performance of the engine is 1. Pass a screwdriver through the pulley
controlled to the great extent by the proper loosen the pulley shaft nut and bolts of
operation of the cooling system. Therefore, the pulley. (Ref. Fig. A136).
the importance of giving due attention to the
recommended periodical maintenance of the
cooling system cannot be over emphasized.
The leading elements of the cooling system
for engine include:
1. Water pump assembly with fan and
drive pulley.
2. Thermostat.
3. Radiator with pressurized cap.
The engine employs the centrifugal water
pump mounted on the front side of the
cylinder block Fig. A136
Dismantling 2. Loosen the mounting bolts of water
pump and remove the pump assembly.
The dismantling involves the following
Hold it in a bench vice.
operation:
3. Pass a screwdriver through the pulley to
After removal of radiator assembly, unscrew
hold it. With the help of SST No. EF0300
the 4 mounting bolts of the fan. To hold the
remove the pulley (Ref. Fig. A137)
pulley pass a screwdriver through the pulley.
Loosen the nut from the shaft and with the
help of SST No EF-0300 remove the water
pump pulley, (Ref. Fig. A135). unscrew the
mounting bolts of the pump assembly and
remove it.

Fig. A137

Fig. A135

A–45
Engine System

Fig.A138
4. Place the water pump assembly on the
arbor press and press the integral shaft
bearing with seal out. (Ref. Fig. 142).

Fig. A139. Water Pump Exploded View

1. Loctite 7 PULLEY WATER PUMP
2. PUMP ASSEMBLY WATER 8 BOLT
3 CLAMP HOSE WORM DRIVE 10 FAN ASSEMBLY
4 CAP WATER PUMP ASSEMBLY 11 SPACER CRANK PULLEY
5 WASHER 12 SPACER FAN
6 BOLT

A–46
 Engine System

C. ASSEMBLING

1. Water pump shaft & bearing is one piece

and is prepacked with grease. Slip the
seal assembly on the shaft. (Ref. Fig.
A140,141)

Fig. A-140
Fig. A-142

3. Put the impeller on the shaft press. After

fitting the impeller it should flush with the
housing. (Ref fig. A143.)

Fig. A-141

2. Place the water pump housing on an

arbor press and slowly press the shaft
and bearing assembly. Taking care that
the shaft goes straight inside the bearing
bore and seal sits on the face of the
bore. (Ref fig.A142)

Fig. A-143

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Engine System

Dimensions mm
S. No. Specification Recommended Repair
Rated Permissible
1. Roller berring axial plays. - 0.25 Replace bearing.
2. 6303z berring seat wear. Dia. 47-0.025 Dia. 47-0.1 Replace pump housing.
3. 6302z berring seat wear. Dia. 40-0.025 Dia. 40-0.1 Replace pump housing.
4. Hub key assembly wears. - 0.5 each side Replace hub.

D. THERMOSTAT E. RADIATOR
The function of thermostat is to maintain Cleaning the Cooling System: Clean the
optimum working temperature of water cooling system periodically every 300 hours
inside engine cooling jackets while engine is of operation. Drain the water, and then fill
running. the cooling system with 5-10% caustic soda
The thermostat should be cleaned with 5- solution in water. Drain the cooling system
10% caustic soda solution in water to again after one-day engine operation under
remove scales. Check the thermostat for its load, and then flush the cooling system with
performance after cleaning, by immersing clean soft water.
the unit in a vessel containing hot water. Leakage Testing of Radiator: Fit rubber
Valve opening begins at the temperature of plugs over all radiator openings and
77° to 83°C. complete valve opens at 90°C; immerse the radiator in water. Supply
complete valve opening lift amounts to 9 compressed air through the filler neck pipe
mm. If the unit does not meet the above under 0.4-0.5 kg/cm2 pressures. Repair
requirements, replace the unit. Also replace damaged spots, if any, by soldering them
the rubber seal underneath the thermostat and again check for leakage.
cover every time while replacing the unit in To improve the efficiency & prevent
the system. evaporation this tractor have pressurized
radiator cap. It has pressure setting of
0.9kg/ cm². (Ref. Fig. A145).

Fig.A-145
Fig.A-144 Bellow Type

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 Engine System

F. SPECIFICATION
Engine Model FT-7110
RADIATOR WATER HOLDING CAPACITY 7.25 Liters
Radiator Cap Pressure 0.9 kg/cm2
Fan Belt Deflection Auto adjustable
Thermostat
Opening Temp 78°-84°C
Full Open 87°-93°C
Water Pump
Type Centrifugal
Drive Poly –V Belt
Fan (Dia.) 457 - 473
NO. of Blades 10
Torque Specification
Water Pump to Cylinder Block N-m 45+2
Water Pump Cover to Pump lbf.ft (Kgf.m) 45+2

A–49
Engine System

5. FUEL INJECTION SYSTEM After filtration, the fuel is fed to the fuel
A. INTRODUCTION gallery of the fuel injection pump. A relief
The fuel system consists of the following valve is mounted on the primary filter of the
assemblies: dual fuel filter. It maintains the low pressure
in the fuel filters and the excessive fuel is fed
1. Fuel tank back to the fuel tank. Four separate high-
2. Fuel cock pressure pipes, feed the fuel under high
3. Preliminary filter pressure to the injectors mounted on the
4. Manifold pressure compressor(LDA) cylinder head. A common leak off pipe fitted
5. Solenoid to the injectors, returns the leak-off fuel to the
6. Dual fuel filter fuel tank through overflow pipe connected in
7. Fuel injection pump fuel tank and dual fuel filter relief valve.
8. Fuel injection nozzles
In this system the fuel from fuel tank is
sucked by the fuel feed pump through pre-
filter and delivered to the dual fuel filter
under pressure.

Fig.A 25

A–50
 Engine System

FUEL TANK: SOLENOID

It is a pressed steel tank of 60 liters A 12V operated solenoid is provided on FIP
capacity and is situated in between the & the supply should always be provided to
steering and the engine in such a manner solenoid before setting the injection timing
that it is not necessary to remove it while of the pump.
effecting repairs or adjustments on the DUAL FUEL FILTERS:
engine. It is designed to ensure that there is
a constant level of fuel even when the To prevent harmful abrasive particles finding
tractor is tilted or when fuel level is low. their way into vital working parts of the
injection pump and the injectors and causing
FUEL COCK: excessive wear, dual fuel filter assembly. Is
The fuel cock is secured to the tank by means incorporated in the fuel system.
of union nut. Screws type valve and seal The dual fuel filter consists of two bowls each
assembly is provided to have two positions, containing a filter element. The Felt-filter
'off' and 'on'. The fuel is allowed to flow while
insert element is used as the primary stage
the valve is screwed out and vice a versa. A filter and the Micro (paper) filter insert element
filter strainer is provided at its inlet side, which is used as the final stage filter. (The arrow on
always remains inside the fuel tank and acts the filter cover indicates the direction of flow.)
as a primary filter of fuel feed pump's pre- Or sometimes paper filter element can also
filter. be used for both the stages.
Remove the fuel cock and blow with Fuel delivered under pressure (1.5 kg/cm2)
compressed air in reverse flow direction to by the fuel feed pump, passes through the
clean it. Replace after cleaning and primary filter element and flows to the
checking for any leakage. secondary filter and the fuel coming out of
secondary filter is thus relieved of all
abrasive particles before flowing into the
injection pump for delivery to the cylinders
through injectors.

Fig.A 146
NOTE: The sealing ring should be replaced properly
between housing cover and housing. Check for any
leakage between the cover and the housing

LDA
When the engine operates with less than
maximum air, fuel delivery must be adjusted
adjusted accordingly. It is the function of LDA
to reduce fuel delivery when manifold
pressure falls below a predetermined value.

Fig.A 147

A-51
 Engine System

Fig.A155 Fig.A156
Cam Profiles: In order to obtain a short duration of injection,
use is made only of the center part of the cam
Apart from driving the pump plunger, the
where the rate of rise is high. Injection is over
profile of the cam also influences the duration
before the rate of rise has reached its
of injection, the pump delivery and the rate of
maximum. This is necessary so that the
delivery. The decisive criteria of the pump
surface pressure between roller tappet and
cam are cam lift and rate of rise (equal to the
cam does not exceed a defined value. For this
plunger velocity) in relation to the cam angle.
reason, a safety margin of 0.3 mm is provided
Fig. shows the plunger lift and plunger
during injection. This limits the material
velocity as a function of the cam angle.
loading to the allowed value. For practical
Cam shapes applications there are various cam profiles.
a. Symmetrical cam shape This is necessary since different shapes of
combustion chambers and combustion
b. Asymmetrical cam shape processes call for specific conditions of
c. Non-reversible cam shape injection. For this reason, the injection process
is specially adapted to the respective engine
Plunger Travel
type. Starting with standard cam shapes it is
Plunger Velocity possible to calculate modified versions for
1. Transition point to small cam radius optimizing the injection characteristics and
pressure loading. Thus, any cam-shaft can be
2. Maximum end of delivery provided with the appropriate shape ofcam.
Symmetrical "a",Asymmetrical"b"

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Engine System

and non-reversible "c" cam shapes are

generally made use of. Non-reversible
means that the engine cannot be started in
the opposite direction of rotation. The
profile of the cam used depends on the
type of pump, the design of the engine and
its area of application.
Pump Element (plunger and assembly):
Each element consists of a plunger and
barrel. The plunger is fitted into the barrel so
perfectly (clearance of a few microns) that it
seals even at very high pressure and low
speeds. No additional sealing is required for
Fig.A158
this purpose. Slight leakages through the
plunger are required for lubrication purposes. Single Port element
The plunger is provided with a vertical Due to the precise matching of plunger and
groove as well as a helical cut. The edge barrel it is important that only complete
formed on the upper section of the plunger element to be replaced and not just the
is known as the 'helix' plunger or the barrel only.
The fuel delivery of injection pumps is a
dynamic process. It consists of several
stroke phases. The pressure required for
injection is produced by the injection pump.
With the plunger at bottom dead center
(BDC) the inlet ports are left open by the
pump plunger. The fuel, which is under the
pressure generated by the feed pump,
flows from the suction gallery through the
inlet ports into the high-pressure chamber.
As the plunger moves up in the barrel, the
Fig.A157 plunger closes the inlet ports. This phase of
Double Port Element the plunger stroke is termed as 'prestroke'.
During the prestroke, hydraulic pre-delivery
The barrel is provided with two radial ports and post-delivery effects are generated
opposite to each other through which the caused by the flow properties of the fuel. In
fuel flows from the suction gallery to the the further course of the plunger stroke the
pressure chamber intake and spill port) fuel is slightly compressed, i.e., due to its
and through which it returns when the elasticity characteristics the fuel is not
delivery ceases due to port opening. incompressible. This delivery phase
However, there are also "single port following the prestroke is known as the
elements". The barrel has only one lateral retraction stroke. After the retraction stroke
port (spill port). The plunger has an axial comes the actual effective stroke.
hole in place of the vertical groove and a
slanted slot instead of a milled helix.

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 Engine System

The pressure generated in the high-pressure a vertical groove or hole.

chamber due to upward movement of
The helix influences the fuel delivery. The
plunger, opens the delivery valve and the fuel
distance covered by the plunger until the
flows through the high-pressure pipe into the
moment of port opening depends on the
nozzle holder and to the nozzle.
position of the helix with respect to inlet
The effective stroke is completed when helix port. This position can be changed by
of the pump plunger opens the spill port/inlet turning the pump plunger.
port. From this point onwards, no more fuel is
In the example shown it means that with
delivered to the injection nozzle. During the
the plunger in the maximum delivery
remaining stroke of the plunger to top dead
position, port opening does not take place
center (TDC), the residual stroke, the fuel is
until the maximum effective stroke is
forced back into the suction gallery B through
reached i.e., after the maximum possible
the vertical groove/hole linking the plunger
quantity of fuel is delivered. If the plunger is
chamber A and the suction gallery B. After
turned to partial delivery position, port
the reversal of direction at top dead center
opening takes place sooner depending
the fuel initially flows back into the pump
upon the position of the plunger.
barrel through the vertical groove/hole until
the helix again closes the inlet. As the In the 'stop'position (zero delivery), the
plunger moves further down in the barrel a pressure chamber above the plunger is
vacuum is created. It is only after the inlet connected to the fuel gallery through the
ports have been opened by the top edge of vertical groove or hole during the entire
the plunger that the fuel under the pressure stroke. There- fore, no fuel is delivered. The
from the feed pump, flows from the suction pump plungers are brought into this position
gallery into the high-pressure chamber. The when it is required to stop the engine.
high-pressure chamber above the pump
plunger is again filled with fuel. The individual
stroke and delivery phases are shown in Fig
Control Of The Fuel Delivery:
The fuel delivery is controlled by varying
the effective stroke. This is done by the
governor by means of the control rack.
The power delivered by a diesel engine
depends, among other things, on the
quantity of fuel injected. Consequently, the
inline fuel injection pump must have a
device by means of which the quantity of
fuel can be matched to the load on the
engine within the power range. Fig.A159
The plungers in the inline pump have a
constant stroke. The time for end of delivery
and the fuel delivery is controlled by turning
the plunger, i.e., the effective stroke is varied.
For this purpose, the plunger has a helix and

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Engine System

Bottom dead Prestroke Retraction Effective Residual Top dead

center Fuel Stroke Stroke Stroke Centre
inlet

Fig.A160 Phase of the Plunger Stroke

Fuel flows from Movement of the Movement of Movement of the Movement of the Reverse
The suction gallery pump plunger from the pump pump plunger from pump plunger movement of the
of the injection bottom dead center to plunger from the the opening of the from the opening pump plunger
pump into the high- the closing of the inlet end of the delivery valve to the of the inlet port
pressure chamber ports by the top edge prestroke to the opening of the inlet (end of delivery)
of the plunger-and- of the plunger opening of the port by the helix to top dead
barrel assembly (variable depending on delivery valve (overflow) center
plunger-and-barrel
assembly)

The upper end of the control sleeve has a The control rack of the pump must be
gear segment. At the bottom it is provided connected to the governor in such a way that
with two, vertical slots in which the plunger no lateral or torsional forces are transmitted
vane slides. The teeth of the control sleeve to the control rack. If the control rack moves
engage the teeth of the control rack. The with difficulty or jams, the governing is not
pump plungers thus can be rotated by the stable; if the control rack is stuck in the full-
control rack during operation so that the load position, the engine may over speed. If
effective stroke and therefore, the fuel a linkage is necessary, the connection
delivery of the pump can be infinitely between control rack and governor is best
varied from zero to maximum delivery. made by a fork head.

Fig.A161 Control of the Fuel Delivery

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 Engine System

LEAK OIL GROOVE ELEMENT: DELIVERY VALVE (RETRACTION TYPE):

If the injection pump is connected to the The delivery valve assembly relieves the
lubricating oil system of the engine, the excess high-pressure pipe and maintains a residual
leakage of fuel (diesel) through the plungers pressure in the high-pressure pipe.
into pump camshaft chamber, leads to dilution The task of the delivery valve assembly is to
of lubricating oil. To minimise this problem, the separate the high-pressure pipe from the
pump barrel is provided with an annular groove, high-pressure chamber and to relieve the
which is connected to the fuel gallery of the high pressure delivery line. During delivery,
pump through a small hole. The leaking fuel the delivery valve is lifted off its seat by the
loses its pressure in the annular groove and pressure generated in the high-pressure
flows back into the fuel gallery. chamber. The fuel is delivered through the
delivery valve holder and the high-pressure
pipe to the injection nozzle. As soon as the
helix of the pump plunger opens the spill port,
the pressure in the high-pressure chamber
drops. As a result, the valve spring forces the
delivery valve back to its seat. The injection
circuit and the high-pressure circuit are thus
separated until the next delivery stroke.
A part of the valve stem below the conical
seat, there is a cylindrical piston (relief
piston) and is perfectly matched to the
valve body. At the end of delivery, this relief
piston first enters the bore in the valve body
and closes the high-pressure pipe from the
pressure chamber above the pump plunger.

Fig.A162
Leak Oil Groove Element
PLUNGERS WITH STARTING GROOVE:
Some diesel engines start more easily when
fuel injection timing is retarded during the
starting process relative to normal operation.
For this purpose, the plunger is provided with
an additional groove machined on the top
edge, called the 'starting groove'. This groove
is effective only when the plunger is in the
starting position and retards the start of
delivery by 5°-10° with reference to the
Fig.A163
position of the crankshaft.

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Engine System

Thereby, the volume available to the fuel in C. F.I. PUMP TIMING

the high-pressure pipe is increased by the More accurate fuel injection timing is set by
swept volume of the relief piston. The fuel fuel-cut-off method using swan neck pipe on
in the high-pressure pipe can expand number 1 delivery valve holder after
quickly and the nozzle needle closes removing the delivery valve spring and peg.
instantaneously. The relief volume is
matched to the length of the high pres- 1. Before setting the injection timing of the
sure pipe and therefore, the length of the pump, connect the Solenoid to the FIP.
high-pressure pipe should not be changed. 2. Remove the timing gear inspection
LUBRICATION OF FUEL PUMP: cover and the timing pin from the
flywheel housing.
Oil chamber for the camshaft and tappets
is combined. A leak- off pipe is provided so 3. Rotate the engine clockwise and observe
as the extra oil filled leaks out when the the 'O' mark on the fuel injection pump
pump runs. gear teeth. When the 'O' mark on pump
gear and intermediate gear teeth are
In a new pump or a pump received after about little away from meshing, insert the
repairs, it is necessary to fill the pump longer end of the timing pin in the
camshaft chamber with good quality clean flywheel housing. Now slowly rotate the
engine oil up to the recommended level. engine clockwise to the point where the
The camshaft chamber of the pump must timing pin goes fully into the first hole in
be sufficiently filled with oil at all times. At the flywheel and slides easily.
each regular engine oil change, proceed
as follows:
1. Clean the surface around the
inspection cover
2. Fill oil from the plug provided on the
governor housing using oilcan until
the oil just starts flowing through the
level plughole provided at the back of
the governor housing.
NOTE: If the oil is too thin and needs to be
replaced then keep adding oil until the Fig.A164
fresh oil starts flowing through oil level plug
and wait till excessive oil comes out. After removing the inspection cover pull,
the fuel shut off rod to the point where the
3. Replace the plug and tighten. control rod quadrant is visible and slightly
4. Remove excess oil from fuel pump by forward of the middle position. Temporarily
loosening level plug, whenever fix fuel shut off rod in this position and
tractor comes for regular service. proceed with fuel injection timing.

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 Engine System

A stream of diesel will flow through the

swan neck pipe.
A point will come when the diesel stream will
reduce to drops. Carefully turn the pump
shaft hub further clockwise till the point where
drops fall at an interval of about 15 seconds.
Holding the pump hub at this position, tighten
the pump gear mounting bolts securely.
Fig.A165 Check, the zero on the gear of F I pump
4. Remove the 1st cylinder high-pressure pipe aligning with the cut of the hub. Ref fig.A168
and the delivery valve holder after loosening
the holder clamp. Remove the delivery valve
spring, peg, and refit the delivery valve holder.
Fit the swan neck pipe. Ref fig.A166

Fig.A168
7. Recheck timing by first taking out the
timing pin and then turning the crankshaft
anticlockwise.
Drops will appear from swan neck pipe.
Fig.A166
Now turn the shaft clockwise till the drops
5. Insert a piece of cloth in the timing reduce again to a drop every 15 seconds.
inspection hole towards the intermediate Insert the pin in the flywheel hole to
gear to protect against any part or tool ascertain the correct timing.to as certain.
falling in the timing housing accidentally.
Loosen the three-pump gear mounting bolts.

Fig.A169
Fig.A167
8. Complete the job and refit the F.I pump
6. Rotate the pump shaft hub clockwise. Gear cover.

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Engine System

D. FUEL FEED PUMP

Fig.A171
Pressure spindle, roller tappet and plunger
are only in slight contact with one another.
As soon as the cam or eccentric has passed
its maximum stroke, plunger, pressure
Fig.A170 spindle and roller tappet accordingly move
"upward" due to the pressure exerted by the
Fuel has to be fed to the injection pump
plunger spring. A portion (quantity delivered
under pressure of about 1 atm. As the
per stroke) of the fuel present in the pressure
quantity of fuel delivered would otherwise be
chamber is there by delivered to the injection
inadequate. MICO BOSCH fuel feed pump is
pump (delivery stroke) through the filter. Fuel
a plunger pump and is provided with a hand
is, however, is slightly less than that swept
priming device and preliminary filter. out by the plunger in the suction chamber.

Drive:
The fuel feed pump is attached to the
injection pump and driven by its camshaft.

OPERATION:
The revolving cam or eccentric presses the
plunger of the feed pump "downwards" by
means of the roller tappet and or pressure
spindle. A portion of the fuel present in the
suction chamber equal to the swept volume
or quantity of fuel delivered per stroke is Fig.A172
delivered through the pressure valve to the The volume swept out in the pressure
pressure chamber, and the plunger spring chamber is the volume swept out in the
compressed in an intermediate stroke. suction chamber less the volume of the
Towards the end of this stroke the spring spindle projecting into the pressure chamber.
loaded pressure valve closes again Therefore, during the intermediate stroke a
quantity of fuel corresponding to the volume
of the spindle is fed to the injection pump.

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 Engine System

Where the pressure in the feed pipe exceeds PRELIMINARY FILTER:

a specified value, the plunger spring lifts the The preliminary filter is usually attached to
plunger only partially. The fuel quantity the feed pump. It may, however, be mounted
delivered per stroke correspondingly smaller. anywhere in the pipe between fuel tank and
Hence, higher the pressure in the feed pipe, feed pump. The function of the preliminary
smaller is the quantity delivered; the fuel feed filter consists of a housing with a nylon/ wire
is made "elastic". Should, for instance, the gauze insert. Where no preliminary filter can
overflow valve be stuck in closed position, be attached, a wire mesh sieve is mounted in
pressure in the feed pipe would quickly rise to the connecting banjo bolt for the feed pipe.
such an extent that the feed pump would stop
functioning. The pipe is thus safe against
excessive pressure.
E. ACCESSORIES
HAND PRIMER:
The hand primer is screwed into the feed pump
above the suction valve. With the aid of the
hand primer the fuel can be pumped from the
fuel tank through the filter to the fuel injection
pump when the engine is at rest. The quantity
delivered per stroke is about 6 cm3.
In order to operate the priming device, the
knurled knob is screwed out until the plunger Fig.A174
can be pulled upward, causing the suction For cleaning, unscrew the clamping nut,
valve to open and fuel flow into the suction swivel out the clip and remove the housing
chamber. When the plunger is pressed down, down wards. The filter sieve is rinsed in
the suction valve closes while the pressure petrol or fuel oil. In due course, the washer
valve opens with fuel flowing through the feed becomes hard and useless. It should be
pipe and filter to the injection pump. After use, it replaced so, as to prevent 'air lock.
is essential to screw the knob tight again.
MAINTENANCE:

Maintenance of the feed pump is limited to

cleaning the preliminary filter or the sieve in
the connecting piece every 125 hours. It
may also happen that, as a result of lengthy
storage or a long break in operation, the
plunger surface of the feed dries up
completely. Where this is the case,
suctioning of the feed pump is facilitated by
filling some fuel or oil through the suction
valve (on the inlet end) prior to use.

Fig.A173

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Engine System

F. THE GOVERNOR Governor control of engine speed is

A governor is a device for keeping the indispensable on a tractor. The load on the
engine at a constant speed when running. engine is subject to rapid variation, and the
Tractor engines are always fitted with driver is generally too busy to control the
governors, and the governors are always of fuel supply direct without difficulty. For
the variable - speed type. In other words the example, on lifting an implement out of the
governed speed can by varied by the ground, the sudden reduction in engine
operator as required. In this respect there is load would tent to make the engine race
an important difference in principle between away unless the throttle was closed. The
the controls of a tractor and those of a operator is well occupied in watching the
motorcar, in the later the fuel supply is under implement and steering the tractor, and the
direct control of the accelerator petal. But in governor relieves him of the duty of
the tractor, the governor controls the fuel regulating the throttle, the whole time to
supply, and the operator varies the engine meet transient variations in engine load.
speed by movement of the governor control
lever. The governor is designed to provide
variation of speed from idling to maximum.

Starter Spring

Fig.A175

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 Engine System

PRINCIPLES OF OPERATION: In mechanical governor type RSV used in FIP

In diesel engines it actuates mechanism of PT tractors the action of the two flyweights
controlling the amount of fuel delivered to presses the guide sleeve against the tension
the cylinder on each stroke of the fuel lever, which is drawn in the opposite direction
injection pump with the usual variable- by the governor spring is tensioned by an
delivery multiple piston pump. This means amount corresponding to the desired speed.
that the governor is connected to the pump The governor spring are so selected that at
control rod, the position of which the desired speed the centrifugal force and
determines the point of spill. the spring force are in equilibrium. If this
speed is exceeded the increasing centrifugal
MECHANICAL GOVERNOR: force of the flyweights acts through a system
The fuel injection pump fitted on engines of levers to move the control rack in the 'stop'
employs a mechanical governor, which is direction and the fuel delivery is decreased.
called a Variable speed governor.
Governors employing the principle of OPERATING CHARACTERISTICS
centrifugal force are called mechanical
governors. These are most widely used on Starting The Engine:
diesel engines. When the engine is stopped, the control
The mechanical governors are mounted on rack will move to the starting fuel delivery
the fuel injection pump. The control rack of position due to the action of starting spring,
the fuel injection pump is connected to the so that the engine can be starting with the
governor through a flexible joint and governor control lever in 'idling' position.
control lever is connected to the accelerator.

Fig.A177
RSV Governor Starting Position
Idling Speed:
When the control lever is in idling position, the
governor spring is almost completely relaxed
Fig.A176
and stands nearly in a vertical position.
Schematic Drawing of Variable Speed Therefore the spring has only a marginal effect;
Governor Pump the flyweights can swing outward at even a low

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Engine System

speed. The guide sleeve along with the of lesser delivery (point C). the speed of
guide lever move to the right in the the engine does not increase further and is
direction of arrow as shown in figure.A182. held constant by the governor as long as
in turn the guide lever swings the fulcrum the operating conditions remain uniform.
lever, which pulls the control rack in the
direction of stop, to idling position.
The tension lever is positioned against the
supplementary idling spring, which
facilitates stable idling speed.

Fig.A179
RSV Governor, Full Load at Low Speed,
starting of Torque Control
Governing Process In Maximum Speed
Range:
If the control lever is moved to the maximum
speed stop position the governor functions in
Fig.A178 the same way as explained above. However
the swiveling lever tensions the governor
RSV Governor Idling Position spring completely.
Governing Process In
Intermediate Speeds:
Even a relatively small movement of the
control lever from the idling position is
sufficient to move the control rack from its
initial (idling) position (point L in) to its full
load position (point B in). the fuel injection
pump delivers the full load fuel quantity into
the engine and the speed increases (B'B").
As soon as the speed increases the flyweights
swing outward (centrifugal force exceeds the
force of the governor spring corresponding to
the position of the control lever) and push the
guide sleeve and guide lever. In turn guide
lever swivels the fulcrum, lever and the control Fig.A180
rack is moved in the 'stop' direction, to a point RSV Governor Full Load at Maximum Speed
and of Torque Control Starting of Full load
Speed Regulation

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 Engine System

The governor spring thus acts with a

greater force and pulls the tension lever
against the full load stop and control rack to
the maximum fuel delivery position. The
engine speed increases and the centrifugal
force steadily rises.

Fig.A182
RSV Governor No Load regulated From
Full Load
STOPPING THE ENGINE:
(A) GOVERNORS WITHOUT SPECIAL STOP
LEVER ARRANGEMENT

Such governors are stopped by pulling the

Fig.A181 control lever to the 'stop'position. As this is
RSV Governor Full Load at Maximum done the projections on the swiveling lever
Speed and of Torque Control Starting of (inclined arrow) press on the guide lever
Full load Speed Regulation swings to the right, taking the fulcrum lever
and thus the control rack to the 'stop' position.
In governor equipped with torque control
Parallels the swiveling lever rocker touches
(adoption capsule) device, as soon as the
the 'stop' screws. Since the pressure exerted
tension lever is positioned against the full
by the governor spring on the guide sleeve is
load stop, the spring in the adoption
released the flyweights swing outward.
capsule is steadily compressed as the
speed increases (D,E in). as a result the
guide lever and fulcrum lever move the
control rack in the 'stop'direction and
reduce the delivery. The reduction in
delivery depends upon the adoption travel.
When the maximum full load speed (nvo) is
reached, the centrifugal force overcomes the
force of the governor spring and the tension
lever is deflected to the right. The guide
sleeve, guide lever and the fulcrum lever will
move the control rack in the 'stop'direction
until the fuel delivery rate is reduced Fig.A183
commensurate with the new load conditions. RSV Governors Stopping the Engine with
If the entire load on the engine is removed the Governor Control Lever
the no load speed nlo is attained.

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Engine System

(B) GOVERNORS WITH SPECIAL STOP LEVER: functioning of its fuel injection system. For
maximum efficiency in operation, it is essential
In the case of governors with special stop
that the engine be not only provided with fuel in
lever arrangement (irrespective of the
quantities exactly timed and proportional to the
flyweight and control lever positions) the
amount of work it is required to do, but also
control rack can be moved to 'stop' position
that it should receive each charge of fuel in a
by operating the stop lever.
condition such that it can be completely
When the stop lever is pressed to 'stop' consumed without causing smoke in the
position, the upper part of the fulcrum lever is exhaust. This is briefly the function of injector
swung to the right around the pivot point C in nozzle, which is held in position in the cylinder
the guide lever. As a result the control rack is head by a nozzle holder. As the nozzle may
pulled by the shackle (line member) to the have to deal with hundreds of fuel charges per
'stop' position. When the stop lever is minute, with widely varying condition of
released, a return spring (not shown in the pressure and temperature, the unerring
figure) brings back to its original position precision necessary in the production of these
(starting position). parts will be appreciated.

Fig.A184
RSV Governor Stopping the Engine with
Stop Lever
NOZZLES
DESCRIPTION AND OPERATION:
Fig.A185
The performance of a modern high-speed
diesel engine depends largely upon proper Hole Type Nozzle With Long Term

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 Engine System

G. Adjusting And Testing of

Nozzle Nozzle Cleaning:
Remove the injector from the cylinder head
and clean the carbon deposits, if any, by
washing them thoroughly in petrol. Remove
the nozzle and dip it in the clean fuel oil and
the nozzle needle too. After cleaning the
needle, insert into the nozzle body.

NOTE: Nozzle needle and body are lapped

together and must not be exchanged.

Initial Test: Fig.A186

Use clean test oil for testing. It is very important
1. Visual test (only on used nozzles): after
that the oil is clean. The nozzles are adjusted
cleaning, used nozzles should be
by their respective nozzle holders.
visually inspected. Look on nozzle
needle for damaged or rough needle
seat, for worn or damaged or carboned
seat and for out of round of needle hole.
When clamping the nozzle into nozzle
2. Slide test: after visual test all nozzles holder, take care that the sealing surface is
should be given slide test. clean and un-damaged. Place nozzle on
First dip the nozzle needle in clean fuel sealing surface of nozzle holder, tighten
oil and insert into the nozzle body. cap nut first by hand and then with a well
Holding the body almost vertically, pull up fitting wrench to torque 6-8 kgm.
the needle by one third of its engaged Connect nozzle holder with its respective
length. When released, the needle should delivery pipe to the outfit. To test for nozzle
slide down by its own weight. jamming, press the hand lever of the nozzle
tester down vigorously a few times (approx.
6-8 downward movements per second) with
Testing of nozzle and Adjustment of
a pressure gauge bypass. With nozzle
Opening Pressure:
needle moving properly, the nozzle should
The opening pressure of the nozzle chatter with shrill whistling buzz.
(assembled with nozzle holder) can be
Opening Pressure:
checked and readjusted on a nozzle tester.
The opening pressure is specified in the
This tester permits accurate checking and
operating instructions for the engine and
setting of opening pressure and observation
should be adjusted correspondingly. With
of the spray pattern of the nozzles.
the pressure gauge open to pressure slowly
The following is tested on the nozzle tester: depress hand lever until the nozzle ejects
Opening pressure. with slight chattering. Take reading on the
pressure gauge, if this pressure differs from
Leakage the specified opening pressure, it is
Chattering characteristics and spray necessary either to turn the adjusting screw
pattern. or to change total shim thickness

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Engine System

CAUTION: When the pressure gauge is To get maximum service life from
open to pressure, increase and decrease turbochargers few good practices are
pressure slowly, otherwise the gauge may followed:
be damaged. 1. Start Up
Leakage Test: When starting the engine use minimum
throttle and run in idle mode for
Operate hand lever of the nozzle tester until
approximately one minute.
pointer on the pressure gauge indicates 20
kg/cm² below the specified opening pressure. Caution: When starting the engine after
long time crank the engine after removing
The nozzle is considered leak-proof if no the solenoid, for 2-3 times to lubricate the
drop of fuel emerges out at end of nozzle turbocharger.
within 10 seconds.
2. After Servicing
Chatter Test and Spray Pattern:
After servfting the engine or turbocharger
For the tests it is absolutely necessary that ensure that the turbocharger is pre-lubed
the pressure gauge be by-passed. by adding clean engine oil into the
Testing speed range, 1 stroke in approx. turbocharger oil inlet until full.
©0.2 to 1 sec. (5 to 7 downward movement 3.10w Air Temperature & Inactive
per sec.) Operation
Pintle nozzles chatter audibly over the entire If the engine has been inactive for some time
range of attainable lever velocity (lowest test or the air temperature is very low, crank the
velocity: One downward movement per engine first and then run at idle. This allows
second). It is only when the lever movement the oil to circulate throughout the full system
is accelerated that the nozzle chatters with before high loads and speeds are applied to
a shrill whistle. Slight non-chattering in engine and turbocharger.
intermediate range is of no significance. 4. Shut Down
Well-atomized oven spray, irrespective of Before shutting your engine down, let the
test velocity observe spray angle. An turbocharger cool down.. Hot shut down
estimate of the shape of spray cone is can cause reduced service life, which is
feasible only when the lever movement is avoidable by a minute or two of idling.
accelerated (about 4 to 6 downward
5. Engine Idle
movement per second). The spray must
there be compact and well atomized Avoid running your engine for long periods
(chattering at full lift of nozzle needle). in idle mode (greater than 20-30 minutes).
Under idling conditions low pressures are
generated in the turbocharger, which can
cause oil mist to leak past seals into the
two end housings. Although no real harm is
done to the turbocharger, as load is
applied, temperatures increase and the oil
will start to burn off and cause blue smoke
emission problems.

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 Engine System

6. TROUBLE SHOOTING CHART

Symptom Probable Cause Remedy Observations
Starter motor does not Battery discharge or aged Recharge/replace battery Lights dim, Horn
crank the engine weak.
Alternator or voltage regulator Repair Alternator, Voltage
defective regulator
Starter motor or switch Repair or replace Lights bright, Horn
defective loud and sharp
Starter Motor cranks the Battery discharged or aged Recharge or replace
engine at insufficient speed
Alternator or voltage regulator Repair or replace
defective
Electrical connections loose, Tighten electrical connections.
battery terminals corroded Clean battery terminals, apply
petroleum jelly
Engine partially seized Get the engine repaired Engine noisy, when it
was stopped earlier
Lubricating oil too thick for the Use the correct grade
season
Starter motor cranks at Insufficient/no fuel in the tank Fill up tank
sufficient speed, but still Fuel tank breather hole blocked Clean
engine does not start Low pressure pipes blocked Clean or replace
Air in fuel system (air lock) Rectify leakage, bleed the Once started, engine
system may stop again
Filter insert(s) clogged Replace
Overflow valve leaky Replace
Pump drive shaft coupling broken Replace
Governor stop-lever not fully Rectify
disengaged
Governor linkages loose or Rectify
broken or restricted
Engine cranking satisfactory, Pump timing wrongly set Re-adjust Once the engine
it starts with great difficulty starts, there may be a
knocking sound,
overheating etc
Starting delivery from pump Get the pump recalibrated /
insufficient overhauled
Nozzle spray-holes clogged Get the nozzles cleaned/
nozzles sticky, spray reconditioned/replaced
unsatisfactorily
Cold starting / excess fuel Rectify
device defective
Engine cranking satisfactory Engine tappet adjustment Re-adjust
it starts with great difficulty incorrect
Air cleaner clogged Replace/rectify Black smoke at High
speeds/loads
Engine compression low Get the engine overhauled Blue smoke at all
engine speeds
1. Engine races after starting (speed uncontrollable)
Accelerator linkages sticky Rectify
Pump control-rack sticky Rectify
Governor linkages broken Replace & recalibrate the pump
Excess fuel-device button Rectify/replace
not snapping back to normal
position after starting

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Engine System

Symptom Probable Cause Remedy Observations

2. Engine runs erratically (Surge, Misfire)
Fuel system Water in fuel Replace fuel Accompanied by
Air in fuel Rectify leakage and bleed the engine missing
system
Restriction in fuel pipes Clean/replace Accompanied by loss
Filter inserts clogged Replace of power
High pressure pipe leaky Rectify/replace
/ broken
Idling speed setting not correct Adjust Hunting only at idling
speed
Pump timing too retarded Re-adjust
Fuel delivery between cylinders Recalibrate/ overhaul the pump
uneven, phasing incorrect
Pump control rack/toothed Replace and recalibrate
quadrants worn out the pump
Injector opening pressure Re-set the opening pressure
uneven
Nozzle sticky, spray holes Clean/recondition/ replace
clogged, poor spray nozzle
Engine problems Air filter/exhaust system Clean/replace
clogged
Valves sticky/valve spring broken Repair/replace
Tappet clearance incorrect Re-adjust
Too much play in accelerator Rectify
linkages
Engine compression poor/ Get the engine overhauled
uneven
3. Knocking -sound in the engine
Mechanical knocks Piston rings sticky/seized, Get the engine overhauled Accompanied by loss
engine cylinders/pistons of power, blue smoke
worn out
Big end/main bearings of Get the engine overhauled Lubricating oil
engine worn out pressure low
Tappet clearance excessive Re-adjust
Crankshaft end thrust excessive Re-adjust
Flywheel pressure plate loose Tighten fixing bolts
Combustion knocks Pump timing too much Re-adjust Accompanied by
advanced erratic running of the
Pump delivery valve spring(s) Replace and recalibrate engine
broken
Pump delivery valve(s) stuck in Replace and recalibrate
open position
Injector opening pressure high Reset
Nozzle needle(s) stuck in, Replace and test Excessive whitish
open position or nozzle smoke from the
engine exhaust
Air cleaner oil level high Correct the level
Engine overheating Refer point 8
Excessive carbon deposits Decarbonise
in combustion chamber

A–72
 Engine System

Symptom Probable Cause Remedy Observations

2. Loss of power
Fuel system Fuel adulterated/wrong grade Use correct fuel
Air in fuel system Rectify leakage and bleed
Water in fuel Replace fuel
Restriction in fuel supply lines Clean/replace
Filter insert(s) clogged Replace
Overflow valve sticky/leaky Replace
Fuel supply from feed pump Clean preliminary filters, get
insufficient the feed pump repaired
High pressure pipe leaky/ Rectify/replace
broken
Pump timing retarded Re-adjust
Full load/course of delivery less Recalibrate/overhaul Pump
Governor cutting-in speed Re-adjust
too low
Injector opening pressure Reset
incorrect
Nozzle spray-holes clogged, Clean/recondition/ replace
nozzles sticky, spray pattern nozzle
unsatisfactory
Engine problems Pump Control lever does not Rectify
butt against full load delivery /
maximum Speed stop screw
Valve clearance incorrect Re-adjust
Valve sticky, valve springs Rectify, replace
broken
Air filter/exhaust system clogged Replace/Rectify
Engine internal friction high, Get it rectified Accompanied by
probably due to partial seizure engine overheating
Engine compression low Get the engine overhauled Accompanied by blue
smoke from exhaust
Clutch slipping, plate worn Adjust the replace clutch plate Engine ‘races’ under
out / burnt load conditions
Brake dragging Re-adjust Wheel drums overheat
Tyres under-inflated Inflated to correct pressure
Engine / vehicle overloaded Avoid overloading
Fuel consumption high
Fuel system Fuel leaking Rectify leakage
Pump timing too advanced Re-adjust Black smoke from
exhaust
Idling speed setting too high Re-adjust
Full load delivery setting too Recalibrate / overhaul the
high pump
Adaption travel incorrect Recalibrate/overhaul the pump
Injector opening pressure low Re-set
Nozzle spray-holes clogged, Clean / recondition / replace
nozzle sticky, spray unsatisfied
Nozzle needle lift excessive Replace nozzles
Engine Valve clearance incorrect, Readjust / rectify
valves Sticky
Air cleaner / exhaust clogged Clean / Replace
Engine internal friction high Rectify Accompanied by
starting trouble
Engine compression low Get the engine overhauled

A–73
Engine System

Symptom Probable Cause Remedy Observations

Operating conditions, driving Engine/vehicle overloaded Avoid overloading Accompanied by
habits loss of power
Clutch slipping, plate worn Adjust replace clutch plate
out / burnt
Brakes dragging Adjust
Tyres under-inflated Inflate to correct pressure
Untimely gear shifting / Improve driving habit
unsteady driving
Excessive smoke from the engine exhaust
7a. Black smoke
Smoke at full load at all Full load delivery from pump Recalibrate pump
engine speeds too high
Injector opening pressure Reset
too low
Excess fuel device not Rectify
snapping back to normal
position after starting
Smoke at full load and high Adaption travel incorrect Recalibrate
speed
Pump timing retarded Re-adjust Engine quieter than
normal
Smoke at full load and high Nozzle spray-holes clogged Clean
speed accompanied by
loss of power Air cleaner clogged Clean/Replace
High pressure pipes of Change the pipes with those
incorrect length, bore or of the correct type
deformed end-nipples
Intermittent puffing smoke Nozzle stuck in open position Clean and reset Accompanied by
knocking
Nozzle holder spring broken Replace and reset
7b. Blue / Greyish white
Blue smoke when Valve guides worn out Replace
accelerating only
Blue smoke at all speeds Worn out piston, piston rings Get the engine overhauled Accompanied by
and loads engine bore, etc. starting trouble / loss
of power
Blue smoke at maximum speed Oil level in air cleaner high Correct the level
Blue or whitish smoke when Nozzle sprays impinging on Remove the extra nozzle-
cold and when starting; cylinder head due to strong sealing washers used.
changes to black when hot fitment Position the injectors
(at all speeds and loads) correctly.
2. Overheating (check first the temperature -gauge)
Overheating at high speeds Full load delivery quantity Recalibrate Accompanied by
and loads too high Black smoke
Nozzle needle lift excessive Replace nozzle
Cooling system problems Cooling system leaky, Rectify/replenish
insufficient water
Replace the tensioner spring
Fan belt loose, broken/greasy loaded pulley.
Thermostat stuck Replace
Engine Valve timing incorrect Re-adjust
Pump timing retarded Re-adjust
Piston/piston rings/bearings Rectify
tight due to wrong assembly
or partial seizure
Valve clearance incorrect Re-adjust

A–74
 Engine System

Symptom Probable Cause Remedy Observations

Cylinder head gasket leaky Replace
Exhaust system clogged Clean
Operating conditions and Clutch slipping, plate worn out Adjust / replace clutch plate
others / burnt
Brake dragging Re-adjust
Overloaded Avoid overloading
High altitude / hot climate
operation
1. Oil pressure low (Chec first with a master oil pressure gauge)
Oil Problem Engine oil level low Top-up as necessary Engine overhauling
Wrong grade of oil Drain and refill with correct
grade of oil
Lubricating system Problem Blocked oil pump Strainer Clean pump screen
Oil filter clogged Replace filter
Oil pressure relief valve stuck Repair/replace Plunger
in open
Worn gear teeth of oil pump Replace gear
Main/big-end-bearing Worn out Get the Engine overhauled
2. Excessive oil consump ion
Oil Problem Engine oil level too high Reduce oil level
Wrong grade of oil Drain and refill correct grade
of Oil
External oil leak from Engine Replace gasket seals where
necessary. Check mating
surfaces for damage or
distortion
Worn valves and guides Replace
or seals
Head gasket not sealing Replace gasket, check head
for damage or distortion
Oil loss past piston and rings Replace rings replace liners Blow-bye

TURBOCHARGING: - INSTRUCTIONS & PRECAUTIONS

There are certain precautions which needs to be followed with a turbocharged engine.

Do’s Don’ts

Ensure protective caps on all openings of Do not store turbochargers in heaps.

turbo Ensure specially deigned trolleys are Do not store turbochargers in moist or wet place.
used for turbocharger storage on assembly. Do not expose turbocharger to dust & dirt.
Ensure pre lubrication of turbocharger. Do not hold turbocharger by actuator rod.
Ensure leak proof joints for oil & air. Do not add any additives in lubricating oil &
Check periodically. fuel unless until specified.
Ensure specified grade of lubricating oil. Do not raise the engine RPM immediately
Ensure correct oil level in engine. after starting.
Run engine at idle RPM for approx 1min. Do not run the vehicle / engine at idle for
Before stopping & after starting. long periods (more than 20 – 30mins).
Check air & oil filter condition regularly to
the manufacturer’s specification.
Ensure that engine maintenance intervals
are adhered to.
Ensure engine & equipment are operated in such a
way that it is not harmful to the life of turbocharger.

A–75
Engine System

OIL LEAKAGE ANALYSIS OF TURBOCHARGER : -

A)Check for turbocharger compressor wheel
damage Disconnect compressor air inlet pipe
Not ok TC Needs to be replaced
Inspect wheel rotor vane damage Ensure zero
damage

B)Check for foreign material in air inlet pipe & air

cleaner choking Not ok Air inlet circuit to be cleaned
1. Inspect air inlet system
2. There should not be any foreign material

C) Check turbocharger rotor excessive movement.

1.Check rotor movement , rotor should spin freely Not ok TC Needs to be replaced
2. There should not be any contact with housing

D) Check oil circuit.

Oil inlet pipe & TC Needs to
1.Check oil inlet & outlet pipe. There should not Not ok
be replaced
be any sign of oil restriction or blockage

E) Check Turbocharger at turbine side.

1.Disassemble turbocharger or exhaust connection. Not ok If TC Needs to be replaced
possible inspect turbinewheel rotor vane damage .
2. There should not be any damage.

LOSS OF POWER/PERFORMANCE ANALYSIS OF TURBOCHARGER :-

A Check for tuning

1 Check unauthorized adjustment of the actuator
rod end.
2 Check unauthorized adjustment of the Not ok TC Needs to be replaced
minimum flow screw.This is factory set and the
paint seal should not be broken.

B Check actuator and rod movement

1 Connect the hand vacuum pump to actuator.
2 Operate vacuum pump until rod end reach its Not ok TC Needs to be replaced
hard stop.
3 Actuator should hold the depression.

C Check other components

1 Flow sensor. Not ok Replace the damaged
2 EGR valve. components
3 Modulation valve. 4 Injection units.

E Check turbo for damages

1 Dismantle turbocharger from engine Not ok Replace Turbocharger
and check for damage.

A–76
 PTO AND
TRANSMISSION
CLUTCH, RELEASE
BEARINGS AND
LINKAGES
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

CONTENTS PAGE

1. GENERAL B-3

2. REMOVAL AND INSTALLATION B-4

3. DISASSEMBLY AND ASSEMBLY B-5

4. ADJUSTMENT B-7

5. RELEASE BEARINGS B-8

6. PTO CLUTCH OUTER CONTROLS B-10

7. CLUTCH OUTER CONTROLS B-11

8. CLUTCH PEDAL ADJUSTMENT B-12

9. TROUBLE SHOOTING B-13

10. SPECIFICATIONS B-17

11. TORQUE SPECIFICATIONS B-18

B–1
PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

B–2
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

1. GENERAL
on these tractors, twin plate diaphragm spring clutch
has been fitted. The clutch is comprised of a cover
assembly, driven plate and release bearing. It is
always best to replace all three if any of the orginal
assemblies have to be changed. Remember that all
parts have worked through the same service life.
NOTE: Loosen each of the clutch mounting bolts one
turn at a time by diagonal selection then remove the
cover assembly and driven plate from the flywheel.
Before finally removing from the vehicle, mark the
position of all the components parts in relation to the
flywheel to assist with correct reassembly.
EXAMINATION
Check the condition of the flywheel face, If badly
scored or heat affected it should be replaced, such
damage will cause rapid wear of the driven plate
friction material. Examine the flywheel spigot
bearing, if wear is evident or there is any doubt as to
its condition, it should be renewed, if considered
serviceable apply a smear of good quality HMP
grease. Oil leaks into the housing must be A. Clutch Assembly
thoroughly investigated and rectified to avoid clutch
contamination. Poor condition or adjustment of such
parts can cause judder or vibration often wrongly close fit but must also slide freely. Spin the driven
attributed to the clutch. plates on the first motion shaft and ensure that the
axial run-out of the outer edge of the facings does
Also,the complete release system should be not exceed 0.5 mm (0.020") Inispigol bearing and
examined to ensure that it is in good serviceable hub splines should be lightly greased with good
condition, with particular emphasis on wear and quality HMP grease. Ensure that the driven plates
fatigue cracks. Areas where cracks may appear and filled the correct wayround.
cause problems include the clutch.
It is most important to centralise the driven plate on
Also, the complete release system should be the fywheel.
examined to ensure that it is in good serviceable
With the plate centralised fit the cover assembly
condition, with particular emphasis on wear and
making sure that the fyweel dowels enter the holes
fatigue cracks. Significant wear on release bearing
in the cover. Screw in the mounting bolts and
guide tubes or any of the pivots in the actuation
tighten progresively by diametric section to the free
mechanism will cause problems and must therefore
state in specification.
be corrected before renewing the clutch. Accurate
alignment between the clutch housing and engine is
essential for good clutch function and acceptable
life, therefore, carefully check that the clutch
housing is free from cracks and that the dowels and
dowel holes are present and in good condition.
Before assembly thoroughly clean the face of the
flywheel and presure plate. Try the driven plate on the
first motion shaft splines, the hub should be a good

B–3
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

2. REMOVAL AND INSTALLATION

STEP 1
Separate the engine from the transmission housing.
STEP 2
Install the clutch centralising tool FC 0226 (D10065940).
STEP 3
Remove two of the bolts and spring washers (1) that
fasten the clutch to the flywheel and install two
8x10x200 mm guide studs.
STEP 4
Remove the remaining bolts and spring washers (1)
and remove the clutch (2) from the flywheel.
NOTE : For Installation, tighten the bolts to a torque of
25 Nm.
STEP 5
Remove the PTO friction plate (3) with the centralising
tool. Inspect the PTO friction disc for wear or damage.
Use an outside micrometer to measure the thickness
of the disc. The friction disc should be replaced if it is
less than 6.5 mm thick.
NOTE : For Installation, use the same procedure in
reverse order.
WARNING : Where removing friction material dust
from various component do not blow - out with are air
line. It could be harmful to inhale the dust - removed
with a vacuum cleaner.
NOTE : Item numbers are in order of disassembly.

B–4
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

3. DISASSEMBLY AND ASSEMBLY

STEP 1
Use a hydraulic press to compress the Belleville spring
(3) and remove the nuts (1) from the clutch housing
(5).
STEP 2
Remove the PTO pressure plate (2). Remove the
adjusting screw (6) and nut (7). Inspect the PTO
pressure plate face for grooves and flatness. If the
face has grooves or is not flat, grind the face
maintaining the dimension shown.

STEP 3
Remove the Belleville spring (3). Check the
Belleville spring for flatness and the correct free
height A. If the dimension A is less than 13 mm
install a new Belleville spring.

STEP 4
Remove the transmission pressure plate (4). Inspect
the transmission pressure plate face for grooves and
flatness. If the face has grooves or a not flat, grind the
face maintaining the dimension shown.
NOTE : Item numbers are in order of disassembly.

B–5
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

STEP 5
Remove the transmission friction plate (8). Inspect it
for wear or damage. Use an outside micrometer to
measure the thickness of the plate. The friction plate
should be replaced if it is less than 6.5 mm thick.
STEP 6
Remove the spring (9), roll pin (10), pivot pin (11),
PTO release finger (12), pin (13) and rod (14) from
the clutch housing (5). Inspect the parts for wear or
damage. If necessary, replace the worn or damaged
parts. Remove the remaining PTO release fingers
assembly.
STEP 7
Remove the spring (15), roll pin (16), pivot pin (17),
transmission release finger (18), pin (19) and rod
(20) from the clutch housing (5). Inspect the parts
for wear or damage. If necessary, replace the worn
or damaged parts. Remove the remaining
transmission release fingers assembly.
STEP 8
Inspect the inside face of the clutch housing for
grooves and flatness. If the face has grooves or is not
flat, grind the face maintaining the dimensions shown.
NOTE : For Assembly, use the same procedure in
reverse order. After assembly of the clutch, refer to
Adjustment.

Note : Item numbers are in order of disassembly

B–6
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

4. ADJUSTMENT
The cover assembly it set during manufacturing and
is disigned to operate throught its service life without
adjustment of any kind, however as the drivan plate
facing wear the relationship of the release fingers, to
the release bearings changes, and therefore required
checking and re-adjusting at the recommended service
intervals.

STEP 1
To adjust the transmission clutch finger setting, install
the plate FC 0227 from special tool (D 10065940) for
clutch setting onto the clutch centeralising Special FC
0226 tool and tighten the nut. Make sure that the
centralising tool is pushed fully onto the PTO shaft
bearing. Adjust the transmission clutch fingers so that
they just touch the plate. The fingers can be moved in
by loosening the locknut and turning the adjusting
screw counterclockwise and moved out by turning the
screw clockwise. Tighten the locknut.
A. Transmission Clutch Finger Setting

STEP 2

To adjust the PTO finger setting, install the plate FC

0228 from special tool (D 10065940) for PTO finger
clutch setting onto the clutch centralising tool, then
tighten the nut. Make sure that the centralising tool
FC 0226 is pushed fully into the PTO shaft bearing.
Adjust the PTO fingers so that they just touch the
plate. The fingers can be moved in by turning the
nut counterclockwise and moved out by turning the
nut clockwise.
B. PTO Finger Setting

Remark: FC 0226, FC 0227 and FC 0228 comes

under the D code D 10065940

B–7
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

5. RELEASE BEARINGS
DISASSEMBLY AND ASSEMBLY
Where a new bearing is to be fitted to the bearing carrier,
it is enentiol to rotate the bearing as it is presed in to
position. Failure to abserve this rule when fittings puts
a heavy static load on the bearing, almost certainly
resulting in damage to the inner and auter race cracks
and to the balls leading to nolsy opration and / or early
failure. Ideally use a hydraulic press and a rotating
talsce but a satisfactory method is to use a vice.
STEP 1
Disconnect the pin (1) that connects and PTO linkage
(2) to the PTO operating shaft (6).
STEP 2
Disconnect the clip (3) that connects the transmission
linkage (4) to the transmission operating shaft (7).
STEP 3
Remove the roll pins (5), PTO operating shaft (6)
and transmission operating shaft (7).
STEP 4
Remove the lever (8) and spring (9).
STEP 5
Remove the release bearings (10), transmission
operating fork (11) and PTO operating fork (12) as a
complete assembly.

STEP 6
Remove the spring clip (13), bolt and spring washer
(14), plate (15) and sleeve (16).

Note : Item numbers are in order of disassembly

B–8
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

STEP 7
Remove the transmission release bearing (17) using
bearing puller and a disc from bearing driver set.

STEP 8
Remove the support sleeve (8) from the PTO release
bearing assembly.

STEP 9
Remove the PTO release bearing (19) and ring (20)
from the support sleeve (21) using bearing puller and
a disc from the bearing driver set.

NOTE : For Assembly, use the bearing driver set to

install the PTO release bearing and ring onto the small
support sleeve.

NOTE : For Assembly, use the same procedure in

reverse order.

B–9
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

6. PTO CLUTCH OUTER CONTROLS

STEP 1 STEP 3
Removal Lock ring (7), Cotter Pin and washer (6) Remove Pin clevis a & remove pin cotter (8) from
and sleeve (11) and disengage the operating rod operating rod (5) and mark operating rod (5) bor.
(5). Remove pin cotter (8) from operating rod and STEP 4
clevis assembly.
Remove cotter pin (8) from ped and clivis anembly
STEP 2 (8) and remove it.
Remove the bolt (3) washers (2) and screw (1) take
out the PTO clutch lever assembly.

1. Screw 7. Lock Ring 13. Spring Washer

2. Washer 8. Pin Cotter 14. Bracket Assembly
3. Nut 9. Pin Clevis 15. Bush
4. Lever Assembly - PTO Clutch 10. Hub & Lever Assembly 16. Washer
5. Rod & Clevis Assy PTO Clutch 11. Sleeve - PTO Clutch 17. Circlip
6. Washer 12. Bolt 18. Rod & Clevis Assembly
19. Clevis

Note : For installation follow the same procedure in

reverse order.

B–10
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

7. CLUTCH OUTER CONTROLS

STEP 1 STEP 2
Remove Spring (4) from clutch pedal assembly. Remove split pin (13) cotter pin (12) remove Rod
Remove cotter pin (5) and disengage operating rod and clevis assembly (9).
(7)

1. Bolt 8. Lever 15. Washer

2. Pedal 9. Rod & Clevis Assembly 16. Circlip
3. Pad Assy Clutch 10. Nut M10 17. Spring
4. Spring 11. Clevis M10 18. Bracket Assembly Pivet
5. Pin 12. Pin Clevis 19. Bolt M12x1.75x25
6. Split Pin 13. Pin Cotter 20. Washer Lock
7. Rod & Clevis Assembly 14. Lever Assembly 21. Grease Nipple
22. Lever

Note : For installation follow the same procedure in

reverse order.

B–11
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

8. CLUTCH PEDAL ADJUSTMENT

STEP 1
Check the free travel of the transmission clutch
operating pedal (1).

The measurement must be 15 to 30 mm. If the free

travel is not correct, complete following step.

STEP 2
Remove the special pin (2). Loosen the locnut (3)
and turn the for (4) until the free travel of the pedal
is correct.
Tighten the locknut and install the special pin.

B–12
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

9. TROUBLE SHOOTING
Before troubleshooting the clutch, make sure of
the following :
1. The Engine is operating correctly.
2. The Engine mountings are in good condition.
3. The alignment of the engine, transmission,
driveshalf and rear axle are correct.

TROUBLE PROBABLE CAUSE REMEDY

Clutch does not release 1. Release bearing clearance is less
1. Adjust release bearing clearence
or release partially 2. Clutch linkage needs adjustment 2. Adjust clutch linkage
3. Worn or damaged linkage 3. Lubricate linkage. Make sure the
linkage is not loose. If condition
still exists, replace linkage.
4. Worn or damaged release bearing 4. Lubricate release bearing. If
condition still exists, replace
release bearing.
5. Worn or damaged splines on 5. Replace input shaft
input shaft
6. Clutch housing loose 6. Tighten bolts to specified torque,
if necessary, replace fasteners
7. Worn or damage pressure plate 7. Replace pressure plate and cover
assembly
8. Worn or damaged center plate 8. Replace center plate
9. Center plate binding 9. Inspect drive pins in flywheel
housing and slots in center plate.
Inspect tabs on center plate and
slots in cover, Service as necessary
10.Damaged hub in clutch discs 10. Replace discs
11.Facings worn below specified 11. Replace discs
dimension
12.Facings damaged 12. Replace discs
13.Oil or grease on facings 13. Clean facings. If oil or grease
cannot be removed, replace discs.
14.Damaged pilot bearing 14. Replace pilot bearing

Clutch pedal is hard to 1. Damaged release bearing pads 1. Replace release bearing
operate assembly, make sure clutch is
correctly adjusted.
2. Tight or stiff pivots in clutch linkage. 2. Lubricate linkage. If condition still
exists, replace linkage.
3. Worn or damaged clutch 3. Replace pressure plate and cover
assembly
4. Worn or damaged pedal shaft and / 4. Repair or replace as necessary
or cross shaft bushings

B–13
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

TROUBLE PROBABLE CAUSE REMEDY

1. Driver keeps foot clutch pedal 1. Use correct tractor operating procedure
out of 2. Clutch release bearing clearence 2. Adjust release bearing clearence
engagement needs adjustment
3. Clutch linkage needs adjustment 3. Adjust clutch linkage
4. Worn or damage clutch 4. Replace pressure plate and cover
components assembly.
5. Worn or damaged facings 5. Replace clutch discs
6. Oil or grease on facings 6. Clean facings. If oil or grease cannot be
removed, replace discs.
7. Worn or damaged flywheel 7. Service flywheel as necessary.

Clutch is noisy 1. Release bearing clearence needs 1. Adjust release bearing clearance
adjustment
2. Clutch linkage needs adjustment2. Adjust linkage
3. Tight or stiff pivots in clutch3. Lubricate linkage. If condition still exists,
linkage replace linkage
4. Worn or damaged release bearing4. Lubricate release bearing. If condition
still exists, replace release bearing
5. Worn or damaged clutch housing 5. Replace clutch housing and pressure
plate assembly.
6. Clutch housing loose 6. Tighten botts to specified torque. If
necessary, replace fasteners
7. Damaged hub or broken co-axial 7. Replace clutch discs.
springs in clutch discs
8. Facings worn below specified 8. Replace clutch discs.
dimension
9. Facings damaged 9. Replace discs
10.Oil or grease on facings 10.Clean facings. If oil or grease cannot be
removed, replace discs
11.Damaged pilot bearing 11.Replace pilot bearing

Clutch vibrates 1. Worn or damaged splines on 1. Replace input shaft.

input shaft
2. Pressure plate and cover 2. Remove, check balance and install
out of balance pressure plate and cover assembly,
if condition still exists, replace pressure
plate and cover assembly
3. Worn or damaged splines in hub 3. Replace clutch discs.
of clutch discs
4. Loose flywheel 4. Tighten fasteners to specified torque.
if necessary, replace fasteners.
Check flywheel mounting surface for
damage, replace if necessary.

Broken tabs on clutch 1. Vibration 1. Inspect hubs of clutch discs, Also check
plate clutch installation. Make sure dampened
clutch discs are used.
2. Release bearing clearence 2. Adjust release bearing clearence.
needs adjustment
3. Clutch linkage needs adjustment 3. Adjust clutch linkage

B–14
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

TROUBLE PROBABLE CAUSE REMEDY

Worn or damaged 1. Driver keeps foot on clutch pedal 1. Use correct tractor operating procedures
release bearing 2. Free travel not adjusted correctly 2. Adjust free travel correctly.
housing 3. Free travel out-of-adjustment 3. Adjust free travel to specifications.

Worn or damaged 1. Transmission not aligned 1. Make sure driveline angles are correct.
input shaft splines 2. Damaged hubs in clutch discs 2. Replace clutch discs
3. Worn or damaged pilot bearing 3. Replace pilot bearing
4. Engine vibration 4. Make sure dampened discs are used
Lubricate at scheduled intervals.

Pressure plate cracked 1. Drive engages clutch while 1. Use correct tractor operating
or damaged by heat tractor is coasting to create procedures.
shock load.
2. Driver uses clutch as a brake to 2. Use correct tractor operating procedure
hold tractor on a grade.
3. Free travel not adjusted correctly. 3. Adjust free travel to specifications
4. Oil or grease on facings 4. clean discs. If Oil grease cannot be
removed, replace discs. Repair cause
of grease or oil leak.
5. Worn or damaged diaphragm 5. Replace pressure plate & cover
assembly spring
6. Drive slips clutch excessively 6. Use correct tractor operating
engagement. procedures.

Grooves worn in 1. During agjustment, clutch pedal 1. Replace clutch disce. Also, replace
Pressure Plate pushed pressure plate, conveter plate fly wheel
if damaged.

Hub seprates from 1. Excessive engine vibration 1. Repair engine

disc 2. Clutch housing loose 2. Tighten clutch housing to
specified torque. If necessary,
replace fastners
3. clutch engaged while tractor is 3. Use correct tractor operating
coasting procesures
4. Shock loading 4. Use correct vehicle operating
procedures

Heat damage on Disc 1. Driver keeps foot on clutch 1. Use correct tractor operating
pedal or slips clutch procedures
2. Clutch does not engage or 2. See Trouble shooting
disengage completely
3. Free travel not adjusted correctly 3. Adjust free travel correctly
4. Worn or damaged diaphragm spring 4. Replace pressure plate and cover
assembly
5. Grease or oil on facings 5. Clean facings. If oil or grease
cannot be removed, replace discs.

B–15
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

TROUBLE PROBABLE CAUSE REMEDY

Lining separate 1. Facings worn past specified 1. Replace discs

from discs dimension
2. Tractor coasting downhill with 2. Use correct tractor operating
tramission in gear and clutch procedures
engaged
3. Worn or damaged drive pins in fly 3. Make sure drive pins are correctly
engaged housing installed. Service drive pins as
necessary
4. Lugs on center plate binding in 4. Replace pressure plate & cover
cover. assembly and/or center plate.
5. Driver slips clutch excessively 5. Use correct tractor operating
druring engagement procedures

B–16
 PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

10. SPECIFICATIONS
DESCRIPTION FARMTRAC

Type Dry Double Clutch with Independent Control

Transmission and PTO Disc Diameter 12.2in (310 mm)

Transmission Clutch PTO Clutch Lever Height 4.76in (121 mm)

From Surface Plate

Release Lever Height From Surface Plate 3.8in (96 mm)

Clutch Pedal Free Play 1.25 - 1.5in (32-38mm)

CROSS SECTIONAL VIEW OF CLUTCH ASSEMBLY

B–17
PTO AND TRANSMISSION CLUTCH, RELEASE BEARINGS AND LINKAGES

11. TORQUE SPECIFICATIONS

B–18
 TRANSAXLE
Mod. T120 24+24
 REPAIR MANUAL

TRANSAXLE
Mod. T120 24+24
SYNCRO HI-LOW (SPLITTER)

5th Edition: 09/2017 P/N: CA270276

 No part of this manual may be reproduced, in any form or by any means,
without prior written permission of CARRARO SpA.

Please consider the environment before printing this document.

Print only the necessary pages and recycle the paper after use.
Mod. T120 24+24 PRODUCT DATA

CODICE 474166 CODE

MACCHINA Trasmissione - Transmission MACHINE
MODELLO T120 MODEL

CONDI ZI ONI DI FORNI TURA CONDITIONS OF SUPPLY

Fissaggio ruote Wheels mounting
I dadi e le relative rondelle per il fissaggio NO The nuts and washers for fixing of the
delle ruote vengono forniti. wheels are supplied.

Olio Oil
Questo prodotto viene fornito da Carraro NO This product is supplied by Carraro filled
rifornito d’olio with oil

DATI T EC NI CI P RI NCI P AL I MAIN TECHNICAL DATA

Peso a secco 997 kg Dry weight
Attuazione idraulica /
Tipo di differenziale Differential type
Hydraulically activated
Numero totale di marce avanti (totale) 24 Forward speed total number
Numero totale di marce indietro (totale) 24 Reverse speed total number
Tipo di inversore Synchro Shuttle type
Tipo selettore gamme Hi-Lo Synchro Hi-Lo splitter type
Miniriduttore Assente/Not present Splitter
Gamme velocità High-Low-Creeper Range gears
Riduzione coppia conica 2.85 (13/37) Bevel gear ratio
Riduzione riduttore epicicloidale 6.86 (14/82) Epicyclic reduction gears ratio
Riduzione totale (c.c.+rid.) 19.516 Total (b.g.+e.r.g.) ratio
Gioco di accoppiamento coppia conica 0.10÷0.30 mm Bevel gear backlash
Precarico P cuscinetti pignone (misurato su Pinion bearings preload P (measured on
P= 7.4÷8.0 daN
ghiera Øest= 80 mm) ring nut Øest= 80 mm)
Precarico totale T cuscinetti conici corona- T=(P +1.2) ÷ (P +2.0) Total pinion-crown bearings preload T
pignone (misurato su ghiera Øest= 80 mm) daN (measured on ring nut Øest= 80 mm)
Comando PDM 4WD Assente/Not present 4WD drop box
Modello PDF 540/540E PTO model
Comando PDF Meccanico/Mechanical PTO actuation
Selezione velocità PDF Presente/Present PTO speed selection
GND Presente/Present GND
Comando GND Presente/Present GND actuation

231497 REVISION DATE: 09/17 DOC. CA270276 CA406115 / CA474166 PAG. DP-5
PRODUCT DATA Mod. T120 24+24

CARATTE RI S TI CHE C ILI NDR O LIFTER CYLINDER

SOLLEVATORE TECHNICAL DATA

Cilindro Rif. Carraro 408271 Cylinder Carraro ref.

Pressione nominale di alimentazione Rockshaft cylinder nominal
190 bar
cilindro sollevatore working pressure
Pressione massima di alimentazione Rockshaft cylinder
240 bar
cilindro sollevatore maximum working pressure
Olio a base minerale
Tipo olio idraulico Hydraulic oil type
Mineral oil

RI FORNI ME NTO OLI O OIL FILLING

Specifiche olio Oil specifications
Vedi: C.7
Olio raccomandato See: C.7 Recommended oil

Quantità olio differenziale Differential oil quantity

In comune con la
Quantità olio riduttore epicicloidale (per lato) trasmissione Epicyclic red. gear oil quantity (each side)
Common with gear box

CA406115 / CA474166 PAG. DP-6 REVISION DATE: 09/17 DOC. CA270276 231497
Mod. T120 24+24 PRODUCT DATA

DI MEN SI ONI PRI NCI P ALI ( mm) MAIN DIMENSIONS (mm)

70°
274 506 422 205

7
Ø409.57

1053.7 (REF)
1224 470.25
1869 (REF)
1614

638

231497 REVISION DATE: 09/17 DOC. CA270276 CA406115 / CA474166 PAG. DP-7
PRODUCT DATA Mod. T120 24+24

D IM ENS I ONI P RI NCI P ALI ( mm) MAIN DIMENSIONS (mm)

1614

1498
Ø203.2
Ø245

M18x1.5
N. 8

37 1540

R IF. CARR ARO CARRARO REF.

Assieme T120 474166 T120 assembly
Scatola frizioni 405503 Clutch housing
Scatola cambio 406182 Gearbox housing
Gruppo comando marce esterno 414747 Outer gear control group
Gruppo comando marce interno 406181 Inner gear control group
Gruppo comando feno manuale 406183 Hand brake control group
PTO 540/540E + GNDPTO 406184 PTO 540/540E + GNDPTO
4RM PDM (SAHR) Z=59 437319 4WD DROP BOX (SAHR) Z=59
Sollevatore a 3 punti 406185 3 point hitch
Sollevatore a 3 punti - Gruppo di comando 408295 3 point hitch - Command group
Sollevatore a 3 punti - Gruppo componenti
408853 3 point hitch - Mechanic group
meccanici
Nota: tutti i presenti codici non rappresentano Note: all reference numbers in this page are not valid for
componenti disponibili come parti di ricambio; consultare parts order purpose; see the CARRARO document
il “Catalogo Parti Ricambio” fornito da CARRARO “Spare Parts List”

CA406115 / CA474166 PAG. DP-8 REVISION DATE: 09/17 DOC. CA270276 231497
Mod. T120 24+24 INDEX

Index
SAFETY INSTRUCTIONS.............................. 11
General safety recommendations .............................12
Safety information .....................................................13
General precautions..................................................16

GENERAL INFORMATION ............................ 27

Manual use ...............................................................28
Information property..................................................29
Agreements and definitions ......................................30
General description...................................................35
Special recommendations.........................................36
Disposal ....................................................................41

GENERAL SPECIFICATIONS ....................... 43

Intended use .............................................................44
Product identification.................................................45
Main features ............................................................46
Tightening torques, sealants and grease..................57
Power flows...............................................................76
Assembly typical data ...............................................80
Filling and checks .....................................................87
Service schedule.......................................................92

SPECIAL TOOLS ........................................... 93

Special tools..............................................................94
Tools design..............................................................95

231497 REVISION DATE: 09/17 DOC. CA270276 PAG. 9

INDEX Mod. T120 24+24

Notes

PAG. 10 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 SAFETY INSTRUCTIONS

A INFORMAZIONI SULLA
SICUREZZA

A SAFETY INSTRUCTIONS

231497 REVISION DATE: 09/17 DOC. CA270276 A PAG. 11

GENERAL SAFETY RECOMMENDATIONS Mod. T120 24+24

A.1 Indicazioni generali per la A.1 General safety

sicurezza recommendations

Þ A VV E RTEN ZA prima di iniziare qualsiasi Þ W A R N I N G before proceeding with any

tipo di operazione leggere attentamente questo operations please read this chapter very carefully.
capitolo.

Fig. 1

Fig. 2

Assicurati di aver letto e compreso tutto il manuale di Make sure to read and comprehend all the
manutenzione (ordinaria e straordinaria) prima di maintenance manual (ordinary and extraordinary)
intervenire sul prodotto. before start the repair operations.
Seguire scrupolosamente TUTTE le istruzioni nel Follow with care ALL the instructions in this document,
seguente documento, è vietato utilizzare scorciatoie it is forbidden to use simplified procedure to curtail the
per abbreviare i tempi di lavoro. working time.

Precauzioni per la sicurezza: Safety precautions:

Il corretto uso e la corretta riparazione dei prodotti Correct use and repair of CARRARO products and of
CARRARO e dei loro componenti sono molto importanti their components is very important for safety and
per la sicurezza e l'affidabilità. reliability.
Le procedure raccomandate e descritte in questo Recommendations and all described procedures given
manuale sono testate, quindi sono effettivi metodi in this manual have been experimented and hence are
operativi. Seguire strettamente ogni procedura facendo effective operational methods. Please follow every
uso sia del testo che delle illustrazioni. procedure. Use the text as well as the illustrations.
Alcune di queste procedure mostrano l'uso di appositi Certain procedures show use of special tools, designed
strumenti progettati perché le operazioni vengano so that the operations can be carried out in a clear and
condotte in modo chiaro e corretto. correct manner.
Alcuni strumenti specifici devono essere usati dove Special tools must be used when a particular operation
necessario per eseguire determinate operazioni. is being carried out.
E' impossibile trattare ogni metodo di lavoro o tutte le It is impossible to advise every working method or know
possibili metodologie per svolgerlo e le rischiose all possible methodologies for carrying it out or to
conseguenze di ognuna, perciò chi usa procedure o predict risky consequences of each operation. Hence,
strumenti non consigliati deve sapere che la sicurezza performing procedures or using instruments which
dell'operatore e del veicolo saranno messi a have not been advised could be dangerous for the
repentaglio. operator/mechanic as well as the vehicle.

Seguire TUTTE le istruzioni di sicurezza! Follow ALL safety instructions!

Seguite i suggerimenti e le raccomandazioni per Follow the DO’s and DON’T’s to operate in total safety.
operare in sicurezza. Unauthorized changes could endanger the functioning,
Modifiche non autorizzate possono compromettere il work safety and machine lifespan.
funzionamento, la sicurezza d'impiego e la durata della If you do not understand any instruction in this manual,
macchina. contact the nearest Carraro agent.
Se non comprendete qualche istruzione in questo
manuale, contattate il rappresentante Carraro a voi più
vicino.

A.1 PAG. 12 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 SAFETY INFORMATION

A.2 Informazioni per la sicurezza A.2 Safety information

Normativa di riferimento Reference safety standards

Le informazioni per la sicurezza presenti in questo The safety information in this manual follows the
manuale seguono le direttive contenute nelle norme recommendations of the main guidelines for the
ISO (Organizzazione Internazionale per la security ISO (International Standards Organization)
Standardizzazione) e ANSI (Istituto Nazionale and ANSI (American National Standards Institute),
Americano per gli Standards), in particolare: especially:
- ISO 3864-2 [2004] - ISO 3864-2 [2004]
- ANSI Z535.6 [2006] - ANSI Z535.6 [2006]
- ANSI Z535.3 (quando si utilizzano rappresentazioni - ANSI Z535.3 (for graphic representation intended to
grafiche senza parole come avvisi di sicurezza) convey a safety message without the use of words)
- ANSI Z535.4 (dove si richiamano simboli e/o etichette - ANSI Z535.4 (to explain the symbols and/or labels
presenti sulle macchine) applied to equipment)

Identificazione delle informazioni sulla sicurezza Recognize safety information

Le informazioni sulla sicurezza sono costituite da tre The safety information is composed of three main
elementi principali: elements:
1) simbolo di allarme 1) safety alert symbol
2) termine di segnalazione 2) signal word
3) messaggio di sicurezza 3) safety messages

il simbolo di allarme per la sicurezza è semplicemente The safety alert symbol is simply an exclamation mark
un punto esclamativo (!) all’interno di un triangolo. (!) inside of a triangle.
Nelle seguenti figure è rappresentato secondo la This symbol is represented in the following figures as
normativa ISO 3864 (Fig. 3) e secondo ANSI Z535.6 comply the ISO 3864 standard (Fig. 3) and the ANSI
(Fig. 4); in questo manuale le due rappresentazioni Z535.6 standard (Fig. 4); in this manual the two graphic
sono equivalenti. representation have the same significance.
Quando trovate questo segnale sulla macchina o sul Whenever you find it in the manual or see it on the
manuale, siete avvisati del pericolo potenziale di machine, you are being warned about potential danger
incidenti o danni alla persona. of accidents or harm to personnel.

Fig. 3

Fig. 4

Il termine di segnalazione è una parola chiave The safety signal word is a key word (DANGER,
(PERICOLO, AVVERTENZA, ATTENZIONE, AVVISO) WARNING, CAUTION, NOTICE) and it’s used with the
utilizzata insieme al simbolo di allarme in presenza di symbol for the security alert whenever there is a risk to
rischio per le persone e richiama l’attenzione sul people. This word calls attention to a safety message
messaggio (o messaggi) di sicurezza seguente o su (or messages) or a property damage message (or
possibili danni materiali ed assegna un livello o classe messages) and designates a degree or level of hazard
di pericolo al rischio che si corre. seriousness.
Nota: può essere utilizzato senza simbolo di allarme Note: can be used without safety alarm symbol where
per identificare la possibilità di soli danni materiali. alerts you if only damage materials is possible.

Vedi: tab. 1 e tab. 2 alla pagina seguente per una chiara See: tab.1 and tab. 2 in the next page to fully
comprensione dei termini segnaletici. understanding signal words.

231497 REVISION DATE: 09/17 DOC. CA270276 A.2 PAG. 13

SAFETY INFORMATION Mod. T120 24+24

Il messaggio di sicurezza segue il termine segnaletico Safety message is a word message that provides
e contiene le seguenti informazioni primarie: information primarily about:
- il tipo e l’origine del pericolo - the nature of hazardous situation
- le conseguenze possibili - the consequences if the hazard is not avoided
- i comportamenti necessari ad eliminare o ridurre il - methods for avoiding a hazardous situation (for
rischio (per esempio: indossare un’adatto Dispositivo di example: wear suitable Personal Protective Equipment,
Protezione Individuale, DPI). PPE)
Il messaggio di sicurezza può anche indirizzare il lettore The safety message can direct readers to such
al luogo dove tali informazioni sono esposte. information.
Il testo del messaggio di sicurezza può essere Safety symbols and other graphics may be used to
completato o sostituito del tutto o in parte da supplement or substitute for part or all of a word
rappresentazioni grafiche esplicative. message.

A.2.1 Significato dei termini segnaletici A.2.2 Understanding signal words

Ogni termine segnaletico definisce la classe di Each signal word defines the class of danger according
pericolosità secondo la normativa ANSI Z535.6-2006 to ANSI Z535.6-2006 as specified in the table below.
come specificato nella tabella seguente. Note: the signal words are arranged in descending
Nota: i termini sono disposti in ordine di pericolosità order of danger.
decrescente.

Tab. 1 Termini segnaletici/Livello di rischio Tab.1 Signal words/Hazard level

Gravi danni a persone

P ER ICOL O Serious personal injury
max DANGER max
Livello di rischio

AVVERTEN ZA
Hazard level

Possibili gravi danni a persone Possible serious personal injury

WARN IN G
Possibili danni moderati a persone
ATTE NZI ONE Possible moderate personal injury
C AUTI ON
Possibili danni materiali min AV V IS O min Possible product damages
NOTI CE

Tab. 2 Significato dei termini segnaletici Tab. 2 Meaning of signal words

Segnala una situazione di pericolo che, se Indicates a hazardous situation which, if not
non evitata, comporta morte o gravi lesioni P ER ICOL O avoided, will result in death or serious injury.
fisiche. L’utilizzo di questo termine è limitato DANGER This signal word is to be limited to the most
alle situazioni di estremo pericolo. extreme situations.
Segnala una situazione di pericolo che, se
non evitata, può comportare morte o gravi
AVVERTEN ZA Indicates a hazardous situation which, if not
lesioni fisiche. WARN IN G avoided, could result in death or serious injury.

Segnala una situazione di pericolo che, se Indicates a hazardous situation which, if not
non evitata, può comportare da leggere
ATTE NZI ONE avoided, could result in minor or moderate
lesioni fisiche a lesioni medio-gravi. (*) C AUTI ON injury. (*)
Segnala una situazione di pericolo che non Is the preferred signal word to address
comporta danni alle persone ma solo danni AV V IS O practices not related to personal injury.
materiali per il prodotto o per l’ambiente. Può NOTI CE The safety alert symbol shall not be used with
essere utilizzato senza il simbolo di allarme. this signal word.
(*) Secondo ANSI Z535.6-2006 è possibile utilizzare (*) Comply the ANSI Z535.6-2006 the signal word
ATTENZIONE senza il segnale di allarme al posto di CAUTION may also be used without the safety alert
AVVISO; per maggiore chiarezza questa convenzione symbol as an alternative to NOTICE; this is not applied in
non viene utilizzata in questo manuale. this manual to avoid confusion.

A.2 PAG. 14 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 SAFETY INFORMATION

A.2.3 Esempi applicativi A.2.4 Application examples

Nel seguito sono illustrate delle tipiche applicazioni Some typical applications of safety information that you
delle informazioni di sicurezza che è possibile trovare can find in this manual are explained in the following
in questo manuale. figure.
Nota: nel caso in cui vengano dati in gruppo una serie Note: where grouped safety messages are listed, one
di messaggi di sicurezza, un solo simbolo di sicurezza symbol is used before the group/section of these
viene utilizzato prima di tale gruppo o della relativa messages according to ANSI Z535.6.
sezione, in accordo con quanto specificato dalla
normativa ANSI Z535.6.

231497 REVISION DATE: 09/17 DOC. CA270276 A.2 PAG. 15

GENERAL PRECAUTIONS Mod. T120 24+24

A.3 Precauzioni generali A.3 General precautions

In ogni movimento dovranno essere osservate le norme Observe safety instructions, accident prevention rules
sulla prevenzione infortuni, tutte le regole generali di and all general safety regulations in each and every
sicurezza e di medicina del lavoro. step at work.
Prima di procedere nelle operazioni di manutenzione o Before going ahead with maintenance or repair work
sistemazione di eventuali problemi, assicurarsi del ensure that all the tools, the supporting bench, stands,
buon stato e del buon funzionamento delle attrezzature levers, extractors and spanners are in good condition
quali banchi di sostegno, cavalletti, martelli, leve, so that the work can be carried out easily.
estrattori e chiavi apposite facilitando le operazioni da Risks to various parts and components will also be
svolgere in modo ottimale riducendo i rischi sia per gli reduced in this way and working condition for the
organi ed i componenti del prodotto che della incolumità operator will also be safer.
dell'operatore. CARRARO SpA declines any responsibility in case of
Tutte le modifiche arbitrarie apportate al prodotto an accident or damage resulting due to changes made
sollevano la CARRARO SpA da ogni responsabilità per arbitrarily on product.
qualsiasi danno o incidente. The product is used for any other purpose different from
Il prodotto, se utilizzato in un impiego diverso da quello the one foreseen, than CARRARO SpA declines any
previsto, è da considerarsi soggetto a "uso non responsibility.
previsto". CARRARO SpA declina ogni responsabilità In this case all consequences will be at the customer’s
per danni o incidenti risultanti da un uso diverso da expense.
quello previsto; tali conseguenze saranno a carico
esclusivo del cliente.

Þ ATTENZION E Þ CAUTI ON
Durante la manutenzione e riparazione: During the maintenance and repair operations make
sure that
• la trasmissione deve sempre essere controllata e
sorvegliata da personale autorizzato • the transmission must always checked and
overseen by authorized staff
• in caso di manomissione delle parti costituenti la
trasmissione, verificarne il corretto funzionamento e • in case of transmission parts tampering, verify the
provvedere al ripristino, quando necessario correct working of the transmission and replace
them, if necessary
• ogni modifica ai segnali di sicurezza e/o
decalcomanie deve sempre essere concordato • every modification of the safety signs and/or
preventivamente con il costruttore transfers and their relative tamper must be always
previously agreed with the manufacturer

AV VI S O NOTI CE
• durante le lubrificazioni e ingrassaggi non • during the lubricating and greasing operations, do
confondere i tempi di manutenzione ordinaria; not confuse the ordinary maintenance times; during
durante la fase di serraggio non confondere le the tightening operations do not confuse the
rispettive coppie di serraggio tightening torques
• durante l’utilizzo della trasmissione tappi, sfiati, • during the transmission use plugs, breathers,
viteria e relativo serraggio devono essere concordi screws and tightening torques must be in agreement
a quanto prescritto with the regulation

A.3 PAG. 16 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL PRECAUTIONS

Þ P ERI COLO Þ DAN GE R

• non utilizzare prodotti infiammabili come etere • do not use inflammable products like ether, oil or
petrolio o benzina rettificata per la pulizia delle parti gasoline for the parts cleaning when the parts are at
quando le stesse sono a temperature elevate o sotto elevated temperature or under the sun rays
l’esposizione di raggi solari: potrebbero essere exposure: it may causes fire
causa d’incendio
• deep impacts may damage the transmission
• urti violenti potrebbero danneggiare i componenti mechanical-magnetic-electrical parts
meccanici-magnetici-elettrici della trasmissione • do not smoke-drink-eat during the assembly-
• non fumare-bere-mangiare durante le operazioni di disassembly-maintenance operations to avoid a
disassemblaggio-assemblaggio-manutenzione: possible contamination of the mechanical parts
sono possibili eventuali contaminazioni agli organi
meccanici.

Norme per la manutenzione in sicurezza Safety maintenance rules

1 Operare sempre in ambiente pulito e asciutto. 1 Operate always in a clean and dry environment.
2 Pulire con cura l’ambiente di lavoro e la macchina 2 Clean carefully the working environment and the
su cui si opera sia prima che durante la machine before carry out the maintenance
manutenzione (Fig. 5). operations (Fig. 5).
3 Utilizzare solo prodotti di pulizia conformi alle 3 Use only cleaning product in agreement with the
specifiche di legge vigenti e sempre nelle modalità regulations and always use them in the prescribed
indicate dalle istruzioni d’uso del produttore. way.
4 Non inalare sostanze chimiche in concentrazioni 4 Do not inhale chemical substances in dangerous
pericolose per la salute (Fig. 6); ventilare gli concentration for the health care (Fig. 6); ventilate
ambienti in cui si utilizzano solventi con componenti the environments in which sprays and solvents,
chimici volatili o spray. with volatile chemical substances, are used.

Fig. 5

Fig. 6

5 Usare indumenti e protezioni adatte allo scopo 5 Wear suitable clothing and protection such as
come: tuta, guanti protettivi e cuffie (Fig. 7). overalls, gloves and ear safety devices (Fig. 7).
Þ AV VE RTE NZA Þ WA RNI NG
Gli occhiali di sicurezza devono essere indossati Safety goggles must always be worn while
sempre durante l’esecuzione di tutte le operazioni carrying out every assembling or disassembling
di montaggio o smontaggio (Fig. 8). operations (Fig. 8).

231497 REVISION DATE: 09/17 DOC. CA270276 A.3 PAG. 17

GENERAL PRECAUTIONS Mod. T120 24+24

Fig. 7

Fig. 8

6 Usare protezioni auricolari appropriate a 6 Use suitable ear protection, like ear plugs, to keep
salvaguardare l'udito, come tappi o cuffie per le out noise and prevent injury to the ears.
orecchie contro rumori molesti o fastidiosi. Una A prolonged exposure to noise can damage your
prolungata esposizione al rumore può danneggiare hearing.
l'udito 7 The operator must be very careful with the
7 Le attrezzature richiedono la piena attenzione equipment. Do not use headphones to listen music
dell'operatore. Non usare cuffie per ascoltare while you are working on the product or on the
musica mentre si interviene sul prodotto o gruppo. group.

8 Non indossare sciarpe, cravatte o altri indumenti 8 Do not wear slings, ties or other pending clothes.
pendenti. Assicurare i capelli lunghi dietro la testa e/ Tie long hair behind the head and/or wear a
o indossare una cuffia protettiva. protective cap.
9 Non indossare anelli, bracciali, collane o altri 9 Do not wear rings, armlets, necklaces or other
oggetti metallici che sono molto pericolosi in metal objects that are dangerous when current is
presenza di corrente elettrica. present.
10 Predisporre sempre le dotazioni di pronto 10 Predispose always the first aid equipment in
intervento previste dalla normativa di sicurezza per agreement with the working environments
gli ambienti di lavoro, come la cassetta di pronto regulations, like the first aid kit (Fig. 9).
soccorso (Fig. 9). 11 Keep the phone numbers of a doctor, an
11 Tenere in evidenza il n° telefonico di medico, ambulance, a hospital and the fire department
ambulanza, ospedale e vigili del fuoco presso il within reach near the telephone set (Fig. 10).
proprio telefono (Fig. 10). In case of accident it is indispensable to quickly ask
In caso d’infortunio è indispensabile richiedere for a medical intervention.
rapidamente l’intervento del medico.

Fig. 9

Fig. 10

A.3 PAG. 18 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL PRECAUTIONS

12 Tenere lontani mani, piedi, indumenti dalle parti in 12 Keep your hands, feet and clothing away from
movimento delle attrezzature. moving parts of the tool machines.
Rimanere a distanza di sicurezza dalla macchina se Keep the safety distance from the machine, if it is
in movimento, come durante le operazioni di moving, like during the testing operations (Fig. 11).
collaudo (Fig. 11). 13 Light properly the working area by using devices in
13 Illuminare adeguatamente l’area di lavoro con agreement with the safety regulations (Fig. 12).
strumenti che rispettino la normativa di sicurezza
(Fig. 12).

Fig. 11

Fig. 12

14 Durante le operazioni di manutenzione è 14 During the maintenance operations it is strictly

assolutamente vietato accendere fiamme libere forbidden to light free flames (Fig. 13) and smoking
(Fig. 13) e fumare (Fig. 14). (Fig. 14).

Fig. 13

Fig. 14

15 Essere sempre pronti per bloccare eventuali 15 Always be prepared for fires. Keep the extinguisher
principi di incendio. Prima di iniziare qualsiasi within reach. Before start any maintenance
operazione individuare con certezza la posizione operation identify the extinguisher nearest to the
dell’estintore più vicino all’area di lavoro e delle working area and the prescribed fire regulations
dotazioni antincendio prescritte (Fig. 15). (Fig. 15).

Fig. 15

Fig. 16

231497 REVISION DATE: 09/17 DOC. CA270276 A.3 PAG. 19

GENERAL PRECAUTIONS Mod. T120 24+24

16 L’ambiente di lavoro deve sempre essere ben 16 The working environment must be always well
aerato con i sistemi previsti dalla normativa relativa aired by using devices in agreement with the safety
agli ambienti di lavoro. regulations.
Se non sono presenti condotti di aerazione, aprire le If local vents are not present, open doors the
porte e finestre dell’area di lavoro. windows in the working area.
Evitare di respirare polvere e fumi, dato che Do not inhale dust and fumes, they can cause
possono causare malattie e portare alla morte. Non sickness or death. Do not inhale toxic substances
i n a l a r e s o s t a nz e po t e n z i a l me n t e to s s i c h e used during the product maintenance. If necessary
necessarie alla manutenzione del prodotto. Se use a certified respirator.
necessario utilizzare un respiratore certificato. All the CARRARO SpA products are in agreement
Tutti i prodotti CARRARO SpA soddisfano i requisiti with the Italian legislation and with the European
imposti dalla legislazione Italiani e dalla Comunità Community technical requirements.
Europea.

A.3 PAG. 20 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL PRECAUTIONS

A.3.1 Eliminazione dei rischi residui A.3.2 Residual risks elimination

Si raccomanda di seguire scrupolosamente le seguenti It is recommended to follow with care the following
indicazioni generali, che sono molto importanti per general indications, that are important to prevent
evitare danni a persone e cose. damages to persons and things.

Þ P ERI COLO Þ DAN GE R

Rischio di schiacciamento e cesoiamento dovuto alla Risk of squashing and shearing due to the presence
presenza di elementi in movimento. of moving parts.

Fig. 17

Fig. 18

Þ AV VE RTE NZA Þ WA RNI NG

Eseguire tutte le operazioni di manutenzione a Carry out all maintenance operations when the
macchina ferma. Non lubrificare, manipolare o machine is stationary. Do not lubricate, handle or
registrare il gruppo con parti meccaniche in adjust the group with mechanical parts in
movimento. movement.

Fig. 19

Fig. 20

Þ P ERI COLO Þ DAN GE R

Rischio di schiacciamento dovuto al movimento di Squashing risk due to the machines or devices
macchinari o attrezzature nell’area di lavoro. movement in the working area.
• Questi rischi residui e le procedure per eliminarli • These residual risks and the procedure to eliminate
completamente, sono evidenziati dettagliatamente them completely, are described in detail in the
nelle procedure di montaggio e smontaggio. Seguire assembly/disassembly procedures. During the
attentamente, durante la manutenzione, tutte le maintenance operations, follow carefully all the
procedure di sicurezza indicate nel manuale. security procedure indicated on the repair manual.

231497 REVISION DATE: 09/17 DOC. CA270276 A.3 PAG. 21

GENERAL PRECAUTIONS Mod. T120 24+24

Þ AV VE RTE NZA Þ WAR NING

Non operare con attrezzature difettose o non Do not carry out any operation by using faulty or
adatte all’intervento da eseguire. not suitable tools.
• Predisporre sempre attrezzi ed utensili • Always predispose the tools and the devices on a
ordinatamente su un adatto banco di lavoro. suitable workbench, in an orderly way.

• Non utilizzare come piani d’appoggio superfici che • Do not use unstable shelves or not flat surfaces as
non siano piane o ben stabili. workbench.
• Il gruppo su cui si opera e gli attrezzi che si utilizzano • The serviced group and used tools must be always
devono sempre essere disposti in posizione stabile, arranged in a stable position, in order to avoid all the
evitare tutte le situazioni di equilibrio incerto. unstable equilibrium situations.

Þ PE RI COLO Þ DANGE R
Rischio dovuto alla violenta espulsione di oggetti dalla Risk due to violent ejection of objects from the
macchina. machine
• Questi rischi residui e le procedure per eliminarli
completamente, sono evidenziati dettagliatamente • These residual risks and the suitable relative
nelle procedure di montaggio e smontaggio. Seguire procedures to eliminate them completely are
attentamente, durante la manutenzione, tutte le pointed out, in detail, in the assembly and
procedure di sicurezza indicate nel manuale. disassembly procedures. During maintenance,
follow carefully all the safety procedures indicated in
the manual.

Fig. 21

Fig. 22

Þ PE RI COLO Þ DANGE R
Rischio dovuto alla caduta o allo sganciamento di Risk due to falling loads or unhooked objects.
oggetti.

Fig. 23

Fig. 24

A.3 PAG. 22 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL PRECAUTIONS

• Questi rischi residui e le procedure per eliminarli • These residual risks and the procedure to eliminate
completamente, sono evidenziati dettagliatamente them completely, are described in detail in the
nelle procedure di montaggio e smontaggio. Seguire assembly/disassembly procedures. During the
attentamente, durante la manutenzione, tutte le maintenance operations, follow carefully all the
procedure di sicurezza indicate nel manuale. security procedure indicated on the repair manual.
• Prima di ogni operazione assicurare le parti pesanti • Before every operation secure all the heavy parts by
con adeguati sistemi di supporto, in modo da evitare using suitable supporting devices, in order to avoid
cadute accidentali e movimenti improvvisi. casual falls and unexpected moves.

• Se il gruppo è sostenuto solamente da funi sospese, • If the group is only supported by hanging ropes, do
non lavorare sotto il carico sospeso. not work under the pending load.
• Utilizzare sistemi di sollevamento a norma di legge, • The used lifting devices must be in agreement with
in perfette condizioni, verificati e correttamente the current regulations, in perfect conditions, verified
manutenzionati. and correctly serviced.

Þ P ERI COLO Þ DAN GE R

Rischio dovuto all’inalazione di gas nocivi che si Risk due to inhalation of poison gases that can be
possono sviluppare scaldando le vernici durante produced by heating the varnishes during any
eventuali saldature. welding.
• Utilizzare postazioni di lavoro dotate di sistemi di • Use work stations equipped with dust and fume
evacuazione di polveri e fumi. discharging systems.
• Prima di saldare o riscaldare, rimuovere la vernice • Before welding or heating a part, remove the paint,
se presente. if present.
• Non usare spray o altri prodotti infiammabili vicino • Do not use sprays or other inflammable substances
alla zona dove si sta saldando o in prossimità di fonti near the welding area or near heat sources.
di calore.

Fig. 25

Fig. 26

Þ ATTE NZI ONE Þ CAU TION

Rischio dov uto all’i nquinamento da sostanze Risk due to the pollution by dangerous substances.
pericolose. Lubrificanti esausti e prodotti residui delle Exhausted lubricant and the residual products of the
operazioni di pulizia e verniciatura sono considerati cleaning/painting operations are considerate special
rifiuti speciali waste.
• Utilizzare gli appositi contenitori per la raccolta dei • During the CARRARO SpA products maintenance
rifiuti liquidi e solidi durante la manutenzione dei operations, use the proper container for the liquid
prodotti CARRARO SpA. and for the solid waste raising.
Smaltire tutti i rifiuti liquidi e solidi secondo le Dispose all liquid and solid waste in agreement with
normative vigenti nell’ambiente di lavoro in cui si the current working environment regulations.
opera.

231497 REVISION DATE: 09/17 DOC. CA270276 A.3 PAG. 23

GENERAL PRECAUTIONS Mod. T120 24+24

Þ PE RI COLO Þ DANGE R
Rischio di incendio e scoppio dovuto ai solventi Risk of fire and explosion due to the solvents used
utilizzati e all’olio presente. and to the oil in the machine.

Fig. 27

Fig. 28

• Tenere lontano dalla zona di lavoro ogni fonte di • Keep away any heat sources from the working area.
calore.
• When solvents or paint removers are used, they
• Quando si usano solventi o svernicianti, rimuoverli should be removed with soap and water, before
con acqua e sapone prima di saldare. welding.
• Rimuovere i contenitori di solvente, sverniciante o • Remove any containers of solvent, paint remover or
altri prodotti infiammabili dall'area di lavoro. any other inflammable products from the working
area.

Þ AV VE RTE NZA Þ WAR NING

Rischio di ustione dovuto alla presenza di Burn risk due to elevated temperature of liquid or
elementi solidi o fluidi ad elevata temperatura. solid elements.

Fig. 29

Fig. 30

• Indossare le protezioni individuali di sicurezza, a • Wear the personal protective clothes, in agreement
norma di legge, adeguate al tipo di operazione da with the current regulations, adequate to the type of
mettere in pratica. operation carried out.
• Verificare il corretto serraggio di tappi e connessioni • Verify the plugs and connectors correct tightening
prima di avviare la macchina o mettere i circuiti in before start up the machine or before give pressure
pressione to the circuits.

A.3 PAG. 24 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL PRECAUTIONS

Þ AV VE RTE NZA Þ WA RNI NG

Rischio dovuto all’espulsione di fluidi caldi o in Risk due to boiling fluids ejection or pressured
pressione. fluids ejection
• Indossare le protezioni individuali di sicurezza a • Wear the personal protective clothes, in agreement
norma di legge. with the current regulations

Fig. 31

Fig. 32

• Evitare la ricerca di eventuali perdite di fluido da • Do not search possible liquid loss on pressured
condotti in pressione con le mani o altre parti del pipes by using hands or others body parts (Fig. 33),
corpo (Fig. 32), utilizzare le attrezzature preposte o use the prescribed devices or not inflammable
comunque elementi non infiammabili (Fig. 33). elements (Fig. 33).

Fig. 33

231497 REVISION DATE: 09/17 DOC. CA270276 A.3 PAG. 25

 Notes

A.3 PAG. 26 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL INFORMATION

B INFORMAZIONI GENERALI

B GENERAL INFORMATION

231497 REVISION DATE: 09/17 DOC. CA270276 B PAG. 27

MANUAL USE Mod. T120 24+24

B.1 Utilizzo del manuale B.1 Manual use

Destinatari End users
• Installatore • Installer
• Riparatore specializzato • Qualified technician
• Manutentore • Maintenance operator

Manutenzione e riparazione Maintenance and repair

PRENDERE VISIONE DI TUTTO IL MANUALE poiché CONSULT THIS MANUAL THOROUGHLY, as proper
il buon funzionamento ed il rendimento degli organi functioning and good efficiency of mechanical organs
meccanici dipendono principalmente da una costante e depends mostly on constant and correct routine
corretta manutenzione e assicurano la durata e maintenance ensuring product integrity and expected
l'integrità del prodotto. life duration.

Nell'eventualità di guasti od anomalie il tempestivo In case of any damages or anomalies, quick

intervento da parte di personale autorizzato da Carraro intervention of trained and highly qualified operators
SpA (in possesso dell’attestato di idoneità) garantisce authorized (with certificate) by Carraro SpA ensure the
una durata più lunga del prodotto, evitando danni longest life of product and avoid future impairment
maggiori nel tempo provocati da una riparazione non caused by not authorized repairing.
autorizzata. Warning: Carraro warranty does not cover every injury
Attenzione: la garanzia non risponde di eventuali to personnel and damage to product caused by
danni provocati a persone o cose causati da riparazioni maintenance operations of not authorized personnel
effettuate da personale non autorizzato e/o non and/or by operations not in compliance with Carraro
conformi alle specifiche e avvertenze Carraro, safety regulations and prescribed procedures.
riguardanti la sicurezza e le procedure di manutenzione
contenute in tutte le sezioni del manuale

Le procedure per lo smontaggio/montaggio consentono The disassembly/assembly procedures have been

di eseguire la revisione totale del prodotto e sono outlined for a total product overhauling. They have also
descritte in sequenza con l’ausilio di illustrazioni, per been described in sequence through photographs with
una guida completa e sicura all’esecuzione di ogni relevant explanation for specific interventions, thus
operazione. obtaining a complete and safe guide for each and every
phase of an operation.

Nella descrizione delle operazioni si presuppone che la Operation description presumes that the transmission
trasmissione sia stata rimossa dal veicolo. Per la has already been removed from the vehicle. To remove
rimozione della trasmissione dal veicolo consultare il the transmission from the vehicle refer to manual
manuale del costruttore del veicolo. provided from vehicle manufacturer.

B.1 PAG. 28 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 INFORMATION PROPERTY

B.2 Proprietà delle informazioni B.2 Information property

Questo manuale contiene informazioni di proprietà This manual should be considered confidential
riservata. Tutti i diritti sono riservati. informations. All rights reserved.

Questo manuale non può essere riprodotto o No part of this manual may be reproduced, in any form
fotocopiato, tutto o in parte, senza il preventivo or by any means, without prior written permission of
consenso scritto di CARRARO SpA. L’uso di questo CARRARO SpA. Only the customer, whom the manual,
materiale documentale è consentito solo al cliente a cui together with the product, has been issued to, is
il manuale è stato fornito come corredo del prodotto, e allowed to use this document, and only in order to use,
solo per scopi di uso, manutenzione e riparazione. maintain and repair the unit.

CARRARO SpA dichiara che le informazioni contenute

in questo manuale sono congruenti con le specifiche CARRARO SpA declares that the subject of this
tecniche e di sicurezza della macchina a cui il manuale manual consists with the technical and safety
si riferisce. Il fabbricante non si assume alcuna specifications of the machine that the manual is
responsabilità per danni diretti o indiretti a persone, referred to. The manufacturer shall not be held liable for
cose o animali, conseguenti all’uso di questo materiale direct or indirect damages to persons, things or animals
documentale o della macchina in condizioni diverse da due to an improper use of this document or of the
quelle previste. machine or to a different use of them, which does not
comply with what is provided for in this manual.

Carraro Spa
Headquarters
Via Olmo, 37
35011 Campodarsego
Padova Italy

231497 REVISION DATE: 09/17 DOC. CA270276 B.2 PAG. 29

AGREEMENTS AND DEFINITIONS Mod. T120 24+24

B.3 Convenzioni e definizioni B.3 Agreements and definitions

Convenzioni Agreements
Le illustrazioni nel manuale NON sono in scala quindi Illustrations like pictures, drawings and components of
NON sono attendibili valutazioni delle dimensioni dei this manual are NOT in scale, because of limited space
componenti basate sulle stesse. and editing limits, therefore they are NOT reliable to
Le illustrazioni hanno il compito di evidenziare le obtain values about size or weight.
corrette procedure da condurre sulla macchina e sui Illustrations are supposed to point out the correct
suoi componenti , per questo potrebbero non m e t h o ds t o w o r k i n g o n th e m a c hi n e a nd i ts
rappresentare esattamente gli elementi di questa components, therefore they could not display exactly
macchina ma componenti meccanici simili. the same elements.

Definizioni Definitions
Lato sinistro (Sx): parte sinistra del gruppo vista nel Left side (Lh): it is the left side (left hand) of the unit
senso di marcia del veicolo (Fig. 1). considering the vehicle running conditions (Fig. 1).
Lato destro (Dx): parte destra del gruppo vista nel Right side (Rh): it is the right side (right hand) of the
senso di marcia del veicolo (Fig. 1). unit considering the vehicle running conditions (Fig. 1).

Fig. 1
Direzione Driving
di marcia direction

Lato posteriore
Lato anteriore
Front side

Back side
Sx Dx
Lh Rh

Fig. 2

Lato anteriore trasmissione: parte anteriore della Transmission front side: it is the front side of the
trasmissione, in accoppiamento con il motore (Fig. 2). transmission, connected with the motor (Fig. 2).
Lato posteriore trasmissione: parte posteriore della Transmission back side: it is the back side of the
trasmissione, opposta alla parte anteriore (Fig. 2). transmission, opposite to the front side (Fig. 2).

Convenzioni tipografiche Typographic agreements

Nota: informazioni importanti, evidenziate al di fuori del Note: the notes, pointed out externally to the text they
testo a cui si riferiscono. refer, include important information.
Attenzione: procedure la cui totale o parziale Warning: warning indications point out the procedures,
inosservanza può produrre danni alla macchina o alle whose partial or complete non-observance can
apparecchiature ad essa collegate. damage the machine or the connected equipment.
P er ic o l o : pr o c ed u r e l a c u i to ta le o p a r z ia l e Danger: danger indications point out the procedures,
inosservanza può produrre lesioni o danni alla salute whose partial or complete non-observance can injure
dell’operatore. the operator.

Unità di misura Measurements

Nel manuale si utilizzano le unità di misura del sistema This manual indicates all measurements in
internazionale (SI). Per la conversione al sistema International System (SI). Use the following conversion
anglosassone riferirsi alla seguente tabella. table to convert Imperial Measure.

B.3 PAG. 30 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 AGREEMENTS AND DEFINITIONS

Tabella di conversione unità di misura Conversion table of units of measurement

S.I. GB/USA SYSTEM

1 mm 0.03937 in
10 mm 0.3937 in
25.4 mm 1 in
6.4516 cm² 1 sq. in
1 m² 1550 sq. in
16.378 m² 1 cu. in
0.473 dm² 1 U.S. pint
1 l 61.02 cu. in
1 l 0.2642 U.S. gal
1.772 g 1 oz
0.4536 kg 1 lb
0.00070308 kg/mm² 1 lb/sq. in
1 bar 14.51 psi
1 kg.m 7.246 lb. ft
1(daN)= 10 (N)= 1,02 (kg.f) 2.24 lb. f

231497 REVISION DATE: 09/17 DOC. CA270276 B.3 PAG. 31

AGREEMENTS AND DEFINITIONS Mod. T120 24+24

Simbologia utilizzata nella descrizione delle Symbology used to describe maintenance (service
procedure di manutenzione (servizio e riparazione) and repair) procedures

DESCRIZIONE SIMBOLI/SYMBOLS DESCRIPTION

WARNING/DANGER
ATTENZIONE/PERICOLO
Follow carefully all the manual
Seguire attentamente le istruzioni nel
instruction, in order to avoid the arise of
manuale per evitare di provocare danni
damages to things or persons; also
a persone o cose; seguire anche tutte le
follow all the current security
normative di sicurezza vigenti in
regulations, in relationship/agreement
relazione all’ambiente di lavoro in cui si
with the operative working ambient.
opera.
Note: do not follow carefully the Carraro
Nota: la mancata osservanza delle
indications and/or current security
indicazioni Carraro e/o delle normative
regulations can causes serious
di sicurezza può causare gravi danni
damages to the persons or to the
alle persone ed alla macchina, tali danni
machines; these damages are not
non sono coperti da garanzia.
warranty covered.

RIMOZIONE/INSTALLAZIONE REMOVE/INSTALL
Si applica a: anelli-guarnizioni-filtri. Applicable to: seals-gaskets-filters.
L’utilizzo di ricambi NON originali The NOT original Carraro spare parts
Carraro comporta la decadenza della use causes the loss of the machine
garanzia sulla macchina. warranty.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered,
raccomanda di seguire oltre alle i t i s rec o mm en de d t o f ol lo w t he
procedure descritte anche le described procedure as well as the
avvertenze in sezione B.5 section B.5 warnings.

RIEMPIMENTO o RABBOCCO OLIO/ OIL FILLING OR OIL LEVEL/

SCARICO OLIO OIL DRAIN
Utilizzare solo i lubrificanti indicati in Use only the prescribed lubricant,
sezione C; l’utilizzo di prodotti non indicated on section C; the use of
corrispondenti alle specifiche indicate products that are not in accordance with
comporta la decadenza della garanzia the indicated specifications involves the
Carraro. Carraro warranty decline.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered,
raccomanda di seguire oltre alle i t i s rec o mm en de d t o f ol lo w t he
procedure descritte anche le described procedure as well as the
avvertenze in sezione B.5. section B.5 warnings.

LUBRIFICAZIONE/INGRASSAGGIO LUBRICATION/GREASING
Utilizzare solo i lubrificanti indicati in Use only the prescribed lubricant,
sezione C; l’utilizzo di prodotti non indicated on section C; the use of
corrispondenti alle specifiche indicate products that are not in accordance with
comporta la decadenza della garanzia the indicated specifications involves the
Carraro. Carraro warranty decline.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered,
raccomanda di seguire oltre alle i t i s rec o mm en de d t o f ol lo w t he
procedure descritte anche le described procedure as well as the
avvertenze in sezione B.5. section B.5 warnings.

B.3 PAG. 32 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 AGREEMENTS AND DEFINITIONS

DESCRIZIONE SIMBOLI/SYMBOLS DESCRIPTION

REGOLAZIONE/MISURAZIONE ADJUSTMENTS/MEASUREMENTS
Si applica a: coppie di serraggio- Applicable to: tightening torques-
precarichi-giochi. preloads-backlash.
Seguire con estrema cura le istruzioni Follow carefully the indicated
descritte per ottenere il miglior risultato. instructions to obtain the best result.
Nota: la mancata osservanza delle Note: do not follow carefully the Carraro
indicazioni Carraro può comportare indications can causes serious
gravi danni alla macchina; tali danni non damages to the machine; these
sono coperti da garanzia. damages are not warranty covered.

SPECIAL TOOLS
ATTREZZATURE SPECIALI
It is recommended to use the special
Si raccomanda l’utilizzo delle
tools as indicated into the repair
attrezzature descritte senza ricorrere a
manual; avoid the use of not-tested
sistemi non collaudati che non
methods that can not guarantee a good
garantiscono un buon risultato.
result.

ADHESIVE AND SEALING FLUIDS

APPLICAZIONE DI ADESIVI E
APPLICATION
SIGILLANTI
Use only the prescribed product,
Utilizzare solo i prodotti indicati in
indicated on section C; the use of
sezione C; l’utilizzo di prodotti diversi da
products that are not in accordance with
quelli indicati comporta la decadenza
the indicated specifications involves the
della garanzia Carraro.
Carraro warranty decline.
Nota: in presenza di questo simbolo si
Note: when this symbol is encountered,
raccomanda di seguire oltre alle
it is r ec o mm e nd ed to f ol l ow t he
procedure descritte anche le
described procedure as well as the
avvertenze in sezione B.5.
section B.5 warnings.

TRACCIATURA MARKING
Eseguire le operazioni descritte Carry out the described operations in
nell’ordine prestabilito. the pre-established order.

SMONTAGGIO/MONTAGGIO DI DISASSEMBLY/ASSEMBLY OF
PARTICOLARI INGOMBRI O BULKY PARTS OR SUBASSEMBLIES
SOTTOGRUPPI

WARNING: RESPECT ASSEMBLY

ATTENZIONE: RISPETTARE IL
ORIENTATION
VERSO DI MONTAGGIO
The assembled elements must be
Gli elementi assemblati devono avere
oriented as described in the relative
verso di montaggio corrispondente a
procedure or as indicated in the relative
quello descritto e/o illustrato.
figure.
Nota: la mancata osservanza delle
Note: do not follow carefully the Carraro
indicazioni Carraro può comportare
indications can causes serious
gravi danni alla macchina, tali danni non
damages to the machine; these
sono coperti da garanzia.
damages are not warranty covered.

231497 REVISION DATE: 09/17 DOC. CA270276 B.3 PAG. 33

AGREEMENTS AND DEFINITIONS Mod. T120 24+24

DESCRIZIONE SIMBOLI/SYMBOLS DESCRIPTION

PULIRE ACCURATAMENTE
CLEANING CAREFULLY
Pulire con estrema cura le parti
Clean with care the parts involved in the
interessate alle operazioni di
described maintenance procedure.
manutenzione descritte.
Note: when this symbol is encountered,
Nota: in presenza di questo simbolo si
i t i s rec o mm en de d t o f ol lo w t he
raccomanda di seguire oltre alle
described procedure as well as the
procedure descritte anche le
section B.5 warnings.
avvertenze in sezione B.5.

IMMETTERE FLUIDO IN PRESSIONE

APPLY PRESSURIZED FLUID
Osservare scrupolosamente le
Follow with great care the indicated
procedure indicate e mettere in pratica
procedure and follow all the security
tutti i comportamenti di sicurezza atti a
procedures in order to avoid damages
salvaguardare l’incolumità di persone e
to persons or things.
cose.

B.3 PAG. 34 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL DESCRIPTION

B.4 Indicazioni generali B.4 General description

La macchina deve essere controllata e/o riparata solo The machine should be checked and/or repaired only
da personale tecnico specializzato che sia a by qualified technicians, acquainted with its peculiar
conoscenza delle sue particolari caratteristiche e delle features and well aware of all safety instructions.
relative norme di sicurezza (prevenzione infortuni).

Prima di svolgere qualsiasi operazione, pulire Before performing any operation it is advisable to carry
accuratamente il gruppo rimuovendo eventuali out unit cleaning accurately by removing oil/ grease
incrostazioni ed accumuli di terriccio e/o grasso. encrustations and accumulation.

Tutti gli organi meccanici smontati devono essere All disassembled mechanical parts must be cleaned
accuratamente puliti con prodotti adeguati, per evitare accurately with suitable products to avoid possible
possibili danni. Verificarne l'integrità, sostituendoli in damage. Parts should be replaced if damaged, worn
caso di danni, usura, incrinature, grippaggi o difetti che out, cracked, seized, etc. as they could affect proper
potrebbero comprometterne il buon funzionamento. working.
In particolar modo si deve verificare l'integrità dei Rotating parts (bearings, gears, shafts) and that of
componenti in movimento (cuscinetti, ingranaggi, hardware/fasteners (O-Rings, seal rings) should be
alberi) e degli organi di tenuta (anelli OR, anelli di examined carefully, as they are subject to intense
tenuta) e di fissaggio, che sono soggetti ad intense stress, wearing and ageing.
sollecitazioni, ad usura e invecchiamento. Note: in case of replacement of one part of the bevel
Nota: si ricordi che l’eventuale sostituzione di un gear set this operation requires the replacement of the
componente della coppia conica comporta la other part too.
sostituzione anche dell'altro.

Si raccomanda di sostituire ad ogni revisione o We highly advise to replace sealing parts (O-Rings,
riparazione gli organi di tenuta (anelli OR, anelli di seal rings, gaskets) during every teardown or repair.
tenuta, guarnizioni).

Utilizzare solo le parti di ricambio e la viteria indicate, Use appropriate spare parts, nuts and bolts to avoid any
inoltre usare utensili metrici per la viteria metrica e other problems. Moreover, use metric tools for metric
inglesi per la viteria inglese. nuts and bolts and Imperial tools for the others.

Come indicato, alcune operazioni sono distruttive per Some operations are destructive for removed
gli elementi rimossi. Leggere attentamente le components.
descrizioni delle varie fasi dell'intervento ed operare Carefully reading and through understanding of these
con attenzione per non compromettere la funzionalità di instructions will avoid damage to other components.
altri elementi.

231497 REVISION DATE: 09/17 DOC. CA270276 B.4 PAG. 35

SPECIAL RECOMMENDATIONS Mod. T120 24+24

B.5 Indicazioni speciali B.5 Special recommendations

Prima di iniziare le operazioni di smontaggio e Before starting any disassembly and assembly
m on tag g io le gg ere at te nt am en te l e se g ue nti operations, read carefully the following
avvertenze. recommendations.

Anelli di tenuta per alberi Shafts seals

Per il montaggio degli anelli di tenuta attenersi alle Respect the following recommendations during shaft
seguenti raccomandazioni: seal assembly:
• Pulire accuratamente l'albero ed assicurarsi che • Clean shaft very carefully and ensure that the part in
non sia danneggiato, rigato od ovalizzato nelle zone contact with the shaft seal is not damaged, cut or out
di contatto con gli anelli. of roundness.
• Non danneggiare gli anelli durante il montaggio • Do not damage the seals while assembling the
dell'albero. shaft.
• Pulire accuratamente l'albero ed assicurarsi che • Clean shaft very carefully and ensure that the part in
non sia danneggiato, rigato od ovalizzato nelle zone contact with the shaft seal is not damaged, cut or out
di contatto con gli anelli (Fig. 3). of roundness (Fig. 3).

Fig. 3

Fig. 4

• Montare gli anelli in modo che il labbro sia rivolto • Assemble the seals so that the lip is fitted towards
verso il lato olio (Fig. 4). the oil side (Fig. 4).
• Lubrificare il labbro degli anelli (usare • Lubricate seal lips (use oil) and fill 3/4 of seal cavity
preferibilmente olio) e riempire per 3/4 di grasso la with grease (Fig. 5).
camera degli anelli stessi (Fig. 5).
• Use appropriate drivers (Fig. 6).
• Montare gli anelli usando un appropriato calettatore
(Fig. 6). NOTI CE do not use a hammer directly on the seals.

A V V I S O non usare il martello direttamente sugli

anelli.

Fig. 5

Fig. 6

B.5 PAG. 36 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 SPECIAL RECOMMENDATIONS

Anelli OR O-rings
Lubrificarli adeguatamente prima di inserirli nella Lubricate adequately before inserting them at the right
propria sede evitando “arrotolamenti” durante il place and avoid o-ring rolling while inserting the shaft
montaggio dell'albero (Fig. 7). (Fig. 7).

Fig. 7

Fig. 8

Spessori di registro Adjusting shims

Per il montaggio degli spessori di registro attenersi alle Respect the following recommendations during the
seguenti raccomandazioni: adjustment shims assembly:
• Per le registrazioni utilizzare gli appropriati spessori • Use appropriate adjusting shims and measure each
di registro, misurandoli singolarmente (Fig. 8). one separately (Fig. 8).
• La misurazione del pacco completo o la • Complete group measurement or stampings on the
stampigliatura riportata sugli spessori stessi può shims are not always reliable: check.
risultare non sempre affidabile: verificare.

Cuscinetti Bearings
Per il montaggio dei cuscinetti attenersi alle seguenti Respect the following recommendations during the
raccomandazioni: bearings assembly:
• Prima di rimontarli, pulirli, ispezionarli e lubrificarli. • Before reassembling the bearings, clean, check and
lubricate them.
• Per un corretto montaggio è consigliabile riscaldarli
in forno ad una temperatura di 80-90 °C prima di • Its advisable to heat up bearings to 80-90 °C before
montarli sui rispettivi alberi o raffreddarli prima di assembling them onto their respective shafts or to
inserirli nelle relative sedi con piantaggio esterno cool them (dry ice) before inserting them into
(Fig. 9). corresponding bore (Fig. 9).
• Usare sempre gli estrattori idonei per rimuovere i Always use suitable extractors to remove the bearings
cuscinetti (Fig. 10). (Fig. 10).

Fig. 9

Fig. 10

231497 REVISION DATE: 09/17 DOC. CA270276 B.5 PAG. 37

SPECIAL RECOMMENDATIONS Mod. T120 24+24

Spine elastiche Split pins

Per il montaggio delle spine elastiche attenersi alle Respect the following recommendations during the split
seguenti raccomandazioni: pins assembly:
• Al montaggio delle spine elastiche ad intaglio • Before assembling elastic pins, make sure that the
assicurarsi che l'intaglio delle stesse sia orientato notch is oriented towards the stressing force (Fig.
nel senso dello sforzo sollecitante la spina (Fig. 11). 11).
• Le spine elastiche a spirale invece non necessitano • Spiral elastic pins do not need orientation.
di alcun orientamento.

Fig. 11

Fig. 12

Adesivi e sigillanti Adhesive and sealant

Per l’applicazione di adesivi e sigillanti attenersi alle Respect the following recommendations during the
seguenti raccomandazioni: adhesive and sealant application:
• Usare adesivi e sigillanti secondo le specifiche del • Use adhesive and sealant as advised by
produttore. manufacturer specifications.
• Non applicare adesivi e sigillanti su prodotti analoghi • Do not use adhesive or sealant where similar
già applicati in precedenza; rimuovere products has been applied previously; totally
completamente i vecchi prodotti prima di applicare i remove the old product before applying the new one.
nuovi. • Ensure that parts to be sealed are clean, dry and
• Assicurarsi che le parti dove si applicano adesivi e completely grease free (Fig. 12) in the application
sigillanti siano pulite, asciutte e completamente area.
prive di grasso (Fig. 12).
• Read the predisposed section in this manual to
• Consultare l’apposita sezione in questo manuale know the required type of adhesive and sealant and
per conoscere i tipi di adesivi e sigillanti ammessi e relative application areas.
le zone in cui devono essere utilizzati.

Scarico dell'olio Oil drain

Prima di intervenire sul prodotto è necessario scaricare Before carry out the disassembly operations, the oil
l'olio dal gruppo. must be drained out.

ATTEN ZIONE CAUTI ON

Smaltire gli oli esausti nel rispetto della vigenti norme Dispose of used oil in compliance with current
per la salvaguardia dell'ambiente. environment regulations.

B.5 PAG. 38 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 SPECIAL RECOMMENDATIONS

Pulizia Cleaning
Per la pulizia della trasmissione attenersi alle seguenti Respect the following recommendations during the
raccomandazioni: transmission cleaning operations:
• Lavare accuratamente tutte le parti in movimento • Wash all moving parts accurately with diesel fuel or
utilizzando gasolio o cherosene. kerosene.
• E' proibito l'uso di benzina e soluzioni acquose • Gasoline and watery alkaline solutions are
alcaline. forbidden.
• Evitare lavaggi con vapore o acqua calda perché • Do not wash with steam or hot water, as it will be
sarebbe difficile eliminare completamente l'umidità very difficult to eliminate surface humidity.
superficiale. • Dry all parts with a rag or air jet to avoid scratching
• Asciugare accuratamente tutti i particolari mediante from abrasive residuals.
un getto d'aria o stracci per evitare di rigare le
• After the cleaning operations, all the surfaces should
superfici con residui abrasivi.
be covered with lubricant so as to protect it from
• Dopo la pulizia, tutte le superfici devono essere future oxidation.
ricoperte da un leggero strato di lubrificante per
proteggerle da eventuali ossidazioni.

Controlli Checks
Per i controlli sulla trasmissione attenersi alle seguenti Respect the following recommendations during the
raccomandazioni: transmission control operations:
• Controllare che tutti gli elementi scanalati siano privi • Check all grooves: assure that they are not worn out
di usure eccessive o di altri danneggiamenti. or damaged.
• Sostituire i particolari avariati con ricambi originali. • Replace spoiled parts with original spare parts.
• Dopo ogni smontaggio, le guarnizioni di tenuta sugli • Before the reassembly, the seals on rotating shafts
alberi rotanti devono essere sostituite. must be replaced.
• Verificare accuratamente tutti i cuscinetti, gli anelli • Examine accurately all bearings, external rings
esterni eventualmente ancora piantati nelle proprie which may be still stuck in their position and pivot
sedi e i perni su cui rotolano i rullini. pins on which rolls rotate.
• Sostituire quei particolari che presentano tracce di • Replace those which are worn out or damaged (Fig.
usura o di danneggiamento (Fig. 13). 13).
• Controllare che tutti gli ingranaggi non presentino • Gears should not be spoiled and teething should not
avarie od usure eccessive delle dentature: gli be excessively worn out. Teeth smoothing should
smussi dei denti non devono essere deteriorati (Fig. not be deteriorated (Fig. 14).
14).

Fig. 13

Fig. 14

231497 REVISION DATE: 09/17 DOC. CA270276 B.5 PAG. 39

SPECIAL RECOMMENDATIONS Mod. T120 24+24

Estremità di flange ed attrezzi speciali Ends of flanges and special tools

Prestare la massima attenzione quando si martellano le Be careful when hammering special tool or flange ends,
estremità di attrezzi speciali o di flange per evitare di in order to avoid jeopardizing functionality and integrity
compromettere la funzionalità e l’integrità sia degli of either the tools or the components on which you are
attrezzi che dei componenti su cui si opera. operating.

Impiego di lubrificante Lubricant use

Per ottenere una corretta lubrificazione ed una esatta In order to lubricate the CARRARO SpA transmissions
temperatura di funzionamento nelle trasmissioni correctly and to reach the exact operation temperature,
CARRARO SpA, è importante usare i lubrificanti it is important to use the recommended lubricants,
raccomandati, mantenendone il livello costante keeping their level constant as indicated in this manual.
secondo quanto indicato nel presente manuale.

B.5 PAG. 40 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 DISPOSAL

B.6 Smaltimento B.6 Disposal

B.6.1 Smaltimento del prodotto e del B.6.1 Disposal of the product and of the
veicolo su cui è installato vehicle where it is installed
DIFENDI L’AMBIENTE! PROTECT ENVIRONMENT!

Previeni l’inquinamento del terreno e dei corsi d’acqua. Prevent pollution of soil and watercourses.

Recupera i prodotti di consumo (come: olio, Recover used consumables (oil, lubricant, fuel,
lubrificante, filtri olio, filtri aria, ecc.) e smaltiscili coolant, oil filters, air filters, etc.) and discard them
nel rispetto dei regolamenti locali dei paesi in cui il in accordance with the current regulations in the
veicolo viene utilizzato. vehicle’s country of use.

Se il veicolo e/o i suoi componenti raggiungono il If the vehicle and/or its components reach the end of
termine della loro vita utile e devono essere rottamati, their service life and must be discharged, components
questi devono essere demoliti presso un centro must be disposed of in accordance with the current
autorizzato, secondo le normative locali; le prescrizioni regulations in force; local authorities prescriptions must
delle autorità locali devono essere rispettate. be respected.

Dal veicolo saranno recuperati From the vehicle will be recovered

• Batteria • Battery
• Olio e liquidi vari • Lubricants and fluids
• Carburante • Fuel

Inoltre potranno essere recuperati componenti ancora Also, working components can be recovered to be
funzionanti per essere riutilizzati, mentre i componenti used, while the components damaged/worn can be
danneggiati/usurati potranno essere riciclati. recycled.

I componenti non valorizzabili non devono essere No more usable components must not be released into
abbandonati nell’ambiente e non possono essere the environment, and can not be disposed of with
smaltiti con i rifiuti domestici, ma devono essere smaltiti household waste, but must be disposed of in a
in modo particolare. Per maggiori informazioni sullo particular way. For more information on waste disposal,
smaltimento, contattate le autorità locali responsabili o contact the local authorities responsible or the nearest
il concessionario più vicino. distributor/dealer.
• I prodotti accompagnati dal simbolo in Fig. 15 non • Products accompanied by symbol in Fig. 15 must
devono essere smaltiti con i rifiuti domestici; not be disposed of with household waste;
• I prodotti utilizzati e accompagnati dal simbolo in • Substances used accompanied by symbol in Fig. 16
Fig. 16 devono essere riciclati; must be recycled;

Fig. 15

Fig. 16

• Recupera qualsiasi componente che può essere • Recover any components which can be reused (e.g.
riutilizzato, anche come ricambio; starters, alternators, etc.);

231497 REVISION DATE: 09/17 DOC. CA270276 B.6 PAG. 41

DISPOSAL Mod. T120 24+24

• Raccogli i materiali da imballo e riciclati; non smaltirli • Recover packaging materials and recycle them; do
con i rifiuti domestici; not dispose of them with household waste;
• Prodotti quali olio, fluidi idraulici o liquido per freni • Batteries, fuel, lubricants and fluids must be treated
devono essere trattati come rifiuti speciali da as hazardous waste by specialized companies with
imprese specializzate dotate di attrezzature e special equipment and techniques and disposed of
tecniche speciali e smaltiti nel rispetto delle leggi in accordance with the regulations in force;
vigenti;
• Respect the prescriptions of the local authorities
• Rispetta le prescrizioni delle autorità locali responsible.
incaricate.

B.6 PAG. 42 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 GENERAL SPECIFICATIONS

C CARATTERISTICHE GENERALI

C GENERAL SPECIFICATIONS

231497 REVISION DATE: 09/17 DOC. CA270276 C PAG. 43

INTENDED USE Mod. T120 24+24

C.1 Uso previsto C.1 Intended use

Questa trasmissione, di tipo transaxle, è stata This transmission, transaxle type, has been designed
progettata e costruita per essere installata in veicoli di and manufactured to be mounted on agricultural
tipo agricolo con la funzione di trasmettere la potenza machines to transmit the power from the engine to the
dal motore alle ruote, consentendo anche: wheels and to allow:
• la variazione del rapporto di trasmissione tra ruote e • changing the transmission ratio between engine and
motore; wheels;
• massima forza di trazione del veicolo; • maximum traction force of the vehicle;
• selezione della trazione a 2 o 4 ruote motrici (con • selection of 2-wheel drive or 4-wheel drive (with
selettore 4RM) 4WD selector);
• ottimizzazione della ripartizione della forza di • optimization of the allocation of the traction force
trazione fra ruote posteriori ed anteriori con innesto between front and rear wheels with 4WD engaged;
4RM;
• optimization of the compensation of the speed
• ottimizzazione della compensazione di velocità di provided between front and rear wheels;
avanzamento prevista fra ruote anteriori e posteriori;
• the compensation of the inner and outer wheel
• la compensazione delle velocità delle ruote interna speed when turning the vehicle.
ed esterna durante la sterzata del veicolo.

Caratteristiche di rilievo Outstanding Features

• Design bialbero in grado di garantire una maggiore • 2-shaft design to guarantee enhanced ergonomics
ergonomia per il conducente for the driver
• Eccellente comfort e affidabilità di guida grazie ad • outstanding driving comfort and reliability thanks to
ingranaggi sempre sincronizzati synchronized constant mesh gears
• Freni di servizio a bagno d’olio praticamente esenti • wet service brakes virtually maintenance free
da manutenzione
• independent and versatile ground drive rear PTO to
• Presa di forza sincronizzabile con la velocità connect various implements
d’avanzamento (Ground PTO) indipendente e • SAE 3 clutch housing for the maximum engine
versatile per l’utilizzo di vari attrezzi flexibility
• Scatola della frizione di tipo SAE 3 per la massima
flessibilità di accoppiamento con il motore

A V V E R T E N Z A Non installare mai questa WARNI NG Never mount this transmission on

trasmissione su macchine diverse da quelle per cui e machines different from the ones for which it has been
stata progettata e costruita. designed and manufactured

Il prodotto, se utilizzato in un impiego diverso da quello If the product is used for any other purpose than the one
previsto, è da considerarsi soggetto ad "uso non foreseen, CARRARO declines any responsibility
previsto". regarding damages or accidents caused by it. All
CARRARO declina ogni responsabilità per danni o consequences will be at the expense of the client.
incidenti risultanti da un uso diverso da quello previsto;
tali conseguenze saranno a carico esclusivo del cliente.

Costituisce inoltre un elemento essenziale, nell'ambito However, when used as foreseen, operational
dell'uso previsto, l'osservanza scrupolosa delle formalities as well as regular maintenance repair
modalità di funzionamento e delle regolari specifications given by CARRARO are to be observed
manutenzioni e riparazioni specificate da CARRARO. strictly.

C.1 PAG. 44 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 PRODUCT IDENTIFICATION

C.2 Identificazione del prodotto C.2 Product identification

Targhetta di identificazione dell’assale Axle tag

231497 REVISION DATE: 09/17 DOC. CA270276 C.2 PAG. 45

MAIN FEATURES Mod. T120 24+24

C.3 Caratteristiche principali C.3 Main features

C.3.1 Caratteristiche tecniche generali C.3.1 General technical specifications

La trasmissione T120 è una trasmissione disponibile T120 transmission is available in the versions with 12
nelle versioni con 12 velocità avanti/indietro e 24 speeds forward/back and 24 speeds forward/back and
velocità avanti/indietro e negli allestimenti “Meccanico”, in the “Mechanical”, “Power Hi-LO” and “Power
“Power Hi-LO” e “Power Reverser” Reverser” fittings.
L’intera gamma degli allestimenti è possibile grazie ad The full range of fittings is possible thanks to a modular
una architettura di tipo modulare per funzioni, ciascuna architecture according to function, each pre-set for
predisposta per il controllo elettronico. electronic control.
G ra z i e a l p ro p r i o d e s i g n c o m p a t t o , l a T 1 2 0 Due to its compact design, the T120 also offers new
rappresenta, inoltre, la nuova possibilità di coniugare le opportunities for combining special (utility) applications
applicazioni speciali (utility) con le applicazioni più with more demanding applications in the open field.
impegnative su campo aperto (open field).

Importante: questo documento descrive un prodotto Important: This document describes a complex
complesso composto da vari elementi opzionali, product composed of several optional elements, refer
consultare la sezione Dati Tecnici per conoscere i dati to the Technical Data section in order to know the
specifici della macchina in esame; alcuni particolari specific data of the machine you are interested; some
rappresentati in questo manuale potrebbero non parts represented in this repair manual might not
essere presenti nel Vs prodotto. be present in your product.

C.3 PAG. 46 REVISION DATE: 09/17 DOC. CA270276 231497

 231497
CA406115
COMANDO MECCANICO PTO
Mod. T120 24+24

PTO MECHANICAL CONTROL

INVERSORE MECCANICO SINCRONIZZATO

SYNCHRO SHUTTLE

SCATOLA DIFFERENZIALE
DIFFERENTIAL HOUSING

MARCE VELOCITÀ GAMME VELOCITÀ

SPEED GEARS RANGE GEARS
Trasmissione T120 - Gruppi principali

24+24 SYNCHRO SHUTTLE AND SYNCHRO SPLITTER

REVISION DATE:
09/17 DOC. CA270276
24+24 INVERSORE MECCANICO SINCRONIZZATO E HI-LO MECCANICO SINCRONIZZATO

HI-LO MECCANICO SINCRONIZZATO

Transmission T120 - Main groups

SYNCHRO SPLITTER
PDM 4RM (A COMANDO IDRAULICO)
4WD DROP BOX (S.A.H.R)

C.3
PAG.
47
MAIN FEATURES
MAIN FEATURES Mod. T120 24+24

Freni ad at tuazione meccanica Mechanical controlled brakes

Numero dischi freno per lato 5 Number of brake discs each side

Numero controdischi freno per lato 3 Number of brake counterdiscs each side

Spessore disco freno 4.80-4.90 mm Brake disc thickness

Spessore controdisco freno 2.55-2.70 mm Brake counterdisc thickness

Spessore minimo disco freno usurato 4.0 mm Warn brake disc minimum thickness

Vedi: figura per i dettagli di assemblaggio See: figure for assembly details

CONTRODISCHI FRENO CA142742 DISCHI FRENO CA386056

BRAKE COUNTERDISCS CA142742 BRAKE DISCS CA386056

CA406182

C.3 PAG. 48 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 MAIN FEATURES

Dischi frizione Clutch discs

Differenziale/Differential Presa di Moto 4RM/4WD

GRUPPO DISCHI CA388334 GRUPPO DISCHI CA403640
CLUTCH PACK CA388334 CLUTCH PACK CA403640

37.8-38.0 mm

sotto carico 160 kg

under load 160 kg
33.45-34.55 mm
(1.317-1.360”)
sotto carico 1600
N

CA388334-CA403640

231497 REVISION DATE: 09/17 DOC. CA270276 C.3 PAG. 49

MAIN FEATURES Mod. T120 24+24

C.3.2 Sensore di velocità C.3.2 Speed sensor

DATI CARATTERISTICI SENSORE SPEED SENSOR TYPICAL DATA

Effetto Hall
Tipo sensore Sensor type
Hall Effect

Modello sensore Zero Speed Sensor model

Lunghezza cavo 370 mm Cable length

Classe di protezione IP 67 Protection class

Tensione di alimentazione 4.5-30 Vdc Supply voltage

Segnale induttivo massimo in uscita 350 mA Output peak inductive load

Risposta in frequenza 0-15 kHz Frequency response

Temperatura di esercizio sensore -40-150°C Sensor head operating temperature

Vedi: figura per i dettagli di assemblaggio figure for assembly details

Schema sensore di velocità Speed sensor scheme

35 Nm

VCC-3
ch 25

GND-2
(OUT) SIG.-1

CA191493

C.3 PAG. 50 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 MAIN FEATURES

Risposta sensore di velocità Speed sensor output signal

1
L-
A
N
G
SI
CA191493-07

Posizione di assemblaggio sensore di velocità Speed sensor assembly position

0.2-2.0 mm

CA406182-08

231497 REVISION DATE: 09/17 DOC. CA270276 C.3 PAG. 51

MAIN FEATURES Mod. T120 24+24

C.3.3 Comando attacco a 3 punti C.3.3 3 point hitch command group

DESCRIZIONE POSIZIONE / POSITION DESCRIPTIONS

Sensore posizione angolare 1 Angular position sensor

Perno sensore di sforzo 2 Load pin sensor

Gruppo di controllo 3 Controller assembly
Distributore idraulico di comando 4 Hydraulic control valve
Impianto cablaggio veicolo (non fornito da Vehicle wiring harness (not supplied by
5
CARRARO) CARRARO)

3 4
5

CA408295

C.3 PAG. 52 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 MAIN FEATURES

C.3.3.1 Sensore posizione angolare C.3.3.1 Angular position sensor

DATI CARATTERISTICI SENSORE SENSOR TYPICAL DATA

Elettrico di rotazione
Tipo sensore Sensor type
Electric rotational

Corsa meccanica (Antioraria) 0-120° Mechanical travel (CCW)

Coppia di rotazione con molla di ritorno 0.12 Nm Rotational torque with return spring

Campo di rotazione utile 5-85° Effective rotational sensing range

Tensione di alimentazione 5.0 V (±10%) Input Voltage

Corrente in ingresso (a 5 V CC) 4-8 mA Input Current (at 5 V DC)

Massima corrente in ingresso (con uscita/e 25 mA Max Input Current (output(S) shorted to
a terra) per uscita ground) per output

Sovratensione massima (CC) 16 V Max overvoltage (DC)

Uscita del sensore a 5 VCC (in rapporto alla Sensor output at 5 V DC (ratiometric to
0.5-4.5 V
tensione in ingresso) input voltage)

Linearità a 5 VCC (uscita analogica) ± 2.0 Output linearity at 5 V DC (Analog Output)

Temperatura di esercizio -40-125°C Operating temperature

Vedi: figura per i dettagli See: figure for details

Schema sensore di posizione angolare Angular position sensor scheme

GND +V DC
OUTPUT

CA407804-02

231497 REVISION DATE: 09/17 DOC. CA270276 C.3 PAG. 53

MAIN FEATURES Mod. T120 24+24

C.3.3.2 Perno sensore di carico C.3.3.2 Load pin sensor

DATI CARATTERISTICI SENSORE SENSOR TYPICAL DATA

Cella di carico
Tipo sensore Sensor type
Load cell

Capacità ±50’000 N Capacity

Sovraccarico in sicurezza 300% Safe overload
Sovraccarico massimo 500% Ultimate overload

Classe di protezione IP 68 Protection class

Tensione di alimentazione 5V Supply voltage

Segnale in uscita 0.5-4.5 V Output signal

Nota: vedi diagramma in figura 2.5 V = 0 kN Note: see diagram in figure

Lunghezza cavo 1000±100 mm Cable length

Deutsch DTM04 3pin

Tipo connettore Connector type
IP67
Vedi: figura per i dettagli See: figure for details
Load sensor scheme

Schema sensore di carico

Direzione carico
Loading direction

RED GREEN
POWER OUTPUT
BLACK
GND

CA407805-02

C.3 PAG. 54 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 MAIN FEATURES

C.3.3.3 Distributore idraulico C.3.3.3 Hydraulic control valve

ELEMENTI PRINCIPALI MAIN PARTS

VALVOLA ALIMENTAZIONE SUPPLY RELIEF VALVE

1
Pressione 195.0±10.0 bar (a 20 l/min) Pressure 195.0±10.0 bar (at 20 l/min)

VALVOLA SENSORE DI CARICO 2 LOAD SENSE RELIEF VALVE

Pressione 175.0±5.0 bar (a 5 l/min) Pressure 175.0±5.0 bar (at 5 l/min)

SOLENOIDE PROPORZIONALE PROPORTIONAL SOLENOID

Tensione di alimentazione 12 V CC Voltage 12 V DC
3
Assorbimento corrente massimo 1.5 A Maximum current 1.5 A
Connettore DEUTSCH DT04 - 2 poli Connector DEUTSCH DT04 - 2 pin

SOLENOIDE ON-OFF ON-OFF SOLENOID

Tensione di alimentazione 12 V CC Voltage 12 V DC
4
Assorbimento corrente iniziale 1.5 A Initial current draw 1.5 A
Connettore DEUTSCH DT04 - 2 poli Connector DEUTSCH DT04 - 2 pin

VALVOLA ALIMENTAZIONE 5 WORK PORT RELIEF VALVE

Pressione 220.0±10.0 bar (a 10 l/min) Pressure 220.0±10.0 bar (at 10 l/min)
Vedi: figura See: figure
Control valve scheme
Schema distributore

2
4

CA407807-06

231497 REVISION DATE: 09/17 DOC. CA270276 C.3 PAG. 55

MAIN FEATURES Mod. T120 24+24

Schema idraulico distributore Control valve hydraulic scheme

CA407807-06

DATI CARATTERISTICI MAIN DATA

Portata pompa 90 l/min Pump delivery capacity

Pressione d’esercizio 200 bar Operating pressure

Temperatura ambiente di lavoro -20÷45 °C Operating ambient temperature

Temperatura operativa dell’olio -20÷120 °C Operating oil temperature

C.3 PAG. 56 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

C.4 Coppie di serraggio, sigillanti e C.4 Tightening torques, sealants

grasso and grease
Applicazione Adesivi/Sigillanti - Adhesive/Sealant Application
Applicare sulle superfici piane a contatto - Apply on the flat contact surfaces
Applicare sulla filettatura delle viti o sulle superfici curve di perni e boccole
Apply on bolts thread or on pins and bushes curved surfaces

Sigillanti per guarnizioni - Gasket sealants

Rif. Carraro Marca e tipo Caratteristiche tecniche Resistenza
Carraro Ref. Brand and type Technical characteristics Strength
Loctite® 510(1) Sigillatura superfici piane Alta
A1
Superbond® 529(1) Flat surface sealing High
Loctite® 573 Sigillatura superfici piane Bassa
A2
Superbond® 519 Flat surface sealing Low
Sigillatura superfici irregolari Alta
A3 Loctite® 518
Uneven surface sealing High
Sigillatura superfici piane con possibilità di
micromovimenti Alta
A4 Loctite® 5205
Even surface sealing with possibility of High
micro movements
Sigillatura superfici piane e/o irregolari con
possibilità di micromovimenti Alta
A5 Loctite® 5188(2)
Even/uneven surface sealing with possibility High
of micro movements
Nota: (1) A3 può essere impiegato al posto di A1; (2) A5 può essere impiegato al posto di A1, A2, A3, A4.
Note: (1) A3 can be used instead of A1; (2) A5 can be used instead of A1, A2, A3, A4.

Adesivi per frenatura organi filettati - Thread parts adhesives

Rif. Carraro Marca e tipo Caratteristiche tecniche Resistenza
Carraro Ref. Brand and type Technical characteristics Strength
Loctite® 542 Frenatura organi filettati Media
B1
Superbond® 321 Locking of threaded parts Medium
Frenatura organi filettati Alta
B2 Loctite® 270
Locking of threaded parts High
Loctite® 986/AVX Frenatura organi filettati Alta, appl. speciali
B3
Superbond® 438 Locking of threaded parts High, special appl.

Adesivi per fissaggio particolari - Fixing parts adhesives

Rif. Carraro Marca e tipo Caratteristiche tecniche Resistenza
Carraro Ref. Brand and type Technical characteristics Strength
Loctite® 402 Adesivo per fissaggio Fissaggio medio
C1
Superbond® istant 25 Fixing adhesive Medium bond
Adesivo per fissaggio Fissaggio forte
C2 Loctite® 638
Fixing adhesive Strong bond
Loctite® 542 Adesivo per fissaggio Fissaggio medio
C3
Superbond® 321 Fixing adhesive Medium bond
Loctite® 496 Adesivo per fissaggio gomma Fissaggio forte
C4
Superbond® SB14 Rubber fixing adhesive Strong bond

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 57

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Applicazione grasso al montaggio - Grease application in assembly

Tecnolube® Applicare sulle superfici indicate

POLYMER 400 Apply on the indicated surfaces

AGIP® Riempire/Applicare in eccesso

MU EP2 Fill/Apply in excess

Presa di moto 4RM a comando idraulico (SAHR) 4WD S.A.H.R. drop box

A3

A
35 Nm

60 Nm
SEZ. A-A

32 Nm
A1

50 Nm
CA406186-06 (Z60) - CA437319-03 (Z59)

C.4 PAG. 58 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Applicazione grasso al montaggio - Grease application in assembly

Tecnolube® Applicare sulle superfici indicate

POLYMER 400 Apply on the indicated surfaces

AGIP® Riempire/Applicare in eccesso

MU EP2 Fill/Apply in excess

Presa di moto 4RM a comando idraulico (SAHR) - 4WD S.A.H.R. drop box - Dog clutch
Innesto forntale

A3

35 Nm

60 Nm

32 Nm

80 Nm

A1

50 Nm

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 59

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Gruppo corpetto Clutch assembly

145 Nm

20 Nm
C

B
A4

10 Nm SEZ. D-D

50 Nm
B
C

23 Nm
D
SEZ. E-E 25 Nm

C2 190 Nm

35 Nm
SEZ. B-B SEZ. C-C

E E

CA405800-07/CA430503-02

C.4 PAG. 60 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Gruppo marce Gears assembly

CA368926-01/CA406180-13/CA430501-06/406490-04

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 61

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Gruppo cambio Gearbox assembly

CA406182-11

C.4 PAG. 62 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Gruppo cambio (particolari) Gearbox assembly (details)

50 Nm
140 Nm

C C

B1

17 Nm

Sez. C-C
130 Nm

B2

23 Nm
35 Nm

CA386082-06/CA406182-11

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 63

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Gruppo freno ad attuazione meccanica Mechanical controlled brake group

Sez. A-A
A

B B

A
Sez. B-B
120 Nm

Only for R.H. group

Sez. C-C
assembly
23 Nm

65-95 Nm

CA142510-04/CA386092-02/CA386099-03

C.4 PAG. 64 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Gruppi comando freno e freno a mano Brake and hand brake control groups

CA385347-03/CA406183-05

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 65

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Gruppo riduttore laterale - tipo UP Final drive group - UP type

C.4 PAG. 66 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Gruppo PTO+GDPTO a comando MECCANICO MECHANICAL control PTO+GDPTO group

PTO 540/540E + GDPTO

20 Nm

A3
20 Nm

50 Nm
B2

105 Nm

CA406184-11

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 67

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Gruppo PTO+GDPTO a comando MECCANICO MECHANICAL control PTO+GDPTO group

(particolari) (details)

PTO 540/540E + GDPTO

C2

25 Nm

B2

50 Nm 45 Nm

B2

45 Nm

CA406184-11

C.4 PAG. 68 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Gruppo comando marce esterno STD Outer gear STD shift group

23 Nm

70 Nm

70 Nm

A3

A3 23 Nm A3
A1
A3

10 Nm

CA414747-02

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 69

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Gruppo comando marce interno Internal gear shift group

B1

40 Nm 80 Nm

CA406181-11

C.4 PAG. 70 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Gruppo comando marce interno (particolari) Internal gear shift group (details)

B2

105 Nm
25 Nm
30 Nm

A1

CA406181-11

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 71

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Attacco a tre punti Three points hitch

200 Nm
300 Nm

70 Nm A3

A3

B
A

Sez. A-A B

25 Nm
25 Nm

Sez. B-B

300 Nm

280 Nm

CA408853-06

C.4 PAG. 72 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Attacco a tre punti Three points hitch

CA408853-06

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 73

TIGHTENING TORQUES, SEALANTS AND GREASE Mod. T120 24+24

Tubi di lubrificazione Lubrication pipes

CA412031-04

C.4 PAG. 74 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 TIGHTENING TORQUES, SEALANTS AND GREASE

Tubi sollevatore Rockshaft pipes

110-121 Nm

60-66 Nm

100-110 Nm

60-66 Nm

60-66 Nm

60-66 Nm

170-187 Nm

60-66 Nm

110-121 Nm

45-49 Nm 60-66 Nm

CA408300-02

231497 REVISION DATE: 09/17 DOC. CA270276 C.4 PAG. 75

POWER FLOWS Mod. T120 24+24

C.5 Flussi di potenza C.5 Power flows

Schema generale General scheme

C.5 PAG. 76 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 POWER FLOWS

STADIO 1: flusso di potenza avanti/indietro STAGE 1: forward/reverse power flow

STADIO 2: prima marcia avanti - Veloce STAGE 2: first speed forward - High

231497 REVISION DATE: 09/17 DOC. CA270276 C.5 PAG. 77

POWER FLOWS Mod. T120 24+24

STADIO 2: prima marcia avanti - Normale STAGE 2: first speed forward - Medium

STADIO 2: prima marcia avanti - Lenta STAGE 2: first speed forward - Low

C.5 PAG. 78 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 POWER FLOWS

STADIO 3: flussi PTO+GDPTO a com. MECCANICO STAGE 3: MECHANICAL contr. PTO+GDPTO flows

PTO 540/540E + GDPTO

231497 REVISION DATE: 09/17 DOC. CA270276 C.5 PAG. 79

ASSEMBLY TYPICAL DATA Mod. T120 24+24

C.6 Caratteristiche di montaggio C.6 Assembly typical data

Posizione/Position Gioco/End float

GND PTO 0÷0.05 mm

Gamma spessori/Shims range

Spessore/Thickness mm 0.10 0.25 0.30 0.50
Quantità/Quantity --- --- --- ---

C.6 PAG. 80 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 ASSEMBLY TYPICAL DATA

Posizione 1/Position 1 Gioco/End float

Cambio/Gear box 0.4÷0.5 mm

Gamma spessori/Shims range

Spessore/Thickness mm 0.10 0.30 0.50
Quantità/Quantity --- --- ---

231497 REVISION DATE: 09/17 DOC. CA270276 C.6 PAG. 81

ASSEMBLY TYPICAL DATA Mod. T120 24+24

Posizione 3 /Position 3 Gioco/End float

Cambio/Gear box 0

Gamma spessori/Shims range

Spessore/Thickness mm 0.10 0.15 0.20 0.50
Quantità/Quantity --- --- --- ---

C.6 PAG. 82 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 ASSEMBLY TYPICAL DATA

Posizione 4 /Position 4 Gioco/End float

Cambio/Gear box min. 0.20 mm

Gamma spessori/Shims range

Spessore/Thickness mm 0.10 0.30 0.50
Quantità/Quantity --- --- ---

231497 REVISION DATE: 09/17 DOC. CA270276 C.6 PAG. 83

ASSEMBLY TYPICAL DATA Mod. T120 24+24

Posizione 5 /Position 5 Gioco/End float

Cambio/Gear box min. 0.20 – max. 0.30 mm

Gamma spessori/Shims range

Spessore/Thickness mm 0.10 0.15 0.20 0.50
Quantità/Quantity --- --- --- ---

C.6 PAG. 84 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 ASSEMBLY TYPICAL DATA

Posizione /Position Gioco/End float

Cambio asse A min. 0.01 – max. 0.06 mm
Gearbox A axis

Gamma spessori/Shims range

Spessore/Thickness mm 1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 2.40
Quantità/Quantity --- --- --- --- --- --- --- --- --- --- ---

231497 REVISION DATE: 09/17 DOC. CA270276 C.6 PAG. 85

ASSEMBLY TYPICAL DATA Mod. T120 24+24

Posizione /Position Gioco/End float

Attacco a 3 punti/ 0.20÷0.30 mm
Three points hitch

Gamma spessori/Shims range

Spessore/Thickness mm 0.10 0.25 0.50 1.00
Quantità/Quantity --- --- --- ---

C.6 PAG. 86 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 FILLING AND CHECKS

C.7 Rifornimento e verifiche C.7 Filling and checks

C.7.1 Dati caratteristici C.7.1 Main data

D ES CRI ZI ONE VALORI / VALUES DESCRIPTION

Specifica olio API GL4 Oil specification
ALLISON C-4
SAE J300: 10W-30
Nota: non usare olio di sintesi o vegetale SAE J306: 75W-80 Note: do not use synthetic or vegetable oil
OLIO RACCOMANDATO RECOMMENDED OIL

L’olio per trasmissioni Carraro è apposita- Carraro transmission oil is specially formu-
mente formulato per fornire la massima Carraro Oil lated to provide maximum protection
protezione contro l'usura meccanica e la Power Life Lub® against mechanical wear and corrosion. It
corrosione. Può essere utilizzato in tutte le Universal 80W may be used in all operating temperatures.
temperature operative. U.T.T.O. Note: the use of a different oil must be
Nota: l’uso di un olio diverso richiede approved by CARRARO Service
l’approvazione specifica del Servizio Department
Assistenza CARRARO

Quantità olio richiesta Required oil quantity

Trasmissione con gruppi riduttore Vedi: manuale veicolo Transmission with reduction groups
See: vehicle manual
Riduttore finale Vedi: Dati Tecnici Final drive
See: Technical Data

231497 REVISION DATE: 09/17 DOC. CA270276 C.7 PAG. 87

FILLING AND CHECKS Mod. T120 24+24

C.7.2 Rifornimento e verifiche C.7.2 Filling and checks

Importante: eseguire le operazioni di scarico, carico e Important: to drain and load the oil and to check the
verifica livello olio con la trasmissione orizzontale. oil level the transmission must be horizontal.

Scarico dell’olio per manutenzione ordinaria

Scheduled maintenance oil drain
Per scaricare l’olio dal corpo centrale rimuovere l’asta
di livello (1) per sfiato e poi il tappo di scarico (2). To drain the oil remove the level plug (1) and the drain
plug (2).
Þ A TTEN ZIONE rischio di violenta espulsione
di getti d’olio, seguire tutte le procedure di sicurezza Þ C A U T I O N risk of violent oil ejection, follow
indicate in questo manuale e dal costruttore del carefully all the safety procedures indicated in this
veicolo. manual and in the vehicle manual.

Vedi: INFORMAZIONI SULLA SICUREZZA See: SAFETY INSTRUCTIONS

Scaricare completamente l’olio. Drain all oil.
Pulire il tappo (2) e richiuderlo alla coppia prevista. Clean the plug (2) and tighten it to the prescribed
torque.

Riempimento di manutenzione ordinaria Scheduled maintenance oil filling

Eseguire le seguenti fasi: Carry out the following instructions:

• riempire la trasmissione fino al limite massimo • Fill the transmission with oil to the maximum level
indicato sull’asta di livello (1). marked on the level dipstick (1).

• inserire il freno di parcheggio. • Apply the parking brake.

• mantenere il comando marce in posizione FOLLE • Keep the speed control in NEUTRAL range.

• avviare il motore mantenendolo a regime minimo di • Start the engine by keeping the slow running of
800÷1000 g/m fino al raggiungimento di una 800÷1000 rpm until an oil temperature higher than
temperatura dell’olio superiore a 25 °C. 25 °C is obtained.

• verificare che il livello dell’olio in trasmissione risulti • Check that the transmission oil level is in the
alla quota prevista sull’asta di livello (1). prescribed range on the level dipstick (1).

• eventualmente rabboccare con olio per rispettare la • If necessary, top up with oil to keep the level in the
precedente quota di riferimento. prescribed range.

Verifica livello dell’olio per manutenzione ordinaria Scheduled maintenance oil level check

Per verificare il livello dell’olio utilizzare l’asta di livello Use the oil level dipstick (1) to check the oil level.
olio (1). Important: If leakage or any other factor determining
Importante: Nel caso in cui si riscontri una perdita o fall in the oil level is found, then it is advisable to check
altro fattore che determini l’abbassamento del livello immediately, in order to avoid damages to the
olio, è opportuno intervenire immediatamente per mechanical parts.
evitare possibili danni agli organi meccanici.

C.7 PAG. 88 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 FILLING AND CHECKS

C.7.3 Punti di rifornimento e verifiche C.7.3 Filling and check points

DESCRIZIONE POSIZIONE / POSITION DESCRIPTIONS

Carico olio/Sfiato 1 Oil filling port/Breather

Tappo scarico olio 2 Oil drain plug
Visore livello olio (tappo in vetro) 3 Oil level indicator (sight glass)
Ingrassatore 4 Greaser
Sfiato spurga freni 5 Brakes breather

5 4

5 4

CA406115

231497 REVISION DATE: 09/17 DOC. CA270276 C.7 PAG. 89

FILLING AND CHECKS Mod. T120 24+24

Punti di rifornimento e verifiche Filling and check points

C.7 PAG. 90 REVISION DATE: 09/17 DOC. CA270276 231497

Mod. T120 24+24 FILLING AND CHECKS

Livello dell’olio richiesto Required oil level

231497 REVISION DATE: 09/17 DOC. CA270276 C.7 PAG. 91

SERVICE SCHEDULE Mod. T120 24+24

C.8 Manutenzione programmata C.8 Service schedule

Gli intervalli di manutenzione indicati sono per un Specified maintenance intervals are for standard-duty
impiego normale della macchina, nel caso di impieghi use.
particolarmente gravosi intervenire con maggior Severe operating conditions may require more short
frequenza. intervals.

T em pi pr ev i sti
Ope r az i one Recommended intervals Ope ra t i on
50 h 40 0 h 80 0 h 1 20 0 h

Cambio olio idraulico e della Change the transmission and

 
trasmissione hydraulic oil

Ingrassaggio cuscinetti semiasse     Grease trumpet bearings

Campi di applicazione dei lubrificanti Lubricants application range

C.8 PAG. 92 REVISION DATE: 09/17 DOC. CA270276 231497

 ATTREZZATURE SPECIALI
Mod. T120 24+24 SPECIAL TOOLS

E ATTREZZATURE SPECIALI

E SPECIAL TOOLS

231497 REVISION DATE: 09/17 DOC. CA270276 PAG. 93

ATTREZZATURE SPECIALI
SPECIAL TOOLS Mod. T120 24+24

E.1 Attrezzature speciali E.1 Special tools

I tamponi speciali per il montaggio di tenute, cuscinetti The special drifts/pad used to assembly the seals,
e bronzine devono essere utilizzati con il manico bearings and bushes should always be used with the
intercambiabile CA716372 (con i relativi adattatori interchangeable handle CA716372 (with relative
quando necessario). adapters where necessary).

Per maggiori informazioni e per l’acquisto delle attrez- For further information or to order the special tools
zature contattare il servizio ricambi all’indirizzo e-mail please contact our spare parts sales office by email
s a le s@ c ar r ar or ic a mbi .c om s a le s @c ar r ar or i ca mb i. com

PAG. 94 REVISION DATE: 09/17 DOC. CA270276 231497

 STUDIO ATTREZZATURE
Mod. T120 24+24 TOOLS DESIGN

E.2 Studio attrezzature E.2 Tools design

E.2.1 Attrezzature per PDM a comando E.2.1 Special tools for mechanical drop
meccanico box

231497 REVISION DATE: 09/17 DOC. CA270276 PAG. 95

STUDIO ATTREZZATURE
TOOLS DESIGN Mod. T120 24+24

E.2.2 Attrezzature per riduttori laterali E.2.2 Special tools for final drive
CA401070 CA401070

PAG. 96 REVISION DATE: 09/17 DOC. CA270276 231497

 STUDIO ATTREZZATURE
Mod. T120 24+24 TOOLS DESIGN

E.2.3 Attrezzature per coperchio e E.2.3 Special tools for PTO cover and
frizione PTO clutch

231497 REVISION DATE: 09/17 DOC. CA270276 PAG. 97

STUDIO ATTREZZATURE
TOOLS DESIGN Mod. T120 24+24

E.2.4 Attrezzature per la scatola cambio E.2.4 Special tools for the gear box

PAG. 98 REVISION DATE: 09/17 DOC. CA270276 231497

 STUDIO ATTREZZATURE
Mod. T120 24+24 TOOLS DESIGN

E.2.5 Attrezzature per la scatola cambio E.2.5 Special tools for the gear box

231497 REVISION DATE: 09/17 DOC. CA270276 PAG. 99

STUDIO ATTREZZATURE
TOOLS DESIGN Mod. T120 24+24

E.2.6 Attrezzature per la scatola cambio E.2.6 Special tools for the gear box

PAG. 100 REVISION DATE: 09/17 DOC. CA270276 231497

 STUDIO ATTREZZATURE
Mod. T120 24+24 TOOLS DESIGN

E.2.7 Attrezzature per la scatola cambio E.2.7 Special tools for the gear box

231497 REVISION DATE: 09/17 DOC. CA270276 PAG. 101

STUDIO ATTREZZATURE
TOOLS DESIGN Mod. T120 24+24

E.2.8 Attrezzature per il corpetto frizione E.2.8 Special tools for the synchro
con inversore meccanico shuttle clutch housing
sincronizzato

PAG. 102 REVISION DATE: 09/17 DOC. CA270276 231497

Carraro Drive Tech Spa Carraro Drive Tech SpA
Headquarters After Sales & Spare Parts
Via Olmo, 37 Via Trentino, 4/6 35043 Monselice Padova, Italy
35011 Campodarsego [email protected]
Padova, Italy www.carry4you.it
www.carrarodrivetech.com
Carraro Warehouses
Rockford, IL, USA
Pune, India
Haedo, Buenos Aires, Argentina
Qingdao, China
FRONT AXLE
 MANUALE DI RIPARAZIONE
REPAIR MANUAL

ASSALE ANTERIORE
FRONT AXLE
Mod. 20.16-1640

1a Edizione - 1s t Edition: 05/2016 Doc. CA270410

AB10710
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 DATI PRODOTTO
Mod. 20.16-1640 PRODUCT DATA

CODICE CA449547 CODE

MACCHINA Assale anteriore - Front Axle MACHINE
MODELLO 20.16-1640 MODEL
TIPO DIFFERENZIALE Limited Slip DIFFERENTIAL TYPE

CONDIZIONI DI FORNITURA CONDITIONS OF SUPPLY

Fissaggio assale Axle mounting
Questo prodotto viene fornito da Carraro CON/WITH This product is supplied by Carraro Drive
Drive Tech con/senza supporti Tech with/without trunnions

Fissaggio ruote Wheels mounting

Questo prodotto viene fornito da Carraro SENZA/WITHOUT This product is supplied by Carraro Drive
Drive Tech con/senza dadi di fissaggio ruote Tech with/without wheel nuts

Scatola di trasmissione Transmission box

Questo prodotto viene fornito da Carraro This product is supplied by Carraro Drive
SENZA/WITHOUT
Drive Tech con/senza scatola di Tech with/without transmission box
trasmissione installed on the axle

Olio Oil
Questo prodotto viene fornito da Carraro CON/WITH This product is supplied by Carraro Drive
Drive Tech con/senza olio Tech with/without oil

DAT I TEC NIC I AS SALE AXLE TECHNICAL DATA

Peso a secco 253 kg Dry weight
Angolo di sterzata massimo 55° Maximum steering angle
Sensore di sterzata Steering sensor
assente/without
Vedi: cap. Caratteristiche Tecniche See: capt. Technical Features
Pressione massima di esercizio Steering cylinder
172 bar
cilindro sterzo maximum working pressure
0
Convergenza A -2 Toe-in

Riduzione coppia conica 2.133/1 Bevel gear ratio

Riduzione riduttore epicicloidale 6.00/1 Epicyclic reduction gear ratio
Riduzione totale assale 12.80/1 Axle total ratio
Rotazione in entrata/uscita ANTIORARIA/C.C.W. Input/output rotation
Freni di servizio assenti/without Service brakes
Freni di stazionamento assenti/without Parking brakes

AB10710 REVISION DATE: 05/16 DOC. CA270410 CA449547 DP-1

DATI PRODOTTO
PRODUCT DATA Mod. 20.16-1640

RIFORNIMENTO OLIO OIL FILLING

Specifiche olio API GL4 Oil specifications

CARRAROOIL
Olio raccomandato Vedi: Manutenzione e cambio olio. Recommended oil
See: Maintenance and oil change.

Quantità olio differenziale 4.4 (±10%) litri/liters Differential oil quantity

Quantità olio riduttore epicicloidale Epicyclic reduction gear oil quantity

0.6 (±15%) litri/liters
(per lato) (each side)

DIME NSIONI PRINCIP ALI (mm) MAIN DIMENSIONS (mm)

M20x1.5

43
Ø220.8
Ø275

1640
Distanza flange - Flange to flange
1800
Ingombro totale - Overall dimensions

V ALORI TIPICI DI ASS EMBLAGGIO ASSEMBLY MAIN DATA

Angolo di riferimento S per la regolazione min. 53° Reference angle S for the adjustment of the
dei fermi sterzata max. 55° steering stops
Quota di riferimento RP per la regolazione Reference dimension RP for the adjustment
21.5 mm
dei fermi sterzata - Lato pignone of the steering stops - Pinion side
Reference dimension ROP for the
Quota di riferimento RO P per la regolazione
f. assenti/without stops adjustment of the steering stops - Side
dei fermi sterzata - Lato opposto pignone
opposite to the pinion

CA449547 DP-2 REVISION DATE: 05/16 DOC. CA270410 AB10710

 DATI PRODOTTO
Mod. 20.16-1640 PRODUCT DATA

VAL ORI TIP ICI DI AS SEMBLAGGIO ASSEMBLY MAIN DATA

A= 11.975÷12.025 mm
Valori per verifica Set Right B= 52.229÷52.279 mm Values for verification Set Right
C= 20.000÷20.100 mm
Coppia conica Bevel gear set
Destra (Dx)/Right (Rh)
Posizione corona dentata (vedi C.4) Crown gear arrangement (see C.4)
Gm i n = 0.15 mm
Gioco di accoppiamento coppia conica Coupling backlash of bevel gear set
Gm a x = 0.21 mm
Diametro esterno External diameter
DP = 29.75 mm
del codolo scanalato pignone of pinion shaft splined end
Precarico cuscinetti pignone( 1 ) Pinion bearings preloading( 1 )
Nota: valori riferiti al diametro pignone FPm in = 107.6 N Note: values related to the pinion diameter
Vedi: par. Gruppo Pignone per la corretta FPm a x = 161.3 N See: instructions for correct adjustment of
procedura di regolazione precarico preload in Pinion Group section
Precarico totale dei cuscinetti sistema Total preloading( 1 ) of pinion-crown gear
corona-pignone( 1 ) FT m i n = FP + 50.4 N bearings
Nota: valori riferiti al diametro pignone Note: values related to the pinion diameter
FT m a x = FP + 75.6 N
Vedi: Gruppo Supporto Differenziale per la See: instructions for correct adjustment of
corretta procedura di regolazione precarico preload in Differential Support Group sec.
Coppia di rotolam.( 1 ) dei cuscinetti pignone MP m i n = 1.6 Nm Pinion bearings rolling torque( 1 )
Vedi: par. Gruppo Pignone per la corretta See: instructions for correct adjustment in
MP m a x = 2.4 Nm
procedura di regolazione Pinion Group section
Coppia di rotolamento totale( 1 ) dei cuscinetti Total rolling torque( 1 ) of pinion-ring gear
corona-pignone MT m in = MP + 0.75 Nm bearings
Vedi: Gruppo Supporto Differenziale per la MT m a x = MP + 1.13 Nm See: instructions for correct adjustment in
corretta procedura di regolazione Differential Support Group section
(1)
Solo per nuovi cuscinetti; i precarichi devono essere (1)
Only for new bearings; all preloads must be measured
rilevati senza anello di tenuta without sealing ring
Vedi: cap. C per i dettagli di assemblaggio See: chap. C for assembly details

AB10710 REVISION DATE: 05/16 DOC. CA270410 CA449547 DP-3

DATI PRODOTTO
PRODUCT DATA Mod. 20.16-1640

Notes

CA449547 DP-4 REVISION DATE: 05/16 DOC. CA270410 AB10710

Mod. 20.16-1640

Indice Index

INFORMAZIONI SULLA SICUREZZA . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . 3

Indicazioni generali per la sicurezza . . . . . . . . . . 4 General safety recommendations . . . . . . . . . . . 4
Informazioni per la sicurezza . . . . . . . . . . . . . . . 5 Safety information . . . . . . . . . . . . . . . . . . . . . . . 5
Precauzioni generali . . . . . . . . . . . . . . . . . . . . . . 8 General precautions . . . . . . . . . . . . . . . . . . . . . . 8

INFORMAZIONI GENERALI . . . . . . . . . . 17 GENERAL INFORMATION . . . . . . . . . . 17

Utilizzo del manuale . . . . . . . . . . . . . . . . . . . . . 18 Manual use . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Proprietà delle informazioni . . . . . . . . . . . . . . . 19 Information property . . . . . . . . . . . . . . . . . . . . . 19
Convenzioni e definizioni . . . . . . . . . . . . . . . . . 20 Agreements and definitions . . . . . . . . . . . . . . . 20
Indicazioni generali . . . . . . . . . . . . . . . . . . . . . . 24 General description . . . . . . . . . . . . . . . . . . . . . 24
Indicazioni speciali . . . . . . . . . . . . . . . . . . . . . . 25 Special recommendations . . . . . . . . . . . . . . . . 25

CARATTERISTICHE GENERALI . . . . . . 33 GENERAL SPECIFICATIONS . . . . . . . . 33

Uso previsto . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Identificazione del prodotto . . . . . . . . . . . . . . . . 34 Product identification . . . . . . . . . . . . . . . . . . . . 34
Descrizione generale . . . . . . . . . . . . . . . . . . . . 36 General description . . . . . . . . . . . . . . . . . . . . . 36
Caratteristiche Tecniche . . . . . . . . . . . . . . . . . . 37 Technical Features . . . . . . . . . . . . . . . . . . . . . 37
Manutenzione e cambio olio . . . . . . . . . . . . . . . 39 Maintenance and oil change . . . . . . . . . . . . . . 39
Grasso al montaggio . . . . . . . . . . . . . . . . . . . . . 44 Grease in assembly . . . . . . . . . . . . . . . . . . . . . 44
Adesivi e coppie di serraggio . . . . . . . . . . . . . . 45 Adhesives and tightening torques . . . . . . . . . . 45

PROCEDURE SPECIALI . . . . . . . . . . . . 49 SPECIAL OPERATIONS . . . . . . . . . . . . 49

Registrazione del precarico cuscinetti differenziale e Differential bearings preload and bevel gear pair
del gioco coppia conica . . . . . . . . . . . . . . . . . . . 50 backlash adjustment . . . . . . . . . . . . . . . . . . . . 50
Precarico dei cuscinetti pignone . . . . . . . . . . . . 60 Pinion bearings preload adjustment . . . . . . . . 60
Convergenza/angolo di sterzata . . . . . . . . . . . . 71 Toe-in/steering angle . . . . . . . . . . . . . . . . . . . . 71
Prove dopo montaggio . . . . . . . . . . . . . . . . . . . 78 Testing after assembly . . . . . . . . . . . . . . . . . . . 78

RICERCA GUASTI . . . . . . . . . . . . . . . . . 79 TROUBLESHOOTING . . . . . . . . . . . . . . 79

Controllo ed esame dei guasti . . . . . . . . . . . . . 82 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnosi per problemi all'assale . . . . . . . . . . . . 86 Axle problem and diagnosis . . . . . . . . . . . . . . . 87

AB10710 REVISION DATE: 05/16 DOC. CA270410 PAG. 1

 Mod. 20.16-1640

Notes

PAG. 2 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INFORMAZIONI SULLA SICUREZZA
Mod. 20.16-1640 SAFETY INSTRUCTIONS

A INFORMAZIONI SULLA
SICUREZZA

A SAFETY INSTRUCTIONS

AB10710 REVISION DATE: 05/16 DOC. CA270410 A PAG. 3

INDICAZIONI GENERALI PER LA SICUREZZA
GENERAL SAFETY RECOMMENDATIONS Mod. 20.16-1640

A.1 Indicazioni generali per la A.1 General safety

sicurezza recommendations

Þ AV VERTENZ A prima di iniziare qualsiasi Þ W A R N I N G before proceeding with any

tipo di operazione leggere attentamente questo operations please read this chapter very carefully.
capitolo.

Fig. 1

Fig. 2

Assicurati di aver letto e compreso tutto il manuale di Make sure to read and comprehend all the
manutenzione (ordinaria e straordinaria) prima di maintenance manual (ordinary and extraordinary)
intervenire sul prodotto. before start the repair operations.
Seguire scrupolosamente TUTTE le istruzioni nel Follow with care ALL the instructions in this document,
seguente documento, è vietato utilizzare scorciatoie it is forbidden to use simplified procedure to curtail the
per abbreviare i tempi di lavoro. working time.

Precauzioni per la sicurezza: Safety precautions:

Il corretto uso e la corretta riparazione dei prodotti Correct use and repair of CARRARO DRIVE TECH
CARRARO DRIVE TECH e dei loro componenti sono products and of their components is very important for
molto importanti per la sicurezza e l'affidabilità. safety and reliability.
Le procedure raccomandate e descritte in questo Recommendations and all described procedures given
manuale sono testate, quindi sono effettivi metodi in this manual have been experimented and hence are
operativi. Seguire strettamente ogni procedura facendo effective operational methods. Please follow every
uso sia del testo che delle illustrazioni. procedure. Use the text as well as the illustrations.
Alcune di queste procedure mostrano l'uso di appositi Certain procedures show use of special tools, designed
strumenti progettati perché le operazioni vengano so that the operations can be carried out in a clear and
condotte in modo chiaro e corretto. correct manner.
Alcuni strumenti specifici devono essere usati dove Special tools must be used when a particular operation
necessario per eseguire determinate operazioni. is being carried out.
E' impossibile trattare ogni metodo di lavoro o tutte le It is impossible to advise every working method or know
possibili metodologie per svolgerlo e le rischiose all possible methodologies for carrying it out or to
conseguenze di ognuna, perciò chi usa procedure o predict risky consequences of each operation. Hence,
strumenti non consigliati deve sapere che la sicurezza performing procedures or using instruments which
dell'operatore e del veicolo saranno messi a have not been advised could be dangerous for the
repentaglio. operator/mechanic as well as the vehicle.

Seguire TUTTE le istruzioni di sicurezza! Follow ALL safety instructions!

Seguite i suggerimenti e le raccomandazioni per Follow the DO’s and DON’T’s to operate in total safety.
operare in sicurezza. Unauthorized changes could endanger the functioning,
Modifiche non autorizzate possono compromettere il work safety and machine lifespan.
funzionamento, la sicurezza d'impiego e la durata della If you do not understand any instruction in this manual,
macchina. contact the nearest Carraro Drive Tech agent.
Se non comprendete qualche istruzione in questo
manuale, contattate il rappresentante Carraro Drive
Tech a voi più vicino.

A.1 PAG. 4 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INFORMAZIONI PER LA SICUREZZA
Mod. 20.16-1640 SAFETY INFORMATION

A.2 Informazioni per la sicurezza A.2 Safety information

Normativa di riferimento Reference safety standards

Le informazioni per la sicurezza presenti in questo The safety information in this manual follows the
manuale seguono le direttive contenute nelle norme recommendations of the main guidelines for the
ISO (Organizzazione Internazionale per la security ISO (International Standards Organization)
Standardizzazione) e ANSI (Istituto Nazionale and ANSI (American National Standards Institute),
Americano per gli Standard), in particolare: especially:
- ISO 3864-2 [2004] - ISO 3864-2 [2004]
- ANSI Z535.6 [2006] - ANSI Z535.6 [2006]
- ANSI Z535.3 (quando si utilizzano rappresentazioni - ANSI Z535.3 (for graphic representation intended to
grafiche senza parole come avvisi di sicurezza) convey a safety message without the use of words)
- ANSI Z535.4 (dove si richiamano simboli e/o etichette - ANSI Z535.4 (to explain the symbols and/or labels
presenti sulle macchine) applied to equipment)

Identificazione delle informazioni sulla sicurezza Recognize safety information

Le informazioni sulla sicurezza sono costituite da tre The safety information is composed of three main
elementi principali: elements:
1) simbolo di allarme 1) safety alert symbol
2) termine di segnalazione 2) signal word
3) messaggio di sicurezza 3) safety messages

il simbolo di allarme per la sicurezza è semplicemente The safety alert symbol is simply an exclamation mark
un punto esclamativo (!) all’interno di un triangolo. (!) inside of a triangle.
Nelle seguenti figure è rappresentato secondo la This symbol is represented in the following figures as
normativa ISO 3864 (Fig. 3) e secondo ANSI Z535.6 comply the ISO 3864 standard (Fig. 3) and the ANSI
(Fig. 4); in questo manuale le due rappresentazioni Z535.6 standard (Fig. 4); in this manual the two graphic
sono equivalenti. representation have the same significance.
Quando trovate questo segnale sulla macchina o sul Whenever you find it in the manual or see it on the
manuale, siete avvisati del pericolo potenziale di machine, you are being warned about potential danger
incidenti o danni alla persona. of accidents or harm to personnel.

Fig. 3

Fig. 4

Il termine di segnalazione è una parola chiave The safety signal word is a key word (DANGER,
(PERICOLO, AVVERTENZA, ATTENZIONE, AVVISO) WARNING, CAUTION, NOTICE) and it’s used with the
utilizzata insieme al simbolo di allarme in presenza di symbol for the security alert whenever there is a risk to
rischio per le persone e richiama l’attenzione sul people. This word calls attention to a safety message
messaggio (o messaggi) di sicurezza seguente o su (or messages) or a property damage message (or
possibili danni materiali ed assegna un livello o classe messages) and designates a degree or level of hazard
di pericolo al rischio che si corre. seriousness.
Nota: può essere utilizzato senza simbolo di allarme Note: can be used without safety alarm symbol where
per identificare la possibilità di soli danni materiali. alerts you if only damage materials is possible.

Vedi: tab. 1 e tab. 2 alla pagina seguente per una chiara See: tab.1 and tab. 2 in the next page to fully
comprensione dei termini segnaletici. understanding signal words.

AB10710 REVISION DATE: 05/16 DOC. CA270410 A.2 PAG. 5

INFORMAZIONI PER LA SICUREZZA
SAFETY INFORMATION Mod. 20.16-1640

Il messaggio di sicurezza segue il termine segnaletico Safety message is a word message that provides
e contiene le seguenti informazioni primarie: information primarily about:
- il tipo e l’origine del pericolo - the nature of hazardous situation
- le conseguenze possibili - the consequences if the hazard is not avoided
- i comportamenti necessari ad eliminare o ridurre il - methods for avoiding a hazardous situation (for
rischio (per esempio: indossare un’adatto Dispositivo di example: wear suitable Personal Protective Equipment,
Protezione Individuale, DPI). PPE)
Il messaggio di sicurezza può anche indirizzare il lettore The safety message can direct readers to such
al luogo dove tali informazioni sono esposte. information.
Il testo del messaggio di sicurezza può essere Safety symbols and other graphics may be used to
completato o sostituito del tutto o in parte da supplement or substitute for part or all of a word
rappresentazioni grafiche esplicative. message.

A.2.1 Significato dei termini segnaletici A.2.2 Understanding signal words

Ogni termine segnaletico definisce la classe di Each signal word defines the class of danger according
pericolosità secondo la normativa ANSI Z535.6-2006 to ANSI Z535.6-2006 as specified in the table below.
come specificato nella tabella seguente. Note: the signal words are arranged in descending
Nota: i termini sono disposti in ordine di pericolosità order of danger.
decrescente.

Tab. 1 Termini segnaletici/Livello di rischio Tab.1 Signal words/Hazard level

Gravi danni a persone

P ERICOLO Serious personal injury
max max
DANGER
Livello di rischio

AV VERTENZA
Hazard level

Possibili gravi danni a persone Possible serious personal injury

WARNING
Possibili danni moderati a persone
ATTENZIONE Possible moderate personal injury
CAUTION
Possibili danni materiali min AVV IS O min Possible product damages
NOTICE

Tab. 2 Significato dei termini segnaletici Tab. 2 Meaning of signal words

Segnala una situazione di pericolo che, se Indicates a hazardous situation which, if not
non evitata, comporta morte o gravi lesioni P ERICOLO avoided, will result in death or serious injury.
fisiche. L’utilizzo di questo termine è limitato DANGER This signal word is to be limited to the most
alle situazioni di estremo pericolo. extreme situations.
Segnala una situazione di pericolo che, se
non evitata, può comportare morte o gravi
AV VERTENZA Indicates a hazardous situation which, if not
WARNING avoided, could result in death or serious injury.
lesioni fisiche.
Segnala una situazione di pericolo che, se Indicates a hazardous situation which, if not
non evitata, può comportare da leggere
A T T E N Z I O N E avoided, could result in minor or moderate
lesioni fisiche a lesioni medio-gravi. (*) CAUTION injury. (*)
Segnala una situazione di pericolo che non Is the preferred signal word to address
comporta danni alle persone ma solo danni AVV IS O practices not related to personal injury.
materiali per il prodotto o per l’ambiente. Può NOTICE The safety alert symbol shall not be used with
essere utilizzato senza il simbolo di allarme. this signal word.
(*) Secondo ANSI Z535.6-2006 è possibile utilizzare (*) Comply the ANSI Z535.6-2006 the signal word
ATTENZIONE senza il segnale di allarme al posto di CAUTION may also be used without the safety alert
AVVISO; per maggiore chiarezza questa convenzione symbol as an alternative to NOTICE; this is not applied in
non viene utilizzata in questo manuale. this manual to avoid confusion.

A.2 PAG. 6 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INFORMAZIONI PER LA SICUREZZA
Mod. 20.16-1640 SAFETY INFORMATION

A.2.3 Esempi applicativi A.2.4 Application examples

Nel seguito sono illustrate delle tipiche applicazioni Some typical applications of safety information that you
delle informazioni di sicurezza che è possibile trovare can find in this manual are explained in the following
in questo manuale. figure.
Nota: nel caso in cui vengano dati in gruppo una serie Note: where grouped safety messages are listed, one
di messaggi di sicurezza, un solo simbolo di sicurezza symbol is used before the group/section of these
viene utilizzato prima di tale gruppo o della relativa messages according to ANSI Z535.6.
sezione, in accordo con quanto specificato dalla
normativa ANSI Z535.6.

AB10710 REVISION DATE: 05/16 DOC. CA270410 A.2 PAG. 7

PRECAUZIONI GENERALI
GENERAL PRECAUTIONS Mod. 20.16-1640

A.3 Precauzioni generali A.3 General precautions

In ogni movimento dovranno essere osservate le norme Observe safety instructions, accident prevention rules
sulla prevenzione infortuni, tutte le regole generali di and all general safety regulations in each and every
sicurezza e di medicina del lavoro. step at work.
Prima di procedere nelle operazioni di manutenzione o Before going ahead with maintenance or repair work
sistemazione di eventuali problemi, assicurarsi del ensure that all the tools, the supporting bench, stands,
buon stato e del buon funzionamento delle attrezzature levers, extractors and spanners are in good condition
quali banchi di sostegno, cavalletti, martelli, leve, so that the work can be carried out easily.
estrattori e chiavi apposite facilitando le operazioni da Risks to various parts and components will also be
svolgere in modo ottimale riducendo i rischi sia per gli reduced in this way and working condition for the
organi ed i componenti del prodotto che della incolumità operator will also be safer.
dell'operatore. CARRARO DRIVE TECH SpA declines any
Tutte le modifiche arbitrarie apportate al prodotto responsibility in case of an accident or damage
sollevano la CARRARO DRIVE TECH SpA da ogni resulting due to changes made arbitrarily on product.
responsabilità per qualsiasi danno o incidente. The product is used for any other purpose different from
Il prodotto, se utilizzato in un impiego diverso da quello the one foreseen, than CARRARO DRIVE TECH SpA
previsto, è da considerarsi soggetto a "uso non declines any responsibility.
previsto". CARRARO DRIVE TECH SpA declina ogni In this case all consequences will be at the customer’s
responsabilità per danni o incidenti risultanti da un uso expense.
diverso da quello previsto; tali conseguenze saranno a
carico esclusivo del cliente.

Þ ATTE NZIONE Þ CAUTION

Durante la manutenzione e riparazione: During the maintenance and repair operations make
sure that
• l’assale deve sempre essere controllato e
sorvegliato da personale autorizzato • the axle must always checked and overseen by
authorized staff
• in caso di manomissione delle parti costituenti
l’assale, verificarne il corretto funzionamento e • in case of axle parts tampering, verify the correct
provvedere al ripristino, quando necessario working of the axle and replace them, if necessary
• ogni modifica ai segnali di sicurezza e/o • every modification of the safety signs and/or
decalcomanie deve sempre essere concordato transfers and their relative tamper must be always
preventivamente con il costruttore previously agreed with the manufacturer

AVVISO NOT ICE

• durante le lubrificazioni e ingrassaggi non • during the lubricating and greasing operations, do
confondere i tempi di manutenzione ordinaria; not confuse the ordinary maintenance times; during
durante la fase di serraggio non confondere le the tightening operations do not confuse the
rispettive coppie di serraggio tightening torques
• durante l’utilizzo dell’assale tappi, sfiati, viteria e • during the axle use plugs, breathers, screws and
relativo serraggio devono essere concordi a quanto tightening torques must be in agreement with the
prescritto regulation

Þ PER IC OLO Þ DANGER

• non utilizzare prodotti infiammabili come etere • do not use inflammable products like ether, oil or
petrolio o benzina rettificata per la pulizia delle parti gasoline for the parts cleaning when the parts are at
quando le stesse sono a temperature elevate o sotto elevated temperature or under the sun rays
l’esposizione di raggi solari: potrebbero essere exposure: it may causes fire
causa d’incendio
• deep impacts may damage the axle mechanical-
• urti violenti potrebbero danneggiare i componenti magnetic-electrical parts
meccanici-magnetici-elettrici dell’assale
• do not smoke-drink-eat during the assembly-
• non fumare-bere-mangiare durante le operazioni di disassembly-maintenance operations to avoid a
disassemblaggio-assemblaggio-manutenzione: possible contamination of the mechanical parts
sono possibili eventuali contaminazioni agli organi
meccanici.

A.3 PAG. 8 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECAUZIONI GENERALI
Mod. 20.16-1640 GENERAL PRECAUTIONS

Norme per la manutenzione in sicurezza Safety maintenance rules

1 Operare sempre in ambiente pulito e asciutto. 1 Operate always in a clean and dry environment.
2 Pulire con cura l’ambiente di lavoro e la macchina 2 Clean carefully the working environment and the
su cui si opera sia prima che durante la machine before carry out the maintenance
manutenzione (Fig. 5). operations (Fig. 5).
3 Utilizzare solo prodotti di pulizia conformi alle 3 Use only cleaning product in agreement with the
specifiche di legge vigenti e sempre nelle modalità regulations and always use them in the prescribed
indicate dalle istruzioni d’uso del produttore. way.
4 Non inalare sostanze chimiche in concentrazioni 4 Do not inhale chemical substances in dangerous
pericolose per la salute (Fig. 6); ventilare gli concentration for the health care (Fig. 6); ventilate
ambienti in cui si utilizzano solventi con componenti the environments in which sprays and solvents,
chimici volatili o spray. with volatile chemical substances, are used.

Fig. 5

Fig. 6

5 Usare indumenti e protezioni adatte allo scopo 5 Wear suitable clothing and protection such as
come: tuta, guanti protettivi e cuffie (Fig. 7). overalls, gloves and ear safety devices (Fig. 7).
Þ AV VERTENZA Þ WARNING
Gli occhiali di sicurezza devono essere indossati Safety goggles must always be worn while carrying
sempre durante l’esecuzione di tutte le operazioni di out every assembling or disassembling operations
montaggio o smontaggio (Fig. 8). (Fig. 8).

Fig. 7

Fig. 8

6 Usare protezioni auricolari appropriate a 6 Use suitable ear protection, like ear plugs, to keep
salvaguardare l'udito, come tappi o cuffie per le out noise and prevent injury to the ears.
orecchie contro rumori molesti o fastidiosi. Una A prolonged exposure to noise can damage your
prolungata esposizione al rumore può danneggiare hearing.
l'udito 7 The operator must be very careful with the
7 Le attrezzature richiedono la piena attenzione equipment. Do not use headphones to listen music
dell'operatore. Non usare cuffie per ascoltare while you are working on the product or on the
musica mentre si interviene sul prodotto o gruppo. group.

AB10710 REVISION DATE: 05/16 DOC. CA270410 A.3 PAG. 9

PRECAUZIONI GENERALI
GENERAL PRECAUTIONS Mod. 20.16-1640

8 Non indossare sciarpe, cravatte o altri indumenti 8 Do not wear slings, ties or other pending clothes.
pendenti. Assicurare i capelli lunghi dietro la testa e/ Tie long hair behind the head and/or wear a
o indossare una cuffia protettiva. protective cap.
9 Non indossare anelli, bracciali, collane o altri 9 Do not wear rings, armlets, necklaces or other
oggetti metallici che sono molto pericolosi in metal objects that are dangerous when current is
presenza di corrente elettrica. present.
10 Predisporre sempre le dotazioni di pronto 10 Predispose always the first aid equipment in
intervento previste dalla normativa di sicurezza per agreement with the working environments
gli ambienti di lavoro, come la cassetta di pronto regulations, like the first aid kit (Fig. 9).
soccorso (Fig. 9). 11 Keep the phone numbers of a doctor, an
11 Tenere in evidenza il n° telefonico di medico, ambulance, a hospital and the fire department
ambulanza, ospedale e vigili del fuoco presso il within reach near the telephone set (Fig. 10).
proprio telefono (Fig. 10). In case of accident it is indispensable to quickly ask
In caso d’infortunio è indispensabile richiedere for a medical intervention.
rapidamente l’intervento del medico.

Fig. 9

Fig. 10

12 Tenere lontani mani, piedi, indumenti dalle parti in 12 Keep your hands, feet and clothing away from
movimento delle attrezzature. moving parts of the tool machines.
Rimanere a distanza di sicurezza dalla macchina se Keep the safety distance from the machine, if it is
in movimento, come durante le operazioni di moving, like during the testing operations (Fig. 11).
collaudo (Fig. 11). 13 Light properly the working area by using devices in
13 Illuminare adeguatamente l’area di lavoro con agreement with the safety regulations (Fig. 12).
strumenti che rispettino la normativa di sicurezza
(Fig. 12).

Fig. 11

Fig. 12

A.3 PAG. 10 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECAUZIONI GENERALI
Mod. 20.16-1640 GENERAL PRECAUTIONS

14 Durante le operazioni di manutenzione è 14 During the maintenance operations it is strictly

assolutamente vietato accendere fiamme libere forbidden to light free flames (Fig. 13) and smoking
(Fig. 13) e fumare (Fig. 14). (Fig. 14).

Fig. 13

Fig. 14

15 Essere sempre pronti per bloccare eventuali 15 Always be prepared for fires. Keep the extinguisher
principi di incendio. Prima di iniziare qualsiasi within reach. Before start any maintenance
operazione individuare con certezza la posizione operation identify the extinguisher nearest to the
dell’estintore più vicino all’area di lavoro e delle working area and the prescribed fire regulations
dotazioni antincendio prescritte (Fig. 15). (Fig. 15).

Fig. 15

Fig. 16

16 L’ambiente di lavoro deve sempre essere ben 16 The working environment must be always well
aerato con i sistemi previsti dalla normativa relativa aired by using devices in agreement with the safety
agli ambienti di lavoro. regulations.
Se non sono presenti condotti di aerazione, aprire le If local vents are not present, open doors the
porte e finestre dell’area di lavoro. windows in the working area.
Evitare di respirare polvere e fumi, dato che Do not inhale dust and fumes, they can cause
possono causare malattie e portare alla morte. Non sickness or death. Do not inhale toxic substances
inalare sostanze potenzialmente tossiche used during the product maintenance. If necessary
necessarie alla manutenzione del prodotto. Se use a certified respirator.
necessario utilizzare un respiratore certificato. All the CARRARO DRIVE TECH SpA products are
Tutti i prodotti CARRARO DRIVE TECH SpA in agreement with the Italian legislation and with
soddisfano i requisiti imposti dalla legislazione the European Community technical requirements.
Italiani e dalla Comunità Europea.

AB10710 REVISION DATE: 05/16 DOC. CA270410 A.3 PAG. 11

PRECAUZIONI GENERALI
GENERAL PRECAUTIONS Mod. 20.16-1640

A.3.1 Eliminazione dei rischi residui A.3.2 Residual risks elimination

Si raccomanda di seguire scrupolosamente le seguenti It is recommended to follow with care the following
indicazioni generali, che sono molto importanti per general indications, that are important to prevent
evitare danni a persone e cose. damages to persons and things.

Þ PER IC OLO Þ DANGER

Rischio di schiacciamento e cesoiamento dovuto alla Risk of squashing and shearing due to the presence
presenza di elementi in movimento. of moving parts.

Fig. 17

Fig. 18

Þ AVV ERTE NZA Þ WARN IN G

Eseguire tutte le operazioni di manutenzione a Carry out all maintenance operations when the
macchina ferma. Non lubrificare, manipolare o machine is stationary. Do not lubricate, handle or
registrare il gruppo con parti meccaniche in adjust the group with mechanical parts in movement.
movimento.

Fig. 19

Fig. 20

Þ PER IC OLO Þ DANGER

Rischio di schiacciamento dovuto al movimento di Squashing risk due to the machines or devices
macchinari o attrezzature nell’area di lavoro. movement in the working area.
• Questi rischi residui e le procedure per eliminarli • These residual risks and the procedure to eliminate
completamente, sono evidenziati dettagliatamente them completely, are described in detail in the
nelle procedure di montaggio e smontaggio. Seguire assembly/disassembly procedures. During the
attentamente, durante la manutenzione, tutte le maintenance operations, follow carefully all the
procedure di sicurezza indicate nel manuale. security procedure indicated on the repair manual.

Þ AVV ERTE NZA Þ WARN IN G

Non operare con attrezzature difettose o non adatte Do not carry out any operation by using faulty or not
all’intervento da eseguire. suitable tools.
• Predisporre sempre attrezzi ed utensili • Always predispose the tools and the devices on a
ordinatamente su un adatto banco di lavoro. suitable workbench, in an orderly way.

A.3 PAG. 12 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECAUZIONI GENERALI
Mod. 20.16-1640 GENERAL PRECAUTIONS

• Non utilizzare come piani d’appoggio superfici che • Do not use unstable shelves or not flat surfaces as
non siano piane o ben stabili. workbench.
• Il gruppo su cui si opera e gli attrezzi che si utilizzano • The serviced group and used tools must be always
devono sempre essere disposti in posizione stabile, arranged in a stable position, in order to avoid all the
evitare tutte le situazioni di equilibrio incerto. unstable equilibrium situations.

Þ PE RICOLO Þ DANGER
Rischio dovuto alla violenta espulsione di oggetti dalla Risk due to violent ejection of objects from the
macchina. machine
• Questi rischi residui e le procedure per eliminarli
completamente, sono evidenziati dettagliatamente • These residual risks and the suitable relative
nelle procedure di montaggio e smontaggio. Seguire procedures to eliminate them completely are
attentamente, durante la manutenzione, tutte le pointed out, in detail, in the assembly and
procedure di sicurezza indicate nel manuale. disassembly procedures. During maintenance,
follow carefully all the safety procedures indicated in
the manual.

Fig. 21

Fig. 22

Þ PE RICOLO Þ DANGER
Rischio dovuto alla caduta o allo sganciamento di Risk due to falling loads or unhooked objects.
oggetti.

Fig. 23

Fig. 24

• Questi rischi residui e le procedure per eliminarli • These residual risks and the procedure to eliminate
completamente, sono evidenziati dettagliatamente them completely, are described in detail in the
nelle procedure di montaggio e smontaggio. Seguire assembly/disassembly procedures. During the
attentamente, durante la manutenzione, tutte le maintenance operations, follow carefully all the
procedure di sicurezza indicate nel manuale. security procedure indicated on the repair manual.
• Prima di ogni operazione assicurare le parti pesanti • Before every operation secure all the heavy parts by
con adeguati sistemi di supporto, in modo da evitare using suitable supporting devices, in order to avoid
cadute accidentali e movimenti improvvisi. casual falls and unexpected moves.

AB10710 REVISION DATE: 05/16 DOC. CA270410 A.3 PAG. 13

PRECAUZIONI GENERALI
GENERAL PRECAUTIONS Mod. 20.16-1640

• Se il gruppo è sostenuto solamente da funi sospese, • If the group is only supported by hanging ropes, do
non lavorare sotto il carico sospeso. not work under the pending load.
• Utilizzare sistemi di sollevamento a norma di legge, • The used lifting devices must be in agreement with
in perfette condizioni, verificati e correttamente the current regulations, in perfect conditions, verified
manutenzionati. and correctly serviced.

Þ PER IC OLO Þ DANGER

Rischio dovuto all’inalazione di gas nocivi che si Risk due to inhalation of poison gases that can be
possono sviluppare scaldando le vernici durante produced by heating the varnishes during any
eventuali saldature. welding.
• Utilizzare postazioni di lavoro dotate di sistemi di • Use work stations equipped with dust and fume
evacuazione di polveri e fumi. discharging systems.
• Prima di saldare o riscaldare, rimuovere la vernice • Before welding or heating a part, remove the paint,
se presente. if present.
• Non usare spray o altri prodotti infiammabili vicino • Do not use sprays or other inflammable substances
alla zona dove si sta saldando o in prossimità di fonti near the welding area or near heat sources.
di calore.

Fig. 25

Fig. 26

Þ ATTE NZIONE Þ CAUTION

Rischio dovuto all’inquinamento da sostanze Risk due to the pollution by dangerous substances.
pericolose. Lubrificanti esausti e prodotti residui delle Exhausted lubricant and the residual products of the
operazioni di pulizia e verniciatura sono considerati cleaning/painting operations are considerate special
rifiuti speciali waste.
• Utilizzare gli appositi contenitori per la raccolta dei • During the CARRARO DRIVE TECH SpA products
rifiuti liquidi e solidi durante la manutenzione dei maintenance operations, use the proper container
prodotti CARRARO DRIVE TECH SpA. for the liquid and for the solid waste raising.
Smaltire i rifiuti liquidi e solidi raccolti secondo le Dispose all liquid and solid waste in agreement with
normative vigenti nell’ambiente di lavoro in cui si the current working environment regulations.
opera.

A.3 PAG. 14 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECAUZIONI GENERALI
Mod. 20.16-1640 GENERAL PRECAUTIONS

Þ PE RICOLO Þ DANGER
Rischio di incendio e scoppio dovuto ai solventi Risk of fire and explosion due to the solvents used
utilizzati e all’olio presente. and to the oil in the machine.

Fig. 27

Fig. 28

• Tenere lontano dalla zona di lavoro ogni fonte di • Keep away any heat sources from the working area.
calore.
• When solvents or paint removers are used, they
• Quando si usano solventi o svernicianti, rimuoverli should be removed with soap and water, before
con acqua e sapone prima di saldare. welding.
• Rimuovere i contenitori di solvente, sverniciante o • Remove any containers of solvent, paint remover or
altri prodotti infiammabili dall'area di lavoro. any other inflammable products from the working
area.

Þ AV VERTENZA Þ WARNING
Rischio di ustione dovuto alla presenza di elementi Burn risk due to elevated temperature of liquid or solid
solidi o fluidi ad elevata temperatura. elements.

Fig. 29

Fig. 30

• Indossare le protezioni individuali di sicurezza, a • Wear the personal protective clothes, in agreement
norma di legge, adeguate al tipo di operazione da with the current regulations, adequate to the type of
mettere in pratica. operation carried out.
• Verificare il corretto serraggio di tappi e connessioni • Verify the plugs and connectors correct tightening
prima di avviare la macchina o mettere i circuiti in before start up the machine or before give pressure
pressione to the circuits.

AB10710 REVISION DATE: 05/16 DOC. CA270410 A.3 PAG. 15

PRECAUZIONI GENERALI
GENERAL PRECAUTIONS Mod. 20.16-1640

Þ AVV ERTE NZA Þ WARN IN G

Rischio dovuto all’espulsione di fluidi caldi o in Risk due to boiling fluids ejection or pressured fluids
pressione. ejection
• Indossare le protezioni individuali di sicurezza a • Wear the personal protective clothes, in agreement
norma di legge. with the current regulations

Fig. 31

Fig. 32

• Evitare la ricerca di eventuali perdite di fluido da • Do not search possible liquid loss on pressured
condotti in pressione con le mani o altre parti del pipes by using hands or others body parts (Fig. 33),
corpo (Fig. 32), utilizzare le attrezzature preposte o use the prescribed devices or not inflammable
comunque elementi non infiammabili (Fig. 33). elements (Fig. 33).

Fig. 33

A.3 PAG. 16 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INFORMAZIONI GENERALI
Mod. 20.16-1640 GENERAL INFORMATION

B INFORMAZIONI GENERALI

B GENERAL INFORMATION

AB10710 REVISION DATE: 05/16 DOC. CA270410 B PAG. 17

UTILIZZO DEL MANUALE
MANUAL USE Mod. 20.16-1640

B.1 Utilizzo del manuale B.1 Manual use

Destinatari End users
• Installatore • Installer
• Riparatore specializzato • Qualified technician
• Manutentore • Maintenance operator

Manutenzione e riparazione Maintenance and repair

PRENDERE VISIONE DI TUTTO IL MANUALE poiché CONSULT THIS MANUAL THOROUGHLY, as proper
il buon funzionamento ed il rendimento degli organi functioning and good efficiency of mechanical organs
meccanici dipendono principalmente da una costante e depends mostly on constant and correct routine
corretta manutenzione e assicurano la durata e maintenance ensuring product integrity and expected
l'integrità del prodotto. life duration.

Nell'eventualità di guasti od anomalie il tempestivo In case of any damages or anomalies, quick

intervento da parte di personale autorizzato da Carraro intervention of trained and highly qualified operators
Drive Tech SpA (in possesso dell’attestato di idoneità) authorized (with certificate) by Carraro Drive Tech SpA
garantisce una durata più lunga del prodotto, evitando ensure the longest life of product and avoid future
danni maggiori nel tempo provocati da una riparazione impairment caused by not authorized repairing.
non autorizzata. Important: Carraro warranty does not cover every
Importante: la garanzia non risponde di eventuali injury to personnel and damage to product caused by
danni provocati a persone o cose causati da riparazioni maintenance operations of not authorized personnel
effettuate da personale non autorizzato e/o non and/or by operations not in compliance with Carraro
conformi alle specifiche e avvertenze Carraro, safety regulations and prescribed procedures.
riguardanti la sicurezza e le procedure di manutenzione
contenute in tutte le sezioni del manuale

Le procedure per lo smontaggio/montaggio consentono The disassembly/assembly procedures have been

di eseguire la revisione totale del prodotto e sono outlined for a total product overhauling. They have also
descritte in sequenza con l’ausilio di illustrazioni, per been described in sequence through photographs with
una guida completa e sicura all’esecuzione di ogni relevant explanation for specific interventions, thus
operazione. obtaining a complete and safe guide for each and every
phase of an operation.

Nella descrizione delle operazioni si presuppone che Operation description presumes that the axle has
l’assale sia stato rimosso dal veicolo. Per la rimozione already been removed from the vehicle. To remove the
dell’assale dal veicolo consultare il manuale del axle from the vehicle refer to manual provided from
costruttore del veicolo. vehicle manufacturer.

B.1 PAG. 18 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PROPRIETÀ DELLE INFORMAZIONI
Mod. 20.16-1640 INFORMATION PROPERTY

B.2 Proprietà delle informazioni B.2 Information property

Questo manuale contiene informazioni di proprietà This manual should be considered confidential
riservata. Tutti i diritti sono riservati. information. All rights reserved.

Questo manuale non può essere riprodotto o No part of this manual may be reproduced, in any form
fotocopiato, tutto o in parte, senza il preventivo or by any means, without prior written permission of
consenso scritto di CARRARO DRIVE TECH SpA. CARRARO DRIVE TECH SpA Only the customer,
L’uso di questo materiale documentale è consentito whom the manual, together with the product, has been
solo al cliente a cui il manuale è stato fornito come issued to, is allowed to use this document, and only in
corredo del prodotto, e solo per scopi di uso, order to use, maintain and repair the unit.
manutenzione e riparazione.
CARRARO DRIVE TECH SpA declares that the subject
CARRARO DRIVE TECH SpA dichiara che le of this manual consists with the technical and safety
informazioni contenute in questo manuale sono specifications of the machine that the manual is
congruenti con le specifiche tecniche e di sicurezza referred to. The manufacturer shall not be held liable for
della macchina a cui il manuale si riferisce. Il direct or indirect damages to persons, things or animals
fabbricante non si assume alcuna responsabilità per due to an improper use of this document or of the
danni diretti o indiretti a persone, cose o animali, machine or to a different use of them, which does not
conseguenti all’uso di questo materiale documentale o comply with what is provided for in this manual.
della macchina in condizioni diverse da quelle previste.

Carraro Drive Tech Spa

Headquarters
Via Olmo, 37
35011 Campodarsego
Padova, Italy

AB10710 REVISION DATE: 05/16 DOC. CA270410 B.2 PAG. 19

CONVENZIONI E DEFINIZIONI
AGREEMENTS AND DEFINITIONS Mod. 20.16-1640

B.3 Convenzioni e definizioni B.3 Agreements and definitions

Convenzioni Agreements
Le illustrazioni nel manuale NON sono in scala quindi Illustrations like pictures, drawings and components of
NON sono attendibili valutazioni delle dimensioni e dei this manual are NOT in scale, because of limited space
pesi dei componenti basate sulle stesse. and editing limits, therefore they are NOT reliable to
Le illustrazioni hanno il compito di evidenziare le obtain values about size or weight.
corrette procedure da condurre sulla macchina e sui Illustrations are supposed to point out the correct
suoi componenti, per questo potrebbero non methods to working on the machine and its
rappresentare esattamente gli elementi di questa components, therefore they could not display exactly
macchina ma componenti meccanici simili. the same elements.

Definizioni Definitions
Lato sinistro (Sx): parte sinistra del gruppo vista nel Left side (Lh): it is the left side (left hand) of the unit
senso di marcia del veicolo (Fig. 1). considering the vehicle running conditions (Fig. 1).
Lato destro (Dx): parte destra del gruppo vista nel Right side (Rh): it is the right side (right hand) of the
senso di marcia del veicolo (Fig. 1). unit considering the vehicle running conditions (Fig. 1).

Direzione di marcia Fig. 1

Driving direction

Sx Dx
Lh Rh Sx Dx
Lh Rh

Lato pignone
Fig. 2 Pinion side

Solo per gli assali con pignone Only for axle with pinion
Lato sinistro assale: parte sinistra dell’assale Axle left side: it is the left side of the axle from pinion
guardandolo dall’albero del pignone verso l’ingranaggio shaft point of view toward the pinion bevel gear (Fig. 2).
conico (Fig. 2). Axle right side: it is the right side of the axle from
Lato destro assale: parte destra dell’assale pinion shaft point of view toward the pinion bevel gear
guardandolo dall’albero del pignone verso l’ingranaggio (Fig. 2).
conico (Fig. 2).

Convenzioni tipografiche Typographic agreements

Nota: informazioni importanti, evidenziate al di fuori del Note: the notes, pointed out externally to the text they
testo a cui si riferiscono. refer, include important information.
Importante: avvertenze importanti o istruzioni critiche Important: important warnings or critical instructions
la cui inosservanza può produrre danni alla macchina o whose inobservance may result in damage to the
alle apparecchiature collegate. machine or interconnected equipment.
Vedi: richiamo ad una sezione di questo documento o See: reference to a section of this document or other
ad altri documenti (come il manuale d’uso del veicolo) documents (such as the user manual of the vehicle)
con informazioni utili allo svolgimento delle operazioni with useful information to perform the operations
descritte. Nel caso di riferimenti a questo documento si described. In the case of references to this document is
indicherà il nome della sezione oppure il riferimento ad given the section name or a reference to a specific
una sezione specifica. section.
Per esempio: For example:
Vedi: Gruppo Freno, assemblaggio. >>> cercare il Gruppo See: Brake Group, assembly. >>> Look for the Brake Group in
Freno nell’indice di questo manuale e consultare la parte the index of this manual and consult the section: assembly.
relativa all’assemblaggio. See: D.8.2.12. >>> Go to Section D, paragraph 8, section 2,
Vedi: D.8.2.12. >>> Andare al capitolo D, paragrafo 8, sezione step 12 (step number is usually shown in the upper left of each
2, passo 12 (il numero del passo è solitamente indicato in alto figure).
a sinistra su ogni figura).

B.3 PAG. 20 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CONVENZIONI E DEFINIZIONI
Mod. 20.16-1640 AGREEMENTS AND DEFINITIONS

Unità di misura Measurements

Nel manuale si utilizzano le unità di misura del sistema This manual indicates all measurements in
internazionale (SI). Per la conversione al sistema International System (SI). Use the following conversion
anglosassone riferirsi alla seguente tabella. table to convert Imperial Measure.

Tabella di conversione unità di misura Conversion table of units of measurement

S .I . GB/USA SYSTEM
1 mm 0.03937 in
10 mm 0.3937 in
25.4 mm 1 in
6.4516 cm² 1 sq. in
1 m² 1550 sq. in
16.378 m² 1 cu. in
0.473 dm² 1 U.S. pint
1 l 61.02 cu. in
1 l 0.2642 U.S. gal
1.772 g 1 oz
0.4536 kg 1 lb
0.00070308 kg/mm² 1 lb/sq. in
1 bar 14.51 psi
1 kg.m 7.246 lb. ft
1(daN)= 10 (N)= 1,02 (kg.f) 2.24 lb. f

AB10710 REVISION DATE: 05/16 DOC. CA270410 B.3 PAG. 21

CONVENZIONI E DEFINIZIONI
AGREEMENTS AND DEFINITIONS Mod. 20.16-1640

Simbologia utilizzata nella descrizione delle Symbology used to describe maintenance (service
procedure di manutenzione (servizio e riparazione) and repair) procedures

SIMBOLO
DE SCRIZIONE DES CRIPTION
SYMBOL
ATTENZIONE/PERICOLO WARNING/DANGER
Seguire attentamente le istruzioni nel manuale Follow carefully all the manual instruction, in
per evitare di provocare danni a persone o order to avoid the arise of damages to things or
cose; seguire scrupolosamente le normative di persons; carefully follow the current security
sicurezza vigenti in relazione all’ambiente di regulations, in relationship/agreement with the
lavoro in cui si opera. operative working ambient.
Nota: la mancata osservanza delle indicazioni Note: do not follow carefully the Carraro
Carraro e/o delle normative di sicurezza può indications and/or current security regulations
causare gravi danni alle persone ed alla can causes serious damages to the persons or
macchina, tali danni non sono coperti da to the machines; these damages are not
garanzia. warranty covered.
RIMOZIONE/INSTALLAZIONE
REMOVE/INSTALL
Si applica a: anelli, guarnizioni e filtri.
Applicable to: seals, gaskets and filters.
L’utilizzo di ricambi NON originali Carraro
The NOT original Carraro spare parts use
comporta la decadenza della garanzia sulla
causes the loss of the machine warranty.
macchina.
Note: when this symbol is encountered, it is
Nota: in presenza di questo simbolo si
recommended to follow the described
raccomanda di seguire oltre alle procedure
procedure as well as the section B.5 warnings.
descritte anche le avvertenze in sezione B.5
CARICO/RABBOCCO OLIO OIL FILLING/OIL TOP-UP
SCARICO OLIO OIL DRAIN
Utilizzare solo i lubrificanti indicati in sezione C; Use only the prescribed lubricant, indicated on
l’utilizzo di prodotti non corrispondenti alle section C; the use of products that are not in
specifiche indicate comporta la decadenza accordance with the indicated specifications
della garanzia Carraro. involves the Carraro warranty decline.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered, it is
raccomanda di seguire oltre alle procedure recommended to follow the described
descritte anche le avvertenze in sezione B.5. procedure as well as the section B.5 warnings.
LUBRIFICAZIONE/INGRASSAGGIO LUBRICATION/GREASING
Utilizzare solo i lubrificanti indicati in sezione C; Use only the prescribed lubricant, indicated on
l’utilizzo di prodotti non corrispondenti alle section C; the use of products that are not in
specifiche indicate comporta la decadenza accordance with the indicated specifications
della garanzia Carraro. involves the Carraro warranty decline.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered, it is
raccomanda di seguire oltre alle procedure recommended to follow the described
descritte anche le avvertenze in sezione B.5. procedure as well as the section B.5 warnings.
REGOLAZIONE/MISURAZIONE ADJUSTMENTS/MEASUREMENTS
Si applica a: coppie di serraggio, precarichi e Applicable to: tightening torques, preloads and
giochi meccanici. mechanical backlash.
Seguire con estrema cura le istruzioni descritte Follow carefully the indicated instructions to
per ottenere il miglior risultato. obtain the best result.
Nota: la mancata osservanza delle indicazioni Note: do not follow carefully the Carraro
Carraro può comportare gravi danni alla indications can causes serious damages to the
macchina; tali danni non sono coperti da machine; these damages are not warranty
garanzia. covered.
ATTREZZATURE SPECIALI SPECIAL TOOLS
Si raccomanda l’utilizzo delle attrezzature It is recommended to use the special tools as
descritte senza ricorrere a sistemi non indicated into the repair manual; avoid the use
collaudati, che non possono garantire un of not-tested methods, that can not guarantee a
risultato ottimale. good result.

B.3 PAG. 22 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CONVENZIONI E DEFINIZIONI
Mod. 20.16-1640 AGREEMENTS AND DEFINITIONS

S IM BO L O
DESCRIZIONE DE SCRIP TION
SYMBOL
APPLICAZIONE DI ADESIVO O SIGILLANTE ADHESIVE OR SEALANT APPLICATION
Utilizzare solo i prodotti prescritti e indicati in Use only the prescribed product, indicated on
sezione C; l’utilizzo di prodotti diversi da quelli section C; the use of products that are not in
indicati comporta la decadenza della garanzia accordance with the indicated specifications
Carraro. involves the Carraro warranty decline.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered, it is
raccomanda di seguire oltre alle procedure recommended to follow the described
descritte anche le avvertenze in sezione B.5. procedure as well as the section B.5 warnings.
TRACCIATURA MARKING
Creare dei segni di riferimento oppure Create reference markings or comply with
rispettare i segni di riferimento presenti, available reference markings, which are
indispensabili per la corretta esecuzione delle essential for the proper execution of the repair
operazioni di riparazione. operations.
RISPETTARE IL VERSO DI MONTAGGIO RESPECT ASSEMBLY ORIENTATION
Gli elementi assemblati devono avere verso di The assembled elements must be oriented as
montaggio corrispondente a quello descritto e/ described in the relative procedure or as
o illustrato. indicated in the relative figure.
Nota: la mancata osservanza delle indicazioni Note: do not follow carefully the Carraro
Carraro può comportare gravi danni alla indications can causes serious damages to the
macchina, tali danni non sono coperti da machine; these damages are not warranty
garanzia. covered.
PULIRE ACCURATAMENTE THOROUGH CLEANING
Pulire con estrema cura le parti interessate alle Clean with care the parts involved in the
operazioni di manutenzione descritte. described maintenance procedure.
Nota: in presenza di questo simbolo si Note: when this symbol is encountered, it is
raccomanda di seguire oltre alle procedure recommended to follow the described
descritte anche le avvertenze in sezione B.5. procedure as well as the section B.5 warnings.
IMMETTERE FLUIDO IN PRESSIONE
APPLY PRESSURIZED FLUID
Osservare scrupolosamente le procedure
Follow with great care the indicated procedure
indicate e mettere in pratica tutti i
and follow all the security procedures in order
comportamenti di sicurezza atti a
to avoid damages to persons or things.
salvaguardare l’incolumità di persone e cose.

AB10710 REVISION DATE: 05/16 DOC. CA270410 B.3 PAG. 23

INDICAZIONI GENERALI
GENERAL DESCRIPTION Mod. 20.16-1640

B.4 Indicazioni generali B.4 General description

La macchina deve essere controllata e/o riparata solo The machine should be checked and/or repaired only
da personale tecnico specializzato che sia a by qualified technicians, acquainted with its peculiar
conoscenza delle sue particolari caratteristiche e delle features and well aware of all safety instructions.
relative norme di sicurezza (prevenzione infortuni).

Prima di svolgere qualsiasi operazione, pulire Before performing any operation it is advisable to carry
accuratamente il gruppo rimuovendo eventuali out unit cleaning accurately by removing oil/ grease
incrostazioni ed accumuli di terriccio e/o grasso. encrustations and accumulation.

Tutti gli organi meccanici smontati devono essere All disassembled mechanical parts must be cleaned
accuratamente puliti con prodotti adeguati, per evitare accurately with suitable products to avoid possible
possibili danni. Verificarne l'integrità, sostituendoli in damage. Parts should be replaced if damaged, worn
caso di danni, usura, incrinature, grippaggi o difetti che out, cracked, seized, etc. as they could affect proper
potrebbero comprometterne il buon funzionamento. working.
In particolar modo si deve verificare l'integrità dei Rotating parts (bearings, gears, shafts) and that of
componenti in movimento (cuscinetti, ingranaggi, hardware/fasteners (O-Rings, seal rings) should be
alberi) e degli organi di tenuta (anelli OR, anelli di examined carefully, as they are subject to intense
tenuta) e di fissaggio, che sono soggetti ad intense stress, wearing and ageing.
sollecitazioni, ad usura e invecchiamento. Note: in case of replacement of one part of the bevel
Nota: si ricordi che l’eventuale sostituzione di un gear set this operation requires the replacement of the
componente della coppia conica comporta la other part too.
sostituzione anche dell'altro.

Si raccomanda di sostituire ad ogni revisione o We highly advise to replace sealing parts (O-Rings,
riparazione gli organi di tenuta (anelli OR, anelli di seal rings, gaskets) during every teardown or repair.
tenuta, guarnizioni).

Utilizzare solo le parti di ricambio e la viteria indicate, Use appropriate spare parts, nuts and bolts to avoid any
inoltre usare utensili metrici per la viteria metrica e other problems. Moreover, use metric tools for metric
inglesi per la viteria inglese. nuts and bolts and Imperial tools for the others.

Come indicato, alcune operazioni sono distruttive per Some operations are destructive for removed
gli elementi rimossi. Leggere attentamente le components.
descrizioni delle varie fasi dell'intervento ed operare Carefully reading and through understanding of these
con attenzione per non compromettere la funzionalità di instructions will avoid damage to other components.
altri elementi.

B.4 PAG. 24 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INDICAZIONI SPECIALI
Mod. 20.16-1640 SPECIAL RECOMMENDATIONS

B.5 Indicazioni speciali B.5 Special recommendations

Prima di iniziare le operazioni di smontaggio e Before starting any disassembly and assembly
montaggio leggere attentamente le seguenti operations, read carefully the following
avvertenze. recommendations.

Anelli di tenuta per alberi Shafts seals

Per il montaggio degli anelli di tenuta attenersi alle Respect the following recommendations during shaft
seguenti raccomandazioni: seal assembly:
• Pulire accuratamente l'albero ed assicurarsi che • Clean shaft very carefully and ensure that the part in
non sia danneggiato, rigato od ovalizzato nelle zone contact with the shaft seal is not damaged, cut or out
di contatto con gli anelli. of roundness.
• Non danneggiare gli anelli durante il montaggio • Do not damage the seals while assembling the
dell'albero. shaft.
• Pulire accuratamente l'albero ed assicurarsi che • Clean shaft very carefully and ensure that the part in
non sia danneggiato, rigato od ovalizzato nelle zone contact with the shaft seal is not damaged, cut or out
di contatto con gli anelli (Fig. 3). of roundness (Fig. 3).

Fig. 3

Fig. 4

• Montare gli anelli in modo che il labbro sia rivolto • Assemble the seals so that the lip is fitted towards
verso il lato olio (Fig. 4). the oil side (Fig. 4).
• Lubrificare il labbro degli anelli (usare • Lubricate seal lips (use oil) and fill 3/4 of seal cavity
preferibilmente olio) e riempire per 3/4 di grasso la with grease (Fig. 5).
camera degli anelli stessi (Fig. 5).
• Use appropriate drivers (Fig. 6).
• Montare gli anelli usando un appropriato calettatore
(Fig. 6). Important: do not use a hammer directly on the seals.

Importante: non usare il martello direttamente sugli

anelli.

Fig. 5

Fig. 6

AB10710 REVISION DATE: 05/16 DOC. CA270410 B.5 PAG. 25

INDICAZIONI SPECIALI
SPECIAL RECOMMENDATIONS Mod. 20.16-1640

Anelli OR O-rings
Lubrificarli adeguatamente prima di inserirli nella Lubricate adequately before inserting them at the right
propria sede evitando “arrotolamenti” durante il place and avoid o-ring rolling while inserting the shaft
montaggio dell'albero (Fig. 7). (Fig. 7).

Fig. 7

Fig. 8

Spessori di registro Adjusting shims

Per il montaggio degli spessori di registro attenersi alle Respect the following recommendations during the
seguenti raccomandazioni: adjustment shims assembly:
• Per le registrazioni utilizzare gli appropriati spessori • Use appropriate adjusting shims and measure each
di registro, misurandoli singolarmente (Fig. 8). one separately (Fig. 8).
• La misurazione del pacco completo o la • Complete group measurement or stampings on the
stampigliatura riportata sugli spessori stessi può shims are not always reliable: check.
risultare non sempre affidabile: verificare.

Cuscinetti Bearings
Per il montaggio dei cuscinetti attenersi alle seguenti Respect the following recommendations during the
raccomandazioni: bearings assembly:
• Prima di rimontarli, pulirli, ispezionarli e lubrificarli. • Before reassembling the bearings, clean, check and
lubricate them.
• Per un corretto montaggio è consigliabile riscaldarli
in forno ad una temperatura di 80-90 °C prima di • Its advisable to heat up bearings to 80-90 °C before
montarli sui rispettivi alberi o raffreddarli prima di assembling them onto their respective shafts or to
inserirli nelle relative sedi con piantaggio esterno cool them (dry ice) before inserting them into
(Fig. 9). corresponding bore (Fig. 9).
• Usare sempre gli estrattori idonei per rimuovere i Always use suitable extractors to remove the bearings
cuscinetti (Fig. 10). (Fig. 10).

Fig. 9

Fig. 10

B.5 PAG. 26 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INDICAZIONI SPECIALI
Mod. 20.16-1640 SPECIAL RECOMMENDATIONS

Tappi e rivetti Plugs and rivets

Mai rimuovere tappi metallici e rivetti se non Never remove metal plugs and rivets unless specifically
espressamente indicato nelle istruzioni di riparazione. indicated in the repair instructions.
Spesso questi componenti richiedono delle Often these elements require special equipment for
apparecchiature speciali per il montaggio e per la mounting and for the leak test required after completing
conseguente verifica di tenuta. the assembly operation.
Vedi: Fig. 11 e Fig. 12. See: Fig. 11 and Fig. 12
AVV IS O NOTICE
Quando non espressamente indicata nelle istruzioni di If not specifically indicated in the instructions for
riparazione, la rimozione di detti elementi comporta repairing, the removal of these parts will result in
l’immediata decadenza della garanzia sul prodotto da immediate forfeiture of the product warranty by
parte di Carraro Drive Tech SpA. Carraro Drive Tech SpA.

Fig. 11 NON RIMUOVERE

DO NOT REMOVE

NON RIMUOVERE
DO NOT REMOVE Fig. 12

Cappucci e protezioni in plastica Plastic caps and protections

Rimuovere tutti i cappucci e le protezioni in plastica Remove all caps and plastic protections that may be
presenti sulle parti di ricambio prima dell’assemblaggio. present on original spare parts before assembly.
Importante: SUBITO DOPO L’INSTALLAZIONE DEL Important: IMMEDIATELY AFTER INSTALLING THE
PRODOTTO, PRIMA DELL’USO DEL VEICOLO, PRODUCT, BEFORE USE OF THE VEHICLE, remove
rimuovere i cappucci protettivi dagli sfiati atmosferici. the protective caps present on all atmospheric vents.

Spine elastiche Split pins

Per il montaggio delle spine elastiche attenersi alle Respect the following recommendations during the split
seguenti raccomandazioni: pins assembly:
• Al montaggio delle spine elastiche ad intaglio • Before assembling elastic pins, make sure that the
assicurarsi che l'intaglio delle stesse sia orientato pin notch is oriented towards the stressing force
nel senso dello sforzo sollecitante la spina (Fig. 13). (Fig. 13).
• Le spine elastiche a spirale invece non necessitano • Spiral elastic pins do not need orientation.
di alcun orientamento.

Fig. 13

Fig. 14

AB10710 REVISION DATE: 05/16 DOC. CA270410 B.5 PAG. 27

INDICAZIONI SPECIALI
SPECIAL RECOMMENDATIONS Mod. 20.16-1640

Adesivi e sigillanti Adhesive and sealant

Þ ATTE NZIONE Þ CAUTION
Leggere attentamente la Scheda di Sicurezza di ogni Carefully read the Safety Data Sheet of each product
prodotto prima dell’uso. before use.
Tutti i prodotti chimici sono pericolosi se non vengono Chemical products are dangerous if not used in
usati rispettando le raccomandazioni d’uso elencate accordance with the recommendations of use in the
nella Scheda di Sicurezza. Safety Data Sheet.
Per l’applicazione di adesivi e sigillanti attenersi alle Respect the following recommendations during the
seguenti raccomandazioni: adhesive and sealant application:
• Usare i prodotti adesivi/sigillanti seguendo le • Use the adhesives/sealants products according to
raccomandazioni del produttore e rispettando le the manufacturer's recommendations and in
specifiche tecniche indicate dallo stesso compliance with the manufacturer's specifications
(temperatura d’applicazione, condizioni di posa in (application temperature, application conditions,
opera, tempo di posa e altri dati). curing times and other data).
• Non applicare adesivi e sigillanti su prodotti analoghi • Do not use adhesive or sealant where similar
già applicati in precedenza; products has been applied previously;
rimuovere completamente i vecchi prodotti prima di totally remove the old product before applying the
applicare i nuovi. new one.
• Assicurarsi che le parti dove si applicano adesivi e • Ensure that parts to be sealed are clean, dry and
sigillanti siano pulite, asciutte e completamente completely grease free (Fig. 14) in the application
prive di grasso (Fig. 14). area.
• Consultare l’apposita sezione in questo manuale • Read the predisposed section in this manual to
per conoscere i tipi di adesivi e sigillanti ammessi e know the required type of adhesive and sealant and
le zone in cui devono essere utilizzati. relative application areas.

Scarico dell'olio Oil drain

Prima di intervenire sul prodotto è necessario scaricare Before carry out the disassembly operations, the oil
l'olio dal gruppo. must be drained out.
Vedi: C.5. See: C.5.
Þ ATTE NZIONE Þ CAUTION
Smaltire gli oli esausti nel rispetto della vigenti norme Dispose of used oil in compliance with current
per la salvaguardia dell'ambiente. environment regulations.

Pulizia Cleaning
Per la pulizia dell’assale attenersi alle seguenti Respect the following recommendations during the axle
raccomandazioni: cleaning operations:
• Lavare accuratamente tutte le parti in movimento • Wash all moving parts accurately with diesel fuel or
utilizzando gasolio o cherosene. kerosene.
• E' proibito l'uso di benzina e soluzioni acquose • Gasoline and watery alkaline solutions are
alcaline. forbidden.
• Evitare lavaggi con vapore o acqua calda perché • Do not wash with steam or hot water, as it will be
sarebbe difficile eliminare completamente l'umidità very difficult to eliminate surface humidity.
superficiale. • Dry all parts with a rag or air jet to avoid scratching
• Asciugare accuratamente tutti i particolari mediante from abrasive residuals.
un getto d'aria o stracci per evitare di rigare le
• After the cleaning operations, all the surfaces should
superfici con residui abrasivi.
be covered with lubricant so as to protect it from
• Dopo la pulizia, tutte le superfici devono essere future oxidation.
ricoperte da un leggero strato di lubrificante per
proteggerle da eventuali ossidazioni.

B.5 PAG. 28 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INDICAZIONI SPECIALI
Mod. 20.16-1640 SPECIAL RECOMMENDATIONS

Controlli Checks
Per i controlli sull’assale attenersi alle seguenti Respect the following recommendations during the axle
raccomandazioni: control operations:
• Controllare che tutti gli elementi scanalati siano privi • Check all grooves: assure that they are not worn out
di usure eccessive o di altri danneggiamenti. or damaged.
• Sostituire i particolari avariati con ricambi originali. • Replace spoiled parts with original spare parts.
• Dopo ogni smontaggio, le guarnizioni di tenuta sugli • Before the reassembly, the seals on rotating shafts
alberi rotanti devono essere sostituite. must be replaced.
• Verificare accuratamente tutti i cuscinetti, gli anelli • Examine accurately all bearings, external rings
esterni eventualmente ancora piantati nelle proprie which may be still stuck in their position and pivot
sedi e i perni su cui rotolano i rullini. pins on which rolls rotate.
• Sostituire quei particolari che presentano tracce di • Replace those parts which show signs of wear or
usura o di danneggiamento (Fig. 15). damage (Fig. 15).
• Controllare che tutti gli ingranaggi non presentino • Gears should not be spoiled and teething should not
avarie o eccessiva usura della dentatura: gli smussi be excessively worn out. Teeth smoothing should
dei denti non devono essere deteriorati (Fig. 16). not be deteriorated (Fig. 16).

Fig. 15

Fig. 16

Estremità di flange ed attrezzi speciali Ends of flanges and special tools

Prestare la massima attenzione quando si martellano le Be careful when hammering special tool or flange ends,
estremità di attrezzi speciali o di flange per evitare di in order to avoid jeopardizing functionality and integrity
compromettere la funzionalità e l’integrità sia degli of either the tools or the components on which you are
attrezzi che dei componenti su cui si opera. operating.

Impiego di lubrificante Lubricant use

Per ottenere una corretta lubrificazione ed una esatta In order to lubricate the CARRARO DRIVE TECH SpA
temperatura di funzionamento negli assali CARRARO axles correctly and to reach the exact operation
DRIVE TECH SpA, è importante usare i lubrificanti temperature, it is important to use the recommended
raccomandati, mantenendone il livello costante lubricants, keeping their level constant as indicated in
secondo quanto indicato nel presente manuale. this manual.

AB10710 REVISION DATE: 05/16 DOC. CA270410 B.5 PAG. 29

INDICAZIONI SPECIALI
SPECIAL RECOMMENDATIONS Mod. 20.16-1640

B.5.1 Serraggio dadi ruota B.5.1 Locking wheel nuts

Importante: tutte le operazioni di smontaggio e Important: all disassembly and assembly operations of
montaggio di ogni ruota del veicolo devono essere each wheel of the vehicle must be conducted as
condotte secondo quanto indicato dal costruttore nel specified by the manufacturer in the service manual of
manuale del veicolo stesso. Le avvertenze date in the vehicle. The information given in this section are
questo paragrafo sono solo complementari a quanto only a complement to the standards prescribed by the
indicato dal costruttore del veicolo. vehicle manufacturer.

Þ AVV ERTE NZA Þ WARN IN G

Non cercare di assemblare/disassemblare una ruota Do not attempt to assemble/disassemble a tire unless
senza disporre dell’equipaggiamento adatto e della you have the proper equipment and experience to
necessaria esperienza. Utilizzare sempre strumenti in perform the job. Always use tools in perfect condition,
perfette condizioni ed adatti all’entità dei carichi da suited to the load to be lifted and work to be
sollevare ed al tipo di lavoro da portare a termine. performed.

Prima di operare su una ruota leggere attentamente Before working on a wheel carefully read the manual
il manuale fornito dal costruttore del veicolo. provided by the vehicle manufacturer.
Riferendosi al manuale del veicolo, controllare la Check the wheel in question for low pressure, cuts,
pressione del pneumatico e se siano presenti tagli, bubbles or others signs of wear, damaged rims or
bolle o segni d’usura oppure danni al cerchio o alle missing stud bolts and nuts, referring to the manual of
colonnette o se ci sono dadi mancanti. the vehicle.

Þ PER IC OLO Þ DANGER

Prendere tutte le precauzioni necessarie ad evitare Take all the necessary precautions to avoid all risk of
rischi per le persone. Supportare adeguatamente sia anyone being injured. Support in an appropriate
l’assale che il veicolo. manner the axle and the vehicle.

Precauzioni generali per la sicurezza General Safety Precautions

Attenersi alle raccomandazioni indicate nel manuale Follow the recommendations outlined in the manual to
del veicolo per operare in totale sicurezza, inoltre: operate the vehicle safely, in addition to this:
• Pulire accuratamente e sgomberare da oggetti inutili • Clean thoroughly and remove all unnecessary
tutta l’area in cui si deve operare. objects from the area where you have to work.
• Prima di cambiare le ruote, disporre il veicolo su un • Before changing wheels, place vehicle on firm and
terreno stabile e orizzontale. level ground.
• Innestare il freno di stazionamento del veicolo ed • Engage the parking brake of the vehicle and prevent
impedire che si possa spostare inavvertitamente it from moving accidentally using special chock
utilizzando delle apposite calzatoie. blocks
• Rimuovere la chiave di accensione del veicolo per • Remove the ignition key of the vehicle to prevent
impedire una messa in funzione non autorizzata. unauthorized operation.
• Durante la sostituzione delle ruote, accertarsi che • When changing wheels, make sure that no-one is
nessuno si trovi nella zona di pericolo. In particolare standing in the danger zone.
non permettere l’accesso alla zona pericolosa a Especially do not allow access to the danger zone to
bambini e a persone con ridotta o impedita capacità children and people with reduced or impaired
motoria o sensoriale. mobility or sensory.

Serraggio dei dadi ruota Locking wheel nuts

Attenersi alle seguenti raccomandazioni: Respect the following recommendations:
• Pulire accuratamente le colonnette ed i dadi da • Clean all stud bolts and nuts very carefully; if
assemblare; se necessario utilizzare una spazzola necessary, use a wire brush to eliminate all traces of
metallica per eliminare ogni traccia di ruggine. rust.
• Verificare la perfetta integrità di ogni elemento e • Verify the integrity of each element and replace any
sostituire gli eventuali elementi danneggiati. damaged parts.

B.5 PAG. 30 REVISION DATE: 05/16 DOC. CA270410 AB10710

 INDICAZIONI SPECIALI
Mod. 20.16-1640 SPECIAL RECOMMENDATIONS

• Pulire accuratamente le superfici di contatto fra • Thoroughly clean the surfaces of contact between
cerchione e mozzo ruota, quindi posizionare la ruota the rim and wheel hub, then place the wheel on the
sul mozzo ruota. wheel hub.
• Assemblare a mano tutti i dadi con le relative • Assemble all nuts with relative washers on the studs
rondelle alle colonnette. by hand.
• Serrare con percorso incrociato (Fig. 17, 18 e 19) i • Tighten to cross path (Fig. 17, 18 and 19) the wheel
dadi ruota al 50% della coppia di serraggio prevista nuts to 50% of the requested torque with a
con avvitatore o a mano con chiave a bussola. screwdriver or by hand with a socket wrench.

I Fig. 17
I VIII

X VI
VI III
III IV

V IX
II V
VII II
Fig. 18

• Verificare che la ruota sia correttamente appoggiata • Verify that the wheel is properly supported to the
al mozzo ruota lungo tutta la circonferenza e che sia wheel hub along the entire circumference and is
centrata rispetto al mozzo ruota. centered in relation to the wheel hub.
Nota: se una di queste due condizioni non fosse Note: if either of these conditions is not satisfied
rispettata disassemblare la ruota ed eliminare la causa disassemble the wheel and remove the cause of the
del problema, poi ripetere le precedenti operazioni di problem , then repeat the previous assembly
assemblaggio. operations.
• Con una chiave dinamometrica serrare i dadi ruota • Using a torque wrench tighten the wheel nuts (see
alla coppia di serraggio prevista (vedi manuale del vehicle service manual) to the requested torque with
veicolo) con percorso incrociato (Fig. 17, 18 e 19). cross path (Fig. 17, 18 and 19).
Importante: non utilizzare un avvitatore ad aria Important: do not use an air impact wrench to tighten
compressa per serrare le viti alla coppia definitiva. the nuts to the final torque.

Fig. 19
I
VI VII

IV III

VIII V
II
Fig. 20

Nota: si consiglia di contrassegnare ogni dado/colon- Note: it is advisable to mark each nut/stud (Fig. 20) that
netta (Fig. 20) appena è stato serrato alla coppia has just been tightened to the required torque.
prevista.
NOTICE
AVV IS O Is recommended to check the tightness of wheel nuts
Si raccomanda di verificare il serraggio dei dadi ruota after the first 4/8 hours of the vehicle.
dopo le prime 4/8 ore di lavoro del veicolo.

AB10710 REVISION DATE: 05/16 DOC. CA270410 B.5 PAG. 31

INDICAZIONI SPECIALI
SPECIAL RECOMMENDATIONS Mod. 20.16-1640

Notes

B.5 PAG. 32 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CARATTERISTICHE GENERALI
Mod. 20.16-1640 GENERAL SPECIFICATIONS

C CARATTERISTICHE GENERALI

C GENERAL SPECIFICATIONS

AB10710 REVISION DATE: 05/16 DOC. CA270410 C PAG. 33

USO PREVISTO
INTENDED USE Mod. 20.16-1640

C.1 Uso previsto C.1 Intended use

Questo assale è stato progettato e costruito per essere This axle has been designed and manufactured to be
installato in veicoli di tipo agricolo con la funzione di mounted on vehicles, used for agricultural purposes, to
trasmettere la potenza dal motore alle ruote, transmit the power from the engine to the wheels and
consentendo anche: to allow:
• l’aumento della forza di trazione del veicolo; • increasing of tractive force of the vehicle
• la compensazione della velocità delle ruote interne • adjusting of inner wheels’ speed with outer wheels’
con quelle esterne durante la sterzata del veicolo. speed during steering of the vehicle.

Non installare mai questo assale su macchine diverse Never mount this axle on machines different from the
da quelle per cui e stato progettato e costruito. ones for which it has been designed and manufactured.

L'assale, se utilizzato in un impiego diverso da quello The axle, when used in an application other than that
previsto, è da considerarsi soggetto ad “uso non intended, is to be considered subject to “use different
previsto” than expected”
CARRARO DRIVE TECH SpA declina ogni CARRARO DRIVE TECH SpA declines all
responsabilità per danni o incidenti risultanti da un uso responsibility for damage or injury resulting from use
diverso da quello previsto; tali conseguenze saranno a different than expected and related consequences will
carico esclusivo del cliente. be borne by the client.
Costituisce inoltre un elemento essenziale, nell'ambito However, when used as expected, operational
dell'uso previsto, l'osservanza scrupolosa delle formalities as well as regular maintenance repair
modalità di funzionamento e delle regolari specifications given by CARRARO DRIVE TECH SpA
manutenzioni e riparazioni specificate da CARRARO are to be observed strictly.
DRIVE TECH SpA.

C.2 Identificazione del prodotto C.2 Product identification

Posizione della targhetta Tag position

C.1 PAG. 34 REVISION DATE: 05/16 DOC. CA270410 AB10710

 USO PREVISTO
Mod. 20.16-1640 INTENDED USE

Targhetta di identificazione dell’assale Axle tag

Importante: quando si contatta il Servizio Assistenza Important: when contacting Customer Service or
Clienti o il Dipartimento Ricambi si raccomanda di Spare Parts Department is recommended to provide
comunicare i seguenti dati: the following information:
• NUMERO RIFERIMENTO CARRARO riportato • CARRARO REFERENCE NUMBER shown in the
nella casella CARRARO N. field CARRARO N.
è il numero di riferimento del prodotto che ne is the reference number of the product, which
definisce il modello e la versione specifica; defines the model and the specific version;
• N/S CARRARO nella casella SERIAL N. • CARRARO S/N in the field SERIAL N.
è il numero di serie (o N/S) che identifica con is the serial number (or S/N) which identifies exactly
esattezza il prodotto. the product.

AB10710 REVISION DATE: 05/16 DOC. CA270410 C.1 PAG. 35

DESCRIZIONE GENERALE
GENERAL DESCRIPTION Mod. 20.16-1640

C.3 Descrizione generale C.3 General description

L’assale monolitico può essere composto dai seguenti The monolithic axle can be made up of the following
gruppi (non tutti presenti nel vostro assale): groups (not all present in your axle):
1 RIDUTTORE EPICICLOIDALE: treno portasatelliti 1 EPICYCLIC REDUCTION GEAR: planetary carrier
con elementi di riduzione with reduction/transmission parts
2 FRENO: componenti del freno e relativa sede 2 BRAKE: brake parts and housing
3 MOZZO RUOTA: elementi di supporto della ruota e 3 WHEEL HUB: wheel support parts containing the
del riduttore epicicloidale epicyclic reduction gears
4 CILINDRO STERZO: componenti del cilindro di 4 STEERING CYLINDER: steering cylinder parts
sterzo con gli elementi di regolazione with adjusting system components
5 SUPPORTO DIFFERENZIALE: supporto del 5 DIFFERENTIAL SUPPORT: differential housing
differenziale e per la registrazione della coppia with ring bevel gear adjusting system
conica 6 FLANGE: flange and relative fastening parts
6 FLANGIA: flangia con elementi di fissaggio 7 PINION: pinion with relative adjusting and support
7 PIGNONE: pignone con gli elementi di parts
registrazione e supporto 8 PARKING BRAKE: brake disc with caliper and
8 FRENO DI STAZIONAMENTO: freno a disco con support parts
pinza ed elementi di supporto 9 DIFFERENTIAL: differential parts with ring bevel
9 DIFFERENZIALE: scatola differenziale e corona gear
della coppia conica 10 SUPPORTS: axle’s trunnion parts to install the axle
10 SUPPORTI: elementi di fissaggio dell’assale al on the vehicle
veicolo 11 AXLE BEAM: load-bearing shell structure of the
11 TRAVE: struttura di supporto principale dell’assale axle

ASSALE STERZANTE ASSALE NON STERZANTE

STEERING AXLE NOT STEERING AXLE
10

9 12
11

2 3
1 2 1
4 5
3 8
6 7

C.3 PAG. 36 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CARATTERISTICHE TECNICHE
Mod. 20.16-1640 TECHNICAL FEATURES

C.4 Caratteristiche Tecniche C.4 Technical Features

Importante: consultare la sezione Dati Prodotto per Important: refer to the Product Data section in order to
conoscere il lato di assemblaggio della corona conica e know the correct assembly side of the bevel gear and
gli altri dati specifici; alcuni particolari rappresentati other specific data; some parts represented in this
in questo manuale potrebbero non essere presenti repair manual might not be present in the product.
nel Vs prodotto.

Valori tipici di assemblaggio ASSEMBLY MAIN DATA

Gioco di accoppiamento coppia conica G= Gm i n ÷ Gm ax Coupling backlash of bevel gear set
Posizione corona coppia conica vedi figura/see figure Bevel gear arrangement
Diametro codolo pignone DP End pinion diameter
Precarico cuscinetti pignone FP = FP m i n ÷ FP m a x Pinion bearings preloading
Total preloading of pinion-ring gear
Precarico tot. cuscinetti corona-pignone FT = FT m i n ÷ FT m a x
bearings
Coppia di rotolamento dei cuscinetti Pinion bearings rolling torque
MP = MPm in ÷ MP m a x
pignone
Coppia di rotolam. totale dei cuscinetti Total pinion-ring gear bearing rolling
MT = MTm in ÷ MT m a x
corona-pignone torque
Vedi: scheda Dati Prodotto per i valori effettivi di See: Product Data sheet for the precise values required
assemblaggio in the assembly

Schema di accoppiamento coppia conica Bevel gear set coupling scheme

corona sinistra/left bevel gear corona destra/right bevel gear

DP DP

AB10710 REVISION DATE: 05/16 DOC. CA270410 C.4 PAG. 37

CARATTERISTICHE TECNICHE
TECHNICAL FEATURES Mod. 20.16-1640

Dati tecnici dischi differenziale limited slip (LS) Limited slip (LS) differential disks specifications

Spessore disco attrito nuovo= 2.80±0.03 mm

Spessore controdisco nuovo= 1.50±0.03 mm Spessore minimo disco usurato= 2.73 mm
New separator plate thickness= 1.50±0.03 mm New friction plate thickness= 2.80±0.03 mm
Worn plate minimum thickness= 2.73 mm
Disco rif. CA110643 - q.tà 10
Plate ref. CA110643 - q.ty 10 Disco rif. CA110642 - q.tà 2
Plate ref. CA110642 - q.ty 2

Disco rif. CA110644 - q.tà 8

Plate ref. CA110644 - q.ty 8

Spessore disco attrito nuovo= 1.60±0.03 mm

Spessore minimo disco usurato= 1.48 mm
New friction plate thickness= 1.60±0.03 mm
Worn plate minimum thickness= 1.48 mm

C.4 PAG. 38 REVISION DATE: 05/16 DOC. CA270410 AB10710

 MANUTENZIONE E CAMBIO OLIO
Mod. 20.16-1640 MAINTENANCE AND OIL CHANGE

C.5 Manutenzione e cambio olio C.5 Maintenance and oil change

C.5.1 Caratteristiche olio C.5.1 Oil specifications

Olio raccomandato Recommended oil
Carraro raccomanda l’uso dell’olio per assali e Carraro recommends the use of oil for axles and
trasmissioni CarraroOil Power Life Lub ™ transmissions CarraroOil Power Life Lub ™
Questa gamma di lubrificanti garantisce la migliore This line of lubricants provides optimal lubrication for
lubrificazione per trasmissioni ed assali con i seguenti transmissions and axles and offers the following
vantaggi: advantages:
• Qualità garantita del prodotto • Guaranteed product quality
Perché testato e approvato da Carraro Because it is tested and approved by Carraro
• Lunga durata della macchina • Long life for your machine
Garantita dall’ottimale lubrificazione di tutte le unità Guaranteed by optimal lubrication of all
di trasmissione, frizioni e freni e dall’elevata transmission, clutch and brake units and high
protezione contro l’usura protection against wear.
• Elevate prestazioni • High performance
Indipendentemente dalla temperatura dell’olio Regardless of the oil temperature
• Lunghi intervalli di manutenzione • Extended maintenance intervals
Grazie all’ottimale formulazione dei componenti Due to the optimal component formulation
L’uso di un olio diverso può compromettere l’affidabilità The use of different oil may compromise reliability and
e le performance del prodotto Carraro. Per ordinare performance of the Carraro product. To order the
Power Life Lub™ contatta il rivenditore più vicino Power Life Lub™ please contact the closest distributor
localizzandolo tramite il sito internet: finding it on the web site:
www.carry4you.it www.carry4you.it

Power Life Lub Universal 80W Power Life Lub 80W-90

• API GL-4 • API GL-4/GL-5

Specifica olio
• SAE J300: 10W-30 • SAE J306: 80W-90
Oil specification
• SAE J306: 75W-80 • MIL-L-2105D
Litri/Liters 5 20 200 5 20 200
Rif. Carraro/Carraro ref. 210120 210121 210122 210123 210124 210125

CAab04910

AB10710 REVISION DATE: 05/16 DOC. CA270410 C.5 PAG. 39

MANUTENZIONE E CAMBIO OLIO
MAINTENANCE AND OIL CHANGE Mod. 20.16-1640

C.5.2 Tappi e porte di connessione C.5.2 Plugs and connection ports

5 1 2 5

3
5 5

DE SCRIZIONE P OS . DES CRIPTION

Tappo carico e livello olio differenziale 1 Differential oil filling and level plug
Tappo scarico olio differenziale 2 Differential oil drain plug
Sfiato 3 Breather
Tappo carico, livello e scarico olio riduttore 4 Fill, level and drain oil plug of reduction gear
Punto di ingrassaggio 5 Greasing point

C.5 PAG. 40 REVISION DATE: 05/16 DOC. CA270410 AB10710

 MANUTENZIONE E CAMBIO OLIO
Mod. 20.16-1640 MAINTENANCE AND OIL CHANGE

C.5.3 Cambio olio assale C.5.3 Axle oil change

AVV IS O NOTICE
eseguire tutte le operazioni di scarico, carico e verifica to drain and fill the oil and to check the oil level the
livello olio con l’assale orizzontale ed installato sul axle must be horizontal and installed on the vehicle.
veicolo.

1
Þ P E R I C O L O rischio di violenta espulsione di getti d’olio,
seguire tutte le procedure di sicurezza indicate in questo manuale e
3 dal costruttore del veicolo (vedi: cap. A - INFORMAZIONI SULLA
SICUREZZA).
Pulire con cura lo sfiato (3) e la zona circostante.

Þ DANGE R risk of violent oil ejection, follow carefully all the

safety procedures indicated in this manual and in the vehicle manual
(see: cap. A - SAFETY INSTRUCTIONS).
Clean with care the breather (3) and the surrounding area.

2
Per scaricare l’olio dal corpo centrale svitare e rimuovere prima il
tappo di carico (1) e poi il tappo di scarico (2).
Scaricare completamente l’olio.
Pulire con cura ed assemblare il tappo (2).
Serrare il tappo alla coppia prevista.
Vedi: ADESIVI E COPPIE DI SERRAGGIO in questo Cap.

To drain the oil unscrew and remove first the fill plug (1) then the drain
1 plug (2). Drain all oil.
Clean with care and assemble the plug (2).
2
Tighten the plug to the prescribed torque.
See: ADHESIVES AND TIGHTENING TORQUES in this Chap.

3
Riempire con l’olio prescritto a filo del foro di carico (1).
Attendere che l’olio fluisca nell’assale quindi verificare il livello e
rabboccare se necessario.
Pulire con cura ed assemblare il tappo (1).
Serrare il tappo alla coppia prevista.
Vedi: ADESIVI E COPPIE DI SERRAGGIO in questo Cap.
Fill to the bottom of the fill plug hole (1) with the specified oil.
Wait to allow the oil to flow through the axle. Check oil level and fill to
the specified level if necessary.
1 Clean with care and assemble the plug (1).
Tighten the plug to the prescribed torque.
See: ADHESIVES AND TIGHTENING TORQUES in this Chap.

AB10710 REVISION DATE: 05/16 DOC. CA270410 C.5 PAG. 41

MANUTENZIONE E CAMBIO OLIO
MAINTENANCE AND OIL CHANGE Mod. 20.16-1640

C.5.4 Cambio olio riduttore epicicloidale C.5.4 Reduction gear oil change
AVVISO NOT ICE
eseguire tutte le operazioni di scarico, carico e verifica to drain and fill the oil and to check the oil level the
livello olio con l’assale orizzontale. axle must be horizontal.

1
Þ P E R I C O L O rischio di violenta espulsione di getti d’olio,
A seguire tutte le procedure di sicurezza indicate in questo manuale e
dal costruttore del veicolo.
Vedi: cap. A - INFORMAZIONI SULLA SICUREZZA
4 AVV IS O eseguire tutte le operazioni di scarico, carico e verifica
livello olio con l’assale orizzontale.
Prima di scaricare l’olio dal riduttore epicicloidale, ruotarlo in modo da
portare il tappo olio (4) nel punto più alto [posizione A].
Svitare il tappo parzialmente per eliminare l’eventuale pressione
interna.
Ruotare il riduttore con il tappo (4) rivolto verso il basso [posizione B].
Togliere il tappo e lasciar defluire tutto l’olio.
B

Þ D A N G E R risk of violent oil ejection, follow carefully all the

safety procedures indicated in this manual and in the vehicle
manual.
See: cap. A - SAFETY INSTRUCTIONS
NOTICE to drain and fill the oil and to check the oil level the axle
must be horizontal.
Before draining the oil from wheel end rotate the wheel end so that the
plug (4) is at the highest position [pos. A] and partially unscrew to
release possible pressure.
Rotate the wheel end so that the plug (4) is toward the ground [pubes].
Remove the plug and drain the oil.

2
Ruotare il riduttore fino a portare il foro (4) nella posizione indicata.
Riempire con olio prescritto.
Vedi: MANUTENZIONE E CAMBIO OLIO, , in questo Cap.
4 Il livello dell’olio deve essere a filo del foro.
Serrare il tappo alla coppia prevista.
Vedi: ADESIVI E COPPIE DI SERRAGGIO in questo Cap.
Rotate the wheel end so that the hole (4) is in the position as shown
in figure.
Fill to the bottom of the fill plug hole with specified oil.
See: MAINTENANCE AND OIL CHANGE, , in this Chap.
Tighten the plug to the prescribed torque.
See: ADHESIVES AND TIGHTENING TORQUES in this Chap.

C.5 PAG. 42 REVISION DATE: 05/16 DOC. CA270410 AB10710

 MANUTENZIONE E CAMBIO OLIO
Mod. 20.16-1640 MAINTENANCE AND OIL CHANGE

C.5.5 Manutenzione programmata C.5.5 Service schedule

Gli intervalli di manutenzione indicati sono per un Specified maintenance intervals are for standard-duty
impiego normale della macchina, nel caso di impieghi use.
particolarmente gravosi intervenire con maggior Severe operating conditions may require more short
frequenza. intervals.

Primo Intervento Manutenzione ordinaria

Operazione Operation
First time Ordinary maintenance

Cambio olio assale 150-200 stagionale od ogni 1500 ore(1) Axle oil change
 
ore/hours seasonally or every 1500 hours(1)
Pulizia tappo magnetico primo cambio olio ogni cambio olio Clean magnetic oil plugs
 
scarico olio first oil change every oil change
Controllo e rabbocco 50-100 mensile od ogni 300-400 ore(1) Check and adjust oil
 
olio ore/hours monthly or every 300-400 hours(1) level

Pulizia sfiato olio 150-200 mensile od ogni 300-400 ore(1) Clean oil breather
 
ore(3)/hours(3) monthly or every 300-400 hours(1)
Ingrassaggio 150-200 settimanale od ogni 150-200 ore(1)(2) Greasing
 
(se previsto) ore(2)/hours(2) weekly or every 150-200 hours(1)(2) (if required)

Lubrificazione 150-200 stagionale od ogni 1500 ore(1) Lubrication works

 
(se prevista) ore(3)/hours(3) seasonally or every 1500 hours(1) (if required)

 operazioni eseguibili solamente da personale  this operation must be performed only by personnel
autorizzato dal costruttore authorized by the manufacturer
 operazioni eseguibili solamente da personale  this operation must be performed only by trained
addestrato personnel
(1) quale delle due condizioni si verifica prima (1)
which of both conditions comes first
(2) 50 ore nel caso di impiego gravoso (2)
50 hours for severe operating condition
(3) a fine stagione nel caso di impiego inferiore a quanto (3)
at the season end if you have not reached the
indicato indicated work-hours

Campi di applicazione dei lubrificanti Lubricants application range

AB10710 REVISION DATE: 05/16 DOC. CA270410 C.5 PAG. 43

GRASSO AL MONTAGGIO
GREASE IN ASSEMBLY Mod. 20.16-1640

C.6 Grasso al montaggio C.6 Grease in assembly

Importante: lubrificare tutte le tenute dei pistoni freno Important: lubricate all brake pistons seals and O-
e gli OR con olio minerale (SAE 90) o grasso al Litio. rings with mineral oil (SAE 90) or Lithium grease.

Applicazione grasso al montaggio - Grease application in assembly

Tecnolube® Applicare sulle superfici indicate

POLYMER 400 Apply on the indicated surfaces
Grasso Riempire in eccesso
Grease Fill in excess

C.6 PAG. 44 REVISION DATE: 05/16 DOC. CA270410 AB10710

 ADESIVI E COPPIE DI SERRAGGIO
Mod. 20.16-1640 ADHESIVES AND TIGHTENING TORQUES

C.7 Adesivi e coppie di serraggio C.7 Adhesives and tightening

torques
Applicazione Adesivi/Sigillanti - Adhesive/Sealant
Steering cylinderApplication
group
Applicare sulle superfici piane a contatto - Apply on the flat contact surfaces
Applicare sulla filettatura delle viti o sulle superfici curve di perni e boccole
Nota: applicare solo sul lato indicato
Apply on bolts thread or on pins and bushes curved surfaces
Note: apply only on indicated side

Sigillanti per guarnizioni - Gasket sealants

Rif. Carraro Marca e tipo Caratteristiche tecniche Resistenza
Carraro Ref. Brand and type Technical characteristics Strength
Loctite® 510 Sigillatura superfici piane Alta
A1
Superbond® 529 Flat surface sealing High
Loctite® 573 Sigillatura superfici piane Bassa
A2
Superbond® 519 Flat surface sealing Low
Sigillatura superfici irregolari Alta
A3 Loctite® 518(1)
Uneven surface sealing High
Sigillatura superfici piane con possibilità di
micromovimenti Alta
A4 Loctite® 5205
Even surface sealing with possibility of High
micro movements
Sigillatura superfici piane e/o irregolari con
possibilità di micromovimenti Alta
A5 Loctite® 5188(2)
Even/uneven surface sealing with possibility High
of micro movements
Nota: (1) A3 può essere impiegato al posto di A1; (2) A5 può essere impiegato al posto di A1, A2, A3, A4.
Note: (1) A3 can be used instead of A1; (2) A5 can be used instead of A1, A2, A3, A4.

Adesivi per frenatura organi filettati - Thread parts adhesives

Rif. Carraro Marca e tipo Caratteristiche tecniche Resistenza
Carraro Ref. Brand and type Technical characteristics Strength
Loctite® 542 Frenatura organi filettati Media
B1
Superbond® 321 Locking of threaded parts Medium
Frenatura organi filettati Alta
B2 Loctite® 270
Locking of threaded parts High
Loctite® 986/AVX Frenatura organi filettati Alta, appl. speciali
B3
Superbond® 438 Locking of threaded parts High, special appl.

Adesivi per fissaggio particolari - Fixing parts adhesives

Rif. Carraro Marca e tipo Caratteristiche tecniche Resistenza
Carraro Ref. Brand and type Technical characteristics Strength
Loctite® 402 Adesivo per fissaggio Fissaggio medio
C1
Superbond® istant 25 Fixing adhesive Medium bond
Adesivo per fissaggio Fissaggio forte
C2 Loctite® 638
Fixing adhesive Strong bond
Loctite® 542 Adesivo per fissaggio Fissaggio medio
C3
Superbond® 321 Fixing adhesive Medium bond
Loctite® 496 Adesivo per fissaggio gomma Fissaggio forte
C4
Superbond® SB14 Rubber fixing adhesive Strong bond

AB10710 REVISION DATE: 05/16 DOC. CA270410 C.7 PAG. 45

ADESIVI E COPPIE DI SERRAGGIO
ADHESIVES AND TIGHTENING TORQUES Mod. 20.16-1640

Adesivi e coppie di serraggio Adhesives and tightening torques

120 Nm
8 Nm
B2

70 Nm

B2

95 Nm

8 Nm
120 Nm

60 Nm
C3 C3

8 Nm

B1

25 Nm

C.7 PAG. 46 REVISION DATE: 05/16 DOC. CA270410 AB10710

 ADESIVI E COPPIE DI SERRAGGIO
Mod. 20.16-1640 ADHESIVES AND TIGHTENING TORQUES

Adesivi e coppie di serraggio Adhesives and tightening torques

300 Nm
120 Nm

165 Nm

150 Nm

120 Nm

8 Nm

70 Nm

AB10710 REVISION DATE: 05/16 DOC. CA270410 C.7 PAG. 47

ADESIVI E COPPIE DI SERRAGGIO
ADHESIVES AND TIGHTENING TORQUES Mod. 20.16-1640

Adesivi e coppie di serraggio Adhesives and tightening torques

70 Nm
169 Nm

70 Nm

B1

200 Nm
13 Nm

10 Nm

A1

C2

B2

95 Nm

C.7 PAG. 48 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PROCEDURE SPECIALI
Mod. 20.16-1640 SPECIAL OPERATIONS

D PROCEDURE SPECIALI

D SPECIAL OPERATIONS

AB10710 REVISION DATE: 05/16 DOC. CA270410 D PAG. 49

PRECARICO DIFF. E GIOCO COPPIA CONICA
DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH Mod. 20.16-1640

D.1 Registrazione del precarico D.1 Differential bearings preload

cuscinetti differenziale e del and bevel gear pair backlash
gioco coppia conica adjustment

14
9
11
8
10

13
7

2b 12

4
2a
3
1

Nota: la posizione della corona rappresentata potrebbe Note: the represented position of the crown gear may
differire da quella del prodotto, vedere posizione be different from the actual product, see the real
indicata in Dati prodotto. position in Product Data.

Attrezzature speciali Posizione Special Tools

Descrizione Position Description
Chiave per ghiere supporto differenziale (t1) Wrench for differential support nuts
Attrezzo per misura precarico (t2) Tool for preloading measurement
Nota: attrezzature necessarie alle operazioni di Note: tools required for the assembly/disassembly
montaggio/smontaggio nella presente sezione. operations in the present section.
Vedi: codici d’ordine delle attrezzature Carraro Drive See: reference numbers of the Carraro Drive Tech tools
Tech in sezione Dati Tecnici dell’assale. in Technical Data section of the axle.

D.1 PAG. 50 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DIFF. E GIOCO COPPIA CONICA
Mod. 20.16-1640 DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH

D.1.1 Smontaggio D.1.1 Disassembly

Alcune figure che seguono potrebbero non mostrare Some of the following pictures may not show exactly
esattamente il vostro assale, ma la procedura descritta your axle, but the indicated operations are correct
è quella corretta. anyway.

1
Se presente, rimuovere la tenuta dal supporto differenziale.
€ AVV ERT ENZA sostenere il supporto differenziale (1) con
una fune o con un sostegno adatto.
Svitare le 5 viti inferiori lunghe (2a) e le 5 viti superiori corte (2b)
Estrarre il supporto differenziale (1).
If present, remove the seal ring from the differential support.
€ WARN IN G support the differential support (1) with a rope or
other appropriate means.
Remove the 5 long screws (2a) (at the bottom) and the 5 short screws
(2b) (at the top).
Remove the differential support (1).

2
Misurare il precarico totale iniziale FT 0 dei cuscinetti (sistema
pignone-corona) utilizzando un dinamometro con la corda avvolta sul
codolo scanalato del pignone.
Annotare il valore FT 0 che è necessario per il riassemblaggio dei
cuscinetti.
Vedi: D.7.2 passo [10]

Measure the starting total preloading FT 0 of the bearings (pinion-

crown gear system), using a dynamometer whose cord is wound on
the pinion splined end.
Note the value FT 0 that is necessary in the bearings reassembly.
See: D.7.2 step [10]

3
Togliere le viti (9) per rimuovere i due fermi ghiera (8).

Loosen and remove the screws (9) to take out the two ring nut
retainers (8).

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.1 PAG. 51

PRECARICO DIFF. E GIOCO COPPIA CONICA
DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH Mod. 20.16-1640

4
Prima di togliere le semicravatte (11), fare dei segni di riferimento
indelebili sulle stesse e sul supporto differenziale in modo da non
invertirle o rovesciarle in fase di rimontaggio. Fare dei segni di
riferimento anche tra le ghiere (3) e (7) ed il supporto differenziale (1).

Before removing the bolts, mark both half-collars (11) and the
differential support with permanent reference marks to avoid inverting
them during re-assembly. Mark the area between the ring nuts (3) and
(7) and the differential support (1) as well.

5
Svitare le due ghiere di registro (3) e (7) utilizzando l’attrezzo speciale
(t1) ed una chiave.

7 t1

3 Unscrew the adjuster ring nuts (5) and (9) by using the special tool (t1)
and a wrench.

6
Svitare le quattro viti (12) e togliere le due semicravatte (11).
Nota: verificare che le bussole (10) rimangano nelle rispettive sedi.
12

11

10

Remove the four screws (12) and remove both half-collars (11).
Note: check that the bushes (10) remains in their housings.

7
Rimuovere la scatola differenziale (5).
5 I coni dei cuscinetti (4) e (6) vengono rimossi assieme alla scatola
differenziale.
4 Importante: non invertire i coni dei cuscinetti se non vengono
sostituiti i cuscinetti.
6

Remove the differential housing (5).

The bearing cones (4) and (6) are removed together with the
differential housing.
Important: do not invert the bearing cone if the bearings are not
replaced.

D.1 PAG. 52 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DIFF. E GIOCO COPPIA CONICA
Mod. 20.16-1640 DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH

D.1.2 Montaggio D.1.2 Assembly

Alcune figure che seguono potrebbero non mostrare Some of the following pictures may not show exactly
esattamente il vostro assale, ma la procedura descritta your axle, but the indicated operations are correct
è quella corretta. anyway.

1
Montare le coppe dei cuscinetti (4) e (6) sul differenziale (5).
Importante: non invertire le coppe dei cuscinetti se non vengono
sostituiti i cuscinetti.
5

6 4

Assemble the bearings cups (4) and (6) on the differential (5).
Important: do not invert the bearing cups if the bearings are not
replaced.

2
Montare la scatola differenziale completa (5) nel supporto
5 differenziale (1).
Importante: verificare il giusto lato di montaggio della corona conica.

Position the complete differential housing (5) in the differential support

(1).
Important: check the right side of the bevel crown assembly.

3
Spostare la scatola differenziale in modo da appoggiare la corona
conica al pignone.
12
Verificare che tutte le bussole (10) siano nelle relative sedi e
11 posizionare le due semicravatte (11) utilizzando i segni di riferimento
riportati sulle medesime e sul supporto differenziale.
Fissare le semicravatte con le viti di fissaggio (12).

10 Move the differential group so to place the bevel crown gear on the
pinion.
Check that all bushes (10) are in their housings and position both half
collars (11) on their seats using the previously traced reference marks.
Lock both collars with their fastening bolts (12).

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.1 PAG. 53

PRECARICO DIFF. E GIOCO COPPIA CONICA
DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH Mod. 20.16-1640

4
Montare le ghiere di registro (3) e (7) nel supporto differenziale.
Importante: le ghiere si devono avvitare senza opporre resistenza;
non danneggiare la filettatura forzando l’assemblaggio delle ghiere.
Avvitare le due ghiere di registrazione (3) e (7) utilizzando gli attrezzi
speciali (t1) fino ad eliminare il gioco e precaricare leggermente i
7 t1 cuscinetti del differenziale.
Verificare che i cuscinetti del differenziale siano ben assestati, se
necessario dare dei piccoli colpi di assestamento con un martello di
materiale tenero.

3 Assemble the adjusting ring nuts (3) and (7) to the differential support.
Important: the ring nuts must be screwed without force; do not
damage the ring nuts thread during the ring nut assembly.
Tighten both ring nuts (3) and (7) by using the special tools (t1), till the
backlash is eliminated and the differential bearings are slightly
preloaded.
Check that the differential bearings are well settled; if necessary,
knock slightly with a soft hammer, in order to properly set the bearings
in position.

5
Posizionare un comparatore con base magnetica sul supporto
differenziale, in modo che il tastatore sia a contatto e a 90° con la
superficie di un dente della corona conica.

Position a magnetic-base dial gauge on the differential support, so

that the feeler stylus touches the surface of one tooth of the crown
gear with a 90° angle.

6
Tenendo fermo il pignone, muovere alternativamente la corona
dentata e rilevare il gioco con il comparatore.
Ripetere questa operazione su due o più denti della corona e
calcolare il valore medio del gioco rilevato.
Verificare se il valore medio del gioco rientra nel campo richiesto (vedi
Dati Prodotto):
G m i n < G m < G m ax [ m m ]
Se il gioco è nel campo indicato passare al punto [10], altrimenti
effettuare la registrazione come segue.
Lock the pinion and move the crown gear alternatively and note the
pinion-ring gear backlash, measured with the comparator.
Repeat this operation on two or more teeth and calculate the average
of measured backlash values.
Check if the average backlash value is within the requested range
(see Product Data):
G m i n < G m < G m ax [ m m ]
If this condition is verified go to the step [10], if not carry out the
backlash adjustment as follows.

D.1 PAG. 54 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DIFF. E GIOCO COPPIA CONICA
Mod. 20.16-1640 DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH

7
Registrare le ghiere (3) e (7) utilizzando l’attrezzo speciale (t1).
Importante: svitare/avvitare le ghiere di registrazione, come indicato
al punto successivo, entrambe di circa 30 gradi per volta quindi
verificare il gioco.

Adjust the ring nuts (3) and (7) by using the special tool (t1).
Important: unscrew/screw the adjuster ring nuts, as indicated in the
next step, both of about 30 degrees at once then check the backlash.

8
Registrare le ghiere (3) e (7) ricordando che:
(A)- se il gioco rilevato è superiore al campo di tolleranza dato,
svitare la ghiera di registrazione (3) ed avvitare la ghiera di
A A registrazione (7) della stessa quantità;
(B)- se il gioco rilevato è inferiore al campo di tolleranza dato,
svitare la ghiera di registrazione (7) ed avvitare la ghiera di
7 3 registrazione (3) della stessa quantità.
Adjust the ring nuts (3) and (7), remembering that:
(A)- if the measured backlash is greater than the given tolerance
B B range, unscrew the adjuster ring nut (3) and screw in the adjuster ring
nut (7) by the same measure;
(B)- if the measured backlash is less than the given tolerance range,
unscrew the adjuster ring nut (7) and screw in the adjuster ring nut (3)
by the same measure.

9
Effettuata la registrazione del gioco pignone-corona verificare anche
che ci sia un minimo di precarico sui cuscinetti della scatola
differenziale
Ripetere l’intera sequenza delle operazioni citate fino al
raggiungimento delle condizioni indicate.

Once the adjustment of the pinion-ring gear backlash has been

carried out, check also that there is a minimum preloading on the
differential box bearings.
Repeat the whole sequence of the above mentioned operations till the
indicated conditions are reached.

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.1 PAG. 55

PRECARICO DIFF. E GIOCO COPPIA CONICA
DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH Mod. 20.16-1640

10
Stabilito il gioco pignone-corona, se i cuscinetti non sono stati
sostituiti, misurare il precarico totale F T m dei cuscinetti (sistema
pignone-corona) utilizzando un dinamometro con la corda avvolta sul
codolo scanalato del pignone.
Importante: utilizzare questo metodo solo se i cuscinetti sono già
rodati, altrimenti vedi passo successivo.
Il valore misurato F T m deve rientrare nel seguente campo (vedi D.1.1
passo [2]):
F T0 < F Tm < ( F T 0 + 1 0 ) [ N ]
procedere come indicato al punto [16].
Once the pinion-ring gear backlash has been established, if the
bearings have been not replaced, measure the total preloading F T m
of the bearings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion splined end.
Important: do not use this method with new bearings, if the bearings
have been replaced see next step.
The measured value F Tm should be within the following range (see
D.1.1 step [2]):
F T0 < F Tm < ( F T 0 + 1 0 ) [ N ]
follow the operating procedures in step [16].

11
Se i cuscinetti sono stati sostituiti, misurare il precarico totale F T m
dei cuscinetti (sistema pignone-corona) utilizzando un dinamometro
con la corda avvolta sull’attrezzo speciale (t2) inserito sul codolo
scanalato del pignone.

If the bearings have been replaced, measure the total preloading

F T m of the bearings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the special tool (t2) inserted
on the pinion splined end.

12
Utilizzo dell’attrezzo speciale (t2).
Vedi: Attrezzature speciali e dati Prodotto.
t2
Dm
DP

Usage of special tool (t2).

See: Special tools and Product Data.

D.1 PAG. 56 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DIFF. E GIOCO COPPIA CONICA
Mod. 20.16-1640 DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH

13
Rilevare il diametro Dm (Diametro di misura) dell’attrezzo (t7) e il
diametro del codolo pignone DP (Diametro pignone), quindi calcolare
t2 FT m il rapporto R fra i diametri:
R = Dm / DP
Il valore del precarico totale misurato F Tm deve rientrare nel campo
seguente
F Tm in / R < F T m < F Tm a x / R [ N ]
DP Vedi: Dati Prodotto per i valori ammessi F T m in e F T m a x .
Dm
Measure the diameter Dm (Diameter of measurement) of the special
tool (t7) and diameter of the pinion end DP (diameter of pinion), then
calculate the ratio R between the diameters:
R= Dm /DP
The measured value of total preloading F T m must be within the
following range:
FTmin/R < F T m < FPmax/R [ N ]
See: values FTmin and FTmax indicated in Product Data.

14
Stabilito il gioco pignone-corona, in alternativa ai passi [12] e [13] è
possibile misurare la coppia di rotolamento totale (MT m ) dei cuscinetti
(sistema pignone-corona) con un torsiometro.
Importante: tutti i precarichi devono essere misurati senza anello di
tenuta.

Once the pinion-ring gear backlash has been established, instead

proceeding with step [12] and [13] measure the total rolling torque (TT)
of the bearings (pinion-crown bevel gear system) by using a torque
meter.
Important: all the preloads must be measured without the seal
installed.

15
La coppia totale MT m deve rientrare nel seguente campo:
M T m in < MTm < M T m a x [ N ]
Vedi: C.4 e Dati Prodotto.

MT m
The total rolling torque MTm must be within the following range:
M Tmin < M Tm < M Tmax [ N ]
See: C.4 and Product Data.

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.1 PAG. 57

PRECARICO DIFF. E GIOCO COPPIA CONICA
DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH Mod. 20.16-1640

16
Se la misurazione non rientrasse nel campo prescritto, controllare
bene l’assemblaggio di ogni singolo componente ed intervenire sulle
ghiere di registrazione (3) e (7) del supporto differenziale:
A A (A)- se il precarico totale è inferiore al campo dato, avvitare della
stessa quantità le ghiere di registrazione (3) e (7), mantenendo
inalterato il valore del gioco pignone-corona;
7 3 (B)- se il precarico totale è superiore al campo dato, svitare della
stessa quantità le ghiere di registrazione (3) e (7), mantenendo
inalterato il valore del gioco pignone-corona.
B B If the measurement is not within the requested range, check well the
assembly of each component and operate on the adjuster ring nuts
(3) and (7) of the differential support:
(A)- if the total preloading is less than the given range, screw in both
adjuster ring nuts (3) and (7) by the same measure, keeping the
pinion-ring gear backlash value unchanged;
(B)- if the total preloading is greater than the given range, unscrew
both adjuster ring nuts (3) and (7) by the same measure, keeping the
pinion-ring gear backlash value unchanged.

17
Dopo aver completato tutte le operazioni di registro, montare i fermo
ghiera (8) e le rispettive viti (9), serrandole alla coppia prevista.
Serrare definitivamente le viti (12) delle due semicravatte (11) alla
coppia prevista.

Once all the adjustment operations have been completed, fit the ring
nut retainers (8) and their screws (9), tightening them to the requested
torque.
Tighten the bolts (12) of both half collars (11) to the requested torque.

18
Sgrassare e pulire con detergenti appositi le superfici di contatto.
Stendere un velo di sigillante sulla superficie di contatto tra il trave (14)
ed il supporto differenziale (1).
Nota: verificare che le due spine di centraggio (13) siano nelle loro
sedi.

Degrease and clean the matching surfaces by using appropriate

detergents.
Spread a film of adhesive on the contact surface between the axle
beam (14) and the differential carrier (1).
Note: check that two dowel pins (13) are in their seats.

D.1 PAG. 58 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DIFF. E GIOCO COPPIA CONICA
Mod. 20.16-1640 DIFF. PRELOAD AND BEVEL GEAR PAIR BACKLASH

19
Inserire il supporto differenziale (1) nel trave (14).
Assemblare le 5 viti inferiori lunghe (2a) e le 5 viti superiori corte (2b).
Serrare le viti alla coppia prescritta.

Insert the differential support (1) in the axle beam (14).

Assemble the 5 long screws (2a) (at the bottom) and the 5 short
screws (2b) (at the top).
Tighten the retaining screws (2) to the requested torque.

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.1 PAG. 59

PRECARICO DEI CUSCINETTI PIGNONE
PINION BEARINGS PRELOAD ADJUSTMENT Mod. 20.16-1640

D.2 Precarico dei cuscinetti D.2 Pinion bearings preload

pignone adjustment

7 5 1

3
4

10

8
9

Attrezzature speciali Posizione Special Tools

Descrizione Position Description
Chiave bloccaggio pignone (t1) Pinion retainer wrench
Chiave per ghiera pignone (t2) Wrench for pinion nut
Falso pignone (t3) False pinion
Falsa scatola differenziale (t4) False differential box
Tampone per cuscinetti pignone (t5) Driver for pinion bearings
Tampone per cuscinetti pignone in Driver for pinion bearings in differential
(t6)
supporto differenziale support
Attrezzo per misura precarico (t7) Tool for preloading measurement
Nota: attrezzature necessarie alle operazioni di Note: tools required for the assembly/disassembly
montaggio/smontaggio nella presente sezione. operations in the present section.
Vedi: codici d’ordine delle attrezzature Carraro Drive See: reference numbers of the Carraro Drive Tech tools
Tech in sezione Dati Tecnici dell’assale. in Technical Data section of the axle.

D.2 PAG. 60 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DEI CUSCINETTI PIGNONE
Mod. 20.16-1640 PINION BEARINGS PRELOAD ADJUSTMENT

D.2.1 Smontaggio D.2.1 Disassembly

Alcune figure che seguono potrebbero non mostrare Some of the following pictures may not show exactly
esattamente il vostro assale, ma la procedura descritta your axle, but the indicated operations are correct
è quella corretta. anyway.

1
Misurare il precarico iniziale F P 0 dei cuscinetti del pignone
utilizzando un dinamometro con la corda avvolta sul codolo scanalato
del pignone.
Attenzione: annotare il valore FP 0 che è necessario per il riassem-
blaggio dei cuscinetti.
Vedi: D.2.2 passo [15]

Measure the starting preloading FP 0 of the pinion bearings using a

dynamometer whose cord is wound on the pinion splined end.
Warning: note the value FP0 that is necessary in the bearings reas-
sembly.
See: D.2.2 step [15]

2
Fissare in morsa il gruppo differenziale.
Svitare la ghiera di serraggio (10) utilizzando gli attrezzi speciali (t2)
e (t1).
Nota: operazione distruttiva per la ghiera.

Lock the differential carrier in a vice.

Unscrew the lock nut (10) by using the special tools (t2) and (t1).
Note: This is a destructive operation for the ring nut.

3
Battere con un martello di materiale tenero sul codolo per sfilare il
pignone conico (1).
Recuperare le rondelle (4) e (6), il distanziale elastico (5), il cono del
cuscinetto (8) e la rondella fermo ghiera (9).

Tap the shaft with a soft hammer to remove the bevel pinion (1).
Collect the washer (4) and (6), the collapsible spacer (5), the bearing
cone (8) and the retaining washer (9).

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.2 PAG. 61

PRECARICO DEI CUSCINETTI PIGNONE
PINION BEARINGS PRELOAD ADJUSTMENT Mod. 20.16-1640

4
Estrarre le coppe dei cuscinetti (3) e (8) con un tampone ed un
martello.

Remove the bearing cups (3) and (8) using a driver and a hammer.

5
Per togliere il cono del cuscinetto (3) dal pignone (1) utilizzare un
estrattore di presa da commercio.
Recuperare il cono del cuscinetto (3) e lo spessore sottostante (2).

To remove the bearing cone (3) of the pinion (1), use a standard
extractor.
Collect the bearing cone (3) and the underlying shim (2).

6
Controllare le condizioni di tutti i particolari del pignone.
La ghiera (10) ed il distanziale elastico (5) in fase di rimontaggio
devono essere sostituiti.

Check all pinion components for wear.

The ring nut (10) and the collapsible spacer (5) must be replaced when
reassembling the unit.

D.2 PAG. 62 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DEI CUSCINETTI PIGNONE
Mod. 20.16-1640 PINION BEARINGS PRELOAD ADJUSTMENT

D.2.2 Montaggio D.2.2 Assembly

Alcune figure che seguono potrebbero non mostrare Some of the following pictures may not show exactly
esattamente il vostro assale, ma la procedura descritta your axle, but the indicated operations are correct
è quella corretta. anyway.

1
Piantare le coppe dei cuscinetti (3) e (8), con il tampone (t1) ed un
martello.

Fit the bearings cups (3) and (8) using the special tool (t1) and a
hammer.

2
Inserire nelle rispettive sedi i coni dei cuscinetti (3) e (8).
Assemblare il falso pignone (t3) e la ghiera (10).
Nota: potrebbe essere prevista una boccola (b) per l’accoppiamento
del falso pignone.
Vedi: schema al punto successivo e sez. Dati Prodotto.
t3 Serrare la ghiera, senza eccedere, fino ad eliminare il gioco.
Insert the bearing cones (3) and (8) in their seats.
Assemble the false pinion (t3) and its ring nut (10).
Note: a bushing (b) could be provided for a correct coupling of the
false pinion.
See: scheme to the next step and Product Data section.
Tighten without exceeding the ring nut, till the backlash is eliminated.

3
Installare il kit falsa scatola differenziale (t4) costituito dal perno (p) e
p t4 dai dischi (d) sulle sedi dei cuscinetti nel supporto differenziale (7) e
bloccarla con le semicravatte.
Nota: potrebbe essere prevista una boccola (b) per l’accoppiamento
d d del falso pignone (t3).
Vedi: sez. Dati Prodotto.

Assemble, as in the figure, the false differential box (t4) composed by

rod (p) and discs (d).
b Note: a bushing (b) could be provided for a correct coupling of the
t3 false pinion (t3).
See: Product Data section.

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.2 PAG. 63

PRECARICO DEI CUSCINETTI PIGNONE
PINION BEARINGS PRELOAD ADJUSTMENT Mod. 20.16-1640

4
Per registrare la coppia conica misurare con un calibro di profondità
la distanza “A”.
Determinare il valore “X” come segue:
X= A+(D/2)-B mm
t4 dove “B” e “D” sono valori noti.
Importante: nel caso che i valori “B” e “D” non siano indicati nel kit,
D/2
D

misurare le dimensioni necessarie dopo aver rimosso le attrezzature

speciali.
Vedi: punto seguente.
X

To adjust bevel gear/pinion measure the distance “A” with a depth

B

gauge.
t3 Calculate the value “X” as follows:
X= A+(D/2)-B mm
where “B” and “D” are known.
Important: if the values “B” and “D” are not indicated in the kit,
measure the distances indicated after removing the special
equipment.
See: the next step.

5
Rimuovere la falsa scatola differenziale (t4) dal supporto differenziale
(7).
D

Disassemblare la ghiera (10), il falso pignone (t3) ed i coni dei

cuscinetti (3) e (8).
Misurare le dimensioni “B” e “D” indicate in figura.

t4

t3 Remove the false differential box (t4) from the differential support (7).
B

Remove the ring nut (10), the false pinion (t3) and the bearing cones
(3) and (8).
Measure the dimensions “B” and “D” shown in the figure.

6
Per determinare il valore (S) dello spessore necessario tra pignone e
cuscinetto sottrarre dal valore (X) misurato il valore (V) stampigliato
sulla testa del pignone (V= distanza prescritta).

S=X-V mm

In order to determine the necessary thickness value (S) between the

pinion and the bearing, subtract the value (V), stamped on the pinion
head (V= requested distance), from the measured value (X).

D.2 PAG. 64 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DEI CUSCINETTI PIGNONE
Mod. 20.16-1640 PINION BEARINGS PRELOAD ADJUSTMENT

7
Scegliere lo spessore (2) di valore (S) tra la gamma di spessori a
disposizione.

GAMMA SPESSORI - SHIMS RANGE

Spessore/Thickness - mm 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4

Quantità/Quantity --- --- --- --- --- --- --- --- --- ---

Select the shim (2) of thickness value (S) among the range of available
shims.

8
Rimuovere l’attrezzo speciale “falsa scatola differenziale” (t4) dal
supporto differenziale (7).
Disassemblare la ghiera (10), il “falso pignone” (t3) ed i coni dei
cuscinetti (3) e (8).

t3

Remove the “false differential box” (t4) special tool from the differential
support (7).
Remove the ring nut (10), the “false pinion” (t3) and the bearing cones
(3) and (8).

9
Dopo aver scelto lo spessore (2) adatto, inserirlo sul codolo del
pignone con lo smusso rivolto verso la testa del pignone, come in
figura.
2

Once you have chosen the suitable shim (2), insert it on the pinion
shaft with the chamfer against the pinion head, as shown in figure.

10
Piantare il cuscinetto (3) sull’albero del pignone (1) sotto l’azione di
una pressa con il tampone (t5), assicurandosi che sia ben assestato.
Inserire gli spessori (4) e (6) ed un nuovo distanziale elastico (5).
Nota: utilizzare sempre un distanziale elastico nuovo.

Force the bearing (3) into the pinion shaft (1) with the special tool (t5)
under a press, making sure that it is well set.
Insert the shims (4) and (6) and the new collapsible spacer (5).
Note: use always a new collapsible spacer (5).

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.2 PAG. 65

PRECARICO DEI CUSCINETTI PIGNONE
PINION BEARINGS PRELOAD ADJUSTMENT Mod. 20.16-1640

11
Nota: verificare il corretto ordine di assemblaggio.

Note: check the right assembly sequence.

12
Inserire il gruppo pignone conico (1) preassemblato nel supporto
differenziale (7) ed il cono del cuscinetto (8) sul codolo pignone, come
in figura.
Per eseguire il piantaggio del cuscinetto (8), utilizzare il tampone (t6)
ed un martello.

Insert the bevel pinion (1) unit into the differential support housing (7)
and the bearing cone (8) into the pinion end, as shown in figure.
Use the special tool (t6) and a hammer to drive the bearing (8).

13
Inserire la rondella fermo ghiera (9) ed avvitare una nuova ghiera di
serraggio (10) sul codolo del pignone.

Insert the ring nut washer (9) and screw a new lock ring nut (10) on
the pinion end.

D.2 PAG. 66 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DEI CUSCINETTI PIGNONE
Mod. 20.16-1640 PINION BEARINGS PRELOAD ADJUSTMENT

14
Avvitare la ghiera (10) utilizzando le chiavi per ghiera (t2) e fermo
pignone (t1) fino a fine corsa senza eccedere.
La coppia di serraggio è data dalla misurazione del precarico sui
cuscinetti (3) e (8): serrare la ghiera (10) progressivamente di 15°÷20°
misurando ogni volta il carico ottenuto.
Attenzione: se il serraggio è eccessivo il distanziale elastico (5) dovrà
essere sostituito e la procedura ripetuta.
Nota: Al momento di verificare il precarico è opportuno dare piccoli
colpi con martello in materiale tenero alle estremità del pignone (1)
per favorire l’assestamento dei cuscinetti (3) e (8).
Screw in the ring nut (10) till the end without exceeding, using the
wrenches (t2) for ring nut and (t1) for pinion retainer.
The torque setting is given by the preloading measurement on
bearings (3) and (8): tighten the ring nut (10) gradually 15°÷20° every
step then measure the resulting preloading.
Warning: if the tightening is excessive, the elastic spacer (5) must be
replaced and the procedure repeated.
Note: When you check the preloading, it is advisable to beat slightly
both pinion ends (1) with a soft hammer, so as to help setting the
bearings (3) and (8).

15
Se i cuscinetti non sono stati sostituiti, per misurare il precarico
F Pm dei cuscinetti conici (3) e (8), utilizzare un dinamometro con una
cordicella avvolta sul codolo del pignone (1).
Attenzione: utilizzare questo metodo solo se i cuscinetti non vengono
sostituiti, altrimenti vedi punto successivo.
Il valore misurato deve essere pari a quello iniziale (vedi D.2.1 passo
[1]):
F P0 < F Pm < ( F P0+ 1 0 ) [ N ]
procedere come indicato al punto [22].
If the bearings have been not replaced, to measure the preloading
F Pm of the pinion taper roller bearings (3) and (8), use a dynamometer
whose cord is wound on the end of pinion shaft (1).
Warning: do not use this method with new bearings, if the bearings
have been replaced see next step.
The measured value must be equal to the initial value (see D.2.1 step
[1]):
F P0 < F Pm < ( F P0+ 1 0 ) [ N ]
follow the operating procedures in step [22].

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.2 PAG. 67

PRECARICO DEI CUSCINETTI PIGNONE
PINION BEARINGS PRELOAD ADJUSTMENT Mod. 20.16-1640

16
Se si utilizzano nuovi cuscinetti conici (3) e (8), per misurare il
precarico F P m dei cuscinetti, utilizzare un dinamometro con una
cordicella avvolta sull’attrezzo (t7), inserito sul codolo del pignone.

If the pinion taper roller bearings (3) and (8) are new, to measure
the preloading F P m of the bearings, use a dynamometer whose cord
is wound on the special tool (t7) inserted on the end of pinion shaft.

17
Utilizzo dell’attrezzo speciale (t7).
Vedi: Attrezzature speciali e dati Prodotto.
Dm
DP

Usage of special tool (t7).

See: Special tools and Product Data.

18
Rilevare il diametro Dm (Diametro di misura) dell’attrezzo (t7) e il
diametro del codolo pignone DP (Diametro pignone), quindi calcolare
FP m il rapporto R fra i diametri:
R = D m / DP
Il valore del precarico misurato F Pm deve rientrare nel campo:
F Pm in / R < F P m < F Pm a x / R [ N ]
Vedi: Dati Prodotto per i valori ammessi F Pm in e F P m ax .
DP
Measure the diameter Dm (Diameter of measurement) of the special
Dm
tool (t7) and diameter of the pinion end DP (diameter of pinion), then
calculate the ratio R between the diameters:
R= Dm /DP
The measured value of preloading must be within the following range:
FPmin/R < FPm < FPmax/R [N]
See: values FPmin and FPmax indicated in Product Data.

D.2 PAG. 68 REVISION DATE: 05/16 DOC. CA270410 AB10710

 PRECARICO DEI CUSCINETTI PIGNONE
Mod. 20.16-1640 PINION BEARINGS PRELOAD ADJUSTMENT

19
Esempio Dati rilevati: Dm = 100.0 mm, DP = 29.75 mm.
Esempio/Example Esempio Dati Prodotto: FP m in = 107.6 N, FP m a x = 161.3 N.
FP m
Si calcola R= 100.0/29.75= 3.36
quindi (107.6/3.36) < F Pm < (161.3/3.36),
in questo caso il precarico misurato deve rientrare nel campo:
3 2 < F Pm < 4 8 N
Example Data measured: Dm = 100.0 mm, DP = 29.75 mm
29.75 Example Product Data: FPmin= 107.6 N FPmax= 161.3 N
100.0
Calculate R= 100.0/29.75= 3.36
then (107.6/3.36) < FPm < (161.3/3.36),
in this case the measured preload value must be within the range
3 2 < FPm < 4 8 N

20
In alternativa ai passi [17] e [18] è possibile misurare la coppia di
rotolamento MP dei cuscinetti conici dell’albero del pignone con un
torsiometro.
Importante: tutti i precarichi devono essere misurati senza anello di
tenuta.

Instead proceeding with step [17] and [18] measure the pinion shaft
bearings rolling torque MP with a torque meter.
Important: all the preloads must be measured without the seal ring.

21
Il valore misurato MP deve rientrare nel seguente campo:
M P m in < M P < MPma x [ N m ]
Vedi: C.4 e Dati Prodotto.

MP

The measured value MP must be within the following range:

MPmin < M P < MPmax [ N m ]
See: C.4 and Product Data.

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.2 PAG. 69

PRECARICO DEI CUSCINETTI PIGNONE
PINION BEARINGS PRELOAD ADJUSTMENT Mod. 20.16-1640

22
La regolazione si effettua aumentando gradualmente il serraggio della
ghiera (10), facendo attenzione a non eccedere.
Importante: tutti i precarichi devono essere misurati senza anelli di
tenuta.
Ottenuto il prescritto valore di carico, cianfrinare la ghiera (10)
utilizzando martello e punzone.

The adjustment is carried out by increasing the ring nut (10) torque
gradually, being careful not to exceed.
Important: all preloadings must be measured without the seal rings.
Once the requested preloading value is achieved, caulk the ring nut
(10), using a hammer and a chisel.

D.2 PAG. 70 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CONVERGENZA/ANGOLO DI STERZATA
Mod. 20.16-1640 TOE-IN/STEERING ANGLE

D.3 Convergenza/angolo di sterzata D.3 Toe-in/steering angle

1 2 2 1
3 3

1 2 2 1
3 3

Attrezzature speciali Posizione Special Tools

Descrizione Position Description
- - -
Nota: attrezzature necessarie alle operazioni di Note: tools required for the assembly/disassembly
montaggio/smontaggio nella presente sezione operations in the present section

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.3 PAG. 71

CONVERGENZA/ANGOLO DI STERZATA
TOE-IN/STEERING ANGLE Mod. 20.16-1640

D.3.1 Verifica della convergenza D.3.1 Toe-in adjustment

Alcune figure che seguono potrebbero non mostrare Some of the following pictures may not show exactly
esattamente il vostro assale, ma la procedura descritta your axle, but the indicated operations are correct
è quella corretta. anyway.

1
Montare 2 barre lineari uguali, lunghe 1 m, sui lati ruota, bloccandole
con due dadi, sui prigionieri mozzo ruota.
€ A V V E R T E N Z A le due barre devono essere fissate alla
loro mezzeria, in modo che siano perfettamente perpendicolari alla
superficie di appoggio e parallele all’asse del pignone; allineare al
meglio le due barre.
Put two equal one-meter-long linear bars on the wheel sides and lock
them with two nuts on the wheel hub stud bolt.
500 mm 500 mm € WARNING the two bars should be fixed on their middle so
that they are perpendicular to the supporting surface and parallel to
the pinion shaft axis; align the two bars.

2
Rilevare con un metro a nastro, dai punti più estremi delle barre, la
distanza millimetrica M.
Nota: prendere il valore minimo oscillando il punto di misurazione.

Measure the distance in mm M between the bars ends with a tapeline.

Note: keep the minimum value, swinging the measurement point.

3
Verificare che la differenza tra le misurazioni alle estremità dei
0
A -2 diametri dei mozzi ruota rientri nel campo di tolleranza richiesto.
Vedi: “Convergenza” in Dati Tecnici.
Il valore della convergenza nominale (A) è riferito al diametro esterno
della flangia dei mozzi ruota, quindi il valore misurato (M) alle
estremità delle barre deve essere rapportato alle loro proporzioni
rispetto a tale diametro
0 0
converg. nominale (sez.C.4) = A - 2 converg. misurata = M - 5

A
0
M-5

Check that the difference of the measurements between the wheel

hubs diameters ends is within the requested tolerance range.
See: “Toe-in” in Technical Data.
The nominal toe-in value (A) is referred to the external diameter of the
wheel hubs flange, therefore the measured value (M) at the bars ends
must be related to the ratio between length of the bar and flange
M diameter
0 0
nominal toe-in (sec.C.4) = A - 2 measured toe-in = M - 5

D.3 PAG. 72 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CONVERGENZA/ANGOLO DI STERZATA
Mod. 20.16-1640 TOE-IN/STEERING ANGLE

4
Nel caso che la convergenza non sia esatta agire con due chiavi sulle
aste guida (1) avvitando e svitando i due tiranti snodo (3) equamente,
in modo che alla fine rientri nella tolleranza prevista.

If toe-in is incorrect, operate with two wrenches on the guide rods (1)
screwing in and out the two joint tie rods (3) equally till the toe-in is
within the requested tolerance.

5
Nota: prima di bloccare i dadi (2), utilizzare una chiave (come in
figura) per non permettere la rotazione dell’asta guida (1); se l’asta
guida ruota, la cuffia in gomma (e) può danneggiarsi.
Vedi: punto successivo.
1

e Note: before tightening the nuts (2), use a wrench (as shown in figure)
to lock the tie-rod (1). If the tie-rod turn the rubber cover (e) can be
damaged.

6
Importante: se l’asta guida ruota, la cuffia in gomma (e) può
danneggiarsi; bloccare l’asta guida con una chiave.

e
Important: if the tie-rod turns the rubber cover (e) can be damaged;
lock the tie-rod with a wrench.

7
Eseguita la regolazione, avvitare i dadi di bloccaggio (2) delle aste
guida (1) alla coppia di serraggio prevista.

After adjusting, screw in the lock nuts (2) of the guide rods (1) to the
requested tightening torque.

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.3 PAG. 73

CONVERGENZA/ANGOLO DI STERZATA
TOE-IN/STEERING ANGLE Mod. 20.16-1640

D.3.2 Regolazione dei fermi sterzata D.3.2 Steering stops adjustment

Alcune figure che seguono potrebbero non mostrare Some of the following pictures may not show exactly
esattamente il vostro assale, ma la procedura descritta your axle, but the indicated operations are correct
è quella corretta. anyway.

D.3.2.1 Regolazione con riferimento D.3.2.1 Adjustment with reference

l’angolo di sterzata steering angle

1
Utilizzare le stesse barre montate per la registrazione della conver-
genza ed una barra lunga, appoggiata perfettamente alla parte
lavorata del corpo centrale (lato pignone), in modo che al massimo
della sterzata le due barre formino un angolo acuto.

Use the same bars assembled for the toe-in adjustment and a long
bar perfectly leaned over the machined part of the central body (pinion
side), so that the two bars form an acute angle at the maximum
steering.

2
Per la registrazione dell angolo di sterzata, regolare un goniometro
alla misura dell’angolo C calcolato come segue:
C= 90°-S
Dove S è l’angolo di registrazione sterzata prescritto.
Vedi: Dati Tecnici.
Posizionare il goniometro sulla barra lunga.
Orientare il gruppo ruota in modo che le due barre formino l’angolo
calcolato C.
For the steering angle adjustment, set a protractor to the following
calculated angle C:
C= 90°-S
Where S is the prescribed adjustment steering angle.
See: Technical Data.
Position the protractor on the long bar.
Move a wheel side till the two bars form the calculated angle C.

3
Svitare il dado (5) per sbloccare il fermo sterzata da registrare.
Effettuare la regolazione del fermo meccanico di sterzata, avvitando
o svitando le apposite viti (4), bloccandole poi con i dadi (5) alla coppia
di serraggio prescritta.

4 5

Unscrew the nut (5) to unlock the stop steering to be adjusted.

Adjust the mechanical steering stop, screwing in or out the stop bolts
(4), locking them with the nuts (5) to the requested tightening torque.

D.3 PAG. 74 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CONVERGENZA/ANGOLO DI STERZATA
Mod. 20.16-1640 TOE-IN/STEERING ANGLE

4
Nota: in alcuni assali potrebbero essere presenti anche 1 o 2 boccole
distanziali (d) sotto il dado (5); non rimuovere i distanziali dove
presenti.

d
Note: in some axles may also be present 1 or 2 spacer bushings (d)
under the locknut (5); do not remove the spacers if present.

5
Sterzare completamente dal lato opposto e ripetere le stesse opera-
zioni sopra descritte.

Steer completely towards the other side and repeat the same opera-
tions described above.

6
Bloccare la vite (4) serrando il controdado (5) alla coppia prevista.
Importante: si consiglia di eseguire la verifica dell’angolo di sterzata
massimo (vedi relativa sezione in questo capitolo).

Lock the stop screw (4) by tightening the locknut (5) to the prescribed
torque.
Important: it’s recommended to check the maximum steering angle
(see related section in this chapter).

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.3 PAG. 75

CONVERGENZA/ANGOLO DI STERZATA
TOE-IN/STEERING ANGLE Mod. 20.16-1640

D.3.2.2 Regolazione con quota di D.3.2.2 Adjustment with reference

riferimento dimension

1
Svitare il dado (5) per sbloccare il fermo sterzata da registrare.

Unscrew the nut (5) to unlock the stop steering to be adjusted.

2
Effettuare la regolazione del fermo meccanico di sterzata alla quota R
indicata (vedi Dati Tecnici), avvitando o svitando l’apposita vite (4).
Nota: in alcuni assali potrebbero essere presenti anche 1 o 2 boccole
4 distanziali (d) sotto il dado (5); non rimuovere i distanziali dove
presenti.
5 Bloccare la vite (4) serrando il controdado (5) alla coppia prevista.
d
Adjust the mechanical steering stop at the indicated dimension R (in
Technical Data), by screwing in or out the stop screw (4).
P
R

Note: in some axles may also be present 1 or 2 spacer bushings (d)

under the locknut (5); do not remove the spacers if present.
Lock the stop screw (4) by tightening the locknut (5) to the prescribed
torque.

3
Sterzare i mozzi ruota dal lato opposto e regolare il secondo fermo
meccanico come sopra descritto.
Bloccare la vite (4) serrando il controdado (5) alla coppia prevista.
4 Importante: si consiglia di eseguire la verifica dell’angolo di sterzata
massimo (vedi relativa sezione in questo capitolo).
5
Steer the wheel hubs on the opposite side and adjust the second
mechanical stop as described above.
RP

Lock the stop screw (4) by tightening the locknut (5) to the prescribed
torque.
Important: it’s recommended to check the maximum steering angle
(see related section in this chapter).

D.3 PAG. 76 REVISION DATE: 05/16 DOC. CA270410 AB10710

 CONVERGENZA/ANGOLO DI STERZATA
Mod. 20.16-1640 TOE-IN/STEERING ANGLE

D.3.2.3 Verifica angolo di sterzata D.3.2.3 Maximum steering angle check

massimo

1
Utilizzare le stesse barre montate per la registrazione della conver-
genza ed una barra lunga, appoggiata perfettamente alla parte
lavorata del corpo centrale (lato pignone), in modo che al massimo
della sterzata le due barre formino un angolo acuto.

Use the same bars assembled for the toe-in adjustment and a long
bar perfectly leaned over the machined part of the central body (pinion
side), so that the two bars form an acute angle at the maximum
steering.

2
Per la verifica dell angolo di sterzata, regolare un goniometro alla
misura dell’angolo C calcolato come segue:
C= 90°-S
Dove S è l’angolo di registrazione prescritto.
Vedi: Dati Tecnici.
Sterzare completamente i mozzi ruota in modo che il fermo sterzata
sia a contatto con l’assale.
Posizionare il goniometro sulla barra lunga e verificare l’angolo
precedentemente calcolato C.
Se necessario regolare la posizione del fermo meccanico di sterzata
come indicato nei paragrafi precedenti.
Importante: ripetere l’operazione di verifica sterzando dal lato
opposto; l’angolo massimo di sterzata deve essere uguale su
entrambi i lati.
For the steering angle check, set a protractor to the following
calculated angle C:
C= 90°-S
Where S is the prescribed adjustment steering angle.
See: Technical Data.
Steer completely the wheel hubs so that the steering stop is in contact
with the axle.
Position the protractor on the long bar and check the previously
calculated angle C.
If necessary, adjust the position of the mechanical stop as indicated
in the previous paragraphs.
Important: repeat the steering check on the opposite side; the
maximum steering angle must be equal on both sides.

AB10710 REVISION DATE: 05/16 DOC. CA270410 D.3 PAG. 77

PROVE DOPO MONTAGGIO
TESTING AFTER ASSEMBLY Mod. 20.16-1640

D.4 Prove dopo montaggio D.4 Testing after assembly

D.4.1 Prova di tenuta pressione D.4.1 Pressure test

Eseguire una prova di tenuta sotto pressione Perform a pressure test on the complete assembled
sull’assale completamente assemblato e verificare che axle and check the whole system to find any possible
non siano presenti perdite. leakage.
Attenzione: la pressione di prova totale massima non Warning: the maximum test total pressure must be
deve mai superare 1500 mbar (1.5 bar). always lower then 1500 mbar (1.5 bar).
Rimuovere le eventuali perdite prima di assemblare Stop every leak before assembling the axle to the
l’assale al veicolo. vehicle.

D.4.2 Procedure di collaudo D.4.2 Testing methods

Passo 1 Step 1
A motore spento, sollevare l'assale della ruota motrice With engine off, lift the axle so that the tyres get away
sino a che i pneumatici si siano staccati da terra. from the ground.
Nota: se presenti, disattivare i freni negativi di Note: if present, disable the negative parking brakes.
parcheggio.

Passo 2 Step 2
Ingranare la marcia in modo che il pignone sia bloccato. Engage the gear so that the pinion gets locked.

Passo 3 Step 3
Con l'aiuto di un'altra persona collocata al lato opposto, With the help of another person standing on the
iniziare la prova di montaggio ruotando per quanto opposite side, begin the assembly testing by rotating as
possibile entrambe le ruote nel senso di marcia avanti. much as possible both the wheels forward. (Both the
(Entrambe le ruote dovrebbero bloccarsi dopo poco). wheels should get locked after a while).

Passo 4 Step 4
Con il pignone sempre bloccato, liberare la ruota di Keeping the pinion locked, free the right wheel and
destra e ruotare la ruota di sinistra nel senso di marcia rotate the left one in the line of march. Rotate the right
avanti. wheels in the opposite direction.
Se il montaggio è corretto si dovrà verificare che la The wheel will move freely without difficulty and the
ruota giri liberamente senza eccessivi sforzi, e la ruota right wheel will move in the opposite direction if the
di destra ruoti in senso opposto. assembly has been carried out correctly.
Ripetere l'operazione nel senso di marcia opposto Repeat the same operation in the opposite direction
(retro marcia). (reverse gear).

SE UNA DELLE RUOTE NON GIRA LIBERAMENTE IF ONE WHEEL DOES NOT ROTATE FREELY IN
IN ENTRAMBE LE DIREZIONI, ricontrollare passo per BOTH DIRECTIONS, then check step by step all
passo il montaggio. assembly operations.
Controllare anche che i freni siano regolati in modo da Check and see that the brakes are regulated correctly
consentirne il corretto funzionamento. and functioning properly.

D.4 PAG. 78 REVISION DATE: 05/16 DOC. CA270410 AB10710

 RICERCA GUASTI
Mod. 20.16-1640 TROUBLESHOOTING

E RICERCA GUASTI

E TROUBLESHOOTING

AB10710 REVISION DATE: 05/16 DOC. CA270410 E PAG. 79

RICERCA GUASTI
TROUBLESHOOTING Mod. 20.16-1640

PROBLEMA POSSIBILI CAUSE

1 2 3 4 5 6 7 8 9 10 11

- Vibrazioni delle ruote; resistenza del pneumatico

    
anteriore; rottura del/i semiasse/i.
- Difficoltà nello sterzare; il veicolo tende ad andare
    
dritto mentre è in curva.
- Non vi è azione del differenziale; inceppamento in
   
curva.
- Rumore eccessivo nella trasmissione.
       

- Usura eccessiva del pneumatico.

       

- Rumore di attrito.
      

- In marcia avanti si avvertono vibrazioni, rumore

    
intermittente.

PROBLEMS POSSIBLE CAUSES

1 2 3 4 5 6 7 8 9 10 11

- Wheel vibration; front tyre resistance; half-shaft

    
breakage.
- Steering is difficult; vehicle goes straight while its
    
turning.
- No differential action; jamming while steering.
   

- No differential action; jamming while steering.

       

- Uneven wear of tyre.

       

- Friction noise.
      

- Vibration during forward drive, intermittent noise.

    

Azione consigliata Solving action

1 Installazione scorretta / assale difettoso 1 Incorrect installation / defective axle
Correggere l'installazione oppure, se il differenziale non Correct installation or repair or replace the differential in
supera una delle fasi di prova, ripararlo o sostituirlo. case it does not survive any one of the test phases.
2 Sovraccarico / distribuzione scorretta del peso 2 Overloading / incorrect weight distribution
Togliere il peso in eccesso e ridistribuire il carico, Remove excessive weight and redistribute load,
rispettando le istruzioni relative al veicolo. following instructions related to the vehicle.

PAG. 80 REVISION DATE: 05/16 DOC. CA270410 AB10710

 RICERCA GUASTI
Mod. 20.16-1640 TROUBLESHOOTING

3 Raggio di rotazione degli pneumatici diversi 3 Different rotation radius of the tyres
Un pneumatico con raggio più piccolo provoca un If one tyre has a smaller radius, it will cause partial
parziale slittamento della ruota quando si applica wheel slipping when force is applied. The other tyre with
energia. L'altro pneumatico con raggio maggiore dovrà bigger radius will have to support all the work. Replace
sopportare tutto il lavoro. Sostituire il pneumatico o the tyre or adjust pressure to have same radius on both
regolare la pressione di entrambi sino a che il raggio di tyre.
rotazione sia uguale. 4 Broken half-shaft
4 Semiasse rotto It is not advisable to operate the vehicle with a broken
E' sconsigliato usare un veicolo con un solo semiasse. half-shaft. It is acceptable to move the vehicle (engine
E' possibile tuttavia spostare il veicolo a vuoto con il off unloaded) a few meters away only.
differenziale bloccato per pochi metri.
5 Bent half-shaft
5 Semiasse piegato Replace half-shaft.
Sostituire i semiassi.
6 Blocked differential
6 Differenziale bloccato Abnormal functioning of the differential or breakage/
Funzionamento anomalo del differenziale e/o rottura blockage of command device. Verify assembly and all
del dispositivo di comando del bloccaggio di comando. components.
Verificare l'installazione, eventualmente smontare e Vehicles with wide steering angle may proceed with
verificare i componenti. kicks, have steering difficulty or cause pneumatic
I veicoli impostati per angoli di sterzata ampi, possono wearing at sharp turns. Reduce the steering angle to
procedere a scatti, avere difficoltà di sterzo e provocare minimum and decelerate when the vehicle begins to
un consumo del pneumatico nelle curve strette. kick.
Ridurre l'angolo di sterzata minimo e decelerare
quando il motore inizia a procedere a scatti. 7 Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
7 Allineamento scorretto della ruota Adjusting according.
Verificare l'integrità della struttura, e cuscinetti lato
ruota. 8 Spoiled or worn out axle parts
Check the condition of ring gear, pinion gear, bearings
8 Parti dell'assale consumate o difettose
etc. Replace when ever necessary.
Controllare le condizioni della corona dentata,
dell'ingranaggio del pignone, dei cuscinetti, delle 9 Contamination in the axle box or incorrect
guarnizioni, ecc. Sostituire dove necessario. assembly of parts
Look for foreign particles. Check assembly of the
9 Corpi estranei nella scatola dell'assale o
various parts of the axle.
montaggio scorretto di alcune sue parti
Controllare se vi sono corpi estranei. Controllare il 10 Incorrect adjustment of bevel gear set: Parts of
montaggio delle parti dell'assale. the transmission worn out.
(transmission gears, U joints, etc.)
10 Regolazioni della coppia conica scorrette: parti
Replace or adjust as required.
di trasmissione consumate
(ingranaggi di trasmissione, giunti, ecc.). Sostituire o 11 Incorrect use of the product
regolare secondo necessità. See the vehicle producer‘s instructions once again.
11 Uso scorretto del prodotto
Rivedere le istruzioni rilasciate dal produttore del
veicolo.

AB10710 REVISION DATE: 05/16 DOC. CA270410 PAG. 81

RICERCA GUASTI
TROUBLESHOOTING Mod. 20.16-1640

E.1 Controllo ed esame dei guasti

Questo capitolo offre una guida descrittiva ed esplicativa di problemi che si possono comunemente riscontrare sugli
assali o di avarie che si possono verificare. La guida suggerisce anche le corrette procedure di riparazione.

Problema Causa Azione consigliata

Rottura verso l'estremità esterna del 1. Carico dell'ingranaggio eccessivo Sostituire la coppia conica.
dente corona dentata rispetto a quello previsto Seguire attentamente le operazioni
2. Regolazione ingranaggio scorretto raccomandate di regolazione del
(gioco eccessivo) gioco della corona dentata e del
3. Dado del pignone allentato. pignone e per la rilevazione
dell’impronta del dente.
Rottura verso l'estremità interna del 1. Urto da carico Sostituire la coppia conica.
dente corona dentata 2. Regolazione ingranaggio scorretto Seguire attentamente le operazioni
(gioco insufficiente) raccomandate di regolazione del
3. Dado del pignone allentato gioco della corona dentata e del
pignone e per la rilevazione
dell’impronta del dente
Denti del pignone e della corona 1. Lubrificazione insufficiente Sostituire la coppia conica.
dentata erosi o rigati 2. Lubrificante sporco Sostituire i cuscinetti del pignone
3. Lubrificante errato o con additivi facendo attenzione a sistemare
impoveriti correttamente la corona, il pignone e i
4. Cuscinetti del pignone consumati precarichi dei cuscinetti.
che provocano un gioco assiale del Usare il lubrificante corretto, riempire
pignone e un contatto tra pignone e fino al giusto livello e sostituirlo agli
corona scorretto. intervalli raccomandati.
Denti della corona e del pignone 1. Funzionamento prolungato a Sostituire la coppia conica.
surriscaldati. Guardare se i denti temperatura eccessiva. Usare il lubrificante corretto, riempire
dell'ingranaggio hanno perso la 2. Lubrificante scorretto fino al giusto livello e sostituirlo agli
colorazione 3. Livello dell'olio basso intervalli raccomandati.
4. Lubrificante sporco.
Denti del pignone di comando 1. Uso estremamente intenso Sostituire la coppia conica.
butterati 2. Lubrificazione insufficiente Usare il lubrificante corretto, riempire
fino al giusto livello e sostituirlo agli
intervalli raccomandati.
Corpo trave dell'assale piegato 1. Sovraccarico del veicolo Sostituire il corpo trave dell'assale
2. Veicolo incidentato
3. Urto da carico
Cuscinetti consumati o butterati 1. Lubrificazione insufficiente Sostituire i cuscinetti.
2. Lubrificante sporco Usare il lubrificante corretto, riempire
3. Uso estremamente intenso fino al giusto livello e sostituirlo agli
4. Consumo normale intervalli raccomandati.
5. Dado del pignone allentato.
Le guarnizioni perdono olio 1. Funzionamento prolungato con Sostituire la guarnizione e la
temperatura dell'olio eccessiva. superficie di accoppiamento se
2. Guarnizione dell'olio montata male danneggiata.
3. Bordo della guarnizione tagliata o Usare il lubrificante corretto, riempire
intaccata fino al giusto livello e sostituirlo agli
4. Lubrificante sporco intervalli raccomandati.

E.1 PAG. 82 REVISION DATE: 05/16 DOC. CA270410 AB10710

 RICERCA GUASTI
Mod. 20.16-1640 TROUBLESHOOTING

Problema Causa Azione consigliata

Usura eccessiva della scanalatura 1. Uso intenso Sostituire la flangia

della flangia di entrata. 2. Dado del pignone allentato Controllare che la scanalatura del
3. Gioco assiale del pignone pignone non sia eccessivamente
consumata
Sostituire la coppia conica, se
necessario.
Rottura per fatica del dente 1. Uso intenso Sostituire la coppia conica.
dell'ingranaggio del pignone. 2. Sovraccarico continuo
Guardare se la linea di frattura ad
onda è ben delineata (linea di
arresto).
Rottura denti pignone e corona Carico d'urto dei componenti del Controllare e/o sostituire altri
differenziale componenti differenziale.
Scanalature dell'ingranaggio Uso intenso Sostituire il gruppo ingranaggi
planetario consumate (gioco differenziale. Sostituire il semiasse, se
eccessivo) necessario.
Superfici della ralla di rasamento 1. Lubrificazione insufficiente Sostituire tutte le ralle graffiate e
consumate o graffiate 2. Lubrificazione scorretta quelle con uno spessore di 0,1 mm
3. Lubrificante sporco inferiore a quello delle ralle nuove.
Usare il lubrificante corretto, riempire
fino al giusto livello e sostituirlo agli
intervalli raccomandati.
Diametro interno del cuscinetto a rulli 1. Uso intenso Sostituire il cuscinetto
conici del pignone consumato 2. Gioco assiale del pignone Controllare il gioco assiale del
eccessivo pignone
3. Lubrificazione inadeguata Usare il lubrificante corretto, riempire
4. Lubrificante sporco fino al giusto livello e sostituirlo agli
intervalli raccomandati.
Semiasse ritorto o rotto Funzionamento intenso del veicolo, Sostituire il semiasse
sovraccarico
Semiasse spezzato presso la flangia 1. Supporto della ruota allentato Sostituire il semiasse
ruota 2. Corpo trave piegato Controllare la distorsione del corpo
trave. Accertarsi che il sostegno della
ruota non sia consumato o mal
regolato.

AB10710 REVISION DATE: 05/16 DOC. CA270410 E.1 PAG. 83

RICERCA GUASTI
TROUBLESHOOTING Mod. 20.16-1640

E.1 Troubleshooting
This chapter is a descriptive and explanatory guide to common axle problems. This guide suggests the repair correct
procedures to be followed.

Problem Cause Action

Ring gear tooth broken at the outer 1. Excessive gear load compared to Replace bevel gear set
side the one foreseen Follow carefully the recommended
2. Incorrect gear adjustment operations for the adjustment of bevel
(excessive backlash) gear set backlash
3. Pinion nut loose
Ring gear tooth broken side 1. Load bump Replace bevel gear set
2. Incorrect gear adjustment Follow carefully the recommended
(insufficient backlash) operations for the adjustment of bevel
3. Pinion nut loose gear set backlash.
Pinion or ring gear teeth or worn 1. Insufficient lubrication Replace bevel gear set.
2. Contaminated oil Follow carefully the recommended
3. Incorrect lubrication or depleted operations for the adjustment of bevel
additives gear set backlash.
4. Worn out pinion bearings that Use correct lubricants, fill up to the
cause an incorrect pinion axle right levels and replace according to
backlash and wrong contact between the recommended program.
pinion and ring.
Overheated ring and pinion teeth. 1. Prolong ed functioning at high Replace bevel gear set.
See if gear teeth have faded temperatures Use proper lubrication, fill up to right
2. Incorrect lubrication level and replace at recommended
3. Low oil level program.
4. Contaminated oil
Pinion teeth pitting 1. Excessive use Replace bevel gear set.
2. Insufficient lubrication Use correct lubrication, fill up to the
right level and substitute at
recommended intervals
Axle beam body bent 1. Vehicle over loaded Replace axle beam body
2. Vehicle's accident
3. Load bump
Worn out or pitted bearings 1. Insufficient lubrication Replace bearings.
2. Contaminated oil Use correct lubrication fill up, to the
3. Excessive use right level and replace at
4. Normal wear out recommended intervals
5. Pinion nut loose
Oil leakage form gaskets and seals 1. Prolonged functioning at high Replace the gasket or seal and
temperature of the oil matching surface if damaged.
2. Oil gasket assembled incorrectly Use correct lubrication and replace at
3. Seal lip damaged recommended intervals.
4. Contaminated oil
Excessive wearing out of input flange 1. Exhaustive use Replace the flange.
spline 2. Pinion nut loose Check that the pinion spline is not
3. Pinion axle backlash excessively worn out.
Replace bevel gear set if required.
Fatigue failure of pinion teeth 1. Exhaustive use Replace bevel gear set
See if the fracture line is well defined 2. Continuos overload
(wave lines, beach lines)

E.1 PAG. 84 REVISION DATE: 05/16 DOC. CA270410 AB10710

 RICERCA GUASTI
Mod. 20.16-1640 TROUBLESHOOTING

Problem Cause Action

Pinion and ring teeth breakage 1. Crash load of differential Check and/or replace other differential
components components.
Side gear spline worn out Excessive use Replace differential gear group.
(Excessive backlash) Replace half-shaft if required
Thrust washer surface worn out or 1. Insufficient lubrication Use correct lubrication and fill up to
scratched. 2. Incorrect lubrication right level.
3. Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1mm thickness lower
than the new ones.
Inner diameter of tapered roller 1. Excessive use Replace bearing.
bearing worn out. 2. Excessive pinion axial backlash Check pinion axial backlash.
3. Insufficient lubrication Use proper lubrication, fill up to right
4. Contaminated oil level and replace at recommended
intervals.
Bent or broken half-shaft Vehicle intensively operated or Replace
overloaded
Half-shaft broken at wheel side 1. Wheel support loose Replace
2. Beam body bent Check that wheel support is not worn
out or wrongly adjusted.

AB10710 REVISION DATE: 05/16 DOC. CA270410 E.1 PAG. 85

RICERCA GUASTI
TROUBLESHOOTING Mod. 20.16-1640

E.2 Diagnosi per problemi all'assale

Problema Causa Azione consigliata

Rumore durante la guida 1. Gioco tra corona dentata e pignone 1. Regolare

eccessivo
2. Pignone e corona dentata 2. Sostituire
consumati
3. Cuscinetti del pignone consumati 3. Sostituire
4. Cuscinetti del pignone allentati 4. Regolare
5. Gioco assiale del pignone 5. Regolare
eccessivo
6. Cuscinetti del differenziale 6. Sostituire
consumati
7. Cuscinetti del differenziale allentati 7. Regolare
8. Eccessiva scentratura della corona 8. Sostituire
dentata
9. Livello lubrificante basso 9. Rabboccare
10. Lubrificante di grado povero od 10. Sostituire
errato
11. Semiasse piegato 11. Sostituire
Rumore durante l’andatura in folle 1. I rumori provenienti dall'assale con 1. Regolare o sostituire (vedere sopra)
il veicolo in movimento di solito si
sentono durante l’andatura in folle
anche se non molto forti
2. Errato gioco tra pignone e corona 2. Regolare
(il rumore che si sente decelerando
sparisce all’aumentare della velocità).
3. Usura scanalatura pignone o
flangia entrata 3. Sostituire
Rumore intermittente 1. Corona dentata danneggiata 1. Sostituire coppia conica
2. Bulloni della scatola del 2. Serrare a coppia
differenziale allentati
Rumore costante 1. Danni sui denti della corona 1. Sostituire coppia conica
dentata o del pignone
2. Cuscinetti usurati 2. Sostituire
3. Scanalature del pignone 3. Sostituire
consumate
4. Semiasse piegato 4. Sostituire
Rumore in curva 1. Ingranaggi del differenziale 1. Sostituire
consumati
2. Scatola differenziale e/o perni del 2. Sostituire
differenziale consumati
3. Ralle di rasamento del differenziale 3. Sostituire
consumate
4. Scanalature del semiasse 4. Sostituire
consumate

E.2 PAG. 86 REVISION DATE: 05/16 DOC. CA270410 AB10710

 RICERCA GUASTI
Mod. 20.16-1640 TROUBLESHOOTING

E.2 Axle problem and diagnosis

Problem Cause Action

Noise while driving 1. Excessive backlash between 1. Adjust

pinion and ring gear
2. Worn out pinion and gear ring 2. Replace
3. Worn out pinion bearings 3. Replace
4. Pinion bearings loose 4. Adjust
5. Excessive axial pinion backlash 5. Adjust
6. Worn out differential bearings 6. Replace
7. Differential bearings loose 7. Adjust
8. Ring gear out of roundness 8. Replace
9. Low lubricant level 9. Oil level
10. Poor or wrong lubricant 10. Replace
11. Bent half-shaft 11. Replace
Noise while driving in neutral 1. Noise coming from axle are usually 1. Replace or adjust (see above)
heard when vehicle moves in neutral
gear but are not loud.
2. Incorrect backlash between pinion 2. Replace
and ring (sound heard while
decelerating disappears while
increasing the speed)
3. Pinion or input flange worn out 3. Adjust
Intermittent noise 1. Ring gear damaged 1. Replace bevel gear set
2. Differential box bolts loose 2. Tighten to torque
Constant noise 1. Ring gear teeth or pinion damaged 1. Replace bevel gear set
2. Worn out bearings 2. Replace
3.Pinion spline worn out 3. Replace
4. Bent half-shaft 4. Replace
Noise while steering 1. Worn out differential gears 1. Replace
2. Worn out differential box or spider 2. Replace
3. Differential thrust washers worn out 3. Replace
4. Half shaft spline worn out 4. Replace

AB10710 REVISION DATE: 05/16 DOC. CA270410 E.2 PAG. 87

RICERCA GUASTI
TROUBLESHOOTING Mod. 20.16-1640

Notes

E.2 PAG. 88 REVISION DATE: 05/16 DOC. CA270410 AB10710

Mod. 20.16-1640

Indice Index

INFORMAZIONI SULLA SICUREZZA . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . 3

Indicazioni generali per la sicurezza . . . . . . . . . . 4 General safety recommendations . . . . . . . . . . . 4
Informazioni per la sicurezza . . . . . . . . . . . . . . . 5 Safety information . . . . . . . . . . . . . . . . . . . . . . . 5
Precauzioni generali . . . . . . . . . . . . . . . . . . . . . . 8 General precautions . . . . . . . . . . . . . . . . . . . . . . 8

INFORMAZIONI GENERALI . . . . . . . . . . 17 GENERAL INFORMATION . . . . . . . . . . 17

Utilizzo del manuale . . . . . . . . . . . . . . . . . . . . . 18 Manual use . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Proprietà delle informazioni . . . . . . . . . . . . . . . 19 Information property . . . . . . . . . . . . . . . . . . . . . 19
Convenzioni e definizioni . . . . . . . . . . . . . . . . . 20 Agreements and definitions . . . . . . . . . . . . . . . 20
Indicazioni generali . . . . . . . . . . . . . . . . . . . . . . 24 General description . . . . . . . . . . . . . . . . . . . . . 24
Indicazioni speciali . . . . . . . . . . . . . . . . . . . . . . 25 Special recommendations . . . . . . . . . . . . . . . . 25

CARATTERISTICHE GENERALI . . . . . . 33 GENERAL SPECIFICATIONS . . . . . . . . 33

Uso previsto . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Identificazione del prodotto . . . . . . . . . . . . . . . . 34 Product identification . . . . . . . . . . . . . . . . . . . . 34
Descrizione generale . . . . . . . . . . . . . . . . . . . . 36 General description . . . . . . . . . . . . . . . . . . . . . 36
Caratteristiche Tecniche . . . . . . . . . . . . . . . . . . 37 Technical Features . . . . . . . . . . . . . . . . . . . . . 37
Manutenzione e cambio olio . . . . . . . . . . . . . . . 39 Maintenance and oil change . . . . . . . . . . . . . . 39
Grasso al montaggio . . . . . . . . . . . . . . . . . . . . . 44 Grease in assembly . . . . . . . . . . . . . . . . . . . . . 44
Adesivi e coppie di serraggio . . . . . . . . . . . . . . 45 Adhesives and tightening torques . . . . . . . . . . 45

PROCEDURE SPECIALI . . . . . . . . . . . . 49 SPECIAL OPERATIONS . . . . . . . . . . . . 49

Registrazione del precarico cuscinetti differenziale e Differential bearings preload and bevel gear pair
del gioco coppia conica . . . . . . . . . . . . . . . . . . . 50 backlash adjustment . . . . . . . . . . . . . . . . . . . . 50
Precarico dei cuscinetti pignone . . . . . . . . . . . . 60 Pinion bearings preload adjustment . . . . . . . . 60
Convergenza/angolo di sterzata . . . . . . . . . . . . 71 Toe-in/steering angle . . . . . . . . . . . . . . . . . . . . 71
Prove dopo montaggio . . . . . . . . . . . . . . . . . . . 78 Testing after assembly . . . . . . . . . . . . . . . . . . . 78

RICERCA GUASTI . . . . . . . . . . . . . . . . . 79 TROUBLESHOOTING . . . . . . . . . . . . . . 79

Controllo ed esame dei guasti . . . . . . . . . . . . . 82 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnosi per problemi all'assale . . . . . . . . . . . . 86 Axle problem and diagnosis . . . . . . . . . . . . . . . 87

AB10710 REVISION DATE: 05/16 DOC. CA270410 PAG. 89

Carraro Drive Tech Spa Carraro Drive Tech SpA
Headquarters After Sales & Spare Parts
Via Olmo, 37 Via Trentino, 4/6 35043 Monselice Padova, Italy
35011 Campodarsego [email protected]
Padova, Italy www.carry4you.it
www.carrarodrivetech.com
Carraro Warehouses
Rockford, IL, USA
Pune, India
Haedo, Buenos Aires, Argentina
Qingdao, China
HYDRAULIC SYSTEM

TANDEM PUMP FIRST STAGE PUMP (For Tractor Hydraulic)

(FOR TRACTOR HYDRAULIC AND STEERING) GENERAL

DESCRIPTION : The first stage Pump is used to feed tractor hydraulic

Figure A on next page. Shows cross section of first
This tractor is equipped with Two stage Tandem Pump. stage pump. First stage pump is preassemble with
First unit is used to feed the tractor hydraulic and two socked head cap screws on the front flange, and
second unit is used for hydraulic steering. two in the rear flange.
NOTE : We recommend that these pump should not Figure B on next page shows cross section of second
be serviced except the replacement of oil seal should stage pump. This stage feeds steering unit of tractor.
be replaced with new unit in case of malfunctioning. This pump is anombled with two socked head cap
srews and on front flange and two in the rear cover.
The front and flanges will then be retained by the
TANDEM PUMP
main studs of the anemblag tandem pump.
This is assembly of two stage, a tang output shaft
Dissambly and assembly procdure offrist and second
and old ham style coupling connect both stages. stage pump are same.
Socket head capscrew retain the front flange rear cover
of the second stage to the front flange of the frist
stage.

Two Stage Tandem Pump

F–36
 HYDRAULIC SYSTEM

First Stage Pump

Pressure sheel Capscrew Double Pin Idler Gear Front Flange

Second Stage Pump

F–37
HYDRAULIC SYSTEM

DISSAMBLY :
GENERAL MARKING THE PARTS

Detailed procedure is given for dissembly and assembly Mark the parts before completly disassembling a pump
of pump prior to proceding, it may be necessary to disamembling. The marks allow components ot be
prepare some subassemblies separately. ressebled in the same relative position. This action
should be applied to the body, bearings and gears
The details for preparing each subassembly are given scribing, bluing, or using a felt tip pern to mark the
in the following section. Also, some general outside of the body on the inlet side is suggested to
recommendation are given below. indicate the relative position of the front flange the rear
CLEANLINESS cover the body. Mark the bearing blockes also on the
inlet side and the gears position relative to each other.
Cleanliness is primary factor for reliable pump
Do NOT scribe internal surfaces.
performance. Wash the outside of the pump
thoroughly before and all pieces prior to STEP 1
assembly.Cealning parts with clean soap solvent and Clamp teh tandem pump in a vice from flange side
air drying is usually adequate. and dissambl it into first stage and second stage pump
LUBRICATION OF MOVING PARTS units.
During assembly, is is jmperative to provide lubrication
with clean hydraulic oil to all the running parts of the
pump.
It is also necessary to coat the seals with grease.
The absence of lubrication during assembly can cause
the unit to seize after a few minutes of running.
CARE OF SURFACE TREATMENT
Be carefull when handling all the internal surface,
especially bearings, gears, and body faces. Do not
touch or reore with metal tools or cutting edges.

F–38
 HYDRAULIC SYSTEM

E. REMOVAL AND INSTALLATION

HYDRAULIC PUMP
Remove left hand engine shield. Drain the transmission
oil.
Note: Close all openings with caps and plugs.

Disconnect all hydraulic lines and hoses. Remove

hydraulic pump and O-ring. Make repairs as
necessary.
Important: Always use new O-rings. Damaged or used
0-rings will leak.
Place new O-ring on pump flange. Install pump on
engine. Install cap screws. Tighten to specifications.
Connect hydraulic lines and hose. Install right-
handengine shield. Refine transmission with proper
oil. Start engine and operate hydraulics. Check and
adjust transmission/hydraulic oil level.

Remove manifold (1) with 0-ring 0-ring (2) and (3).

Removenut (4) and lock -washer (5). Remove and
inpect gear (6). Unscrew bolts (7) and remove flange
(8). Make repair as necessary.

During reassembling use a sealant compound on the

flange.

F–39
HYDRAULIC SYSTEM

STEP 2
Clamp the unit in a vice from flange side. Make sure
that vice jaws are clean and have smooth surface to
preevent damage to the Pump.

STEP 3
Use a 17 mm socket wrench and loosedn the four
capascres on the cover. Next completely unsrew the
capscrews and remove them. Inspect the threads of
the capacrews for damage.

STEP 4
Using a 4 mm internal hex wrench, loosen and remove
the two small socked screws placed in the center of
the cover. Repeat the same opration for the
corresponding screws on the rear flange.

STEP 5
Place the Pump on the table and slowly remove the
front flange.
Be careful not to damge the shaft seal when removing
the flange. Avoid contact of the shaft seal lips with
keywey adges (in tapered and parallel shaft) or splined
shaft teeth.
Inspect the front flange and seal area.
Cleaning with shop sovent, dry, and set aside.

F–40
 HYDRAULIC SYSTEM

STEP 6
Remover rear cover.
Clean with shop solvent dry and set aside.
Visually inspect rear cover and seal area.

STEP 7
Place the pump on its side and carefully remove the
bearing block and gear set. To accomplosh this, hold
the pump body and push with your figure on the rear
bearing block
Mark the relative positions of the gear mesh drive
(gear tooth to idler gear tooth) and the bearing blocks
to the body so they can be reassembled in the same
position.

STEP 8
Check the seal quality, Replacement is recommended
whenever there are burrs, evidence of extrusion, or
marks caused by overheating, If the seals need to
be replaced, carefully remove them from the falnge
cover, beginning with the backup ring and then the
pressure seal.

Important: Do not use tools with sharp edge to

remove the seals as samage to the cover can result
After removal, dispose of damaged seals

STEP 9
Chack the quality of this seal, If necessary replace it.
Follow the same removal recomandation given in
step.8
After removal discard the damaged seal.

Important: Do not use tools with sharp edges to

remove the scales as damage to the cover can result.

F–41
HYDRAULIC SYSTEM

STEP 10
Place the flange on the work surface, Using internal
snap ring.

STEP 11
Check the shaft seal quality and remove if necessary.
To remove pry the botom of the shaft seal and force if
out while rotating the falnge to lift if out evenly.
Do not use the falnge pilot to gain leverge damge may
result Use a plastic rod or wooden dowel as fulcrum
After remoal dispose of the damage seal

F–42
 HYDRAULIC SYSTEM

ASSEMBLY
STEP 1
Have the entire seal kit available.
Light coat all seals with seal grease. The grease is
needed to adhere the seals to their grooves.
NOTE: Do not install dry seals.

STEP 2
Prepare the flange and shaft seal by lightly lubricating
with grease.
Seat the seal in the flange by hand. Then, using the
shaft seal installation tool, press the seal unitl the tool
stops on to the proper flange. This will insure the seal
is inserted the proper depth.

STEP 3
Install the snap ring using internal snap ring pliers.
Ensure the snap ring fits securely in its groove. This
is necessarory to retian the shaft seal.

STEP 4
Prepare the pressure seals by lightly lubricating them
with grease.
Install pressure seals into the grooves on the front
flange and rear cover. Then install the teflon backup
ring.
Ensure that the seals are located in the grooves, as
shown

F–43
HYDRAULIC SYSTEM

STEP 5
Clean the body
Inspect the internal and mating surfaces.
Ensure the surface are free of burrs and scrathes.
Check both teh bearing block mating surface and teh
cut-in-path. The cut-in-path should be no deeper than
0.1 mm (0.004 in).

STEP 6
Prepare the outer seal by lightly lubricating with grease.
Install outer seals in the grooves on both sides of the
body.

STEP 7
Caution: The gear surfaces are superfinished. Residue
on hands and fingers may be corrosive to the this
surface. do not touch.
Carefully clean the two gears. If the gears are new,
wash them with shop solvent to remove any
anticorrosive grease on the surfaces.
Inspect the journals and the flat faces on the top and
bottom of the gears. Ensure these surfaces are free
from burrs or screatches. If scratches or burrs are
found, clean them with a flat stone and/or very fine
emerypaper. Rewash the gears after the opration.

F–44
 HYDRAULIC SYSTEM

STEP 8
Clean the two bearing blockes.
Inspect the flat surfaces of the bearing blockes for
burrs or scratches on the edges. if necessary, remove
burrs with very fine every paper. Then rewash the
bearings.
Inspect the DU busings for wear. There should be no
bronze showing.
Using clean hydraulic oil, lubricate the internal and
external surraces of the bearing blocks.
STEP 9
Lubricat the joumals and the gear faces.
Assemble the bearing blocks and gears.
Ensure that the recessed bearing faces are intalled
adjacent to the gear faces. Align all assembly markes
made during disassembly. Ensure the front and rear
bearing blockes occupy the same location with
respect to the housing as before disassembly. Ensure
that the realtive potition of the gear mesh is maintained
as before diasassembly. Misalignment of the gear
teeth may increase oprating noise.

STEP 10
Install the bearing block and gear assembly into the
body cavity. Align the asembly marks to ensure that
the gear assembly is installed with the same orientetion
as before dissembly.

STEP 11
Remove any excess lubrication and grease from the
mating surface of the pump body. Ensure that these
surface are dry and free of contamination before
moving on to the next step.

F–45
HYDRAULIC SYSTEM

STEP 12
Install four 5 mm dowel pins into the proper cavities
on both sides of the body (refer to the illustration). Swab
the pins with assembly grease or petroleum jelly to
retain them during assembly.
Do not install dowel pins to the rear cover or flange, as
one of them may drop inside the pump during assembly.

STEP 13
Remove any excess lubrication and grease from the
mating surfaces of the front flange and rear cover.
Ensure that these surfaces are dry and free of
contamination before moving on to the next step.
Ensure the pressure seals ae seated properly after
this opration.

F–46
 HYDRAULIC SYSTEM

STEP 14
Mount the cover on the body. Ensure the arrow on the
back is oriented properly. The arrow should be in the
same direction as the flow.

STEP 15
Place the pump with rear cover downwards.
Ensure that the assembly marks on the bearing block/
body are property aligned.

STEP 16
Install a protective sleeve over the shaft. the sleeve
is used to protect the shaft seal from damage by the
shaft splines/keyway during front fange assembly.
Install the flange onto the body, than remvoe the
protective sleeve.
Ensure that the seals remain seated in their grooves
during this opration.

F–47
HYDRAULIC SYSTEM

STEP 17
Using a 4mm internal hex wrench, install the socket
head capscrews to the front flange and rear cover.
Torque 2.5-3.4 mm (22.30 lbf .in) If used, install new
o-ring to flange pilot.

STEP 18
After pump has been disassembled and reasrembled,
it is suggested that the pump be run in and tested on
the appropriate test stand. This is done to verify the
volumetric efficiency and the integrify of the unit.
Test specifications and procedure are given in end of
this section

F–48
 HYDRAULIC SYSTEM

ASSEMBLY OF TENDEM PUMPS :

STEP 1
Place the frist stage pump on the work bench, so that
the rear flange is in the upward position.
If necessory, remove burrs on the flance. Blow the
surface and cavity of the flange with compressed air
to remove any debris before assembly.
Fit the coupling onto the rear tang of the shaft.

STEP 2
Clamp the first stage of the pump in vice on the front
flange side. Install the studs.
Torque to 5-10 Nm (ibf'ft)

STEP 3
If necessary remove burrs from the front flange of the
second stage pump, then clen with compressed air.
Lubricate the pilot and o-ring with grease.
Mount the second stage pump on to the rear pad of
the first stage. Align the tang of the shaft with the
couplingng. The two tangs must be rotated 90 0 from
each other. The coupling will not engage the shaft if it
is not properly alingned. Press Unit together unit the
pilot is fully engaged.

STEP 4
Torque to 50-60 Nm (37-44 iibt*ft).
Use the torque sequence show at the right.

F–49
HYDRAULIC SYSTEM

TESTING THE PUMPS AND MOTORS

GENERAL
After assembling a pump, it should be tested to verify
that volumetric efficiency is sufficient to insure satis-
factory performance.
In order to test a pump, it must be operated on an
appropriate test apparatus. Schematic diagram for a
typical test apparatus is shown in the figure at the right.
Ensure that the test apparatus has sufficient power
available to meet the demand of the pump under test
( see specifications, )
The output flow should meet or exceed the specified
value given in the table. If the pump does not pass
test, it is necessary to disassemble the pump and find
the cause. Refer to Troubleshooting,for more
information.
It may be necessaryto check some dimensions and
replace either incor-rect,damaged, or worn parts.
TEST PROCEDURE
Run the pump for one minute at the pressure noted in
the table and check the output flow at the flow meter.
If the pump is in good condition, the measured flow
rates will meet limits given in the flow limits table.
Set up the pump on the test apparatus with suit-able
shaft couplings and port adaptors. Use ap-propriate
fluid per ISO VG468. Start the prime mover and run
the pump until the oil temperature is 40° to 45°C [104°
to 113°F] as measured in the inlet line.
Set up the following test parameters :
• Pump Speed 1500 rpm
• Inlet Vacuum 0.15 bar [2.175 psi]
• Outlet Pressure See Table
Pump Flow Tables
Type Minimum Out put flow
l/min USgal/min
first stage(in India) 20.7 5.47
first stage(Out of India) 24.3 6.42
second stage 15.5 4.09

Test Pressure Table

Type Minimum Out put flow
bar psi
first stage(in India) 250 3625
first stage(Out of India) 250 3625
second stage 250 3625

F–50
 HYDRAULIC SYSTEM

SHAFT SEAL INSTALLATION TOOL

F–51
HYDRAULIC SYSTEM

TROUBLE SHOOTING
Low or no flow from gear Pump
PROBLEM POSSIBLE CAUSES REMEDY

1. Check oul level in reservoir. Insufficient oil to supply gearpump. Fill reservoir to proper level
2. Check input spline condition. Input shaft broken or stripped. Repair or replace grear pump.
3. Check pressure at pump inlet. Clogged suction filter or intel Replace filter or clean suction
Recomended inlet pressure : screen. screen.
0.8 to 3.0 bar absolute. 0.6
Minimum at cold dtart.
4. Check condition of gear faces Scored bearing block and gear Repair or replace gear pump.
and bearing block. faces will reduce pump efficiency.
5. Check bushing Our pressure of gear pump will
cause idler gear pushing is fail
Excessive Noise
ItemDescription Action
1. Check oil level in reservoir. Excessive air will cause cavitation Fill reservour to proper level
sound.
2. Check inlet line for leaks. Excessive air will cause cavitation Repair inlet line
sound.
3. Check pressure at pump inlet. Lower than normal inlet pressure Return inlet pressure to
cause excessive pump noise. recomended levels.
Recommended inlet pressure :
0.8 to 3.0 barabslute. 0.6
Minimum at cold start.
External Leakage
ItemDescription Action
1. Check & ring for Pinched seal will allow leage. Replace pinched seal.
piched o-rings or check
back up ring real
2. Check premyre real Damage to pressure seals is Inspect condition of bearings
typically caused by reduced blocks if they are pump to be
"stack-up" in the pump assembly worm repair or replace item pump.
This may be due to under torqued Or replace the pump.
assembly fasteners, or more If bearing blocks are not worn,
commonly is attributed to replace pressure seals and
excessive wear on the bearing torequed pump assembly
Rlocks. reduced "stack-up" will fasteners.
affect seal effifiency possibly
to the point of seal extrusion.

F–52
 HYDRAULIC SYSTEM

SPECIFICATIONS
TYPE
GEAR45-49 Liter/Min
at 2200 rpm (pump rpm)
STEERING UNIT FARMTRAC
TYPE GEAR
Displacement 22.5 / 11.5 cc
Maximum Pressure 180 bar
Flow at 2200 45.5 lpm

HYDRAULIC PUMP
DESCRIPTION UNIT OTHER ITEM INDIA IN INDIA
Ist Stage IInd Stage Ist Stage IInd Stage

Displacement Cm3/rev 19.2 10.8 14.4 10-8

3
In /rev 1.17 0.66 0.88 0.66

Peak Pressure bar 230 280 280 280

psi 3335 4060 4060 4060

Rated Pressure bar 210 250 250 250

psi 3045 3625 3625 3625

Minimum Speed rpm 500 500 500 500

at 0-100 bar

Minimum Speed rpm 700 800 750 800

at 100-180 bar
Maximum Speed rmp 1000 1200 1000 1200
at 180 bar to roted
pressure
Maximum Speed rpm 3000 4000 3500 4000
weight Kg 3.1 2.7 2.9 2.7
lb 6.7 5.8 6.3 3.8
-6
Moment of x10 Kg on2 5.75 37.3 45.9 373
-6
Inertial of x10 Kg on2 57.5 37.3 45.9 373
-6 2
rotating Compenent x10 lbff 1364 885 1089 885
Thearitical fbw L/min 57.6 43.2 50.4 5.04
at maximum speed us gal/min 15.2 11.4 11.3 13.3
Direction of rotation - clock wise frow shaft end

Oil Viscosity at 400 C 32-46CST

900C
Max. Allowabli Vacuum Suction Pressure 0-0.8 bar (absolute)

F–53
STEERING SYSTEM

F–2
 STEERING SYSTEM

TYPICAL OIL FLOW

F–3
STEERING SYSTEM

STEERING SYSTEM
1. DESCRIPTION AND OPERATION
Farmtrac feature an hydraulic power assisted,
hydrostatic steering system. The components are
serviced separately and consist of the steering column
shaft, steering motor, front steering cylinder, power
steering pump, oil cover and reservoir, and the hoses
and tubes required to connect the system.
The integral power steering pump is mounted on
the rear of the engine front cover plate at the left-
hand side of the engine. The pump is connected to
the steering motor by two oil tubes. A. Steering Moter Connections and Pipes
The steering wheel is secured to the steering column 3. HYDROSTATIC STEERING SYSTEM OVERHAUL
shaft. The steering column upper shaft is joined to the
power steering motor input shaft by a coupling secured A. REMOVAL
with a pinch bolt. The power steering motor and 1. Disconnect the battery ground cable at the battery.
steering column assembly are mounted on a housing
bracket which is bolted at the clutch housing. 2. Clean the flexible steering hose to rigid pipe
connections.
The hydrostatic steering motor uses a linear control
valve to control the direction of the steered wheels
3. With a suitable container to store the escaping
and a metering unit to control the rate of turn. In the
steering oil, mark and separate the flexible
event of pump failure the metering unit functions as
steering hoses from the rigid pipes. Cap and
an hydraulic pump and the wheels can be turned
manually. seal the pipes, using suitable plugs.

4. Slacken the retainer bolts securing the pipes to

2. STEERING CYLINDER the side of the engine.

The double acting steering cylinder is transversely 5. Unclip the separate the throttle screws and
mounted on the front axle. The cylinder end of the remove the lower steering column shroud by
assembly is bolted to an adjuster bar which forms an withdrawing main harness connector to gain
inlegral part of the front axle assembly and facilitialies
access to the steering column to motor coupling.
re-positioning of the cylinder when adjusting the track
setting. The rod end is attached to the left-hand 7. Remove the four bolts retaining the steering
spindle arm which is connected by the track rod to the motor support bracket.
right-hand spindle arm. The cylinder incorporates a
piston centrally mounted on the piston rod. This 8. Slacken clamp bolts securing the steering column
arrangement enables the piston to present surfaces of to the motor and carefully withdraw the motor
equal area to the operating oil and the resultant forces assembly from the left-hand side of the tractor.
ensure similar right and left-hand turning circles.

F–4
 STEERING SYSTEM

B. SEAL REPLACEMENT INSTRUCTIONS IMPORTANT: Cleanliness in servicing the power

steering system is impretative. If it is necessary
NOTE : Follow the Instruction and do not
disassemble the steering unit upper cover, to disassemble and of the units, ensure a clean
to replace the shaft, seal. work bench or table is used.
1. Remove the dirt seal over the end of the steering
unit upper cover, if applicable. Discard this part. IMPORTANT:Clean off external dirt before the unit
2. Remove the retaining ring do not discard, this part is placed on the work bench.
must be reinstalled during assembly procedure.
3. To remove the seal package parts from the steering
unit plug three of the four ports in the steering unit IMPORTANT:When disassembled, parts should be
and pressurize the other port with air pressure to cleaned only in clear-clean petroleum base
force the seal package out. Discard these parts. solvent and blown dry with clean air. Other
solvents may cause deterioration of rubber
NOTE : Clean the steering Unit input shaft and
seals. Avoid wiping parts with cloth and never
upper cover seal bore to remove particle of
dirt, felt, lint, etc. with a clean, lint-free rag. steam clean hydraulic steering assemblies.

CAUTION : Excessive particle of felt of lint can

cause the new seal package to leak.
4. Cover the end of the steering unit input shaft with NOTE : The spool and housing, the commutator and
cellophane tape to protect the new seal when it is commutator ring and the rotor and stator
assembled over the sharp edges of the input shaft. are selectively fitted and must be serviced
5. Lubricate the new seal using hydraulic oil and as follows :
install the new seal with lip side first, onto the
steering unit input shaft. If the spool or housing must be replaced,
6. Remove the cellophane tape from the steering replace the complete motor.
unit input shaft.
7. Assemble the new washer, with small end first, If the commutator or commutator ring must be
onto the steering unit input shaft and push the new replaced, replace both as a matched set.
washer and the new seal, previously installed,
down into the steering unit upper cover. Short
If the rotor or stator must be replaced, replace
piece of metal tubing 15/16 minimum I.D. x 1-3/16
maximum O.D. or a 7/8 deep well socket may be the complete metering element.
used to push these parts into place.
8. Assemble the previously used retaining ring onto If the pin in the end cover or the end cover must be
the steering unit input shaft and down into the replaced, replace the pin and end cover assembly.
steering unit upper cover groove. Be sure the
rounded edge of the retaining ring is faced inward.
Refer to Figure on next page for identification of
9. Assemble the new seal onto the steering unit
parts during disassembly and re-assembly.
input shaft and down into the steering unit upper
cover counter bore.

F–5
STEERING SYSTEM
STEERING SYSTEM

HYDRASTATIC STEERING UNIT

1. Dust seal ring 16. Distrubutor Plate

2. Housing, spool, sleeve 17. Gearwheel set
3. Ball dia 8.5 mm 18. O-ring
5. O-ring used with 19. End cover
kin-ring 20. Washer
7. Bearing assembly 22. Special screw
10. Ring 23. Screw
11. Cross pin 24. Name Plate
12. Set of springs 30. Pressure relief valve
13. Cardan shaft 31. Spring wire
15. O-ring 37. Check Valve

F–6
 STEERING SYSTEM

DISSASSEMBLY

1. Dismantling the steering column from steering

unit and place the steering unit in the holding tool.
Screw out the screws in the end cover (6-off plus
one special screw).

2. Remove the end cover, sideways.

3. Lift the gearwheel set (with spacer if fitted) off the

unit. Take out the two o-rings.

4. Remove cardan shaft.

F–7
STEERING SYSTEM

5. Remove distributor plate

6. Screw out the threaded bush over the check valve

7. Remove ‘O’ Ring

8. Shake out the check valve ball and suction valve

pins and balls.

NOTE: On some pins there are two springs.

Replace three pins prior to the reassembly.

F–8
 STEERING SYSTEM

9. Take care to keep the cross pin in the sleeve and

spool horizontal. The pin can be seen through the
open end of the spool. Press the spool inwards and
the sleeve, ring, bearing races and needle bearing
will be pushed out of the housing together.

10. Take ring, bearing races and needle bearing from

sleeve spool. The outer (thin) bearing race can
sometimes “stick” in the housing, therefore check
that it has come out.

11. Press out the cross pin. Use the special screw
from the end cover.

NOTE: A small mark has been made with a pumice

stone on both spool and sleeve close to one of the
slots for the neutral position spring.
If the mark is not visible remember to leave a mark
of your owre on sleeve and spool before the neutral
position springs are dismantled.

F–9
STEERING SYSTEM

12. Carefully press the spool out of sleeve.

13. Press the neutral position springs out of their

slots in the spool.

14. Remove dust seal and o-ring/kin-ring.

F–10
 STEERING SYSTEM

D. DISMANTLING PRESSURE RELIEF VALVE

15. Screwout the plug using 6 mm hexagon socket

spanner. Remove seal washers.

16. Unscrew the setting screw using an 6 mm

hexagon socket spanner.

17. Shake out spring and piston. The valve seat is

bonded into the housing and cannot be removed.

18. The pressure relief valve is dismantled and

steering unit is nowcompletely dismantled.

F–11
STEERING SYSTEM

CLEANING
Clean all parts carefully in Shellsol K or the like.
INSPECTION AND REPLACEMENT
Replace all seals and washers. Check all parts carefully
and make any replacements necessary.
LUBRICATION
Before assembly, lubricate all parts with hydraulic oil

E. ASSEMBLY
NOTE : Assemble the spool isleeve and make sure the
marks on spool and sleeve are opposite to each other.
1. Place the two flat neutral position springs in the slot.
Place the curved springs between the flat ones
and press them into the place.

2. Line up the spring set.

3. Guide the spool into the sleeve. Make sure that spool
and sleeve are placed correctly in relation to each
other.

F–12
 STEERING SYSTEM

4. Press the springs together and push the neutral

position springs into place in the sleeve. line up the
spring and centre them

5. Guide the ring down over the sleeve.

NOTE: The ring should be able to rotate free of springs.

6. Fit the cross pin into the spool / sleeve.

7. Fit bearing races and needle bearing as shown

on below drawing.

F–13
STEERING SYSTEM

F. ASSEMBLY PATTERN FOR STANDARD

BEARING
1. Outer bearing race
2. Nedle bearing
3. Inner bearing race
4. Spool
5. Sleeve

F–14
 STEERING SYSTEM

G. INSTALLATION INSTRUCTIONS FOR O-

RING/KIN-RING
8. Turn the steering unit until the bore is horizontal.
Guide the outer part of the assembly tool into the
bore for the spool/sleeve.

9. Grease o-ring and kin-ring/with hydraulic oil and

place them on the tool.

10. Hold the outer parts of the assembly tool in the

bottom of the steering unit housing and guide the
inner part of the tool right to the bottom.

11. Press and turn the o-ring/kin ring into position in

the housing.

F–15
STEERING SYSTEM

12. Draw the inner and outer parts of the assembly

tool outer of the steering unit bore, leaving the guide
from the inner part in the bore.

H. INSTALLATION INSTRUCTION FOR LIP SEAL

13. Lubricate the lip seal with hydraulic oil and place
it on the assembly tool.

14. Guide the assembly tool right to the bottom.

15. Press and turn the lip seal into place in the housing.

F–16
 STEERING SYSTEM

16. With a light turning movement, guide the spool

and sleeve into the bore.

NOTE: Fit the spool set holding the cross pin horizontal.
The spool set will push out the assembly tool guide.
The o-ring kin-ring/roto Glyd are now in position.

17. Turn the steering unit until the bore is vertical

again. Put the check valve ball into the hole
indicated by the arrow.

18. Screw the threaded bush lightly into the check

valve bore. The top of the bush must lie just below
the surface of the housing.

19. Place a ball in the two holes indicated by the arrows.

F–17
STEERING SYSTEM

20. Place a new pin in the same two holes.

21. Grease the o-ring the mineral oil approx.

2 0
viscosity 500mm /s at 20 C.

22. Place the distributor plate so that the channel

holes match the holes in the housing.

23. Guide the carden shaft down into the bore so

that the slot is parallel with the connection flage.

F–18
 STEERING SYSTEM

24. Place the carden shaft as shown - so that it is

held in position by the mounting fork.

25. Grease the two o-rings with mineral oil approx.

2 0
viscosity 500 mm /s at 20 C and place them in the
two grooves in the gear rim. Fit the gearwheel and
rim on the cardan shaft.

IMPORTANT: Fit the gearwheel (rotor) and cardan shaft

so that a tooth base in the rotor is positioned in relation to
the shaft slot as shown. Turn the gear rim so that the
seven trough holes match the holes in the housing.

26. Place the end cover in position.

F–19
STEERING SYSTEM

27. Fit the special screw with washer and place it in

the hole shown.

28. Fit the the six screws with washers and insert
them. Cross-tighten all the screws and the rolled pin
with a torque of 3.0 +/-0.6 Nm.
This unit can now be function tested.

F–20
 STEERING SYSTEM

I. ASSEMBLY OF PRESSURE RELIEF VALVE

29. Fit the piston.

30. Fit the spring

31. Screw in the setting screw with an 8 mm

hexagon socket spanner. Make the pressure setting
on the tractor.
Ø 1.7 spring for 50 - 70 bar
Ø 1.9 spring for 70 - 105 bar
Ø 2.1 spring for 110 - 155 bar

32. Screw plug with dust seal into the housing using
an 8 mm hexagon socket spanner. Tightening
torque : 5 +/-1 daNm.
(1daNm = 10 Nm)

F–21
 STEERING SYSTEM

J. INSTALLATION
l
Installation of the steering motor assembly follows
the removal procedure in reverse. On installation
observe the following requirements:
• Tighten all nuts, bolts and connections to the
correct torques, see "Specifications".
• Purge the air from the system by starting the
engine and turning the front wheels from lock-to-
lock several times. If necessary, add oil to the
reserrvoir. Repeat until steering is normal and
the oil level in the reservoir remains constant.
4. HYDROSTATIC STEERING SYSTEM Double acting Steering Cylinder
CYLINDER-OVERHAUL 1. Cylinder Rod end (LH/RH)
REMOVAL AND DISSASSEMBLY 2. Cylinder feed pipe (LH/RH)
3. Cylinder support bracket.
1. Disconnect the two oil feed pipes from the
power cylinders. Cap the pipe ends.
2. Unscrew the ball stud nuts.
3. Remove the power cylinder assembly from the
tractor.
4. Loosen the clamp retaining the ball end to the
piston rod and unscrew the ball end assembly.
5. Remove the piston rod bush retaining snap ring
and remove the scraper, outer seal, retainer and
inner seal.

Note: The power cylinder asembly cannot be further

dismantled and if faulty, must be replaced as a unit.
RE-ASSEMLY AND INSTALLATION
Re-assembly and installation follows the
disassembly and removal procedures in reverse.
On installation observe the following requirements.
Tighten all nuts to the correct torque.
Fill the power steering reservoir with the correct
grade and quantity of oil.
Operate the Steering several times with the
engine running to expel all air from the system
then re-check the oil level.

WARNING : Do not mix oil types any mixture or an

unapproved oil, could deteriorate the seal, Enough
fluid could then leak to create a loss of power
steering assists. Do not allow fluid level to go below
fill line on dipstick. Before adding new fluid,
completely drain oil from the system. It may be
necessary also that you flush systems with clean oil.

F–22
 STEERING SYSTEM

5. TORQUE SPECIFICATIONS AND HYDRAULIC CONNECTIONS

L Left Port
R Right Port
T Tank
P Pump

T
L P
R

Max. tightening torque daNm (lbt. in)

Screwed Connection With cutting edge With copper washer With aluminium washer With O-ring

G 1/4 4 (350) 2 (180) 3 ( 270)

G 3/8 6 (530) 2 (180) 5 (440)

G 1/2 (10 (900) 3 (270) 8 (700)

7/16-20 UNF 2 (180)

3/4-16 UNF 6 (530)

M 12 x 1.5 4 (350) 2 (180) 3 (270) 2 (180)

M 18 x 1.5 7 (620) 2 (180) 5 (440) 5 (440)

M 22 x 1.5 10 (900) 3 (270) 8 (700) 7 (620)

F–23
HYDRAULIC LIFT
HYDRAULIC LIFT Mod. T10

D.12 D.12 Hydraulic lift

Safety instructions:

Section D.12/Page Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC LIFT

D.12.1 Montaggio D.12.1 Assembly

1

Take hydraulic lift bottom plate. Apply loctite 518 on its face by roller
method. Fit two dowel pins on range gear box housing for hydraulic lift
bottom plate mounting.

Mount the hydraulic lift bottom plate by aligning with dowel pins and tap
it on top. Fit hydraulic lift bottom plate on range gear box housing by six
bolts and apply torque of 70 Nm.

Fit two bushes for hydraulic lift assembly over bottom plate.

Fit two dowel pins on bottom side of hydraulic lift sub-assembly. Then lift
hydraulic sub-assembly by tackle and fit over hydraulic bottom plate by
two bolts (longer length) on clutch housing side. Apply torque of 300 Nm.

EGS Revision date: 07/15 DOC. 270276 Section D.12/Page 185

HYDRAULIC LIFT Mod. T10

Fit hydraulic lift sub-assembly by clamping two bolts (shorter length) on

PTO side. Tighten the bolts by applying the torque of 200 Nm.

Fit two dowel pins on both side of range gear box housing for bottom
bracket fitment.

Align right hand side and left hand side lower link support with two dowel
pin and tap for fitment against range gear box housing face.

Fit lower link support by eight bolts. Apply torque of 300 Nm to tighten the
bolts.

Section D.12/Page Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC LIFT

Fit two lower link support bolts and apply torque of 280 Nm.

10

Fit two draft sensor supports on both side of lower link support. Fit four
clamping bolts with four bush for draft sensor support and torque on both
lower link support. Apply torque of 50 Nm.

11

Hold cylinder body with tackle, align bottom end with lower link support
and insert pin from outer side.

12

Fit grease nipple over pin. Apply torque of 10 Nm.

EGS Revision date: 07/15 DOC. 270276 Section D.12/Page 187

HYDRAULIC LIFT Mod. T10

13

Align pin with hole and fit pin rotation locking bolt with washer. Apply
torque of 25 Nm.

14

Remove tackle and place the cylinder down. Repeat same steps as per
activity sequence for other cylinder fitment.

15

Lift the right hand side arm of hydraulic lift body with the lifting tackle and
hold it.

Insert shim between rocker arm and hydraulic lift support. Acceptable
backlash 0.2 mm to 0.3 mm.

GAMMA SPESSORI SHIMS RANGE

Spessore - mm mm 0.1 0.5 0.25 0.10 Thickness - mm 0.1 0.5 0.25 0.10
Quantità --- --- --- --- Quantity --- --- --- ---

Section D.12/Page Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC LIFT

16

Lift right hand side cylinder from free end and align cylinder top end hole
with middle link of arm by the hoist up/down movement.

17

Insert pin through the aligned holes of arm and cylinder.

18

Align pin hole with such as no restriction for fitment of coil pin and then fit
coil pin to lock pin from other end.

19

Fit grease nipple over pin then apply torque of 10 Nm.

EGS Revision date: 07/15 DOC. 270276 Section D.12/Page 189

HYDRAULIC LIFT Mod. T10

20

Insert pin through the aligned holes of arm and cylinder.

• • Reverse the above procedure for removal of hydraulic

lift.

Section D.12/Page Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HITCH SYSTEM

D.13 Hydraulic system

Handling
Store the components indoors away from extreme temperatures. Avoid dropping components and never handle
components using their attached wiring.

Environmental specifications
Component Angular position sensor Load pin Controller Valve
Operating temp. -40°C to +125°C -20°C to +80°C -20°C to +70°C -30°C to +120°C
Storage temp. -40°C to +135°C -20°C to +80°C -30°C to +80°C NA
Protection class IP67 IP67-IP68 IP67 IP67

Load pin specifications and considerations

Capacity +/- 50 kN
Safe overload 300% (150 kN)
Ultimate overload 500% (250 kN)
Cable length 2m
Accuracy class 2%
Red wire - input voltage +5 VDC
Black wire - ground 0 VDC
Green wire - signal +0.5 VDC to +4.5 VDC
Max voltage loading direction at rated capacity +4.5 VDC
Voltage at 0 load 2.5 VDC
Min voltage against loading direction at rated capacity 0.5 VDC
Connector Deutsch DTM04-03P
• Install such that the wiring is either facing directly toward or directly away from the loading direction.
• The rotational orientation of both load pins needs to be the same and consistently the same direction for
production.
• The section between the reduced diameters should only contact the connecting link.
• Don’t hammer pins into position.
• For drawing see load pin specific document.
• Loading is applied parallel to ground plane.

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 191

HITCH SYSTEM Mod. T10

Controller specifications
Recommended fastener M4 Flat head socket cap screw
Recommended torque 2.0 +/- 0.2 N-m
Button life 1 million cycles
DT4 Mating connector DT06-4S with W4S Wedgelock
DT12 Mating connector DT06-12S with W12S Wedgelock
Input voltage 12 VDC
Regulated sensor voltage out +5 VDC
Sensor voltage range 0 to 5 VDC
Maximum overvoltage 26.5 VDC

Controller pin mapping

Pin Description Function
21 Coil 1 PWM Out Proportional
22 Coil 2 PWM Out On/off
23 DIN 1 Raise Remote
24 +5 VDC Power Sensor Supply
25 AIN 1 - 0 to 5 V Signal Position
26 AIN 2 - 0 to 5 V Signal Draft 1
27 AIN 3 - 0 to 5 V Signal Draft 2
28 AIN A - 0 to 12 V Signal Alternator voltage
29 +5 VDC Ground Sensor ground
30 DIN 2 Lower remote
31 Coil 2 feedback On/Off Feedback
32 Coil 1 feedback Proportional feedback

1 CAN - Low CAN BUS Low

2 Ignition +12 VDC Switched power input -> Via ignition
3 Ground Battery ground
4 CAN - High CAN BUS High

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Mod. T10 HITCH SYSTEM

Angular position sensor specifications and considerations

Mechanical travel 120° CCW maximum
Rotational torque 0.12 N-m with return spring
Mass 12 grams
Life 10 million cycles
Mating Connector Delphi metri pack 150 series housing: 12162185
Terminal: 12124075 / 12047680
Recommended fastener M5
Recommended torque 3.96 N-m
Effective rotational sensing Range 5° to 85° (Fig 1)
Input voltage 5.0V +/- 10%
Input current 4 mA to 8 mA at 5 VDC
Output shorted to ground 12 mA max.
Maximum overvoltage 16 VDC
Sensor output @ 5 VDC (Ratiometric to input voltage) 0.5 VDC to 4.5 VDC max.
Output linearity @ 5 VDC (Analog output) +/- 2% of full scale
• Install such that the mating blade is narrower than the receiving slot to allow for misalignment.
• Minimize rotational play between mating blade and receiving slot although return spring will ensure engagement
with one side.
• For drawing see angular position sensor specific document.

Wiring Considerations
• The Supply Power should be routed through a 10 Amp Fuse.
• 20 AWG (0.81mm diameter, 0.51 mm^2) wiring is recommended although any wire capable of 2 amps and that
allows for proper sealing of the connector is sufficient.
• Follow manufacturer’s guidelines for proper assembly of Deutsch connectors.
• T-13 Seal and open barrel terminal crimper (Equivalent to: Delphi/Packard 12085270, SPX Kent Moore J-38125-6)
or equivalent required for Metri - pack 150 connectors.
• Protect exposed wire by looming together or using equivalent or better protection.
• Allow adequate length to support mechanism movement.
• Avoid mounting near pinch points or other areas that may cause wear with movement.
• Avoid running sensor wiring near other vehicle wiring.

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HITCH SYSTEM Mod. T10

Section D.13/Page 194 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HITCH SYSTEM

Initial calibration
Initial calibration is required to determine the mechanical limits of the system as well as determine the valve specific
parameters such as threshold. Calibration is accomplished through a routine programmed into the controller.
Calibration must be repeated if any of the components are replaced or the mechanical stops change.

Pre-check
• Confirm that all system components are properly installed with all connectors fully connected.
• Confirm wiring is routed away from pinch points and wear points.
• Before starting the calibration procedure, please ensure the engine RPM is set to a level sufficient to meet the
cycle times and that the oil temperature is 50 Deg C.
• Ensure work port pressure is between 20 BAR and 30 BAR or high enough to achieve the required lower rate.
• Ensure that hitch arms can lower to their lower stops without any part touching the ground.
• Go to the measurements page by pressing the menu button and navigating to Diagnostics->
• Measurements. Position sensor voltage should be between 0.5 VDC and 4.5 VDC. Draft sensor voltage should
near 2.5 VDC without load applied and between 0.5 VDC and 4.5 VDC in normal operation. Both ignition and
alternator voltages should be above 10 VDC.

Calibration

1 Navigate to Diagnostics->Calibrate System and press enter to start calibration. Note: The rocker switch must be in
the neutral position for calibration to run.
2 Calibration is complete when the controller reverts to the locked state.
3 Confirm proper operation by raising and lowering hitch and operating the remote switch if present.

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HITCH SYSTEM Mod. T10

Troubleshooting

Indicators of a Problem
There are several indicators built in to inform you of an error if one is detected. The most common is the Trouble Code
Symbol.

This symbol will appear in the top right hand corner of the screen whenever a trouble code is detected. In addition to this,
some of the particular trouble codes have other indicators:

Current Position Arrow flashes:

The Current Position Arrow flashes if the position sensor voltage is high or low indicating a potential problem with the
Position Sensor. Under these conditions automatic modes will be disabled and therefore the rocker switch will work like
the remote switches in that they will command a slow raise or slow lower.

Height and Depth Values flashing:

If the unit is yet to be calibrated or failed calibration then the Height and Depth values will flash indicating that the upper
and lower position limits are unknown. Under these conditions automatic modes will be disabled and therefore the
rocker switch will work like the remote switches in that they will command a slow raise or slow lower.

Mix Setting flashes:

If one of the Draft Sensor voltages is High or Low, indicating a potential problem with one of the Draft Sensors, the Mix
Setting icon will flash. Under these conditions automatic modes will not be disabled, only the Draft mode will be
disabled, allowing the user to continue to work in position mode.

Common Problems

Moved Wrong Way:

If after calibration is attempted, the controller gives the above screen, the position sensor input needs to be inverted.
This is done by navigating to Diagnostics -> Invert Position and changing the value from 0 to 1. After inverting,
recalibrate.

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Mod. T10 HITCH SYSTEM

Error Code Location

If you do have an error code you can look at what codes you have by navigating to the Alerts page in the menu by
navigating to Diagnostics->Alerts. Once on the Alerts page the error code with the highest priority as described in the
‘Error Code Description’ section will be displayed. Pressing Enter on this screen will display a full list of the error codes
that are present.
To further investigate any problem the Measurements page can be used. The Measurements page is at Diagnostics ->
Measurements. This will show you the current values of all inputs and outputs and can be used to diagnose failures of
certain equipment.

Error Codes

Priority Diagnostic Trouble Code SPN FMI Condition to set active

1 ECU failure 628 12 Raise button AND lower button are active for 100
milliseconds
2 ECU never calibrated 628 13 Active when shipped from CARRARO
3 ECU needs calibration 628 14 Set when calibration aborts
4 Battery voltage high 158 0 Battery voltage > 18 volts for 5 seconds
5 Battery voltage low 158 17 Battery voltage < 7 volts for 1 second

6 Proportional coil short to 701 5 Current command and current feedback differ by at least
ground/open 328 milliamps for greater than 100 milliseconds

7 Proportional coil short to 701 6 Current command and current feedback differ by at least
battery 328 milliamps for greater than 100 milliseconds

8 On/Off coil short to ground/ 702 5 Current command and current feedback differ by at least
open 328 milliamps for greater than 100 milliseconds

9 702 6 Current command and current feedback differ by at least

On/Off coil short to battery
328 milliamps for greater than 100 milliseconds
10 Position sensor under voltage 703 4 Position sensor voltage < 0.25 volts for 100 milliseconds
11 Position sensor over voltage 703 3 Position sensor voltage > 4.75 volts for 100 milliseconds
12 Draft pin1 under voltage 704 4 Draft 1 sensor voltage < 0.25 volts for 100 milliseconds
13 Draft pin1 over voltage 704 3 Draft 1 sensor voltage > 4.75 volts for 100 milliseconds
14 Draft pin2 under voltage 705 4 Draft 2 sensor voltage < 0.25 volts for 100 milliseconds
15 Draft pin2 over voltage 705 3 Draft 2 sensor voltage > 4.75 volts for 100 milliseconds

16 706 6 Remote raise is active at reset and stays active for 5

Remote raise switch stuck on
seconds

17 Remote lower switch stuck 707 6 Remote Lower is active at reset and stays active for 5
on seconds

18 Sensor supply short to 3509 5 Sensor supply voltage < 4.5 volts for 50 milliseconds
ground/open
19 Coil short to ground at startup 2839 14 Failed coil short to ground test @ startup

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 197

ANGULAR POSITION SENSOR Mod. T10

Mechanical Specifications
Mechanical Travel 120° CCW maximum
Rotational Torque 0.12 N-m with return spring
Mass 12 grams
Life 10 million cycles
Recommended Fastener M5
Recommended Torque 3.96 N-m
Mating Connector Delphi Metri Pack 150 series Housing: 12162185
Terminal: 12124075 / 12047680

Electrical Specifications
Effective Rotational Sensing Range 5° to 85°
Input Voltage 5.0V +/- 10%
Input Current 4 mA to 8 mA at 5 VDC
Output Shorted to Ground 12 mA max.
Output Shorted to Ground 16 VDC
Sensor Output @ 5 VDC (Ratiometric 0.5 VDC to 4.5 VDC max.
to Input Voltage)
Output Linearity @ 5 VDC (Analog +/- 2% of full scale
Output)

Environmental Specifications
Operating Temperature -40°C to +125°C
Storage Temperature -40°C to +135°C
Protection Class IP67

Environmental Specifications
• Install such that the mating blade is narrower than the receiving slot to allow for misalignment.
• Minimize rotational play between mating blade and receiving slot although return spring will ensure engagement
with one side.
• Exceeding the mechanical limits will cause failure of position sensor.

Section D.13/Page 198 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 ANGULAR POSITION SENSOR

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 199

ANGULAR POSITION SENSOR Mod. T10

Right
3
Front
2

Rear
Left

2
6

Section D.13/Page 200 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 ANGULAR POSITION SENSOR

Remote Switches
The remote switches allow the operator to actuate the hitch valve from outside the tractor cab. Mount the
remote switches on the fender of the machine above the wheel or where the operator can operate the switch without
being trapped between the machine and the implement as it is raised and lowered.

Front

Rear

Position sensor - Installed by carraro

The position sensor is mounted to the rock shaft of the 3 point system. This ensures proper readings as the hitch is run
through its cycle. Each position sensor is capable of reading 0.5 to 4.5 volts DC. The sensor should be oriented so that
the electrical plug is pointed towards the front of the tractor. This ensures the electrical wires will not be in the way of
implement operations.

Front

Rear

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 201

ANGULAR POSITION SENSOR Mod. T10

Initial Calibration
Initial calibration is required to determine the mechanical limits of the system as
well as determine the valve specific parameters such as threshold current for raise
and lower. Calibration is accomplished through a routine programmed into the
controller. Calibration must be repeated if any of the system’s electronic or
mechanical components are replaced or if the mechanical stops change.

Pre-check
• Confirm that all system components are properly installed with all connectors
fully connected
• Confirm wiring is routed away from pinch points and wear points
• Confirm a drip loop is included near exposed electrical connectors
• Before starting the calibration procedure, please ensure the Engine RPM is
set to a level sufficient to meet the desired cycle times and that the oil
temperature is at or above 50 Deg C
• Ensure work port pressure is between 20 BAR and 30 BAR or high enough to achieve the required lower rate
• Ensure that hitch arms can lower to their lower mechanical stops without any part touching the ground
• Go to the measurements page by pressing the menu button and navigating to Diagnostics Measurements.
Position sensor voltage should be between 0.5 VDC and 4.5 VDC. Draft sensor voltage should be near 2.5 VDC
without load applied and between 0.5 VDC and 4.5 VDC in normal operation. Both ignition and alternator voltages
should be above 10 VDC.

Calibration
• Navigate to Diagnostics->Calibrate System and press enter to start calibration.
Note: The rocker switch must be in the neutral position for calibration to run.
• If two load pins are sensed and the proper load is applied, the T10
transmission model will be selected automatically
• Otherwise the transmission select screen will be shown. Pick the appropriate
transmission from the list.
• Calibration is complete when the controller reverts to the locked state.

Confirm proper operation by raising and lowering hitch and operating the remote switch if present.

Service Mode
When a controller is new, it defaults into service mode. Service mode is shown by a wrench symbol in the upper right
corner. New controllers also give an error because the system needs to be calibrated. This error is shown both on the
alerts screen and as a diamond shaped icon in the upper right corner.

Section D.13/Page 202 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 ANGULAR POSITION SENSOR

Entering Service Mode

After the controller has been calibrated and has been power cycled, the controller will go out of service mode. If the
system needs to be recalibrated, enter service mode by holding the menu and enter keys for 5 seconds. The wrench
symbol should now be flashing in the upper right corner. Service mode is exited by power cycling the controller.

Reset To Defaults
The controller allows the saving of one previous calibration. The initial
calibration is saved as the Factory Calibration after the first successful
System Calibration. The “Reset To Defaults” menu option restores the
valve calibrations to those generated in the Factory during the first
System Calibration. This restores the default user parameters,
including a reset of the EZ-Select parameters.

Replace Factory Calibration

Factory calibrations are automatically stored during the first successful
calibration. When “Reset To Defaults” is selected, these calibrations
are restored. If parts need to be replaced and a new calibration is run,
this menu option allows you to store the current calibrations as the
Factory Calibration; making them available when the user selects
“Reset To Defaults”. This menu option is not available if the tractor has
not been successfully calibrated.

Factory Calibration
The system operates, using the Current Calibrations to determine the position sensor span and to command the valve.
Prior to a successful calibration, the Current Calibrations are loaded with a set of default values.
Each successful execution of “Calibrate System” will update the Current Calibrations. During the 1st successful
calibration, these Current Calibrations are stored as the Factory Calibrations.
If parts are replaced, such as the valve or the position sensor, and the vehicle is recalibrated, these new calibrations
can be stored as the Factory Calibrations, by selecting the Replace Factory Cals menu option. This will copy the
Current Calibrations to the Factory Calibrations.
If the customer has a failed calibration and wants to reset the vehicle to the state when it was built, the customer cannot
select the “Reset To Defaults” menu option. This will copy the Factory Calibrations to the Current Calibrations.

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 203

ANGULAR POSITION SENSOR Mod. T10

Run System Calibration

Reset to Defaults
Calibrate System

Factory
Current
Calibrations
Calibrations

Replace Factory Cals

Troubleshooting:
1 The arms are slow to raise or lower:
Before the system has been calibrated, a set of generic valve currents are used. Because threshold varies from valve
to valve, the current command may ramp through values for the current command which are below the value needed
to move the hitch known as threshold. After calibration the system should be OK.
• Slow raise could be caused by insufficient pump flow.
• Slow lower could be caused by insufficient weight on the hitch arms.
2 Calibration Error: LH Draft / RH Draft Differs:
The voltage for the LH Draft pin and the RH Draft pin must be within 1 Volt of each other at the start of calibration.
This could be caused by a failed draft sensor. The draft sensors should measure 2.5 Volts in the unloaded condition.
Both draft sensors should have similar voltages.
A significant difference between the two sensors could be caused if there is a significant side loading present on the
hitch arms. The load pin on one side would be in tension and the load pin on the other side would be in compression.
This occurs sometimes at the top and bottom of stroke when the three point hitch is incorrectly adjusted to take the
load of the implement. The geometry of the three point hitch needs to be adjusted.
3 Calibration Error: Moved Wrong Way:
This can occur if the Valve wiring is reversed. Coil1 is Raise. Coil2 is Lower.
This can occur during calibration if there is significant leakage in the cylinder (either work port to tank or pump to work
port), such that the arms move by more counts than the deadband (0.015 Volts). Changing the Deadband can
address this.
This can occur if there is binding on the arms caused by an improperly set up three point hitch.

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Mod. T10 ANGULAR POSITION SENSOR

4 Calibration Error: Raise Too Slow:

The system did not complete a full raise cycle in the expected time (3-4 seconds). This could occur if the pump does
not deliver sufficient flow.
It would also occur of the raise coil was not connected or if it was connected to the lower coil improperly.
5 Calibration Error: Lower Too Slow:
The system did not complete a full lower cycle in the expected time (3-4 seconds). This could occur if there is not
enough weight on hitch arms.
6 Calibration Error: Upper Stop Invalid:
This occurs when the Upper Stop is outside of the range from 2.5 Volts to 4.75 Volts. The position sensor should be
adjusted to deliver 3.6 to 3.9 Volts (depending on the tractor model) when the arms are all of the way up.
7 Calibration Error: Upper Stop Difference:
This occurs when the Upper Stop measured during the 1st and 2nd full raise differ by too much (0.030 Volts). Check
the position sensor voltage on the measurement screen during raise using the Remote Raise switch.
This could happen due if the position sensor is mounted loose or there is too much slop between the groove on the
position sensor and the engaging blade. Check the torque on the mounting bolts for the position sensor.
8 Calibration Error: Lower Stop Invalid:
This occurs when the Lower Stop is outside of the range from 0.25 Volts to 2.5 Volts. The position sensor should be
adjusted to deliver 1.1 to 1.2 Volts (depending on the tractor model) when the arms are all of the way down.
9 Calibration Error: Lower Stop Difference:
This occurs when the Lower Stop measured during the 1st and 2nd full lower differ by too much (0.030 Volts). Check
the position sensor voltage on the measurement screen when lowering using the Remote Lower switch.
This can occur if there is a significant amount of air in the system. The beginning of the calibration cycle is designed
to purge the air from the system. If this occurs, then repeat the calibration process.
This could happen due if the position sensor is mounted loose or there is too much slop between the groove on the
position sensor and the engaging blade. Check the torque on the mounting bolts for the position sensor.
10 Calibration Error: Stop Span Out of Specifications:
This occurs when the different between the Lower Stop and the Upper Stop is less than 1 Volt or more than 4 Volts.
Check the position sensor voltage over the entire range from fully lowered to fully raise.

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ANGULAR POSITION SENSOR Mod. T10

Schematic

Section D.13/Page 206 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HITCH CONTROLLER

Handling and Storage

Store inside away from extreme temperatures. Avoid dropping controller.

Mechanical Specifications
Recommended Fastener M4 Flat Head Socket Cap Screw
Recommended Torque 2.0 +/- 0.2 N-m
Button Life 1 million cycles
DT4 Mating Connector DT06-4S with W4S Wedgelock
DT12 Mating Connector DT06-12S with W12S Wedgelock

Electrical Specifications
Input Voltage 12 VDC
Regulated Sensor Voltage Out +5 VDC
Sensor Voltage Range 0 to 5 VDC
Maximum Overvoltage 26.5 VDC

Environmental Specifications
Operating Temperature -20°C to +70°C
Storage Temperature -30°C to +80°C
Protection Class IP67

Pin Mapping
Pin Description Function
1 Coil 1 PWM Out Proportional
2 Coil 2 PWM Out On/Off
3 DIN 1 Raise Remote
4 +5 VDC Power Sensor Supply
5 AIN 1 - 0 to 5 V Signal Position
6 AIN 2 - 0 to 5 V Signal Left Hand Draft
7 AIN 3 - 0 to 5 V Signal Right Hand Draft
8 AIN A - 0 to 12 V Signal Alternator Voltage
9 +5 VDC Ground Sensor Ground
10 DIN 2 Lower Remote
11 Coil 2 Feedback On/Off
12 Coil 1 Feedback Proportional

1 CAN-Low CAN BUS Low

2 Ignition +12 VDC Switched Power -> Via Ignition
3 Ground Battery Ground
4 CAN-High CAN BUS High

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HITCH CONTROLLER Mod. T10

Installation
• Route wires through installation hole and attach connectors.
• Use recommended fastener (M4 Flat Head Socket Cap Screw) to attach control panel. Pre-drill attachment point if
necessary. Avoid over tightening.
• Ignition power requires 10 Amp fuse.
• Faults are indicated by the trouble code symbol (right) and can be diagnosed under the Diagnostics menu
using the Alerts and Measurements screens.

Section D.13/Page 208 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC SYSTEM

Introduction
System Components BOM Table
Item Description Carraro P/N CARRARO P/N Document Page
5 Hitch controller CA407806 HCP-010B 6
6 Load pins CA407805 HDSL2-050010A 3
7 Angular position sensor CA407804 HPS-R080020A 8
8 Hitch valve CA407807 VFH900-1 4
9 Wiring harness CA408808 N/A 7
10 Remote switch 8

• Hitch valve is pre installed on the transmission from Carraro

• Position sensor is mounted
• Items OEM will need to do:
• Install load pins and hitch arms
• Connect valve to pump supply
• Install hitch controller
• Install wire harness and rear remote switch/switches
• Connect wire harness to vehicle power and alternator voltage

Right
3
Front
2

Rear
Left

2
6

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HYDRAULIC SYSTEM Mod. T10

Load Pins
Install the load pins in the lower link arms at the pivot point on the machine, making sure the center section between the
grooves is inside the lower link arms. Follow the instructions from Carraro for the hitch linkages. The outer sections of
the load pin should align with the mounting brackets on the machine. Improper installation will produce faulty readings,
which will result in poor system operation. The pin bracket ensures proper alignment when installed as shown.
Never hit wired end of pins. Hitting the pins can result in permanent damage.

Grooves

Center Section
Pin Bracket

Hitch Valve
The hitch valve is mounted on the transmission near the rear of the machine. The hitch is oriented with the pump to the
front, tank to the left, coils to the right, and work port to the rear when viewed from the rear. The manual lower is a screw
under the specified plug. Connect pump port (M27 X 2 metric o-ring port). See figures below for clarification.

Pump

Front
Coil 1

Tank

Tank

Work Port
Manual Rear
Lower
Coil 2
Work Port

Section D.13/Page 210 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC SYSTEM

Front

Rear
To Pump

Controller
Mount the controller inside the cab within reach of the operator. Install the controller on a flat surface and torque the
mounting screws to 2.3 Nm (20 in-lbs). The Red (Switched +12VDC - Ignition), Black (Ground), and Yellow (+12VDC
Alternator Signal) connect to the corresponding places on the tractor as shown in “Wire Harness Connection” on page
9. Plug in the 12 pin connector before the 4 pin connector. The Alternator signal indicates that the engine is running.
Alternator voltage below 10VDC will prevent the hitch from operating.

Rig ht
3
Front
2

Rear
Left

2
5

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 211

HYDRAULIC SYSTEM Mod. T10

1 Hitch controller
2 Load pins
3 Position sensor
4 Hitch valve
5 Remote switch (Optional or Customer Supplied)
6 Alternator voltage, switched vehicle power, vehicle ground

Wiring Harness
The wiring harness may be placed among the overall wiring of the machine. The wiring harness is used to connect the
components of the CARRARO Hitch System. Page 8 shows a connection diagram of the wiring harness along with a
schematic of the wiring harness for creating custom harnesses on page 10.

Front Wiring
Harness
Rear

For CARRARO supplied wire harness assembly

• Switched supply power should include a 10 amp fuse.
• Protect exposed wire by looming together or using equivalent/ better protection.
• Avoid mounting near pinch points or other areas that may cause wear with movement.
• When connecting the 12 pin and 4 pin Deutsch connectors to the controller, always connect the 12 pin connector
first and then the 4 pin connector.
• If CAN functionality is included, the CAN wiring must meet J1939 requirements.
• The harness to the draft sensor must use a shielded cable if 100 V/m EMI rating is required.
• This immunity can also be improved by twisting together the sensor signal and ground wire.
• Proper routing of the harness can improve the immunity.

Section D.13/Page 212 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC SYSTEM

Wiring harness connection

with 10 Amp Fuse

Black - Ground
Yellow - Alternator Voltage

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 213

HYDRAULIC SYSTEM Mod. T10

Remote Switches
The remote switches allow the operator to actuate the hitch valve from outside the tractor cab. Mount the
remote switches on the fender of the machine above the wheel or where the operator can operate the switch without
being trapped between the machine and the implement as it is raised and lowered.

Front

Rear

Position sensor - Installed by carraro

The position sensor is mounted to the rock shaft of the 3 point system. This ensures proper readings as the hitch is run
through its cycle. Each position sensor is capable of reading 0.5 to 4.5 volts DC. The sensor should be oriented so that
the electrical plug is pointed towards the front of the tractor. This ensures the electrical wires will not be in the way of
implement operations.

Front

Rear

Section D.13/Page 214 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC SYSTEM

Initial Calibration
Initial calibration is required to determine the mechanical limits of the system as
well as determine the valve specific parameters such as threshold current for raise
and lower. Calibration is accomplished through a routine programmed into the
controller. Calibration must be repeated if any of the system’s electronic or
mechanical components are replaced or if the mechanical stops change.

Pre-check
• Confirm that all system components are properly installed with all connectors
fully connected
• Confirm wiring is routed away from pinch points and wear points
• Confirm a drip loop is included near exposed electrical connectors
• Before starting the calibration procedure, please ensure the Engine RPM is
set to a level sufficient to meet the desired cycle times and that the oil
temperature is at or above 50 Deg C
• Ensure work port pressure is between 20 BAR and 30 BAR or high enough to achieve the required lower rate
• Ensure that hitch arms can lower to their lower mechanical stops without any part touching the ground
• Go to the measurements page by pressing the menu button and navigating to Diagnostics Measurements.
Position sensor voltage should be between 0.5 VDC and 4.5 VDC. Draft sensor voltage should be near 2.5 VDC
without load applied and between 0.5 VDC and 4.5 VDC in normal operation. Both ignition and alternator voltages
should be above 10 VDC.

Calibration
• Navigate to Diagnostics->Calibrate System and press enter to start calibration.
Note: The rocker switch must be in the neutral position for calibration to run.
• If two load pins are sensed and the proper load is applied, the T10
transmission model will be selected automatically
• Otherwise the transmission select screen will be shown. Pick the appropriate
transmission from the list.
• Calibration is complete when the controller reverts to the locked state.

Confirm proper operation by raising and lowering hitch and operating the remote switch if present.

Service Mode
When a controller is new, it defaults into service mode. Service mode is shown by a wrench symbol in the upper right
corner. New controllers also give an error because the system needs to be calibrated. This error is shown both on the
alerts screen and as a diamond shaped icon in the upper right corner.

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 215

HYDRAULIC SYSTEM Mod. T10

Entering Service Mode

After the controller has been calibrated and has been power cycled, the controller will go out of service mode. If the
system needs to be recalibrated, enter service mode by holding the menu and enter keys for 5 seconds. The wrench
symbol should now be flashing in the upper right corner. Service mode is exited by power cycling the controller.

Reset To Defaults
The controller allows the saving of one previous calibration. The initial
calibration is saved as the Factory Calibration after the first successful
System Calibration. The “Reset To Defaults” menu option restores the
valve calibrations to those generated in the Factory during the first
System Calibration. This restores the default user parameters,
including a reset of the EZ-Select parameters.

Replace Factory Calibration

Factory calibrations are automatically stored during the first successful
calibration. When “Reset To Defaults” is selected, these calibrations
are restored. If parts need to be replaced and a new calibration is run,
this menu option allows you to store the current calibrations as the
Factory Calibration; making them available when the user selects
“Reset To Defaults”. This menu option is not available if the tractor has
not been successfully calibrated.

Factory Calibration
The system operates, using the Current Calibrations to determine the position sensor span and to command the valve.
Prior to a successful calibration, the Current Calibrations are loaded with a set of default values.
Each successful execution of “Calibrate System” will update the Current Calibrations. During the 1st successful
calibration, these Current Calibrations are stored as the Factory Calibrations.
If parts are replaced, such as the valve or the position sensor, and the vehicle is recalibrated, these new calibrations
can be stored as the Factory Calibrations, by selecting the Replace Factory Cals menu option. This will copy the
Current Calibrations to the Factory Calibrations.
If the customer has a failed calibration and wants to reset the vehicle to the state when it was built, the customer cannot
select the “Reset To Defaults” menu option. This will copy the Factory Calibrations to the Current Calibrations.

Section D.13/Page 216 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HYDRAULIC SYSTEM

Run System Calibration

Reset to Defaults
Calibrate System

Factory
Current
Calibrations
Calibrations

Replace Factory Cals

Troubleshooting:
1 The arms are slow to raise or lower:
Before the system has been calibrated, a set of generic valve currents are used. Because threshold varies from valve
to valve, the current command may ramp through values for the current command which are below the value needed
to move the hitch known as threshold. After calibration the system should be OK.
• Slow raise could be caused by insufficient pump flow.
• Slow lower could be caused by insufficient weight on the hitch arms.
2 Calibration Error: LH Draft / RH Draft Differs:
The voltage for the LH Draft pin and the RH Draft pin must be within 1 Volt of each other at the start of calibration.
This could be caused by a failed draft sensor. The draft sensors should measure 2.5 Volts in the unloaded condition.
Both draft sensors should have similar voltages.
A significant difference between the two sensors could be caused if there is a significant side loading present on the
hitch arms. The load pin on one side would be in tension and the load pin on the other side would be in compression.
This occurs sometimes at the top and bottom of stroke when the three point hitch is incorrectly adjusted to take the
load of the implement. The geometry of the three point hitch needs to be adjusted.
3 Calibration Error: Moved Wrong Way:
This can occur if the Valve wiring is reversed. Coil1 is Raise. Coil2 is Lower.
This can occur during calibration if there is significant leakage in the cylinder (either work port to tank or pump to work
port), such that the arms move by more counts than the deadband (0.015 Volts). Changing the Deadband can
address this.
This can occur if there is binding on the arms caused by an improperly set up three point hitch.

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HYDRAULIC SYSTEM Mod. T10

4 Calibration Error: Raise Too Slow:

The system did not complete a full raise cycle in the expected time (3-4 seconds). This could occur if the pump does
not deliver sufficient flow.
It would also occur of the raise coil was not connected or if it was connected to the lower coil improperly.
5 Calibration Error: Lower Too Slow:
The system did not complete a full lower cycle in the expected time (3-4 seconds). This could occur if there is not
enough weight on hitch arms.
6 Calibration Error: Upper Stop Invalid:
This occurs when the Upper Stop is outside of the range from 2.5 Volts to 4.75 Volts. The position sensor should be
adjusted to deliver 3.6 to 3.9 Volts (depending on the tractor model) when the arms are all of the way up.
7 Calibration Error: Upper Stop Difference:
This occurs when the Upper Stop measured during the 1st and 2nd full raise differ by too much (0.030 Volts). Check
the position sensor voltage on the measurement screen during raise using the Remote Raise switch.
This could happen due if the position sensor is mounted loose or there is too much slop between the groove on the
position sensor and the engaging blade. Check the torque on the mounting bolts for the position sensor.
8 Calibration Error: Lower Stop Invalid:
This occurs when the Lower Stop is outside of the range from 0.25 Volts to 2.5 Volts. The position sensor should be
adjusted to deliver 1.1 to 1.2 Volts (depending on the tractor model) when the arms are all of the way down.
9 Calibration Error: Lower Stop Difference:
This occurs when the Lower Stop measured during the 1st and 2nd full lower differ by too much (0.030 Volts). Check
the position sensor voltage on the measurement screen when lowering using the Remote Lower switch.
This can occur if there is a significant amount of air in the system. The beginning of the calibration cycle is designed
to purge the air from the system. If this occurs, then repeat the calibration process.
This could happen due if the position sensor is mounted loose or there is too much slop between the groove on the
position sensor and the engaging blade. Check the torque on the mounting bolts for the position sensor.
10 Calibration Error: Stop Span Out of Specifications:
This occurs when the different between the Lower Stop and the Upper Stop is less than 1 Volt or more than 4 Volts.
Check the position sensor voltage over the entire range from fully lowered to fully raise.

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Schematic

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HITCH LOAD PIN Mod. T10

Handling and Specifications

Store inside away from extreme temperatures. Avoid dropping and never handle by the wiring.

Mechanical Specifications
Capacity +/- 50 kN
Safe Overload 300% (150 kN)
Ultimate Overload 500% (250 kN)
Cable Length 2m

Electrical Specifications
Accuracy Class 2%
Red Wire – Input Voltages +5 VDC
Black Wire – Ground 0 VDC
Green Wire – Signal +0.5 VDC to +4.5 VDC
Max Voltage Loading Direction at Rated Capacity +4.5 VDC
Voltage at 0 load 2.5 VDC
Min Voltage Against Loading Direction at Rated 0.5 VDC
Capacity
Connector Deutsch DTM04-03P

Environmental Specifications
Load Pin Protection Class IP67/IP69K
Connector Protection Class IP67
Temperature Range -20°C to +80°C

Installation Notes
• Install such that the wiring is either facing directly toward or directly away from the loading direction.
• The rotational orientation of both load pins needs to be the same and consistently the same direction for
production.
• The section between the reduced diameters should only contact the connecting link.
• Don’t hammer pins into position.
• Loading is applied parallel to ground plane.

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HITCH CONTROL PANEL Mod. T10

Introduction
The HUSCO Hitch with EZ-Select® is a complete hitch control system that uses sensors and an electro-hydraulic valve
coupled to an easy-to-use controller to accurately and intuitively provide position control, draft control and transport
stabilization functions. These advanced functions allow the operator to plow consistently and efficiently with minimal inputs
of the operator after initial setup and more safely travel from field to field.
This document relates to the HUSCO Hitch Control Panel with EZ-Select®, HUSCO Part number HCP-010B, HUSCO
Position Sensor part number HPS-R080020A, two of the HUSCO Load pin Assemblies HUSCO part number HDSL2-
050010A, and HUSCO Hitch Valve part number VFH900-1. Remote Switches (usually fender mounted) can also be
connected to the system.

Hitch Control Panel HCP-010B Position Sensor HPS-R080020A

Carraro Part Number: 407806 Carraro Part Number: 407804

Hitch Valve VFH900-1

Carraro Part Number: 407807

Load Pin Assembly HDSL2-050010A

Carraro Part Number: 407805
All system components must be connected correctly for the hitch to work properly. The diagram in Appendix A illustrates
how these components should be connected to the control panel.

Control Panel Basics

The Control Panel at a Glance

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Mod. T10 HITCH CONTROL PANEL

Locked Icon: This signifies the system is in locked mode and illustrates what is needed to unlock it. In order for the system
to be unlocked the Raise-Stop-Lower Toggle Switch must go through all modes (Raise-Stop-Lower) and return to Stop
position. As each mode is entered the associated arrow on the Icon will appear solid. When both are solid and the rocker
is returned to Stop the system is unlocked.
EZ-Select Implement Number or Diagnostic Symbol: The EZ-Select Implement Number will be displayed in this area,
see the EZSelect description on page 18 for further details. In the event of a trouble code the Trouble Code icon will be
shown. (See below)

= Trouble Code icon

Software and Revision: The software identification and revision is displayed in this area.
Depth: The depth setpoint is displayed.
Current Position Arrow: Points to the current position on the Position Bar.
Current Position Value: This signifies the numerical value for current position.
Position Bar: The scrolling position bar displays the 60 increments around the current position. There are two wider bars
that signify the Height and Depth setpoints. Below the Depth setpoint and above the Height setpoint the bar is thinner
showing the portion of the full operating range which is outside of the user setpoints. The total bar length signifies the
maximum range of the positions available. The bar has 101 positions numbered from 0-100, where 0 is the lowest available
point and 100 is the highest available point. This scale changes if the Ground Level is set making positions below Ground
Level negative, although the total number of increments will remain 101. There is also a float position below 0 which is
discussed in the float section.
Height: The height is displayed.
If the Enter Key is pressed on this screen a box will appear around the Depth. This means the Depth value can be
changed by rotating
the Scroll Knob. If the Enter Key is pressed for a second time the box moves from around the Depth value and appears
around the Height value. Rotating the Scroll Knob will now adjust the Height setpoint. Pressing the Enter Key a third
time will remove the box
and the Scroll Knob will not adjust anything if moved.
Anytime a box is present around a value it is adjustable with the Scroll Knob.

The Stop Mode Screen (or Unlocked Screen)

When the system has been unlocked by going through all modes (Raise-Stop-Lower) then returning to Stop, the screen
below is displayed.

In addition to the items already described, this mode displays the following:
Unlocked Icon: This icon signifies the system is unlocked but in Stop Mode.
Height and Depth values can be changed in the same manner as on the Startup Screen.

The Lower Mode Screen

When the Raise-Stop-Lower toggle switch is switched to the lower position the screen below is displayed.

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In addition to the items already described, this mode displays the following:
Lower Mode Icon: This icon signifies the system is unlocked and in the lower mode.
Active Direction Indicator: This icon appears whenever the controller is providing a significant current to the raise or
lower component of the valve. The arrow shown can either point in the direction shown or the opposite direction. In the
example screen, the direction shown signifies the controller is commanding the hitch to lower.
In this mode a box appears around the depth value by default, allowing it to be changed with the scroll Knob. Pressing
the enter key will move the box back and forth between the depth and mix setting values.

Set Ground
The ‘Set Ground’ option allows the user to change the level
indicated by the number “0” on the Position Bar by replacing
it with the current position of the implement.
To set this correctly the user should lower the implement onto
the level ground and then navigate to this screen. If Ground
level is not active then “OFF” will be displayed and if it is active
then “ON” will be displayed on the screen. To Turn Ground
Level OFF and ON, hold the Enter Key for 5 seconds
respectively. If the Enter Key is pressed with Ground Level
Menu “ON” the current position will be recorded as ground
level. The Ground Level icon will appear on the bottom side
of Position Bar:
The calibration cycle sets the lower limit on the position scale
to the level it could reach during calibration, which is indicated
by the number “0” on the Position Bar. This level will be the
mechanical limits of the lower links, reflecting the maximum
depth the lower links can reach. This is usually below the
ground level. That maximum depth point is assigned a position
of “0”, and therefore the ground level would be a positive
number above “0”.

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Mod. T10 HITCH CONTROL PANEL

The ‘Set Ground’ option resets the level indicated by the

number “0” on the position bar by replacing it to the current
position of the implement. Then all the levels below this
position will be indicated by a negative value while the levels
above will be indicated by a positive number on the position
Bar. This feature is usually used on a field where the user
wishes to gage the depth of cut achieved during plowing. By
setting the ground level as zero using this ‘Set ground’ option
the negative values read as the ‘Current Position Arrow’ on the
position bar would become more negative as the implement
reaches a deeper depth.
For example, with Set Ground deactivated (set to off), the
position is shown as 24.
When Set Ground is activated, that same position becomes
0. Notice the presence of the ground indicator at the 0 position.
Furthermore, the Raise Setpoint has been shifted from 80 to
56 and the Lower Setpoint has been shifted from 20 to -4
(below ground level). Now all positions below ground are
negative values and all positions above ground are positive
values.

Draft Control
Draft Control adjusts the hitch depth based on a measured load on the implement. For best operation the operator should
set and maintain a constant engine speed and maintain that. Variation in engine speed can cause variation in the measured
load. This can result in reduced traction and unwanted variation in plowing depth.
The mix (draft or function) setting is accessed by pressing the toggle switch to lower. While in Draft Control the enter key
allows the operator to switch between changing the depth and the mix setting. Turning the knob allows both to be changed.

Traditional Draft Mode

In Traditional Draft Mode the depth setting defines and Measured
electronically limits the position that the hitch will lower to (14 Draft
in the example shown). The number from 0 to 100 in the mix Load
setting (100 in the example shown) defines the amount of
measured draft load (aka pulling force) before the hitch system Mix
will raise. The number above the mix setting is the measured Setting -
draft load sensed by the system. Traditional
Draft
The hitch arms will lower if either the depth has not been
Mode
reached, or the measured draft load has not been achieved.
When the measured draft load is greater than the mix setting then the hitch system will raise. Otherwise, the hitch arms
will be allowed to lower until the depth setting is reached. If the tractor loses traction or begins to stall, the mix setting
should be decreased, forcing the hitch system to raise and reduce the measured draft load.

Automatic Draft Mode

Carraro automatic draft control allows the operator to maintain Measured
proper plowing depths over a range of plowing situations. In Draft
Automatic Draft Mode the operator first sets the depth of the Load
implement (14 in the example shown).
Mix
After the plow has reached the user selected depth, the system Setting -
evaluates the soil conditions and sets a draft setpoint. For the Automatic
system to properly acquire draft, the user selected depth needs Draft
to be achievable while also allowing the vehicle to maintain Mode
traction. The draft setpoint will be re-evaluated when the depth
setting has been changed or on any time the Raise-Stop-Lower Toggle Switch changes position. Additionally, the user

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HITCH CONTROL PANEL Mod. T10

can manually override the automatically calculated draft setpoint by pressing the enter key to establish a new draft setpoint.
Draft setpoint acquisition is signaled by the Mix icon being displayed in reverse video.
Automatic Mode is signified by A1 through A10 in the mix setting on either the main page or in the menu. In Automatic
Draft Mode A10 responds more quickly to draft changes than A1. The number above the draft setting shows the current
draft being measured by the system.
After the system acquires the draft setpoint, the system will move the hitch
to maintain the acquired load. This allows the tractor to maintain a consistent
plowing depth through a variety of terrains as well as lift in the event of hard
spots or obstacles.
In the example shown, the tractor is on level ground and the hitch arms
have lowered to reach the depth setting. The measured draft load will
become the draft setpoint.

When the tractor drives over the top of a rise, the measured load will naturally
decrease. Automatic Draft Control will lower the hitch arms, even though this will
make the hitch arms go below the depth setting. They will lower until the measured
draft load increases to the draft setpoint.

When the tractor drives into a depression, the measured load will naturally increase.
Automatic Draft Control will raise the hitch arms, much like Traditional Draft Control
would do. The hitch arms will raise until the measured draft load decreases to the
draft setpoint.

When the tractor hits a rock, or a tougher patch of soil, the measured load will
increase quickly. Automatic Draft Control will raise the hitch arms, but because the
measured load quickly decreases, the change in position will not last long, and the
hitch will lower back to the desired original depth.

Position Control Mode

Position control mode is accessed by changing the mix setting to PC
(Position Control) which is located between Traditional Mode and
Automatic Mode when rotating the encoder. In position control the system
will disregard draft and keep the hitch at the user defined position.

The Float Mode Screen

When the Raise-Stop-Lower Toggle Switch is moved to the Lower Position with Mix set to PC, and the Depth is set below
the minimum value the screen below is displayed.

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Mod. T10 HITCH CONTROL PANEL

In addition to the items already described, this mode displays the following:
Float Icon: This icon signifies the system is unlocked and in the Float Mode with the Depth set below the lowest setpoint.
This means that the valve will be commanded to continuously provide current to lower the hitch. This will allow oil to pass
between the hitch cylinder(s) and the tank as needed and in both directions.
Float: This is shown in place of the Depth setting when the Scroll Knob has set the Depth to below the minimum setpoint.

The Raise Mode Screen

When the Raise-Stop-Lower Toggle Switch is moved in to the Raise Position the screen below is displayed.

Height Raise Icon

Active Direction
Indicator

Depth

Raise Icon: This icon signifies the system is unlocked and in the Raise Mode. When Transport Mode is enabled, the icon
shown below is displayed. Transport Mode can be toggled on or off by changing the On/Off indicator in the Transport
Mode menu or pressing the enter key while the Raise-Stop-Lower Toggle Switch is in the raise position.
If Transport Mode is activated a box will appear on the Scrolling Position
Bar and the hitch will lower to the middle of the box. The box signifies
the range of movement the hitch is allowed to move through under
dynamic loading conditions. The size of the box can be manipulated
by adjusting the height and depth setpoints. By moving the height and
depth settings
closer to each other, the operating position and position range can
beadjusted.
In this mode a box appears around the Height by default, this means
the Height value can be changed by rotating the Scroll Knob.

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HITCH CONTROL PANEL Mod. T10

The operator can “Lock” the controller to remain in Transport Mode.

This will prevent an accidental movement of the toggle switch from
causing the hitch arms to lower during roading. This is done by holding
the MENU key for 5 seconds. To unlock the controller the Raise-Stop-
Lower toggle switch must be toggled through all three position (Stop,
Lower and return to Raise). When the rocker switch returns to the Raise
position, Transport Lock will return to normal Transport mode.

Manual Mode

Remote Switch Actuation

The Remote Switches should be accessible from the rear of the tractor and can be used to make adjustments.
Pressing the Raise remote switch will command the hitch arms to raise and pressing the Lower remote switch
will command the hitch arms to lower. When the remote switches are used the hitch operates at reduced speeds.
The operation is not restricted by the Height or Depth setting. If the remote switches are used, the system will
revert to locked mode and the control panel controls will be disabled until the system is unlocked again.

Operation when Automatic Modes are not available

If the system has an error associated with the Position Sensor or coil drivers/feedback, then the Raise-Stop-Lower Toggle
Switch will act like the remote switches. The controller will allow the operator to slowly raise the hitch arms when the
Raise-Stop-Lower Toggle Switch is in the Raise position and slowly lower when the Raise-Stop-Lower Toggle Switch is
in the Lower position. This condition results in the hitch operating at reduced speeds.

Manual Lower to be used in case of malfunction

A manual lower feature is included on the valve to allow the hitch to be lowered when the tractor engine cannot or is not
able to be run. This feature is intended to allow the operator to lower hitch arms without the control panel or remote switches.
The manual lower is operated by first taking out the plug with a 6 mm allen (hex) wrench. This exposes another hex that
is operated by a 4 mm allen wrench. Loosening this internal hex lowers the hitch. When operating the manual lower, stop
turning the internal hex out when the part hits the retaining ring after approximately 1.5 turns. After the hitch is lowered,
tighten both internal hex and plug.

Retaining Ring

Plug

Internal Hex

EZ – Select Mode/ Diagnostic

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Mod. T10 HITCH CONTROL PANEL

EZ-Select Implement Number: The EZ-Select Implement allows

the user to save desired settings for up to four different
implements for quick implement changes. More information on
using EZ-Select is located in the “Navigating the Menus”.
To use EZ select, first enter the EZ-Select menu. Select the
implement you would like to modify by scrolling through the list
and pressing enter on the desired implement. On the main screen
a number will be displayed showing the selected implement in
the upper right hand corner. Whenever a setting has been
changed, this number will have a dark background and light letter.
To save the EZ-Select settings hold the enter button for five Implement Selected
seconds. The EZ-select number in the upper right corner of the List Implement
main screen will now turn dark with a light background. Number

EZ-Select Implement Number/

Diagnostic Symbol

Diagnostic Symbol: In the event of an error the Trouble Code icon will be shown in place of the Implement number.
(See Right) If this error code message appears see Trouble Shooting section.

Navigating the Menus

Navigation through the screens is done by pressing the Menu key to get to the Menu screens, then using the Scroll Knob
to scroll through the menu. Once the Menu Key is pressed the current mode is displayed in the upper left hand corner of
the screen and the EZ-Select Implement Number or Diagnostic Symbol remains in the upper right hand corner of the
screen. The menus are described below:

If Ground level is turned off then “OFF” will be displayed on this screen. If the Enter
Key is pressed the current position is recorded as ground level. To set this correctly
the user should lower the implement to the ground and then navigate to this screen
and press Enter. To Turn Ground Level off, hold the Enter Key for 5 seconds. The
Ground Level icon is shown below:

The current Lower Speed value is displayed. If the Enter Key is pressed a box will
appear around the value and the Lower Speed value can be adjusted using the Scroll
Knob. Pressing Enter again removes the box from around the Lower Speed value
and allows you to use the Scroll Knob to scroll through the menu again.

Lower Speed

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The current Raise Speed value is displayed. If the Enter Key is pressed a box will
appear around the value and the Raise Speed value can be adjusted using the Scroll
Knob. Pressing Enter again removes the box from around the Raise Speed value
and allows you to use the Scroll Knob to scroll through the menu again.

Raise Speed

The current Mix Setting value is displayed. If the Enter Key is pressed a box will
appear around the value and the Mix Setting value can be adjusted using the Scroll
Knob. Pressing Enter again removes the box from around the Mix Setting value and
allows you to use the Scroll Knob to scroll through the menu again.

Mix

The resolution of the traditional mode draft setting can

be modified by changing the draft setting. This works by
modifying the system so the 0 to 100 of the traditional
mode is spread over a narrower draft range to increase
the resolution to allow finer adjustments of draft.
The Max value tells what percentage of actual load on
Draft Max/Min the load pin will be mapped to 100%.
The Min value tells what percentage of actual load on the
load pin will be mapped to 0%.
The status of Transport Mode is displayed. If the Enter Key is pressed a box will
appear around the status and Transport Mode can be turned on or off using the
Scroll Knob Pressing Enter again removes the box from the status and allows you
to use the Scroll Knob to scroll through the menu again.

Transport Mode

Wagon Dump allows the hitch valve to be used for an external single acting cylinder
such as a wagon. To use wagon dump, first attach the auxiliary cylinder and disable
the hitch cylinders. This may be done using an external valve or may be integrated
into the valve. While in wagon dump, the raise and lower toggle switch works to
extend and retract the cylinder. Turning the scroll knob while extending or retracting
allows the flow rate to be changed for the boxed selection.
Wagon Dump

If the Enter Key is pressed the Diagnostic sub-menu will be displayed. The Scroll
Knob will now scroll through this sub-set of menu screens.

Diagnostics

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Mod. T10 HITCH CONTROL PANEL

The current highest priority trouble code is displayed or

if no codes are active then ‘No Problem’ will be dislayed.
The list of error codes and the priority is displayed in the
Troubleshooting section of this guide. If the Enter Key is
pressed another screen is displayed that shows a list of
Alert all error codes active, if none are active ‘None’ will be
displayed.

If the Enter Key is pressed another screen is displayed

that shows the following information:
1. Position in Volts

Measurements 2. Load Pin Draft 1 in Volts

3. Load Pin Draft 2 in Volts
4. Ignition Voltage in Volts
5. Alternator Voltage in Volts
6. Remote Raise on(1) or off(0)
7. Remote Lower on(1) or off(0)
8. Coil 1 Current in milliamps
9. Coil 2 Current in milliamps
10. Coil 1 Current Feedback in milliamps
11. Coil 2 Current Feedback in milliamps
The Scroll Knob can be used to scroll down to be able
to see the values further down the list. Pressing Menu
allows you to use the Scroll Knob to scroll through the
Diagnostic sub-menu again.

The current Language is displayed on the Change

Language menu. If the Enter Key is pressed a list of
available languages is displayed. The Scroll Knob is used
to cycle through the list. Pressing the Enter Key again will
Change Language set the highlighted language as active. Pressing the
Menu Key will return the screen to the Diagnostics sub-
menu.

The current Brightness value is displayed. If the Enter

Key is pressed a box will appear around the value and
the Brightness value can be adjusted using the Scroll
Knob. Pressing Enter again removes the box from around
the Brightness value and allows you to use the Scroll
Knob to scroll through the Diagnostic sub-menu again.

The current Contrast value is displayed. If the Enter Key

is pressed a box will appear around the value and the
Contrast value can be adjusted using the Scroll Knob.
Pressing Enter again removes the box from around the
Contrast value and allows you to use the Scroll Knob to
scroll through the Diagnostic sub-menu again.

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The current selected implement will be displayed. If the Enter Key is pressed the
EZ-Select Screen appears showing up to 4 stored implements, this page is only
accessible when the Raise-Stop-Lower Toggle Switch is in the Stop position. The
Scroll Knob is used to scroll through the list and the Enter key is used to select the
desired implement and load its stored settings. Press Menu to return to the previ-
ous screen.
On every page the EZ-Select number is displayed in the top right hand corner. An
example of the EZ-Select number displayed is shown below:

If a user changes one of the settings away from the stored value, the displayed
EZ-Select number will change as displayed below:

To save the changes made simply hold the Enter Key for 5 seconds. To discard
the changes, navigate to the EZ-Select menu page, press Enter and scroll to
highlight a different implement. Press Enter again to select a different implement.
Then Scroll back to the original implement and press Enter to re-select it.

Troubleshooting

Problem Indicators
There are several indicators built in to inform the user of an error if one is detected. The most common is the
Trouble Code symbol (right). This symbol will appear in the top right hand corner of the screen whenever a trouble
code is detected. In addition to this, some of the particular trouble codes have other indicators:
Current Position Arrow flashes: The Current Position Arrow flashes if the position sensor voltage is high or low indicating
a potential problem with the Position Sensor. Under these conditions automatic modes will be disabled and therefore the
rocker switch will work like the remote switches in that they will command a slow raise or slow lower.
Height and Depth Values flashing: If the unit is yet to be calibrated or failed calibration then the Height and Depth values
will flash indicating that the upper and lower position limits are unknown. Under these conditions automatic modes will
be disabled and the rocker switch will work like the remote switches in that they will command a slow raise or slow lower.
Mix Setting flashes: If one of the load pin voltages is high or low, indicating a potential problem with one of the load
pins, the Mix Setting icon will flash. Under these conditions automatic modes will not be disabled, only the Draft mode
will be disabled, allowing the user to continue to work in position mode.

Error Code Location

If an error code is displayed, a list of the errors may be obtained by navigating to the Trouble Code page in the menu as
described in the ‘Navigating the Menus’ section of this manual. Once on the Trouble Code page the error code with the
highest priority as described in the ‘Error Code Description’ section will be displayed. Pressing Enter on this screen will
display a full list of the error codes that are present.
To further investigate any problem the Measurements page can be used.
Navigate to the Measurements page as described in the ‘Navigating the
Menus’ section of this manual and then press Enter. This will show the
current values of all inputs and outputs and can be used to diagnose failures
of certain equipment.
See the appendix for language translations of the error codes and
measurement screens.

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Error Code Description

Priority Diagnostic Trouble Code SPN FMI Condition to set active Remedial Action
1 ECU Failure 628 12 Raise button AND Lower button Remote Switch will still control
are active for 100 milliseconds valve.
Replace the controller.
2 ECU Failure 628 14 Active when shipped from Calibrate the system
HUSCO. The tractor should not
leave the plant with this error code
present.
3 ECU Needs calibration 628 13 Set when calibration aborts
4 Coil1 Short to 701 5 Current command and current The measurement screen shows
ground/open feedback differ by at least 328 both current command as well as
milliamps for greater than 250 current feedback. Feedback
milliseconds should be close to commanded
5 Coil1 Short to battery 701 6 Current command and current current.
feedback differ by at least 328
milliamps for greater than 250 Investigate wiring to the hitch
milliseconds valve.
6 Coil2 short to ground/open 702 5 Current command and current
feedback differ by at least 750 Replace problem coil.
milliamps for greater than 250
milliseconds
7 Coil2 short to battery 702 6 Current command and current
feedback differ by at least 750
milliamps for greater than 250
milliseconds
8 Position Sensor under volt- 703 4 Position Sensor voltage < 0.25 The measurement screen shows
age Volts for 100 milliseconds position sensor voltage.
9 Position Sensor over volt- 703 3 Position Sensor voltage > 4.75 Investigate wiring to the position
age Volts for 100 milliseconds sensor.
The sensor can be tested by rotat-
ing the sensor with a screw driver
and monitoring the voltage on the
measurement screen. The sensor
should have a range at least from
1 VDC to 4 VDC
10 Draft Pin 1 under voltage 704 4 Draft Sensor voltage < 0.25 Volts The measurement screen shows
for 100 milliseconds Draft 1 sensor voltage.
11 Draft Pin 1 over voltage 704 3 Draft Sensor voltage > 4.75 Volts
for 100 milliseconds Investigate wiring to the load pin.

The sensor should read approxi-

mately 2.5 Volts when no load is
applied.
12 Draft Pin 2 under voltage 705 4 Draft Sensor voltage < 0.25 Volts The measurement screen shows
for 100 milliseconds Draft 2 sensor voltage.
Investigate wiring to the load pin.
13 Draft Pin 2 over voltage 705 3 Draft Sensor voltage > 4.75 Volts The sensor should read approxi-
for 100 milliseconds mately 2.5 Volts when no load is
applied.

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 233

HITCH CONTROL PANEL Mod. T10

14 Remote Raise switch stuck 706 6 Remote Raise is active at reset The measurement screen shows
on and stays active for 5 seconds whether or not the switch is active.
15 Remote Lower switch 707 6 Remote Lower is active at reset It will show a “1” when the switch is
stuck on and stays active for 5 seconds pressed and a “0” when the switch
is released.

Investigate the wiring to the

switch.

The measurement screen should

show a “0” when the switch is dis-
connected from the wiring har-
ness.
16 Battery Voltage high 158 0 Battery Voltage > 18 Volts for 5 The measurement screen shows
seconds Battery Voltage as well as Alterna-
17 Battery Voltage low 158 17 Battery Voltage < 7 Volts for 1 tor Voltage.
second
Investigate the wiring to the volt-
age input for the hitch electrical cir-
cuit.

When the engine is off, the Battery

Voltage should be around 12 Volts.

When the engine is

on, both measurements should go
to approximately 13.5 Volts.
18 Coil Short to Ground at 2839 14 Failed Coil STG Startup Test Can be caused by attaching DT4
Startup pin connector before DT12 con-
nector on to controller while
vehicle is on.

The measurement screen shows

both current command as well as
current feedback. Feedback
should be close to commanded
current.

Restart tractor

Investigate wiring to the hitch

valve.

Replace problem coil.

Section D.13/Page 234 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HITCH CONTROL PANEL

19 Sensor Supply Short To 3509 5 Sensor Supply Voltage < 4.5V for There is a short in the harness on
Ground / Open 50 milliseconds the sensor power connection that
goes to the position and draft sen-
sors. This is mostly to occur at the
sensors, but may also occur at the
controller, or anywhere in between
along the harness.

The Measurement screen shows

all of the sensor’s voltage mea-
surement.

Disconnect all of the sensors and

re-attach them one at a time,
observing all of the sensors volt-
age measurements.

Appendix A - Harness

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HITCH CONTROL PANEL Mod. T10

Appendix B – Control Panel Drawing

Section D.13/Page 236 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HITCH CONTROL PANEL

Appendix C – System States

Reset From Any
#1 CALIBRATION
CAL_ACTIVE_VAR == TRUE State
1
#3

From Any DISABLE_COILS_VAR == TRUE OR

State ALTERNATO R_VOLTAG E_VAR < Exit Calibrtation
#2 SYSTEM_ENABLE_VOLTAG E_VAR
(see Note3) From Any
Remote Lower Switch == TRUE AND
Remote Raise Switch == TRUE
State
#4

DISABLE_COILS_VAR == FALSE AND DISABLE_COILS_VAR == FALSE AND

From Any Previous Remote Lower Switch == FALSE AND REMOTE ( Remote Lower Switch == FALSE AND ---------------------------------------------- (Remote Lower Switch == FALSE AND REMOTE Previous Remote Raise Switch == FALSE AND From Any
Remote Lower Switch == TRUE AND Remote Lower Switch == FALSE AND
State Remote Raise Switch == FALSE AND LOWER Remote Raise Switch == FALSE ) OR Raise Check = FALSE Remote Raise Switch == FALSE ) OR RAISE Remote Raise Switch == TRUE AND
State
#6 Remote Lower command times out (see Note2 below) Lower Check = FALSE Remote Raise command times out (see Note2 below) #5
ALTERNATO R_VOLTAG E_VAR >= 3 2 ALTERNATO R_VOLTAG E_VAR >=
SYSTEM_ENABLE_VOLTAG E_VAR SYSTEM_ENABLE_VOLTAG E_VAR

( CONTROL_LEVER_VAR == LOWER AND ( CONTROL_LEVER_VAR == RAISE AND

Previous Control Lever != LOWER ) Previous Control Lever != RAISE )
OR OR
( CONTROL_LEVER_VAR != LOWER AND ( CONTROL_LEVER_VAR != RAISE AND
From Any Control Lever == Invalid OR Previous Control Lever == LOWER ) Previous Control Lever == RAISE )
State Previous Control Lever == Invalid --------------------------------------------------- ---------------------------------------------------
-------------------------------------------- Lower Check = TRUE LOCKED Raise Check = TRUE
#7
0

Automatic
Control Modes

DISABLE_COILS_VAR == FALSE AND

CONTROL_LEVER_VAR == LOWER AND CONTROL_LEVER_VAR == NEUTRAL AND CONTROL_LEVER_VAR == RAISE AND
INHIBIT_AUTOMATIC_CONTROL_VAR == TRUE Raise Check == TRUE AND INHIBIT_AUTOMATIC_CONTROL_VAR == TRUE
Lower Check == TRUE AND
PREVENT_LEVER_CONTROL_VAR == FALSE AND
ALTERNATO R_VOLTAG E_VAR >= SYSTEM_ENABLE_VOLTAG E_VAR

FLASH @ 50%
FLASH @ 50%
Duty Cycle, 1 Hz
Duty Cycle, 1 Hz SLOW
SLOW
LOWER
CONTROL_LEVER_VAR != LOWER UNLOCKED
CONTROL_LEVER_VAR != RAISE RAISE
5
6 4

CONTROL_LEVER_VAR != RAISE
CONTROL_LEVER_VAR
CONTROL_LEVER_VAR != LOWER !=
LOWER
AND
CONTROL_LEVER_VAR == LOWER AND CONTROL_LEVER_VAR CONTROL_LEVER_VAR == RAISE AND
INHIBIT_AUTOMATIC_CONTROL_VAR == FALSE AND DRAFT != INHIBIT_AUTOMATIC_CONTOL_VAR == FALSE AND
DISPLAY_MIX_VAR != ME_DISPLAY_MIX_POS_CONTROL AND RAISE
TRANSPORT DISPLAY_TRANSPORT_MODE == TRUE AND
DRAFT_CONTROL_DISABLED is not defined
CONTROL CONTROL TRANSPORT_CONTROL_DISABLED is not defined
---------------------------------------------------------- 8 9 ----------------------------------------------------------
ACHIEVE_SETPOINT_VAR = TRUE ACHIEVE_SETPOINT_VAR = TRUE

CONTROL_LEVER_VAR == LOWER AND CONTROL_LEVER_VAR == RAISE AND

INHIBIT_AUTOMATIC_CONTROL_VAR == FALSE AND INHIBIT_AUTOMATIC_CONTROL_VAR == FALSE AND
DISPLAY_MIX_VAR == ME_DISPLAY_MIX_POS_CONTROL DISPLAY_TRANSPORT_MODE_VAR == FALSE

CONTROL_LEVER_VAR == LOWER AND CONTROL_LEVER_VAR == RAISE AND

INHIBIT_AUTOMATIC_CONTROL_VAR == FALSE AND POSITION DISPLAY_TRANSPORT_MODE_VAR == FALSE
DISPLAY_MIX_VAR == ME_DISPLAY_MIX_POS_CONTROL CONTROL
7

INHIBIT_AUTOMATIC_CONTROL_VAR == TRUE
----------------------------------

CONTROL_ NOTE1: A Remote Raise command will time out, if there is no movement within REMOTE_RAISE_START_TIMEOUT_VAR of
Raise Button Lower Button LEVER_ the initiation of the command; or within REMOTE_MOVEMENT_TIMEOUT_VAR once movement has begun.
VAR A Remote Lower command will time out, if there is no movement within REMOTE_MOVEMENT_TIMEOUT_VAR.
NOTE2: Lowering Slowing and Raising Slowly are provided as means for the driver in the cab to move the hitch arms in a
TRUE FALSE RAISE manner similar to the usage of the Remote switches.
FALSE TRUE LOWER
TRUE TRUE INVALID
FALSE FALSE NEUTRAL

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HITCH CONTROL PANEL Mod. T10

Appendix D – Language Translations for Menus

Section D.13/Page 238 Revision date: 07/15 DOC. 270276 EGS

Mod. T10 HITCH CONTROL PANEL

Appendix E - Language Translations for Error Codes

Appendix F – Language Translations for Measurements

EGS Revision date: 07/15 DOC. 270276 Section D.13/Page 239

HITCH CONTROL PANEL Mod. T10

Appendix G – Language Translations for Calibration Error Messages

English text is displayed when Thai is the current language.

Section D.13/Page 240 Revision date: 07/15 DOC. 270276 EGS

Electric Service Manual

J–1
 ELECTRICAL SYSTEM

B. CHARGING SYSTEM
A belt driven, two poles, two brush generator
supplies the current to the charging system
when the engine is running above idling speed.
The output of the alternator depends directly
upon speed and the condition of the charge in
the battery. With these limits, the output is
regulated by a control box, Voltage Regulator.
The Voltage Regulator whilst enabling, rapidly
controls the charging rate so that no damage
occurs to the battery during the charging period
and thus prevents overcharging. When the
battery approaches fully charged condition, the
charging rate is automatically reduced. A cutout
incorporated in the control box prevents the
battery from discharging through the windings
when engine is idling or stopped.

ALTERNATOR

3. DESCRIPTION AND OPERATION

Alternators provide a higher maximum output

than the equivalent direct current generators and The alternator is mounted at the front of the engine
also increased charge rates at lower engine being belt driven from the crankshaft pulley.
speeds. Unlike a direct current generator, the
alternator does not require a commutator and can The alternator terminals are identified.
be run safely at higher speeds.
This Section deals with the overhaul and repair of
the alternators featuring an integral regulator.

NOTE: ACR means Alternating Current

charging system with integral regulator.
2
3

Figure 8
Alternator Installed on Tractor
1. RPM Wire
Figure 7 2. Charge Indicator Wire
Alternator Terminal Indentification 3. Connection to Battery
1. IND (Indicator) Terminal
2. Main Output Terminals (+ve)
4. Regulator and Brush box
3. Tachnometer/Overspeed Terminal

J–7
ELECTRICAL SYSTEM

Figure 9
Alternator Components
1. Rotor 9. Bolt 17. Rear End Bracket 25. Spacer
2. Insulator 10. Nut 18. Insulator 26. Washer
3. Washer 11. Washer 19. Stator 27. Through Bolt
4. Spring Washer 12. Regulator/Brush Box 20. Rectifier 28. Fan
5. Nut 13. Bearing 21. Insulator 29. Double Spacer
6. Suppressor 14. Nut 22. Nut 30. Front End Bracket
7. Washer 15. Washer 23. Washer
8. Nut 16. Insulator 24. Pulley
With reference to Figure 9, the alternator comprises Current is supplied to and returned from the rotor
principally: field coil via two carbon brushes which bear against
Rotor slip rings on the rotor shaft.

Stator As current passes through the copper wire of the

rotor field coil a magnetic field is produced and
Rectifier Pack
contained within an armature formed into pole
Regulator/Brush Box shoes. The configuration of the pole shoes ensures
ROTOR concentration of the magnetic field.
STATOR
The rotor and brush gear provide the magnetic field
of the alternator unlike a direct current generator The stator contains the windings into which current is
where the field is stationary. induced by the revolving magnetic field of the rotor.
The rotor is belt driven from the engine through a The stator is fabricatd from laminations of thin steel
pulley keyed to the rotor shaft which runs in heavy-duty pressings onto which three separate wires are
sealed ball race bearings. An integral fan, adjacent to wound. The laminations are specially formed to
the pulley, draws cooling air through the alternator. concentrate and collect the magnetic field.

J–8
 ELECTRICAL SYSTEM

Figure 10 Figure 11
Rectifier Assembly Regulator and Brush Box Assembly
1. Field Diode Module 1. Brushes
2. IND (Indicator) Terminal
3. Alternator Output Terminal (+ve)
4. Positive Plate Diodes
5. Negative Plate
6. Positive Plate Diodes

During each complete revolution of the rotor, all which allows current to flow in one direction only.
three stator windings have induced currents passing
Three of the six output diodes are mounted in a
first in one direction and then the other; in other
positive plate and three in a negative plate. The two
words a 3-phase alternating current.
plates are separated and terminal links enable each
Because alternating current is generated in a series of the three-stator output wires to connect to a
of pulsations, the rotor featurs six pairs of poles to different diode in each plate.
provide an overall smoother output. For every
As the rotor revolves, the diodes rectify or convert the
revolution of the rotor the output characteristic of
alternating current of the stator to a direct current,
each stator winding completes six cycles.
which may be used to effectively charge the battery.
Alternating current (AC) is unsuitable for charging
The three field diodes are mounted in a third plate, similar
the battery, which requires pure direct current
to the output diodes, and each of the three stator output
(D.C.). Therefore the three-stator windings are
wires also connects to one of these diodes. The field
connected to a rectifier pack, which rectifies or
diodes supply direct current to the rotor field winding and
converts the alternator output to direct current.
can only be replaced as a compelte unit.
RECTIFIER
REGULATOR AND BRUSHES
The rectifier consists of a pack of six outputs and
The regulator controls and maintains the alternator
three field diodes.
output voltage at a safe working level.
NOTE: A diode is basically an electronic 'check valve'

J–9
ELECTRICAL SYSTEM

Figure 12
Alternator Charging Circuit (With Battery Temperature Compensation)
A. To Starter Motor B. To Load

1. Solenoid 5. Regulator 9. Surge Protection Diode

2. Battery 6. Frame 10. Charge Indicator Light
3. Battery Temperature Sensor 7. Stator Output Windings 11. Key Start Switch
4. Rotor Field Winding 8. Rectifier Pack

The regulated voltage level is established in manufacture This direct current is fed back to supplement the
and can not be adjusted in service: The regulator current flowing through the rotor field winding. This
components are housed in a sealed assembly which is action results in an ever increasing magnetic
integral with the alternator brush box. influence of the rotor along with an associated rapid
Individual brush box and regulator components are rise in generated output current and voltage.
not serviceable and have to be replaced as a During the rise in generated output voltage
complete assembly. (reflected at terminal IND) the brilliance of the
2. OPERATION warning light is reduced and when the voltage at the
When the key start switch is turned on a small IND terminal equates to that at the battery side of
current flows from the battery through the rotor field the warning light the lamp is extinguished.
winding. The circuit is made via the charge indicator The voltage continues to rise until the
warning light, alternator terminal IND, the rotor field predetermined regulated voltage level is reached.
winding, the alternator regulator and ground. In the event of drive belt breakage the voltage will
At this stage the warning light is illuminated and the not build up within the alternator and so the charge
rotor partially magnetised. indicator light will remain on to indicate failure.
When the engine is started and the partially magnetised
rotor revolves within the stator windings a 3-phase
alternating current is generated. A constant portion of the
generated current is converted to direct current by the
three field diodes incorporated in the rectifier pack.

J–10
 ELECTRICAL SYSTEM

3. SERVICE PRECAUTIONS AND

PRELIMINARY TEST

SERVICE PRECAUTIONS

To avoid damage to the components of the alternator

charging system, service precautions must be observed
as follows:
NEVER make or break any of the charging
circuit connections, including the battery,
when the engine is running.
NEVER short any of the charging
components to ground.
ALWAYS disconnect the battery ground cable Figure 13
when installing or removing the alternator. Drive Belt Deflection
ALWAYS disconnect the battery ground
cable when charging the battery in the If the warning light is not fully illuminated, check the
tractor using a battery charger. bulb. If the bulb is not the cause of the fault, carry
ALWAYS observe correct polarity when out the Alternator Plug Connections Test as detailed
installing the battery or using a slave under "Initial Tests" in this Chapter.
battery to start the engine. If the warning light is illuminated, start the engine
NOTE : Connect positive to positive and negative and run above the idling speed when the warning
light should be extinguished.
to negative.
If the warning light does not go out, stop the engine
PRELIMINARY CHECKS and remove the alternator main terminal connector
plug. If the warning light is extinguished, a faulty surge
Prior to electrical testing, thoroughly inspect the
protection diode, temperature sensor or alternator
charging and electrical system.
component is indicated. Conduct the "Alternator
Check all leads and connections for continuity and Components Tests" as detailed in this Chapter.
tightness.
If the warning light remains illuminated, check for a
1. Check the Battery shorting to frame in the area between the "IND"
With an hydrometer, check the battery is at cable end and the warning light.
least 70% charged and in good condition.
2. Check the Drive Belt
Ensure the alternator drive belt and pulley are in
satisfactory condition. Allow 0.50-0.75 in. (13-19
mm.) deflection when moderate finger pressure is
applied to the longest run of the belt.
3. Check the Warning Light
Turn on the key start switch and check the
warning light is fully illuminated.

J–11
ELECTRICAL SYSTEM

4. INITIAL TESTS
The initial tests may be performed without removing
any of the charging circuit components from the tractor
and enable the following items to be checked:
Alternator Plug Connections.
Alternator Charging Current and Controlled
Voltage.
Alternator Charging Circuit Volt Drops
Alternator Maximum Output Performance
Test equipment required:
Voltmeter (0-20 Volts)
Millivoltmeter (0-1 Volt)
Ammeter (0-60 Amperes Moving Coil Type)
Figure 14
1.5 Ohm 40 Amperes Variable Load Resistor Alternator Plug Connections Test
205 Ohm Resistor 1. Alternator Main Connector Plug
Jumper Lead 0.25 in. (6.35 mm.) Male to 2. Voltmeter (0-30 Volts)
Female Blade Terminal. 3. Alternator Frame

NOTE: Most commercial test equipment incorporates

several testing devices within a single unit.
NOTE: If the warning light fails to illuminate when
Use such equipment according to the
the plug is reconnected to the alternator
manufacturer's instructions.
regulator or rotor circuits. Ensure the
(I). ALTERNATOR PLUG CONNECTIONS TEST alternator "IND" terminal is clean and then
1. Turn the key start switch on but do not start the conduct the "Alternator Component Tests"
engine. as detailed in this Chapter.
2. Remove the main connector plug from the
alternator and connect a voltmeter in turn
between each of the plug terminals and the
alternator frame (negative side of voltmeter to
frame). Battery voltage should be registered.
NOTE: In some cases only one of the two main
terminals in the connector plug is actually
connected to the harness.
If battery voltage is not registered, a continuity
fault in the external cable circuitry must be
traced and remedied.
3. Connect one end of a jumper lead to the "IND"
terminal of the connector plug and the other
end to the alternator frame. The warning light
should be illuminated.
4. Disconnected the jumper lead and reconnect
the plug to the alternator.

J–12
 ELECTRICAL SYSTEM

(II). CHARGING CURRENT AND CONTROLLED

VOLTAGE TESTS
1. Ensure all tractor electrical components are
switched off and the key start switch is in the
"OFF" position.

2. Disconnect the battery ground cable

(negative and remove the main connector
plug from the alternator but leave the sensor
lead connected to the "S" terminal.
3. Connect a jumper lead between the "IND"
terminals of the connector plug and the alternator.
4. Securely connect an ammeter negative side
to the connector plug main terminal and
positive side to the alternator output terminal. Figure 15
5. Connect a voltmeter between the alternator Charging Current and Controlled Voltage Tests
output terminal and the frame (negative side 1. Jumper Lead
to frame). 2. Alternator Main Connector Plug
6. Reconnect the battery and turn the key start 3. Voltmeter (0-30 Volts)
switch to the "ON" position. 4. Alternator Frame
5. Ammeter
7. Start the engine and increase the speed to
2000 rev/min. and observe the ammeter and
voltmenter readings.
If the ammeter registers a charging current
stop the engine.
If the ammeter registers zero amperes a faulty
alternator component is indicated. Turn off the
engine and conduct the "Alternator Components
Tests" as detailed in this Chapter.
8. Disconnect the harness to sensor plug and
connect a 205 ohm resistor across the plug
terminals.
9. Restart the engine and increase the speed to
2000 rev/min. Observe the ammeter and
voltmeter readings.
The voltmeter reading exceeds 14.5 volts, the
alternator regulator must be replaced as described
in this Chapter. (When a new regulator has been
installed, conduct Tests 4 and 5).
If the voltmeter reading is below 13.8 volts a
faulty alternator component or a high
resistance fault in the external connections of
the charging system is indicated.
10. Stop the engine.

J–13
ELECTRICAL SYSTEM

(III). CHARGING CIRCUIT VOLT DROP TESTS

a. INSULATED-SIDE VOLT DROP TESTS
1. Ensure the key start switch is in the "OFF"
position.
2. Disconnect the battery ground cable (negative)
and remove the main connector plug from the
alternator but leave the sensor lead connected
to the "S" terminal.
3. Connect a jumper lead between the "IND" terminals
of the connector plug and the alternator.
4. Connect a millivoltmeter between the battery
positive terminal and the connector plug main
terminal (positive side to plug).
5. Securely connect an ammeter between the main
output terminal of the alternator and the connector Figure 16
plug main terminal (negative side to plug). Insulated-side Volt Drop Test
6. Re-connect the battery earth cable and connect a (Inset showing connection of Millivoltmeter and
variable load resistor, with the slider in the variable Load Resistor to Battery)
1. Alternator Main Connector Plug
minimum current draw position (maximum
2. Ammeter
resistance), across the battery terminals.
3. Jumper Lead
7. Start the engine and increase the speed to 4. Millivoltmeter (0-1 Volts)
2000 rev/min. 5. Variable Load Resistor
8. Slowly increase the current loading of the
resistor (decrease resistance) until the
ammeter registers 55 amperes.
9. Observe the millivoltmeter reading which
should not exceed 400 millivolts.
If the reading in excess of 400 millivolts, a high
resistance fault is indicated in the external
circuitry.
If the required alternator output can not be
achieved, and the millivoltmeter reading is less than
400 millivolts, then a faulty alternator component is
indicated. Conducted the "Alternator Component -
Tests" as detailed in this Chapter.
10. Stop the engine.

J–14
 ELECTRICAL SYSTEM

b. GROUND-SIDE VOLT DROP TEST

1. Ensure the key start switch is in the "OFF"
position.
2. The circuit is the same as that used in the previous
test except for the millivoltmeter which is now
connected between the battery negative terminal
and the alternator frame (negative side to frame).
NOTE: Ensure the variable load resistor is in the
minimum current draw position (maximum
resistance).
3. Start the engine and increase the speed to
2000 rev/min.
4. Slowly increase the current loading of the
resistor (decrease resistance) until the
Figure 17
ammeter registers 50 amperes.
Ground-side Volt Drop Test
5. Observe the voltmeter reading which should (Inset showing connection of Millivoltmeter and
not exceed 200 millivolts. variable Load Resistor to Battery)
If the reading is in excess of 200 millivolts, a 1. Alternator Main Connector
high resistance fault is indicated in the external 2. Ammeter
circuitry. 3. Jumper Lead
If the required alternator output can not be 4. Millivoltmeter (0-1 Volt)
achieved, and the millivoltmeter reading is 5. Variable Load Resistor
component is indicated. Conduct the "Alternator
Component" Tests? as detailed in this Chapter.
6. Stop the engine.
(IV). ALETERNATOR MAXIMUM OUTPUT
PERFORMANCE TEST

1. Ensure the key start swtich is in the "OFF"

position.
2. Disconnect the battery ground cable (negative)
and remove the main connector plug from the
alternator, but leave the sensor lead connected
to the "S" terminal.
3. Connect a jumper lead between the "IND" terminals
of the connector plug and the alternator.
4. Securely connect an ammeter negative side to Figure 18
the connector plug main terminal and positive Maximum Output Performance Test
side to the alternator output terminal. (Inset showing connection of variable Load
5. Connect a voltmeter between the alternator output Resistor to Battery)
1. Alternator Main Connector Plug
terminal and the frame (negative side to frame).
2. Voltmeter (0-30 Volts)
6. Disconnect the harness to sensor plug and 3. Jumper Lead
connect a 205 ohm resistor across the plug 4. Ammeter
terminals. 5. Variable Load Resistor

J–15
ELECTRICAL SYSTEM

7. Reconnect the battery and turn the key start

switch to the "ON" position.
8. Start the engine and increase the speed to
2000 rev/min.
9. Slowly increase the current loading of the
resistor (decrease resistance) unitl the
ammeter registers 50 amperes.
10. Observe the voltmeter reading which should
not fall below 13.4 volts.
If the reading falls below 13.4 volts a faulty alternator
component is indicated. Conduct the "Alternator
Component Tests" as detailed in this Section.

5. ALTERNATOR COMPONENT TESTS Figure 19

The component tests, which should only be conducted
Regulator and Rotor Field Circuit Test
1. 2.2 Watt Test Lamp
if the INITIAL TESTS have indicated a faulty alternator
2. IND (Indicator) Terminal
component, enable the following items to be checked:
3. 12 Volt Battery
Regulator 4. 205 Ohm Resistor
Brushes-and-Springs and Rotor Slip Rings 5. Sensor Terminal

Rotor Field Winding Continuity

(I). REGULATOR TEST
1. Connect a 12 volt battery and a 2.2 Watt test
NOTE: The component tests may be performed
lamp in series between the "IND" terminal and
without removing the alternator from the
the alternator frame (negative side to frame).
tractor but will necessitate removal of the
2. Connect a 205 Ohm resistor between the
alternator moulded slip ring end cover.
Testing of any other alternator components positive terminal of the battery and the sensor
will necessitate removal of the alternator terminal. The test lamp should be illuminated.
from the tractor. Refer to "Overhaul- If the test lamp is not illuminated make the
Electrical Tests" as detailed in this Section. regulator inoperative by linking the regulator
IMPORTANT: Prior to removal of the main connector case to the alternator frame.
plug from the alternator ensure the key start If the test lamp is now illuminated the regulator
switch is in the "OFF" position and the battery is faulty and must be renewed as detailed in
ground cable (negative) is disconnected. this Section.
Test equipment required: If the test lamp is not illuminated, a fault is
12 Volt Battery indicated in the rotor circuit.

12 Volt 2.2 Watt Test Lamp

J–16
 ELECTRICAL SYSTEM

(II). BRUSHES-AND-SPRINGS & ROTOR SLIP RINGS

1. Remove the brush box moulding as described

in this Section.

2. Ensure the brushes and slip rings are clean

and check for freedom of movement in the
brush box moulding.

If the visible length of the brushes, in the free

position, is less than 0.25 in. (6 mm.) this is a
probable cause of non-continuity in the field
circuit. The brush-and-spring assemblies
should be renewed if the overall length of the
brushes is less than 0.3 in. (8 mm.).

(III). ROTOR FIELD WINDING CONTINUITY TEST

1. Remove the regulator and brush box assembly

as described in this section.

2. Connect a 12 volt battery and a 2.2 watt test

lamp in series across the rotor slip rings. Figure 20
Rotor Field Winding Continuity Test
The test lamp should be illuminated.
1. Rotor
If the test lamp is not illuminated renew the rotor
2. Slip Rings
3. Ohmmeter
as detailed in the following Overhaul Section.

3. Connect on ohm meter between the two slip

rings. The resistance is outside of the
specification renew the rotor assy.

6. ALTERNATOR OVERHAUL

(I). REMOVAL

1. Disconnect the battery negative cable.

2. Disconnect the alternator connector plug,

3. Withdraw the adjustment and mounting bolts

and remove the alternator and pulley guard
from the tractor. Figure 21
Alternator Installed on Tractor
1. Alternator Assembly
2. Alternator Main Connector Plug
3. Regulator and Brush Box

J–17
ELECTRICAL SYSTEM

Figure 22
Alternator Components
1. Rotor 9. Bolt 17. Rear End Bracket 25. Spacer
2. Insulator 10. Nut 18. Insulator 26. Washer
3. Washer 11. Washer 19. Stator 27. Through Bolt
4. Spring Washer 12. Regulator/Brush Box 20. Rectifier 28. Fan
5. Nut 13. Bearing 21. Insulator 29. Double Spacer
6. Suppressor 14. Nut 22. Nut 30. Front End Bracket
7. Washer 15. Washer 23. Washer
8. Nut 16. Insulator 24. Pulley

(II). DISASSEMBLY

1. Remove the three securing bolts and withdraw

the regulator/bush box assembly. Separate the
wiring connection to the regulator.

2. Unscrew and remove the remaining three nuts

from the alternator through bolts. With a soft
mallet tap the threaded end of the through bolts
to release the spline at hexagon head end.

3. Mark the alternator front end bracket, stator,

and rear end bracket to ensure correct
alignment on re-assembly.
Figure 23
4. Gently tap the rear face of the alternator front Soldering and Unsoldering Diode Connections
end bracket to separate the front end bracket Using Pliers as a Heat Guard
and rotor assembly from the rear end bracket, 1. Diode
stator and rectifier assembly. 2. Stator Output Wire
3. Pliers Placed Between Diode and Solder Point
4. Soldering Iron

J–18
 ELECTRICAL SYSTEM

7. Remove the nuts, washers and insulators from the

stud terminals on the alternator rear end bracket
and the two rectifier retaining screws. Remove the
stator and rectifier from the rear end bracket.
8. Unsolder the stator leads from the tags on the
rectifier, using a pair of pliers as a heat sink to
prevent the diodes from becoming overheated.
9. Remove the nut, washer, pully spacer, washer,
fan and double spacer from the rotor shaft.
10. Press the rotor shaft out of the front and
bracket bearing.
(III). COMPONENT TEST
The following electrical equipment is required to test
the rotor, stator windings and rectifier diodes.
Figure 24
12 Volt Battery Output Diode Test
Test Lamp (12 Volts 2.2 Watts) 1. Diode Connecting Pin
2. 2.2 Watt Test Lamp
Test Lamp (12 Volts 36 Watts Minimum)
3. 12 Volt Battery
110 Volt Insulation Tester or 250V Megohm Meter/
Rectifier Assembly-Positive/Negative Diodes
Test each of the six diodes separately as follows:
1. Connect a 12 Volt battery and a 2.2 Watt test
lamp in series with one of the diodes. One test
lead is applied to the diode connecting pin and
the other lead to the plate into which the diode
is mounted.
2. Note if the lamp lights.
3. Reverse the test lead connections.
The lamp should light during one half of this test
only. If any one diode fails this test, the complete
rectifier assembly must be renewed.
Rectifier Assembly - Field Diodes
Three separate field diodes are contained within the Figure 25
field diode module. Test each diode separately as Field Diode Test
follows: 1. IND (Indicator) Terminal
2. 2.2 Watt Test Lamp
1. Connect a 12 volt battery and a 2.2 watt test
3. 12 Volt Battery
lamp in series with the field diode module. 4. Field Diode Connections
Apply the negative test lead to the "IND"
terminal and the other lead in turn to each of 2. Note if the lamp lights.
the field diode module connections. 3. Reverse the test lead connections.
The lamp should light during one half of this test
only. If any one diodes fails this test, the complete
rectifier assembly must be renewed.

J–19
ELECTRICAL SYSTEM

(IV). STATOR
Winding Insulation Test
1. Using a 110V insulation tester or 250V megohm
meter test the insulation between each of the three
stator output leads and the stator laminations.
If the test results prove unsatisfactory the
stator assembly must be renewed.
Windings continuity Test

1. Connect any two of the three stator output

wires in series with a 12 volt battery operated
test lamp of not less than 36 watts. The test
lamp should light.
Figure 26
2. Transfer one of the test lamp leads to the third Stator Winding Insulation Test
wire. The test lamp should light. 1. Stator Laminations
If the test results prove unsatisfactory the stator 2. Stator Output Wires
assembly must be renewed. 3. 110V/Insulation Tester or 250V Megohm Meter

(V). ROTOR
Prior to performing component tests on the
rotor the following slip ring inspection should
be carried out.
1. Ensure the slip rings are clean and smooth. If
necessary the slip rings may be cleaned with a
petrol-moistened cloth. If the slip rings are
burnt and require re-finishing use very fine
glass paper (not emery cloth) and wipe clean.
NOTE: Ensure the re-finishing glass paper is
sufficiently fine to produce a highly
polished slip ring surface otherwise
excessive brush wear will occur.
2. If the slip rings are excessively worn a new
rotor must be installed.
Figure 27
Stator Winding Continuity Test
1. Stator Windings
2. Stator Output Wires
3. 12 Volts Battery
4. 36 Watt Test Lamp

J–20
 ELECTRICAL SYSTEM

Field Winding Continuity/Resistance Test

Connect an ohmmeter between the two rotor
slip rings. Check that the rotor field winding
resistance is within acceptable tolerances, see
"Specifications".
If the test result proves unsatisfactory, the rotor
must be renewed.

Figure 28
Field Winding Continuity/Resistance Test
1. Rotor
2. Slip Rings
3. Ohm Meter

1
Field Winding Insulation Test
Using a 110V insulation tester or 250V
megohm meter test the insulation between
each of the slip rings and the rotor poles.
If the test results prove unsatisfactory the
rotor assembly must be renewed.

(VI). INSPECTION AND REPAIR 3 2

1. Inspect the roto poles and stator for signs of
rubbing. Areas of rubbing indicate both bearings
Figure 29
are excessively worn and need replacing.
Field Winding Insulation Test
2. If the front (drive) end bearing is defective the 1. Rotor Pole
complete housing (front end bracket) and 2. Slip Rings
bearing assembly must be renewed. 3. 110V/230V insulation Tester qr250V Megohm Meter

3. Inspect the roller bearing located in the rear

(slip ring) end bracket for wear and damage.

J–21
ELECTRICAL SYSTEM

4. If bearing replacement is necessary support the

housing (rear end bracket) and, using a suitable
size mandrel, carefully drive out the bearing. 1

5. Clean and examine all components.

6. Press the new bearing into the housing. The bearing
should be positioned 0.50-0.70 mm. (.020-
.028 in.) proud of the inner face of the bearing
boss.

2
(VII). RE-ASSEMBLY
Figure 30
1. Re-assembly of the alternator follows the
Rear End Bearing Removal
disassembly procedure in reverse.
1. Bearing
On re-assembly observe the following requirement: 2. Housing (Rear End Bracket)

To avoid misalignment of the end brackets,

install the stator assembly in the drive end
bracket then assemble the slip ring end
1
bracket to the stator laminations.

(VIII). INSTALLATION

1. Installation of the alternator is the removal

procedure in reverse.
On installation observe the following requirement:
Ensure the battery ground (negative) cable is
disconnected from the battery when installing 3 2
the alternator.
Adjust the alternator drive belt tension as Figure 31
previously described in this Chapter. Rear End Bearing Installation
1. Housing
2. Bearing
3. Bearing Protrusion

J–22
 ELECTRICAL SYSTEM

C. STARTER MOTOR Note: a. Amps meter 0-300 Amps with external

shunt.
TECHNICAL CHARACTERISTICS
b. Volt meter 0-20 Volt.
The starter motor is four pole series connected
D.C. Unit. The armature shaft runs on self This usually solves most of the starting problems. If
lubricated bearings. Drive engagement into the the slow speed cranking still persists or the starter
ring gear is made by energising a solenoid motor fails to function at all, it is necessary to
switch, which actuates a roller clutch mounted on remove the unit from the engine. After its removal
a helical spline formed on the end of the from the engine a simple functional check can be
armature shaft. Only following drive engagement made on the solenoid switch and the motor
with the ring gear is the electrical supply made to separately. To check the solenoid, connect the one
the starter, thereby ensuring a long life for the lead from a 12 volt battery to the supply terminal
pinion and ring gear. Over speed the roller switch and the other battery lead to the body of the starter.
gives protection for the starter armature.
PERFORMANCE DATA This should cause the starter drive to move
Performance with 120Ah fully charged battery along the armature shaft. If an ammeter is put
at +20°C. in series with the solenoid and a connectin
also made between the solenoid terminal and
5SM 114 the top main terminal, then, with 12V applied,
the ammeter should read approximately 20
Power Output 2.2 Kw amps. when the drive is fully engaged.

Lock torque 3.6 Kg.m.(min) at 5.6 volts A high current reading (20A) of failure of the drive to
current 1020 Amps (max) move at all, means the solenoid is faulty and should
be returned for rectification or replacement. A direct
Run torque 0.97 Kg.m. (min) at 9.3V light run check can also be made on the starter at
current 390 Amps (max) this time. Free run test can be carried out with
1600 RPM (min) reference to chart-I. If the motor fails to rotate, is
sluggish or takes a high current, it should be
CHART-1
returned to a recognised service center.
CHECKING OF THE STARTER MOTOR
In the event of the starter motor failing to crank If prior to removing the starter from the engine, the
the engine at a high engine speed to allow it to starter rotates but the engine does not, this
start, first check the state of charge of the indicates either a sticky or faulty roller clutch drive.
battery and the tightness and cleanliness of all The subsequent solenoid check will reveal whether
the heavy duty electrical joints. the drive is sticky on the shaft and a simple hand
check can be made on the drive itself. It should be
FREE RUN & LOCK TORQUE TEST possible to free wheel the drive pinion in a clockwise
direction, but the whole armature should rotate
when the pinion is turned anti-clockwise. If the
pinion rotates freely in both directions, the drive will
need to be replaced as a unit. Similarly, if the drive
slips under load, replacement is also necessary; this
fault, however, is unusual.

Figure 32

J–23
ELECTRICAL SYSTEM

Figure 33
Exploded View of Starter Motor

1. Screw Brush Carrier Assy. 21. Field Terminal 41. Leaver & Peg Assy.
2. Sealing Bush 22. Solenoid Terminal Nut 42. Grommet
3. C.E. Bracket Assy. 23. Spring Washer 43. Drive Assy.
4. Sealing Ring C.E. 24. Solenoid Terminal 44. Lock Nut
5. Dowel 25. Main Terminal Nut 45. Pivot pin
6. C.E. Bush 26. Spring Washer 46. Dowel
7. Thrust Washer Steel 27. Main Terminal 47. Sealing Bush
8. Thrust Washer Insul 28. Solenoid Base Assy. 48. Gasket
9. Brush Assy. 29. Pole Screw 49. Thrust Collar
10. Brake Shoe Spring 30. Spring Washer 50. Jump Ring
11. Brake Shoe 31. Tab Washer 51. Fixing Bracket Assy.
12. Brush Carrier Assy. 32. Sealing Bush 52. Spring Washer
13. Brush Spring 33. Through Bolt 53. Screw Sol. Fixing
14. Armature Assy. 34. Solenoid Switch 54. Earth Terminal Nut
15. Connector 35. Plunger Spring 55. Spring Washer
16. Field Terminal Nut 36. Plunger Assy. 56. Plain Washer
17. Spring Washer 37. Field Coil Assy. 57. Earth Terminal
18. Insul Bush 38. Sealing Ring D.E. 58. Bearing Bush Fixing Bracket
19. Plain Washer 39. Intermediate Bracket Assy.
20. Insul Bush 40. Bearing Bush Intermediate Bracket

J–24
 ELECTRICAL SYSTEM

D. BATTERY TEST

1. SPECIFIC GRAVITY TEST 2. CHARGE

Check the specific gravity of a battery with The voltage of the individual cell can be
hydrometer. checked with the help of a battery tester.
1. With the float in a vertical position, away from 1. voltage of 2 to 2.2 volt. per cell with a
the side of the barrel, take the reading with eye hydrometer reading of 1.235 indicates that the
at the level of the bottom of the curved portion battery is fully charged and in good condition.
of the liquid. 2. A voltage of less than 1.0 volt per cell with a
2. Specific gravity should not vary more than hydrometer reading of 1.050 or less, indicates
0.025 points from cell to cell. that the battery is nearly discharged.
3. If the specific gravity is below 1.250, charge 3. A voltage reading of 1.2 volt or less per cell,
the battery and inspect the charging system to with hydrometer reading of 1.200 or more,
determine the cause of the low battery charge. indicates that excessive acid gravity has been
added to the cell.

ALTERNATOR SPECIFICATIONS

DESCRIPTION FARMTRAC

Alternator Type A127 - 55

Polarity Negative Ground
Nominal Voltage 12.0 V
Maximum Rev./Min. 10,000
Maximum Output 55A
Regulator Controlled Voltage 13.6 - 14.4 V
Rotor Field Winding Resistance -
Stator Winding Resistance (Per Phase) -
New Brush Length 17.0 mm.
Minimum Brush Length 5.0 mm.
Brush Spring Pressure 1.3 - 2.7N (4.7 - 9.8 oz)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS UNITS FARMTRAC

Alternator Through Bolt lbf.ft (kgf.m) 4.0 (0.55)

Shaft Nut lbf.ft (kgf.m) 27.5 (3.82)
Rectifier Attaching Screws lbf.ft (kgf.m) 2.5 (0.35)
Regulator And Brush Box Screws lbf.ft (kgf.m) 2.0 (0.27)
Main Output Terminal Nut lbf.ft (kgf.m) 2.0 (0.27)
Phase Terminal Nut lbf.ft (kgf.m) 3.0 (0.42)

J–25
ELECTRICAL SYSTEM

4. TROUBLE SHOOTING
IMPORTANT: Whenever effecting a repair the cause of the problem must be investigated and corrected to
avoid repeat failures. The following table lists problems and their possible causes with
recommended remedial action.
LIGHTING SYSTEM
PROBLEM POSSIBLE CAUSES REMEDY
Several or all lights do not 1. Battery discharged. 1. Check battery and charge or
illuminate renew.
2. Loose or defective battery cable 2. Inspect, clean and tighten
connections. connections.
3. Loose harness connection. 3. Check and ensure connections
securely engaged.
4. Fuse(s) burnt out. 4. Inspect and renew, check circuit
before reconnecting power.
5. Faulty wiring. 5. Check lighting circuit wiring and
repair or renew.
6. Defective light switch. 6. Check and renew.
7. Several light bulbs burnt out due 7. Check and renew voltage regulator.
to defective voltage regulation.

Individual lights do not 1. Burnt out bulb. 1. Check and renew.

illuminate 2. Defective or corroded bulb 2. Inspect, clean or renew.
contacts.
3. Fuse burnt out. 3. Inspect and renew, check circuit
before reconnecting power.
4. Loose or broken wires. 4. Inspect, secure, repair or renew
wiring.
5. Poor ground connection. 5. Inspect, clean and tighten ground
connections.

Lights burn not repeatedly 1. Loose or corroded wiring 1. Inspect, secure, repair or renew
connections. wiring.
2. Loose bulb or lamp mounting 2. Inspect, tighten or renew.
bracket.
3. Faulty Voltage Regulator. 3. Check and renew voltage regulator.

Plough lamps inoperative 1. Side lights switch not turned on. 1. Ensure side lights are illuminated.
2. See "Individual lights do not 2. See "Individual lights do not
illuminate. illuminate".

J–26
 ELECTRICAL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Flasher lamps do not 1. Fuse blown. 1. Inspect and renew, check circuit
illuminate before reconnecting power.
2. Flasher unit inoperative. 2. Check and renew.
NOTE: Flasher unit may be by
passed by interconnecting terminals.
This enables circuit continuity to be
checked.
3. Flasher switch inoperative. 3. Check and renew.
4. Defective wiring or connections. 4. Inspect circuit, clean and tighten
connections or renew wiring.

Individual flasher lamp 1. Burnt out bulb. 1. Check and renew.

does not illuminate. 2. Corroded or loose bulb contacts. 2. Inspect, clean, tighten or renew.
3. Poor ground connection or damaged 3. Inspect, clean and tighten connection,
wiring. repair or renew wiring.

Turn indicator pilot 1. Faulty bulb(s). 1. Check and renew.

bulb(s) inoperative. 2. Defective flasher unit. 2. Check and renew.
3. Faulty wiring or connections. 3. Inspect, clean and tighten connections
or renew wiring.
4. Main flasher lamp bulb contacts or 4. Inspect, clean and tighten connections
ground connection corroded (failing to and ground connections.
draw full current).

INSTRUMENTATION 1. Faulty key start switch. 1. Inspect and check.

Warning lights and 2. Fuse(s) burnt out. 2. Inspect and renew, check circuit
gauges inoperative before reconnecting power.
3. Loose or broken wiring. 3. Inspect circuit, tighten connections or
renew wiring.

STARTING SYSTEM 1. Battery discharged. 1. Check battery and charge or renew.

Engine will not crank 2. Key start switch, safety start switch, 2. Check circuit and repair or renew
and starting motor relay or solenoid inoperative. faulty components.
relay or solenoid does 3. Starting circuit open or high resistance. 3. Check circuit connections and repair
not engage or renew faulty wiring.

Engine will not crank 1. Battery discharged. 1. Check battery and charge or renew.
but starting motor 2. Defective starting motor connections 2. Check, clean and tighten connection.
relay or solenoid or loose battery connections.
engages 3. Starting motor faulty. 3. Inspection, repair or renew.
4. Relay or solenoid contacts burnt. 4. Renew relay or solenoid.
5. Engine Seized. 5. Check engine crankshaft free to turn.

J–27
ELECTRICAL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Starting motor turns 1. Defective starting motor drive 1. Inspect and repair or renew.
but does not crank assembly.
engine 2. Defective solenoid or pinion 2. Inspect and repair or renew.
engagement levers.
3. Defective flywheel ring gear. 3. Inspect and renew.

Engine crank slowly 1. Discharged battery. 1. Check battery and charge renew.
2. Excessive resistance in starting 2. Check circuit connections and repair
circuit. or renew faulty wiring.
3. Defective starting motor. 3. Inspect and repair or renew.
4. Tight Engine. 4. Investigate cause and effect repair.

CHARGING SYSTEM 1. Loose or worn dynamo/alternator drive 1. Check & adjust tension or renew.
Battery low in charge belt.
or discharged 2. Defective battery, will not accept or 2. Check condition of battery and renew.
hold charge.
3. Electrolyte level low. 3. Check, fill and charge.
4. Excessive resistance due to loose 4. Check, clean and tighten circuit
charging system connections. connections.
5. Defective voltage regulator. 5. Check and renew.
6. Defective dynamo/alternator. 6. See dynamo/alternator trouble
shooting guide.

Dynamo/Alternator 1. Defective battery. 1. Check condition of battery and renew.

charging at high rate 2. Defective voltage regulator. 2. Check and renew.
(battery consumes 3. Defective dynamo/alternator. 3. See dynamo/alternator trouble
more Electrolyte) shooting.

Dynamo/Alternator 1. Dynamo/Alternator drive belt broken. 1. Renew and tension correctly.

charging at high rate 2. Loose connection or broken cable in 2. Inspect system, tighten connections
(battery consumes charging system. and repair or renew faulty wiring.
more Electrolyte) 3. Defective voltage regulator. 3. Check and renew.
4. Defective dynamo/alternator. 4. See dynamo/alternator trouble
shooting.

Intermittent or low 1. Dynamo/Alternator drive belt slipping. 1. Check and adjust tension or renew.
dynamo/alternator 2. Loose connection or broken cable in 2. Inspect system, tighten connections
output charging system. and repair or renew faulty wiring.
3. Defective voltage regulator. 3. Check and renew.
4. Defective dynamo/alternator. 4. See dynamo/alternator

J–28
 ELECTRICAL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

ALTERNATOR 1. Faulty external charging circuit 1. Inspect system, clean and tighten
Alternator light dims connections. connections.
and/or battery low 2. Faulty rotor slip rings or brushes. 2. Inspect and repair or renew.

Warning light goes 1. Faulty external charging circuit 1. Inspect system, clean and tighten
out-becomes brighter connections. connections.
with increased speed 2. Faulty rectifier or rectifying diodes. 2. Check and renew.

Warning light normal 1. Defective voltage regulator. 1. Check and renew

but battery boiling

Warning light normal 1. Defective voltage regulator. 1. Check and renew

but battery discharged 2. Faulty stator. 2. Check and renew.
3. Faulty rectifier or rectifying diodes. 3. Check and renew.

Warning light 1. Loose or worn alternator drive belt. 1. Check and adjust tension or renew.
illuminated 2. Faulty rotor, slip rings or brushes. 2. Inspect, repair or renew.
continuously and/or 3. Faulty voltage regulator. 3. Check and renew
flat battery 4. Defective stator. 4. Inspect and renew
5. Defective rectifier or rectifying diodes. 5. Check and renew.

Warning light 1. Burnt out bulb. 1. Check and renew

extinguished 2. Alternator internal connections. 2. Inspect & test circuitry, repair or
continuously and/or renew.
flat battery 3. Defective voltage regulator. 3. Check and renew.
4. Faulty rotor, slip rings or brushes. 4. Check, repair or renew.
5. Defective stator. 5. Check and renew.

Warning light flashes 1. Faulty external charging circuit. 1. Inspect circuit, clean and tighten
intermittently connections, repair or renew faulty
wiring.
2. Alternator internal connections. 2. Inspect and test circuitry, repair or
renew.

Warning light dims 1. Defective rotor, slip rings or brushes. 1. Check, repair or renew.
continuously and/or 2. Defective voltage regulator. 2. Check and renew.
flat battery

J–29
 n

3
2
1
FRONT WORK LEFT

FRONT WORK RIGHT

REAR WORK LEFT

REAR WORK RIGHT

IGNITION SW

TERM BATT. IGN START

POSITION 1 2 4
0 BATT.
P1 ACC
P2 START

0.75 B
0.75 L/B

30 87

86 85
30 87

86 85
 STARTER RELAY
4.00 W/R 4.00 P/B

0.75 B/G 0.50 R/B 0.50 R/B 0.50 W/B 0.50 B/W

Neutral Safety Clutch Switch

Switch

PTO SW. RELAY

AUX RELAY 0.75 B/G PTO SW.1
0.75 B 0.75 B/Y 0.75 B

0.75 L 0.75 B/Y

0.75 B
0.75 B/Y
PTO SW.2

SHUT OFF SOLENOID RELAY SHUT OFF SOLENOID CONNECTOR

(HOLD COIL) 2

4.00 P/B 4.00 R/W 4.00 R/W 1(PULL COIL)

1.50 Y/B

0.50 B/W 0.50 B

 AUX RELAY
4.00 P/B 4.00 L 1 1
RAISE PROPOTIONAL COIL

2 12
0.50 B/Y 0.50 B
1 2
LOWER PROPOTIONAL COIL

2 11 EHR CONTROLLER EHR CONTROLLER

(12 PIN) (4 PIN)
1 4
POSITION SENSOR 2 9
1 2 3 4
3 5
6
1 7 3 10 8
RIGHT HAND DRAFT
PIN SENSOR 2
3

1
LEFT HAND DRAFT
PIN SENSOR
2

ROCKSHAFT UP & DOWN SWITCH RH

1 2 1

2 3 3

ROCKSHAFT UP & DOWN SWITCH LH

 FT7110 STAGE 3A
Front Axle Removal Procedure.
Step 1:- Remove front Wheel Assembly LH & RH Step 2 :- Remove front Mud Guard Assembly.

Loose 4 nos
Bolt and
washer

Loose 8 nos
Nut and
washer
 FT7110 STAGE 3A
Front Axle Removal Procedure.
Step 3:- Remove Propeller shaft Guard Step 4 :- Remove Propeller shaft.

Loose 6 nos Screw

Loose 8 nos
Bolt and
washer
 FT7110 STAGE 3A
Front Axle Removal Procedure.

Step 5:- Dismantle Hydraulic Hoses Step 6:- Remove front Axle Bolt ( 4 nos ) Step 7 :- Front Axle Could be
LH & RH from Axle. removed separately.

Hydraulic Hose

Loose 4 nos
Bolt and
washer
 FT7110 STAGE
Cabin By part Procedure.
3A
Step 1:- Dismantle heater hoses from Cooling package. Step 2 :- Remove foot Assembly LH and RH.
And drain Coolant .

Heater Hose Dismantle both

Connection to side foot step
be loose and assembly.
drain coolant.
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 3:- Dismantle HVAC Pipe from Cabin at A pillar. Step 4 :- Remove Battery and Harness Connection from
Battery isolator and Starter motor.

Dismantle
Dismantle Harness From
HVAC Pipes Isolator and
Starter Motor
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 5:- Dismantle Exhaust Tail Pipe from CABIN and Chassis
Dismantle
Hardware

Dismantle
Hardware

Dismantle
Hardware

Dismantle
Hardware
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 6:- Dismantle Fuel Feed Pump and strainer
from Cabin

Feed Pump Strainer

 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 7:- Harness Dismantle Procedure from Chassis with Cabin- Interconnection Main with IP harness

Dismantle
Interconnection IP and
Dismantle Cabin Main Harness.
Rear Hood
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 8:- Remove Brake Reservoir Harness and Grommet at rear heat shield

Remove Harness
from brake Reservoir

Remove rubber
Grommet and Disconnect Speed Sensor,
Harness From rear Safety Switch and Solenoid
plate Valve Harness.
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 9:- Remove EHR Harness ,Draft Sensor Step 10 :- Remove front Mud Guard Assembly.
Harness and Trailer Socket harness

Disconnect EHR , Draft Sensor, Trailer Socket

Disconnect Fuel tank indicator, PTO
Harness
Live Ground sensor and PTO 540/1000
Sensor Harness
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 11:- dismantle Hydraulic Power Steering Hoses .

Dismantle steering hose

Dismantle steering Dismantle steering steering unit to Cylinder Dismantle steering
hose pump to hose steering unit to Solenoid Valve ( Behind hose steering unit to
steering unit Cylinder LH Side Battery Box) Cylinder RH Side
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 12:- Dismantle of Controls – Brake Hoses Step 13:- Dismantle Hi Low Lever Push Pull Cable.

Dismantle Brake Hoses Dismantle Push Pull

Both ( Lh & RH ) Cable
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 14:- Dismantle of Gear Lever Boot and Knobs. Step 15 :- Dismantle foot and hand throttle cables
Keep range lever
neutral and Speed
in 4rth position.

Dismantle Both Lever Dismantle Throttle

Dismantle Gear Lever
Knobs( Range and cables.
Boot
speed)
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 16:- Dismantle DCV cables. Step 17 :- Remove front Mud Guard Assembly.

Dismantle DCV cables.

Disconnect Clutch Cable, forward reverse cable, Parking
3 nos
linkage, PTO live Ground Linkage, PTO 540/1000 Linkage (
forward Reverse, Clutch cables are behind the Fuel Tank )
 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 18:- Remove front Running Board Mat Step 19 :- Dismantle front and rear Cabin Mountings
Bolts both sides of cabin total 6 nos.

Front Side Bolt Rear Side Bolt

 FT7110 STAGE
Cabin Bypart Procedure.
3A
Step 20 :- Cabin Lift Off
Hook for Cabin
Lift LH
Cabin Mass Approx 700 to 800 Kg

Hook for Cabin

Lift RH