Massey Ferguson 8200 - Workshop Manual PDF

Workshop service manual N° 3378177 M1
CONTENTS
1 2 3
Introduction Splitting Engine
the tractor
4 5 6
Clutch Gearbox Rear axle
7 8 9
Power Take-Off Front Axle Hydraulics
10 11 12
Electrical Electronics Cab and
equipment Equipement
13 14
Accessories Service tools
8200 SERIES TRACTORS
1 . INTRODUCTION
Contents
1A01 INTRODUCTION
Issue 1 May 2001

Introduction 1A01.1
1 A01 Introduction
CONTENTS
A. Reading the manual 2
B. General specifications 3
C. Safety instructions 19
D. Practical advice 20
E. Instructions for putting the tractor in service 23
F. Conversion tables 24
G. Locking compounds and sealants 32
H. Tightening torques 33
Issue 2 May 2002

1A01.2 Introduction
In certain countries, the legislation actually forbids the
A . Reading the manual fitting of parts that do not comply with the tractor
manufacturer’s specifications. All tightening torques
General indicated in the manual must be scrupulously complied
The aim of this manual is to assist Distributors and with.
Dealer to put AGCO tractors into service and ensure their At specific locations, locking devices are fitted. If any
efficient maintenance and repair. locking device is damaged during disassembly, a new
By following the methods outlined in the manual and locking device must be fitted.
where necessary by using the specialised service tools Fitting spare parts other than AGCO original spare parts
indicated, the necessary maintenance operations can be voids the warranty of the tractor since all AGCO parts are
carried out within the times specified in the Repair Times guaranteed by the manufacturer. AGCO Distributors and
Schedule. Dealers are required to supply original spare parts only.
Page numbering Repair Times Schedule

Example: 7C01.3 The chapters in the Repair Times Schedule are identical
This manual is divided into chapters and sections, with to those found in this Workshop Manual.
each page providing the following information:
7 = Chapter
C = Section
01 = Sequence number in the section
3 = Page number in the section.
At the bottom of the page is shown the issue number and

date.
Using the manual

To facilitate searching, at the beginning of each chapter
is an index showing the different sections contained in
the chapter. Then, at the beginning of each section, is a
list of contents.
Meaning of symbols
circle (..) : identifies the component part only
Amendments
Amended pages are issued using precisely the same
numbering system as the previous pages: only the issue
number and the date are changed.
The old pages should be removed from the manual and
destroyed.
Service tools
During operations where a specific service tool needs to
be used, the tool reference number is specified.
Repairs and replacement of parts

When replacing parts, it is essential that only AGCO
original spare parts are used.
Special attention should be paid to the following facts
concerning the carrying out of repairs and the fitting of
spare parts and replacement accessories.
The fitting of spare parts, other than AGCO original spare
parts can compromise the safety of the tractor.
Issue 2 May 2002

Introduction 1A01.3
B . General specifications
Engine
Specifications 8210 8220 / 8240 / 8250 /
8220 Xtra 8240 Xtra 8250 Xtra
PERKINS ENGINE 1006 1006

VALMET ENGINE 620 634
Number of cylinders 6 6 6 6
Turbocharger Yes Yes Yes Yes
Air / Air intercooler Yes Yes Yes
Bore (mm) 100 100 108 108
Stroke (mm) 127 127 120 134
Capacity (l) 6 6 6.6 7.4
Rated power (ISO Kw) 113 119.5 125 / 142 136 / 159
At engine speed (rpm) 2200 2200 2200 2200
Maximum torque (ISO Nm) 620 663 727 / 855 797 / 920
Engine speed at maximum torque 1400 1400 1400 1400
Idle speed 950 950 950 950
Maximum power speed (rpm) 2200 2200 2200 2200
Maximum speed at no load (rpm) 2354 2354 2354 2354
Lubrication: By gear pump - suction strainer and interchangeable external cartridge filters
Valves: Overhead valves operated by pushrods
Rocker arm clearance (cold)
- Inlet - mm (inches) 0.20 0.20 0.35 0.35
- Exhaust - mm (inches) 0.45 0.45 0.35 0.35
Engine oil cooler Yes Yes Yes Yes
Injection and air filter
8210 8220 / 8240 / 8250 /

8220 Xtra 8240 Xtra 8250 Xtra
Fuel filter Yes Yes Yes Yes

No. of elements 2 2 2 2
Injection pump Lucas Lucas Stanadyne/Bosch Bosch
Injectors and nozzle holder Lucas Lucas Stanadyne Stanadyne
Two-stage air filter, a dry filter element with a filter-clogging indicator.
Start up in cold weather Thermostart
Issue 2 May 2002

1A01.4 Introduction
Specifications 8260 / 8260 Xtra 8270 / 8270 Xtra 8280 / 8280 Xtra
VALMET ENGINE 634 645 645

Number of cylinders 6 6 6
Turbocharger Yes Yes Yes
Air / Water intercooler Yes / No Yes / No Yes / No
Air / Air intercooler No / Yes No / Yes No / Yes
Bore (mm) 108 111 111
Stroke (mm) 134 145 145
Capacity (l) 7.4 8.4 8.4
Rated power (ISO Kw) 162 / 172 181 / 192 200 / 212
At engine speed . 2200 2200 2200
Maximum torque (ISON Nm) 878 / 980 1002 / 1120 1150 / 1260
Engine speed at maximum torque 1400 1400 1400
Idle speed 950 950 950
Maximum power speed (rpm) 2200 2200 2200
Maximum speed at no load (rpm) 2354 2354 2354
Lubrication: By gear pump - suction strainer and interchangeable external cartridge filters
Valves: Overhead valves operated by pushrods
Rocker arm clearance (cold)
- Inlet - mm (inches) 0.35 0.35 0.35
- Exhaust - mm (inches) 0.35 0.35 0.35
Engine oil cooler Yes Yes Yes
Injection and air filter
8260 / 8260 Xtra 8270 / 8270 Xtra 8280 / 8280 Xtra

Fuel filter Yes Yes Yes
No. of elements 2 2 2
Injection pump Bosch Bosch Bosch
Injectors and nozzle holder Stanadyne Stanadyne/Bosch Stanadyne/Bosch
Two stage air filter, dry filter element with filter clogging indicator.
Start up in cold weather Thermostart
Issue 2 May 2002

Introduction 1A01.5
Road speeds at 2200 rpm - Dynashift transmission with ¼ creeper unit - Heavy Duty
reduction drive units - 20.8R38 tyres.
RANGE FORWARD REVERSE

Heavy Duty Heavy Duty Heavy Duty Heavy Duty
reduction drive reduction drive reduction drive reduction drive
unit km/h unit km/h unit km/h unit km/h
1 A 2.36 0.6 2.30 0.6

B 2.76 0.7 2.70 0.7
C 3.26 0.8 3.19 0.8
D 3.81 0.9 3.74 0.9
2 A 3.58 0.9 3.51 0.9
TORTOISE B 4.19 1.0 4.10 1.0
C 4.94 1.2 4.84 1.2
D 5.79 1.4 5.67 1.4
3 A 5.11 1.2 5.01 1.2
B 5.98 1.5 5.86 1.4
C 7.06 1.7 6.92 1.7
D 8.27 2.0 8.10 2.0
4 A 6.96 1.7 6.82 1.7
B 8.14 2.0 7.98 1.9
C 9.61 2.3 9.42 2.3
D 11.25 2.7 11.02 2.7
1 A 7.77 1.9 7.61 1.9
B 9.09 2.2 8.91 2.2
C 10.73 2.6 10.51 2.6
D 12.56 3.1 12.30 3.0
2 A 11.79 2.9 11.55 2.8
HARE B 13.80 3.4 11.55 2.8
C 16.29 4.0 15.95 3.9
D 19.06 4.7 18.67 4.6
3 A 16.84 4.1 16.50 4.0
B 19.71 4.8 19.31 4.7
C 23.27 5.7 22.79 5.6
D 27.23 6.6 26.68 6.5
4 A 22.92 5.6 22.45 5.5
B 26.83 6.5 26.28 6.4
C 31.67 7.7 31.02 7.6
D 37.06 9.0 36.31 8.9
Issue 2 May 2002

1A01.6 Introduction
Road speeds at 2200 rpm - Full Powershift transmission AG150, sealed Heavy Duty
reduction drive units - 20.8R38 tyres.
RANGE FORWARD REVERSE

(km/h) (km/h)
1 2.28 2.28
2 2.94 3.80
3 3.80 4.32
4 4.32 6.33
5 4.91 7.21
6 5.59 10.54
7 6.33 12.01
8 7.21 17.57
9 8.18
10 9.31
11 10.54
12 12.01
13 13.62
14 15.52
15 17.57
16 22.69
17 29.28
18 37.82
Issue 2 May 2002

Introduction 1A01.7
Road speeds at 2200 rpm - Full Powershift transmission AG150, sealed Heavy Duty
reduction drive units with ¼ creeper unit - 20.8R38 tyres.
RANGE FRONT REAR

(km/h) (km/h)
1 0,6 0,6
2 0,7 0,9
3 0,9 1,1
4 1,1 1,5
5 1,2 1,8
6 1,4 2,6
7 1,5 2,9
8 1,8 4,3
9 2,0
10 2,3
11 2,6
12 2,9
13 3,3
14 3,8
15 4,3
16 5,5
17 7,1
18 9,2
Issue 2 May 2002

1A01.8 Introduction
Road speed at 2200 rpm - AG250 Full Powershift Transmission, double drive units
- 650 / 85R38 tires
RANGE FRONT REAR

(km/h) (km/h)
1 2.40 2.40
2 3.10 4.00
3 4.00 4.60
4 4.60 6.70
5 5.10 7.60
6 5.90 11.10
7 6.70 12.70
8 7.60 18.50
9 8.60
10 9.80
11 11.10
12 12.70
13 14.30
14 16.30
15 18.50
16 23.90
17 30.90
18 39.80
Issue 2 May 2002

Introduction 1A01.9
Road speed at 2200 rpm AG250 Full Powershift Transmission, double drive units
- 650 / 85R38 tires with ¼ gearbox
RANGE FRONT REAR

(km/h) (km/h)
1 0.60 0.60
2 0.80 1.00
3 1.00 1.10
4 1.10 1.60
5 1.30 1.90
6 1.40 2.70
7 1.60 3.10
8 1.90 4.50
9 2.10
10 2.40
11 2.70
12 3.10
13 3.50
14 4.00
15 4.50
16 5.80
17 7.50
18 9.70
Issue 2 May 2002

1A01.10 Introduction
Electrical circuit
Voltage : 12 volt, negative to ground
Batteries : 2 maintenance-free batteries
Alternator : 120 Amp.
Starter safety : Controlled by clutch pedal
Headlights : European dipped beam 40/45 W
Parking lights : 5W
Direction indicators : 21 W
Number plate light : 10 W
Work lights : 55 W - H3
Dials and signal lamp lighting : 3 W - 2 W - 1,2 W
Roof light: 10 W
Cooling system
Mode : Thermostat controlled, open temperature: 82º C.
Fan: Viscostatic releasable type
Water pump : - gear-driven in 8210 / 8220 / 8270 / 8280 tractors
- belt-driven in 8240 / 8245 / 8250 / 8260 tractors
Fan belt tension : 15 mm (0.6") to 20 mm (0.8") on the longest run
Transmission
Dynashift gearbox with mechanical - 32 forward speeds
reverse shuttle - 32 reverse speeds
- four ratios selectable without declutching
- synchromesh reverse shuttle
• Clutch : - wet clutch : 8210 / 8220 : 6 plates
8240 : 7 plates
8250 : 8 plates
• ¼ Creeper gearbox : - 48 forward speeds
- 48 reverse speeds
• Filtering - 1 x 60 micron suction strainer
Dynashift gearbox with power shuttle - 32 forward speeds

- 32 reverse speeds
- four ratios selectable without declutching
- power shuttle
• 8210 - 8220 power shuttle - clutch controlled

- 6 forward speed discs
- 5 reverse speed discs
• 8240 power shuttle - clutch controlled

• 8250 power shuttle - clutch controlled

• ¼ Creeper gearbox : - 48 forward speeds

- 48 reverse speeds
• Filtering - 1 x 60 micron suction strainer
Issue 2 May 2002

Introduction 1A01.11
Full Powershift gearbox : - 17 or 18 forward speeds (depending on 30 km/h or 40 km/h version)

- 8 reverse speeds
• Clutches : 9 clutches controlled by solenoid valves
• ¼ ratio creeper gearbox : - 34 or 36 forward speeds (depending on 30 km/h or 40 km/h version)
- 16 reverse speeds
• Hydraulics : 1 "Gerotor" pump - Capacity 110 l/min at 2200 rpm provides (for lu-
brication and supply of clutches, cooling system and boosting of)
the master cylinders.
• Filtering : 1 x 150 micron suction strainer, located inside the housing.
External 15-micron filter, 3-way filter protects solenoid valves
from particles.
Final reduction drive units

Reduction drive units: Epicyclical, located in rear axle housings.
Reduction ratios: 8210 / 8220 Heavy duty ...................................... 6.21:1
8220/8240/8245 Heavy duty sealed compartment 6.21:1
8240 / 8245 / 8250 / 8260 Composite ........ 7.14:1
8260 / 8270 / 8280 Dual ............................. 9.47:1
Front axle with 2-wheel drive

• Optional in 8210 to 8260 tractors
Front axle with 4-wheel drive

Suspension : Option available on models Carraro 20.29 and 20.43 (8210 to 8250) only
Clutch mechanism: Electro-hydraulically controlled from a button on the armrest
inside the cab.
Differential lock: Differential lock coupling is electro-hydraulically controlled.
Lock :
- oil-bath clutch on Carraro (20.29 and 20.43) and Dana AG280 front axles
- hydromechanical dog coupling on Dana AG155 and AG200 front axles.
Gear ratios: 8210 / 8220 / 8240 ..... AG155 20,872/1 up to K137012
8210 / 8220 / 8240 ..... 20.29 20,769/1 from K137013
8240 /8245 /8250 /8260 AG200 20.475/1
8250 ........................... 20.43 20.769/1 From K116015
8250 Xtra .................... 20.48 20.945/1
8270 / 8280 ................ APL5052 20.475/1 Up to L074008

8270 : 8280 ................ AG280 20.363/1 From L074009
Power take-off
• interchangeable shaft : 540 (6 splines) or 1000 rpm (21 splines) at engine speed
of 2000 rpm.
• Shiftable : with 540 rpm or 1000 rpm interchangeable end
• 750 rpm economy PTO : 750 rpm at engine speed of 2000 rpm
6 splines, shaft Ø 35 mm
20 splines shaft Ø 44.5 mm or
21 splines shaft Ø 35 mm
Issue 2 May 2002

Hydraulic circuit
Closed centre hydraulic circuit with flow and pressure regulation.
2 possible circuits :
- 110 l/min at 200 bar
- 150 l/min at 200 bar, optionally available on 8200 tractors only if they are equipped with a Full Powershift
gearbox
Booster pump: maximum flow 150 l/min or 215 l/min (o 150 l/min hydraulic circuit) at 2200 rpm guaranteeing a
constant 5 bar boost for the variable displacement pump, also provides lubrication for the rear axle.
Low-pressure circuit (17 bar) supplies the following functions :

4 WD clutch Engine clutch (mechanical reverse shuttle)
Differential lock Power shuttle
Power take-off clutch Hare / Tortoise range (Heavy Duty gearbox)
Low pressure circuit for Full Powershift gearbox

- the Full Powershift gearbox has its own low pressure pump that ensures lubrication of the transmission and operation
of these clutches at a 17 bar pressure
High-pressure circuit: maximum pump flow 110 l/min or 150 l/min (optionally) at 2200 rpm, maximum pressure 200
bar that supplies:
the steering the 17 bar valve
the auxiliary spool valves the hydraulic lift system
Filtering : 1 x 150 micron suction strainer located on the left-hand side of the
transmission housing.
Main external high-pressure 15-micron oil filter, located on the right-
hand side of the transmission housing.
Hydraulic lift
Type: 3-point, category 3
Lift rams: dia. 95 (8210, 8220, 8240, 8250) quantity 2 - capacity (see table)
Position of lift Length Horizontal Drawbar in

rod on drawbar of lift rod drawbar transport position
(mm) (mm) (Kg) (Kg)
547.5 824 7149 9365
918 7373 8627
600.0 824 7769 9865
918 7927 9109
Issue 2 May 2002

Lift rams: dia. 105 (8260 to 8280) quantity 2 - capacity (see table)
Position of lift Length Horizontal Drawbar in

rod on drawbar of lift rod drawbar transport position
(mm) (mm) (Kg) (Kg)
Mini 530.4 838 8741 11387
915 8994 10656
Maxi 580.9 838 9475 12001
915 9667 11252
Brakes
Type : disc brakes, two discs per wheel with double reduction unit constant flow
lubrication, external dia. 313 mm.
Lining internal dia. : 239 mm.
Operation : Hydraulic, using two master cylinders.
Parking brake : operates on intermediate shaft of drive pinion.
Park lock : mechanically locks the intermediate shaft of the drive pinion.
Rear differential lock

Type :
- 8210 to 8250 : Hydro-mechanical , standard torque
- 8210 to 8250 : 5'' or 7'' multidisc (according to version) in oil bath, standard torque
- 8260 to 8280 : 7'' Multi-disc in oil bath, hypoid torque
Control: Electrically controlled hydraulics.
Issue 2 May 2002

Steering
Type: Hydrostatic, telescopic or fixed tilting steering column double action steering ram (8200 with Dana or
Carraro front axle), two double action steering rams (8270 and 8280 with APL5052 front axle only).
Wheels
Front (4 wheel drive): adjustable steel rims
Rear: steel rims (fixed or adjustable), manually adjustable pressed steel rim with cast iron disc.
Capacities
Fuel tank with additional reserve : ............................................ 8210/8220/8240/8250/8260 : 410 l
......................................................................................................................... 8270/8280 : 456 l
Cooling system ................................................................................................. 8210/8220 : 28,5 l

..................................................................................................................... 8240 to 8280 : 34 l
Engine sump ..................................................................................................... 8210/8220 : 15,6 l

.................................................................................................................................. 8240 : 20 l
........................................................................................................ 8250/8260/8270/8280 : 19 l
Transmission / rear axle Dynashift gearbox (Heavy Duty) ................................. 8210/8220 : 123 l
Transmission / rear axle Full Powershift gearbox(Heavy Duty) .......................... 8210/8220 : 157 l
Transmission / rear axle Dynashift gearbox (Heavy Duty sealed) ...................... 8220/8240 : 120 l
Transmission / rear axle Full Powershift (Heavy Duty sealed) ........................... 8220/8240 : 150 l
Transmission / rear axle Dynashift gearbox (Composite) .................................. 8240/8250 : 114 l
Transmission / rear axle Full Powershift gearbox (Composite) ......... 8240/8245/8250/8260 : 147 l
Transmission / rear axle Full Powershift gearbox (double drive unit) ......... 8260/8270/8280 : 156 l
Note: Transmission/rear axle assembly filling tolerances ± 5 l.
Issue 2 May 2002

AG155 and AG200 front axle assembly .................................................................. 8210 to 8260 10.2 l
APL5052 front axle assembly .................................................................................... 8270/8280 10 l
AG280 front axle assembly ........................................................................................ 8270/8280 16 l
20.29ACP and 20.43ACP fixed front axle assembly ............................................... 8210 to 8250 6l
20.29S and 20.43S suspension front axle assembly .............................................. 8210 to 8250 8.6 l
20.48ACP fixed front axle assembly ........................................................................... 8250 Xtra 10 l
20.48S suspension front axle assembly ...................................................................... 8250 Xtra 10 l
AG 155H front final drive unit (each) ............................... .................................... 8210 to 8240 1.6 l
20.29 or 20.43 front final drive unit (each) .............................................................. 8210 to 8250 1.3 l
20.48 front final drive unit (each) ................................................................................. 8250 Xtra 1.9 l
AG 200 front final drive unit (each) ..................... ..................................... 8240/8245/8250/8260 1,8 l
APL 5052 front final drive unit (each) ................................................................. ... 8270/8280 4l
AG280 front final drive unit (each) .............................................................................. 8270/8280 2.7 l
Heavy Duty Sealed Rear final drive unit (each) .................................................. .... 8220/8240 3,6 l
Composite rear final drive drive units (each) ......................... .................. 8240/8245/8250/8360 4,5 l
Issue 2 May 2002

Tightening torque
Wheel to rear axle
• Standard final drive
- rim to disc ........................................................................... 250 - 350 Nm
- rim to axle hub: ................................................................... 400 - 450 Nm
• Straight shaft
- disc to single conical hub (shaft dia. 95) .............................. 350 - 460 Nm
- half conical hub to hub (shaft dia. 95) .................................. 350 - 460 Nm
- half conical hub to hub (shaft dia. 110) ................................ 500 - 600 Nm
- disc to half conical hub ........................................................ 640 - 680 Nm
- rim to disc ........................................................................... 250 - 350 Nm
Wheel to front axle

- 4 WD wheel to hub (dry M22 studs) ...................................... 640 - 680 Nm
Miscellaneous
- Extending arms ....................................................................... 400 - 600 Nm
- Power take-off shaft ............................................................... 100 - 130 Nm
- Steering rams ......................................................................... 75 - 80 Nm
- Engine oil drain plug ................................................................ 80 Nm
- Fuel tank drain plug ................................................................. 15 - 18 Nm
Noise levels (Dba) reaching the driver's ears

- Measured according to EEC instruction 77/311 Appendix II
CEE 77/311 CEE 77/311

Appendix II Appendix II
Type Type
Windows Windows Windows Windows
closed open closed open
8210 78 80 8240 Xtra 75 80

8220 / 8220 Xtra 77 83 8250 Xtra 74 79
8240 74 80 8260 Xtra 77 81
8250 77 84 8270 Xtra 76 81
8270 76 81 8280 Xtra 76 81
8280 77 82
Issue 2 May 2002

Dimensions and weights

SPECIFICATIONS 8210 8220 8240 8250 8260
mm - kg 4RM. Dynashift/Powershift
A Wheelbase 2825 2825 2985 3075 3075

B Overall length (with 3PT, without front weights) 4949/4951 4949/4951 5111/5109 5111/5201 5251
C Height to roof (cab tractor) 2980 2980 3042 3042 3038
D Overall width (1) 2854 2854 2880 2998 3007
E Ground clearance 453 453 453 453 453
Min. weight (with full tank, without extra 6750/6925 6885/7160 7580/7665 8295 8850
weight steel wheels).
Front tyres 16.9R28 16.9R30 480/70

Rear tyres 20.8 R38 20.8 R42 620/70 R42
Dynashift /Full Powershift

rear front axle Front axle
Flanged Straight shaft
shaft Ø95 Ø110 20.29 /20.43 20.48 AG155 AG200
G Distance between flanges 1940 1900 1890 1892 1892
Short straight shaft : 2334 2494
Long straight shaft: 2990 2990
H Stud distance 203,2 335 335 280 280 280,8 280,8
L Centring diameter 149,35 280,80 280,8 335 335 335 335
I Stud length (according to rim) 63 87 / 110 40 40 40 40

J Stud diameter M18 x 1,5 M22 x 1,5 M22 x 1,5 M22 x 1,5 M22 x 1,5 M22 x 1,5
K Number of studs 8/10 x 2 10 x 2 10 x2 10 x2 10 x2 10 x2
(1) These dimensions are for max. track (without straight shaft).
V
V639 V
e V642
V
A G
V
V
V
B D
V
V
V
I I
J H L J
K K
Issue 2 May 2002

SPECIFICATIONS 8270 8280
mm - kg 4RM. Powershift
A Wheelbase 3075 3075

B Overall length (with 3PT, without front weights) 5251 5251
C Height to roof (cab tractor) 3117 3117
D Overall width (1) 3032 3030
E Ground clearance 432 432
Min. weight (with full tank, without extra weight 9250 9250
steel wheels).
Front tyres 600/70R28 600/70R28

Rear tyres 650/85R38 650/85R38
Front axle
APL 5052 AG 280
1875 1892
G Distance between flanges - -
H Stud distance 425 425
L Centring diameter 370 370
I Stud length (according to rim) 40 47
J Stud diameter M22 x 1.5 M22 x 1,5
K Number of studs 12 12
(1) These dimensions are for maxi track (without straight shaft).
V639 V
e V642
V
A G
V
V
V
B D
V
V
V
I I
J H L J
K K
Issue 2 May 2002

C. Safety instructions
See Operator Instruction Book
Issue 2 May 2002

D . Practical advice
Safety
When working on machinery, of whatever type, the first
concern must always be the safety of oneself and
others. To work in complete safety it is necessary to fully
understand the nature of the work that has to be carried
out, to use the appropriate tools and various equipment
correctly and to employ common sense in all situations.
Troubleshooting
CORRECT INCORRECT
Using the information supplied in the workshop manual,
the following method enables problems on the tractor to
be pinpointed with accuracy.
The method consists of following a certain number of
logical steps to identify the problem, to locate it and then
to correct it:
1. Define the problem
2. List the possible causes for the problem
3. Discriminate between the causes
4. Carry out checks in logical order in order to
discover the exact cause B
5. Evaluate the remaining life of components, the
price of the components and the cost of labour.
6. Carry out the repair thus judged necessary C
7. Check for the correct operation of the system and
functions that were affected.
D
Lifting heavy components and assemblies A

Unless specified otherwise, all disassembly should be
carried out using adjustable lifting tackle. The slings
bearing the weight must all be parallel to each other and
as near as possible vertical in relation to the object being
lifted. However, it is permitted where the slings are of a
much greater strength than the load being lifted that
slings may be used in a triangle (2, 3 or 4 loops from a Support for a forged lifting ring
single ring beneath the pulley-block hook). A: Load – B: Lifting shackle – C: Shackle support plate
To remove a tilted component, it is necessary to bear in (3 mm thick) – D: Sleeve (preferably welded to the plate).
mind that the capacity of a lifting ring diminishes when In certain cases, lifting accessories can be obtained to
the angle formed by the elements supporting the object provide the required equilibrium for lifting without danger.
is less than 90º (good and bad lifting methods). Consult the section concerned in the workshop manual.
Lifting rings and their supports must never be bent and Note: Where difficulties are encountered on removing a
they must only be used in tension. A short length of component, first check that all the retaining nuts and
tubing and a washer can be used to reduce side forces bolts have actually been removed and that neighbouring
on lifting rings. components are not hindering its removal.
Issue 2 May 2002

Cleanliness
To ensure a long life cycle to any machine, it is important
4
that its moving parts are protected from dust and foreign
bodies. Precautions must be taken against such danger. 5
Sealed compartments, seals and filters ensure the clean-
liness of air, fuel and lubricating oil. None of these
protection systems should be removed. 3
When disconnecting piping, whether it be hydraulic, fuel,
lubricating or air lines, clean both the connecting points
and the surrounding area. As soon as the piping is 2
disconnected insert a plug, a cover or fasten adhesive
tape over the opening to prevent foreign bodies from
entering.
In the same way, clean and cover all access covers and 1
inspection plates when they are removed. Clean and
check all components. Take care that all passageways
and holes are unobstructed. Cover all components so
that they remain clean. Ensure that all components are
clean at the time of reassembly. Leave new parts in their
packaging up until the time that they are actually used. Seals
Take care that the holes in seals match exactly the
lubricating channels in the corresponding components. If
Assembly
gaskets need to be made, select the thickness and type
To reassemble a piece of equipment, complete each
of material carefully. Take care that the seal is correctly
step in turn. Never partially assemble one subassembly
shaped and cut. Badly cut and fitting seal can cause
and then begin to assemble another. Carry out all the
major breakdowns.
recommended adjustments. Always recheck the work
that has been carried out to ensure that nothing has been
SPY type lip seals
forgotten.
Before fitting, lubricate the lips of SPY type seals with oil.
Check the various adjustments again before putting the
Do not use grease on seals, unless they are grease
equipment back into service.
seals.
Note: Before fitting new parts, remove the anti-rust
The main components of SPY type seals are the enve-
compound from all machined surfaces (usually a peel-off
lope (1), oil tightness element (2) and annular spring (3).
material).
The cross section shows the heel (4) and the pivot (5),
these impart the dimensions to a single element seal.
Lubrication With one or two exceptions, the pivot of a lip seal faces
According to recommendations, fill the compartments of the lubricant side. Some seals also have an auxiliary lip
the repaired or replaced elements with the correct quan- without a spring.
tity of clean oil of the type recommended in the mainte-
nance section of the Operator Instruction Book. Cables and wires
When removing or disconnecting a group of cables or
Shims wires, they must be identified and labelled in order to
Whenever shims are removed, they should be attached ensure that they are refitted correctly later.
together and their location marked. Ensure that distance
pieces are clean and take care that they are not bent in
any way when refitting.
Issue 2 May 2002

Locking devices on nuts and bolts
To avoid the accidental loosening of nuts and bolts, lock
washers, tab washers and split pins are used. In addition
to such mechanical means, compounds of the Loctite
type are also used.
To be efficient, the flat locking tabs must be correctly
fitted. Bend one end of the locking tab over the edge of
the part. Bend the other end to fit flush against one of the
flats on the head of the nut or bolt.
Always fit new locking tabs in compartments that house
moving parts. When fitting a lock washer on aluminium
housings, place a flat washer between the lock washer
and the housing.
Note:
1) Never fit a lock washer (Grower washer, lock washer,
spring washer, etc.) beneath a nut or the head of a bolt
to which a recommended torque must be applied to (see Correct and incorrect use of folded metal locking tabs
section H).
2) When using locking compounds of the Loctite type,
always degrease the components before application.
Lubricating bushes and force fitting

Do not fit bushes using a hammer only. Use an appropri-
ate tool in addition to a hammer, and where possible use
a press.
When using a press, take care that the pressure being
exerted is in exactly the same direction as the bore.
Where a lubricating bush has an oil hole, carefully align
it with the hole on the matching part.
When force fitting one component within another, lubri-
cate the corresponding surfaces. Adjust tapered parts
without lubricating. Before fitting, ensure that the cones
are clean, dry and have no burs.
Correct and incorrect methods of fitting and bending
Fitting bolts in blind holes the flat locking tabs
Select a bolt of the correct length. Too long a bolt may
come to a halt before its head is in contact with the part
that it is intended to hold; the threads may then be
damaged when trying to tighten it further.
If the bolt is too short, there may not be sufficient thread
engaged to efficiently hold the part.
Issue 2 May 2002

- Check the correct operation of all control instruments

E . Instructions for putting the and signal and warning lights.
tractor in service - Check the engine speed on the tachometer, using both
foot and hand throttles.
General - Hitch an implement and check the correct operation of
To ensure the regular servicing of the tractor during the the tractor’s hydraulic accessories.
twelve-month warranty period, the AGCO supplying - Check and adjust tyre pressures (road or field work).
Distributor or Dealer must carry out the first 50-hour and - Check the tightness of all nuts, bolts, studs, piping
250-hour servicing operations. connections and attachment points.
These periods are calculated so as to provide maximum - Check that there are no hose or piping leaks.
efficiency of the tractor throughout the warranty period, - Check that the headlights are correctly adjusted.
and thus ensure later reliability of the tractor. - Carry out a road test on the tractor and check the
correct operation of the brakes, instruments and ac-
cessories.
Checks before delivery
The Distributor, before delivery to a Dealer; and the 2. Electronic systems
Dealer before delivery to a Customer or driver, must carry - Check the correct operation of the electronic linkage
out the following operations: control. Carry out the quick check procedure detailed in
1. General installation Chapter 11C01.
- Clean the top of the battery and coat the battery - Check the various functions of the Autotronic, carry out
terminals with Vaseline grease. test procedure 11A01 or 11B01 depending on the
- Charge the battery if necessary. version.
- Check all electrical connections, cable attachments, - Check the installation of the onboard computer in
piping and warning lights. accordance with procedure 11D01.
- Check and top-up the oil in the engine and transmission
housings. 3. Tightening torques
- Grease all grease points. - Check the tightening torques on all chassis attachment
- Check and adjust where necessary the tension of belts nuts and bolts:
(alternator, fan, auxiliary pump and air-conditioning . Front axle / Engine
compressor). . Engine / Gearbox
- Flush the cooling circuit and fill it with soft water, . Gearbox / Rear axle
unless it contains anti-freeze. . Trumpet housings / Rear axle.
- Ensure that the tank contains enough fuel of the correct - Check the tightening torque on nuts or studs fitted on
type. wheels and wheel webs.
- Check the tightening of the cylinder head bolts and nuts
to the correct torque. Check the tightness of the inlet
pipe and the exhaust manifold.
- Check and adjust the rocker arm clearance and visu-
ally check the valve springs.
- Check the injectors, bleed the fuel circuit and tighten all
fuel supply connections.
- Check the fitting of the engine air filter hoses.
- Check the adjustment of the engine control linkage and
ensure that it is operating freely.
- Run the engine.
Issue 2 May 2002

Instructions for the driver 12. Operation of the hydraulic lift control
The following instructions must be provided to the 13. Hitching and unhitching towed implements
Customer or driver: 14. Grease points
15. Changing of oil grades
1. Safety precautions to be taken when starting the 16. Replacing the engine and transmission oil filters
engine 17. Operation of the fuel supply circuit – bleeding of
2. Location and meaning of the tractor and engine supply circuit and injectors – air filter – filter-
serial numbers clogging indicator
3. Controls – control instruments 18. Cooling circuit. Anti-freeze precautions. Tension of
4. Running-in instructions the two fan belts
5. Starting and stopping the engine 19. Maintenance of electrical equipment (batteries).
6. Selection of gears, use of gear shift and reverse Negative earthed circuit
shuttle levers 20. Adjustment of front and rear track
7. Dangers of towing downhill without engine braking 21. Tyre pressures
and correct use of the gearbox 22. Tightness of nuts, bolts and screws
8. Use and adjustment of the brakes and the coupling 23. Storing and handling fuel
and locking of the pedals 24. Use of auxiliary hydraulic equipment
9. Use of the tractor’s clutch 25. Marking of the tractor serial number and engine
10. Use of the hydraulic differential lock serial number in the Operator Instruction Book
11. Use of the hydraulic PTO - clutch and brake 26. Reading of the Operator Instruction Book.
F . Conversion tables
Units of Pressure
1 PSI = 1 lbf/in2 = 0.0689 bar
1 bar = 14.512 lbf/in2 = 14.512 PSI
Bar lbf / in2 Bar lbf / in2 Bar lbf / in2

0.5 7.256 9.5 137.9 35 508
1.0 14.510 10.0 145.0 40 588
1.5 21.770 11.0 159.6 45 653
2.0 290.00 12.0 174.0 50 726
2.5 36.280 13.0 189.0 60 871
3.0 43.540 14.0 203.0 70 1029
3.5 50.800 15.0 218.0 80 1161
4.0 58.800 16.0 232.0 90 1306
4.5 65.300 17.0 247.0 100 1451
5.0 72.600 18.0 261.0 200 2903
5.5 79.800 19.0 276.0 300 4354
6.0 87.100 20.0 290.0 400 5805
6.5 94.300 21.0 309.0 500 7257
7.0 101.600 22.0 319.0 600 8708
7.5 108.800 23.0 334.0 700 10160
8.0 116.100 24.0 348.0 800 11611
8.5 123.400 25.0 368.0 900 13235
9.0 130.600 30.0 435 1000 14514
Issue 2 May 2002

Units of torque
1 Nm = 0.7376 lbf/ft
1 lbf/ft = 1.3558 Nm
Nm lbf/ft Nm lbf/ft Nm lbf/ft
1.3558 1 0.7376 46.0972 34 25.0784 90.8396 67 49.4912

2.7116 2 1.4752 47.4530 35 25.8160 92.1944 68 50.1568
4.0674 3 2.2128 48.8088 36 26.5536 93.5502 69 50.8944
5.4232 4 2.9504 50.1646 37 27.2912 94.9060 70 51.6320
6.7790 5 3.6880 51.5204 38 28.0288 96.2618 71 52.3696
8.1348 6 4.4256 52.8762 39 28.7664 97.6176 72 53.1072
9.4906 7 5.1632 54.2320 40 29.5040 98.9734 73 53.8448
10.8464 8 5.9008 55.5878 41 30.2416 100.329 74 54.5824
12.2022 9 6.6384 56.9436 42 30.9792 101.685 75 55.3200
13.5580 10 7.3760 58.2994 43 31.7168 103.041 76 56.0576
14.9138 11 8.1136 59.6552 44 32.4544 104.397 77 56.7952
16.2696 12 8.8512 61.0110 45 33.1920 105.752 78 57.5328
17.6254 13 9.5888 62.3668 46 33.9296 107.108 79 58.2704
18.812 14 10.3264 63.7226 47 34.6672 108.464 80 59.0080
20.3370 15 11.0640 65.0784 48 35.4048 109.820 81 59.7456
21.6928 16 11.8016 66.4342 49 36.1424 111.176 82 60.4832
23.0486 17 12.5392 67.7900 50 36.8800 112.531 83 61.2208
24.4044 18 13.2768 69.1458 51 37.6176 113.887 84 61.9584
25.7602 19 14.0144 70.5016 52 38.3552 115.243 85 62.6960
27.1160 20 14.7520 71.8574 53 39.0928 116.600 86 63.4336
28.4718 21 15.4896 73.2132 54 39.8304 117.955 87 64.1712
29.8276 22 16.2272 74.5690 55 40.5680 119.310 88 64.9088
31.1834 23 16.9648 75.9248 56 41.3056 120.666 89 65.6464
32.5392 24 17.7024 77.2806 57 42.0432 122.022 90 66.3840
33.8950 25 18.4400 78.6364 58 42.7808 123.378 91 67.1216
35.2508 26 19.1776 79.9992 59 43.5184 124.734 92 67.8592
36.6066 27 19.9152 81.3480 60 44.2560 126.089 93 68.5968
37.9624 28 20.6528 82.7038 61 44.9936 127.445 94 69.3344
39.3182 29 21.3904 84.0596 62 45.7312 128.801 95 70.0720
40.6740 30 22.1280 85.4154 63 46.4688 130.157 96 70.8096
42.0298 31 22.8656 86.7712 64 47.2064 131.513 97 71.5472
43.3856 32 23.6032 88.1270 65 47.9440 132.868 98 72.2848
44.7414 33 24.3408 89.4828 66 48.6816 134.224 99 73.0224
Issue 2 May 2002

Units of Capacity
1 litre = 0.2199 imperial gallon
1 imp. gallon = 4.5459 litres
Imp. gal. Litres Imp. gal. Litres Imp. gal. Litres
0.2199 1 4.5459 7.4766 34 154.561 14.7330 67 304.575

0.4398 2 9.0918 7.6965 35 159.107 14.9532 68 309.121
0.6597 3 13.6377 7.9164 36 163.652 15.1731 69 313.667
0.8796 4 18.1836 8.1363 37 168.198 15.3930 70 318.213
1.0995 5 22.7295 8.3562 38 172.744 15.6129 71 322.759
1.3194 6 27.2754 8.5761 39 177.290 15.8328 72 327.305
1.5393 7 31.8213 8.7960 40 181.836 16.0527 73 331.851
1.7592 8 36.3672 9.0159 41 186.382 16.2726 74 336.397
1.9791 9 40.9131 9.2358 42 190.929 16.4925 75 340.943
2.1990 10 45.4590 9.4557 43 195.474 16.7124 76 345.488
2.4189 11 50.0049 9.6756 44 200.019 16.9323 77 350.034
2.6388 12 54.5508 9.8955 45 204.566 17.1522 78 354.580
2.8587 13 59.0967 10.1154 46 209.111 17.3721 79 359.126
3.0786 14 63.6426 10.3353 47 213.657 17.5920 80 363.672
3.2985 15 68.1885 10.5552 48 218.203 17.8119 81 368.218
3.5184 16 72.7344 10.7751 49 222.749 18.0318 82 372.764
3.7383 17 77.2803 10.9950 50 227.295 18.2517 83 377.310
3.9582 18 81.8262 11.2149 51 231.841 18.4716 84 381.856
4.1781 19 86.3721 11.4348 52 236.387 18.6915 85 386.402
4.3980 20 90.9180 11.6547 53 240.933 18.9114 86 390.947
4.6179 21 95.4639 11.8746 54 245.479 19.1313 87 395.493
4.8378 22 100.0090 12.0945 55 250.025 19.3512 88 400.039
5.0577 23 104.5560 12.3144 56 254.570 19.5711 89 404.585
5.2776 24 109.1020 12.5343 57 259.116 19.7910 90 409.131
5.4975 25 113.6480 12.7542 58 263.662 20.0109 91 413.677
5.7174 26 118.1930 12.9741 59 268.209 20.2308 92 418.223
5.9373 27 122.7390 13.1940 60 272.754 20.4507 93 422.769
6.1572 28 127.2850 13.4139 61 277.299 20.6706 94 427.315
6.3771 29 131.8310 13.6338 62 281.846 20.8905 95 431.861
6.5970 30 136.3770 13.8537 63 286.392 21.1104 96 436.406
6.8169 31 140.9230 14.0736 64 290.938 21.3303 97 440.952
7.0368 32 145.4690 14.2935 65 295.483 21.5502 98 445.498
7.2567 33 150.0150 14.5134 66 300.029 21.7701 99 450.044
Issue 2 May 2002

Units of Capacity
1 litre = 1.7599 imperial pints
1 imp. pint = 0.5682 litres
Imp. pt. Litres Imp. pt. Litres Imp. pt. Litres
1.7599 1 0.5682 59.8366 34 19.3188 117.913 67 38.0694

3.5198 2 1.1364 61.5965 35 19.8870 119.673 68 38.6376
5.2797 3 1.7046 63.3564 36 20.4552 121.433 69 39.2058
7.0396 4 2.2728 65.1163 37 21.0234 123.193 70 39.7740
8.7995 5 2.8400 66.8762 38 21.5916 124.953 71 40.3422
10.5594 6 3.4902 68.6361 39 22.1598 126.713 72 40.9104
12.3193 7 3.9774 70.3960 40 22.7280 128.473 73 41.4786
14.0792 8 4.5456 72.1559 41 23.2962 130.233 74 42.0468
15.8391 9 5.1138 73.9158 42 23.8644 131.993 75 42.6150
17.5990 10 5.6820 75.6757 43 24.4326 133.752 76 43.1832
19.3589 11 6.2502 77.4356 44 25.0008 135.512 77 43.7514
21.1188 12 6.8184 79.1955 45 25.5690 137.272 78 44.3196
22.8787 13 7.3866 80.9554 46 26.1372 139.032 79 44.8878
24.6386 14 7.9548 82.7153 47 26.7054 140.792 80 45.4560
26.3985 15 8.5230 84.4752 48 27.2736 142.552 81 46.0242
28.1854 16 9.0912 86.2351 49 27.8418 144.312 82 46.5924
29.9183 17 9.6594 87.9950 50 28.4100 146.072 83 47.1606
31.6782 18 10.2276 89.7549 51 28.9782 147.832 84 47.7288
33.4381 19 10.7958 91.5148 52 29.5464 149.592 85 48.2970
35.1980 20 11.3640 93.2747 53 30.1146 151.351 86 48.8652
36.9579 21 11.9322 95.0346 54 30.6828 153.111 87 49.4334
38.7178 22 12.5004 96.7945 55 31.2510 154.871 88 50.0016
40.4770 23 13.0686 98.5544 56 31.8192 156.631 89 50.5698
42.2376 24 13.6368 100.3140 57 32.3874 158.391 90 51.1380
43.9975 25 14.2050 102.0740 58 32.9556 160.151 91 51.7062
45.7574 26 14.7732 103.8340 59 33.5238 161.912 92 52.2744
57.5173 27 15.3414 105.5940 60 34.0920 163.671 93 52.8426
49.2772 28 15.9096 107.3540 61 34.6602 165.431 94 53.4108
51.0371 29 16.4778 109.1140 62 35.2284 167.191 95 53.9790
52.7970 30 17.0460 110.8740 63 35.7966 168.950 96 54.5472
54.5569 31 17.6142 112.6340 64 36.3648 170.710 97 55.1154
56.3168 32 18.1824 114.3940 65 36.9330 172.470 98 55.6836
58.0767 33 18.7506 116.1530 66 37.5012 174.230 99 56.2518
Issue 2 May 2002

Units of Length
1 m = 3.2808 feet
1 foot = 0.3048 metres
m ft m ft m ft
0.3048 1 3.2808 10.3632 34 111.549 20.4216 67 219.816

0.6096 2 6.5617 10.6680 35 114.829 20.7264 68 223.097
0.9144 3 9.8425 10.9728 36 118.110 21.0312 69 226.378
1.2192 4 13.1234 11.2776 37 121.391 21.3360 70 229.659
1.5240 5 16.4042 11.5824 38 124.672 21.6408 71 232.940
1.8288 6 19.6850 11.8872 39 127.953 21.9456 72 236.220
2.1336 7 22.9659 12.1920 40 131.234 22.2504 73 239.501
2.4384 8 26.2467 12.4968 41 134.514 22.5552 74 242.782
2.7432 9 29.5276 12.8016 42 137.795 22.8600 75 246.063
3.0480 10 32.8084 13.1064 43 141.076 23.1648 76 249.344
3.3528 11 36.0892 13.4112 44 144.357 23.4696 77 252.625
3.6576 12 39.3701 13.7160 45 147.638 23.7744 78 255.906
3.9624 13 42.6509 14.0208 46 150.919 24.0792 79 259.186
4.2672 14 45.9318 14.3256 47 154.199 24.3840 80 262.467
4.5720 15 49.2126 14.6304 48 157.480 24.6888 81 265.748
4.8768 16 52.4934 14.9352 49 160.761 24.9936 82 269.029
5.1816 17 55.7743 15.2400 50 164.042 25.2984 83 272.310
5.4864 18 59.0551 15.5448 51 167.323 25.6032 84 275.591
5.7912 19 62.3360 15.8496 52 170.604 25.9080 85 278.871
6.0960 20 65.6168 16.1544 53 173.885 26.2128 86 282.152
6.4008 21 68.8976 16.4592 54 177.165 26.5176 87 285.433
6.7056 22 72.1785 16.7640 55 180.446 26.8224 88 288.714
7.0104 23 75.4593 17.0688 56 183.727 27.1272 89 291.995
7.3152 24 78.7402 17.3736 57 187.008 27.4320 90 295.276
7.6200 25 82.0210 17.6784 58 190.289 27.7368 91 298.556
7.9248 26 85.3018 17.9832 59 193.570 28.0416 92 301.837
8.2296 27 88.5827 18.2880 60 196.850 28.3464 93 305.118
8.5344 28 91.8635 18.5928 61 200.131 28.6512 94 308.399
8.8392 29 95.1444 18.8976 61 203.412 28.9560 95 311.680
9.1440 30 98.4252 19.2024 63 206.693 29.2608 96 314.961
9.4488 31 101.7060 19.5072 64 209.974 29.5656 97 318.241
9.7536 32 104.9870 19.8120 65 213.255 29.8704 98 321.522
10.0584 33 108.2680 20.1168 66 216.535 30.1752 99 324.803
Issue 2 May 2002

Units of Weight
1 kg = 2.2046 lb
1 lb = 0.4536 kg
kg lb kg lb kg lb
0.4536 1 2.2046 15.4224 34 74.9564 30.3912 67 147.708

0.9072 2 4.4092 15.8760 35 77.1610 30.8448 68 149.913
1.3608 3 6.6138 16.3296 36 79.3656 31.2984 69 152.117
1.8144 4 8.8184 16.7832 37 81.5702 31.7520 70 154.322
2.2680 5 11.0230 17.2368 38 83.7748 32.2056 71 156.527
2.7216 6 13.2276 17.6904 39 85.9794 32.6592 72 158.731
3.1752 7 15.4322 18.1440 40 88.1840 33.1128 73 160.936
3.6288 8 17.6368 18.5976 41 90.3886 33.5664 74 163.140
4.0824 9 19.8414 19.0512 42 92.5932 34.0200 75 165.345
4.5360 10 22.0460 19.5048 43 94.7978 34.4736 76 167.549
4.9896 11 24.2506 19.9584 44 97.0024 34.9272 77 169.754
5.4432 12 26.4552 20.4120 45 99.207 35.3808 78 171.958
5.8968 13 28.6598 20.8656 46 101.412 35.8344 79 174.163
6.3504 14 30.8644 21.3192 47 103.616 36.2880 80 176.368
6.8040 15 33.0690 21.7728 48 105.821 36.7416 81 178.573
7.2576 16 35.2736 22.2264 49 108.025 37.1952 82 180.777
7.7112 17 37.4782 22.6800 50 110.230 37.6488 83 182.982
8.1648 18 39.6828 23.1336 51 112.435 38.1024 84 185.186
8.6184 19 41.8874 23.5872 52 114.639 38.5560 85 187.391
9.0720 20 44.0920 24.0408 53 116.844 39.0096 86 189.596
9.5256 21 46.2966 24.4944 54 119.048 39.4632 87 191.800
9.9792 22 48.5012 24.9489 55 121.253 39.9168 88 194.005
10.4328 23 50.7058 25.4016 56 123.458 40.3704 89 196.209
10.8864 24 52.9104 25.8552 57 125.662 40.8240 90 198.414
11.3400 25 55.1150 26.3088 58 127.867 41.2776 91 200.619
11.7936 26 57.3196 26.7624 59 130.071 41.7312 92 202.823
12.2472 27 59.5242 27.2160 60 132.276 42.1848 93 205.028
12.7008 28 61.7288 27.6696 61 134.481 42.6384 94 207.232
13.1544 29 63.9334 28.1232 62 136.685 43.0920 95 209.437
13.6080 30 66.1380 28.5768 63 138.889 43.5456 96 211.642
14.0616 31 68.3426 29.0304 64 141.094 43.9992 97 213.846
14.5152 32 70.5472 29.4840 65 143.299 44.4528 98 216.051
16.9688 33 72.7518 29.9376 66 145.504 44.9064 99 218.255
Issue 2 May 2002

Conversion table of English Measurements
LENGTHS
TEMPERATURES
1 inch = 25.4 mm
Fractions Inches in mm mm in inches Fahrenheit to Celsius
Decimal mm
inches Inches mm mm Inches °F °C °C °F
1/64 .015625 0.3969 - 20 - 28.9 - 30 - 22

1/32 .031250 0.7937 - 15 - 26.1 - 28 - 18.4
3/64 .468750 1.1906 - 10 - 23.3 - 26 - 14.8
1/16 .062500 1.5875 0.0001 0.00254 0.004 0.00015 - 5 - 20.6 - 24 - 11.2
5/64 .078125 1.9844 .0002 .00508 0.005 .00019 0 - 17.8 - 22 - 7.6
3/32 .093750 2.3812 .0003 .00762 0.006 .00023 1 - 17.2 - 20 - 4
7/64 .109375 2.7781 .0004 .01016 0.007 .00027 2 - 16.7 - 18 - 0.4
1/8 .125000 3.1750 .0005 .01270 0.008 .00031 3 - 16.1 - 16 3.2
9/64 .140625 3.5719 .0006 .01524 0.009 .00035 4 - 15.6 - 14 6.8
5/32 .156250 3.9687 .0007 .01778 0.010 .00039 5 - 15.0 - 12 10.4
11/64 .171875 4.3656 .0008 .02032 0.020 .00079 10 - 12.2 - 10 14
3/16 .187500 4.7625 .0009 .02286 0.030 .00118 15 - 9.4 - 8 17.6
13/64 .203125 5.1594 .001 .02540 0.040 .00157 20 - 6.7 - 6 21.2
7/32 .218750 5.5562 .002 .05080 0.050 .00197 25 - 3.9 - 4 24.8
15/64 .234375 5.9531 .003 .07620 0.060 .00236 30 - 1.1 - 2 28.4
1/4 .250000 6.3500 .004 .10160 0.070 .00276 35 1.7 0 32
17/64 .265625 6.7469 .005 .12700 0.080 .00315 40 4.4 2 35.6
9/32 .281250 7.1437 .006 .15240 0.090 .00354 45 7.2 4 39.2
19/64 .296875 7.5406 .007 .17780 0.100 .00394 50 10.0 6 42.8
5/16 .312500 7.9375 .008 .20320 0.200 .00780 55 12.8 8 46.4
21/64 .328125 8.3344 .009 .22860 0.300 .01181 60 15.6 10 50
11/32 .343750 8.7312 .01 .25400 0.400 .01575 65 18.3 12 53.6
23/64 .359375 9.1281 .02 .50800 0.500 .01969 70 21.1 14 57.2
3/8 .375000 9.5250 .03 .76200 0.600 .02362 75 23.9 16 60.8
25/64 .390625 9.9219 .04 1.01600 0.700 .02756 80 26.7 18 64.4
13/32 .406250 10.3187 .05 1.27000 0.800 .03149 85 29.4 20 68
27/64 .421875 10.7156 .06 1.52400 0.900 .03543 90 32.2 22 71.6
7/16 .437500 11.1125 .07 1.77800 1.900 .03937 95 35.0 24 75.2
29/64 .453125 11.5094 .08 2.03200 2.900 .07874 100 37.8 26 78.8
15,32 .468750 11.9062 .09 2.28600 3.900 .11811 105 40.6 28 82.4
31/64 .484375 12.3031 .10 2.54000 4.900 .15748 110 43.3 30 86
1/2 .500000 12.7000 .20 5.08000 5.900 .19685 115 46.1 32 89.6
33/64 .515625 13.0969 .30 7.62000 6.900 .23622 120 48.9 34 93.2
17/32 .53125 13.4937 .40 10.16000 7.900 .27559 125 51.7 36 96.8
Issue 2 May 2002

LENGTHS
TEMPERATURES
1 Pouce (inch) = 25.4 mm
Fractions Inches in mm mm in inches Fahrenheit to Celsius
Decimal mm
of inches Inches mm mm Inches °F °C °C °F
35/64 .546875 13.8906 0.5 12.70 8 0.31496 130 54.4 38 100.4

9/16 .562500 14.2875 .6 15.24 9 .35433 135 57.2 40 104.0
37/64 .578125 14.6844 .7 17.78 10 .39370 140 60.0 42 107.6
19/32 .593750 15.0812 .8 20.32 11 .43307 145 62.8 44 112.2
39/64 .609375 15.4781 .9 22.86 12 .47244 150 65.6 46 114.8
5/8 .625000 15.8750 1 25.40 13 .51181 155 68.3 48 118.4
41/64 .640625 16.2719 2 50.80 14 .55118 160 71.1 50 122.0
21/32 .656250 16.6687 3 76.20 15 .59055 165 73.9 52 125.6
43/64 .671875 17.0656 4 101.60 16 .62992 170 76.7 54 129.2
11/16 .687500 17.4625 5 127.00 17 .66929 175 79.4 56 132.8
45/64 .703125 17.8594 6 152.40 18 .70866 180 82.2 58 136.4
23/32 .718750 18.2562 7 177.80 19 .74803 185 85.0 60 140.0
47/64 .734375 18.6531 8 203.20 20 .78740 190 87.8 62 143.6
3/4 .750000 19.0500 9 228.60 21 .82677 195 90.6 64 147.2
49/64 .765625 19.4469 10 2540.0 22 .86614 200 93.3 66 150.8
25/32 .781250 19.8437 11 279.40 23 .90551 205 96.1 68 154.4
51/64 .796875 20.2406 12 304.80 24 .94480 210 98.9 70 158.0
13/16 .812500 20.6375 13 330.20 25 .98425 212 100.0 75 167.0
53/64 .828125 21.0344 14 355.60 26 1.02362 215 101.7 80 176.0
27/32 .843750 21.4312 15 381.00. 27 1.06299 220 104.4 85 185.0
55/64 .859375 21.8281 16 406.40 28 1.10236 225 107.2 90 194.0
7/8 .875000 22.2250 17 431.80 29 1.14173 230 110.0 95 203.0
57/64 .890625 22.6219 18 457.20 30 1.18110 235 112.8 100 212.0
29/32 .906250 23.0187 19 482.60 31 1.22047 240 115.6 105 221.0
59/64 .921875 23.4156 20 5080.0 32 1.25984 245 118.3 110 230.0
15/16 .937500 23.8125 21 533.40 33 1.29921 250 121.1 115 239.0
61/64 .953125 24.2094 22 558.80 34 1.33858
31/32 .968750 24.6062 23 584.20 34 1.37795
63/64 .984375 25.0031 24 609.60 36 1.41732
1 1.000000 25.4000 25 635.00 37 1.45669
26 660.40 38 1.49606
39 1.53543
40 1.57480
Issue 2 May 2002

3. Evaporate off the solvent
G . Locking compounds and seal- 4. Smear the parts with the recommended grade of
ants LOCTITE:
- for blind tapped holes, place a small quantity of
The Loctite compounds mentioned in this manual are the product on the last of the tapped threads.
referred to by their industrial names. - for cylindrical fitting components, place the prod-
For repairs, use the brands or AGCO references shown uct on both areas using a clean brush.
in the following table: - for mating faces, apply a bead of product on one
of the two faces, forming rings around any commu-
nicating holes and tighten the parts together as
Loctite Brand AGCO quickly as possible.
industrial name reference
Note:
242 - 241 - 542 Frenetanche 3 930 904 M1 a) Apply the minimum quantity of product required in
order to avoid sticking adjacent parts.
270 Frenbloc 3 405 352 M5 b) Do not further tighten or loosen bolts after 5 minutes
of polymerisation in order not to break the film.
510 - 221 Formajoint 3 900 613 M2 c) If the ambient temperature is less than +10º C and
in order to speed up the process (except with
638 - 648 Scelbloc 1 633 268 M2 SILICOMET), after operation 2 use LOCTITE T 747
quick setting on at least one of the parts. Any excess
Silicomet Auto-joint clair 3 405 423 M2 of product outside the sealed area will not harden
(anaerobic product – polymerises only in the ab-
Note: Use the product “Form A Gasket 2” in cases where sence of oxygen).
sealing is required between plastic and steel or cast-iron.
For example: PTO sensor, forward speed sensor…
Grease
These products can be ordered from the following ad- When grease is used in components that are in contact
dress: with transmission oil, employ a miscible grease to avoid
LOCTITE clogging the hydraulic filters.
10 Avenue Eugène Gazeau Use “Amber Technical” grease, supplied by WITCO
Zone Industrielle 76320 Saint-Pierre les Elbeuf.
6034 – SENLIS
France
Application method for Loctite products

1. Remove all traces of the old sealing product and
corrosion
- by rubbing with a cloth or brushing
- by chemical action: “DECAPLOC 88”. Leave to
act, then scrape off and dry.
2. Degrease the parts in solvent
- preferably, use “Super Solvent Sec LOCTITE 706”
Issue 2 May 2002

H . Tightening torques
Use the recommended tightening torques for nuts and
bolts in accordance with tables:
- 1 and 2: for metric threads
- 3 and 4: for non-metric threads
Where a particular torque is required, it is mentioned in

the text.
Tables 1 and 3 indicate the normal values of the tighten-
ing torques applicable with zinc-plated threaded ele-
ments with normal nuts, coarse or fine threads, with or
without flat or lock washers, and weld nuts having a
height greater than 0.8 d.
Tables 2 and 4 indicate the lower torque values applica-

ble to threaded elements in assemblies using self-
locking safety nuts, zinc-plated, phosphate coated nuts
and bolts, flat nuts, and weld nuts having a height less
than 0.8 d.
These values apply to all dry assemblies. If the threads
are lubricated, reduce the tightening torques in conse-
quence.
Note: Read the strength classification on the head of

the bolt and determine the corresponding torque to
be applied.
Example:
8,8
Issue 2 May 2002

Table 1
Tightening torque values: zinc-plated metric threads
Strength classification Strength classification

Nominal ISO 8,8 (SAE 5, BS S) ISO 10,9 (SAE 8, BS V)
dimension d. Torque Nm Torque Nm
Max Min Max Min
M3 1.7 1.3 2.4 1

M4 4.1 3.1 5.7 4
M5 8.7 6.7 11.5 8
M6 14.7 10.7 20.7 14
M8 35.7 25.7 46.7 36
M10 70.7 50.7 96.7 72
M12 120.7 90.7 160.7 120
M16 260.7 200.7 400.7 300
M20 560.7 420.7 800.7 600
M24 960.7 720.7 1300.7 1000
M30 1800.7 1400.7 2800.7 2100
M36 3300.7 2500.7 4800.7 3600
Table 2
Reduced tightening torque values: metric threads

Nominal ISO 8,8 (SAE 5, BS S) ISO 10,9 (SAE 8, BS V)
Max Min Max Min
M3 1.4 1 1.9 1
M4 3.3 2.5 4.6 3
M5 6.4 4.8 9.2 6
M6 11.7 8.7 16.7 12
M8 28.7 20.7 37.7 29
M10 56.7 40.7 77.7 57
M12 96.7 72.7 130.7 100
M16 210.7 160.7 320.7 240
M20 450.7 340.7 640.7 480
M24 770.7 570.7 1040.7 800
M30 1400.7 1100.7 2200.7 1700
M36 2600.7 2000.7 3800.7.7 2900
Issue 2 May 2002

Table 3
Tightening torque values: zinc-plated non-metric threads

Nominal SAE 5 ( ISO 8,8 BS S) SAE 8 (ISO 10,9 BS V)
Max Min Max Min
#6 2.4 1.8 3.3 2

#8 4.4 3.4 6.3 4
#10 6.3 4.7 8.9 6
1/4 15.7 11.7 22.7 16
5/16 30.7 22.7 43.7 31
3/8 53.7 39.7 75.7 55
7/16 86.7 64.7 120.7 90
1/2 130.7 100.7 180.7 140
5/8 260.7 200.7 370.7 280
3/4 460.7 350.7 660.7 490
7/8 760.7 560.7 1060.7 800
1 1120.7 840.7 1600.7 1200
1 1/8 1390.7 1050.7 2200.7 1700
1 1/4 2000.7 1500.7 3200.7 2400
1 1/2 3400.7 2600.7 5400.7 4100
Table 4
Tightening torque values: zinc-plated non-metric threads

Nominale SAE 5 ( ISO 8,8 BS S) SAE 8 (ISO 10,9 BS V)
Max Min Max Min
#6 1.9 1.5 2.6 2

#8 3.5 2.7 5.6 3.
#10 5.7 3.8 7.1 5
1/4 12.7 8.8 18.7 13.
5/16 24.7 18.7 34.7 25
3/8 42.7 31.7 60.7 44
7/16 69.7 51.7 96.7 72
1/2 104.7 80.7 140.7 110
5/8 210.7 160.7 300.7 220
3/4 370.7 280.7 530.7 390
7/8 610.7 450.7 850.7 640
1 900.7 670.7 1280.7 960
1 1/8 1100.7 840.7 1760.7 1360
1 1/4 1600.7 1200.7 2560.7 1920
1 1/2 2700.7 2100.7 4320.7 3280
Issue 21
Issue May 2002
May 2002
2 . SPLITTING THE TRACTOR
Contents
2A01 SPLITTING THE TRACTOR BETWEEN FRONT FRAME / ENGINE
2B01 SPLITTING THE TRACTOR BETWEEN ENGINE / GEARBOX
2C01 SPLITTING THE TRACTOR BETWEEN GEARBOX / INTERMEDIATE HOUSING
2D01 SPLITTING THE TRACTOR BETWEEN INTERMEDIATE HOUSING / CENTRE

HOUSING
2E01 SPLITTING THE TRACTOR BETWEEN PTO HOUSING / CENTRE HOUSING
2F01 CHASSIS REINFORCEMENTS
2G01 REAR WHEELS / HUBS
Issue 1 May 2001

Splitting - Front Frame / Engine 2A01.1
2 A01 Splitting the tractor between front frame /

Engine
CONTENTS
- General ________________________________________________ 2
A. Preliminary operations __________________________________ 2
B. Disassembling __________________________________________ 5
C. Reassembling __________________________________________ 5
D. Final operations ________________________________________ 5
E. Version with Carraro front axle ___________________________ 7
F. Service tools ___________________________________________ 11
Issue 12 May 2001

2002
2A01.2 Splitting - Front frame / Engine
General
This section presents a general disassembly procedure.
Due to the diversity of the hydraulic or mechanical
options available on the 8200 series tractors, mention
will only be made of those pipes or main connections to
be disconnected.
For this reason, before and when disassembling the
tractor, ensure no connections remain between the fixed
assembly and the moving assembly. C
Disassembling the front frame and the engine allows
working on the mechanical parts located at the front of
the engine. 1
A . Preliminary operations
1. Remove the side panels. Unlock and hinge open the
bonnet, or remove (if necessary).
Position of locks:
- tractors 8210 8220 and 8240 to 8260: below the
front nose assembly;
- tractors 8270 and 8280: below the front nose
assembly, on the rear left-hand side of the bonnet.
Disconnect the battery terminals.
2. Disconnect the front differential-locking control pipe C
at both ends (front axles AG155H and AG200) (blank
the pipe).
Remove the transmission guard and shaft (4 WD)
(all tractor types). 1
3. Remove the guards located either side of the radia-
tor.
4. Disconnect the horn wiring harness located inside
the nose assembly.
5. Mark then disconnect the steering hoses from the Fig. 1
side pipes fitted on the engine mount. Blank the
pipes. 11. Disconnect the air conditioning intakes at the front
6. Disconnect the vacuum-gauge harness. Remove left of the cab. Fit blanking plugs.
the suction pipe from the air cleaner above the 12. Remove the compressor from its mounting and tilt
radiator. forward without disconnecting the hoses.
7. Drain the cooling system. 13. If necessary, remove the steering cylinder (front
8. On the radiator, disconnect: axles AG155H and AG200H) to gain access to the
- the hoses (lower and upper), screws securing the frame to the engine.
- the hose connecting the radiator and the expansion 14. Remove the chassis reinforcements located either
tank. side of the engine (if installed) (see section 2F01).
9. Remove the cleat above the radiator. Set the handbrake and block front axle (1), using
10. Mark the position then disconnect the following suitable chocks "C" (Fig. 1). Chock the rear wheels.
hoses: 15. Remove one screw (3) (Fig. 2 - 3) on each front
Full Powershift gearbox engine mount, replacing by two guide studs of
- the hoses from the cooler to the thermostatic sufficient length.
valve.
Heavy Duty gearbox
- the cooler hoses routed to the right-hand hydraulic
cover.
Issue
Issue 12 May 2002
2001
A : Perkins engine
B : Valmet engine Fig. 3 Fig. 2
Issue 1 May 2001

2 1
A : Front axles AG155H or AG200H

B : Front axle ZF5052
C : 2 WD axle
C
Fig. 2 Fig. 3
Issue 1 May 2001

B . Disassembling (Fig. 4) D . Final operations

Note: Remove the front weights and belly weights (if 22. Remove the shims between the frame and the front
installed). axle.
If necessary, reinstall the chassis reinforcements (s
16. Position a fixed axle stand under the engine sump. 2F01) and the front weights.
17. Position a movable axle stand under the front axle (2 23. If disassembled, reinstall the steering cylinder. Ap-
or 4 WD), in the longitudinal axis of the tractor, or use ply a light coating of Loctite 270 then torque the
suitable lifting equipment. screws to 180 - 200 Nm and torque ball nuts to 140
18. Finish removing the other attachment screws (1) (2) - 155 Nm. Lock the nuts using new pins.
(3) (Fig. 2 - 3) from the front engine frame. 24. Tilt the compressor towards the rear and rest it on the
19. Assisted by an operator, separate the assemblies. support.
25. Remove the blanking plugs. Reconnect the air con-
ditioning intakes.
26. Reconnect the hoses, reverse operation 10.
Danger 27. Reinstall the cleat above the radiator.
28. On the radiator, reconnect:
- Ensure there is no risk of accidental tipping of the front - the hoses (lower and upper),
frame assembly during the disassembly operation. - the hoses connected to the radiator seat and the
expansion tank.
29. Service the cooling system and the expansion tank.
30. Reinstall the suction pipe on the air cleaner above the
radiator.
C . Reassembling
20. Assemble the frame with the engine.
21. Remove the guide studs. Install and torque the
screws as follows (Fig. 2 - 3) :
- (1) : 670 - 900 Nm
- (2) : 520 - 640 Nm
- (3) : 300 - 400 Nm
Fig. 4
Issue 12 May 2002

2001

31. Reconnect the steering hoses on the side pipes fitted
on the engine mount.
32. Reconnect the horn wiring harness.
33. Reinstall the guards located either side of the radiator.
34. Reassemble the transmission shaft and guard. Re-
connect the front differential-locking control pipe (4
WD) (Front axles AG155H and AG200H).
35. Reconnecting the battery terminals. Close the bonnet.
36. Start the engine.
37. Perform a road test.
38. Check the following points:
- leaktightness of hydraulic circuits,
- operation of electrical circuits,
- coolant level.
If required, complete servicing of the circuit in
question.
Tightening torques (if required)

- Front wheel nuts : 640 - 680 Nm
- Belly weight screws (if fitted) 300 - 350 Nm, Loctite 270.
Issue 1 May 2001

E. Version with Carraro front axle

Note
- 8210 – 8220 - 8240 and 8250 tractors are now equipped C
with Carraro front axle.
- The front frame (axle support) has a different shape to
that with a Dana front axle. However, it can be fitted
with a Dana front axle (optional).
- The procedure applied to split the front frame with
Carraro front axle is practically identical to that used for
Dana front axles. However, a few differences in layout
and number of parts to be removed should be noted.
Preliminary operations 1
39. Set the handbrake and immobilize the front axle (5) Fig. 5
using triangular chocks “C” (Fig. 5). Chock the rear
wheels.
40. Remove the front weights (if fitted).
41. Remove the side panels. Unlock the bonnet and
hinge it open. Use a rope to hold the bonnet open and
disconnect the lower clamps on the holding cylin-
ders.
42. Disconnect the negative terminals on the batteries on
the right-hand side of the tractor.
43. Remove the guards (2) (2A) and the universal drive
shaft (see section 8F03).
44. Remove the guards located either side of the radiator.
45. Remove the clamp that holds the tubes, hoses and
harnesses above the radiator.
46. Remove the chassis reinforcements on either side of
the engine (if fitted).
47. Mark and disconnect all the hydraulic or electric
unions connected to the frame / front axle and
steering cylinder unit, but leave the air conditioning
hoses in place.
Note
- These links are located above the radiator and on
the right- and left-hand sides of the tractor.
48. Remove the air filter intake pipe above the radiator.
49. Drain the cooling system.
Issue
Issue 11 May
May 2001
2002

50. On the radiator, partially disconnect: 57. Assisted by an operator, separate the assemblies
- hoses (upper and lower) (Fig. 7).
- the linking hoses between the radiator and the
expansion tank. Danger
51. Tilt the air conditioning condenser housed in the front
nose assembly to the front and rear of the engine - Ensure there is no risk of accidental tipping of the
without disconnecting the hose involved. front frame assembly during the disassembly
52. Remove the steering cylinder to access the adjust- operation.
ing screw that attaches the frame on the engine.
53. Remove a screw (3) (Fig. 6 - 8) from each square at
the front of the engine, replacing it by a long guide
stud of sufficient length.
Disassembling
Danger
- Remove the belly weight (if fitted).

54. Position a fixed axle stand under the engine sump.
55. Position a movable axle stand under the front axle in
the longitudinal axis of the tractor, or use a suitable
lifting fixture.
56. Finish removing the other attachment screws (1) (2)
(3) (Fig. 6 - 8) from the engine frame.
Fig. 7
Issue 11 May 2001

2002
1
A : Perkins engine - 8210 - 8220 tractors
B : Valmet engine - 8240 - 8250 tractors
Fig. 6
Issue
Issue 1 May
May 2002
2001

Reassembling
58. Assemble the frame with the engine.
59. Remove the guide studs. Fit screws and torque to
(Fig. 8):
- (1) : 670 – 900 Nm
- (2) : 520 – 640 Nm
- (3) : 300 – 400 Nm
3
2
Fig. 8
Issue 11 May 2002

2001
Final operations
60. Refit the steering cylinder.
61. Refit the condenser.
62. Reconnect all the cooling hoses.
63. Refit the air filter intake pipe.
64. Reconnect the hydraulic and electric unions.
65. Refit the clamp above the radiator.
66. Reinstall the radiator side guards.
67. Refit the universal drive shaft and the guards (2) (2A).
68. Reconnect the negative terminals to the batteries.
69. Top up the fluid level in the cooling system and the
expansion tank.
70. Start the engine. Check the electrical equipment for
proper operation and check for hydraulic tightness:
- of hydraulic hoses and unions
- of hoses.
Fig. 9
Front axles with a suspension system
- Activate front axle suspension system several times
making it move from low position to high position and
vice versa in order to check it and detect leaks, if any.
- In case of dysfunction, use the calibration procedure
(see section 11 – Electronics).
Front axles – fixed or with a suspension system

71. Close the bonnet and reinstall the side panels.
72. Carry out a road test.
Tightening torques (if necessary)

- Front wheel nuts: 640 – 680 Nm.
- Belly weight screw: 420 – 560 Nm, Loctite 270.
F. Service tools
Tools available in the AGCO network

- 3376935M91 – Set of plugs for air conditioning
unions (Fig. 9).
Issue 11 May 2002

2001
Splitting - Engine / Gearbox 2B01.1
2 B01 Splitting the tractor betwwen Engine /

Gearbox
CONTENTS
- General ________________________________________________ 3
B. Disassembling __________________________________________ 5
C. Reassembling __________________________________________ 6
E. Service tools ___________________________________________ 11
Issue 2 May 2002

2B01.2 Splitting - Engine / Gearbox
Issue 2 May 2002

6. Mark the position then disconnect the following

General hoses:
This section presents a general disassembly procedure. Full Powershift gearbox
Due to the diversity of the hydraulic and mechanical the - the charge and return hoses to/from the brake
options available on the 8200 series tractors, mention master-cylinders,
will only be made of those the pipes or main connections - the hoses to the thermostatic valve.
to be disconnected. Heavy Duty gearbox
For this reason, before and when disassembling the - Mark and disconnect the hoses coming from the
tractor, ensure no connections remain between the fixed right-hand hydraulic cover towards the cooler. Blank
assembly and the moving assembly. the hoses and ports,
The 8200-Series tractors may be equipped either with a - the charge and return hoses to/from the brake-
Full Powershift gearbox or a Heavy Duty gearbox. Disas- master-cylinder tank.
sembly remains basically identical for both versions. 7. Disconnect the harness and remove the starter.
8. Disconnect the gas-oil supply and return hoses. If
Available equipment fits necessary, drain the fuel tanks, disconnect the
gauge harness and remove the side tank.
- Tractors 8210-8220 and 8240: Full Powershift gearbox
9. If required, remove the guards located either side of
AG150
the radiator.
- Tractors 8250 to 8280: Full Powershift gearbox AG250,
10. Disconnect the throttle control at the fuel injection
- Tractors 8210-8220 and 8240-8250: Heavy Duty gear-
pump.
box.
11. Disconnect:
- the heating hoses under the right-hand floor of the
The cab remains attached to the rear axle.
cab, or on the engine, ensuring their positions are
Disassembling the engine and gearbox allows working
identified. Blank the hoses and ports in order to
on the mechanical parts located to the rear of the engine
prevent complete drainage of the cooling system,
and principally in front of the Heavy Duty gearbox.
- the air conditioning intakes at the front left of the
cab. Fit blanking plugs (see § E),
- the main harness connections above and to the left
of the engine.
12. Mark then disconnect the steering hoses on the
Orbitrol steering unit.
A . Preliminary operations 13. Remove the engine oil filter (Valmet only), to gain
access to the hidden screw securing the gearbox.
bonnet, or remove (if necessary).
Position of locks:
- tractors 8210-8220 and 8240 to 8260: below the front
nose assembly,
- tractors 8270 and 8280: below the front nose assem-
bly, on the rear left-hand side of the bonnet.
2. Remove the front weights. Disconnect the battery
terminals.
3. Remove the turbocharger guard.
4. Remove the vertical exhaust assembly, the pipe
sleeve-fitted on the turbo, and the flexible sleeve
connected to the air cleaner.
5. Disconnect the front differential lock control pipe at
both ends (if fitted). Blank the pipe. Remove the
transmission guard and shaft (4 WD) (all tractor
types).
Issue 2 May 2002


14. Set the handbrake and block front axle (1) using
appropriate chocks "C" (Fig. 1). If necessary, remove
the chassis reinforcements (see section 2F01).
15. If required, raise the cab slightly and wedge in place.
Note: If the side tank was not removed, check
the condition of the flexible unions between the
tanks and the filler pipe hose connection.
On Heavy Duty gearboxes, check the condition
of the gear control and reverser lifting arm and C
the selector cover. If the gear lifting arm inter-
feres with raising of the cab, disconnect it (see
sections 5C01 - 5C02 and 5C03 depending on 1
option).
16. Remove screws (3) placed either side of the engine
(1) and gearbox (2) (Fig. 2 or 3 depending on version).
Replace with two guide studs of suitable length.
Note: If necessary, remove the access door set in
the inner floor of the cab, to gain easier access
to the upper screws fixing the engine to the
gearbox.
Fig. 1
1 3 3
2 3
Fig. 2 Fig. 3
Issue 2 May 2002

B . Disassembling (Fig. 4)
17. Position the disassembly tooling.
18. Finish removing the other attachment screws secur-
ing the engine on the gearbox.
19. Assisted by an operator, separate the assemblies.
(1) Full Powershift gearbox

(2) Heavy Duty gearbox
(3) 8210 - 8220 and 8240 to 8260 bonnet
(4) 8270 and 8280 bonnet
Fig. 4
Issue 2 May 2002

C . Reassembling Fig. 5
On the Full Powershift gearbox

20. Coat one seat of spring (2) with adhesive (Loctite 401 1
or equivalent). Slide the spring on shaft (1) (Fig. 6),
the Loctited seat pointed towards the shoulder of the
shaft. Allow the Loctite to dry a few seconds. Lightly
lubricate the splines of main shaft (1) (Fig. 6) with
grease (type GN + Molycote) or equivalent.
On the Heavy Duty gearbox

- Lightly lubricate the splines of main shaft (1) (Fig. 5)
using the type of grease mentioned previously.
Version with mechanical shuttle
Version with Power shuttle
Issue 2 May 2002

2 1
Fig. 6
Issue 2 May 2002


21. Clean the mating surfaces:
Full Powershift gearbox
- of the engine and gearbox.
Heavy Duty gearbox
- of the engine and spacer.
22. Coat the mating face of the gearbox or the spacer
with a sealing product (Loctite 510 or equivalent).
23. Screw two guide studs of suitable length onto the
gearbox or spacer (depending on option).
24. Check the presence of the two locating pins (10) on
the engine (Fig. 8).
25. Assemble the engine to the gearbox or the spacer.
In order to facilitate engagement of the main-shaft
splines with those in the hub of the damper, manu-
ally rotate the crown wheel on the engine flywheel,
inserting a suitable tool in the hole provided for fixing
the starter.
Full Powershift gearbox AG250 (Fig. 7)

26. Remove the two guide studs. Install screw (1),
washers (2), spacers (4) and nuts (3).
Apply a light coating of Loctite 270 then torque the
screws to 480-640 Nm.
Full Powershift (AG150) and Heavy Duty

gearboxes (Fig. 8)
- Remove the two guide studs. Fit washers (8). Apply a
light coating of Loctite 270, then torque the screws as
follows:
. (1) : 240 - 320 Nm
. (2) : 300 - 400 Nm
. (3) : 400 - 540 Nm
. (4) : 100 - 130 Nm
. (5) : 300 - 400 Nm
. (6) : 790 - 1050 Nm
. (7) (9) : 630 - 840 Nm
Issue 2 May 2002

1 3 2 1 1 1 2 3 1
1 1
2 2
3 3
1 1
1 1
1 1
2 2
3 4 2 1 3
Fig. 7
AG150
F 3
6
7 10
Heavy Duty 9 F 8
F
Fig. 8
Issue 2 May 2002


D . Final operations 45. Close the bonnet.
27. If the cab was raised, reposition it on its front 46. Perform a road test.
supports. On tractors fitted with the Heavy Duty 47. Check the following points:
gearbox, monitor the behaviour of the gear control - leaktightness of hydraulic circuits,
lifting arm during refitting of the cab. If necessary, - operation of electrical circuits,
reinstall and adjust the gear lifting arm (see section - coolant level. If required, complete servicing of the
5C01 - 5C02 or 5C03 depending on option). Install circuit in question.
and screws in silent blocks and torque to 200 -
270 Nm.
28. Remove the disassembly tooling.
29. Remove the chocks from the front axle. Reinstall
and if necessary adjust the chassis reinforcements
(see section 2F01).
30. Reinstall the engine oil filter (Valmet only).
Special point:
- The filter must be in contact with its support;
tighten it through an extra quarter-turn approxi-
mately.
31. Reconnect the steering-cylinder hoses.
32. Reconnect the main harness connections.
33. Assemble the air conditioning intakes.
34. Reconnect the heating hoses under the cab or on the
engine (depending on option).
35. Reconnect the throttle control at the fuel injection
pump.
If necessary, reinstall the guards located either side
of the radiator.
36. If disassembled, reinstall the side tank and recon-
nect the gauge harness, the gas-oil supply and the
return hoses.
37. Reinstall the starter. Tighten the screws. Reconnect
the harness.
38. Reconnect the hoses, reversing operation 6.
39. Reinstall the transmission shaft and guard. Recon-
nect the differential lock control pipe (4 WD)(if fitted).
40. Reinstall the flexible pipe connection, the tube on the
turbocharger and the vertical exhaust assembly.
Install the Guard.
41. Reconnecting the battery terminals.
42. Check the setting of the throttle control.
43. If the side tank was removed, pour fuel into the
tanks. Service the cooling system and the expan-
sion tank.
Issue 21 May 2002

E . Service tools
- 3376935M91 - Set of plugs for air conditioning
couplings (Fig. 9).
Fig. 9
Issue 21 May 2002

Splitting - Gearbox / Intermediate Housing 2C01.1
2 C01 Splitting the tractor between Gearbox /

Intermediate housing
CONTENTS
- General ________________________________________________ 2
B. Disassembling __________________________________________ 4
C. Reassembling __________________________________________ 5
E. Service tools ___________________________________________ 7
F. Heavy Duty Version _____________________________________ 8
Issue 12 May 2002

2001
2C01.2 Splitting - Gearbox / Intermediate Housing

8. Disconnect the charge hose from the brake-master-
General cylinder tank.
This section presents a general disassembly procedure. 9. Mark then disconnect the steering hoses from the
Due to the diversity of the hydraulic and mechanical the Orbitrol steering unit.
options available on the 8200-Series tractors, mention 10. Remove the radiator guards (depending on option).
will only be made of those the pipes or main connections 11. Disconnect the heating hoses under the right floor of
to be disconnected. the cab or on the engine (depending on option);
For this reason, before and when disassembling the identify their positions. Blank the hoses and ports to
tractor, ensure no connections remain between the fixed prevent complete drainage the cooling system.
assembly and the moving assembly. 12. Remove the left footstep.
The 8200-Series tractors may be equipped with either a 13. Drain the fuel tanks.
Full Powershift gearbox, or a Heavy Duty gearbox. 14. Mark then disconnect:
Disassembly remains basically identical for both ver- - the harness to the side-tank gauge,
sions. - the gas-oil supply and return hoses.
15. Remove the side tank.
Available equipment fits 16. Slightly raise the front of the cab and wedge in place
- Tractors 8210-8220 and 8240-8250: Full Powershift per Fig. 2, using suitable axle stands.
gearbox AG150 17. Mark positions of following parts then disas-
- Tractors 8250 to 8280: Full Powershift gearbox AG250 semble from the gearbox:
- Tractors 8210-8220 and 8240-8250: Heavy Duty gear- - solenoid valves (if necessary, remove the access
box. door in cab floor to access the upper solenoid
The cab remains attached to the rear axle. valves),
Disassembling the gearbox and the intermediate hous- - sensors (intermediate speeds, engine speeds, road
ing allows working on the Gerotor hydraulic pump (Full speed, gearbox temperature and pressure),
Powershift gearbox) or on the output shaft (Heavy Duty - connectors to receptacles A, B, C, D, E, F of the
gearbox), located respectively on the rear of the stated TC unit installed on the right-hand side of the
gearboxes. gearbox.
18. Drain the intermediate housing.
19. Disconnect the gearbox return hoses (Orbitrol steer-
ing unit, power-assisted braking).
1. Position the rear wheels in wide tread.
bonnet and remove (if necessary).
Position of locks:
- tractors 8210-8220 and 8240 to 8260: below the front
nose assembly,
- tractors 8270 and 8280: below the front nose assem-
bly, on the rear left-hand side of the bonnet.
3. Disconnect the battery terminals.
4. Remove the battery compartment and the right foot-
step.
5. Remove the turbocharger guard.
6. Disconnect the front differential-locking control pipe at
both ends ((if fitted). Blank the pipe.
7. Remove the guard and the 4 WD transmission shaft
(all tractor types).
Issue 1 May 2001

20. Disconnect the return hose from the brake-master-

cylinder tank on the intermediate housing. 1
21. Disconnect hose (17 bar) towards the power-as-
sisted braking on the right-hand hydraulic cover.
22. Remove suction pipe (1) (Fig. 1) at the Gerotor pump,
and the elbow unions fitted on the intermediate AG 250
housing and the Full Powershift gearbox.
23. Disconnect:
- the creeper-speed control on the right-hand side of
the intermediate housing (depending on option, all
tractor types)
cab. Fit blanking plugs (see § E)
of the engine. AG 150
24. Disconnect the throttle control on the injection pump.

25. Block front axle (1), using suitable chocks - "C" (Fig. Fig. 1
1A).
26. Chock the rear wheels.
Fig. 1A
Issue 1 May 2001

B . Disassembling (Fig. 2)
1
Separating the gearbox from the interme-
diate housing (Fig. 2)
27. In order to free lower shaft (2) (Fig. 3 - 3A), turn the
special screw on the Park lock control unit clock- 3
wise until a hard point is felt (see section 6F01, Full
Powershift gearbox only).
28. Install the disassembly tooling (see § E).
29. Remove the screw attaching the gearbox to the
housing.
4
30. Assisted by an operator, separate the assemblies,
taking care to identify the position of the coupling
sleeves on connection shafts (1) and (2) (Fig. 3).
2
Fig. 3
Fig. 3A
Fig. 2
Issue 12 May 2002

2001
C . Reassembling
Assembling the gearbox and the intermedi- 19
Y
ate housing
31. Clean the mating surfaces of the gearbox and the
housing.
32. Coat the mating face of the housing with sealing
product Loctite 510 or equivalent.
33. Check the presence of the locating pins on the
housing.
34. Check the presence of connection shafts (1) and (2)
and sleeves (3) (4) (Fig. 3).
Note: Position the machined groove on the
outside diameter of each sleeve towards the
gearbox (optional). Y
Special point: 8
- On 8200 series tractors without creeper speeds,
fitted with the Full Powershift transmission, spring 8 1
(1) located at the front of shaft (2) maintains the
latter in position (Fig. 3A).
35. Screw two diametrically opposed guide studs into
the gearbox.
36. Assemble gearbox (8) onto housing (19).
37. Remove the guide studs. Install screw (1) (Fig. 4)
and torque to 240 - 320 Nm. 1 1
Section Y Y
Fig. 4
Issue 1 May 2001

D . Final operations
38. Remove the chocks from the front axle.
39. Reconnect the throttle control on the injection pump.
40. Reinstall the left-hand radiator guard (if fitted).
41. Reconnect:
of the engine,
cab.
42. Reinstall:
- the creeper control (if fitted). For setting instruc-
tions, see section 6H01
- the Gerotorpump sleeves and suction pipe.
43. Reconnect the power-assisted braking hose (17 bar) 1
on the right-hand hydraulic cover.
44. Reconnect the return hose from the brake master- Fig. 5
cylinder tank.
45. Reconnect the return hoses for the Orbitrol steering
unit and power-assisted braking on the gearbox.
46. Reconnect following items to gearbox:
- connectors for receptacles A, B, C, D, E, F of the
TC unit,
- sensors,
- solenoid valves.
47. Position the cab on its front supports (Fig. 5). Install
screws (1) in silent blocks and torque to 200 -
270 Nm.
48. Reinstall the side tank.
49. Reconnect the following items:
- the gas-oil supply and return hoses,
- the tank-gauge harness.
50. Reinstall the left footstep.
51. Reconnect the heating hoses.
52. Reinstall the right-hand radiator guard (if fitted).
53. Reconnect the steering hoses on the Orbitrol stee-
ring unit.
Issue 1 May 2001

54. Reconnect the charge hose to the brake-master-

cylinder tank.
55. Reinstall the transmission shaft and guard.
Reconnect the differential-locking control pipe (4
WD) (front axles AG155H and AG200).
56. Reinstall the battery compartment and right foot-
step.
57. Reconnect the battery terminals.
58. Reinstall the turbocharger guard.
59. Check the setting of the throttle control.
60. Service the oil system and check the level in the
transparent tube on the left of the centre housing.
Note: The drain plug in the intermediate housing
is special. It has a cylindrical part which the
other plugs do not. It is therefore essential to
check its position during reassembly.
61. Pour fuel into the tanks. Fig. 6
62. Service the cooling system and the expansion tank.
63. Reset the special screw on the Park lock control unit
to its initial position (see section 6F01) (Full Powershift
gearbox only).
64. Close the bonnet.
65. Align the wheels to their initial position. Torque
screws or nuts to values shown (see section 2G01).
66. Road test all the controls.
- leaktightness of hydraulic circuits,
- sealing of mating face between gearbox and inter-
mediate housing,
- operation of electronic and electrical circuits,
- coolant level. If required, complete servicing of the
circuit in question.
E . Service tools
Tools available in the AGCO network:
- 3376935M91 - Set of plugs for air-conditioning cou-
plings (Fig. 9)
Issue 12 May 2001

2002

74. Remove or disconnect the following items on the
F . Heavy Duty Version selector cover:
On tractors fitted with the Heavy Duty gearbox, the - harness of temperature sensor and Hare/Tortoise
disassembly method remains basically identical to that electro-valve,
used on the version employing the Full Powershift - return hose from brake-master-cylinder tank,
gearbox. Only special points concerning the Heavy Duty - return hoses from Orbitrol steering unit and power-
gearbox will be covered in this chapter. assisted braking,
Note: The contour of the intermediate housing is - gear control lifting arm (see section 5C01 - 5C02 or
different. The drain plugs have the same special 5C03 depending on version)
feature as mentioned for the one on the intermediate - control cables of the mechanical reverse shuttle
housing, Full Powershift gearbox) (see operation (see section 5C01)
60). - creeper unit control (depending on option).
75. Drain the fuel tanks. Remove the side tank.
Preliminary operations
Special point
68. Mark then disconnect the hoses coming from the
right-hand hydraulic cover to the cooler. Blank the
hoses and ports.
69. On the gearbox, mark then demate the connectors
on the solenoid valves at the Dynashift valve (ver-
sion with mechanical reverse shuttle) or at the clutch
control unit (version with power shuttle).
70. Remove the chassis reinforcements located either
side of the gearbox (if installed, see section 2F01).
Remove:
- the pipes near the clutch control valve and remove
latter, without disconnecting the hose coming
from the master-cylinder (version with mechanical
reverse shuttle).
- the pipes near the clutch control unit (version with
power shuttle).
71. Remove clutch lube pipe (17) located between
intermediate housing (19) and spacer (16) (Fig. 7 -
7B).
72. Remove the 17-bar pipe coming from the right-hand
hydraulic cover to the selector cover and the 17-bar
hose feeding to the power-assisted braking.
73. Disconnect the end of the gearbox lube pipe fitted on
the outlet of the right-hand hydraulic cover.
Issue 12 May 2002

2001
Version with mechanical reverse shuttle
19
16 17
Fig. 7
Fig. 7A
Version with power shuttle
19
16 17
Fig. 7B
Issue
Issue 12 May
May 2002
2001

diate housing (Fig. 7A)
Special point
1
76. To access screws (7) (Fig. 9), remove the closing
plate under the gearbox. During separation, mark the
direction of assembly of sleeve (1) on output shaft
(47) on gearbox housing "C" (Fig. 8).
47
C
Fig. 8
Issue 12 May 2002

2001
19 8 2
1 3 4 3 1 19
5
8 7 4 7 5 1
8 5
19
1 8
(8) Gearbox
(19) Intermediate housing
Fig. 9
Issue 12 May 2001

2002

Assembling the gearbox and the interme-
diate housing
Special point 2 1 3
77. Check the presence of locating pins (4) (Fig. 9) on the
gearbox.
78. Check that the undercut part of the PTO shaft (2) is
pointing towards hydraulic-pump drive gear (1)
(Fig. 10).
Note: Before assembling, coat one seat of spring
(3) with Loctite 401 adhesive. Slide the spring on
shaft (2), the Loctited seat pointed towards the
shouldered part of the shaft.
79. Clean the mating surfaces of the gearbox and the
intermediate housing.
80. Coat the jointing surface of the housing with a sealing
product Loctite 510 or equivalent.
81. Screw two studs diametrically opposite into the Fig. 10
82. Check the presence of sleeve (1) on output shaft (47)
(Fig. 8).
Note: The internal unsplined part of sleeve (1)
must be pointed towards the rear axle.
Special point
- In order to facilitate assembly of the gearbox with the
intermediate housing on 8200 tractors fitted with creeper
speeds, point the reducer link located on the right of the
intermediate housing upwards. If resistance is noted
during assembly of the various parts (gearbox - interme-
diate housing), avoid forcing, and find the reason.
83. Assemble the gearbox to the housing.

84. Remove the guide studs. Install the following screws
and nuts and torque as shown (Fig. 9) :
- (1) : 240 - 320 Nm
- (3) : 300 - 400 Nm
- (5) : 240 - 320 Nm
- (7) : 300 - 400 Nm
Notes:
- Studs (2) and (6) (Fig. 9) are lightly coated with
Loctite 270 and locked into the intermediate hous-
ing,
- Locating pins (4) (Fig. 9) are hard-sleeved into the
gearbox housing.
Issue 12 May 2002

2001
Final operations
Special point
85. During positioning of the cab, check the behaviour of
the gear control lifting arm. Reinstall and adjust the
gear lifting arm (see section 5C01 - 5C02 or 5C03
depending on version).
86. Reconnect and adjust the control cables of the
mechanical reverse shuttle (see section 5C01).
87. Reinstall or reconnect the following items on the
selector cover:
- creeper control, if fitted (see section 5K01),
- return hose from power-assisted braking and return
hose from Orbitrol steering unit,
- return hose from brake master-cylinder tank,
- harness of temperature sensor and Hare/Tortoise
solenoid valve.
88. Perform the following operations:
- reconnect the transmission lube pipe,
- reinstall the 17-bar pipe on the selector cover, and
the 17-bar hose feeding to the power-assisted
braking,
- reinstall lube pipe (17) (Fig. 8),
- clean the mating surfaces of the clutch valve or of
the clutch control unit (depending on version) and of
the housing.
- coat the mating face of the housing with sealing
product Loctite 510 or equivalent,
- reinstall the clutch control valve (version with
mechanical reverse shuttle) or the clutch control
unit (version with power shuttle).
Torque the screws to 25 - 35 Nm. Reconnect the
pipes and the solenoid valve connectors on the
Dynashift valve or on the clutch control unit (de-
pending on version).
- Fit the solenoid-valve connectors onto the of
Dynashift valve.
- Reconnect the cooler hoses, observing the mar-
kings made during disassembly.
89. Reinstall the side tank. Reinstall and adjust the
chassis reinforcements (see section 2F01).
Issue 1
Issue May 2002
May 2001
8200 SERIES-TRACTORS
Splitting - Intermediate housing / Centre housing 2D01.1
2 D01 Splitting the tractor between Intermediate

housing / Centre housing
CONTENTS
- General ________________________________________________ 2
B. Disassembling __________________________________________ 5
C. Reassembling __________________________________________ 7
Issue 2 May 2002

2D01.2 Splitting - Intermediate housing /Centre housing

8. Mark then disconnect:
General - the harness on the side-tank gauge,
This Section presents a general disassembly procedure. - the gas-oil supply and return hoses.
Due to the diversity of the hydraulic or mechanical 9. Remove the side tank.
options available on the 8200-Series tractors, mention 10. Mark then disconnect the control cables and hoses
will only be made of those pipes or main connections of the compensating spool valves on the auxiliary
requiring to be disconnected. spool valves.
For this reason, before and when disassembling the Important: During the Removal of the cables, it
tractor, ensure no connections remain between the fixed is essential to avoid turning the main spool of
assembly and the moving assembly. the valves through a half-turn , to avoid acciden-
The 8200-Series tractors may be equipped with either a tal connecting of the service and pilot-pressure
Full Powershift gearbox, or a Heavy Duty gearbox. pipes.
Disassembly remains basically identical for both ver- 11. Remove the rear cab attachments and slightly raise
sions. the cab, ensuring there is no interference with the
vertical exhaust assembly or windshield. During the
operation, also check the behaviour of the speed
Available equipment fits:
control and of the mechanical reverse shuttle (if
- Tractors 8210-8220 and 8240: Full Powershift gearbox
fitted), on the selector cover (Heavy Duty gearbox).
AG150
If the gear lifting arm interferes with lifting of the cab,
- Tractors 8250 to 8280: Full Power-shift gearbox AG250
disconnect it (see section 5C01 - 5C02 or 5C03
- Tractors 8210-8220 and 8240-8250: Heavy Duty gear-
depending on option).
box
Chock the cab using suitable axle stands (Fig. 4).
The cab will remain integral with the gearbox.
- the return hose from the brake tank on the interme-
Disassembling the intermediate housing from the centre
diate housing (Full Powershift gearbox),
housing allows working on the following items: drive
- the hoses of the left and right brake pipes located
pinion, ring gear, differential and housings.
above the intermediate housing (blank hoses and
tubes),
- the hose (17 bar) towards the power-assisted
braking on the right-hand hydraulic cover,
A . Preliminary operations cover (Heavy Duty gearbox),
- the pipe (17 bar) on the right-hand hydraulic cover
1. Set the lifting arm to the fully DOWN position. (Heavy Duty gearbox),
2. Position the rear wheels in wide tread. - the supply and pilot-flow hoses on the Orbitrol
3. Remove the side panels. Unlock and hinge open the steering unit on the priority block(s).
bonnet. 13. Drain the intermediate housing and Centre housing.
Position of locks: Note the contour of the plugs.
- Tractors 8210-8220 and 8240 to 8260: below the
front nose assembly;
- Tractors 8270 and 8280: below the front nose as-
sembly, on the rear left-hand side of the bonnet.
4. Disconnect the battery terminals;
5. Disconnect the front differential-locking control pipe at
both ends (if fitted). Blank the pipe. Remove the guard
and (4 WD) transmission shaft (all tractor types).
6. Remove the left footstep and if necessary, the right
footstep and battery compartment.
7. Drain the fuel tanks.
Issue 2 May 2002

14. Remove suction pipe (1) (Fig. 1) from the Gerotor

pump, and the elbow unions fitted in the intermedi-
1
ate housing and Full Powershift gearbox.
15. Remove the chassis reinforcements located either
side of the Heavy Duty gearbox (if installed, see
section 2F01). Remove clutch lube pipe (17) located
AG 250
between the intermediate housing (19) and spacer
(16) (Fig. 2 - 2A) (Heavy Duty gearbox).
16. Disconnect the handbrake control cable above the
intermediate housing and creeper-speed control on
the right-hand side of the intermediate housing (de-
pending on option, all tractor types).
- the harness to the solenoid valves on the right-hand
hydraulic cover, and the harness to the Park lock AG
150
transmission lock located on the right-hand side of
the intermediate housing (if the tractor is fitted with Fig. 1
this device),
- the harness to the low-pressure switch and the one
to the clogging switch on the main filter (15 mi-
crons),
- the harnesses to the load sensors,
- the connectors to the (MoveUp-MoveDown) sole-
noid valves of the lift control valve,
- the harnesses to the position sensors on the right-
hand lift bearing and the drive sensor on the centre
housing,
- the PTO sensors (dual driving pinion and output
shaft) on the rear housing.
18. Block the front axle (1), using suitable chocks - "C"
(depending on the type of front axle Dana - ZF 5052
or Carraro) (Fig. 3).
Issue 2 May 2002

19
16 17
Fig. 2
Version with power shuttle
19
16 17
Fig. 2A
Issue 2 May 2002

B . Disassembling
diate housing
19. For tractors fitted with Park lock transmission lock-
ing, free lower shaft (2) (see section 2C01, Fig. 3) by
turning the special screw on the unit located on the
right-hand side of the intermediate housing clock-
wise until a hard point is felt (see section 6F01). C
20. Install the disassembly tooling.
21. Remove the screws securing the gearbox to the
1
1
Fig. 3
Issue 2 May 2002


22. Assisted by an operator, separate the assemblies
(Fig. 4).
Note: On the tractors fitted with a Heavy Duty
transmission with creeper unit, monitor the 2
separation at the gearbox output shaft and drive
pinion.
Separating the intermediate housing and

the centre housing
23. Remove the right- and left-hand covers in order to
access hidden screws (2) (Fig. 5) (see respective
sections 9G01, 9G02 or 9H01).
24. Remove and unstick cover (3) from 4 WD unit (if
installed (Fig. 7). Identify positions of screws (2)
securing intermediate housing (19) to centre hou-
sing. Fig. 5
25. Disconnect any hoses or pipes that may have
remained connected to the various assemblies.
26. Chock the rear wheels. Place a fixed axle stand
under the centre housing.
27. Sling the intermediate housing using suitable lifting
equipment.

(3) Bonnet 8210-8220-8240 to 8260
(4) Bonnet 8270 and 8280
4 2
1
Fig. 4
Issue 2 May 2002

28. Remove housing attachment screws (2). Install

guide studs of sufficient length then start the sepa-
ration (Fig. 7).
Note: In the event of resistance being felt during
separation, screw two screws of suitable length
into tapped holes "T" located on the right and
left attachment flanges of intermediate housing
(Fig. 6). Continue the extraction until the sumps
are completely apart.
Shaft (28) (Fig. 7) located between the drive
bearing of the pumps and the PTO clutch comes
out with the intermediate housing. T
efore setting down the shaft, if required visually
mark land "D" to allow passage of the crown
wheel (Fig. 7).
Fig. 6
C . Reassembling
Assembling the intermediate housing and
the centre housing
29. Clean the mating surfaces of the housings.
30. Coat the mating face of the centre housing with
sealing product - Loctite 510 or equivalent.
31. Check for presence and position of locating pin (1)
sleeve- itted into the centre housing (Fig. 7).
Note: The stud has two flats positioned parallel
with the centre line of the housing (Fig. 7).
32. If removed, reposition PTO shaft (28), checking the
position of land "D" (Fig. 7).
33. Screw two guide studs at diametrically opposite
positions on the centre housing.
34. Assemble the intermediate housing to the centre
housing. Turn the pump driving pinion in order to
mate the splines of shaft (28) with the splines on the
PTO clutch.
35. Remove the guide studs. Install screws (2) and
torque to 300 - 400 Nm.
36. Clean the mating surfaces of intermediate housing
(19) and cover (3) (Fig. 7).
Issue 2 May 2002


37. Coat the mating face of the housing Loctite 510.
Reinstall the cover. Torque screws (4) to 50 - 70 Nm
(Fig. 7).
38. Reinstall the right- and left-hand covers (see respec-
tive sections 9G01 - 9G02 or 9H01, depending on
hydraulic equipment fit).
Assembling the gearbox and the interme-

diate housing
With the Full Powershift gearbox:
39. Assemble the gearbox and intermediate housing
(see section 2C01, § C).
With the Heavy Duty gearbox:

40. Assemble the gearbox and intermediate housing
(see section 2C01, § F).
19 2 28
4 3 1
Fig. 7
Issue 2 May 2002

41. Reconnect the following items:
- PTO sensors
- position and status sensors
- solenoid valves (MoveUp - MoveDown) on lift
control valve
- load sensors
- switch harnesses (low pressure and clogging)
- solenoid-valve harness on the right-hand hydraulic
cover and Park lock transmission locking on inter-
mediate housing (if installed)
- clutch lube pipe (17) (Fig. 2 - 2A) on Heavy Duty
gearbox 1 2
- suction pipe (1) at Gerotor pump and sleeves (Full
Powershift gearbox) (Fig. 1)
- creeper-speed control (if fitted) - for adjustment Fig. 8
instructions, see section 5K01 or 6H01, depending
on version)
- the supply and pilot-flow hoses to the Orbitrol
steering unit on the priority block(s)
- the 17 bar pipe on the right-hand hydraulic cover
(Heavy Duty gearbox),
cover (Heavy Duty gearbox)
- the 17-bar hose to the power-assisted braking on
the right-hand hydraulic cover
- the hoses on the brake pipes
- the return hose from the brake tank on the interme-
diate housing (Full Powershift gearbox)
42. Rest the cab on its rear supports (Fig. 8). Install the
screws in the silent blocks. Torque nuts (1) to 27 -
35 Nm and locknuts (2) to 13 - 20 Nm (installed with
Loctite 270). Reinstall and if necessary adjust the
chassis reinforcements (see section 2F01).
43. Reconnect the hoses of the compensating spool
valves and the control cables of the auxiliary spool
valve units (see section 9D01 § B).
44. Reinstall the side tank.
45. Reconnect:
- the gas-oil supply and return hoses,
- the tank-gauge harness.
46. Reinstall the transmission shaft and guard.
47. Reconnect the front differential-locking control pipe
(if fitted).
Issue 2 May 2002


48. Reinstall the left footstep. If disassembled, reinstall
the battery compartment and the right footstep.
Reconnect the battery terminals.
49. Align the wheels to their initial position. Torque
screws or nuts to values shown (see section 2G01).
Service the oil system and check the level in the
transparent tube located on the left of the centre
housing.
is special. It has a cylindrical part which the
other plugs do not. It is therefore essential to
check its position during reassembly.
50. Pour fuel into the tanks.
51. If the tractor is equipped with "Park lock" transmis-
sion locking, return the special screw on the control
panel to its initial position (see section 6F01).
53. Bleed the main brake system (see section 9I01).
54. Close the bonnet.
55. Road test all of the controls.
- leaktightness of hydraulic circuits
- leaktightness of the mating surfaces between
gearbox / intermediate housing, intermediate hou
sing / centre housing, and cover (3) of the 4 WD
system (if installed) (Fig. 7)
- presence of electronic and electrical functions
- hydraulic functions (low and high pressure)
Issue 12 May 2002

Splitting - PTO housing / Centre housing 2E01.1
2 E01 Separating PTO housing / Centre housing
CONTENTS
B. Disassembling __________________________________________ 3
C. Reassembling __________________________________________ 3
Issue 1 May 2001

2E01.2 Splitting - PTO housing / Centre housing
A . Preliminary operations 1
2
1. Drain the centre housing.
2. Mark the position of the hoses (1) and disconnect
hydraulic couplers (2) (Fig. 1).
3. Disconnect the clutch pipes (low pressure and lubrica-
tion) located on the right-hand side of the PTO housing.
4. Disconnect PTO sensors (1) and (3) (Fig. 2) on the
driving gear and the output shaft.
5. Remove the right- and left-hand guards over the
harnesses connected to the load sensors.
6. On housing (4), remove two diametrically opposite
screws (2) (Fig. 2), and replace with two guide studs
of sufficient length (230 mm approximately) (local
manufacture).
7. Assisted by an operator, or using a suitable sling,
remove support hook (1) (Fig. 3). Fig. 1
1
4
Fig. 2
Fig. 3
Issue 1 May 2001

Splitting - PTO housing / Centre housing 2E01.3
B . Disassembling (Fig. 4) C . Reassembling (Fig. 4)

8. Remove the remaining screws. Unstick and disen- 9. Clean the mating surfaces of the housings.
gage the PTO housing from the centre housing by 10. Coat the mating face of the centre housing with
levering, then remove using suitable lifting equip- sealing product - Loctite 510 or equivalent.
ment.
Note:
- The PTO housing comes out complete with the
clutch and driving/driven pinions. Shaft (28) remains
in the intermediate housing and centre housing.
28 4
12
24
20
7 2
18
3 4 12
7 18
Fig. 4
Issue 1 May 2001

2E01.4 Splitting - PTO housing / Centre housing

11. Check the presence of the locating pins on the centre
housing.
Note: The insertion dimension for the studs is
11.40 mm in relation to the surface of the centre
housing. The studs are coated with Loctite 638
or equivalent before fitting.
12. Check that piston (1) in the PTO brake slides freely.
Place the piston in abutment on cylinder (3) (Fig. 4)
to allow passing the PTO clutch during reassembly
of the housing.
13. Coat friction washer (20) with miscible grease and
apply against bearing (24) (removable-shaft PTO
only).
14. Ensure that driven pinions (7) and (18) are correctly
positioned on shaft (12) and that they rotate normally
(PTO all types).
15. Position complete housing (4) (Fig. 4) on the guide
studs installed previously.
16. Progressively slide the housing onto the studs in
order to engage the splines of shaft (28) in the clutch
splines, and those on end of shaft (12) inside bearing
(24).
17. Offer up the PTO housing to the centre housing.
Install the support hook (1) (Fig. 3). Remove the
guide studs. Install screws (2) (Fig. 3 and 4) and
torque to 480-640 Nm (apply Loctite 542).
18. Reinstall the side guards.
19. Connect pipes and sensors (1) and (3) (Fig. 2).
20. Fix the hoses to the hydraulic couplers.
21. Service the oil system and check the level on the
transparent tube located on the left of the centre
housing.
- leaktightness of mating face of PTO housing:
leaktightness of hydraulic unions,
- operation of PTO clutch, including PTO brake (all
types).
Issue 1 May 2001

Splitting - Chassis reinforcements 2F01.1
2 F01 Chassis reinforcements
CONTENTS
A. General ________________________________________________ 3
B. Installation and setting of the reinforcements (Heavy Duty

gearbox) ________________________________________________ 5
Issue 1 May 2001

2F01.2 Splitting - Chassis reinforcements
Issue 1 May 2001


3
Parts list
A . General (1) Perkins engine
(2) Valmet engine
The side-rails placed either side of the engine reinforce
the tractor chassis.
(5) Cab support
Different sections of side-rails are used (see (6) Crossbeams or side-rails
Fig. 1)
a : Type 8210-8220 tractors Torque values
- Perkins engine Screw (7): 420-560 Nm
- Full Powershift AG150 or Heavy Duty gearbox Screw (8): 480-640 Nm, plus Loctite 270 or equivalent
Note: The side-rails are installed only on trac-
tors having the "Front lifting arm" option. 1
Fig. 1
b : Type 8240 tractors
- Valmet engine Fig. 2
- Full Powershift AG150 or Heavy Duty gearbox
Tractors 8250 Fig. 3
- Valmet engine
- Heavy Duty gearbox
c : Tractors 8250-8260 4
- Valmet engine 2
- Full Powershift AG250 gearbox
5
d : Tractors 8270-8280
- Valmet engine
- Full Powershift AG250 gearbox
7
Danger
- The chassis reinforcements are heavy items. They must

be handled with care, with presence of an operator
and possibly suitable lifting equipment.
c
8
7 6
d
a
Fig. 1
Parts list Fig. 2 Fig. 3
Issue 1 May 2001

2F01.4 Splitting - Chassis reinforcements
Notes:
Tractors 8240-8250 (Valmet engine) fitted with a Heavy
Duty transmission have additional reinforcements lo- F Left side view
cated of each side of the gearbox (Fig. 2).
These comprise two crossbeams maintained as fol-
lows:
- at the front, on the gearbox spacer,
- at the rear, on the intermediate housing of the rear axle.
Tractors 8210-8220 (Perkins engine) may be fitted with
the type of reinforcements described previously, pro-
vided that the "Front lifting arm" option is envisaged. 2
Tractors 8270 and 8280 are fitted with side-rails whose 2

cross-section allows the fitting of adjustable thrust
bearings used during oscillating of the ZF 5052 front axle. 1
If access to screw (8) (Fig. 1) proves difficult, remove the
left footstep and support, and the side fuel tank.
3 4 5 6
7 8
3
F
2 1 6 9 10 19
11
10
2 4
8
1
6 11 8 7
3 Bottom view
Fig. 2 Fig. 3
Issue 1 May 2001
B . Installing and adjusting the rein-

forcements (Heavy Duty gearbox)
(Fig. 2 - 3)
Note:
See “Danger” at § A.
- Pre-assemble crossbeams (6) with screws and wa-

shers (1) and (7), spacers (4) and the nut,
- Coat the threads of screws (2) and (3) and nut (5) with
Loctite 270. Torque the screws as follows:
. Screw (2): 630 - 840 Nm
. Screw (3): 790 - 1050 Nm
- Pre-tighten screw (8) to 20 Nm
- Position the tensioner screws (9) in contact with curved
washers (10) and loosen so as to obtain a pressure
equivalent to a torque of 100 Nm on housing (19),
- Torque blocking screw (11) to 36 - 46 Nm
- Final torque screw (8) to 240 - 320 Nm.
Issue 1 May 2001

Splitting - Rear wheels / Hubs 2G01.1
2 G01 Rear wheels / Hubs
CONTENTS
- General ________________________________________________ 2
A. Presentation of the main assemblies and torque values ____ 3
B. Changing track _________________________________________ 11
C. Replacing a wheel stud __________________________________ 15
Issue 1 May 2001

2G01.2 Splitting - Rear wheels / Hubs
General Parts list (Figs 2 to 5)

(3) Stubshaft
The 8200 tractors are fitted with quite different stub axles (6) Circlip
whose specifications vary depending on the type of (7) Plastic plug
trumpet (Figs. 1 to 8) and the transmissible torque: (8) Single cone
- Flange shaft (3): Ø 82 mm (Fig. 1), (9) Washer
- Long straight shaft (3) (smooth), short or long: Ø 95 or (10) Spline
110 mm (Fig. 2 to 8). (11) Spline
(12) Adaptor
Allocations (13) Washer
Tractors 8210 and 8220:
- Flange shafts: Ø 82 mm or
- Long straight shafts: Ø 95 mm
Tractors 8240 and 8250:

- Long straight shafts: Ø 95 mm or 110 mm
Tractors 8260 to 8280:

- Long straight shafts: Ø 110 mm
Changing tread is obtained:

- either by driving then locking the taper-fitting (long
straight shaft),
- or by turning over the rim and/or the disk (flange shaft).
The material used for making the rim disk may be steel
or cast iron.
The contour of the disk is also different depending on the
buyer’s option.
Issue 1 May 2001

A . Presentation of the main assem-

blies and torque values
- Trumpet: Heavy Duty,
- Flange shaft: Ø 82 mm,
- "Steel" disc.
Tightening torque
- Nuts (1): 400 - 450 Nm
3
1
Fig. 1
Issue 1 May 2001


Type of trumpets used Tightening torque
- Heavy Duty - Nuts (4): 640 - 680 Nm
- Heavy Duty sealed - Screws (5): 350 - 460 Nm
- with composite reducer
- Long straight shaft (smooth): Ø 95 mm with single cone
and adaptor
- "Steel" disc
13
Fig. 2
Issue 1 May 2001

Type of trumpets used Tightening torque

- Heavy Duty - Nuts (4): 640 - 680 Nm
- Heavy Duty sealed - Screws (5): 350 - 460 Nm
- Long straight shaft (smooth): Ø 95 mm with single cone
and adaptor
- "Steel" disc.
5 5
4 4
Fig. 3
Issue 1 May 2001


- Trumpet: with composite reducer Tightening torque
- Long straight shaft (smooth): Ø 95 mm with single cone - Nuts (2): 250 - 350 Nm
and adaptor - Nuts (4): 640 - 680 Nm
- "Cast iron" disc. - Screws (5): 350 - 460 Nm
8 9 7
10
11
12
Fig. 4
Issue 1 May 2001

Type of trumpets used Note: The section of cone (8) is identical for figures
- Heavy Duty 2, 4 and 5.
- Heavy Duty sealed
- Long straight shaft (smooth): Ø 95 mm with single
cone
- "Cast iron" disc
Tightening torque
- Nuts (2): 250 - 350 Nm
- Screws (5): 350 - 460 Nm
F 9
Fig. 5
Issue 1 May 2001


Parts list (Figs. 6 to 8) Tightening torque
(3) Stubshaft - Nuts (2): 250 - 350 Nm
(6) Circlips - Nuts (4): 640 - 680 Nm
(7) "Plastic" plug - Screws (5): 500 - 600 Nm
(8) Single cones
(10) Spline Note: The section of the single cones (8) is identical
(11) Spline for Figures 7 and 8.
(12) Adaptor
Trumpet with dual reducer

- Long straight shaft (smooth): Ø 110 mm with single
cones and adaptor
- "Cast iron" disc.
3 2
6
10
4
11
12
Fig. 6
Issue 1 May 2001

Trumpet with dual reducer Tightening torque

- Long straight shaft (smooth): Ø 110 mm and with single - Nuts (4): 640 - 680 Nm
cones and adaptor - Screws (5): 500 - 600 Nm
- "Steel" disc
Fig. 7
Issue 1 May 2001


Trumpet with dual reducer Tightening torque
- Long straight shaft (smooth): Ø 110 mm with single - Nuts (4): 640 - 680 Nm
cones and adaptor - Screws (5): 500 - 600 Nm
- "Steel" disc
Fig. 8
Issue 1 May 2001

B . Changing track
1. Immobilise the tractor. Set the handbrake.
2. Chock the front wheels.
Setting and positioning the wheels

Flange shaft (Fig. 1)
3. Loosen nuts (1). Using a trolley jack of suitable
capacity, lift the appropriate side of the tractor. Com-
plete removal of the nuts.
4. Change the rim or the disc in order to obtain the
required track.
12 8 5 3 6
Fig. 9
Issue 1 May 2001


Long straight shaft (Fig. 2 to 8) With the wheel in the required position, fix as
5. Unblock screws (5). Using a trolley jack of suitable follows:
capacity, lift the appropriate side of the tractor. Finish Flange shaft
slackening the screws by a few turns. 10. Tighten nuts (1) (see tightening torque § A).
6. Take the "V" screw from the tractor toolbox (see Fig.
9), this is a special device for changing the tread. Long straight shaft
7. Remove the push-on "plastic" protectors from the 11. Remove "V" screw (Fig. 9). Tighten original screws
tapped holes in male single cones (8), adaptor (12) or (5) uniformly and alternately. During tightening, en-
the "cast iron" disk (depending on option). sure that male single cones (8) remain aligned on "A"
8. Lubricate, install and tighten the "V" screw uniformly (Fig. 9).
and alternately to extract taper-fitting (Fig. 9). 12. Tighten screws (5) to the torque recommended in §
9. Remove any traces of mud or dried earth on the A.
stubshaft (3). Assisted by an operator, pull or push on 13. Grease the tapped holes in the "V" screws and install
the wheel in order to slide the cone or the male single the "plastic" protectors.
cones on the shaft to obtain the sought position.
Note: Circlip (6), installed on the end of the shaft,
is to limit the axial travel of the taper fitting.
Final operation
14. Remove the chocks from the front wheels, and
Special point:
release the handbrake.
- The tapered part of male single cones (8), adaptor (12)
or the "cast iron" disk (depending on option) must not be
greased. Before assembly, clean and dry the parts. On
the other hand, the stubshaft must be lightly coated
with "Antiseize" grease or equivalent, along the full
length, in order to avoid any corrosion spots and thus
facilitate travel movement of the wheel during tread-
changing.
Danger
- When removing tractor wheels, use lifting equipment

and a suitable sling.
Issue 1 May 2001

Steel wheels, reinforced axle, hub Ø 203 mm

Theoretical treads (mm)
1 1600
2 1804
3 2100
4 2304
1 2 3 4
Theoretical treads (mm)
- A (M18)=40 to daNm A
Fixed steel wheels, long straight shaft

Short shaft Long shaft
Min. Max. Min. Max.
Theoretical tread 1
reinforced axle 1636 2006 1636 2600
sealed trumpet 1658 2020 1658 2664
composite Ø 95 1702 2124 1702 2624
Theoretical tread 2
reinforced axle 1960 2330 1960 2924
sealed trumpet 1982 2344 1982 2988
composite Ø 95 2026 2448 2026 2948
Tightening torques
- B = 35 to 46 daNm
- C = 64 to 68 daNm
Theoretical tread 3
composite Ø 110 1632 2054 1632 2554
Dual reductions 1674 2052 1664 2552
Theoretical tread 4
composite Ø 110 1954 2376 1954 2876
Tightening torques
- C = 64 to 68 daNm
- D = 50 to 60 daNm
10951.3 10951.4
1 C 2 4 3 C
B D
Issue 1 May 2001

Wheels fitted with cast-iron disk, hub with two single cones
Short shaft Long shaft
Min. Max. Min. Max.
Straight shaft Ø 95
Theoretical treads1 1490 1912 1490 2412
2 1810 2232 1810 2732
3 1962 2384 1962 2884
4 2294 2716 2294 3216
Theoretical tread
- B = 35 à 46 daNm
- C = 64 à 68 daNm
- E = 25 à 35 daNm
Theoretical tread 5
composite Ø 110 1418 1840 1418 2340
Theoretical tread 6
composite Ø 110 1744 2166 1744 2666
Theoretical tread 7
composite Ø 110 1896 2318 1896 2818
Theoretical tread 8
composite Ø 110 2222 2644 2222 3144
Tightening torques
- C = 64 to 68 daNm
- D = 50 to 60 daNm
- E = 25 to 35 daNm
10951.5
10951.2
2 3 6 7
E E
C C
1 B 4 5 D 8
Issue 1 May 2001

C . Replacing a wheel stud

15. Drive out the bad stud.
16. Clean the new stud and its housing in the hub.
17. Coat the splined part of the replacement stud lightly
with Loctite 270 or equivalent.
18. Fit the new stud using a bronze drift and a suitable
hammer.
Issue 1 May 2001

3 . ENGINE
Contents
3 A01 GENERAL
3 B01 FLYWHEEL AND DAMPERS
3 C01 SPACER
3 C02 SPACER - POWER SHUTTLE
Issue 2 May 2002

Engine - General 3A01.1
3 A01 General
CONTENTS
A. Introduction ____________________________________________ 3
B. Main specifications _____________________________________ 4
C. Viscostatic fan __________________________________________ 8
Issue 1 May 2001

3A01.2 Engine - General
Issue 1 May 2001

A . Introduction
This section is limited to providing general information on
the engines fitted in the 8200 range.
To obtain all information about technical data, adjust-

ments, disassembly and assembly procedures, refer to
the following publications:
1. Perkins engines
- Workshop manual covering all Perkins diesel engines
in the 4.41, 900 and 1000 series for all Massey Ferguson
tractors and published by AGCO with the following
reference numbers:
. 1857075 M1 in English
. 1857076 M1 in French
. 1857077 M1 in Spanish
. 1857078 M1 in German
. 1857243 M1 in Italian
2. Valmet engines
- Workshop manual covering all 620 DS and 634 DS type
engines published in English by Valmet, reference
number 836 640 364.
- Workshop manual specific to the 645 engine published
in English by Valmet, reference number 836 841 000.
Issue 1 May 2001

B . Main characteristics
Tractors fitted with Perkins engine
8210 8220
Type of engine 1006-60TWG 1006-60TWG
Perkins engine list no. YH31441 YH31441
No. of cylinders 6 6
Bore (mm) 100 100
Stroke (mm) 127 127
Capacity (litre) 6 6
Compression ratio 17.25/1 17.25/1
DIN (kw) at 2200 rpm 145 (107) 155 (114)
Max. torque (Nm) 620 663
at (rpm) 1400 1400
Idle speed (rpm) 950 950
Nominal speed (rpm) 2200 2200
Max. speed at no load (rpm) 2354 2354
Injection pump
Make and type Lucas DP203 Lucas DP203
Boost control Yes Yes
Reference 8921A512T 8921A283T
Code 2644K622 2644D133
Pump code letter FH DH
Governor spring code 1 1
Rotation Clockwise Clockwise
Static timing angle 7º 6º
Engine position TDC TDC
Pump / engine check angle Timing (using a Timing (using a
measuring gauge) measuring gauge)
Injectors
Make Lucas Lucas
Code KP KH
Nozzle holder 2645A318 2645A314
Nozzle 2645A636 2645A630
New and service calibration 294 atm 294 atm
Suction system Turbowastegate Turbowastegate
intercooler
Min. boost pressure at

2200 rpm at full load (mm Hg) 1035 1035
(Kpa) 138 ± 5 138 ± 5
(PSI) 20.03 20.03
Valve spring Single Single

Valve seat insert (inlet / exhaust) Yes Yes
Valve angle (degree) (in / ex) 45 / 45 30 / 30
Valve clearance (mm) (in / ex) 0.2 / 0.45 0.2 / 0.45
Oil cooler Yes Yes
No. of thermostats 2 2
Opening temp. (begin / full) 82º / 96º 82º / 96º
Fan Viscostatic Viscostatic
Piston cooling nozzle Yes Yes
Oil filter 2 2
Fuel filter 2 2
Issue 1 May 2001

Tractors fitted with Valmet engine

8240 8250
Type of engine 620DSRAE 634DWE
Perkins/Valmet engine list no. V620DSRAE V634DSBAE
Bore (mm) 108 108
Stroke (mm) 120 134
Capacity (litre) 6.6 7.4
Compression ratio 16.5 / 1 16.5 / 1
DIN (kw) at 2200 rpm 170 (125) 185 (136)
at (rpm) 1400 1400
Injection pump
Make and type Stanadyne DB4 Bosch type P
Reference DB4629/5347 PES6P
Code 5347 or 5535 3382
Pump code letter A G
Governor spring code - -
Injectors
Make Stanadyne Stanadyne
Code 446 876
Nozzle holder M34446 M33876
Nozzle M34447 M33877
Suction system Turbo intercooler Turbo intercooler
(Kpa) 120 120
(PSI) 17.42 17.42

Valve seat insert (inl / ex) Yes Yes
Oil cooler Yes Yes
Oil filter 2 2
Fuel filter 2 2
Issue 1 December 2000


8260 8270
Type of engine 634DSBIE 645DSBIE
Perkins/Valmet engine list no. V634DSBIE V645DSBIE
Bore (mm) 108 108
Stroke (mm) 134 145
Capacity (litre) 7.4 8.4
Compression ratio 16.5 / 1 16.5 / 1
DIN (kw) at 2200 rpm 210 (154) 230 (169)
at (rpm) 1400 1400
Injection pump
Make and type Bosch type P Bosch type P
Reference PES6P PES6P120D
Code 3382 3382
Pump code letter C A
Governor spring code - -
Injectors
Make Stanadyne Bosch
Code 876 -
Nozzle holder M33876 DLLA143P45
Nozzle M33877 P495
Suction system Turbo intercooler Turbo intercooler
(Kpa) 170 150
(PSI) 24.67 21.77

Valve seat insert (inl / ex) Yes Yes
Oil cooler Yes Yes
Oil filter 2 2
Fuel filter 2 2
1
May 2002
8280
Type of engine 645DSBIE
Perkins/Valmet engine list no. V645DSBIE
No. of cylinders 6
Bore (mm) 111
Stroke (mm) 145
Capacity (litre) 8.4
Compression ratio 16 / 1
DIN (kw) at 2200 rpm 260 (191)
Max. torque (Nm) 1150
at (rpm) 1400
Idle speed (rpm) 950
Nominal speed (rpm) 2200
Max. speed at no load (rpm) 2354
Injection pump
Make and type Bosch type P
Boost control Yes
Reference PES6P120A
Code 3382
Pump code letter -
Governor spring code -
Rotation Clockwise
Static timing angle 14º
Engine position TDC
Pump / engine check angle Timing (using a measuring gauge)
Injectors
Make Bosch
Code -
Nozzle holder DLLA143P455
Nozzle P495
New and service calibration 250 atm
Suction system Turbo intercooler
2200-rpm at full load (mm Hg) 1275
(Kpa) 170
(PSI) 24.67
Valve spring Single

Valve seat insert (inl / ex) Yes
Valve angle (degree) (in / ex) 35 / 45
Valve clearance (mm) (in / ex) 0.35 / 0.35
Oil cooler Yes
No. of thermostats 2
Opening temp. (begin / full) 82º / 96º
Fan Viscostatic
Piston cooling nozzle Yes
Oil filter 2
Fuel filter 2
Issue
Issue 21 May 2002
December 2000
C . Viscostatic fan
6
Description b
The engines are fitted with a cooling fan equipped with a
viscostatic coupling. This device permits a gain in power
7 2
in the order of 2 to 3 horsepower.
The viscostatic coupling comprises three main parts:

- the driving part driven by the engine and composed of 5 1
a shaft (1) integral with a plate (2) fitted with annular
grooves,
- the driven part constituted by a hub (6) receiving the fan 3
and the body (7) and equally fitted with annular grooves,
- the regulating section comprising a thermostatic spring
(3) that controls valve (4). 4 a
The centre of the device contains a tank (5) filled with a

viscous silicone fluid.
Operation
When the temperature of the air passing through the
radiator reaches a preset value, thermostatic spring (3)
acts upon valve (4) which opens port a. The liquid is
directed by centrifugal force to the annular grooves of hub
(2) and body (7). The torque is transmitted through the
internal friction of the extremely viscous liquid and its
adherence to the inner walls. The fan is thus driven and
permits a better air cooling of the radiator.
The speed of the fan varies continuously over the whole

range of regulation depending on the temperature.
When the temperature of the air passing through the

radiator drops, the spring closes the valve and stops the
liquid from reaching the friction area. The fluid gradually
returns to the tank (5) via channel b, the fan thus
becomes de-clutched, leaving only residual resistive
torque.

Engine - Flywheel 3B01.1
3 B01 Flywheel and dampers
CONTENTS
A. General ________________________________________________ 2
B. Removing and refitting the damper _______________________ 2
C. Removing and refitting the flywheel and bearing __________ 5
D. Replacing the starter ring gear ___________________________ 6
E. Service tools ___________________________________________ 6
Issue 1 May 2001

8200-ERIES TRACTORS
3B01.2 Engine - Flywheel
A . General B . Removing and refitting the dam-

The “Luk” type damper (3) installed on the flywheel is per (Figs 1 - 2)
secured by splines onto main shaft (6). It provides a
Removal
flexible connection between the engine and gearbox and
1. Split the tractor between the engine and the gearbox
damps any vibrations caused by the transmission. It is
(see section 2B01).
installed on 8200-Series tractors fitted with the Full
2. Remove screws (4).
Powershift (AG150 - AG250) and Heavy Duty gearboxes
3. Remove damper (3).
AG 150 - AG250 versions (Fig. 1)
Refitting
- Bearing (1) fit in the flywheel is sealed on both faces.
4. Check the parts and replace any that are faulty.
The seal is to give better reliability. The bearing supports
Special point
main shaft (6) and does not itself rotate. Its position in
If the operation consists in changing the damper, also
the flywheel remains variable depending on the type of
replace the bearing (see § C).
gearbox and the engine type. It may be bearing on a
5. Lightly coat the splines of the damper hub with GN
shoulder of the flywheel, or on a circlip.
grease + Molycote. Refit and centre the damper using
- Spring (5) maintains the main shaft in position.
service tool, P/N 3378262M1 (see § E) , the offset on
- The damper, the main shaft and the bearing form an
the hub pointing towards the gearbox (Figs. 1 - 2).
assembly rotating at the speed of the flywheel.
6. Lightly coat the threads of screws (4) with Loctite 270
and torque to following values:
Heavy Duty version (Fig. 2) - Full Powershift gearbox (AG150-AG250):
- The principle of installation and operation remain similar. . M10 screws: 68 - 92 Nm.
Note, however, that: - Heavy Duty gearbox:
. the spring is excluded, since the main shaft installa- . M12 screws: 102 - 138 Nm
tion differs from that shown for the previous version; 7. Reassemble the tractor between the engine and
. the bearing has one position only, and is in contact gearbox (see section 2B01).
with the shoulder of the flywheel.
Note
The part number of damper (3) differs according to the
version.
Issue 1 May 2001

Full Powershift gearbox AG150 Flywheel Distance btw. Perkins Valmet

Parts list centres of A
(1) Bearing attachment holes "T"
(2) Starter ring gear 2 4 3 5 6 7
(3) Damper A 86 mm - X
(4) Screw
(5) Spring B 107,95 mm X -
(6) Main shaft
(7) Gearbox
8
1
T
Full Powershift gearbox AG250 Flywheel Distance btw. centres Valmet

Parts list of attachment holes "T"
(1) Bearing
(2) Starter ring gear A 86 mm X
(3) Damper
(4) Screw B 94 mm X
(5) Spring
1 2 4 3 5 6 7 (6) Main shaft
(7) Gearbox
B (8) Circlip Parts list
Fig. 2
Fig. 1
Issue 1 May 2001

Heavy Duty gearbox Flywheel Perkins Valmet

Parts list
(1) Bearing A - X 1 2 A 4 3 6 7
(2) Starter ring gear
(3) Damper B X -
(4) Screw
(6) Main shaft
(7) Spacer / Gearbox
2 A-B 1 3 B
Parts list Fig. 1
Fig. 2
Issue 1 May 2001

C . Removing and refitting the fly-

wheel and the bearing
Removal
8. Split the tractor between the engine and the gearbox
(see section 2B01).
9. Lock the flywheel using a suitable fixture.
10. Remove the damper (see § B).
11. Remove the flywheel.
12. Drive out bearing (1) (Figs. 1 - 2)
Remarks
- On certain types of installation (Figs. 1 - 2) , extrac-
tion of the bearing is possible without removing the
flywheel, using a slide hammer.
- If installing a type A flywheel and a Full Powershift
gearbox AG250, replace circlips (8) and the bearing
(Fig. 1)
Refitting
13. Check the parts, replacing any that are defective.
14. Screw two guide studs opposite one another into the
holes used for attaching the flywheel on the crank-
shaft.
15. Refit the flywheel.
Note: Depending on the type of fixture, fit bear-
ing (1) before or after refitting the flywheel, using
a suitable mandrel (dia. 62 mm, corresponding
to the hole in the external cage of the bearing).
16. Remove the guide studs. Torque the screws to
140 Nm (Perkins engine). For the screw torquing
values on Valmet flywheels, refer to the engine
repair manual.
17. Refit the damper (see § B).
18. Reassemble the tractor between the engine and
gearbox (see section 2B01).
Issue 1 May 2001

8200-ERIES TRACTORS
D . Replacing the starter ring gear

Disassembly
19. Split the tractor between the engine and gearbox
(see section 2B01).
20. Remove the damper (see § B).
21. Remove the flywheel (see § C).
22. Using a suitable-strength drill bit, drill a hole (Ø 5) to
the same depth as the width of ring gear (2) to avoid
touching the flywheel. Use a suitable cold chisel to
split the ring gear (Fig. 3).
Note: When breaking the ring gear, provide
some protection to stop splinters of material.
Ø5
2
Reassembly
23. Heat a new ring gear to 245° C in a furnace only.
Fig. 3
24. Install ring gear (2) on the flywheel, with the teeth
opening pointing towards the starter, and fit rapidly
into abutment. Allow to cool slowly.
25. Refit the flywheel (see § C) and the damper (see §
B).
E . Service tools
Tool available in the AGCO network
- 3378262M1 - Damper centring tool (Fig. 4)
Fig. 4
Issue 1 May 2001

Engine - Spacer 3C01.1
3 C01 Spacer
CONTENTS
A. Removing and refitting the spacer ________________________ 2
B. Service tools ___________________________________________ 6
Issue 1 May 2001

3C01.2 Engine - Spacer
A . Removing and refitting the spacer

5
General
Type-8210 - 8220 -8240 and 8250 tractors may be fitted
10
with either a Heavy Duty gearbox or a Full Powershift
gearbox.
This section is limited to parts concerning the Heavy
Duty gearbox. The Heavy Duty gearbox comprises two
casings:
- the main housing which encloses the pinions, the
shafts and the input unit,
- the spacer, providing the connection with the engine.
1. Split the tractor between the engine and gearbox (see 16
62 7
section 2B01).
2. Disassemble the four screws (dia. 10 mm) on each Fig. 1
front Silent Block on the right- and left-hand engine
bearers.
Note: If the side fuel tank was not removed during
the separation operation, drain the gas-oil and
remove the footstep in question then the fuel
tank.
3. Raise and block the cab. Remove the cab supports
(right and left) and any adjacent parts likely to obstruct
removal of the spacer. Drain the gearbox.
4. Install protector, P/N 3378012M2 (see § B) on main
shaft (7) (Fig. 1).
5. Remove screws (5) (62) in order to facilitate unsticking
66
of closure disk (10) (Fig. 1). Use the tapped holes and
two screws of sufficient length to extract and main-
tain the disk before removing it.
6. Scrap seal (8) (Fig. 6).
7. Remove lube tube (17) from the engine clutch located
under the gearbox between spacer (16) and interme- Fig. 2
diate housing (19) (Fig. 4).
8. Remove tubes (20) (65) (70) and union (66) (Figs. 2 -
3).
9. Remove the clutch using locally procured tooling (see
section 4A01).
70
65
20
Fig. 3
Issue 1 May 2001

Loctite 5206
1 2 3 16 3 1
4 4
3 3
5 5
6 6
7 7
3 3
3 8 9
16 17
19
A A -A
F
Fig. 4
Issue 1 May 2001

Issue 1 May 2001

Removing the spacer (Fig. 4)

Note
The cab inner floor contains an access door. If neces- P
sary, use the latter for accessing the top screws securing
the spacer to the gearbox.
10. Remove screws (1) (4) (5) (7) and nuts (8) on spacer
(16). Remove washers (3).
11. Assisted by an operator, unstick and remove the P
spacer.
12. If necessary, extract studs (9) from the gearbox
housing.
Refitting
13. Clean the parts and replace any that are defective. P
14. Remove all traces of old Loctite from the mating
surfaces. Coat the mating face of the spacer (gear- Fig. 5
box side) with Loctite 5206 or equivalent.
15. Ensure presence of locating pins (6) (Fig. 4).
Note: Studs (9) are smeared with Loctite 270
and locked into the gearbox.
16. Refit the spacer. Coat the screws and nuts with
Loctite 270 and torque to following values:
- screws (1) and nuts (2): 150 - 200 Nm,
- screws (4) (5) (7) and nuts (8): 100 - 130 Nm.
17. Coat union (66) with Loctite 542 then screw onto the
spacer (Fig. 2).
12
Final operations 63
18. Refit the clutch and tubes. Reverse operations 7 to
8
9.
19. Ensure the presence of centring pins on the closure 10
disk, and shims on the clutch assembly. Replace
O’rings (8) (Fig. 6).
Fig. 6
20. Coat surrounds P of the tapped holes with
Loctite 5206. (Fig. 5).
21. Grease the lip of the seal. Fit the shaft with the
protector used during disassembly. Screw two guide
studs in opposing locations on the spacer, and
reinstall closure disk (10) and finger (63) in the slot in
pump body (12) (Fig. 6).
Install long screws (62) in the same holes as those
provided for the centring pins. Install screws (5) (Fig.
1). Torque all screws to 25 - 35 Nm.
Issue 1 May 2001


22. Refit the cab supports and any neighbouring parts
that were removed. Coat the screws for the supports
with Loctite 270 then insert and torque to 200-
260 Nm. If it was removed, reinstall the access door
in the cab floor. Service the oil in the sumps and
check level on sightglass located on left of centre
housing.
23. Remove the props and set back the cab. Torque up
the screws (Ø 10 mm) on each Silent Block support
to 50 - 70 Nm.
25. Check the following:
- leaktightness of hydraulic connections and the
mating face;
- operation of the engine clutch.
Fig. 7
B . Service tools
- 3378012M2 - Protector (Fig. 7)
Issue 1 May 2001

3 C02 Spacer - Power Shuttle
CONTENTS
A. Removing and refitting the spacer ________________________ 2
B. Service tool ____________________________________________ 6
Issue 1 May 2001

A . Removing and refitting the spacer

5
General
8210 - 8220 - 8240 and 8250 series tractors equipped
10
with a Power Shuttle are fitted with a spacer (16) (Fig.
1) inserted between the engine and the gearbox. The
design of this spacer is similar to that fitted on the 8200
equipped with a mechanical reverse shuttle (see sec-
tion 3C01).
However, it should be noted that its closure disk has a
different profile so that it can be fitted with the
hydromechanical assembly of the power shuttle.
Preliminary operations 62 7
16
1. Split the tractor between the engine and gearbox (see
section 2B01). Fig. 1
2. Disassemble the four screws (dia. 10 mm) on each
front Silent Block on the right- and left-hand cab
bearers.
Note: If the side fuel tank was not removed during
the separation operation, drain the gas-oil and
remove the footstep in question then the fuel
tank.
3. Raise and block the cab. Remove the cab supports
(right and left) and any adjacent parts likely to obstruct
removal of the spacer. Drain the gearbox.
4. Install protector 3378012M2 (see § B) on main shaft
(19) (Fig. 1).
66
5. Remove screws (1) (2) (Fig. 1).
Special point
- In order to facilitate unsticking of closure disk (4)
(Fig. 1), use the tapped holes and two screws of
sufficient length to extract and maintain the disk
before removing it. Fig. 2
6. Scrap seal (3) (Fig. 6).
7. Remove lube tube (78) from the power shuttle clutches
located under the gearbox between spacer (16) and
intermediate housing (19) (Fig. 4).
8. Remove tubes (31) (86) (optional) and (74) (87) (94)
and finally union (66) (Figs. 2 - 3).
9. Remove the clutch from the power shuttle (optional)
using the locally-made tool (see section 5B06).
70
65
20
Fig. 3
Issue 1 May 2001

Loctite 5206
1 2 3 16 3 1
4 4
3 3
5 5
6 6
7 7
3 3
3 8 9
16 17
19
A A -A
F
Fig. 4
Issue 1 May 2001

Issue 1 May 2001

Removing the spacer (Fig. 4)

Note
The cab inner floor contains an access door. If neces- P
sary, use the latter for accessing the top screws securing
the spacer to the gearbox.
10. Remove screws (1) (4) (5) (7) and nuts (8) on spacer
(16). Remove washers (3).
11. Assisted by an operator, unstick and remove the P
spacer.
12. If necessary, extract studs (9) from the gearbox
housing.
Refitting
13. Clean the parts and replace any that are defective. P
14. Remove all traces of old Loctite from the mating
surfaces. Coat the mating face of the spacer (gear- Fig. 5
box side) with Loctite 5206 or equivalent.
15. Ensure presence of locating pins (6) (Fig. 4).
Note: Studs (9) are smeared with Loctite 270 and
locked into the gearbox.
16. Refit the spacer. Coat the screws and nuts with
Loctite 270 and torque to following values:
- screws (1) and nuts (2): 150 - 200 Nm,
- screws (4) (5) (7) and nuts (8): 100 - 130 Nm.
17. If necessary, coat union (96) with Loctite 542 then
screw it onto the spacer (Fig. 2).
Issue 1 May 2001


Final operations
18. If necessary, refit the front clutch of the power
shuttle. Reconnect the tubes. Refit the clutch and
tubes. Reverse operations 7 to 9.
19. Ensure the presence of centring pins G (Fig. 1) on the
closure disk (4) and of shims lubricating pump cover.
Replace O'ring (3) (Fig. 6).
20. Coat surrounds P of the tapped holes with
Loctite 5206. (Fig. 5).
21. Grease the lip of the seal fitted on the closure disk.
Fit the shaft with the protector used during disas-
4
sembly.
Screw two guide studs in opposing locations on the
spacer, and reinstall closure disk (4) and finger (2) in
the slot in pump body (1) (Fig. 6).
Install long screws (2) in the same holes as those
provided for the centring pins. Install screws (1) (Fig.
1). Torque all screws to 36 - 46 Nm.
22. Refit the cab supports and any neighbouring parts
that were removed. Coat the screws for the supports
with Loctite 270 then insert and torque to 200-
260 Nm. If it was removed, reinstall the access door
in the cab floor. Service the oil in the sumps and
check level on sightglass located on left of centre
housing.
23. Remove the props and set back the cab. Torque up
the screws (Ø 10 mm) on each Silent Block support
to 50 - 70 Nm.
24. Reassemble the tractor between the engine and 3 2 1
25. Check the following:
- tightness of hydraulic unions and mating face.
- operation of the power shuttle.
Fig. 6
B . Service tool
- 3378012M2 - Protector (Fig. 7)
Fig. 7
Issue 1 May 2001

4 . CLUTCH
Contents
4 A01 PRESSURE LOADED CLUTCH
Issue 1 May 2001

Clutch - Pressure loaded 4A01.1
4 A01 Pressure loaded clutch
CONTENTS
- General ________________________________________________ 2
A. Removing and refitting the closing plate and replacing

the lip seal and the O'ring _______________________________ 7
B. Removing and refitting the clutch ________________________ 8
C. Adjusting the clutch ____________________________________ 10
D. Disassembling and reassembling the clutch _______________ 11
E. Removing and refitting the control valve __________________ 13
F. Service tools ___________________________________________ 13
Issue 1 May 2001

4A01.2 Clutch - Pressure loaded

Operation
General Clutching
Description When the clutch pedal is released, the hydraulic valve
located on the right-hand side of the gearbox delivers a
The engine clutch system installed on the Heavy Duty
pressure of 17 bar which moves piston (46); the latter in
gearboxes equipping type 8210 - 8220 - 8240 and 8250
turn compresses intermediate plates (45) against discs
tractors is of the oil-immersed multidisc type.
(44), entraining clutch shaft (33).
The hydraulic clutch - which transmits the movement -
The valve monitors the smoothness and progressive
is similar to a Direct-drive clutch but is larger.
engagement of the clutch, and modulates the pressure
This clutch is controlled by an hydraulic valve mounted
applied on the piston.
on the right-hand side of the gearbox, itself actuated by
the clutch master-cylinder.
Release
Once the pressure is no longer applied, piston (46) is
Construction pushed back by Belleville washers (42), and intermedi-
The clutch assembly is installed between the flywheel ate plates (45) are no longer in contact with the discs.
and the transmission shaft of the Dynashift unit. The lubrication and cooling flow to the discs is interrupted
Main shaft (7) penetrates closing plate (10) which sepa- in the declutched position to avoid driving the discs by
rates the flywheel from the transmission fluid. Shaft (7) drag effect. For the same reason, the discs have a face
is in constant engagement with the damper fixed on the curved to facilitate disengagement.
flywheel.
Due to the splines, it is rotates together with clutch
housing (23) which includes intermediate plates (45) and
which houses piston (46).
Drive hub (37) comprising discs (44) is integral with
clutch shaft (33).
Fixed unit (12) has two functions:
- it receives the 17-bar pressure,
- it serves as the lubrication and cooling pump body
(30 l/min, rated pressure 0.4 bar).
The pump supply is obtained from the centre housing via
a 500-micron strainer (replaceable), tube (17) placed
under the transmission, and a second tube (20).
Depending on the type, the clutch assembly comprises
a different number of discs and intermediate plates:
- 8210 and 8220: 6 discs, 6 intermediate plates
- 8240: 7 discs, 7 intermediate plates
- 8250: 8 discs, 8 intermediate plates.
Discs (44) have a paper lining for smoother engagement
and reduced noise.
Issue 1 May 2001

Clutch - Pressure loaded 4A01.3 Overall view
Parts list (50) Bearing

(1) O’rings (51) Bush
(2) Backup washers (52) Seal rings
(3) Splined bush (53) Lubricating pump 68
(4) Locking ring (54) Screw
(5) Screw (55) Bearing
(6) Washer (56) Circlip
(7) Main shaft (57) Lip seal 69 64
(8) O’ring (58) Circlip
(9) Shim(s) (61) Centring pin
(10) Closing plate (62) Screw
70 65
(11) Pump cover (63) Finger
(12) Pump body (64) Union
(13) Dynashift cover (65) Tube
(14) O’ring (66) Union 67 73
(15) O’rings (67) Diagnostic connector
(16) Spacer (68) 1.5-bar valve
(17) Tube (69) O’ring
(18) Screw (70) Tube
(19) Flange (71) O’ring
(20) Tube (72) Union
(21) Spacer casing (73) Plug
(74) 500 micron strainer 66
(22) Screw
(23) Clutch housing (75) O’ring
(24) Pin (76) Plug
(25) Flange (77) Indexing port 71
(26) Screw
(27) Dust shield
(28) O’ring Fig. 1
(29) O’ring 72
(30) Seal holder
(31) Screw Fig. 1A
(32) Direct-drive shaft
(33) Clutch shaft 30 26 30 29 28
(34) Circlip Fig. 2
(35) Washer
(36) Bearing
(37) Drive hub 17
A
(38) Screw
(39) Clutch cover
(40) Bearing 25 74
(42) Belleville washers
(43) Circlip
(44) Disks 27 75
(45) Intermediate plates A
(46) Piston
(47) Clutch assembly 31
(48) Seal
(49) Seal
76 A-A
Parts list Fig. 1A Fig. 2

Fig. 1
Issue 1 May 2001

Overall view
58 56 11 55 56 8 54 12 53 77 23 46 39 18
42
B
21
58
43
47
40
2 7
37
34
1 4
B 33
32
3
57 52 10 24 9
35
7
A 36
23 A
44
10
61
51 50
C
12
63 5 6 62 16 15 17 38 19 20 22 14 48 49 45 13
10
Fig. 1A
Issue 1 May 2001

Exploded View
21
35
13
18 16
32 63
33 8
34 10
39 61
36 6
37 62
44
45
73
68
57 69
4
67 66
58 64
2
1
70 65
2
71
3
72 27
58
6
5
40
42 25
52 14
50 20
51 15
43 17
7 19
46
38
48
49
29
54 31
30
55 22
56 24
23
12 74
53
11 75
9
28 76
26
Fig. 2
Issue 1 May 2001 Parts list Fig. 1 Fig. 1A

Issue 1 May 2001

A . Removing and refitting the clos-

ing plate and replacing lip seal (57) P
and O’ring (1)
Removal
1. Split the tractor between the engine and gearbox P
(Section 2B01).
2. Drain the gearbox.
3. In order to facilitate unsticking of closing plate (10),
install two jacking screws of sufficient length in the
tapped holes in the closing plate, then remove the
disc.
4. Remove front circlips (58) and remove splined bush P
(3), backup washers (2) and seal (1).
5. Extract seal (57). Fig. 3
Refitting
6. Fit seal (57) using a suitable fixture.
7. Place O’ring (1) between rings (2). Reinstall splined
bush (3). Replace front circlip (58) and position
correctly in the groove.
8. Ensure presence of centring pins (61) and shims (9).
9. Replace O’ring (8).
10. Coat tapped-hole surrounds P with Loctite 5206 (Fig.
3).
12
11. Grease the lip of seal (57). Place protector P/N
3378012M2 (see § F) on shaft (7). Screw two guide
studs in opposing locations on the spacer and 63
reinstall closing plate (10), with finger (63) in the slot
of pump body (12) (Fig. 4).
12. Install long screws (62) in the same holes as those 10
provided for centring pins (61). Install screws (5),
Fig. 4
13. Service the oil in the sumps and check on the
sightglass located on the left of the centre housing.
gearbox (see section 2B01) and check adjustment of
the chassis reinforcements (if installed) (see section
2F01).
1
Issue 2 2001
May 2002

20. Remove tube (20).
B . Removing and refitting the clutch 21. Remove union (72) and tubes (70) and (65).
22. Remove clutch (47) using the locally manufactured
Removal
tool (Fig. 5 and § F).
(see section 2B01).
16. Drain the gearbox and the intermediate housing. Refitting
Note: Visually identify the contour of the plugs. 23. Replace O’rings (14) and (69).
17. If the tractor is fitted with chassis reinforcements, it 24. Replace O’rings (15) and (71).
may be necessary to remove the right-hand rein- 25. Refit tubes (20) (65) (70) and union (72).
forcement. 26. Coat feeler gauges (9) used at operation 45 with
18. Remove tube (17). miscible grease, and place on pump cover (11).
19. Remove closing plate (10). Repeat operation 3. 27. Refit feed tube (2) (Fig. 11).
32 R
47
32
7 33
Fig. 5
Issue 1 May 2001

28. If disassembled, coat finger (63) with Loctite 270

and screw into closing plate (10).
29. Ensure presence of centring pins (61). Replace
O’ring (8).
30. Clean and coat hole surrounds P with Loctite 5206 10 11 36 13
(Fig. 3).
31. Refit the closing plate. Repeat operation 11.
32. Fit screws (5) (62) with washers (6) then insert and
Note: The two long screws (62) are installed
with centring pins (61).
33. Replace O’rings (28) (29). Reinstall seal holder (30).
Install screws (31) and torque to 14 -20 Nm.
34. Replace dust shield (27). Reinstall tube (17) and
flanges (19) and (25), ensuring that groove G in
flange (25) is aligned with the face of seal holder (30)
(Fig. 7). Tighten screw (26). Torque screws (31) and
(38) to 25 -3 5 Nm. If disassembled, reinstall and
adjust the right-hand chassis reinforcement (see
section 2F01).
35. Service the oil in the sumps and check on the
7
is special. It has a cylindrical part that is missing
on the other plugs. It is therefore essential to
observe the position during reassembly.
gearbox (Section 2B01).
37. Bleed the clutch control valve (see section 9I01) and
check the clutch lubrication pressure (see section
9N01).
38. Check the operation of the direct-drive clutch.
39. Road-test the engine clutch.
40. Check the leaktightness of flange (19) and seal J1 = 0,60 / 0,80 mm
holder (30).
Fig. 6
Fig. 7
G
26 29
28
17
25
30 27
Issue 1 May 2001

C . Adjusting the clutch

41. Remove the clutch (see § B) and Direct-drive shaft
(32).
42. Temporarily refit clutch assembly (47) onto clutch
shaft (33), using the tool used at operation 22 (and
temporarily excluding the direct-drive shaft). Place 2
mm feeler gauge (9) on cover (11).
43. Grease the lip of seal (57). Slide protector 3378012M2
(see § F) over the splines of shaft (7) to protect the
seals. Screw two studs in opposing locations on the
spacer and reinstall closing plate (10). Install and
tighten a few of the screws.
Adjustin
g
Note: This operation consists in obtaining an axial
clearance of J1 = 0.60 to 0.80 mm between pump
cover (11) and closing plate (10) (Fig. 6)
44. Install a dial-gauge comparator on the end of shaft (7)
and check the play by moving the clutch assembly
sideways.
Note: Ensure bearing (36) in the clutch assembly
is fully abutted against cover (13) before pulling
on the shaft (Fig. 6)
45. Remove closing plate (10); depending on the meas-
ured clearance, select thickness of feeler gauges (9)
to obtain a clearance J1 of between 0.6 and
0.8 mm.
Final operations
46. Remove the clutch and reinstall Direct-drive shaft
(32), turning the undercut part (designed to receive
spring R towards the rear axle (Fig. 5).
47. Proceed to final refitting of the clutch assembly (see
§ B).
Issue 1 May 2001

D . Disassembling and reassembling

the clutch 7
Disassembly
48. Remove the clutch (see § B) and place in the vertical 23 58
position, that is, cover (39) resting on a suitable
fixture.
49. Remove front circlip (58). Remove bush (3), rings (2)
and seal (1).
50. Remove circlip (56). Remove pump cover (11) and
bearing (55).
51. Extract lubrication pump (53) from pump body (12).
42
Separate the pump body from clutch housing (23).
52. Remove seal rings (52).
53. If necessary, extract bush (51) and disassemble 1.5-
bar valve (68).
54. Separate clutch housing (23) from cover (39). Re- Fig. 8
move discs (44) and intermediate plates (45).
55. Remove drive hub (37).
56. If necessary, extract bearing (36).
57. Using a suitable fixture (see § F) , compress Belleville
washers (42). Remove rear circlip (58) (Fig. 8).
Remove locking ring (4). Untension the Belleville 23
washers.
58. Separate clutch housing (23) from shaft (7). Remove
the Belleville washers.
59. Remove piston (46). If necessary, extract bearing
(50).
60. If necessary, remove circlip (43) and bearing (40).
Reassembly
46
61. Ensure presence of pin (24).
62. If it was removed, refit bearing (50), using a suitable
fixture. Fig. 9
63. Install seals (48) (49).
64. Install piston (46).
Remark
Note: The angular position of the piston de-
On type 8210 -8220 -8240 and -8250 tractors fitted with
pends on that of the lubrication ports of clutch
the Heavy Duty gearbox, the hydraulic engine clutch
housing (23). Align the indexing holes drilled in
comprises six Belleville washers.
the unit and piston (Fig. 9). Proceed by inserting
a suitable diameter pin.
66. Fit Belleville washers (42) on shaft (7) (Fig. 8).
Finish refitting the piston by progressively tap-
ping around the edge, using a plastic hammer.
Ensure no seal fragment remains after assembly.
65. If it was removed, refit bearing (40), using a suitable
fixture, the sealed face pointing towards the Dynashift.
Fit circlip (43).
Issue 1 May 2001


67. Slide clutch housing (23) onto clutch shaft (7).
68. Compress the Belleville washers using the tool used
at operation 57. Locate bush (4) by aligning the two
flats with those on clutch housing (23). Replace rear 51
circlip (58) and properly position in bottom of groove.
69. If it was removed, fit bearing (36) using a suitable
fixture; ensure the sealed face is facing the Dynashift.
70. Install the hub and the bearing inside cover (39).
71. Soak the discs in a bath of transmission fluid for C
approximately one hour. Check they are totally
impregnated. Depending on the type, the number of
discs and intermediate plates is different (see Gen-
eral), as well as the length of the splines on drive hub
(37) and the thickness of cover (39).
72. Position intermediate plates (45) and discs (44) on
drive hub (37), by aligning the respective recesses.
73. Place clutch housing (23) assembly on cover (39).
Fig. 10
Torque screws (22) to 25.5 - 34.5 Nm.
74. Check by hand that drive hub (37) is free to rotate.
75. Check that seal rings (52) turn correctly in their
grooves. Coat the seal rings with miscible grease
then install, ensuring that they do not project beyond
the contour of the unit.
76. If it was removed, torque-tighten the 1.5-bar valve to
47 - 54 Nm. Next coat the outside diameter of bush
(51) with Loctite 270 then fit the bush using a
suitable fixture. Ensure chamfer C is oriented as
shown in Fig. 10.
77. After fitting the bush, check that the oil pressure
ports are not blocked with Loctite. Clean and lubri-
cate the bush. Assemble pump body (12) to clutch
housing (23).
78. Lubricate pump (53) and set it by orienting the flats
with those of clutch housing (23). Manually check
the angular travel of the rotor against the flats on
clutch housing (23).
79. Refit pump cover (11). Fit bearing (55). Fit circlip (56).
Torque screws (54) to 36 -46 Nm.
80. Fit O’ring (1) and rings (2). Repeat operation 7.
Reinstall the clutch (see § B).
Issue 2
1 May 2002
2001
E . Removing and refitting control

5 3
valve (Fig. 11)
Removal
82. Remove any neighbouring parts likely to hinder 2
removal of the valve. Disconnect tubes (1) and (2),
hose (3), and the connectors to solenoid valves EV1
and EV2 (mark connector positions).
83. Remove the valve.
Refitting
84. Clean the mating surfaces. Coat the one on the
gearbox housing with sealing compound. 1 EV1
EV2
85. Replace the O’rings on the 17-bar transfer tubes. Fig. 11
Reinstall the valve. Coat screws (5) with sealing
compound, install, and torque to 25-35 Nm.
86. Reconnect the tubes, the hose and the connectors.
87. Service the oil in the sumps and check the level on
the sightglass located on the left-hand side of the
centre housing.
88. Bleed the clutch control valve (see section 9I01).
89. Check the valve regulating pressure (see section
9N01 - Hydraulic Tests).
90. Reinstall any items previously removed from around
the valve.
91. Check the sealing of the mating face and the cou-
plings, and operation of the Dynashift.
Fig. 12
F . Service tools
1 . Tool available in the AGCO network
- 3378012M2 - Protector (Fig. 12)
Issue 1 May 2001


2 . Locally manufactured tools
- Compression tool for Belleville washers (Fig. 13)
(1) Channel section: 60
(2) Threaded rod: Ø. = 8
(3) Round iron to be machined depending on the following
dimensions:
Ø = 36
L = 60
A -A A
1 3 2
180
A
248 60
286
Fig. 13
- Sleeve for removal & refitting of clutch assembly (Fig. 14)

(1) Tube: Tu52B - O.D. 42.4 Th.= 5
(2) Tube: Tu52B - O.D. 48.3 Th.= 2.9
86
1
23 80
Ø7
86
2
100
165
Fig. 14
Issue
Issue21 May
May2002
2001
5 . GEARBOX
Contents
5 A01 GENERAL - OPERATION GEARBOX WITH MECHANICAL REVERSE SHUTTLE

5 A02 GENERAL - OPERATION GEARBOX WITH POWER SHUTTLE
5 B01 INPUT UNIT WITH MECHANICAL REVERSE SHUTTLE
5 B02 INPUT UNIT WITH POWER SHUTTLE
5 B03 DYNASHIFT WITH MECHANICAL REVERSE SHUTTLE
5 B04 DYNASHIFT WITH POWER SHUTTLE
5 B05 MECHANICAL REVERSE SHUTTLE
5 B06 POWER SHUTTLE
5 C01 SELECTOR COVER - GEARBOX WITH MECHANICAL REVERSE SHUTTLE
5 C02 SELECTOR COVER - GEARBOX WITH POWER SHUTTLE
5 C03 SELECTOR COVER OPTIMISED HARE/TORTOISE FUNCTION - GEARBOX WITH
POWER SHUTTLE
5 D01 SELECTOR RAILS - GEARBOX WITH MECHANICAL REVERSE SHUTTLE
5 D02 SELECTOR RAILS - GEARBOX WITH POWER SHUTTLE
5 E01 OUTPUT SHAFT
5 F01 MAINSHAFT - GEARBOX WITH MECHANICAL REVERSE SHUTTLE
5 F02 MAINSHAFT - GEARBOX WITH POWER SHUTTLE
5 G01 LAYSHAFT
5 H01 FULL POWERSHIFT GEARBOX - GENERAL
5 I01 FULL POWERSHIFT GEARBOX - TRANSMISSION HYDRAULIC CIRCUIT
5 J01 FULL POWERSHIFT GEARBOX - TRANSMISSION/REPAIR
5 K01 CREEPER UNIT
Issue 2 May 2002

Gearbox - General 5A01.1
5 A01 General - Operation
CONTENTS
A. General ________________________________________________ 3
B. Operation ______________________________________________ 7
C. Specifications __________________________________________ 11
Issue 1 May 2001

5A01.2 Gearbox - General
Issue 1 May 2001

Low range (Tortoise)

A . General A synchronised gear is engaged by moving of one of the
Various types of transmissions are available: slides of synchromesh gears (16) or (27) for engage
- Type 8210 -8220 -8240 tractors: Heavy Duty gearbox or transfer shaft (7) in one of the four idling pinions. Irrespec-
Full Powershift AG 150 tive of the speed selected, the movement is transmitted
- Type 8250 tractors: Heavy Duty gearbox to layshaft (51). Output shaft (47) is driven by the gear
- Type 8250 to 8280 tractors: Full Powershift gearbox teeth machined on the layshaft intermeshing with tor-
AG250. toise gear (40), engaged to output shaft (47), by moving
the slide of synchromesh gear (69) rearwards.
This section covers only the Heavy Duty version. For the
Full Powershift version, refer to section 5H01.
High range (Hare)
The Heavy Duty gearbox comprises 32 forward speeds This range is selected by forward movement of the slide
and 32 reverse. The transfer shafts and output shafts are of synchromesh gear (69), which establishes a direct
supported by tapered roller bearings and are drilled as drive between third gear (35) and output shaft (47).
necessary to pressure-lubricate the bearings, the idler Consequently in 3rd gear, layshaft (51) is passive. The
gears and the Hare/Tortoise synchronisation system. other gears are obtained by moving the slides of synchros
The layshaft is supported at the front by a cylindrical roller (16) or (27) as for the Low range.
bearing and at the rear, by two tapered roller bearings.
The main gearbox comprises four synchronised gears.
An idler gear on the output shaft positively connected via Lubrication
a double cone synchromesh doubles the four synchro- The lube oil is supplied from tube (4) connected to the
nised gears, to give the eight basic speeds. input unit. It circulates in a series of axial channels, one
All pinions are helically cut and in constant engagement. of which crosses the transfer shaft while the other is
The drive shaft of the direct-drive clutch traverses the blind, machined in the output shaft. Radial channels feed
layshaft. the various pinions, the bearings and the Hare/Tortoise
The input unit assembly located at the front (see section synchromesh.
5B01) provides four input ratios into the main box. Needle roller bearings (67) are lubricated by an oil film
circulating between the direct-drive shaft and the layshaft.
The shaft-end bearings on shaft (51) are lubricated by an
Description additional oil flow from the drive bearing of the hydraulic
The gearbox drive is provided by input gear (1) integral pumps located on the rear-axle intermediate housing, via
with transfer shaft (7). The two hubs of synchromesh radial ports drilled respectively in shim (53) and the shaft.
gears (16) and (27), as well as gear (1) are hard-mounted
to transfer shaft (7) by splines. First gear (19) and fourth
gear (24) are idler gears on shaft (7). Second gear (13) is
an idler gear on bush (8), which is hard-mounted to shaft
(7) by splines. Third gear 3rd (35) is installed on tapered
roller bearings.
All the pinions on layshaft (51) are splined to and rotate
with the latter. The gear teeth on shaft (51) mesh with
tortoise gear (40) which idles on the output shaft.
Issue 1 May 2001


Parts list (55) Bearing cup
(1) Input gear (56) Circlip
(2) Belleville washers (57) Driven pinion (3rd)
(3) Special screw (58) Spacer
(4) Lube tube (59) Driven pinion (4th)
(5) Snap ring (60) Spacer
(6) Spring (61) Driven pinion (1st)
(7) Transfer shaft (62) Spacer
(8) Bush (63) Shim(s)
(9) Bearing cone (64) Driven pinion (2nd)
(10) Bearing cup (65) Washer
(11) Shim(s) (66) Snap ring
(12) Thick shim (67) Needle roller bearings
(13) Driving pinion (2nd) (68) Gearbox housing
(14) Synchromesh cone (2nd) (69) H/T synchromesh (double cone)
(15) Synchro ring (2nd)
(16) Synchro (1st - 2nd)
(17) Synchro ring (1st
(18) Synchromesh cone (1st ) Legend:
(19) Driving pinion (1st ) G : Groove
(20) Bearing cone
(21) Bearing cup
(22) Bearing cup
(23) Bearing cone Fig. 1
(24) Driving pinion (4th)
(25) Synchromesh cone (4th)
(26) Synchromesh ring (4th)
(27) Synchro (3rd - 4th)
(28) Seal ring
(29) Snap ring
(30) Synchromesh ring (3rd)
(31) Special washer
(32) Synchromesh cone (3rd)
(33) Bearing cone
(34) Bearing cup
(35) Driving pinion (3rd) (Hare)
(36) Bearing cup
(37) Bearing cone
(38) Shim(s)
(39) Thick shim
(40) Tortoise gear
(41) Centring pin
(43) Bearing cone
(44) Bearing cup
(45) Shim(s)
(46) Rear bearing
(47) Output shaft
(48) Screw
(49) Bearing cup
(50) Bearing cone
(51) Layshaft
(52) Nut
(53) Shim
(54) Bearing cone
Issue 1 May 2001

8200 SERIES TRACTORS Overall view

64 63 62 61 60 59 58 57 56 69 51 54 55 53
49
68
50
65 1
2
3 52
66 4
67
41
B A 48
1 D
5 46
4 45
3 44
47
C
43
36
E
6 37
7 8 13 14 15 16 17 18 19 20 21 24 25 26 27 30 32 35 40 75
G 27 28 29 34
24
12
22
38 70
10 39 23 71
35 A 9 11 B 2 C D 31 33 73 74 E 72
Fig. 1
Parts list
Issue 1 May 2001
Issue 1 May 2001

B . Operation
Notes G A
- On Heavy Duty gearboxes, the synchromesh gears for
1st and 2nd (16) and 3rd and 4th (27)) are single-cone.
H
- The Hare/Tortoise range has another synchromesh
version (69) employing double cones.
Synchromesh gears (16) (27) (single cone)

(Fig. 2)
Locking position
Axial displacement of slide A presses synchronisation
brake B against friction cone C through the action of balls
F
D and pressure system E. The speed difference existing
between the parts being coupled causes a radial rotation
limited by pressure system E resulting in turn in a C
D
pressure causing the chamfered teeth of synchronisa-
tion brake B to move against slide A, opposing all relative B
movement of the latter. The pressure exerted by slide A
E X
and the angular difference of synchronisation brake B
create an axial pressure between the friction cones of V 16 27
synchronisation brake B, and cone C, due to the cham-
fers of the gear teeth; this axial pressure establishes
synchronism by progressive reduction of the speed E
difference of the parts to connect. D
Once synchronism is established, the persistent pres- F
sure exerted by slide A against synchronisation brake B
returns the latter backwards until the teeth of slide A are
opposite the recess in synchronisation brake B. At this
moment, the resistance applied till this point preventing
movement of slide A during gear-changing is overcome
A
and slide A can thus mesh without noise in the gear teeth B
of cone C on the gear to be brought into drive. The rigid C
connection between the shaft and the gear is now
established, and the gears change. If during gear-chang- Fig. 2
ing both gears end up tooth-on-tooth, the chamfers
machined on the tooth flanks displace the arriving gear
until each tooth is opposite a recess.
Neutral position
Slide A is in the central position. The balls are pushed
back into the groove at V on slide A by pressure springs
F. The pinions are free to turn on the shaft. In this neutral
position, slide A is locked by three balls G maintained by
springs H.
Issue 1 May 2001


Overhaul
In the event of removal of the synchromesh gears, check
the wear of synchronisation brakes B (Fig. 2).
Place Cone C on a flat surface and position brake B in
abutment by rotating it a few turns under finger pressure
(Fig. 3).
Measure dimension X at several points using a set of
feeler gauges (Fig. 2 and 3): if a value of less than 0.8 mm
is found, check the cone and install a new brake B.
Value of dimension X with brake and new synchro-

mesh cone
- synchro (1st - 2nd) (16): 0.9 to 1.5 mm X
- synchro (3rd - 4th) (27): 0.9 to 1.5 mm
Fig. 3
Issue 1 May 2001

Synchromesh gears (69) (double cone) (Fig.

4)
Locking position
Axial displacement of slide A provides a thrust against
ring K, which in turn bears on synchronisation brake B,
pushing it towards Cone J through the action of balls D,
spring F and pressure system E.
When the corresponding pinions are at the required
speed, the slide meshes with the coupling flange C of the
candidate gear.
Remark
Locking of the synchromesh in position (and the neutral
position) employ the same principle as for single-cone
synchromesh gears.
Advantages of the double cone synchromesh

- better reliability
- increased stress strength
69
E
D
F
A
K
B
J
C
Fig. 4
Issue 1 May 2001

Overhaul (double cone)

- If needing to disassemble synchromesh (69), check
the wear on synchronisation brakes B.
- Proceed by stacking coupling flange C, cone J, syn-
chronisation brake B and ring K.
- Position brake B correctly by alternately rotating it
through a few turns and applying finger pressure.
- Using a set of feeler gauges, measure dimension X
(Fig. 5) at three equidistant points. Take the average of
the three readings.
Remark
Value of dimension X (Fig. 5)
- on a new synchromesh gear, dimension X must be
1.6 mm minimum;
- after operation, if this dimension is less than or equal to
0.60 - 0.80 mm, replace the synchronisation brake B.
- Repeat the measurement of X using the same process.
- If dimension X remains incorrect, also replace ring K
and cone J or the complete synchromesh if required.
Fig. 5
Issue 1 May 2001

8200 SERIES TRACTORS C . Specifications

J1 = 0,02 / 0,31
25 - 35 Nm 31 - 35 Nm 29 - 37 Nm 13 - 15 Nm 25 - 32 Nm
A
J = 0,60 / 0,80 241 241
B
8,60 / 8,68
72 - 96 Nm
31 - 35 Nm
100 - 150 Nm
270
B A C
603
638
510
P2 = 0,01 / 0,05
5206 5206 F =1,25 / 1,75 P1 =0,10 / 0,20 maxi
40 - 56 Nm 320 - 360 Nm P =0,10 / 0,20 57- 67 Nm
25 - 35 Nm 25,5 - 34,5 Nm 241 J = 0,05 / 0,18 270

C 270
Fig. 6
Issue 1 May 2001

Gearbox with Power shuttle - General 5A02.1
5 A02 General - Operation
CONTENTS
A. General ________________________________________________ 2
B. Operation ______________________________________________ 7
C. Specifications __________________________________________ 9
D. Tightening torques ______________________________________ 11
Issue 1 May 2001

5A02.2 Gearbox with Power shuttle - General

Description
A . General The gearbox drive is provided by input gear (1) integral
Various types of transmissions are available: with transfer shaft (7). The two hubs of synchromesh
- Type 8210 - 8220 - 8240 and 8250 tractors: gearbox gears (16) and (27), as well as gear (1) are hard-mounted
with Power shuttle to transfer shaft (7) by splines. First gear (19) and fourth
- Type 8210 - 8220 and 8240 tractors: Full Powershift gear (24) are idler gears on shaft (7). Second gear (13) is
AG150 gearbox an idler gear on bush (8), which is hard-mounted to shaft
- Type 8250 to 8280: Full Powershift AG250 gearbox. (7) by splines. Third gear 3rd (35) is installed on tapered
roller bearings.
This section only covers the version with Power shuttle. All the pinions on layshaft (51) are splined to and rotate
For the Heavy Duty version with mechanical reverse with the latter. The gear teeth on shaft (51) mesh with
shuttle or the Full Powershift versions, refer to section tortoise gear (40) which idles on the output shaft.
5B05 or 5H01 respectively.
Low range (Tortoise)
The Heavy Duty gearbox with Power shuttle comprises
A synchronised gear is engaged by moving of one of the
32 forward speeds and 32 reverse. The transfer shafts
slides of synchromesh gears (16) or (27) for engage
and output shafts are supported by tapered roller bear-
transfer shaft (7) in one of the four idling pinions. Irrespec-
ings and are drilled as necessary to pressure-lubricate
tive of the speed selected, the movement is transmitted
the bearings, the idler gears and the Hare/Tortoise syn-
to layshaft (51). Output shaft (47) is driven by the gear
chronisation system.The layshaft is supported at cylindical
teeth machined on the layshaft intermeshing with tor-
roller bearing and at the rear, by twotapered roller bearings.
toise gear (40), engaged to output shaft (47), by moving
the slide of synchromesh gear (69) rearwards.
On gearboxes with a Power shuttle, 1st and 2nd gear
synchromesh gears (16) and 3rd and 4th gear synchro-
mesh gears (27) are double cone type as well as the
Hare/Tortoise range one. High range (Hare)
This range is selected by forward movement of the slide
When the Hare/Tortoise synchromesh gear (69) is moved of synchromesh gear (69), which establishes a direct
to the rear, it makes the Tortoise pinion rotate and drive between third gear (35) and output shaft (47).
doubles the four speeds to give the eight basic speeds. Consequently in 3rd gear, layshaft (51) is passive. The
other gears are obtained by moving the slides of synchros
All pinions have rectified teeth and are helically cut. They (16) or (27) as for the Low range.
are in constant engagement. The drive shaft of the direct-
drive clutch traverses the layshaft.
The input unit assembly located at the front (see section
5B02) provides four input ratios into the main box.
Issue 1 May 2001

Lubrication
The lube oil is supplied from tube (4) connected to the
input unit (Fig.1).
It circulates in a series of axial channels, one of which

crosses the transfer shaft while the other is blind,
machined in the output shaft. Radial channels feed the
various pinions, the bearings and the Hare/Tortoise
synchromesh.
Needle roller bearings (67) are lubricated by an oil film

circulating between the direct-drive shaft and the layshaft.
An oil deflector "C" maintains the oil near the bearing
mounted at the back of the input unit.
The shaft-end bearings on shaft (51) are lubricated by an

additional oil flow from the drive bearing of the hydraulic
pumps located on the rear-axle intermediate housing, via
radial ports drilled respectively in shim (53) and the shaft.
Issue 1 May 2001


Parts list (55) Bearing cup
(1) Input gear (56) Circlip
(2) Washer (57) Driven pinion (3rd)
(3) Nut (58) Spacer
(4) Lube tube (59) Driven pinion (4th)
(5) Snap ring (60) Spacer
(6) Spring (61) Driven pinion (1st)
(7) Transfer shaft (62) Spacer
(8) Bush (63) Shim(s)
(9) Bearing cone (64) Driven pinion (2nd)
(10) Bearing cup (65) Washer
(11) Shim(s) (66) Snap ring
(12) Thick shim (67) Needle roller bearings
(13) Driving pinion (2nd) (68) Gearbox housing
(14) Synchromesh cone (2nd) (69) Hare / Tortoise synchromesh (double cone)
(15) Synchro ring (2nd) (71) Progressive sensor
(16) 1st - 2nd synchro (double cone) (72) Nut
(19) Driving pinion (1st ) (75) Cover
(20) Bearing cone
(21) Bearing cup
(22) Bearing cup
(23) Bearing cone Legend
(24) Driving pinion (4th) G : Groove
(27) 3rd - 4th synchro (double cone)
(28) Seal ring
(30) Synchromesh ring (3rd)
(31) Special washer
(33) Bearing cone
(34) Bearing cup
(35) Driving pinion (3rd) (Hare)
(36) Bearing cup
(37) Bearing cone
(40) Tortoise gear
(41) Locating pin
(43) Bearing cone
(44) Bearing cup
(45) Shim(s)
(46) Rear bearing
(47) Output shaft
(48) Screw
(49) Bearing cup
(50) Bearing cone
(51) Layshaft
(52) Nut
(53) Shim
(54) Bearing cone
Issue 1 May 2001

Overall view
68 64 63 62 71 72 61 60 59 58 57 56 69 51 54 55 53
65
49
66 1
2 50
3
4
67
52
41
C 48
B A
1
D
45
2
47
5
43
R 41
44
F F
F
46
36
48
4 3 6 7 8 13 16 19 20 21 24 27 35 40 75 37
46
F
69 12 24 27 28 29 34 45
27 G
16
44
47
43
B D A
10 9 11 22 23 31 33 35
Parts list Fig. 1
Issue 1 May 2001

Issue 1 May 2001

B . Operation
Notes
- On gearboxes with Power shuttle, all gears are syn-
chronised including the Hare/Tortoise function. The
synchromesh gears are all double cone items.
Hare/Tortoise synchromesh gears (69) (dou-

ble cone) (Fig. 2)
Locking position
Axial displacement of slide A provides a thrust against
ring K, which in turn bears on synchronisation brake B,
pushing it towards Cone J through the action of balls D,
springs F and pressure system E.
When the corresponding pinions are at the required
speed, the slide meshes with the coupling flange C of the
candidate gear.
The operating principle is identical for 1st - 2nd (16)
synchromesh gears and 3rd - 4th synchromesh gears
(27).
69
Advantages of the double cone synchromesh
- better reliability
- increased stress strength
E
D
F
A
K
B
J
C
Fig. 2
Issue 1 May 2001


Overhaul (double cone)
- If needing to disassemble synchromesh gears (16) (27)
and (69), check the wear on synchronisation brakes B.
- Proceed by stacking coupling flange C, cone J, syn-
chronisation brake B and ring K.
- Position brake B correctly by alternately rotating it
through a few turns and applying finger pressure.
- Using a set of feeler gauges, measure dimension X
(Fig. 3) at three equidistant points. Take the average of
the three readings.
Remark
Value of dimension X (Fig. 3)
- on a new synchromesh gear, dimension X must be
1.6 mm minimum;
- after operation, if this dimension is less than or equal to
0.60 - 0.80 mm, replace the synchronisation brake B.
- Repeat the measurement of X using the same process.
- If dimension X remains incorrect, also replace ring K
and cone J or the complete synchromesh if required.
Fig. 3
Issue 1 May 2001

C . Spécifications D : Semi set-right adjustment
8200 SERIES TRACTORS G : Groove oriented towards the Hare / Tortoise synchromesh gear
A and B : Détails O : Port for synchromesh lubrication (Tortoise side)
C : ½ to ¾ turn adjustment
Gearbox with Power shuttle - Generall 5A02.9
P= 0/0,10mm
C X= 8,60/8,68mm
J1= 0,02/0,31mm D
VALMET
A B
PERKINS
P2= 0,01/0,05mm
J= 0,60/0,80mm
P1 = 0,10/0,20mm maxi
G
B
A
Fig. 4
Issue 1 May 2002

5A02.10 Gearbox with Power shuttle - Generall
Issue 1 May 2002

8200 SERIES TRACTORS D . Tightening torques
A : Tighten at 30 - 70 Nm progressively. Rotate the shaft a few turns. Then, complete tighten at 100 - 150 Nm, with Loctite 270
plus mechanical lock.
Gearbox with Power shuttle - Generall 5A02.11 B : Selector rail support.
36 - 46 Nm M6 12 - 16Nm 47 - 57Nm 31 - 35Nm 13 - 15Nm 12 - 16Nm 29 - 37Nm 36 - 46Nm

5 - 7Nm
M8 20 - 28Nm
242 242 242 242 577 242 221
grade 10,9 - 140Nm

grade 12,9 - 160Nm
5206
B
36 - 46Nm
A
F
57- 67Nm
110 - 140Nm 102 - 138Nm
270 270
25,5 - 34,5Nm
47 - 68Nm
12,5 - 13Nm
13 bar 510
36 - 46Nm 549 5206 648 47 - 68Nm 130 - 170Nm 85 - 120Nm
270
40- 48Nm
47 - 54Nm 29 - 37Nm 29 - 37Nm 10- 14Nm
1,5 bar
Fig. 5
Issue 1 May 2002

Gearbox - 5B01.1
Input unit with mechanical reverse shuttle
5 B01 Input unit with mechanical reverse shuttle
CONTENTS
- General ________________________________________________ 2
A. Removing and refitting the unit __________________________ 2
B. Service tools ___________________________________________ 4
Issue 1 May 2001

5B01.2 Gearbox -
General
1
The input unit transmits the movement from the engine

to the transmission via the clutch (Pressure loaded). It is
in the form of an interchangeable module installed on the
gearbox inlet. It comprises two quite distinct parts: the
Dynashift and the reverse shuttle.
The Dynashift is fixed to the front of the input unit. For

details of operation, see section 5B03.
The reverse shuttle is located in the rear cavity of the

input unit. For details of operation, see section 5B05.
Fig. 1
A . Removing and refitting the unit

Remark
Type 8210 -8220 -8240 and 8250 tractors may be fitted
with a Heavy Duty gearbox comprising an input unit with
a Dynashift and a reverse shuttle.
Removal
1. Split the tractor between the engine and gearbox (see 3376883M1 7
section 2B01).
2. Drain the gearbox. 3378004M1
3. Remove the selector cover (see section 5C01).
13
4. Remove selector (1) (Fig. 1).
5. Remove the clutch assembly (see section 4A01). 3378013M1
6. Remove the direct drive shaft.
7. Remove the clutch control valve without disconnect-
ing the hose coming from the master-cylinder (see
21
section 9J01) as well as the transfer tubes connected
to the unit (lubrication and 17-bar pressure).
8. Install adapter plate, P/N 3378013M1 on cover (13), B
using four screws A of the correct length, then fix sling,
P/N 3376883M1, on the plate as shown in Fig. 2.
A
DANGER
- It is essential to use screws A of suitable length in order

to positively secure the sling and unit assembly.
Fig. 2
Issue 1 May 2001

Gearbox - 5B01.3
9. Remove the screws fixing the unit to the gearbox.
10. Unstick and pull the input unit towards the front.
1
Assisted by an operator, open the selector cover and
check that the selector rails come free of their front
support. Tilt the unit fully downwards (Fig. 4) to allow
the support to pass through the bore in the gearbox.
11. Retrieve locating pin (1) (Fig. 3).
12. Place the unit on a work bench in the vertical
position.
Special points (Fig. 2)
A : Attachment of adapter plate on front cover
B : Avoid removing screws
Refitting
Special point
- To facilitate engagement of input unit end bearing (1) Fig. 3
into the gearbox layshaft (Fig. 4), coat the bearing rollers
with miscible grease to stick them in place.
13. Insert locating pin (1) (Fig. 3).
14. Screw two guide studs (L = 80 mm) in opposing
locations on the gearbox housing (optional). Using
sling, P/N 3376883M1 and adapter plate, P/N
3378013M1, engage the input unit in the clutch
housing. Tilt it fully downwards to allow the selector
rail support to pass through the front bore of the
gearbox.
3376883M1
1 - Pull
2 - Tilt
Fig. 4
Issue 1 May 2001

5B01.4 Gearbox -
15. Assisted by an operator, check through the opening
in the selector cover that the selector rails correctly
engage in the front support. Use sleeve, P/N
3378004M11 (Fig. 2) to turn shaft (7) in order to
facilitate meshing of the pinions.
16. Position the unit on the locating pin. Remove the
guide studs (if installed). Torque the screws securing
the unit to the gearbox housing, to a value of 39 -
54 Nm. Remove the sling then proceed to assembly
of the Dynashift front cover: coat the four original
screws (temporarily replaced by screws "A", Fig. 2)
with Loctite 241, then install and torque to 29 -
37 Nm. Reinstall the clutch control valve and the
transfer tubes (lubrication and 17-bar) (see section
9J01).
17. Refit the direct-drive shaft. Refit the clutch (see
section 4A01). Fig. 5
18. Refit reverse-gear selector (1). Coat the screws with
Loctite 221 and torque to 35 Nm (Fig. 1).
19. Refit the selector cover (see 5C01).
21. Service the oil in the sumps and check the level in the
22. Bleed the clutch control if necessary (see section
9I01).
23. Proceed to road-test of all Dynashift controls and
gear ranges A, B, C and D.
24. Check for leaktightness at couplings and mating
face of selector cover.
Fig. 6
B . Service tools
1 . Tools available in the AGCO network
- 3376883M1 - Sling for front unit (Fig. 5)
- 3378013M1 - Adapter plate (Fig. 6)
- 3378004M1 - Sleeve (Fig. 7)
Fig. 7
Issue 1 May 2001

Gearbox - 5B01.5
2 . Locally manufactured tooling
- Handling bar (Fig. 8))
2500
5xØ7
Ø 32
75 75 75 180 80
Fig. 8
Issue 1 May 2001

Gearbox with power 5B02.1

shuttle - Input unit
5 B02 Input unit with power shuttle
CONTENTS
. General ________________________________________________ 2
B. Removal ________________________________________________ 5
C. Refitting ________________________________________________ 6
D. Adjusting of the progressive sensor ______________________ 6
E. Final operations ________________________________________ 7
F. Service tools ___________________________________________ 7
Issue 1 May 2002

5B02.2 Gearbox with power

General
The power unit with power shuttle is in the form of an
interchangeable module on which a reverse shuttle is
assembled that can power the forward or reverse gear.
It is mounted at the input of the gearbox and is fitted on
tractors 8210 - 8220 - 8240 and 8250.
It is made of two distinct parts: the power shuttle (see

section 5B06) and the Dynashift.
Dynashift
The Dynashift electro-hydraulically controls four
powershift ratios using a lever mounted to the left under
the steering wheel.
It is located between the power shuttle and the driving
gear mounted in the rear housing.
The Dynashift function is performed by two epicyclic
gear trains associated with two hydraulic clutches. For
information on operation, see section 5B04.
Issue 1 May 2002


A. Preliminary operations
Special points
- A removable flange (2) supports the front end of the
selector rails (Fig. 1).
- This assembly enables easy horizontal removal of the
input unit (Fig. 2). 2
1. Uncouple the tractor between the engine and the

1
3. Remove the selector cover (see section 5C02 or 5C03
according to version) and through the opening, over
the gearbox, remove the screw (1) attaching the
flange (2) (Fig. 1).
1
2
Fig. 1
1 2
Fig. 2
Issue 1 May 2002


4. Move the flange away from the housing by making it
slide along the selector rails.
Note
- The flange (2) is positioned on the rear housing of the
input unit by means of two cotter pins (3) (Fig. 3).
5. Remove the clutch cover plate (see section 3C02).
6. Remove the power shuttle control unit (see section
9K01). Remove and mark the position of the hydraulic
pipes connected to the following functions:
- gearbox lubrication
- Dynashift low pressure
- power shuttle rear clutch low pressure
2 3
Fig. 3
Issue 1 May 2002


B . Removal 2
7. Remove the power shuttle front clutch (see section
5B06).
8. Take out the PTO shaft (1) from the gearbox (Fig. 2)
and mark its position.
9. Disconnect and remove the progressive sensor (2)
located above the gearbox (Fig. 2 and 4).
10. Sling the input unit using tool ref. 3378225M11, a
locally made handling bar (see § F) and a lifting
device adapted as per Fig. 2.
Note
- Before using the sling, remove the four screws (64)
(L = 145 mm) unless removed beforehand they will
not be accessible to the "U" profile of the tool.
11. Remove the remaining screws (64A) (L = 145 mm)
securing the input unit to the gearbox (Fig. 5). Fig. 4
Reminder
Do not intervene on the short screws (70) (L =
25 mm) so as to avoid splitting the unit (Fig. 5).
12. With the help of an assistant, carefully pull the unit
forward and disengage it from the gearbox to pro-
ceed with removal. 64 64A 70
13. Remove the handling bar and tool.
14. Place the unit in vertical position on a workbench.
15. Separate the rear clutch from the input unit (see 64
section 5B06).
64
64
64A
64A 70
Fig. 5
Issue 1 May 2002


C . Refitting
16. Install the previously removed rear clutch on the 1 2
input unit (see section 5B06).
17. If necessary, screw a guide stud (L = 55 mm) on the
gearbox housing, through the opening revealed by
the removal of the power shuttle control unit.
18. Place the locating pin (1). Check presence of the
flange (2), lubrication tube (4) (Fig. 6) and the locating
pins (3) (Fig. 3).
19. With the help of an assistant and using the tools used
during removal, position the input unit in the gearbox
housing taking the same safety precautions as
previously.
20. Push and position the input unit on the housing 4
mating face. Remove the guide stud (if used).
21. Remove the sling. Tighten the screws (64) (64A) Fig. 6
(Fig. 5) of the input unit to a torque of 47 - 57 Nm.
Note
- the thread of each screw should be cleaned and
lightly coated with Loctite 542 or equivalent. If new 2
screws are used, they should not be coated with
Loctite or equivalent since they are coated with a
locking product in the factory.
22. Reinstall and adjust the progressive sensor (see § D).
23. Adjust the turned section of the PTO shaft to the rear
and insert the shaft into the upper shaftline of the
gearbox.
24. Refit the front clutch (see section 5B06).
D . Adjusting of the progressive sen-

sor Fig. 7
25. Lightly coat the sensor with Loctite 577 (Sensor
Sealing or equivalent). Install and adjust the sensor.
26. Fully screw home the sensor (2) (Fig. 7) without
forcing. Make sure that its end is in contact with the
driving pinion mounted in the rear housing (see
section 5B06).
27. Unscrew the sensor by approximately a half or three-
quarter turn, then torque the nut to a value of 5 to 7
Nm.
Note: For details on operation, see section 11 -
Electronics
Issue 1 May 2002


E . Final operations F . Service tools
28. Refit the power shuttle control unit (see section 1. Tool available in AGCO network
9K01) and the hydraulic pipes according to the - 3378225 M11 - Sling for power shuttle housing
positions previously marked. (Fig. 8)
29. Fit the clutch cover plate (see section 3C02).
30. Check presence of the locating pins (3) and apply the 2. Locally made tool
flange (2) to the rear part of the housing (Fig. 3). Clean
- Handling bar (Fig. 9)
screw thread (1) and apply a light coating of Loctite
221 or equivalent (Fig. 1) and torque to 36 - 46 Nm.
31. Refit the selector cover (see section 5C02 or 5C03
according to version).
32. Top up housings with oil and check the level on the
sight-glass on left at rear of central housing.
33. Couple the tractor between the engine and the
34. Carry out a road test with the power shuttle, testing
gears A, B, C, D of the Dynashift
35. Check the oil tightness of the selector cover mating
face and of hydraulic unions.
Fig. 8
2500
5xØ7
Ø 32
75 75 75 180 80
Fig. 9
Issue 1 May 2002

Gearbox - Dynashift 5B03.1
5 B03 Dynashift
CONTENTS
- General _____________________________________________ 2
- Theory of Operation __________________________________ 2
A. Preliminary operations _______________________________ 9
B. Removing and disassembling the cover, housing,

front clutch and brake ________________________________ 9
C. Removing and separating the planet

pinion cage assembly ________________________________ 10
D. Disassembling the rear clutch and brake _______________ 10
E. Assembling the planet pinion cages ___________________ 11
F. Reassembling the rear clutch and brake _______________ 11
G. Reassembling the cover, front clutch,

brake and housing ___________________________________ 12
H. Shimming the planet pinion cage _____________________ 14
I. Assembling the input unit ____________________________ 15
J. Final operations _____________________________________ 16
K. Service tools ________________________________________ 16
Issue 1 May 2001

5B03.2 Gearbox - Dynashift
When not actuated, piston (22) is drawn backwards by

General twelve springs (20) and cup washer (4) via thrust plate
The Dynashift is fixed on the front of the input unit. It is (16).
an hydraulically controlled gear shifting device that pro-
vides four gearbox input ratios. This function is provided When it is actuated under pressure from the 17-bar
by two epicyclic gear trains associated with two hydrau- circuit, piston (22) moves forwards, blocking brake discs
lic clutches. (15) and pushing plate (16), which compresses cup
The design of the Dynashift allows selecting the four washer (4).
ratios while moving, without needing to disengage the The speed of the secondary ring gear stabilises as
clutch, using a lever located under the steering wheel. follows:
The Dynashift unit is controlled by two solenoid valves - speed equal to the engine speed when the front piston
installed on the low-pressure hydraulic line (17 bar). Both is not actuated,
solenoid valves are monitored by the tractor’s electronic - speed null when the front piston is actuated.
system.
Secondary sun gear (61) is either:
- locked on the secondary shaft by means of four clutch
discs (50) and two cup washers (52) located on the rear
part of the unit, or
- immobilised in relation to the unit by means of three
brake discs (41) and piston (37).
Theory of Operation
The Dynashift input unit includes two epicyclic trains: When not actuated, piston (37) is pushed forwards by the
- the primary epicyclic train, the main part of the input cup washers and six springs (65).
unit, used to transfer movement from the engine to the Under the effect of the 17-bar pressure, piston (37)
gearbox moves towards the rear and blocks brake discs (41). It
- the secondary epicyclic train, for controlling the speed compresses cup washers (52) through the action of
of the primary sun gear. thrust plate (45), which frees the clutch discs on the
secondary shaft.
Primary epicyclic train By immobilising secondary ring gear (34) or secondary

The movement comes in via primary ring gear (31) which sun gear (61), the speed of secondary planet-pinion cage
is splined onto transmission shaft (7). This turns at the (39) is modified. The secondary planet-pinion cage drives
same speed as the engine. primary sun gear (64), which establishes the reduction
The movement exits via planet pinion cage (28) which is ratio of the box.
splined onto secondary shaft (53). Primary sun gear (64)
is driven by the secondary epicyclic train. The speed of
this sun gear determines the reduction ratio of the box.
Secondary epicyclic train

This epicyclic train is controlled by hydraulic clutches
and brakes.
Secondary ring gear (34) is:
- either locked to transmission shaft (7) by three clutch
discs (3) and cup washer (4) located in the front part of
the unit,
- or locked in relation to the unit by three brake discs (15)
and piston (22).
Issue 1 May 2001

Gearbox - Dynashift 5B03.3 Overall view
,,,,,,,,,,,,,,,,,,,,,,,,,
18 20 21 23 25 24 27 26 28 29 30 32 31 33 35 36 34 37 38
Parts list (Fig. 1) (50) Rear clutch discs
, ,,,,,,,,,
,,,,,,,,,
(1) Secondary ring gear carrier (51) Friction washer
(52) Cup washers 15 39
(2) Intermediate plates
,,,,,,,,
,,,,,,,,,,,,,,
(53) Secondary shaft
,,,,,,,,,,,,,,,,,,,,,,,,, ,
(3) Clutch discs
,

17 41
,,,,,,,,,,,,,,,,,,,
(4) Cup washer (54) Splined hub
(5) Splined hub (55) Circlip

,

(7) Transmission shaft (56) Spacer 16 40

,

(10) Friction washer (57) Ball bearing
(13) Front cover (58) Ball bearing 15 42

,
(14) Clutch housing (59) Rear clutch housing

(15) Front brake discs (60) Retaining ring 14 43
(16) Thrust plate (clutch - brake) (61) Secondary sun gear
(17) Clutch plate (62) Retaining ring 13 44

(18) Screw (63) Needles
,

(20) Springs (64) Primary sun gear 10 45
(21) Spacer housing (65) Springs

(22) Piston (66) Screw
,,,,,,,,,,
79 46

(23) Rivet (68) O’ring
,

(24) O’ring (69) Circlip

80 48
(25) Screw (70) Stop

(26) O’ring (71) Shim(s)
(72) Retaining ring 7 49
(27) Ball bearing

,

(28) Primary planet pinion cage (73) O’ring
51

(29) Rivet (74) Plug
(30) Screw (75) Oil splasher

(31) Primary ring gear (76) Stud washer 76 47
,

(32) O’ring (77) Spring washer

,

69 52
,

(33) Screw (79) Washer

(34) Secondary ring gear (80) Circlip
(35) O’ring 5 50

(36) O’ring
,

, ,
(37) Rear piston Fig. 1
,

,

77 53
(38) Clutch plate

,

(39) Secondary planet pinion cage Fig. 2 70 71
,

(40) Reverse shuttle unit

(41) Rear brake discs 72 54
(42) Housing

,

(43) Screw 4 55
(44) Clutch plate
,

(45) Thrust plate (clutch-brake)
3 59
,

(46) Screw

(47) Cover
(48) Intermediate plates 2 56
(49) Retaining ring
1 57
61
73 58
22 75 64 62 68 66 63 60 65
Issue 1 May 2001

Exploded view
69
10
27
79
25
13 1
18 36
7 37
80 35
32
50
29
48
,
23 33
, , ,
22 34
, ,
31
,
,
5
,
, ,
59
,,,,,,,
,
20
, , , ,
17 38
, ,
,
,
,,,,,,
,
,
,
54
, ,
15
, , ,,
77
,
, ,
73
,,,,,,,, ,
,, ,,,
,
74 71
, ,
,,,,,,,,
,
49
, ,
2
,
,
, , , ,
61
, ,
3
, , ,
,
,
53
,
16
,
,
,
,
,
39
, , ,
4
, , ,
,,,,,,
,
21
,
,
,
15
,
,
,
30
,
,
,
,
14
, ,
,
26
,,,,,,
, ,
24 66
,,,,,,
,
,
,
,
,
62
,
,
63 42
,
64
,
43
,
,,
75 51
,,
28 47
,
71
52
76
72 41
,
55
,
70
,
57
, , ,
56
,
,
, , ,
,,,,,,,
,
60
, , ,
68
,,
,,,,,,,,,, , ,
58
, ,
,,,,,,,,,,,,,
40
,
,,,,,,,
,
,
65
,
,
,
,
,
46
,, ,
,
,
,
45 Parts list
,
44
Fig. 1
Fig. 2
Issue 1 May 2001

Explanation of gearbox ratios The reduction ratio is determined by the primary epicyclic
Ratio A : 1/1.620 reduction (Fig. 3) train only. The kinematics are conventional, the move-
Pistons (22) and (37) simultaneously receive the pres- ment entering via the ring gear and exiting via the planet
sure of the 17-bar circuit. pinion cage, with the sun gear remaining fixed.
Secondary ring gear (34) is locked to the housing by the
action of the front brake. Secondary sun gear (61) is
locked to the housing by the action of the rear brake.
Consequently, the secondary epicyclic train is locked.
Primary sun gear (64) is blocked.
37
34
22
64
61
Lubrication Transmission of engine power to gearbox
17-bar low pressure
Fig. 3
Issue 1 May 2001

Ratio B : 1/1.386 reduction (Fig. 4)

Front piston (22) is under pressure.
Secondary ring gear (34) is locked to the housing by the
front brake.
Rear piston (37) is not under pressure.
Secondary sun gear (61) rotates with secondary shaft
(53) (clutch engaged).
Secondary planet-pinion cage (39) turns at low speed,
driving primary sun gear (64).
The reduction effect is therefore lower.
37
34
22 39
64
61
53
17-bar low pressure Driving of primary sun gear
Fig. 4
Issue 1 May 2001

Ratio C : 1/1.1704 reduction (Fig. 5)

Rear piston (37) receives the pressure.
Secondary sun gear (61) is locked to the housing by the
effect of the rear brake.
Front piston (22) is not under pressure.
Secondary ring gear (34) rotates with transmission shaft
(7) (clutch engaged), giving a speed higher than that of
secondary planet-pinion cage (39).
Primary sun gear (64) is driven by secondary planet-
pinion cage (39), at a speed greater than for ratio B. The
reduction effect is therefore lower still.
37
22 34
39
64
7 61
Lubrication Transmission of engine power to

gearbox
17-bar low pressure Driving of primary sun gear (64)
Fig. 5

Ratio D : Ratio 1/1 (Fig. 6)

Neither piston is actuated. Both clutches are therefore
engaged.
Secondary ring gear (34) rotates with transmission shaft
(7).
Secondary sun gear (61) is locked to secondary shaft
(53), resulting in mechanical locking of the complete
system.
The ratio is consequently 1:1 (direct transmission).
34
61
7 53
17-bar low pressure Mechanical locking
Fig. 6
Issue 12 December
May 2000
2002
13 7
(see section 2B01).
4. Remove the reverse shuttle selector (see section 21
5B01).
5. Remove the clutch assembly (see section 4A01).
6. Remove the direct drive shaft.
7. Remove the clutch control valve (see section 9J01)
as well as the transfer tubes connected to the unit
(lube and 17-bar pressure).
8. Remove the input unit (see section 5B01) and place
on a work bench in the vertical position.
Fig. 7
34 Fig. 8
B . Removing and disassembling

the cover, housing, front clutch and
brake
9. Using two locally manufactured lugs or rings, re-
move the assembly comprising shaft (7), cover (13)
and housing (21) (Fig. 7).
10. Retrieve stop (70). Compress spring washer (77) by
pressing on ring gear (31). Remove circlip (69) and
withdraw shaft (7).
11. Withdraw piston (37) from housing (21).
12. Use tool, P/N 3376888 M1 to lock ring gear (34). 25
Remove screws (25) (Fig. 8).
13. Extract the assembly comprising ring gear (34),
crownwheel carrier (1), ring gear (31) and bearing
(27).
14. Separate ring gear (34) from crownwheel carrier (1).
Remove spring washer (77) and bearing (27).
15. Remove housing (21) and piston (22).
16. Remove discs (3) and (15), intermediate plates (2),
and clutch plate (17), drive hub (5), springs (20) and
thrust plate (16).
17. Extract cup washer (4) and unit (14).
Issue 1 May 2001

C . Removing and separating the

planet pinion cage assembly
18. Compress the planet pinion cage assembly using
tool, P/N 3376920 M2 (Fig. 9).
19. Remove ring (72). Remove stud washer (76), the
planet pinion cage assembly and shims (71) in-
stalled against the front and rear faces of planet
pinion cage (28).
20. Remove secondary sun gear (61) and retaining ring
(49) (if necessary).
21. Remove circlip (55). Remove bearing (57) and spacer
(56).
22. Separate secondary planet-pinion cage (39) from
primary planet-pinion cage (28).
23. Remove retaining ring (60) and bearing (58).
Fig. 9
24. Set the secondary planet-pinion cage in the vertical
position. Tap the cage lightly on a wooden block in
order to extract needles (63) (Fig. 10). Separate the
planet pinion cage from primary sun gear (64),
63
complete with ring (62) and oil splasher (75).
D . Disassembling the rear clutch

Fig. 10
and brake
25. Remove clutch plate (38), springs (65), discs (41)
separated from clutch plate (44).
26. Remove the assembly comprising housing (59),
thrust plate (45) and last disc (41). Remove friction
washer (51).
27. Remove screws (46). Remove cover (47) and cup
washers (52). Separate thrust plate (45), discs (50)
and intermediate plates (48). Remove drive hub (54).
28. Remove screws (43). Unstick and remove unit (42)
take care to mark its position.
Issue 1 May 2001

E . Assembling the planet pinion

42
cages
29. Clean and check the parts, replacing any that are
faulty.
30. Ensure that the lube ports in the planet pinion cage
shafts are not blocked.
31. Manually check the axial play and rotation of each
sun gear.
32. Install primary sun gear (64) fitted with ring (62) and
oil splasher (75), in secondary planet-pinion cage
(39).
33. Insert three needles (63) through holes in primary
sun gear, so that they abut on bottom of groove in
secondary planet-pinion cage.
34. Fit bearing (58), install ring (60).
Fig. 11
35. Assemble the secondary planet-pinion cage on pri-
mary planet-pinion cage (28). Turn the sun gears in
order to facilitate meshing.
36. Fit spacer (56) and bearing (57); install circlip (55).
37. Check manually for normal backlash between the
primary sun gears. 54 59
38. Install ring (49) (if it was removed) on secondary sun
gear (61).
F . Reassembling the rear clutch and

brake
39. Clean and check the parts, replacing any that are
Fig. 12
faulty.
40. Blast compressed air into the tube of the reverse-
drive idling gear to ensure it is not blocked.
41. Coat the mating face of unit (42) with sealing
compound around the lube line (Fig. 11) and install.
42. Coat screw (43) with Loctite 241, install and torque
to 31 - 35 Nm.
43. To access screws (46), turn the planet pinion cage
upside down. Install secondary sun gear (61), hous-
ing (59) and hub (54), the inside splines facing
downwards (Fig. 12).
Install discs (50), intermediate plates (48), thrust
plate (45) and cup washers (52) per Fig. 1, and cover
(47).
Issue 1 May 2001

44. Centre housing assembly (59), using tool, P/N

3376887M1 (Fig. 13). Coat screws (46) with Loc-
tite 241 and torque to 13 - 15 Nm. Remove the tool.
Separate the housing assembly from the planetpinion
cage.
45. Coat washer (51) with miscible grease and apply to
cover (47).
46. Install one disc (41) inside unit (42).
47. Place housing assembly (59) and washer (51) on
shaft (53). Install drive hub (54), the inside splines
facing upwards (Fig. 14).
48. Install the other two discs (41), separated by clutch
plate (44).
Fig. 13
G . Reassembling the cover, front
clutch, brake and housing
54 53
Special point
If replacement of front cover (13) proves to be necessary,
degrease washer (79) and its mating face on the cover. 59
Lightly smear one face of this washer with Loctite 648 or
similar then stick on the cover. Leave to dry for a few
moments.
49. Ensure presence of rivets on cover.

50. Place the cover on a suitable support.
51. Check for presence of washer (79). Coat friction
washer (10) with miscible grease and apply to
housing (14). Install transmission shaft (7) and
housing.
52. Position cup washer (4) per Fig. 1, fit one disc (15)
and thrust plate (16).
53. Fit drive hub (5) with internal splines facing upwards Fig. 14
on transmission shaft (7) (Fig. 15). Install discs (3)
and intermediate plates (2).
54. Install the other two discs (15), separated by clutch
plate (17). 5
55. Refit springs (20). Fit O’ring (73).
56. Ensure presence of rivets (23) and (29). Ensure that
7
the pipes to pistons (22) and (37) in housing (21) are
not blocked.
57. Lubricate seals (24) and (26) and install respectively
on piston (22) and inside housing (21).
58. Position the piston in the housing and fit using a
plastic hammer to tap progressively and alternately
around the edge.
59. Screw two guide studs into housing (21) and position
on cover (13). Check that the lube pipe in the housing
corresponds to the one on the cover.
Fig. 15
Issue 22
Issue 1 March
December 2002
May 2002
2000
Special point
Replacing cover (13) on housing (21) or reverse-shuttle
housing (40) requires checking and if necessary readjust-
ing the clutch (see section 4 A01).
60. Remove the guide studs. Coat screw (18) with Loc-
tite 241, install, and torque to 29 - 37 Nm.
Leaktightness test of piston (22)

- Connect a pressure gauge fitted with a sealed valve and
a suitable fixture on the port of the front piston. Ensure
piston and seals are correctly seated by pressurising
the system several times to two or three bar, then feed
the circuit with compressed air at 0.3 bar. Close the
valve and check that no pressure drop occurs for one
minute.
61. Refit bearing (27) on ring gear (31) and place inside
crown-wheel carrier (1) together with spring washer
(77). Install ring gear (34). Apply Loctite 241 to
screws (33), install the screws and torque to 13 -
15 Nm.
Fit the crownwheel assemblies onto transmission
shaft (7).
Lock ring gear (34) per Fig. 8. Apply Loctite 241 to
screws (25) and torque to 31 - 35 Nm.
62. Compress spring washer (77) by pressing ring gear
(31). Install circlip (69). Coat stop (70) with miscible
grease and install.
63. Lubricate and install seals (35) and (36). Position the
piston in the housing and fit by tapping progressively
around the edges with a plastic hammer.
Leaktightness test of piston (37)

- Maintain the piston using a suitable fixture. Check
sealing of the joints, as for the front piston.
Issue 1 May 2001

,,,,,,,,,,,,,
H . Shimming the planet pinion cage J1 = 0,50 / 0,70 mm
, ,,,,,,,,,,,
Adjusting J1 clearance (Fig. 16)
,,,,,,,,,,,,,
Note: For adjusting clearances J1 and J2, springs
,,,,,,,,,,,,
(65) and clutch plate (38) must be removed.
,,,,,,
,
,
Operations on rear clutch housing (Fig. 18):
,,, ,
,
,,,,
,
64. Use a depth gauge to measure dimensions b and c
, ,
,
at two opposing points. Take the average of the two
,
, ,
readings.
,,
Calculate dimension: A = b - c
, ,
,
,
Operations on the planet pinion cage as-
sembly (Fig. 17) J2 = 0 / 0,20 mm 71
47
,
65. Install secondary sun gear (61) complete with retain-
ing ring (49) on ball bearing (57). Fig. 16
66. Measure dimension D using a depth gauge.
67. Determine gap E between primary planet-pinion
cage (28) and hub (54) (Fig. 19) according to the
formula: E = A + D
, ,,,,,
,
68. Fill space E with shims (71) having a value of E +0.50
,,,,,,,,,, , ,
61 49 57
mini to + 0.70 maxi, to give a clearance of : D

,,
,,, ,,,,,,

,

J1 = E + 0.50 to 0.70 mm

, ,

,,

,
,

Fig. 17
,,,,,,,,,,,

,,,,,,
,

,,,

,

,,,,

,

B C A

,
,

,

,
,

,

,

,

,

,

,

,

,

42

,

,

,

,

,

Fig. 18

Issue 1 May 2001


, ,,,,,
,,, ,,,
Adjusting J2 clearance(Fig. 16)

69. Place sun gear (61) on housing (59) and the planet
pinion cage assembly on shaft (53). Install washer
(76) and ring (72).

,

70. Position the feeler of a dial gauge per Fig. 20 and
check the clearance by moving the planet pinion
cage assembly vertically.

71. Depending on the measured clearance, select the
thickness of shims (71) to obtain J2 = 0 / 0.20 mm.
72. Remove the planet pinion cage assembly.
73. Install springs (65). Position clutch plate (38), ensur-
ing that the notches align with the tabs of unit (42).
74. Ensure presence of shims (71) defined at operation
68.
75. Refit sun gear (61) and the planet pinion cage
assembly, and compress the parts using tool, P/N 28 E 54
3376920M2. Fig. 19
76. Set shims (71) selected at operation 71 against pla-
net pinion cage (28). Install washer (76) and ring (72)
(Fig. 20).
77. Check manually for normal backlash between the
,, ,,,,,,,,, 72 76
secondary sun gears.
,,,,,,,,,,,,,,,,,,,,,,,

,
,,,,,,,,,,
,,, ,, 28 28
71
,,,,
,
I . Assembling the input unit
,
78. Fit new O’rings (32) and (68) on reverse shuttle

housing (40). Screw in two guide studs at opposing
locations.
79. Use a sling to reinstall the assembly comprising
transmission shaft (7), cover (13) and housing (21)
(Fig. 7), ensuring the lube pipe is aligned. Fig. 20
80. Rotate the shaft in order to mesh the sun gears in the
ring gears.
81. Remove the guide studs. Install screws (30) and
82. Check for proper rotation of the shaft.
Issue 1 May 2001

,
, , ,
, ,
, , ,
J . Final operations
,,,,,,,
83. Refit the input unit (see section 5B01) and the PTO
drive line.
84. Reassemble the front clutch (see section 4A01).
,, ,,
85. Refit the reverse shuttle (see section 5B01).
86. Refit the selector cover (see section 5C01).
89. Bleed the clutch control if necessary (see section
9I01).
90. Proceed to road-test of all Dynashift controls and
gear ranges A, B, C and D.
91. Check for leaktightness at couplings and mating
face of selector cover. Fig. 21
K . Service tools
Tools available in the AGCO network:
- 3376887M1 - Centring tool (Fig. 21)
- 3376888M1 - Secondary planet-gear cage holding
tool (Fig. 22)
- 3376920M2 - Planet-gear cage compression tool
(Fig. 7)
Fig. 22
Fig. 23
Issue 1 May 2001

Gearbox - 5B04.1
Dynashift with power shuttle
5 B04 Dynashift
CONTENTS
- General ________________________________________________ 2
- Operating principle _____________________________________ 2
B. Removing and disassembling the cover, front clutch casing

and brake ______________________________________________ 9
C. Removing and splitting the planet carrier unit _____________ 11
D. Disassembling the rear clutch and brake __________________ 12
E. Assembling the planet carriers ___________________________ 12
F. Refitting the rear clutch and brake _______________________ 13
G. Refitting the cover, front clutch, brake and casing _________ 14
H. Shimming the planet carriers ____________________________ 15
I. Assembling the input unit _______________________________ 17
J. Final operations ________________________________________ 17
K. Service tools ___________________________________________ 18
Issue 1 May 2002

5B04.2 Gearbox -
Primary epicyclic gear train
General - The movement comes in via the primary ring gear (31)
- On tractors 8210 - 8220 - 8240 and 8250, the Dynashift which is splined onto the transmission shaft (7). The
can also be mounted on an input unit fitted with a ring gear turns at the same speed as the engine.
mechanical reverse shuttle. - The movement exits via the planet carrier (28) which is
- This section only describes the Dynashift with power splined onto the secondary shaft (53). The primary sun
shuttle. For the Dynashift with mechanical reverse gear (64) is driven by the secondary epicyclic train. The
shuttle, see section 5B03. speed of this sun gear determines the reduction ratio of
- The operating principles of the two Dynashift versions the gearbox.
are similar.
- However, housing profile of the Dynashift with power Secondary epicyclic gear train
shuttle is different because of the location of the power - This epicyclic gear train is controlled by two hydraulic
shuttle rear clutch and the driving gear located at the clutches and brakes.
rear end of the housing. - The secondary ring gear (34) is:
- The Dynashift is located between the rear clutch and . either locked onto the transmission shaft (7) by the
the driving gear of the power shuttle (see section 5B06). three clutch discs (3) and the Belleville washer (4)
- It is a hydraulically controlled gear shift mechanism and located in the front part of the housing,
provides the gearbox with four input ratios. . or immobilised in relation to the housing by three
- The function is ensured by two epicyclic gear trains brake discs (15) and a piston (22).
associated with two hydraulic clutches. Dynashift - When there is no pressure, the piston (22) is pulled back
design enables selection of each of the four ratios while by the twelve springs (20) and the Belleville washer (4)
driving, and under load, without de-clutching, using a by means of the thrust plate (16).
lever mounted to the left under the steering wheel. - When the 17 bar pressure is built up in the circuit, the
- The Dynashift housing is controlled by two solenoid piston (22) moves forward and blocks the brake discs
valves mounted on the clutch unit located on the front (15) while pushing the thrust plate (16) that com-
right hand side of the gearbox. presses the Belleville washer (4).
- The two solenoid valves are controlled by the tractor’s - Speed of the secondary ring gear is established as
electronic system. follows:
. speed equals engine speed if the front piston is not
under pressure.
. speed nil when the front piston is under pressure.
- The secondary sun gear (61) is:
. either locked onto the secondary transmission shaft
by means of four clutch discs (50) and two Belleville
washers (52) located on the rear section of the
housing,
. or immobilised in relation to the housing by means of
three brake discs (41) and a piston (37).
- When there is no pressure, the piston (37) is pushed
forward by the Belleville washers and the six springs
Operating principle (65).
- The 17 bar pressure moves the piston (37) back and
The Dynashift input unit comprises two epicyclic gear
locks the brake discs (41). The piston compresses the
trains:
Belleville washers (52) by means of the thrust plate (45)
- the primary epicyclic gear train is the input unit’s main
that releases the secondary transmission shaft clutch
component and transmits the movement of the engine
discs.
to the gearbox,
- Immobilisation of either the secondary ring gear (34) or
- the secondary epicyclic gear train controls the speed of
the secondary sun gear (61) modifies the speed of the
the primary sun gear.
secondary planet carrier (39). The latter drives the
primary sun gear (64), and this establishes the gearbox
reduction ratio.
Issue 1 May 2002

Gearbox - 5B04.3 Overall view

Parts list (Fig. 1 - 2) (55) Circlip
(1) Secondary ring gear carrier (56) Spacer
(2) Intermediate plates (57) Ball bearing
(3) Front clutch discs (58) Ball bearing
(4) Belleville washer (59) Rear clutch housing
(5) Splined hub (60) Retaining ring
(6) Needle bearing (61) Secondary sun gear
(62) Retaining ring 17 11 2 3 5 7 6 12 10 4 14 42 9
(7) Transmission shaft
(8) Ring restrictor (63) Needles
(9) Screw (64) Primary sun gear
(10) Friction washer (65) Springs 18 13 8
(11) Bearing (69) Circlip
(12) Washer (70) Stop 23
(13) Front cover (71) Shim(s) 25
(14) Clutch housing (72) Retaining ring 29
(15) Front brake discs (74) Rivets
20
(16) Thrust plate (clutch - brake) (75) Oil splasher
(17) Clutch plate (76) Stud washer
(18) Screw (77) Spring washer 16
(20) Springs (78) Washer
(21) Spacer casing (79) Locating pin 15 22
(22) Front piston
(23) Rivet
24 77
(24) O’ring
(25) Screw 27
(26) O’ring 26 37 33
(27) Ball bearing
(28) Primary planet carrier Fig. 1
31 21 74 70 69 79
(29) Rivets
(30) Screw Fig. 2
(31) Primary ring gear 1
(33) Screw 28 64 75 76 53 50 71 72 58 63
(34) Secondary ring gear 34 39
(35) O’ring
62
(36) O’ring
(37) Rear piston 35 56
(38) Clutch plate 61 60
(39) Secondary planet carrier 36 57
(40) Cover
(41) Rear brake discs
49 55
(42) Screw
(44) Clutch plate
(45) Thrust plate (clutch - brake) 59 65
(46) Screw
(47) Cover
48
(49) Retaining ring
(50) Rear clutch discs 30
(51) Friction washer
(52) Belleville washers 38 44 45 40 41 47 51 54 78 52 46
(53) Secondary shaft
(54) Splined hub
Issue 1 May 2002

5B04.4 Gearbox -
Exploded view
42
9
20
18
25
1 37
16 36
4 35
15 33
79 34
14 72
10 70
12 69
6 54
11 7
22 31 50
13 39 48
23 27 50
29 77 48
50
8
48
74
50
21
59
63 78
24 38
26 46
28 71
15 49
17 61
15 39
5
3 55
57 53
2
56 30
3
60 40
2
58 65
3
62 51
64 47
75 52
28
41
71
45
76
41
44
41
Issue 1 May 2002

Gearbox - 5B04.5
Explanation of the ratios - Consequently:
. the secondary epicyclic gear train is locked
Ratio A : Reduction 1/1.620 (Fig. 3)
. the primary sun gear (64) is locked
- The two pistons (22) (37) are simultaneously under
. the reduction ratio is only set by the primary epicyclic
pressure from the 17 bar circuit.
gear train.
- The secondary ring gear (34) is locked onto the casing
- This is standard kinematics, movement comes in via
by means of the front brake.
the ring gear and exits via the planet carrier; the sun gear
- The secondary sun gear (61) is locked onto the casing
does not move.
by the rear brake.
37
22 34
64
61
Transmission of movement to the gearbox

Lubrication
17 bar low pressure

Fig. 3
Issue 1 May 2002

5B04.6 Gearbox -
Ratio B : Reduction 1/1.386 (Fig. 4)
- Front piston (22) is under pressure
- Front brake locks the secondary ring gear (34) onto the
casing.
- Rear piston (37) is not under pressure.
- The secondary sun gear (61) rotates with the secondary
transmission shaft (53) (clutch engaged).
- The secondary planet carrier (39) is rotating at a low
speed, driving the primary sun gear (64).
- The rotational speed of the primary planet carrier (28)
corresponds to the speed difference between the pri-
mary ring gear (31) and the primary sun gear (64).
- Reduction effect is therefore minor.
22 37
34
39
31
64
28
61
53
Lubrication Transmission of movement to the gearbox
17 bar low pressure Pilot flow to the primary sun gear (64)
Fig. 4
Issue 1 May 2002

Gearbox - 5B04.7
Ratio C : Reduction 1/1.1704 (Fig. 5)
- Rear piston (37) is under pressure
- The rear brake locks the secondary sun gear (61) onto
the casing.
- The front piston (22) is not under pressure.
- The secondary ring gear (34) rotates with the transmis-
sion shaft (7) thereby transmitting a higher speed to the
secondary planet carrier (39).
- The primary sun gear (64) is driven by the secondary
planet carrier (39) at a higher speed than in ratio B.
- Reduction is therefore lower.
22 37
34
39
7
64
61
Lubrication Transmission of movement to the gearbox
17 bar low pressure Pilot flow to the primary sun gear (64)
Fig. 5
Issue 1 May 2002

5B04.8 Gearbox -
Ratio D : Reduction 1/1 ratio (Fig. 6)
- The two pistons are not under pressure. The two
clutches are therefore engaged.
- The secondary ring gear (34) rotates with the transmis-
sion shaft (7).
- The secondary sun gear (61) is locked on the secondary
shaft (53) thereby mechanically locking the entire
system.
- The ratio is therefore 1:1 (direct transmission).
34
7 61
53
Lubrication
Transmission of movement to the gearbox Mechanical locking

Fig. 6
Issue 1 May 2002

Gearbox - 5B04.9
1.Uncouple the tractor between the engine and the
3. Remove the selector cover (see section 5C02)
4. Remove the clutch cover plate (see section 3C02),
hydraulic control unit and front clutch from the power
shuttle (see sections 9K01 and 5B06 respectively).
Remove the input unit (see section 5B02).
5. Place the housing in vertical position and split the 13 7
power shuttle rear clutch from the input unit (see
section 5B06).
21

the cover, front clutch casing and
brake (Fig. 7 - 8)
Removal
6. Using two locally made lugs or rings, remove the shaft
(7), cover (13) and casing (21) assembly (Fig. 7)
recover both the stop (70) and the locating pin.
Fig. 7
Issue 1 May 2002

5B04.10 Gearbox -
Disassembly (Fig. 8) 11. Hold the transmission shaft (7) and remove the
7. Remove the piston (37) from the casing (21). Scrap screws (25). Take out the secondary ring gear
the O’rings (35) (36). carrier (1).
8. Place the cover and casing assembly vertically on a 12. Remove the casing (21) along with the piston (22).
workbench in which a hole (Ø approximately 65 Remove the piston and scrap the O’rings (24) (26).
mm) has been drilled in order to accommodate the 13. Remove the discs (3) (15), intermediate plates (2),
transmission shaft. clutch plate (17), hub (5), springs (20) and the thrust
9. Immobilise the transmission shaft (7) with the help plate (16).
of an assistant, using tool ref. 3378004M1 (see § K) 14. Extract the Belleville washer (4), clutch housing
and a locally made spindle. Remove the screws (33) (14) and transmission shaft (7) taking care to draw
and split the secondary ring gear (34) from the them towards the inside face of the cover (13) as
secondary ring gear carrier (1). shown by the arrow in Fig. 8 and recover the friction
10. Remove the circlip (69), pressing on the center of the washer (10).
primary ring gear (31) in order to compress the spring
washer (77). Remove the primary ring gear (31) and
ball bearing (27). Recover the spring washer.
3378004M1
37 69 27 34
31
33 35
77
26 36
24 21
16 22
20
25 2 3 10 5 7 4 14 1 17 15 13
Fig. 8
Issue 1 May 2002

Gearbox - 5B04.11
C . Removing and splitting the planet
carrier unit 63
Removal (Fig. 9)
15. Using tool ref. 3376920M2 (see § K) gently com-
press the planet carrier assembly (Fig. 9).
16. Remove the retaining ring (72). Remove the stud
washer (76), planet carrier assembly and the shims
(71) mounted along the mating faces of the primary
planet carrier (28).
17. Remove the secondary sun gear (61) and the retain-
ing ring (49) (if necessary).
18. Remove the circlip (55). Remove the bearing (57)
and the spacer (56).
Fig. 10
Splitting
19. Split the secondary planet carrier (39) from the
primary planet carrier (28).
20. Remove the retaining ring (60) and bearing (58).
21. Place the secondary planet carrier in vertical posi-
tion. Remove the needles (63) (Fig. 10) by hitting the
planet carrier gently against a wooden shim. Split the
planet carrier from the primary sun gear (64) along
with the retaining ring (62) and oil splasher (75).
28 60 28 76 71 72 58 56
39 57 55
61 39
49
3376920M2
Fig. 9
Issue 1 May 2002

5B04.12 Gearbox -
D . Disassembling the rear clutch
and brake
22. Remove the clutch plate (38), springs (65) and discs
(41) (the latter should be separated from the clutch
plate (44)).
23. Remove the rear clutch housing assembly (59),
thrust plate (45) and the last disc (41). Remove the
friction washer (51).
24. Remove the screws (46). Remove the cover (47)
and the Belleville washers (52). Separate the thrust
plate (45), discs (50) and intermediate plates (48).
25. Remove the hub (54).
E . Assembling the planet carriers

26. Clean and check parts, replace any defective ones.
27. Make sure the lubrication holes on the planet carrier
axes are not obstructed.
28. Check the axial clearance and rotation of each pinion
gear by hand.
29. Assemble the primary sun gear (64), complete with
retaining ring (62) and oil splasher (75), on the
secondary planet carrier (39).
30. Into each hole of the primary sun gear, slide a needle
(63) home in the groove of the secondary planet
carrier.
31. Fit the bearing (58), mount the retaining ring (60).
32. Assemble the secondary planet carrier on the pri-
mary planet carrier (28). Turn the pinion gears to
ensure they mesh correctly.
33. Position the spacer (56), bearing (57) and fit the
circlip (55).
34. Check the primary pinion gears backlash by hand.
35. Assemble the retaining ring (49) (if it was removed)
on the secondary sun gear (61).
Issue 1 May 2002

Gearbox - 5B04.13
F. Refitting the rear clutch and brake
36. Clean and check parts, replace any defective ones. 54 59 61
37. Turn the planet carriers over in order to access the
screws (46) (Fig. 11).
38. Fit the secondary sun gear (61), the housing (59) and
the hub (54), with its internal grooves pointing down-
wards (Fig. 11).
39. Assemble: discs (50), intermediate plates (48), the
thrust plate (45), the Belleville washers (52) as
indicated in Fig. 1 and refit the cover (47).
40. Center the housing assembly (59) using tool ref.
3376887M1 (see § K and Fig. 12).
41. Smear the screws (46) with Loctite 242 and torque
them to 12 - 16 Nm (Fig. 12). Remove the tool.
Separate the housing unit from the planet carriers.
42. Coat the washer (51) with miscible grease and fit it Fig. 11
on cover (47).
Note: Type 648 Loctite or equivalent should be used
to make the washer (78) glue to the cover (40).
43. Fit a disc (41).
44. Fit the housing assembly (59) and the washer (51) 46
on the transmission shaft (53). Assemble the hub
(54), making sure its internal grooves face upwards
(Fig. 13).
45. Fit the two other discs (41) separated by the thrust
plate (44). Refit the springs (65) (Fig. 13).
Fig. 12
54 53
65
59 51 41 44
Fig. 13
Issue 1 May 2002

5B04.14 Gearbox -
G . Refitting the cover, front clutch,
brake and casing 5
46. Check presence of rivets (23) on the cover (13). 14

Special points 7
- If it proves necessary to replace the bearing (11), 12
force fit a new bearing (6) with its face flush with
the back end of the bearing.
- Degrease the mating faces of the bearing and of the
washer (12). Apply a light coating of Loctite 648 or
equivalent to one of the washer faces. Make the
washer adhere to the bearing and leave to dry for a
few minutes.
47. Place the bearing on the front cover (13) making sure
to align the lubricating channels. Lightly coat the 13
screws with Loctite 242 and torque them as follows:
Fig. 14
- M6 screw (9) : 12 - 16 Nm
- M8 (42) : 20 - 28 Nm
48. Place the cover on a suitable fixture.
49. Assemble the transmission shaft (7) via the inside
surface of the cover (13) and the housing (14) toge- 58. Fit the screws (18) and torque to 29 - 37 Nm.
ther with the washer (12) (Fig. 14). Piston (22) hydraulic test
50. Fit the Belleville washer (4) as indicated in Fig. 1, a Connect a pressure gauge fitted with a valve and
disc (15) and the thrust plate (16). suitable fixture to the front piston port. Feed the
51. Place the hub (5) on the transmission shaft (7) with circuit with compressed air at 0.3 bar. Close the
the internal grooves facing upwards (Fig. 14). As- valve and check that pressure does not drop over a
semble the discs (3) and the intermediate plates (2). period of approximately 60 seconds.
52. Fit the two remaining discs (15) one on each side of 59. Fit the bearing (27) on the primary ring gear (31).
the clutch plate (17). 60. Refit the ring gears (31) (34), secondary ring gear
53. Refit the springs (20). carrier (1), bearing (27) and spring washer (77).
54. Check presence of the rivets (74) on the spacer Carry out operations 8 to 11 in reverse order.
casing (21). Make sure the channels in the pistons Note: In order to avoid any difficulties during assem-
(22) (37) within the casing (21) are not blocked. bly, refit the primary ring gear (31) before tightening
55. Lubricate the O’rings (24) (26) and assemble them the screws (25).
on the piston (22) and in the casing (21) respectively. Torque as follows:
56. Position the piston in the casing and fit it using a - screw (25) : 31 - 35 Nm, Loctite 242
small plastic mallet to hit progressively round the - screw (33) : 13 - 15 Nm, Loctite 242
edge. 61. Lubricate and assemble new O’rings (35) (36). Place
57. Fit the casing (21) on the cover (13). Check that the the piston (37) in the casing (21) and force fit it using
casing lubricating channel aligns with that of the a small plastic mallet to hit progressively round the
cover. edge.
Piston (37) hydraulic test
Special point - Use a suitable fixture to hold the piston.
- If either the cover (13) or the casing (21) is replaced it - Check seal tightness as for the front piston.
is necessary to check and possibly renew the shim-
ming of the power shuttle front clutch (see section
5B06).
Issue 1 May 2002

Gearbox - 5B04.15
H . Shimming the planet carriers
Note: For adjusting clearances J1 and J2, springs
(65) and clutch plate (38) must be removed.
On rear clutch housing (Fig. 17)

62. Use a depth gauge to measure dimensions B and C
at two opposing points. Take the average of the two
readings.
Calculate dimension: A = B - C
J2 = 0/0,20 mm J1 = 0,50/0,70 mm
71
On the planet carrier assembly (Fig 16)
63. Install secondary sun gear (61) complete with retai-
Fig. 15
ning ring (49) on ball bearing (57).
64. Measure dimension D using a depth gauge.
65. Determine gap E between primary planet carrier
(28) and hub (54) (Fig. 18) according to the formula:
E=A+D
66. Fill space E with shims (71) having a value of E + 61 49 57
0.50 min. to + 0.70 max., to obtain a clearance of:
J1 = E + 0.50 to 0.70 mm
D
Fig. 16
A C
Fig. 17
Issue 1 May 2002

5B04.16 Gearbox -
67. Place secondary sun gear (61) on housing (59) and
the planet carrier assembly on the shaft (53). Install
washer (76) and ring (72).
68. Position the feeler of a dial gauge as per Fig. 19 and
check the clearance by moving the planet carrier
assembly vertically.
69. Depending on the measured clearance, select the
thickness of shims (71) to obtain J2 = 0 to 0.20 mm
70. Remove the planet carrier assembly. 28
71. Install springs (65). Position clutch plate (38),
ensuring that the notches align with the tabs of the
cover (40).
72. Ensure presence of shims (71) defined at operation
66. 54
73. Refit secondary sun gear (61) and planet carrier E
assembly and compress using tool ref. 3376920M2 Fig. 18
(see Fig. 9 and § K).
74. Set shims (71) selected at operation 69 against the
primary planet carrier (28). Install washer (76) and
ring (72) (Fig. 19).
75. Check the secondary sun gear backlash by hand.
28
72
76
28
71
Fig. 19
Issue 1 May 2002

Gearbox - 5B04.17
I . Assembling the input unit
76. Screw two guide studs on the casing (21) (Optional).
Check presence of positioning pin and oil splasher on
cover (40).
77. Use a sling (Fig. 7) to reinstall the transmission shaft
assembly (7), cover (13) and casing (21) aligning the
positioning pin with its housing on the cover (40).
78. Turn the shaft in order to engage the planet carriers
in the ring gears.
79. Remove the guide studs (if used). Install the screws
(30) and torque to 29 - 37 Nm, having lightly coated
the threads with Loctite 242 beforehand.
80. Check shaft rotation.
81. In case the cover (13) has been replaced, position
the ring restrictor (8) having first lightly coated it with
Loctite 648. Check that the product does not block
the lubricating ports.
J . Final operations
82. Reinstall the power shuttle rear clutch (see section
5B06).
83. Refit the input unit (see section 5 B02) and the power
shuttle hydraulic unit (see sections 5B06 and 9K01
respectively).
Refit the clutch cover (see section 3C02).
85. Top up housings with oil and check the level on the
sight-glass on left at rear of central housing.
87. Check the oil tightness of the hydraulic unions and of
the selector cover mating face.
Issue 1 May 2002

5B04.18 Gearbox -
K . Service tools 3376887 M1

- 3376887 M1 - Center punch (Fig. 20)
- 3376920 M2 - Planet carrier compression tool

(Fig. 21)
- 3378004 M1 - Transmission shaft sleeve (Fig. 22)
Fig. 20
3376920 M2
Fig. 21
3378004 M1
Fig. 22
Issue 1 May 2002

Gearbox - Mechanical reverse shuttle 5B05.1
5 B05 Mechanical reverse shuttle
CONTENTS
- General ________________________________________________ 2
- Operation ______________________________________________ 2
B. Disassembling and reassembling the reverse shuttle ______ 5
C. Preparing and shimming the secondary shaft _____________ 7
D. Preparing and shimming the reverse-drive idling gear ______ 8
Issue 1 May 2001

5B05.2 Gearbox - Mechanical reverse shuttle

Parts List
General (1) Shim(s)
Type 8210 - 8220 - 8240 and 8250 tractors may be fitted (2) Secondary shaft
with a Heavy Duty gearbox featuring a mechanical (3) Bearing cone
reverse shuttle. (4) Needle roller bearing
(5) Needle roller bearing
The reverse shuttle transmits movement commanded at (6) Bush
the Dynashift into the transfer shaft installed at the front (7) Washer
of the main gearbox, by the action of the dual gear (see (8) Bearing cone
section 5A01). (9) Bearing cup
(10) Roller bearing
The reverse shuttle assembly is located in the rear cavity (11) Screw
of the input housing behind the Dynashift. It includes: (12) Bearing cone
- two helically cut pinions (19) and (28) installed on two (13) Bearing cone
needle bearings (4) and (5). These pinions are respec- (14) Idling gear shaft
tively in constant engagement with the dual gear at the (15) Bearing cup
box main input drive and reverse-drive idling gear (17) (16) Spacer ring
- twin-cone synchromesh assembly (34), the hub is (17) Reverse-drive idling gear
locked by the splines on secondary shaft (2) (18) Bearing cup
- a synchromesh-control selector rail and fork assembly (19) Forward drive gear
(see section 5D01) (20) Synchromesh slide
- secondary shaft (2) installed on two tapered roller (21) Rings
bearings supported by two bearings in the input housing (22) Rings
- reverse drive idling gear (17) rotating on two tapered (23) Cones
roller bearings installed on shaft (14) mounted in two (24) Synchromesh flanges
bores in the housing. (25) Locking device
The latter gear is in constant engagement with the front (26) Shoes
teeth of the gearbox dual input gear. (27) Synchromesh hub
(28) Reverse-drive gear
(29) Washer
(30) Bearing cup
(31) Screw
(32) Retaining plate
(33) Housing
(34) Synchromesh assembly
Operation
Forward drive
When the synchromesh slide is over on the right, it Fig. 1
transmits movement to forward drive gear (19) in direct
connection with the rear teeth of the gearbox dual input
gear. Fig. 2
Reverse drive
Forward-drive gear (28) is in constant engagement with
idling gear (17) which meshes with the front teeth of the
gearbox dual input gear.
Issue 1 May 2001

Overall view
33 29 28 19
31
30
32
2 34
3 10
1 9
4 5 6 7 8
16
18 17 26 25
15
27
20
21
22 23 24 19
11 12 13 14
Issue 1 May 2001


Exploded view
14
13
15
16
10
17
33 18
6 12
11
2
9
8
3
7
30
5
1
19
24 32
23 31
22
21
26
27
25
20
21
22
23
24
28
34
4
Parts list Fig. 1 29

Fig. 2
Issue 1 May 2001

(see section 2B01).
2. Drain the gearbox and the intermediate housing. 7
Note: Visually identify the contour of the plugs.
3. Remove the hydraulic clutch (see section 4A01). 19
4. Remove the selector cover (see section 5C01). 28
5. Remove the input housing (see section 5B01).
6. Disassemble the locking device, the selector rail and 34
the reverse shuttle fork (see section 5D01).
7. Place the housing on a work bench in the vertical
position. Remove the sling.
8. Disassemble the Dynashift (see section 5B03).
Fig. 3
B . Disassembling and reassembling

the reverse shuttle
Disassembly
9. Remove screws (11), extract shaft (14). Remove
gear (17) and bearing cones (12) and (13).
10. Drive out cups (15) and (18). Remove spacer ring
(16).
Note: Pair the cones and cups if they are to be re-
used.
11. Remove screws (31). Remove retaining plate (32),
shims (1) and cup (30).
12. Extract secondary shaft (2).
13. Remove the assembly comprising pinions (19) and
(28), synchro (34) (Fig. 3) and washer (7).
14. Remove cone (8) and cup (9).
15. Separate the following parts on the pinion / synchro-
mesh assembly:
- gear (19), bush (6), needle roller bearings (5), cones
(23), rings (21), rings (22), synchromesh flanges
(24), gear (28) and needle roller bearings (4).
16. If necessary, withdraw cone (3) from the shaft,
remove washer (29), and drive out roller bearing (10).
Issue 1 May 2001


Reassembly 24. Refit the assembly comprising pinions (19) and (28),
17. Clean and check the parts and replace any that are synchro (34) and washer (7) (Fig. 3).
faulty. 25. Centre the washer. Insert secondary shaft (2) through
18. Check that the pipes and ports in secondary shaft the front bore in the housing, into the pinion / synchro
(2), shaft (14), housing (33), synchromesh (34) and assembly.
bush (6) are not blocked. 26. Install shaft (2), with shoulder E in contact with the
19. Ensure that the plug (rivet) is crimped into the synchromesh hub (Fig. 4).
housing, on the end of the lube pipe to the reverse- Note: If shimming of the secondary shaft proves
drive idling gear. to be necessary, see § C, otherwise continue the
20. If necessary, overhaul synchromesh (34) (see Gen- assembly operation.
eral and operation, section 5A01).
21. If it was removed, refit washer (29) on shaft (2) then
fit cone (3) in abutment on the washer, using a press
and a suitable fixture.
22. Lubricate the shaft, the cones and the bearing cups.
23. Assemble gear (19) and bush (6) by positioning the
inner recess towards drive hub (27) of the assembly
comprising (34), needle roller bearings (5), cones
(23), rings (21), rings (22), synchromesh flanges
(24), gear (28) and needle roller bearings (4).
31 32 1 30
28
E
34
19
Fig. 4
Issue 1 May 2001

27. Fit cup (30), shims (1) and retaining plate (32) (Fig. 4).
28. Coat screw (31) with Loctite 241 or equivalent;
install and torque to 25 - 32 Nm (Fig. 4).
29. Manually check the axial play and rotation of pinions 2
(19) and (28) and shaft (2).
Note: If shimming of the reverse-drive idling
gear proves to be necessary, see § D otherwise
continue the assembly operation.
30. Fit idling gear (17) fitted with spacer ring (16), bearing
cones (12) (13) and shaft (14).
31. Apply a light quantity of Loctite 241 or equivalent to
screw (11); install and torque to 40 - 56 Nm.
32. Check with fingers for for normal backlash of gear
(17) and rotation of the complete gear train.
33. Fit roller bearing (10).
Fig. 5
C . Preparing and shimming the se-

condary shaft P1 = 0,10 / 0,20 mm
34. Position the housing in a vice.
Preliminary steps
35. Calculate shim thickness E (1) to obtain a temporary
clearance of 0.10 to 0.20 mm maximum.
36. Position cup (30), shims (1) as calculated earlier, and
retaining plate (32).
37. Install and provisionally tighten screw (31) without
Loctite to 25 - 32 Nm.
Shimming (Fig. 5 and 6)

38. Place the feeler of a dial gauge on the extremity of
shaft (2).
39. Exert a hard pull on the shaft, rotating it alternately
right and left in order to correctly seat the cones in the
bearing cups.
40. Adjust the dial gauge pointer to zero.
41. Repeat operation 39, this time pushing on the shaft.
42. Depending on the clearance value J obtained, select
a new thickness of shims C (1) to obtain a preload:
P1 = 0.10 to 0.20 mm
According to the formula: C = E + J + P1
Note: If possible, set at the top value of the
tolerance.
43. Remove screw (31), remove retaining plate (32).
44. Fit final shims (1) selected at operation 42, on cup
(30). Reinstall the retaining plate. Install and torque
screw (31) as described at operation 28.
Fig. 6
Issue 1 May 2001

D . Preparing and shimming the re-

verse drive idling gear 14
45. Position the housing in a vice.
Preparation
46. Install minimum spacer ring (16) in the groove of
gear (17) then fit cups (15) and (18) in abutment on
the segment.
47. Position gear (17) per Fig. 7 and cones (12) and (13) 13
on the housing. Slide shaft (14).
48. Install screw (11) (Fig. 7) without Loctite, and torque
to 40-56 Nm. 17
49. Adjust shims (Fig. 8) to obtain a clearance:
J2 = 0.05 to 0.18 mm. 12 11
Fig. 7
Shimming
50. Apply the feeler of a dial gauge to gear (17) (Fig. 7).
51. Exert a hard push on the gear, alternately rotating to
right and left in order to seat the cones correctly in the
cups.
52. Adjust the dial gauge to zero.
53. Repeat operation 51, this time pulling on the shaft.
54. Depending on the value read on the dial gauge, select
the definitive spacer ring (16) to obtain J2.
55. If necessary, remove gear (17). Drive out cups (15)
and (18). Remove spacer ring (16).
Fit the spacer ring selected at operation 54.
Fit the cups. Reinstall the gear. Repeat operation 30.
56. Coat screw (11) with Loctite 241 or equivalent,
install and definitively torque to 40 - 56 Nm.
57. Check with fingers for normal backlash at gear (17) J2J2==0,05
0,05 //0,18
0,18mm
mm
and rotation of the gear train.
Fig. 8
Issue 1 May 2001

E . Final operations
58. Reassemble the Dynashift (see section 5B03).
59. Reassemble the reverse shuttle fork, the selector
rail and the locking device (see section 5D01).
60. Refit the input housing (see section 5B01).
61. Refit the selector cover (see section 5C01).
62. Refit the hydraulic clutch (pressure loaded) (see
section 4A01).
64. Service the oil in the sumps and check the level on
the sightglass located on the left of the centre
housing.
65. If necessary, bleed the hydraulically controlled clutch
(see section 9I01).
66. Proceed to road test of all Dynashift controls (reverse
shuttle and ratios A, B, C, D).
67. Check the leaktightness of the hydraulic connec-
tions and the mating face of the selector cover.
Issue 1 May 2001

Gearbox - 5B06.1
Power Shuttle
5 B06 Power Shuttle
CONTENTS
- General ________________________________________________ 3
A. Removing and refitting the front clutch ___________________ 11
B. Disassembling and reassembling the front clutch _________ 12
C. Shimming the front clutch _______________________________ 15
D. Disassembling and reassembling the rear clutch __________ 16
E. Disassembling and reassembling the driving pinion -

Shimming the shaft _____________________________________ 20
F. Service tools ___________________________________________ 23
Issue 1 May 2002

5B06.2 Gearbox -
Power Shuttle
Issue 1 May 2002

Gearbox - 5B06.3
Power Shuttle
Design
General The front and rear clutches of the Power Shuttle are of
- The power shuttle, also called “I.S.C.”, consists of two different design.
electro-hydraulically controlled clutches. It is so de-
signed as to allow for reverse direction under load and The front clutch consists of:
can be fitted in parallel to the mechanical reverse - a conventional type oil-bath multi-disc clutch consist-
shuttle to all 8210 - 8220 - 8240 and 8250 tractors ing of a cover (33), the rear side of which is splined to
equipped with Heavy Duty transmission. assemble the input sun gear (53),
- The power shuttle transmits the movement from the - an input shaft (19) passing through the clutch cover
engine to the layshaft mounted on the front of the main plate (4) that separates the engine flywheel from the
gearbox by means of pinions located respectively to the transmission oil. The shaft is constantly meshed with
rear of the input unit and at the gearbox input. the damper secured to the engine flywheel. It is splined
- A lever, mounted to the left under the steering wheel, so as to rotate with the clutch unit (18) comprising the
controls both the power shuttle and A, B, C, D gear intermediate plates (30) and the discs (29) in which
range of the Dynashift. It is also fitted with a position piston (28) moves,
especially used for manual de-clutching of the trans- - a drive hub (27) comprising the discs (29) and integral
mission. with the primary shaft (55). The front clutch is centered
- Depending on the position selected by the operator in the cover (38) of the rear clutch by ball bearing (32).
(forward, neutral, reverse or manual de-clutching), the
lever manages the progressive solenoid valves of the The rear clutch consists of :
front and rear clutches by means of the electronic - an epicyclic gear train consisting of three double pinion
system of the tractor. gears (52) and three single pinion gears (59),
- The solenoid valves are located to the front and to the - a hydraulic braking device for planet carrier (49),
right of the gearbox on a clutch unit integrating the - a cover (38) supporting the front clutch and with an inner
Dynashift hydraulic control system. A filter (60 mi- side machined to assemble hydraulic parts.
crons) located under the right-hand selector cover,
upstream of the clutch units, provides additional filter- - The double and single pinion gears (52) (59) of the
ing for oil supplying the solenoid valves (Dynashift epicyclic gear train mesh respectively on the input and
clutches). output sun gears (53) (58). The pins (50) are mounted
- A progressive sensor, screwed to the top of the box idle and held in the planet carrier by plates (63). A central
housing, sends shaft rotational speed information to the drilled channel and radial ports supply lubrication to
electronic system. needle bearings (60).
- Shifting of any forward gear to the corresponding - The planet carrier braking device consists of an annular
reverse gear, or vice versa, is easy without de-clutch- piston (39) and a plate (43) that is loaded by springs (62)
ing or stopping the tractor. This “assisted” gear re- and discs (47) integral with the planet carrier through
versal enables gradual changing of the operating direc- splines.
tion, even at high travel speeds without abrupt changes - The intermediate plates (46) are immobilised by the
in speed. The clutches slow down tractor movement pins (71).
until the required speed is reached so that the direction - The fixed unit (1) performs two functions:
of operation can be reversed. . it receives the low pressure supplying the front clutch
- The traditional hydraulically operated clutch pedal is via pipe (74),
replaced by an electro-hydraulic action maneuvering . it acts as the body of the clutch lubricating and cooling
pedal. This pedal modulates the pressure in the front or pump.
rear clutches through the electronic system of the
tractor and thus facilitates precise movements such as
hitching tools.
Issue 1 May 2002

5B06.4 Gearbox -
Power Shuttle
The pipes (31) (86) connecting the pump unit (1) and This unit comprises:
cover (38) lubricate the rear clutch braking device. The - a secondary shaft (1) and helical pinion (2) machined
pipe (87) provides the hydraulic link to the lubrication in one piece (Fig. 1).
diagnostics connector.
The shaft is mounted on two taper roller bearings having
The shims (3) located between clutch cover plate (4) and different cross-sections and is carried by two bearings
the fixed pump unit (1) provide the axial clearance for the (Fig. 1).
front clutch.
The shims (3) (Fig. 1) fitted between bearing cup (16) and
Drive from the power shuttle is transmitted to a mechani- the rear casing (5) are used to preload the bearings.
cal unit located in the rear compartment of the input box.
5 2 1
16 3
Fig. 1
Issue 1 May 2002

Gearbox - 5B06.5
Power Shuttle
Operating principle The input sun gear then drives the double pinion gears
Front clutch (52) freely mounted on the pins (50) which, in turn, drive
When the lever under the steering wheel is in the Forward the single pinion gear (59), integral with primary shaft (55)
position, the solenoid valve is activated and supplies a thus reversing rotation of the output sun gear (58) splined
pressure that moves piston (28). This, in turn, com- to the primary shaft (55). The primary shaft then sends
presses the intermediate plates (30) and the discs (29) the movement from the engine to the layshaft of the main
against cover (33). The movement from the engine to the gearbox via the input pinion.
gearbox complies with the following kinematics: Remark: As with Forward operation, simply pull the
- input shaft (19) splined to unit (18) control lever towards the steering wheel to obtain the
- front clutch unit (18) “manual de-clutching” of the rear clutch. A valve screwed
- intermediate plates (30) to the top of cover (38) ensures a small permanent bleed
- discs (29) compressed by the piston (28) starting from 13 bar to provide an automatic bleed of the
- hub (27) hydraulic supply of piston (39).
- primary shaft (55)
- main box layshaft via the input pinion. Lubrication
Simultaneously, the pressure applied behind piston (39) As piston (39) moves, it operates spools (44) that act as
of the braking device drops and the planet carrier assem- valves and compress springs (45) via plate (43). The
bly (discs (47), intermediate plates (46) and epicyclic spools have a drilled center channel and radial ports,
gear train) rotate freely. allowing oil to flow to the channels in cover (38) and the
Remark: When the control lever is pulled towards the channels in the front cover of the input unit, thus lubricat-
steering wheel, a "manual de-clutching" position of the ing the discs (47) and the intermediate plates (46).
front clutch is produced. Lubrication of the mechanical parts of the epicyclic gear
train is via the lubricating system of the input unit.
Lubrication At the same time, the lubricating oil flow to discs (29) and
During forward operation, the oil flow from the centre intermediate plates (30) of the front clutch is stopped,
housing via the pump (14) is directed towards the thus halting any possible driving of the discs through a
intermediate plates (30) and the discs (29) via the ports drag effect.
of the front clutch unit (18) opened by movement of
piston (28).
At the same time, lubrication of the braking device of the
planet carrier (discs (47) and intermediate plates (46)) of Neutral position
the rear clutch is interrupted. In neutral position, the supply to the solenoid valves is
cut, placing the front and rear clutches at rest and
Rear clutch eliminating transmission of the engine movement to the
When the previously mentioned lever is moved from the gearbox.
Forward to Reverse position, the solenoid valve con- The oil flow is also interrupted. The pressure in the circuit
cerned is activated and supplies the piston (39) of the opens the valve (1) (Fig. 17) and directs the oil to the
braking device of the planet carrier. The piston then housing.
presses on plate (43) which compresses discs (47) and
the intermediate plates (46) against the front cover of the Note: After replacement of a solenoid valve or sole-
input unit and stops the rotation of the planet carrier. The noid, power shuttle hydraulic unit or one of the
movement from the engine is directly transmitted to components of the transmission control unit, it is
cover (33) that is integral with the input sun gear (53) via necessary to carry out clutch calibration again (see
splines, without passing through the discs and interme- section 11).
diate plates of the front clutch. Simultaneously, the
pressure of oil in piston chamber (28) drops and frees
discs (29) and intermediate plates (30).
Issue 1 May 2002

5B06.6 Gearbox -
Power Shuttle
Parts list (55) Primary shaft
(1) Pump unit (56) Snap ring
(2) Pump cover (57) Ball bearing
(3) Shim(s) (58) Output sun gear
(4) Clutch cover plate (59) Single pinion gear
(5) Locking ring (60) Needle bearings
(6) Splined ring (61) Snap rings
(7) O’ring (62) Springs
(8) Anti-extrusion ring (63) Stop plates
(9) Snap ring (64) Screw
(10) Seal (65) Snap ring
(11) Circlip (66) Screw
(12) Ball bearing (67) O’ring
(13) Screw (68) Ball bearing
(14) Lubricating pump (69) Seal
(15) Sealing rings (70) Screw
(16) Ring (71) Pin
(17) Centering pin (72) Unions
(18) Front clutch unit (73) 1.5 bar valve
(19) Input shaft (74) Pipe
(20) Pin (75) O’rings
(21) Circlip (76) Pipe (17 bar rear clutch)
(22) Ball bearing (77) 13 bar valve
(23) Snap ring (78) Pipe (shuttle lubrication)
(24) Seal (79) Screw
(25) Belleville washers (80) Flange
(26) Indexing ports (81) Seal
(27) Drive hub (82) 500 micron strainer
(28) Front clutch piston (83) Union
(29) Front clutch discs (84) Plug
(30) Front clutch intermediate plates (85) Seal
(31) Lubricating pipe (86) Lubricating pipe
(32) Ball bearing (87) Pipe
(33) Front clutch cover (88) Union
(34) Planet carrier cover (90) Diagnostics connector (lubrication)
(35) Rivets (91) Union
(36) Seal (93) Union
(38) Rear clutch cover (94) Pipe
(39) Rear clutch piston (95) O’rings
(40) Rivets (96) Union
(41) Seal (97) Screw
(42) Seal (98) Snap ring
(43) Plate (99) Screw
(44) Spools
(45) Springs
(46) Rear clutch intermediate plates
(47) Rear clutch discs
(48) Ring restrictor
Fig. 2
(49) Planet carrier
(50) Pinion gear pin
(51) Spacers Fig. 3
(52) Double pinion gear
(53) Input sun gear
(54) Snap ring Fig. 4
Issue 1 May 2002

Gearbox - 5B06.7
Power Shuttle
Overall view
38 70 33 32 72 35 34 36 38 40 42 43 45 44 64 46
A
47
48
A
B 49
9 11 12 13 14 15 16 18 50
4 31 86 51
10 30 52
9 29 53
28 54
8 26 55
7 19 56
6 24 61
5 20 25 B 57
3 18 98
2 1 69 58
C 68 59
C
67 60
21
23
22 66 27 65 71 41 39 63 54
Fig. 3
38 43 62
Fig. 2
Fig. 4
Issue 1 May 2002

5B06.8 Gearbox -
Power Shuttle
Overall view
73
31
72
86
76
72
75
88
F
74 F
75
89 83
91 Lubrication Dynashift
96
90
75
95 97
94 67 87 93
78
82
79 80 81
Hydraulic control unit 84 85

Fig. 3
Fig. 2
Issue 1 May 2002 Fig. 4

Gearbox - 5B06.9
Power Shuttle
Exploded view
Front clutch Rear clutch
65
45
33 44
27
54 77
53
32
29
30
5 46
9 62
8
47
7
8 71
6 49
9 17
43 57
42 56
41 98
36 63
25 52
39
15
38 60
40 51
70 60
50
63
21
34
19
99
22
2
13 28
24 59
23
69 60
3
18 51
12
66 60
11
20 50
68 61
16 58
1 61
14 Fig. 2
73
Fig. 4
Fig. 3
Issue 1 May 2002

5B06.10 Gearbox -
Power Shuttle
Issue 1 May 2002

Gearbox - 5B06.11
Power Shuttle
Final operations
A . Removing and refitting the front 10. Replace the pipe seals (74) (94).
clutch 11. Refit the pipes, carry out operation 5 in reverse order.
12. Replace the pipe seals (78) and refit them the pipe.
Preliminary operations Tighten the flange holding screw at each end of the
1. Split the tractor between the engine and the gearbox pipe to a torque of 25 Nm - 35 Nm.
(see section 2B01). 13. Refit the gearbox clutch cover plate (see section
2. Drain the gearbox and the centre housing. 3C02).
3. Remove the clutch cover plate from the gearbox (see 14. Top up the housing oil level and check it with the
section 3C02). sight glass located at the rear left of the centre
4. Remove the flange from each end of the pipe (78) and housing.
remove it (Fig. 3). 15. Couple the tractor between the engine and the
5. Remove pipes (31) (74) (86) (87) and (94). gearbox (see section 2B01).
16. Carry out a road test using the power shuttle and
Removal using ratios A, B, C and D of the Dynashift.
6. Remove the front clutch (2) (Fig. 5) and pull it from the 17. Check oil tightness of the mating faces and hydraulic
housing using a locally made tool (see § F). unions.
Refitting
7. Clean the parts. Replace any defective ones.
Remark: If front clutch shimming is necessary,
refer to § C.
8. Check that PTO shaft (1) is installed (Fig. 5).
9. Refit the clutch using the tool used for removal.
Fig. 5
Issue 1 May 2002

5B06.12 Gearbox -
Power Shuttle
27. Remove the Belleville washers.
B . Disassembling and reassembling 28. Remove snap ring (23). Pull out the shaft (19)
the front clutch complete with bearing (22) from hub (27).
29. Remove the circlip (21). Extract the bearing (22) from
Disassembly shaft (19).
18. Separate cover (33) from unit (18). Remove the discs 30. Remove the piston. Remove seals (24) (69) and
(29) and the intermediate plates (30). discard them. If necessary, extract the bearing (68)
19. Remove the front snap ring (9). Remove the splined from unit (18).
ring (6), the anti-extrusion rings (8) and seal (7). 31. If necessary, remove snap ring (54) and remove the
20. Remove circlip (11), take off cover (2) from the pump input sun gear (53). Remove snap ring (65). Extract
(14) complete with bearing (12). bearing (32).
21. Pull the lubricating pump out of the pump unit (1) and
take it apart from the clutch housing (18). Reassembly
22. Remove seal rings (15). If necessary, extract ring 32. Make sure that pin (20) is fitted.
(16) and remove the 1.5 bar valve (73). 33. If removed, fit the bearing (32) on cover (33), using
23. Place the partially disassembled clutch on a suitable a press and a suitable tool. Install snap ring (65).
locally made fixture (Fig. 6) (see § F). 34. If disassembled, refit bearing (68).
24. Compress the Belleville washers (25) and remove 40. Lubricate the new seals (24) (69) and fit them on the
the rear snap ring (9) (Fig. 6). piston.
25. Remove locking ring (5). Gradually release the
Belleville washers.
26. Split unit (18) fitted with piston (28) from shaft (19).
25
Fig. 6
Issue 1 May 2002

Gearbox - 5B06.13
Power Shuttle
36. Fitting piston (28).
Remark: The angular position of the piston depends
on the position of unit (18) lubricating ports. Align the
indexing holes drilled in the unit and the piston (Fig. 7).
To align, use a pin of a suitable diameter. Complete
the installation of the piston by gradually and alter- 18
nately striking around its top rim with a plastic
mallet. Check that there are no fragments of the seal
after assembly.
37. Using a suitable tool, force fit bearing (22) on shaft
(19), the seal side facing towards the rear clutch. Fit
circlip (21).
38. Put the assembly (shaft, bearing, circlip) in the hub
(27). Fit the snap ring (23).
28
39. Refit the Belleville washers as shown in Fig. 8.
Remark: 8200 series tractors are fitted with six
Belleville washers. Fig. 7
40. Assemble unit (18) fitted with the piston (28) on shaft
(19).
41. Compress the Belleville washers using the tool used
in operation 23. Position ring (5), aligning two of the
flats with the flats on unit (18). Replace the rear snap
ring (9) and correctly position it in the bottom of the
groove.
42. Remove the fixture.
43. Check that the seal rings (15) turn freely in their
grooves. Fit the seal rings, lightly coated with mis-
cible grease, making sure that they do not protrude
beyond the rim of unit (18).
44. If necessary, fit the 1.5 bar valve (73) and tighten to
a torque of 47 - 54 Nm. Insert ring (16) using a
suitable fixture, with the chamfer “C” in the direction
shown in Fig. 9.
45. Lubricate the bush. Assemble pump unit (1) on unit
(18).
46. Lubricate pump (14) with transmission oil and posi- Fig. 8
tion it aligning the flats of the rotor with those on the
unit (18).
47. Manually check the angular movement of the rotor
on the flats of unit (18).
48. Fit bearing (12) on cover (2) of the pump. Fit the 16
cover. Install circlip (11) and screws (13) and tighten
to a torque of 36 - 46 Nm.
49. Lubricate and install a new assembly (O’ring (7) and
anti-extrusion ring (8)). Slide on the splined bush (6).
Fit a new front snap ring (9). C
50. Soak the discs (29) in a transmission oil bath for
approximately 1 hour. Check that they are correctly
saturated.
Fig. 9
Issue 1 May 2002

5B06.14 Gearbox -
Power Shuttle
51. Position the intermediate plates (30), aligning the
tabs and the discs (29) on hub (27) according to the
type of tractor (see remark and Fig. 10).
Remarks: 29 27 30
- 8210 to 8220 tractors: 6 discs and 6 intermedi-
ate plates.
- 8240 tractors: 7 discs and 7 intermediate plates.
- 8250 tractors: 8 discs and 8 intermediate plates.
52. Lightly smear the mating face of the clutch cover
(33) on the unit (18) with Loctite 549 or its equivalent.
Place the cover on the unit, the tabs of the interme-
diate plates lodged in the cut out notches on the
clutch cover.
Fit and tighten screws (66) to 25.5 - 34.5 Nm.
53. Manually check the rotation of the hub (27).
54. If necessary, refit the input sun gear (53) and fit snap
ring (54). Fig. 10
Issue 1 May 2002

Gearbox - 5B06.15
Power Shuttle
C . Shimming the front clutch
This operation consists in obtaining an axial clearance J1
of 0.60 to 0.80 mm between the pump cover (2) and
clutch cover plate (4) (Fig. 11). 65 38
Remark
To carry out this operation, remove the PTO shaft so as
to remove the effect of the spring fitted at the rear end of
the shaft to alow the clutch assembly to move.
55. Refit the clutch on cover (38) of the rear clutch, using 4
a locally made tool as in Fig. 5, § A.
56. Place a approx. thick 2 mm shim (3) on cover (2) 3
(Fig. 11).
57. Lubricate the lip of the cover plate seal . Protect the
lip of the seal by fitting a protective material (see 19
section 3C02) over the splines of the shaft (19). Fit
two guide studs on opposite sides of the gearbox
housing and temporarily install the clutch cover plate
(4) without using Loctite. Gradually tighten sev-
eral screws.
58. Place a dial gauge at the end of shaft (19) and check
the clearance by moving the shaft sideways (Fig. 11).
Note: Check that the snap ring (65) of bearing (32)
is correctly in contact with cover (38) (Fig. 11) by 2 32
pushing the shaft (19) back as far as possible.
59. Remove clutch cover plate (4). Depending on the
reading previously obtained with the dial gauge,
define a new thickness for shim(s) (3) in order to
obtain a J1 clearance of between 0.60 mm and
0.80 mm (Fig. 11). J1 = 0,60/0,80 mm
Fig. 11
Issue 1 May 2002

5B06.16 Gearbox -
Power Shuttle
64. Remove the thick springs (62) and the pins (71).
D . Disassembling and reassembling 65. On cover (38), remove:
the rear clutch - the plate (43)
- the seal (42) and discard it
Preliminary operations - the piston (39)
60. Remove the front clutch (see § A). - the seals (36) (41) and discard them
61. Remove the input unit (see section 5B02). - the unions (72), the 13 bar valve (77) (Fig. 17) and
seal (75) on the 17 bar supply port (Fig. 3).
Disassembly (Fig. 12)

62. Remove the screws (70) and remove the cover (38).
63. Recover the spools (44) and the springs (45).
61
70
38
58
56 99
34
17
98
61
44
62 45
71
55
Fig. 12
Issue 1 May 2002

Gearbox - 5B06.17
Power Shuttle
66. Immobilise planet carrier (49) with tool ref.
3378240M1 (see fig. 12A and § F).
67. Remove screws (99) securing the cover (34) (Fig. 12 99
-12A) and remove it.
68. Remove the discs (47) and the intermediate plates
(46). 34
69. Separate the output sun gear (58), held by the snap
rings (61), from the primary shaft (55) (Fig. 12). 49
70. Remove snap ring (98) (Fig. 12).
71. Remove the planet carrier (49) with the double and
single pinion gears (52) (59).
72. On the planet carrier (49), remove:
- the plates (63)
- the double pinion gears (52) and the pins (50). Note
and mark their location.
- the single pinion gears (59) and pins (50). Note and
mark their location.
Fig. 12A
- the snap ring (56) and bearing (57).
Remarks:
- rotation of pinion gears around the pins (50) is
on two rows of needle bearings (60), joined and
59 49
separated by a spacer (51).
Important:
- if the pinion gears and the pins are to be 52
removed, check that no unwanted needle or
spacer remains in the planet carrier after refit-
ting.
Reassembly
73. Clean and check all parts. Replace any defective
ones.
74. Check that the ports in the pinion gear pins and the
channels in the planet carriers are not clogged.
75. Where necessary, fit the pinion gears with two rows
of needle bearings coated with miscible grease and
separated by a spacer. Fig. 13
76. On the planet carrier, refit:
- bearing (57) and position snap ring (56– ),
- the double and single pinion gears (52) (59) posi-
tioned as shown in Fig. 13,
- pins (50), with the lubricating ports placed facing
those in the planet carrier (49).
Special points
Each end of the pins (50) contains:
- a port, one of which is closed off by a rivet (35) while
the other is used for pinion gear lubrication,
- a flat and a shoulder that stop any pin rotation or any
side movement.
Issue 1 May 2002

5B06.18 Gearbox -
Power Shuttle
77. Install the partially assembled planet carrier. Fit the
snap ring (98) and the rear snap ring (61) on the output
sun gear (58). R
78. Position marks "R" (punch marks) on the double
pinion gears (52) (Fig. 14) so that they pass through 52
a centerline meeting at "O" (Fig. 14).
Remark : The mark on the front side of the planet
carrier corresponds to the alignment of the two
52
splines. It is mandatory to respect these posi-
tions of the punch marks during assembly of the
output sun gear (58). "0"
79. Slide the output sun gear (58), correctly oriented as
shown in Fig. 2, on to the primary shaft (55), making
sure that the punch marks of each pinion gear remain
in the required position.
80. Fit the front snap ring (61).
81. Soak the discs (47) in a transmission oil bath for Fig. 14
approximately 1 hour. Check that they are correctly
saturated.
82. Fit the discs (47) and the intermediate plates (46)
depending on the type of tractor (see Remark and
Fig. 15). 62
Remark: 47
- 8210 - 8220 tractors: 5 discs - 4 intermediate 46
plates
- 8240 and 8250 tractors: 6 discs - 5 intermediate
plates. 71
83. Check that the centering pin (17) is fitted (Fig. 12).
84. Refit cover (34). Check that it is correctly positioned
on the pins (50) of the pinion gears and in the
centering pin (Fig. 12).
85. Immobilise the planet carrier, using the same method
as used during disassembly.
86. Fit and tighten screws (99) (Fig. 12) to a torque of
36 - 46 Nm with the threads previously lightly
smeared with Loctite 242 or equivalent. Fig. 15
87. On cover (38), check for the presence of rivets (40)
at the end of the channels and refit:
- piston (39) with new lubricated seals (36) (41),
gradually and alternately striking around the piston
rim with a plastic mallet. Check that no fragments
of the seal remain after assembly,
- plate (43) with a new lubricated seal (42), aligning
the holes of the plate with those in the cover (38).
Insert the plate using the same method as used for
piston (39).
Remark : The thickness of the plate (43) differs
according to the number of discs and intermedi-
ate plates.
Issue 1 May 2002

Gearbox - 5B06.19
Power Shuttle
88. Refit pins (71) and springs (62) (Figs. 15 -16) in their
respective locations on the input unit.
89. Coat the spools (44) and the springs (45) with mis-
cible grease. Fit and stick the spools in each com-
partment of cover (38), with the points towards the
unions (72) (Fig. 2). Slide and stick a spring (45) in
each spool.
90. On the outside face of the cover (38), place three
sufficiently long and equally spaced studs in the
holes provided for screws (64).
91. Fit and position the cover, with the 13 bar valve port 38
(77) turned upwards (Fig. 17).
Important : Before fitting screws (70), check that P
the spools (44) slide freely in each compartment
of the front cover on the input unit. 44
To do this, compress the springs (45), using a
screwdriver passed through the tapped holes of
45
the unions (72).
Remark: If the springs cannot be compressed, it
is important to find the reason.
92. Pre-tighten screws (70).
93. During pre-tightening, check that the spools (44) still 71 62
slide freely. Also check that each end of the (thick
section) springs (62) are correctly housed in their
bases.
94. Definitively tighten the screws (70) (Fig. 12) to a
torque of 29 - 37 Nm. After completing the tighten-
ing, check the sliding movement again and return of
each spool to its initial position.
Remark: A spool that is blocked open may limit
or interrupt lubrication to the front clutch.
95. Install the 13 bar valve (77) with its seal on cover (38)
and tighten to a torque of 12.5 Nm - 13.5 Nm maxi-
mum. (Fig. 17). Fit and tighten the unions (72).
Final operation Fig. 16

96. Install the input unit (see section 5B02) and the front
clutch (see § A).
77
38
Fig. 17
Issue 1 May 2002

5B06.20 Gearbox -
Power Shuttle
E . Disassembling and reassembling Disassembly (Fig. 19)
Reminder:
the driving pinion - Shimming the - Pair bearing cones and bearing cups together if they are
shaft to be re-used.
101. Remove screws (13) and casing (5). Recover the
Special point locating pin (4).
The rearward position of the Dynashift, caused by the 102. Where necessary, remove bearing cup (16) and
presence of the rear shuttle clutch in the housing of the shims (3).
unit, limits the space available at the rear of the input unit. 103. Take out the secondary shaft (1), pinion and bearing
This is why the secondary shaft (1) and the pinion (2) are cones (7) (9) assembly from cover (14).
machined as a single component (Fig. 19). 104. Remove bearing cup (8).
105. Where needed, separate the bearing cones from
Preliminary operations the shaft.
97. Remove the front clutch (see § A). 106. Drive out the roller bearing (1), the gearbox front
98. Remove the input unit (see section 5B02). intermediary shaft support (see section 5G01).
99. Remove the rear clutch (see § D). Take off oil deflector (2) and discard it if necessary
100. Remove the Dynashift device (see section 5B04). (Fig. 18).
3 2 1
1 2
Fig. 18
Issue 1 May 2002

Gearbox - 5B06.21
Power Shuttle
Reassembly (Fig. 19) Preparation for shimming
107. Check that the ports of the secondary shaft are not 113. Determine the thickness of shims (3) required in
clogged and check for the presence of lubrication order to obtain a temporary clearance of 0.10 mm
restrictor "R" to 0.15 mm approximately. For the definitive shim-
108. Clean and check parts. Replace any defective ming with pre-loading, see the following para-
ones. graphs.
109. Lubricate the bearing cones and cups with trans- 114. Place the previously determined shims in casing
mission oil before assembly. (5) followed by the bearing cup (16).
110. Insert bearing cones (7) (9) in contact with pinion (2) 115. Place the locating pin (4) and the unit on cover (14).
using a suitable press and fixture. Tighten screws (13) to a torque of 29 - 37 Nm.
111. Place the bearing cup (8) in cover (14). 116. Place the unit in a vice with jaw protectors, and
112. Refit the secondary shaft (1), pinion and bearing carry out a definitive shimming of the shaft.
cones assembly inside the cover.
4 13 16 5 3
14
R
2 1
Fig. 19
Issue 1 May 2002

5B06.22 Gearbox -
Power Shuttle
Shimming the shaft (1) (Figs. 19 - 20)
Remark:
- The principle consists in determining a thickness of
shims (3) to fit between the bearing cup of bearing (16)
and casing (5) (Fig. 19).
Reminder:
- It is recommended to remove oil deflector (2) (Fig. 18)
in order to avoid any interference between it and the
shaft (1) (Fig. 19).
117. Position the feeler of the dial gauge on the end of the
shaft.
118. Pull hard on shaft (1), alternately turning it from left
to right in order to correctly seat the cones in the
bearing cups.
119. Set the needle of the dial gauge to zero.
120. Repeat operation 118 this time while pushing.
121. Depending on the clearance measured (Fig. 20),
select a new shim thickness (3) to provide a P1 pre-
loading of:
P1 = 0.05 mm to 0.15 mm 1
Note:
- Where possible, shim to the maximum tolerance. 3
122. Remove screws (13). Remove casing (5).
123. Position the definitive shims (3) selected during
operation 121 along with bearing cup (16) in the
casing (5). P1=0,05 / 0,15mm
124. Refit the casing, shim(s) and bearing cup assem-
bly on cover 14, first checking for the presence of
locating pin (4).
125. Fit and definitively tighten screws (13) to a torque
of 29 - 37 Nm, the threads previously smeared
126. Manually check the rotation of the shaft.
127. Turn the oil deflector (2) in accordance with Fig. 18 Fig. 20
and insert the roller bearing (1) in thrust against the
unit housing.
Final operations
128. Refit the Dynashift device (see section 5B04).
129. Refit the rear clutch (see § D).
130. Refit the input unit (see section 5B02).
131. Refit the front clutch (see § A).
Issue 1 May 2002

Gearbox - 5B06.23
Power Shuttle
F . Service tools
1. Tools available in the AGCO network
- 3378240 M1 - Planetary carrier immobilizing tool
(Fig. 21)
2. Locally made tools

- Sleeve for removing and refitting the clutch assem-
bly (Fig. 22)
(1) - Pipe: Tu52B, external Ø 42.4, thickness 5
(2) - Pipe: Tu52B, external Ø 48.3, thickness 2.9
- Belleville washer compression tool (Fig. 23)
(1) U iron profile: 60
(2) Threaded rod: Ø 8
(3) Round iron machined with the following dimen-
sions: Fig. 21
Ø = 36, L = 60.
86
1
23 80
Ø7
86
2
100
165
Fig. 22
1 3 2
180
248 60
286 Fig. 23
Issue 1 May 2002

Gearbox - Selector cover 5C01.1
5 C01 Selector cover
CONTENTS
- General ________________________________________________ 2
A. Operation ______________________________________________ 7
B. Removing and refitting the cover _________________________ 9
C. Replacing the Hare/Tortoise piston seals _________________ 12
D. Disassembling and reassembling the selector mechanisms 12
E. Installing and adjusting the gear linkage and reverse shuttle

control cables (tractors with cabs) _______________________ 14
F. Version for tractors with platforms _______________________ 18
G. Adjusting the Hare/Tortoise range ________________________ 22
H. Service tools ___________________________________________ 23

5C01.2 Gearbox - Selector cover
General
8200-series tractors with a mechanical reverse shuttle
are equipped with either a cab or a platform and a selector
cover of similar construction. For the version with the
footstep, see § F.
The selector cover, installed on the right-hand side of the
housing on the Heavy Duty gearbox, has two separate
levers providing two different functions:
- front lever - for controlling the reverse shuttle,
- rear lever - for selecting the four basic speeds and the
two Hare / Tortoise ratios (Hi - Lo).
Tractors with cab

- Control lever (1) (Fig. 3) mounted on the left-hand part
of the instrument panel fascia actuates the reverse
shuttle via a control cable.
- Control lever (2) (Fig. 3) located above and to the right
of the console selects the four basic speeds and also
acts on the Hare/Tortoise function, via a rod and cable.
Special point
When the tractor is stopped, cell “C” mounted on a
bracket on the selector cover (Fig. 3) informs the user
that a gear has remained engaged, and that the hand-
brake is on.
The warning is issued by a buzzer located under the
instrument panel surround.
Parts list
(1) Return ports
(2) Grounding lug
(3) Screw
(4) Temperature probe with seal.
(5) Seal
(6) Shouldered ring
(7) Selector cover
(8) Finger-pin assembly (reverse shuttle)
(9) Finger-pin assembly (speeds)
(10) Grid
(11) Screw
(12) Spring
(13) Spring cup
(14) Spring cup
(15) Spring
(16) Spring cup
(17) Seal
(18) Shouldered ring
(19) Seal(s)
(20) Hare / Tortoise switch
Fig. 1
Fig. 2
Issue 21 May 2002

December 2000
Overall view
9 12 13 14 15 16 A 20 9 11 10 18 17
1.2 3.4
19 20
7
3 2
5
7
3 6
Parts list
Fig. 2
Fig. 1
Issue 1 May 2001

Exploded view
9
12
13
11
10
14
15
16
7 S
1
18
17
8
6
2
1
3
19
20
Parts list
Fig. 1
Fig. 2
Issue 1 May 2001

2 A 1/2
1 3
Z
2 4
9
1
3/4
C
Fig. 3
Issue 1 May 2001

Issue 1 May 2001

A . Operation
Reverse / Forward lever
On tractors with cabs, lever (1) (Fig. 3) has the following
positions:
- upwards (forward drive)
- downwards (reverse drive)
Moving lever (1) (Fig. 3) results in rotation of the pin which
is hard-mounted to finger (8); the follower moves selec-
tor “S” (Fig. 1).
Gear lever
Selecting 1st / 2nd gear
- Gear lever (2) pushes lever “L” (Fig. 3) and engages
finger (9) in the 1st / 2nd gear selector fork (Fig. 1).
- The first ratio is obtained by moving lever “L” upwards,
and the second ratio by moving it downwards.
Selecting 3rd / 4th gear

- In this configuration, gear lever (2) (Fig. 3) is in the
intermediate position; finger (9) integral with shaft “A”
is engaged in the 3rd / 4th gear selector fork (Fig. 1).
- The third ratio is obtained by moving lever “L” upwards,
and the fourth ratio by moving it downwards.
Safety interlock (see section 5D01)

- A locking system located on the rear face of the gear-
box, on the end of the selector rails, prohibits accidental
gearshifting.
Issue 1 May 2001


Hare / Tortoise function Tortoise position (Fig. 4)
Identification of components (Fig. 4) Moving switch (20) (Fig. 1) again causes opening of
(1) Solenoid valve solenoid valve (1) (Fig. 4).
(2) O’ring Oil pressurised at 17 bar arrives in chamber "B". Since the
(3) Piston pressure acting on the large diameter of the piston is
(4) Bearing greater than that acting on the annular face, it forces the
(5) O’rings piston to retract, driving selector "S" and fork "F1" towards
(6) Circlip the Tortoise position. The oil contained in chamber "A"
(7) Selector cover returns to the 17 bar circuit.
Selecting the Hare / Tortoise range is done with the gear Safety interlock (see section 5D01)
lever in the neutral position, by pulling lever "L" towards The Hare/Tortoise selector rail is also locked in each of
the outside of cover (Fig. 3). Finger (9) presses the end its positions (Hare or Tortoise) for the first to fourth gear
of switch (20) (Fig. 1) which informs the electronic positions, under the same system as stated previously.
system that the Hare / Tortoise solenoid valve can be
switched.
Hare position (Fig. 4)

Solenoid valve (1) mounted on selector cover (7) is
closed, which causes a pressure drop in chamber "B".
The constant pressure (17 bar) in chamber "A"is applied
to the annular face of piston (3), which moves forward
and entrains fork "F1" towards the Hare position under the
action of selector "S".
The oil contained in chamber "B" returns to the sump via
the solenoid valve.
F1
S 1
A
B
6 5 4 3 2
F 17 bar
Fig. 4
Issue 1 May 2001

B . Removing and refitting the cover

12 2
1. Immobilise the tractor. Chock the left rear wheel. Set 11
the handbrake. 6
2. Place chocks between the frame and the front axle.
3. Remove the right rear wheel or set to wide tread.
4 11
Install an axle stand if necessary.
4. Pivot the footstep assembly and battery chest or
remove any neighbouring parts likely to impede
removal of the selector cover (depending on ver-
sion).
6. Disconnect the electrical harnesses on the cover. 5
7. Unscrew the tube and hose unions.
3
Fig. 5
Removal
Tractors with cabs
Gear control (Fig. 5)
8. Disconnect the harness from cell "C" (Fig. 3). Re-
move ball joint (4). Remove screw (3).
9. Remove pins (11). Disconnect ball joint (5).
10. Note the adjustment of cable (6). Slightly loosen
upper nut (12) and separate the cable from bracket
(2).
Issue 1 May 2001


Reverse shuttle control (Fig. 6)
11. Remove clips (1). Note the adjustment of cables (2).
Loosen nuts (3). Separate the cables from bracket (4).
Note: On tractors fitted with a creeper unit, dis-
connect control cable (1) (Fig. 7).
12. Remove screws (3), taking care to identify the
position of grounding lug (2).
Note: If installed, remove bracket (2) supporting
the creeper control cable (Fig. 7).
13. Release and remove the selector cover.
3
Refitting
4
14. Clean the mating faces on the gearbox and cover.
15. Install the following parts:
On the cover: the Hare / Tortoise piston in the "Hare" 1 2
position Fig. 6
On the gearbox: the Hare / Tortoise fork in the "Hare"
position, the 1st / 2nd gear and 3rd / 4th-gear selector
forks and the reverse shuttle fork in the neutral posi-
tion.
16. Coat the mating face of the gearbox housing with
sealing compound (Masterjoint 510 Loctite or equiva-
lent).
Fig. 7
Issue 1 May 2001

17. Turn the gear and reversing control linkage on the

cover to engage them in their respective selectors
(Fig. 8) during positioning of the cover on the gear-
box.
Note: Refit the bracket for the creeper control
cable (if installed).
18. Position lug (2). Install screw (3) and torque to 34 -
51 Nm.
Note: Depending on the option, reconnect and
adjust the creeper gear control (see section
5K01).
19. Reassemble the gear control. Reverse operations 8
to 10.
20. Reassemble the reverse shuttle control. Reverse
operation 11.
21. Use a grease gun to grease the joints of the gear
control on the selector cover. Fig. 8
Final operations
22. Refit any items previously removed around the
cover.
23. Replace the wheel and torque the screws or nuts
depending on the version (see section 2G01).
sightglass located on the left-hand of the centre
housing.
25. Remove the chocks between the frame and front
axle. Release the handbrake.
26. With the engine running, check passage of all gears
and the reverse shuttle. Also check the Hare/Tor-
toise position. If necessary, and with the engine
stopped, adjust the controls (see § E).
27. Check that the buzzer of the safety cell vibrates
correctly (contact set, handbrake on and gear en-
gaged).
Issue 12 December
May 2000
2002
C . Replacing the Hare/Tortoise pis-

ton seals (Fig. 4)
Disassembly 2 4
29. Remove the cover (see § B).
30. Remove circlip (6). Extract piston (3) with bearing (4)
and scrap O’rings (2) and (5).
Reassembly 3
31. Clean and check the parts; replace any that are
faulty.
32. Without installing the O’rings on the piston, check
that the latter slides freely in the bore in the cover.
33. After inspection, lubricate and fit new O’rings. Re- 1 5
verse operation 30.
34. Refit the selector cover (see § B). Fig. 9
Note
- Replacing piston (3), bearing (4) or circlip (6) implies
checking or repeating the setting of selector "S" on the
Hare/Tortoise range (see § G).

the selector mechanisms
35. Remove the cover (see § B) and tighten in a soft-jaw
vice.
Disassembly
Tractors with cabs
36. Remove screws (1) and (4). Remove selector (3),
link rod (5) and bracket (2) (Fig. 9).
37. Remove the pin integral with finger (8).
38. Remove screw (11). Remove the gear control as-
sembly.
39. Remove cup washers (14) and (16) and spring (15).
40. Separate the assembly comprising pin and finger (9)
from grid (10). Remove spring cup (13) and spring
(12).
41. If necessary, unscrew and remove Hare/Tortoise
switch (20), the threaded fittings on return ports (1),
and temperature probe (4). Recover seal(s) (19) from
the Hare / Tortoise switch.
42. Extract seals (5) and (17).

Reassembly Positioning bracket (2) (Fig. 10)

Special point 49. Refit bracket (2), observing a clearance of 29 mm
If considered necessary to replace guide rings (6) and between the bracket and the 22-mm diameter of
(18), lightly coat the edges of the replacement rings with shaft “A” (Fig. 10). Lightly coat screw (1) with
Loctite 638 or equivalent and fit them tight so that they Loctite 270 or equivalent, fit the screw and torque to
come into contact with the shoulders on the cover. 25 - 35 Nm.
Reminder: This clearance MUST be observed to
43. If removed, reinstall Hare / Tortoise switch (20) with ensure correct operation of the cell (see General).
the same number of seals as removed. Apply a light 50. Reassemble linkage (3). Coat threads of screw (4)
coat of Loctite 542 to the threads of the return port with Loctite 241 or equivalent (Fig. 9), fit the screw
and the temperature probe unions, then refit the and torque to 30 -35 Nm.
unions.
44. Lightly coat the outside diameter of seals (5) (17)
with Loctite 542, then fit the seals tight onto cover Final operations
using a suitable fixture. 51. Check that the selector mechanisms move freely.
45. From the inside of the cover, refit the pin-finger Remove the cover from the vice and refit to the
assembly (8) without damaging the lip of seal (5). gearbox (see § B).
46. Refit reversing linkage (5). Coat the threads of screw
(4) (Fig. 9) with Loctite 241 or equivalent and install
the screw. Torque to 30 - 35 Nm.
47. Reassemble spring (12) and spring cup (13) on shaft
(9). Assemble the shaft with grid (10). Reassemble
cup washers (14) (16), with spring (15) in between.
48. Refit the pin-finger assembly (9) without damaging
the lip of seal (17). Coat threads of screw (11) with
Loctite 270 or equivalent. Install the screw and
29 mm Fig. 10
Issue 1 May 2001

E . Installing and adjusting the gear

linkage and reverse shuttle control 1 3
cables (tractors with cab) 2 4
2
Gear linkage (cab side)
Preparation (Fig. 11) 3
52. On the end of control linkage (1) representing an 166
angle of 166°, direct ball joint (2) according to the
Figure. Tighten nut (3). 1
53. Screw ball joint (4) into abutment on cable (6).
Tighten nut (5).
7
Fitting (Fig. 11)
54. Fit bracket (7) on a work bench.
55. Fit and torque-tighten the following parts onto the
bracket:
- the gear lever 4
- the previously prepared control linkage and cable
56. Refit and fix the bracket on the right wheel housing
5
in the cab. During the operation, ensure the rod and
cable are inserted through the openings in the bulk-
heads. Position the rub rings. 1 6
Gear linkage (selector cover side) Fig. 11

Preparation (Fig. 12)
57. Fit nuts (3) and ball joint (4) on threaded rod (9) then
screw latter onto link rod (1).
58. Screw ball joint (5) fully onto cable (6). Tighten nut
(7).
1 12
Fitting (Fig. 12) C
59. Screw and lock the other end of ball joint (5) onto cam X
(8). 9
60. Refit bracket (2) and lever "L", then position cam (8) D
and bellcrank (10). Fit pins (11) and lock using new 3
splitpins.
4
61. Install ball joint (4) on lever "L". Fit the washer and 6
tighten the locknut.
12
1 11 2
7
9 11 10
5
L
8 6
Fig. 12
Issue 1 May 2001

Adjusting link rod (1) (Fig. 12)

62. Turn threaded rod (9) and ball joint (4) so as to obtain
a dimension "X" of 11 ± 1 mm between nuts (3) once
latter are tightened.
Adjusting cable (6) (Fig. 12)

63. Adjust the cable stop so as to balance dimensions
"C"and "D". Tighten nuts (12) without changing the
setting.
Check for proper engagement of each gear ratio; also

check the position of the gear lever in the opening in
the control panel.
Note: This check is to be performed by temporarily
moving the boot on the gear lever.
64. Engage each gear ratio and select the Hare / Tortoise Fig. 13
range. During this operation, check that the lever
does not come within 5 mm of the edge of the control
panel (Fig. 13 and 14).
Remark
If no interference between the lever and the control panel
is observed, the setting is correct. Put back the boot.
If the position of the lever is incorrect, return to the
adjustment on the selector cover side.
- if interference in 1st or 3rd gears (Fig. 13), reduce dimen-
sion "X" (Fig. 12).
- if interference in 2nd or 4th gears (Fig. 13), increase
dimension "X" (Fig. 12).
- by playing on dimensions "C" and "D" (Fig. 12), the gear
lever can be moved around in the control-panel opening,
as shown by the arrows in Fig. 14.
Fig. 14
Issue 1 May 2001


Reverse shuttle control cables (cab side)
65. Screw clevises (1) level with the end of the threaded
part of the cables (2).
66. Install the clevises on oscillating lever (3) and posi-
tion the clips. Tighten the nuts. 4 9
67. Slide the cable stops into the notches provided on
housing (4). Position and tighten cover (5). 6
Fitting (Fig. 15)

68. Assemble bracket (6) to housing (4).
69. Fix housing assy (4) and bracket (6) onto the frame
of instrument panel (8). Ensure that the cables are
fed through the openings in the cab floor. Position the
feed-through ducts (7). 8
70. Fit the floor covering.
71. Install the surround of the instrument panel and
associated items.
72. Position the reverse/forward lever. Coat screws
with Loctite 241 and install. Fit the boot.
73. Slide the cables through the clamp located above the
4 WD transmission-shaft bearing and under the plate
connecting the engine to the gearbox.
Z
7
2
1
Fig. 15
Issue 1 May 2001

Reverse shuttle control cables (selector co-

ver side)
74. Screw clevises (1) level with the end of the threaded 1 3
part of cables (2).
Installation (Fig. 16) R

75. Slide the cable stops (3) in the notches provided on
bracket (4). 4 2
Special feature
The cable marked with coloured adhesive tape
(represented on figure by the letter "R") must be
installed in the upper slot on bracket (4).
Should the mark be missing, position the cables in
the notches such that the position of the reverse/
5 1
forward lever in the cab represents the logical driving
position, that is: Fig. 16
- forward drive: lever up
- reverse drive: lever down
76. With the engine stopped, set link (5) to the neutral
position then fit the clevises. Position the clips.
Tighten the nuts. 2 3
X
Adjusting cables (2) (Fig. 17)
77. Progressively and alternately adjust the tension of
the cables using cable stops (3) so that dimensions
"X" and "Y" are identical (Fig. 17). Tighten nuts (1).
After adjustment, the unbent section of reverse/ Y
forward lever (9) must be almost horizontal (Fig. 15).
Inspection
78. Consecutively engage forward drive and reverse
drive.
79. Next check that linkage (5) (Fig. 16) locks correctly X =Y
3 1
without excessive tension in the cables.
Fig. 17
Issue 1 May 2001

F . Version for tractors with plat-

forms 3 4 2
Layout
1
- Two levers installed on the right floor of the footstep are
respectively connected directly with related parts on
the cover (Fig. 19). They control operation of the reverse
shuttle, selection of the four basic speeds of the
gearbox, and the Hare/Tortoise range.
4
Remark
The operating principle (mechanical or hydraulic) re-
mains identical to the system employed on the cab
version. In addition, removal, refitting and disassembly
of the cover are also similar operations.
It is worth noting that the position and contour of the Fig. 18
levers is generally different, and that the system is
simpler and more direct than on the cab version.
Reverse / Forward lever Creeper unit option

- On tractors with a platform, the reverse shuttle is - See cab version
engaged when lever (1) (Fig. 19) is moved either
forward (for forward drive) or backwards (for reverse Removal - Refitting of cover
drive). - See cab version
- Moving lever (1) causes rotation of the pin hard- If necessary, adjust the covers on the levers (see below).
mounted to finger (8), the follower moves selector "S"
(Fig. 19). Torque values (Fig. 18)
- Screw (4): 30 - 35 Nm (Loctite 241 or equivalent)
Gear lever (Fig. 19)

Selecting 1st / 2nd gear
- Gear lever (2) pushes lever "L"and engages finger (9) in
the 1st / 2nd gear fork.
- First gear is obtained by moving lever "L" forward and
second gear by moving it rearward.
Selecting 3rd / 4th gear

- In this configuration, gear lever (2) is in the intermediate
position. Finger (9) integral with shaft "A" is engaged in
the 3rd / 4th gear fork.
- The third ratio is obtained by moving lever "L" forward,
and the fourth ratio by moving it backward.
Reminder before disassembly

- Visually identify the location and position of gear lever
(2) and reversing lever (1). Remove pin (3) and set-
screw (4) (Fig. 18).
Issue 1 May 2001

4 2
N
3 1
1 2
9 A
1.2 3.4
20
9 S
8
20
Fig. 19
Issue 1 May 2001

Issue 1 May 2001

Adjusting the covers on the gear and re-

versing levers
Remark
Adjusting consists in positioning the covers without their
interfering with levers (2) (3) (Fig. 20), whilst ensuring
maximum protection of the ball joints, irrespective of 3
which gear is engaged. Interference between the cover
and the lever may cause vibration in the stacked parts,
and possibly jumping out of gear.
1
Adjustment (Fig. 20)
Note: Before adjusting, partially coat the inside of
the covers with anti-seize grease or equivalent.
80. Set the reverse/forward lever and the gear lever to
the neutral position.
81. Loosen nuts (1). Adjust the covers according to
figure 20.
82. After adjustment, check the condition of the ball joint 2
in the cover, for all positions of the lever.
Tightening torque
- Nuts (1): 44 - 55 Nm
Fig. 20
Issue 1 May 2001

G . Adjusting the Hare/Tortoise range

On cover (7) (Fig. 21) 7
V
83. Install piston (3) fully against the bottom of the
chamber (Hare position).
84. Position the arm of service tool MF 462A in the
piston groove, and place into contact with face "F" as
shown.
Note: Maintain piston (3) in abutment before
tightening knurled screws "V" on the tool cur-
sor.
On the gearbox (Fig. 22)

85. Fit the tool onto the gearbox housing.
86. Fit the synchromesh ring against third gear "P" (Hare
position) (Fig. 4). The shoes of the fork must be
bearing on the synchromesh ring, on the 3rd gear
side.
87. Coat the screws of selector "S" with Loctite 221 or
equivalent and adjust so that face "F" is in from the F
arm of the tool by 0.2 mm minimum.
88. Provisionally refit the cover (see § B). Use a com- 3
pressed-air source at 3 bar minimum to blow piston
(3) into the Tortoise position.
89. Locate the opening under the gearbox and check the
Fig. 21
play of the Hare /Tortoise fork in the synchromesh
ring. Maximum clearance = 1 mm.
90. After checking the play, remove the cover and
definitively tighten the selector screws to 35 Nm
without changing the setting. Definitively reinstall
the cover (see § B).
0,2 mm
Fig. 22
Issue 1 May 2001

H . Service tools
- MF462A - Hare / Tortoise selector adjustment
gauge (Fig. 23).
Fig. 23
Issue 1 May 2001

Issue 1 May 2001

Gearbox with Power Shuttle - 5C02.1

Selector cover
5 C02 Selector cover
CONTENTS
- General ________________________________________________ 2
A. Operation ______________________________________________ 7
C. Replacing Hare / Tortoise piston seals ____________________ 11
D. Disassembling and reassembling the selector

mechanisms ____________________________________________ 11
E. Fitting and adjusting the gear linkage ____________________ 13
F. Adjustment of the Hare / Tortoise range __________________ 15
G. Service tools ___________________________________________ 16
Issue 1 May 2002

5C02.2 Gearbox with Power Shuttle -

Selector cover
General
Tractors fitted with a gearbox and power shuttle have a
selector cover that features a single control lever.
This lever selects the four basic gears as well as the
hydraulic Hare / Tortoise (Hi-Lo) function.
The gear lever (2) is controlled by a single linkage and

cable (Fig. 3) and is located on the right above the
console.
Special point
When the tractor is stopped with the handbrake on, a "C"
cell fixed onto the selector cover by means of a bracket
(Fig. 3) informs the user that a gear is still engaged and
that the handbrake is on.
This information is issued by a buzzer located under the

instrument panel surround.
Parts list
(1) Return port
(2) Grounding lug
(3) Screw
(4) Temperature probe and seal
(5) Plug
(6) hose pipes holding lug
(7) Selector cover
(9) Finger and pin assembly (gears)
(10) Grid
(11) Screw
(12) Spring
(13) Cup
(14) Cup
(15) Spring
(16) Cup Fig. 1
(17) Seal
(18) Shouldered ring
(19) Seal(s) Fig. 2
(20) Hare / Tortoise switch
Issue 1 May 2002


Selector cover
Overall view
9 12 13 14 15 16 A
1.2 3.4
18 17
20
19 20
3 2
20 9 11 10
5
1
3 6
Issue 1 May 2002


Selector cover
Exploded view
9
12
13
11
10
14
15
16
7
1
18
17
5
2
1 6
3
19
20
Issue 1 May 2002


Selector cover
1 3
A 1/2
2 4
3/4
Fig. 3
Issue 1 May 2002


Selector cover
Issue 1 May 2002


Selector cover
A . Operation
The gear lever
Selecting 1st and 2nd gear ratios
- The gear lever (2) pushes lever "L" (Fig. 3) and engages
the finger (9) in the 1st and 2nd gear fork (Fig. 1).
- The first gear ratio is obtained by moving lever "L" up-
wards, and second gear by moving it downwards.
Selecting 3rd and 4th gear ratios

- In this configuration, the gear lever (2) (Fig. 3) is in the
intermediate position. The finger (9) integral with pin "A"
engages in the fork of the 3rd and 4th gear ratios (Fig. 1).
- Third gear is obtained by moving lever "L" upwards, and
the fourth gear by moving it downwards.

- A locking system located on the rear face of the
gearbox, at the end of the selector rails, prohibits any
accidental gear shifting.
Issue 1 May 2002


Selector cover
Hare / Tortoise function The Tortoise position (Fig. 4)
Identification of components (Fig. 4) A fresh operation of the switch (20) (Fig. 1) causes the
(1) Solenoid valve opening of solenoid valve (1) (Fig. 4).
(2) O’ring The 17-bar pressure enters chamber "B". The pressure
(3) Piston acting on the larger piston diameter is higher than that on
(4) Bearing the annular face of the piston and forces it to return,
(5) O’rings moving selector "S" and fork "F1" into the Tortoise posi-
(6) Circlip tion. The oil contained in chamber "A" returns to the 17 bar
(7) Selector cover circuit.

Selecting the Hare / Tortoise range is carried out with the The Hare / Tortoise selector rail is similarly locked in each
gear lever in neutral position, by pulling lever "L" towards of its positions (Hare or Tortoise) in the 1st to 4th gear
the outside of the cover (Fig. 3). The finger (9) presses the ratios, by the same previously described system.
end of switch (20) (Fig. 1) which informs the electronic
system that the Hare / Tortoise valve is available and
can be switched.
The Hare position (Fig. 4)

The solenoid valve (1) mounted on the selector cover (7)
is closed and causes a drop in pressure in chamber "B".
The constant pressure (17 bar) in chamber "A" thrusts on
the annular face of piston (3) which moves forward and
pushes the fork "F1" to the Hare position via the selector
"S".
The oil contained in chamber "B" returns to the housing
via the solenoid valve.
F1
S 1
A
B
6 5 4 3 2
F 17 bar. Fig. 4
Issue 1 May 2002


Selector cover
12 2
1. Immobilise the tractor. Chock the rear left wheel. Put 11
on the handbrake. 6
2. Place wedges for safety between the frame and the
front axle. 4 11
3. Remove the rear right wheel or set it to wide track
position. Install an axle stand if necessary.
4. Pivot the footstep and battery chest assembly or
remove the neighbouring elements that may hinder
the removal of the selector cover (depending on the
version).
5. Drain the gearbox. 5
6. Disconnect the electrical connectors on the cover. 3
7. Unscrew or loosen the pipes and hoses on the cover.
Fig. 5
Removal
Gear shift control (Fig. 5)
8. Disconnect the harness from cell "C" (Fig. 3). Re-
move the ball joint (4). Remove screws (3).
9. Remove pins (11). Remove the ball joint (5).
10. Note the adjustment of the cable (6). Slightly loosen the
top nut (12) and separate the cable from bracket (2).
11. Remove screws (3), mark the location of the ground-
ing lug (2) and the the hose pipe clamp (6) (Fig. 1).
Note :
- On tractors fitted with a creeper unit, disconnect
the control cable (1) and remove bracket (2) (Fig. 6).
12. Loosen and remove the selector cover.
1
Refitting
13. Clean the mating faces of the gearbox and the cover.
14. Install :
On the cover: the Hare / Tortoise piston in the Hare
position.
On the gearbox: the Hare / Tortoise fork in the Hare
position, the 1st, 2nd, 3rd, and 4th forks in the neutral
position.
15. Lightly smear the housing /gearbox mating face with
Master Loctite 510 or equivalent.
Fig. 6
Issue 1 May 2002


Selector cover
16. Turn the gear shift control linkage on the cover so that
it fits into selectors "S" (Fig. 7) when positioning the
cover on the gearbox. S
17. If necessary, refit the creeper unit cable bracket.
Reconnect and adjust the control (see section 5K01).
18. Refit the bracket (2). Fit and tighten up the screws (3)
19. Refit the gear shift control. Carry out operations 8 to
10 in reverse order.
20. Using a grease gun, grease the various linkages of
the gear shift control on the selector cover.
Final operations
21. As necessary, refit those components removed
previously from around the cover.
22. Refit the wheel and tighten the wheel nuts or studs Fig. 7
to the correct torque depending on the version (see
section 2G01).
23. Top up the housing oil level and check it with the
sight glass located at the rear of the centre housing.
24. Remove the wedges from between the frame and
the front axle. Release the handbrake.
25. With the engine running, check the gear shifting of all
gears and Hare / Tortoise positions.
26. Stop the engine and where necessary adjust the gear
shift control (see § E).
27. Check that the buzzer of the safety cell vibrates cor-
rectly (ignition on, handbrake on and gear engaged).
Issue 1 May 2002


Selector cover
C . Replacing Hare / Tortoise piston
seals (Fig. 4)
Disassembly 2 4
30. Take off circlip (6). Extract piston (3) with the bearing
(4) and discard the O’rings (2) (5).
Reassembly
31. Clean and check the parts. Replace any defective 3
components.
32. Without fitting O’rings on the piston, check that the
piston slides smoothly in the bore of the cover.
33. The above check completed, lubricate and fit new
O’rings. Carry out operation 30 in reverse order. 1
Remark
- The replacement of piston (3), bearing (4) or circlip (6)
requires the checking and readjustment of selector "S"
of the Hare / Tortoise range (see § F).

Preliminary operation
35. Remove the cover (see § B) and hold it in a vice with
jaw protectors.
Disassembly
36. Remove the screws (1) (4). Take off the selector (3),
and bracket (2) (Fig. 8).
37. Remove screw (11).
38. Remove the gear shift control assembly.
39. Remove the spring cups (14) (16) and spring (15).
40. Separate the finger and pin assembly (9) from the
grid (10). Remove spring cup (13) and spring (12).
41. If necessary, unscrew and remove the Hare/Tor-
toise switch (20), the unions screwed on the return
ports (1) and the temperature probe (4). Recover the
seal(s) (19) from the Hare/Tortoise switch.
42. Extract the seal (17).
Issue 1 May 2002


Selector cover
Reassembly Positioning bracket (2) (Fig. 9)
Special point 49. Refit bracket (2), ensuring a clearance of 29 mm
If the guide ring (18) has to be replaced, coat its rim lightly between the bracket and the 22 mm diameter of pin
with Loctite 638 or its equivalent and insert it in thrust "A" (Fig. 9). Lightly smear the screws (1) with Loctite
against the shoulder of the cover. 270 or equivalent, and tighten them to a torque of 25
- 35 Nm.
43. If removed, refit the Hare/Tortoise switch (20) with Reminder: This clearance must be complied with in
the same number of seals as removed, and with the order to ensure the correct operation of the cell (see
unions on the return ports, and the temperature probe General).
lightly smeared with Loctite 542 or its equivalent. 50. Refit the link (3) and tighten screw (4) to a torque of
44. Lightly smear the external diameter of seal (17) with 30 - 35 Nm, the threads previously smeared with
Loctite 542 or its equivalent and insert it into the Loctite 241, or equivalent (Fig. 8).
cover using a suitable tool.
45. Refit spring (12) and cup (13) on pin (9). Final operations
46. Assemble pin and grid (10). 51. Check that the selector mechanism moves freely
47. Refit cups (14) (16) seperated by spring (15). without constraint. Remove the cover from the vice
48. Refit the pin (9) and finger assembly without damag- and refit it on the gearbox (see § B).
ing the lip of seal (17). Fit and tighten screw (11) to
a torque of 25 - 35 Nm, the thread previously lightly
smeared with Loctite 270, or equivalent.
29 mm Fig. 9
Issue 1 May 2002


Selector cover
E . Fitting and adjusting the gear
linkage
1 3
2 4
Preparation (Fig. 10) 2
52. On the end of control linkage (1), shaped with an
angle of 166°, turn the ball joint (2) as shown in the 3
figure. Tighten nut (3). 166
53. Screw the ball joint (4) to thrust against the cable (6).
Tighten nut (5). 1
Fitting (Fig. 10)

54. Fit bracket (7) on a bench. 7
55. Onto this bracket, fit and tighten the following com-
ponents:
- the gear lever
- the previously prepared control linkage and cable.
56. Refit and secure the bracket on the right wheel 4
housing in the cab. During this operation, ensure the
control linkage and cable are inserted through the 5
openings in the bulkheads. Fit the grommets.
1 6
Gear linkage (selector cover end)
Preparation (Fig. 11) Fig. 10
57. Screw the threaded rod (9) (complete with nuts (3)
and the ball joint (4)) onto link rod (1).
58. Tighten ball joint (5) in thrust against cable (6).
Tighten nut (7).
Fitting (Fig. 11) 1 12

59. Tighten and lock the other end of the ball joint (5) onto
cam (8). C
X
60. On bracket (2), and with lever "L" fitted beforehand, 9
position cam (8) and its extension piece (10). Fit pins D
(11), and lock them in place with new cotter pins. 3
61. Install the ball joint (4) on lever "L". Position the
washer, and tighten the locknut. 4
6
12
1 11 2
7
9 11 10
5
L
8 6
Fig. 11
Issue 1 May 2002


Selector cover
Adjusting the link rod (1) (Fig. 11)
62. Rotate threaded rod (9) and the ball joint (4) so as to
obtain a distance "X" of 11 mm ± 1 mm between the
two nuts (3) when these are tightened.
Adjusting the cable (6) (Fig. 11)

63. Adjust the end-point of the sheath so as to balance
dimensions "C" and "D". Tighten nuts (12) without
altering the adjustment.
Check for the proper engagement of each gear ratio

and the position of the gear lever in the opening of
the console.
Note: This check should be performed with the dust
cover of the gear lever temporarily removed.
64. Engage each gear, and select the Hare/Tortoise
Fig. 12
does not come closer than 5 mm to the edge of the
console (Fig. 12 -13).
Remark
When there is no interference with the operation of the
lever by the console, then the adjustment is correct. Refit
the dust cover.
If the position of the lever is incorrect, repeat the
adjustment procedure at the selector cover end.
- if there is interference when engaging 1st or 3rd gears
(Fig. 12), reduce dimension "X" (Fig. 11)
- if there is interference when engaging 2nd or 4th gears
(Fig. 12), increase dimension "X" (Fig. 11)
- by altering dimensions "C" and "D" (Fig. 11), the gear
lever moves in the console opening in the direction
shown by the arrows in Fig. 13.
Fig. 13
Issue 1 May 2002


Selector cover
F . Adjusting the Hare / Tortoise range
On the cover (7) (Fig. 14) V
65. Place piston (3) in thrust against the bottom of the 7
66. Position the arm of tool ref. MF 462A, in the groove
of the piston and place it in contact with face "F" as
shown.
Note. Hold piston (3) thrust against face “F”
before tightening the thumbscrew “V” of the
cursor.

67. Place the tool on the gearbox housing.
68. Manually hold the ring of the synchromesh against
the pinion of 3rd "P" (Hare position) (Fig. 4) and with
the fork pads thrust against the synchromesh ring
(on the side of the 3rd gear pinion).
69. Smear the screws of selector "S" with Loctite 221 or F
equivalent and adjust them so that face "F" clears the
arm of the tool by a minimum of 0.2 mm.
3
70. Temporarily refit the cover (see § B). Use a com-
pressed air supply sufficient to move piston (3) into
the Tortoise position. Fig. 14
71. Adjust and maintain the pressure to aproximately
3 bar. Through the opening located beneath the
gearbox, check the clearance between the Hare /
Tortoise fork and the synchromesh ring. The clear-
ance should be 1 mm maximum.
72. After verifying the clearance, take off the selector
cover and definitively tighten the screws of selector
"S" to a torque of 35 Nm without modifying the
adjustment. Definitively refit the cover (see § B).
MF 462A
0,2mm
Fig. 15
Issue 1 May 2002


Selector cover
G . Service tools
- MF462A - Hare / Tortoise adjustment gauge (Fig.
16)
Fig. 16
Issue 1 May 2002


Selector cover
5 C03 Selector cover - Optimised Hare /

Tortoise function
CONTENTS
- General ________________________________________________ 2
A. Identification of components - Hare / Tortoise function ____ 7
C. Replacing Hare / Tortoise piston seals ____________________ 12
D. Disassembling and reassembling the selector mechanism _ 12
E. Fitting and adjusting the gear linkage ____________________ 15
F. Adjusting of the Hare / Tortoise range ____________________ 17
G. Service tool ____________________________________________ 18
Issue 1 May 2002


Selector cover
Parts list Fig. 1
General (1) Return ports
8210 - 8220 - 8240 and 8250 series tractors fitted with a (2) Grounding lug
Heavy Duty gearbox now benefit from an optimised (3) Screw Fig. 2
selector cover. (4) Temperature probe
(6) Hydraulic hose flange
It is located on the right-hand side of the gearbox and (7) Selector cover
comprises : (9) Gear shift control finger
- a toggle (34) (10) Bracket
- a neutral position switch (20). (11) Screw
(14) Gear Selector grid
This cover has been introduced on the previously de- (17) Seal
signed tractors from serial number K309019 onwards. (18) Shouldered ring
The single lever, fitted on the cover, controls the gear (19) Screw
shifting for ratios 1 to 4. A hydraulic device provides the (20) Neutral position switch
Hare / Tortoise function. (21) Washer
(22) Circlip
The mechanical locking of the 1st - 2nd / 3rd - 4th selector (23) Spring
rails and the Hare / Tortoise range is carried out as (24) Ball
previously, by pins placed between the gear selector (25) Centring rings
rails and the selector rail located at the rear part of the (27) Seal
gearbox (see section 5D02 - General). (33) Washer
(34) Toggle
The ergonomics of the pulse button located on the
pommel of the gear lever, to the right of the driver, allows
the Hare / Tortoise range. To change the range, simply
put the gear lever in the neutral position and press the
button.
Special point
- In parallel with the selector covers already fitted on
tractors with different options (see section 5C01 and
5C02) a cell C (Fig. 3) informs the driver that a gear is
engaged and that the handbrake is on.
Issue 1 May 2002


Selector cover
Overall view
9 12 13 14 15 16 A
1.2 3.4
18 17
20
19 20
3 2
20 9 11 10
5
1
3 6
Issue 1 May 2002


Selector cover
Exploded view
9
12
13
11
10
14
15
16
7
1
18
17
5
2
1 6
3
19
20
Fig. 1 Fig. 2
Parts list
Issue 1 May 2002


Selector cover
1 3
A 1/2
2 4
3/4
Fig. 3
Issue 1 May 2002


Selector cover
Issue 1 May 2002


Selector cover
A . Identification and functions of
components - Hare / Tortoise func-
tion
Toggle (34)
- The toggle runs free on pin A (Fig. 3) and pivots with it
by means of a flat. It controls the Neutral position of pin
A (gear lever) by means of switch (20) (Fig. 1).
Switch (20)
- Controlled by the toggle, its function is to supply
information to the electronic system of the tractor when
the gear lever is in the Neutral position.
General operation
Gear lever
Selecting 1st - 2nd gear
- The gear lever (2) pushes lever L (Fig. 3) and engages
finger (9) in the 1st - 2nd fork (Fig. 3)
- The first ratio is obtained by moving lever L upwards
and the second ratio downwards.
Simultaneously the toggle (34) pivots with pin A and
leaves the Neutral position.
Selecting 3rd - 4th gear

- In this configuration, the finger (9) integral with pin A is
engaged in 3rd - 4th gear fork.
- The 3rd ratio is obtained by moving the lever L upwards
and the 4th ratio downwards (Fig. 3).
- As with the previous ratios the toggle is moved by
rotation of pin A.

- A locking system located on the rear face of the
gearbox, at the end of the selector rails, prohibits the
accidental engagement of a non-selected gear.
Issue 1 May 2002


Selector cover
Hare / Tortoise function The Tortoise position (Fig. 4)
Identification of components (Fig. 4) A fresh operation of the pulse button (Fig. 3) causes the
(1) Solenoid valve opening of the solenoid valve (1) (Fig. 4).
(2) O’ring The 17-bar pressure enters chamber B. The pressure
(3) Piston acting on the larger piston diameter is higher than that on
(4) Bearing the annular face of the piston and forces it to return,
(5) O’rings moving selector S and fork F1 into the Tortoise position.
(6) Circlip The oil contained in chamber A returns to the 17 bar
(7) Selector cover circuit.
Selecting the Hare / Tortoise range is carried out in the Safety interlock (see section 5D02)
Neutral position by pressing the pulse button incorpo- The Hare / Tortoise selector rail is similarly locked in each
rated in the gear lever pommel. of its positions (Hare or Tortoise) in the 1st to 4th gear
ratios, by the same previously described system.
Remark
- The new Parker Hare / Tortoise solenoid valve is now
fitted on the selector cover. This enhancement re-
moves any risk of overtightening the spool.
The Hare position (Fig. 4)

The solenoid valve (1) mounted on the selector cover (7)
is closed and causes a drop in pressure in chamber B.
The constant pressure (17 bar) in chamber A thrusts on
the annular face of piston (3) which moves forward and
pushes the fork F1 to the Hare position via the selector S.
The oil contained in chamber B returns to the housing via
the solenoid valve.
F1
S 1
A
B
6 5 4 3 2
F 17 bar. Fig. 4
Issue 1 May 2002


Selector cover
1. Immobilise the tractor. Chock the rear left wheel. Put 11
on the handbrake. 6
2. Place wedges for safety between the frame and the
front axle.
3. Remove the rear right wheel or set it to wide track 4 11
position. Install an axle stand if necessary.
4. Pivot the footstep and battery chest assembly or
remove the neighbouring elements that may hinder
the removal of the selector cover (depending on the
version).
5. Drain the gearbox. 5
6. Disconnect the electrical connectors on the cover.
7. Unscrew or loosen the pipes and hoses on the cover. 3
Fig. 5
Removal
Gear shift control removal (Fig. 5)
8. Disconnect the harness from cell C (Fig. 3). Remove
the ball joint (4). Remove screws (3).
9. Remove pins (11). Remove the ball joint (5).
10. Note the adjustment of the cable (6). Slightly loosen the
top nut (12) and separate the cable from bracket (2).
Fig. 6
Issue 1 May 2002


Selector cover
11. Remove screws (3), mark the location of the ground-
ing lug (2) and the the hoses pipe clamp (6) (Fig. 1).
Reminder S
- On tractors fitted with a creeper unit, disconnect
the control cable (1) and remove bracket (2) (Fig. 6).
12. Loosen and remove the selector cover.
Refitting
13. Clean the mating faces of the gearbox and the cover.
14. Install:
On the cover: the Hare / Tortoise piston in the Hare
position.
On the gearbox: the Hare / Tortoise fork in the Hare
position, the 1st, 2nd, 3rd and 4th forks in the neutral
position.
15. Lightly smear the housing /gearbox mating face with Fig. 7
Master Loctite 510 or equivalent.
16. Turn the gear shift control linkage on the cover so that
it fits into selectors S (Fig. 7) when positioning the
cover on the gearbox.
17. If necessary, refit the creeper unit cable bracket.
Reconnect and adjust the control (see section 5K01).
18. Refit the bracket (2). Fit and tighten up the screws (3)
19. Refit the gear shift control. Carry out operations 8 to
10 in reverse order.
20. Using a grease gun, grease the various linkages of
the gear shift control on the selector cover.
Issue 1 May 2002


Selector cover
Final operations
21. As necessary, refit those components removed
previously from around the cover.
22. Refit the wheel and tighten the wheel nuts or studs
section 2G01).
23. Top up the housing oil level and check it with the
sight glass located at the rear of the centre housing.
24. Remove the wedges from between the frame and
the front axle. Release the handbrake.
25. With the engine running, check the gear shifting of all
gears and Hare / Tortoise positions.
26. Stop the engine and where necessary adjust the gear
shift control (see § E).
27. Check that the buzzer of the safety cell vibrates
correctly (ignition on, handbrake on and gear en-
gaged).
Issue 1 May 2002


Selector cover
C . Replacing Hare / Tortoise piston
seals (Fig. 4)
Disassembly
2 4
30. Take off circlip (6). Extract piston (3) with the
bearing (4) and discard the O’rings (2) (5).
Reassembly
31. Clean and check the parts. Replace any defective 3
components.
32. Without fitting O’rings on the piston, check that the
piston slides smoothly in the bore of the cover.
33. The above check completed, lubricate and fit new
O’rings. Carry out operation 30 in reverse order. 1
Remark
- The replacement of piston (3), bearing (4) or circlip (6)
requires the checking and readjustment of selector S of
the Hare / Tortoise range (see § F).

35. Remove the cover (see § B) and hold it in a vice with
jaw protectors.
Disassembly
36. Remove screws (1). Take out key (4) and selector
(3). Separate the bracket (2) from the cover (Fig. 8).
37. Remove screws (11). Separate the bracket (10)
including the gear shift control asssembly, from the
cover. If necessary, extract the centring rings (25).
On cover (7)
38. Take off the Neutral position switch (20). Recover
seal (27) and ball (24).
39. If necessary, take off the temperature probe (4) and
the unions screwed onto the return ports (1).
40. Extract and discard seal (17).
Issue 1 May 2002


Selector cover
On the bracket (10)
41. Take off circlip (22), washer (21) and remove spring
(23).
42. Remove washer (33) and toggle (34), marking its
position and profile.
43. If necessary, take out screws (19). Take off the gear
selector grid (14) and extract the centring rings (25).
Reassembly
Special point
- If guide ring (18) has to be replaced, lightly smear its rim
with Loctite 648 or its equivalent and insert it thrust
against the shoulder of the cover.
On the bracket (10)

44. If removed, insert the centring rings (25). Refit the
gear selector grid (14) and tighten screws (19)
previously lightly smeared with Loctite 271 or its
equivalent and tighten to a torque of 29 - 37 Nm.
45. Check that the flat on toggle (34) slides freely over
finger (9) flat.
46. Slide the pin and finger assembly (9) into bracket
(10).
47. Suitably turn toggle (34) and position it on the flat of
finger (9). Place washer (33).
48. Refit spring (23) and washer (21). Fit circlip (22).
On the cover (7)

49. Check for the presence of centring rings (25).
50. Refit the bracket (10) and gear shift control assembly.
51. Lightly smear the threads of screw (11) with Loctite
242 or its equivalent and tighten to a torque of 29 - 37
Nm.
52. Protect the lip of seal (17) by covering the cylindrical
end of finger (9) with a flexible protection. Lightly
smear the external rim of the seal with Loctite 542
or its equivalent and slide it over the protection.
Remove the protection. Insert the seal into the cover
using an appropriate fixture.
53. Place finger (9) in the Neutral position.
54. Slide ball (24) into the depression on the toggle (34).
Issue 1 May 2002


Selector cover
Checking the Neutral switch (20) position before Final operation
assembly 60. Take out the cover from the vice and fit it on the
55. Press manually on the button located at the end of gearbox (see § B).
the switch. Release the button and check that the
button returns freely to its initial position.
Repeat the operation several times. The check must
be carried out using a multimeter.
56. Refit the switch complete with its seal and tighten to
a torque of 15 - 25 Nm
57. Refit bracket (2) respecting the dimension of 29 mm
between the bracket and the 22 mm diameter of pin
A (Fig. 9). Lightly smear screws (1) with Loctite 270
and tighten them to a torque of 25 - 35 Nm.
Reminder
- This dimension must be strictly met in order for the
cell to operate correctly (see General).
58. Refit selector (3). Insert and tighten the key (4) (Fig. 8).
59. In the selector grid (14), move finger (9) from 1st to
4th gear using selector (3) (Fig. 8) and check that the
finger moves freely into each of its positions.
29 mm
Fig. 9
Issue 1 May 2002


Selector cover
E . Fitting and adjusting the gear
linkage
1 3
2 4
2
61. On the end of control linkage (1), shaped with an
angle of 166°, turn the ball joint (2) as shown in the 3
figure. Tighten nut (3). 166
62. Screw the ball joint (4) to thrust against the cable (6).
Tighten nut (5). 1
Fitting (Fig. 10)

63. Fit bracket (7) on a bench. 7
64. Onto this bracket, fit and tighten the following com-
ponents:
- the gear lever
- the previously prepared control linkage and cable.
65. Refit and secure the bracket on the right wheel 4
housing in the cab. During this operation, ensure the
control linkage and cable are inserted through the
5
openings in the bulkheads. Fit the grommets.
1 6
Gear linkage (selector cover side)
Preparation (Fig. 11) Fig. 10
66. Screw the threaded rod (9) (complete with nuts (3)
and the ball joint (4)) onto link rod (1).
67. Tighten ball joint (5) in thrust against cable (6).
Tighten nut (7).
Fitting (Fig. 11) 1 12

68. Tighten and lock the other end of the ball joint (5) onto
cam (8). C
X
69. On bracket (2), and with lever L fitted beforehand, 9
position cam (8) and its extension piece (10). Fit pins D
(11), and lock them in place with new cotter pins. 3
70. Install the ball joint (4) on lever L. Position the
washer, and tighten the locknut. 4
6
12
1 11 2
7
9 11 10
5
L
8 6
Fig. 11
Issue 1 May 2002


Selector cover
Adjusting the link rod (1) (Fig. 11)
71. Rotate threaded rod (9) and the ball joint (4) so as to
obtain a distance X of 11 mm ± 1 mm between the
two nuts (3) when these are tightened.
Adjusting the cable (6) (Fig. 11)

72. Adjust the end-point of the sheath so as to equally
balance dimensions C and D as far as possible.
Tighten nuts (12) without altering the adjustment.
Check for the proper engagement of each gear ratio

and the position of the gear lever in the opening of
the console.
Note: This check should be performed with the dust
cover of the gear lever temporarily removed.
73. Engage each gear, and select the Hare/Tortoise
Fig. 12
does not come closer than 5 mm to the edge of the
console (Fig. 12 -13).
Remark
When there is no interference with the operation of the
lever by the console, then the adjustment is correct. Refit
the dust cover.
If the position of the lever is incorrect, repeat the
adjustment procedure at the selector cover end.
- if there is interference when engaging 1st or 3rd gears
(Fig. 12), reduce dimension X (Fig. 11),
- if there is interference when engaging 2nd or 4th gears
(Fig. 12), increase dimension X (Fig. 11),
- by altering dimensions C and D (Fig. 11), the gear lever
moves in the console opening in the direction shown by
the arrows in Fig. 13.
Fig. 13
Issue 1 May 2002


Selector cover
F . Adjusting the Hare / Tortoise
range MF 462 A
On the cover (7) (Fig. 14) 7

74. Place piston (3) in thrust against the bottom of the
75. Position the arm of tool ref. MF 462A, in the groove
of the piston and place it in contact with face F as
shown.
Note: Carefully hold piston (3) in the Hare posi-
tion with the arm of the implement thrust against
face F before manually tightening thumbscrew V V
of the cursor.
3
76. Place the tool on the gearbox housing.
77. Manually hold the ring of the synchromesh against
the pinion of 3rd P (Hare position) (Fig. 4) and with the 3
fork pads thrust against the synchromesh ring (on
the side of the 3rd gear pinion). F
78. Smear the screws of selector S with Loctite 221 or
equivalent and adjust them so that face F clears the
arm of the tool by a minimum of 0.2 mm.
79. Temporarily refit the cover (see § B). Use a com-
pressed air supply sufficient to move piston (3) into Fig. 14
the Tortoise position.
80. Adjust and maintain the pressure to aproximately
3 bar. Through the opening located beneath the
gearbox, check the clearance between the Hare /
Tortoise fork and the synchromesh ring. The clear-
ance should be 1 mm maximum.
81. After verifying the clearance, take off the selector
cover and definitively tighten the screws of selector
S to a torque of 35 Nm without modifying the
adjustment. Definitively refit the cover (see § B).
MF 462A
0,2mm
Fig. 15
Issue 1 May 2002


Selector cover
G . Service tools
- MF462A - Hare / Tortoise adjustment gauge
(Fig. 16).
Fig. 16
Issue 1 May 2002

Gearbox - Selector rails 5D01.1
5 D01 Selector rails
CONTENTS
- General ________________________________________________ 2
A. Disassembling and reassembling selector rails and adjusting

forks and gearbox selector _______________________________ 5
B. Disassembling and reassembling selector rails and adjusting

input unit forks _________________________________________ 7
Issue 1 May 2001

5D01.2 Gearbox - Selector rails
General
On 8200 series tractors fitted with a Heavy Duty gearbox,
the selector rails used for gear selection are located on
the right-hand side of the gearbox behind the control
cover.
The gear selector comprises four selector rails of which
three are for the gearbox and one for the input unit.
Each selector rail supports its own fork and respective
selector and moves longitudinally in end-bearings.
The forks are adjustable, thus ensuring a functional
clearance between the pads and the synchromesh
sliding coupler.
Safety locking of the gearbox selector

The system comprises two cylindrical locks of different
lengths.
- short locking pin: selector rail 1st - 2nd
- long locking pin: selector rail 3rd - 4th
Their extremities are spherical and one of them has an
extended lug.
Each selector rail is machined both to lodge and to allow
movement of the locks.
Operating principle
Example: Ratio 1 engaged - Hare range
When the selector rail is moved to select 1st gear, it
forces its lock to move out of its lodging place and to lock
the range selector rail in the "Hare" position. At the same
time, this lock pushes another lock that in turn locks the
3rd - 4th selector rail, thus prohibiting any undue move-
ment that might block the gearbox.
The same reasoning applies to the Tortoise range and
other gear ratios.
Issue 1 May 2001

Overall view
6 S 7 8 9 10 11 12 13
Parts list
(1) Selector rail 3rd - 4th
(2) Short locking pin 1st - 2nd
(3) Hare / Tortoise selector rail
(4) Selector rail 1st - 2nd
(5) Long locking pin 3rd - 4th
(6) Gearbox housing
(7) Selector 1st - 2nd
(8) Reverse shuttle selector 1 5 3 4 2 C
(9) Reverse shuttle selector rail
(10) Locking pin
(11) Spring
(12) Plug
(13) Input unit housing
(14) Reverse shuttle fork
(15) Fork 1st - 2nd
(16) Fork 3rd - 4th
(17) Hare / Tortoise fork
(18) Long spacer
(19) Short spacer F
(20) Bolt
(21) Pin
S : Hare / Tortoise selector
Fig. 1 C
14
Fig. 2
17 16 15
4 3 4 1 2
2 10 11 18
3
Y
20
5 19
1 12
Parts list
Z
Partial view Fig. 2
View along F Fig. 1

Cross-section CC
Issue 1 May 2001

Exploded view
21 9 8 10 11 12
10 11 12 18 2
4
5
20
10
7
11
14
12
19
15
21 17 20 16 1
Parts list
Fig. 1
Fig. 2
Issue 1 May 2001

Special points
A . Disassembling and reassembling - The short locking pin (2) locks selector rail 1st - 2nd.
selector rails and adjusting forks and - The long locking pin (5) locks selector rail 3rd - 4th.
gearbox selector - The index assembly (10) (11) (12) (18) places selector
rail 1st -2nd.
Preliminary operations - The index assembly (10) (11) (12) (19) places selector
1. Uncouple the tractor between the gearbox and the rail 3rd - 4th.
intermediate housing (see section 2C01).
2. Remove the selector cover (see section 5C01). 12. Adjust forks and selector (7) (see below).
Disassembly
Remark
On tractors fitted with a creeper gearbox, the reducer unit
located on the rear face of the gearbox does not hinder
disassembly or reassembly of the selector.
3. Remove the bolts (20) from the selector (7) and forks
(15) (16).
Note: To carry out operations on the 1st - 2nd fork,
use a short Allen key due to the limited space
between the fork and the housing.
4. Disassemble the index assemblies (10) (11) (12)
(18).
5. Push selector rail (4) towards the front and remove
lock (2). Proceed in the same way for selector rail (1)
and locking pin (5).
6. Take out selector rails (1) (4) through the rear of the
gearbox.
7. Using a suitable pin punch, drive out pin (21) from the
Hare / Tortoise fork (17) (Fig. 2).
8. Take out selector rail (3) through the rear of the
housing.
9. Remove the 3rd - 4th (16) and the Hare / Tortoise forks.
Remark : The 1st - 2nd fork (15) cannot be removed
from the housing unless the main shaft has pre-
viously been removed (see section 5F01).
Reassembly
10. Clean and inspect the components. Replace any
defective parts.
11. Refit the selector rails, forks and selectors in the
reverse order of disassembly.
Note: During refitting, pin (21) on the Hare /
Tortoise fork must be replaced.
Issue 1 May 2001


Adjustment Final operations
Principle 18. Refit the selector cover (see section 5C01).
The positioning of forks (15) (16) and selector (7) is With the gear lever in neutral, check that locks (2) (5)
obtained via the difference between the distance be- are free in the rear bearing in the Hare / Tortoise
tween the centre of threaded holes "Y" and mark "Z" on range.
the selector rails (1) (4) (Fig. 1). 19. Couple the tractor between the gearbox and the
A different forward or rearward movement of the forks is intermediate housing (see section 2C01).
obtained by acting on bolt (20) as required. 20. Road test. Check:
The adjustment of forks is carried out with the gear - gear changing
engaged. - correct operation of the Hare / Tortoise range.
21. Check oil tightness of the gearbox and intermediate
13. Smear the plugs of the indexing assemblies (10) (11) housing mating faces, selector cover and hydraulic
(12) (18) with Loctite 542 or equivalent and tighten. unions.
Lock fork (15) in 1st. Maintain the synchromesh
sliding coupler against the pinion. Check that the rear
pads are not in contact with the synchromesh sliding
coupler by slightly moving the selector rail without
moving the sliding coupler itself.
14. Repeat the operation (fork locked in 2nd), checking
that the rear pads are not in contact with the
synchromesh sliding coupler, by using the same
method as in operation 13. Where necessary, adjust
the fork using bolt (20) previously smeared with
Loctite 221 or equivalent.
15. Proceed in the same way to adjust fork (16).
Tightening torques
- Bolt (20): 35 Nm without modifying its adjustment,
Loctite 221.
- Plug (12): 50 - 70 Nm, Loctite 542.
16. Next, adjust selector (7) in line with the selector

incorporated in fork (16).
17. Adjust the "S" Hare / Tortoise selector (see section
5C01).
Issue 1 May 2001


selector rail and adjusting input unit 12
fork
22. Uncouple the tractor between the engine and the
10
23. Remove the input unit (see section 5B01).
24. Disassemble the indexing assembly (10) (11) (12).
9
25. Remove bolt (20) from the reverse shuttle fork (14). 14
26. Take out selector rail (9) and fork.
Reassembly 20
27. Clean and inspect the components. Replace any Fig. 3
defective parts.
28. Refit the fork and selector rail.
29. Carry out the adjustment of the fork (see further on).
Y
9 20
Adjustment
Principle
The positioning of fork (14) is obtained by the difference
between the distance between "Y" and mark "Z" on the
selector rails (9) (Fig. 4). A different forward or rearward
movement of the forks is obtained by acting on the
forward bolt (20) or the rear bolt, as required (Fig. 4).
30. Fit the locking stud (10), spring (11) and plug (12)
tightened to 50 - 70 Nm and previously smeared with
Loctite 542 or equivalent. Fit bolt (20) smeared with
Loctite 221 or equivalent.
31. Position the fork, locked at the front. Maintain the
synchromesh sliding coupler in thrust against the 14
Z
pinion. Pre-adjust the fork in accordance with the Fig. 4
above principle.
32. Check that the front pads are not pinched against the
synchromesh sliding coupler.
33. Repeat the operation (fork locked at the rear). Check
that the rear pads are not pinched against the
synchromesh sliding coupler.
Remark
The adjustment is correct when the space is identical
between the pads located on either side of the fork and
the synchromesh sliding coupler, when in the forward
and reverse positions.
34. Alternatively and progressively tighten bolt (20) to
35 Nm without modifying its adjustment.
Issue 1 May 2001


Final operations
35. Fit the input unit (see section 5B01).
37. Carry out a road test, checking for the correct
operation of the mechanical reverse shuttle .
38. Check for the oil tightness of the selector cover and
hydraulic unions.
Issue 1 May 2001

Gearboxes with Power Shuttle - Selector rails 5D02.1
5 D02 Selector rails
CONTENTS
- General ________________________________________________ 2
A. Disassembling and reassembling selector rails and

adjusting forks and gearbox selector _____________________ 5
Issue 1 May 2002

5D02.2 Gearboxes with Power Shuttle - Selector rails
General
On 8200 series tractors fitted with a gearbox with Power
shuttle, the selector rails used for gear selection are
located on the right-hand side of the gearbox and behind
the control cover.
The gear selector comprises the following selector

rails for:
- 1st and 2nd gear
- Hare/Tortoise (Hi-Lo)
- 3rd and 4th gear
Each selector rail supports its own fork and respective

selector and moves longitudinally in end-bearings.
The front bearing fixed on the rear part of the input unit is
removable and serves as a support for the selector rails.
The forks are adjustable, thus ensuring a functional

clearance between the pads and the synchromesh
sliding coupler.
Safety locking of the gearbox selector

The system comprises two cylindrical locks of different
lengths.
- short locking pin: selector rail 1st - 2nd
- long locking pin: selector rail 3rd - 4th
Their extremities are spherical and one of them has an
extended lug.
Each selector rail is machined both to lodge and to allow
movement of the locks.
Operating principle
Example: Ratio 1 engaged - Hare range
When the selector rail is moved to select 1st gear, it
forces its lock to move out of its lodging place and to lock
the range selector rail in the "Hare" position. At the same
time, this lock pushes another lock that in turn locks the
3rd - 4th selector rail, thus prohibiting any undue move-
ment that might block the gearbox.
The same reasoning applies to the Tortoise range and
other gear ratios.
Issue 1 May 2002

Overall view
Gearboxes with 5D02.3
Power Shuttle - Selector rails 6 S 7 13
Parts list
(1) Selector rail 3rd - 4th Fig. 1
(2) Short locking pin 1st - 2nd
(3) Hare / Tortoise selector rail
(4) Selector rail 1st - 2nd Fig. 2
(5) Long locking pin 3rd - 4th
(6) Gearbox housing
(7) Selector 1st - 2nd
(10) Locking pin 1 5 3 4 2 C
(11) Spring
F1
(12) Plug
(13) Input unit housings
(14) Reverse shuttle fork
(15) Fork 1st - 2nd
(16) Fork 3rd - 4th
(17) Hare / Tortoise fork
(18) Long spacer
(19) Short spacer
(20) Bolt
(21) Pin F
(22) Removable front support
(23) Rear support
S : Hare / Tortoise selector
21 17 16 15
4 3 4 1 2
2 10 11 18
3
Y
20
5 19
1 12
1 2
Partial view
Z
CC 3 4
View along F View along F
Fig. 1
Issue 1 May 2002 Fig. 2 Parts list

5D02.4 Gearboxes with

Power Shuttle - Selector rails
Exploded view
23 2 10 11 12 18
7
4
15
3
5
21
17
10 11 12 19
20
16
1
C 22
C : Selector cover
Fig. 1 Parts list Fig. 2
Issue 1 May 2002

Gearboxes with Power Shuttle - Selector rails 5D02.5
A . Disassembling and reassembling

selector rails and adjusting forks and
gearbox selector
1. Uncouple the tractor between the gearbox and the
1
Disassembly
Remark
On tractors fitted with a creeper gearbox, the reducer unit
(1) (Fig. 3) located on the rear face of the gearbox does
not hinder disassembly or reassembly of the selector.
3. Remove the bolts (20) from the selector (7) and forks Fig. 3
(15) (16).
Note: To carry out operations on the 1st - 2nd fork,
use a short Allen key due to the limited space
between the fork and the housing.
4. Disassemble the index assemblies (10) (11) (12)
(18).
5. Push selector rail (4) towards the front and remove
lock (2). Proceed in the same way for selector rail (1)
and locking pin (5).
6. Take out selector rails (1) (4) through the rear of the
gearbox (Fig. 4).
3
7. Using a suitable pin punch, drive out pin (21) from the
Hare / Tortoise fork (17) (Fig. 2).
8. Take out selector rail (3) through the rear of the
housing (Fig. 4). 4
9. Remove the 3rd - 4th (16) and the Hare / Tortoise forks.
Remark : The 1st - 2nd fork (15) cannot be removed
from the housing unless the main shaft has pre- 1
Fig. 4
viously been removed (see section 5F02).
Reassembly
defective parts.
11. Refit the selector rails, forks and selectors in the
reverse order of disassembly.
Note: During refitting, pin (21) on the Hare /
Tortoise fork must be replaced.
Issue 1 May 2002

5D02.6 Gearboxes with Power Shuttle - Selector rails

Special points
- The short locking pin (2) locks selector rail 1st - 2nd. Y
- The long locking pin (5) locks selector rail 3rd - 4th. 1 4 20
- The index assembly (10) (11) (12) (18) places selector
rail 1st -2nd.
- The index assembly (10) (11) (12) (19) places selector
rail 3rd - 4th.
12. Adjust forks and selector (7) (see below).
Adjustment
Principle
The positioning of forks (15) (16) and selector (7) is
obtained via the difference between the distance be- 7 15 16
Z
tween the centre of threaded holes "Y" and mark "Z" on
the selector rails (1) (4) (Fig. 5). Fig. 5
A different forward or rearward movement of the forks is
obtained by acting on bolt (20) as required.
The adjustment of forks is carried out with the gear
engaged.
Final operations
13. Smear the plugs of the indexing assemblies (10) (11) 18. Refit the selector cover (see section 5C02).
(12) (18) with Loctite 542 or equivalent and tighten With the gear lever in neutral, check that locks (2) (5)
onto the housing. Lock fork (15) in 1st. Maintain the are free in the rear bearing in the Hare / Tortoise
synchromesh sliding coupler against the pinion. range.
Check that the rear pads are not in contact with the 19. Couple the tractor between the gearbox and the
synchromesh sliding coupler by slightly moving the intermediate housing (see section 2C01).
selector rail without moving the sliding coupler itself. 20. Road test. Check:
14. Repeat the operation (fork locked in 2nd), checking - gear changing (all gears)
that the rear pads are not in contact with the - correct operation of the Hare / Tortoise range.
synchromesh sliding coupler, by using the same 21. Check oil tightness of the gearbox and intermediate
method as in operation 13. If the pads are in contact housing mating faces, selector cover and hydraulic
with the sliding coupler, adjust the fork using bolt (20) unions.
lightly smeared with Loctite 221 or equivalent.
15. Proceed in the same way to adjust fork (16).
Tightening torques
- Bolt (20): 35 Nm without modifying its adjustment,
Loctite 221.
- Plug (12): 50 - 70 Nm, Loctite 542.
16. Next, adjust selector (7) in line with the selector

incorporated in fork (16).
17. Adjust the "S" Hare / Tortoise selector (see section
5C02).
Issue 1 May 2002

Gearbox - Output shaft 5E01.1
5 E01 Output shaft
CONTENTS
- General ________________________________________________ 3
B. Removing and refitting the selector rail and forks _________ 6
C. Removing, refitting and shimming the shaft _______________ 6
Issue 1 May 2001

5E01.2 Gearbox - Output shaft
Issue 1 May 2001

Parts list
General (22) Bearing cup
The output shaft fitted to Heavy Duty gearboxes with (23) Bearing cone
mechanical reverse shuttle or Power shuttle, transmits (28) Seal ring
the rotation supplied by the different gears to the drive (31) Special washer
pinion, via a coupling sleeve or a coupler (an option with (33) Bearing cone
the creeper gearbox). (34) Bearing cup
(35) 3rd Hare gear
It is fitted on the lower transmission line at the rear of the (36) Bearing cup
gearbox. (37) Bearing cone
(40) Tortoise gear
The output shaft is supported by two taper roller bearings; (41) Locating pin
the first is centred in the bore of the mainshaft and the (43) Bearing cone
second in the rear bearing. (44) Bearing cup
(45) Shim(s)
The shaft supports: (46) Rear bearing
- the 3rd Hare gear (35) fitted on two taper roller bearings (47) Shaft
and comprising bearing cups and cones (33) (34) and (48) Bolt
(36) (37). (69) Hare / Tortoise synchromesh (double cone)
- the synchromesh and the twin Hare / Tortoise cones (70) Synchromesh ring (creeper gearbox option)
assembly (69)
- the Tortoise gear (40) which is free mounted on the F : Rear bearing (creeper gearbox option)
shaft (47). G : Syncromesh flange
P : Lubricating channel
A seal ring (28) fitted on washer (31) maintains lubricat- R : Groove
ing pressure in the channel. The calibrated port in washer
(31) allows for decompression in the cavity located
behind the bearing cone (23). A channel drilled in the hub
lubricates both cones of the syncromesh (69).
Fig. 1
The pre-loading of bearings (22) (23), (33) (34), (36) (37) Fig. 2
and (43) (44) is carried out by means of shim(s) (45)
placed behind the bearing cup (44).
Designation of double cone synchromesh

components (69)
See section 5A01 or 5A02 (depending on assembly),
General and Operation.
Issue 2
1 March
May 2002
December 2000

Overall view
48 46 41 40 35 36 37 34 33
G 3
69
22
47
43 C
23
45
B
A C
44
A
B
31 28
P
35
Parts list
R Fig. 2
Fig. 1

Exploded view
F
46
41
45
48 44
43
70
47
40
37
69
36
35
34
33
31
28
23
22
Fig. 1
3 Parts list
Fig. 2

2. Remove the selector cover (see section 5C01 - 5C02
or 5C03 depending on the version).
B . Removing and refitting the selec-

tor rails and forks
Removal
3. Remove the selector rails and forks from the gearbox
(see section 5D01 - or 5D02, depending on assembly).
Refitting
defective parts.
5. Refit the forks and the selector rails (see section 5D01
- or 5D02, depending on assembly).
C . Removing, refitting and shim-

ming the shaft
Removal
Remark
- If the tractor is fitted with the creeper gearbox option,
remove the reduction unit (see section 5K01).
6. Remove the rear bearing (46). By opening the plate

located at the rear underside of the gearbox, maintain
the gear train in place. Pull on the shaft and remove it.
7. Through the open selector cover, remove the entire
synchromesh unit (69), the 3rd Hare gear (35) with the
bearing cones (33) (37), special washer (31), bearing
cone (23) and Tortoise gear (40)
Issue 21 May 2002

December 2000
Reassembly (Fig. 3)
8. Clean and check the components. Replace any
defective part. A-A
9. Check that the channels in shaft (47) and the decom-
V
pression port of washer (31) are not blocked.
10. If necessary, insert:
- cup (22) in the layshaft A
- cups (34) (36) in pinion (35)
D
- cone (43) on shaft (47)
11. Fit seal ring (28) in the throat of special washer (31). A
12. Smear the special washer and the bearing cone (23)
with miscible grease. Place cone (23) and washer V
(31), the seal turned towards the front in the bore of
47 43
the mainshaft (7). A B C
Pre-assembly (detail E) Gearbox with mechanical

37 36 35 34 33 7
13. Insert shaft (47) without its pinion in the previously reverse shuttle
mentioned washer and cone.
14. Mark a line of paint “T” on the feed through, the
synchromesh (27) and shaft (47) corresponding to
the flat on washer (31) and that on shaft (47).
15. Remove the shaft while holding in place washer (31)
and cone (23) without turning shaft (7) (Fig. 3).
V Gearbox with power shuttle
E D
V
47 43
A B C
T T
37 36 35 34 33 7
D A B 31 C
31
47 7
23
31 27
22
R 28 23
Fig. 3
Issue 1 May 2001

Assembly
16. In the housing, introduce:
- the Tortoise pinion (40)
40
- pinion (35), with mark “R” turned to face the
synchromesh (69) (Fig. 1) and with cones (33) (37)
moderately smeared with miscible grease.
17. Fit syncromesh flange “G” (Fig. 1) on the Hare /
Tortoise pinions.
18. Lightly smear the cones and synchromesh bushes
with miscible grease.
19. Fit the synchromesh, the drilled hole “P” or the paint
mark turned towards the Tortoise pinion (40) (Fig. 4).
20. Position and centre the Tortoise pinion by holding it
via the opening of the plate located below and at the
rear of the gearbox or by using two bolts “V” as P
shown in figure 3.
21. If necessary, with the help of another operator, Fig. 4
engage the shaft with cone (43) in the pinion assem-
bly by aligning the paint marks previously made on
the shaft, synchromesh and feed-through of the
gearbox (Fig. 5).
T
Fig. 5
Issue 1 May 2001

Preparation for shimming

22. Determine the thickness of the shim(s) in order to
obtain a provisional pre-loading clearance of 0.10 to 45
0.15 mm approximately (see further on). Place
bearing cup (44) in the bearing using the previously
determined shims (45) and placing the thickest shim
on the bearing cup side. Position the bearing with the
locating pin (41) (tractors without creeper gearbox)
on the gearbox housing using of bolts (48). Tighten to
a torque of 57 - 67 Nm (Fig. 6).
23. Proceed with the shimming operation.
P2 = 0,01 / 0,05 mm
Shimming
24. Place the index of the dial gauge on the end of the
48
shaft (47) (Fig. 7).
25. Push the short protruding length of the shaft using of
a suitably adapted vice jaw fitted with protection, Fig. 6
and turn the shaft left and right in order to seat the
bearing cones in their cups.
26. Set the dial gauge to zero.
27. Repeat operation 25, but this time while pulling.
48
28. In relation to the clearance shown, select the thick-
ness of shim(s) required to obtain a pre-loading of:
P2 = 0.01 to 0.05 mm (Fig. 6) 47
29. Remove bolts (48) and bearing (46) (Fig. 7).
30. Take off bearing cup (44) and fit the definitive shims
(45) selected during operation 28.
31. Refit the cup. Place the bearing. Tighten bolts (48)
lightly smeared with Loctite 270 to a torque of 57 -
67 Nm (Fig. 7).
32. Manually check the rotation of the shaft and its gear
train.
46
Fig. 7
33. Refit the selector rails and adjust the forks (see § B).
34. Adjust the Hare / Tortoise selector and refit the
selector cover (see section 5C01 - 5C02 or 5C03
depending on the version).
35. Re-couple the tractor between the gearbox and the
36. Check for the oil tightness of all seals and hydraulic
unions.
37. Road test all controls.
2
Issue 1 March 2000
December 2002
Gearbox - Mainshaft 5F01.1
5 F01 Mainshaft
CONTENTS
- General ________________________________________________ 2
B. Disassembling and reassembling the shaft ________________ 5
C. Final operations ________________________________________ 7
D. Shimming the input pinion ______________________________ 8
E. Shimming the shaft _____________________________________ 9
Issue 1 May 2001

5F01.2 Gearbox - Mainshaft

Parts list
General (1) Input pinion
The mainshaft (7) fitted to Heavy Duty gearboxes rotates (2) Belleville washers
on two taper roller bearings (9) (10) and (20) (21) lying in (3) Special bolt
the two lower bearings of the main gearbox. The input (4) Lubricating pipe
gear (1) fitted at the front, engages with the shaft via (5) Snap ring
splines. It is held by Belleville washers (2) fixed by the (6) Spring
special cone-locking bolt (3). (7) Mainshaft
The Belleville washers also provide a constant load on (8) Bush
bush (8), the synchromesh hub (16) and the shoulder of (9) Bearing cone
the shaft. (10) Bearing cup
This flexible assembly permits permanent contact of the (11) Shim(s)
stated parts, when forces are applied to the gears. (12) Spacer
Between the two lower bearings, the shaft bears the (13) 2nd gear pinion
freely rotating driving pinions of 2nd gear (13) and 1st gear (14) 2nd gear synchromesh bearing cone
(19), as well as the synchromesh assembly of 1st and 2nd, (15) 2nd gear synchromesh ring
the hub of which engages splines on the shaft. At the (16) 1st - 2nd synchromesh
rear, it bears the freely rotating driving pinion of 4th gear (17) 1st gear synchromesh ring
(24) and the synchromesh assembly for 3rd and 4th gear. (18) 1st gear synchromesh bearing cone
The rear bore receives bearing cup (22) of the taper roller (19) 1st gear driving pinion
bearing of the output shaft. (20) Bearing cone
The lubrication of 1st gear pinion and the bush of the 2nd (21) Bearing cup
gear pinion are ensured by a central channel and radial (22) Bearing cup
drillings. (24) 4th gear driving pinion
The pre-loading of the bearings is adjusted by means of (25) 4th gear synchromesh bearing cone
shims (11) placed behind bearing cup (10). The input (26) 4th gear synchromesh ring
pinion (1) is shimmed by means of shims (38) (39) fitted (27) 3rd - 4th synchromesh
on the special bolt (3) to obtain a flexing of the Belleville (29) Snap ring
washers (2). (30) 3rd gear synchromesh ring
(32) 3rd gear synchromesh bearing cone
(38) Shim(s)
(39) Spacer
Fig. 1
Fig. 2
Issue 1 May 2001

Overall view
11
12 10
21 20 19 13 9 8 7 1
4 1 2
6
29
5
22
4
32 30 27 26 25 24 18 17 16 15 14
38
2 39
Issue 1 May 2001

Exploded view
29
32
27
30
26
25
4 24
20
21
19
18
17
16 15
14
13
8
Parts list
12 39 Fig. 1
11 38
10 3
6
9
4
5
1
2
Fig. 2
Issue 1 May 2001

Remark 57
To dismantle the mainshaft, it is necessary to remove
the gearbox. 56 51

2. Separate the gearbox from the engine (see section
2B01).
4. Place the gearbox on a suitable fixture.
5. Take off the input unit (see section 5B01).
6. Remove the selector rails and forks (see section
5D01).
7. Remove the output shaft (see section 5E01).
Fig. 3

the shaft
Disassembly
Special point (Fig. 3)
To remove the bearing cone (25), the synchromesh (27)
and the 4th gear driving pinion (24), it is necessary to
remove circlip (56) (Fig. 3) from the machined throat of
the mainshaft. Then to push back pinion (57).
Fig. 4
8. Take off the snap ring (29). Remove 3rd - 4th gear
synchromesh (27) and mark its position.
9. Remove the synchromesh ring (26), the bearing
cone (25) and the pinion (24).
Note: Keep the synchromesh ring and bearing
cone together if they are to be re-used.
10. Keep the shaft under rotation by using a locally
manufactured tool and by using a 4 WD clutch, ref.
3617232M1 (Fig. 4).
11. If necessary, remove lubricating pipe (4) and spring
(6).
12. Unscrew bolt (3) by means of a 32 mm socket and
a suitable length extension.
13. Remove shims (38) (39), Belleville washers (2) and
input pinion (1).
14. Remove bush (8) fitted with cone bearing (9).


15. Remove the tool. Take out the shaft from its housing
with the 1st gear pinion (19) (Fig. 5) located at the
rear, through the bearing aperture, while maintaining
the fork, pinion and 1st - 2nd gear synchromesh
assembly.
Special point
The extracting of the 1st - 2nd gear fork from the
housing must be accompanied by the synchromesh
assembly (16) and the 2nd gear driving pinion (13).
16. Remove the whole assembly (synchromesh, 2nd
gear pinion assembly and fork) through the selector
cover aperture (Fig. 6).
17. Take off the bearing cups (10) (21). 19
Note: In the case of re-use, keep cups and cones
together.
18. Remove shims (11), spacer (12).
19. Where necessary, extract the bearing cones (9) (20), Fig. 5
cup (22). Take off snap ring (5) from bolt (3).
Reassembly
defective parts.
21. Check that the central channel and radial ports of
shaft (7) are not blocked.
22. If disassembled, with the aid of a press and a
suitable fixture, respectively insert bearing cones (9)
(20) on bush (8) and shaft (7). Position the snap ring
(5) in bolt (3). Insert bearing cup (22) in shaft (7).
23. Lubricate the bearing cones and cups.
24. Fit cup (21).
25. Place the spacer (12), the shims (11) selected during
operation 59 and the bearing cup (10) in the bore of
the housing.
Remark:
- The shims (11) must be fitted between the spacer
(12) and the bearing cup (10) (Fig. 1). Fig. 6
26. Check for wear on syncromesh rings (15) (17)
against bearing cones (14) (18) (see section 5A01).
27. Assemble the 2nd gear pinion (13), bearing cone
(14), synchromesh ring (15), 1st - 2nd gear synchro-
mesh (16), 1st gear synchromesh ring (17) and
bearing cone (18) on the workbench.
28. Refit the entire assembly between the separations
with the 1st - 2nd gear fork correctly positioned (Fig. 6).
29. Slide in the shaft and 1st gear pinion (19) through the
rear of the housing (Fig. 5) while holding the pinion /
synchromesh assembly.
30. Slide synchromesh ring (8) fitted with bearing cone
(9) on to the shaft (7).
Issue 21 March
December 2000
May 2002
31. Fit the pinion (1), the Belleville washers (2) posi-
tioned as in Fig. 7, and the shims (39) (38) deter-
mined during operation 50, along with bolt (3). 2 39
Remark: The shims (38) must be placed against the
shoulder of the bolt (3).
32. Hold the shaft in place as in operation 10.
33. Tighten bolt (3) lightly smeared with Loctite 270 to a
torque of 320 - 360 Nm. Remove the tool. Manually
check the rotation of the shaft.
34. If disassembled, fit spring (6) and lubricating pipe (4)
with bolt (3).
35. Check for wear of synchromesh ring (26) against
cone (25) (see section 5A01).
36. Fit the pinion (24), cone (25), synchromesh ring (26)
and the 3rd - 4th gear synchromesh (27) while respec- 38
ting the direction of assembly.
37. Advance pinion (57) on the intermediate shaft and
Fig. 7
place circlip (56) in the throat without bending it and
ensuring that it is correctly fitted (Fig. 3).
38. Place snap ring (29).
39. Manually check:
- the axial clearance of the pinions
- the rotation of the shaft and its gear train.
C . Final operations
40. Refit the output shaft (see section 5E01).
42. Refit the selector rails. Adjust the forks and selectors
of 1st - 2nd and Hare / Tortoise (see sections 5D01 and
5C01 respectively).
43. Replace the selector cover (see section 5C01).
Check that changing of the gears is correctly carried
out and that the Hare / Tortoise position is present.
44. Connect the gearbox to the engine (see section
2B01).
45. Reconnect the tractor between the gearbox and the
46. Check the oil tightness of seals and hydraulic un-
ions.
47. Road test the clutch controls, the reverse shuttle, the
Hare / Tortoise range of gears and the A, B, C, D
ratios of the Dynashift.
Issue 12 May 2000

December 2002
D . Shimming the input pinion (Fig.

8) 38 39
48. Place the shaft (7) in a vice fitted with jaw protectors.
Provisionally fit the synchromesh (18), the ring (8),
input pinion (1), the Belleville washers (2) without the
shims (38) (39). It is essential that special bolt (3) is
tightened to a torque of 30 Nm maximum. 3
49. Place the dial gauge index on the end of the shaft,
measure axial clearance of pinion (1) (Fig. 8). 2
50. In relation to the clearance measured and the thick-
ness of the shim removed (39), select shim thick- 1
ness (38) to obtain a flexing of the Belleville washers
of between 1.25 mm and 1.75 mm. 8
Note: If the axial clearance is greater than 1 mm,
it is recommended to reduce it by adding only 16
one shim (38) in order to measure it again with
greater precision.
51. Take out bolts (3) and the elements provisionally
7
fitted during operation 48. Go on with the final
assembly of the shaft and carry out its shimming
(see § E).
Remark: In cases where input pinion (1) is replaced
on the tractor (Fig. 9), the shimming method is
identical. First temporarily remove the cup (10) and
shims (11) (12) (Fig. 9) in order to eliminate the pre- Fig. 8
loading effect on bearings (9) (10) and (20) (21).
When the shimming of the pinion is completed,
replace the shims and the cup (Fig. 9).
11 12 10
Fig. 9

E . Shimming the shaft

52. Determine the thickness of the shim(s) (11) in order
to obtain a temporary clearance of approximately
0.10 mm to 0.15 mm, while awaiting the shimming
with pre-loading (see further on).
It is essential to place the spacer (12) against the
housing, previously determined shims (11) and cup 7
(10).
53. Fit the shaft locking tool (Fig. 4). Tighten bolt (3).
Remove the tool.
54. Proceed with the shimming.
Shimming
55. Place the index of the dial gauge on the end of shaft Fig. 10
(7) (Fig. 10).
56. From the front of the housing, pull hard on the shaft
while turning it left and right to seat it correctly in the
bearing cups and cones.
57. Reset the dial gauge to zero.
58. Repeat operation 56 this time by pushing.
59. In relation to the clearance read on the gauge, select
the correct thickness for the definitive shims (11) in
order to obtain a pre-loading of:
P1 = 0.10 mm to 0.20 mm maximum (Fig. 11).
60. Fit the locking tool on the shaft. Unscrew bolt (3).
Take off the shims (38) (39), the Belleville washers
(2) and the pinion (1).
61. Take out bush (8) fitted with bearing cone (9) and cup
(10) (Fig. 1).
62. Place the shims (11), selected in operation 59, P1 0,10 / 0,20
between spacer (12) and cup (10) (Fig. 1). maxi
63. Fit bush (8) fitted with cone (9), pinion (1), Belleville
washers (2) and shims (38) (39) placed as during Fig. 11
operation 31.
64. Tighten bolt (3) smeared with Loctite 270 to a final
torque of 320 - 360 Nm. Remove the tool.
65. Manually check the rotation of the shaft and its gear
train.
Issue 12 December
May 2000
2002
Gearbox with Power 5F02.1

Shuttle - Mainshaft
5 F02 Mainshaft
CONTENTS
- General ________________________________________________ 2
B. Disassembling and reassembling the shaft ________________ 5
C. Final operations ________________________________________ 7
D. Shimming the shaft _____________________________________ 8
E. Service tools ___________________________________________ 9
Issue 1 May 2002

5F02.2 Gearbox with Power

Shuttle - Mainshaft
Parts list
General (1) Input pinion
The mainshaft (7) fitted to Heavy Duty gearboxes with a (2) Tab washer
power shuttle rotates on two taper roller bearings (9) (10) (3) Nut
and (20) (21) lying in the two lower bearing blocks of the (4) Lubricating pipe
main gearbox. The input pinion (1), fitted at the front, is (5) Snap ring
integral with the shaft via splines. It is held by washer (2) (6) Spring
and nut (3). (7) Mainshaft
Between the two lower bearing blocks, the shaft holds (8) Bush
the driving pinions of 2nd (13) and 1st (19) that run free, as (9) Bearing cone
well as the synchromesh assembly for 1st and 2nd, the (10) Bearing cup
hub of which is splined to the shaft. At the rear the shaft (11) Shim(s)
holds the 4th gear driving pinion (24) that runs free and the (12) Spacer
synchromesh assembly for 3rd and 4th gear. (13) 2nd gear driving pinion
The synchromesh is of the double cone type. (14) 2nd gear synchromesh cone
The rear bore receives bearing cup (22) of the taper roller (16) 1st and 2nd gear synchromesh
bearing of the output shaft. (18) 1st gear synchromesh cone
The lubrication of the 1st gear pinion and 2nd gear bush is (19) 1st gear driving pinion
ensured by a central channel with radial ports. (20) Bearing cone
The pre-loading of bearings is adjusted by means of (21) Bearing cup
shim(s) (11) placed behind bearing cup (10). (22) Bearing cup
(24) 4th gear driving pinion
(25) 4th gear synchromesh cone
Fig. 1
(27) 3rd and 4th gear synchromesh
(29) Snap ring
(32) 3rd gear synchromesh cone. Fig. 2
Issue 1 May 2002


Shuttle - Mainshaft
Overall view
11
12 10
21 20 19 13 8 7 1
4 1 2
2
22
29
32 27 25 24 18 16 14
Fig. 2
Parts list
Fig. 1
Issue 1 May 2002


Shuttle - Mainshaft
Exploded view
29
27 24
6
5
4
20
32 18 21
1
19
16
2
13
14
25
12
11
10
9 Fig. 1
1
2 Parts list
3 Fig. 2
Issue 1 May 2002


Shuttle - Mainshaft
Remark 57
To take out the mainshaft, it is necessary to remove the
gearbox. 56 51

2B01).
3. Remove the selector cover (see section 5C02 or
5C03 according to version).
5. Take off the input unit (see section 5B02).
6. Remove the selector rails and forks (see section
5D02).
7. Remove the output shaft (see section 5E01). Fig. 3

the shaft
Disassembly
To remove the synchromesh (27) and 4th gear driving
pinion (24) (Fig. 1), it is necessary to remove circlip (56)
(Fig. 3) from the machined groove of layshaft (51). Then,
push back the pinion (57).
8. Take off snap ring (29). Remove the 3rd and 4th gear
synchromesh (27), carefully marking its position. Fig. 4
9. Remove the synchromesh parts (rings, cones and
bushes) carefully marking their locations if the pinion
(24) is to be re-used later.
10. Immobilise the shaft using a locally made tool using
a 4 WD clutch plate, ref. 3617 232M1 (Fig. 4).
11. If necessary, remove lubricating pipe (4) and spring
(6).
12. Completely unscrew nut (3) (60 mm flat) using
socket, ref 3378009M1 (see § E).
13. Remove tab washer (2) and the input pinion (1).
14. Take out bush (8) complete with bearing cone (9).
Issue 1 May 2002


Shuttle - Mainshaft
15. Remove the tool. Take the shaft out of the housing
complete with the 1st gear driving pinion (19) (Fig. 5)
towards the rear via the bearing block opening, while
holding together the 1st and 2nd synchromesh, pinion
and fork assembly.
Special point
The extraction of the 1st and 2nd gear fork from the
housing is carried out along with the synchromesh
assembly (16) and the 2nd gear driving pinion (13).
16. Remove the complete assembly (synchromesh, 2nd
gear pinion and fork) through the selector cover
opening (Fig. 6).
17. Take out bearing cups (10) (21). 19
Note: Carefully match the cups and cones if they
are to be re-used.
18. Remove the shim(s) (11) and spacer (12).
19. If necessary, extract bearing cones (9) (20) Fig. 5
and bearing cup (22). Take off snap ring (5).
Reassembly
20. Clean and check the parts, discard any defective
ones.
21. Ensure that the central and radial lubricating chan-
nels of shaft (7) are not blocked.
22. If removed, using a press and a suitable fixture,
insert the bearing cones (9) (20) on bush (8) and shaft
(7). On the latter, also position snap ring (5) and insert
cup (22).
23. Lubricate the bearing cups and cones.
24. Fit bearing cup (21).
25. Check for wear on synchromesh parts of 1st and 2nd
gear (see section 5A02).
26. Outside the housing, assemble the 2nd gear pinion
(13), new synchromesh parts and 1st and 2nd gear
synchromesh. Fig. 6
Remark
- If the synchromesh parts are to be re-used, refit
each part in its initial position, as marked during
disassembly.
27. Between the two compartments, refit the complete
assembly with the 1st and 2nd gear fork correctly
positioned (Fig. 6).
28. Slide the shaft and 1st gear pinion (19) through the
rear of the housing (Fig. 5) while holding the pinion /
synchromesh assembly.
29. Shim the shaft (see § D).
30. Fit pinion (1).
Issue 1 May 2002


Shuttle - Mainshaft
31. Degrease the threaded end of the shaft using sol-
vent.
Hold the shaft as desribed in operation 10. Clean and
lightly smear the new nut (3) with Loctite 270 or
equivalent (Fig. 7) then tighten it to a torque of 130 -
170 Nm using the socket previously used. 3
32. Remove the tool.
33. Lock the nut by bending its collar, without breaking
it, into the grooves of the shaft using a suitable drift.
Manually check the rotation of the shaft.
34. If removed, fit spring (6) and lubricating pipe (4) in
shaft (7).
35. Check the wear of the 3rd and 4th gear synchromesh
parts (see section 5A02).
36. Refit the synchromesh parts that are being re-used,
according to the markings made during disassem-
bly. Position the driving pinion of 4th gear (24) and the
Fig. 7
synchromesh of 3rd - 4th (27).
37. Move forward pinion (57) on the mainshaft. Fit circlip
(56) in its throat without bending it, and ensuring that
it is correctly positioned (Fig. 3).
38. Place snap ring (29).
39. Manually check:
- the axial clearance of the pinions
- the rotation of the shaft and its pinions.
C . Final operations
40. Reassemble the output shaft (see section 5E01).
42. Reassemble the selector rails. Adjust the 1st - 2nd
and Hare / Tortoise forks and selectors (see sections
5D02, 5C02 or 5C03 respectively, according to
version).
depending on version). Check that the gear shifting
operates correctly and also check for the presence
of the Hare / Tortoise position.
44. Connect the gearbox with the engine (see section
2B01).
45. Couple the tractor to the gearbox and the intermedi-
ate housing (see section 2C01).
46. Check the oil tightness of mating faces and hydraulic
unions.
47. Carry out a road test of the Power Shuttle, gears,
Hare / Tortoise range and A, B, C and D ratios of the
Dynashift.
Issue 1 May 2002


Shuttle - Mainshaft
D . Shimming the shaft
48. Determine the thickness of shim(s) (11) required to
obtain a provisional clearance of 0.10 to 0.15 mm for
the later loading of the bearings (see following).
Reminder:
- It is essential to place spacer (12) against the
housing, the previously determined shim(s) (11) 7
and bearing cup (10).
49. Slide bush (8) fitted with cone (9) and pinion (1) onto
shaft (7).
50. Fit washer (2) and nut (3).
51. Place the locking tool on the shaft (Fig. 4), tighten the
nut to a torque of 130 - 170 Nm and remove the tool.
Fig. 8
Shimming
52. Place the finger of the dial gauge on the end of the
shaft (7) (Fig. 8).
53. From the front of the housing, pull hard on the shaft,
turning alternately from left to right to correctly seat
the cones in their bearing cups. 11
55. Repeat operation 53, this time pushing.
56. In relation to the clearance measured, select a
definitive thickness for shim (11) in order to provide
12
a pre-loading of (Fig. 9):
P1 = 0.10 to 0.20 mm maximum.
Remark:
- Preferably shim to the maximum tolerance. P1 = 0.10/0.20
0,10/0,20
maxi
max.
57. Place the locking tool on the shaft, loosen nut (3) and
take off the pinion (1).
58. Take off bush (8) complete with bearing cone (9)
from shaft (7). Remove bearing cup (10) from the
housing.
59. Place shims (11) selected during operation 56 be-
tween spacer (12) and bearing cup (10) (Fig. 1).
60. Slide the bush (8) and cone (9) assembly onto shaft
(7).
61. Proceed with the reassembly phase. Carry out
operations 30 to 39.
Fig. 9
Issue 1 May 2002


Shuttle - Mainshaft
E . Service tools
1. Tool available in the AGCO network
- 3378009 M1: Nut socket - Mainshaft (Fig. 10).
2. Locally made tool

- Locking tool - Mainshaft (Fig. 11).
a : 4 WD clutch plate - 8200 ref. 3617232 M1 to be
ordered from your spare parts supplier
b : 40 flat iron
c : M12 bolts
Fig. 10
Fig. 11
Issue 1 May 2002

Gearbox - Layshaft 5G01.1
5 G01 Layshaft
CONTENTS
- General ________________________________________________ 2
B. Removing and disassembling the layshaft ________________ 5
C. Reassembling and refitting the layshaft ___________________ 6
E. Shimming the pinions ___________________________________ 8
F. Shimming the bearings __________________________________ 8
G. Service tools ___________________________________________ 10
Issue 1 May 2001

5G01.2 Gearbox - Layshaft

Parts list
General (49) Bearing cup
The layshaft and its pinions form the upper transmission (50) Bearing cone
line of the Heavy Duty gearbox with mechanical reverse (51) Layshaft
shuttle or Power shuttle. (52) Nut
Shaft (51) bears, in this order, the driving pinions of 2nd (53) Shim
gear (64), 1st gear (61), 4th gear (59) and 3rd gear (57). (54) Bearing cone
These pinions are splined to the shaft and separated by (55) Bearing cup
spacers (62) (60) and (58). Axial clearance of the gear (56) Circlip
train is provided by one or more shims (63). The rear teeth (57) 3rd gear driven pinion
of the layshaft (51) continuously engage the Tortoise (58) Spacer
pinion mounted on the output shaft. The front of the shaft (59) 4th gear driven pinion
is supported by a roller bearing fitted to the rear of the (60) Spacer
input unit. Its rear extremity is supported by two taper (61) 1st gear driven pinion
roller bearings (49) (50) and (54) (55). (62) Spacer
The adjustment of these bearings is of the "Semi Set (63) Shim(s)
Right" type. It is carried out by placing a shim (53) (64) 2nd gear driven pinion
between the bearing cones (50) (54) in order to obtain a (65) Washer
clearance of a predetermined value between the cups (66) Snap ring
(49) (55) (see § F). (67) Needle bearing
(76) Friction ring with shoulder
Special points
- The friction ring (76) forms an oil tight link of the upper Fig. 1
shaftline between the gearbox and the intermediate
housing (see section 9G01). It is adjusted and sealed
with Loctite 648 or its equivalent in the rear bore of the Fig. 2
shaft (Fig. 6).
- Shim (53) has several radial ports permitting lubrication
of bearings (49) (50) and (54) (55).
Issue 2
1 December 2000
May 2002
Overall view
76 52 51 57 59 61 63 64
3 4 1 2
56 58 60 62 65 66 67
50 54
49 55 B
53
F
52
Rear and partial view of the input unit:

- A : with mechanical reverse shuttle and without oil
deflector
- B : with Power shuttle and oil deflector Parts list Fig. 2 Fig. 1
Issue 12 December
May 2000
2002
Exploded view
52
50
49
53
55
54
51
67
56 2
57
58
59
60
61
62
63
64
65
66
Issue
Issue 21 May 2002
December 2000
Remark
To take out the layshaft it is necessary to remove the
gearbox.

intermediate housing (see section 2B01).
2B01).
3. Take off the selector cover (see section 5C01 or
5C02 depending on assembly).
5. Remove the input unit (see section 5B01 or 5B02
depending on assembly).
6. Disassemble the selector rails and the forks (see
section 5D01 or 5D02 depending on assembly). Fig. 3
7. Where necessary, immobilise the gear train in the
gearbox. Unlock and slightly loosen nut (52) with the
aid of an appropriate chisel in order to overcome the
resistance of the Loctite.
Remark :
- Of course, this nut is replaced during reassembly.
This operation facilitates the removal of the nut
with the service tool once the output shaft and
mainshaft have been disassembled.
8. Remove the output shaft (see section 5E01).
9. Remove the mainshaft (see section 5F01 or 5F02

the layshaft
Removal
10. Finish unscrewing the nut (52) using service tool
MF391 (see § G) and remove bearing cone (50).
Note: Keep the bearing cups and cones together
if they are to be re-used.
11. Take out the shaft (51) and pinion assembly (Fig. 3).
12. Remove the shim (53) and take off the cone (54).
13. Where necessary, drive off the cups (49) (55) and
mark their locations (Fig.5).
Issue 12 May 2000

December 2002

Disassembly
14. On shaft (51) remove the snap ring (66) and washer
(65) and mark the locations. Take off the 2nd gear
pinion (64), shim(s) (63), spacer (62), 1st gear pinion 65 67 66
(61), spacer (60), 4th gear pinion (59), spacer (58),
3rd gear pinion (57) and circlip (56) (Fig. 4).
15. If necessary, drive off needle bearing (67) (Fig. 4).
64
63
62
61
60
C . Reassembling and refitting the
59
layshaft
58
Reassembly
16. Clean and inspect the components. Replace the
defective parts. 57
17. On the shaft, check that the lubricating ports leading
to the bearing cones (50) (54) are not blocked. Check
for the presence of friction ring (76) (Fig. 4).
18. If disassembled, insert the needle bearing (67) to
thrust against the shoulder of shaft (51) with the aid
of a suitable fixture. 51 56
Note: Check that the needle bearings turn freely
in the cage after insertion.
19. Fit a new circlip (56).
Replace the 3rd gear pinion (57), spacer (53), 4th 76
gear pinion (59), spacer (60), 1st gear pinion (61) and
spacer (62).
Replace 2nd gear pinion (64) without the shims (63).
Carry out the shimming of the pinions (see § E). Fig. 4
20. Shim the pinions (see § E).
Refitting
Reminder
- If necessary, shim the bearings (54) (55) and (49) (50)
(see § F). 49
21. Lubricate the cones (50) (54) and the bearing cups
(49) (55).
22. If disassembled, insert the cups to thrust against the
shoulder of the housing, with large cup (49) fitted into
the rear bore of the gearbox (Fig. 5).
23. Slide cone (54) onto shaft with shim (53) the thick-
ness of which has been determined at operation 46. 55
24. Place the assembled shaft in the housing. Fit cone
(50). Pre-tighten nut (52) in contact with the cone
(50).
Fig. 5

Special point
- This nut will be definitively tightened to torque once the
52
input unit has been refitted, in order to obtain the correct
alignment of the layshaft in the two bearings.
25. Reassemble the layshaft (see section 5F01 or 5F02
26. Reassemble the output shaft (see section 5E01). R 76
27. Refit the input unit (see section 5B01 or 5B02 Fig. 6
Reminders (Fig. 6)
- Tighten nut (52) to a torque of 50 Nm. Rotate the
layshaft several times to progressively seat the bear-
ings. Carry out final tightening of the nut to a torque of
100 - 150 Nm, the threads having previously been lightly
smeared with Loctite 270 or equivalent.
- Lock the nut by bending the collar without breaking it
into grooves "R" on the shaft with the aid of an
appropriate pin punch.
28. Reassemble and adjust the gear selector device

(see sections 5D01 or 5D02 and 5C01 or 5C02
30. Check that the gears change correctly and that the
Hare / Tortoise position functions.
31. Couple the gearbox to the engine (see section 2B01).
32. Couple the tractor between the gearbox and the
33. Check the oil tightness of seals and hydraulic unions
34. Road test the clutch controls, the A, B, C, D ratios of
the Dynashift mechanical reverse shuttle or power
shuttle, the gears and the Hare / Tortoise range.
Issue 12 December
May 2000
2002
E . Shimming the pinions (Fig. 7)

Reminder 65 66
The pinions must be stacked with the shims (63)
temporarily removed. 2
35. Using a set of feeler gauges, measure the distance

between the 2nd gear pinion (64) and spacer (62).
36. In relation to the measurement, determine the re-
quired thickness of the shim(s) (63) in order to obtain
a clearance of:
J1 = 0.02 to 0.31 mm
Remark: If possible, preferably shim towards the
nominal tolerance. 63
37. Remove snap ring (66) and washer (65). Remove
the 2nd gear pinion.
38. Slide the previously selected definitive shims on to
the shaft. Refit the pinion and washer (65), turning
the chamfer to the exterior. Fit a new snap ring (66) J1 = 0,02/0,31
and check that it is correctly positioned.
39. Refit the assembled shaft with its pinions into the
gearbox housing (see § C). Carry out the remaining 64
operations (see § D).
62
F . Shimming the bearings
Reminder (Fig. 8)
- The principle consists in defining the thickness of the
Fig. 7
shim (53) to be fitted between the bearing cones (50)
(54) under load (500 N) and in order to obtain an "X"
measurement of 8.60 to 8.68 mm between cups (49)
(55) mounted loose.
50 53 54
Remark
- Bearings will be shimmed before refitting the layshaft.
If the removed bearings which, extract cups (49) (55)
from the gearbox housing when pairing them with their
respective cones.
49 55
Fig. 8

Preparation for shimming (Fig. 9)

40. Fit bearing cones (50) (54) and cups (49) (55) without
shim (53) on service tool, ref. 3378263M11 (see § G).
Tighten the tool in a vertical position in a vice.
41. Compress the spring until the shoulder of the special
bolt is in contact with the top of the tool.
Special point
The spring characteristics and the length of the bolt
shoulder provide the correct load to apply to the
bearings.
42. Turn cylinder "C" several times, in order to correctly
seat the cones in the cups.
49
Shimming (Fig. 9)
Measure the distance between the bearing cones
(50) (54)
43. Position the pressure plate of the tool on the face of
the cone (54). Place the index of the dial gauge on the
extremity of the pressure plate.
44. On the dial gauge:
- set the long hand to zero
- note the position of the short hand
45. Turn the pressure plate half a turn while maintaining
it on the face of the cone (50).
Immobilise the rod by moderately manually tighten-
ing the stop bolt.
46. In relation to the measurement noted on the dial 54 55 C
gauge, select the corresponding shim (53) to be
definitively fitted between the bearing cones (50)
(54).
47. Carry out the remaining operations (see § C and D).
50
Fig. 9
Issue 12 December
May 2000
2002
G . Service tools
- MF391 - Socket for layshaft nut (Fig. 10).
- 3378263M11 - Bearing shimming tool (Fig. 11).
Fig. 10
Fig. 11

Full Powershift Gearbox 5H01.1
5H01 General
CONTENTS
A. General ________________________________________________ 2
B. Characteristics __________________________________________ 2
C. Transmission ___________________________________________ 3
D. Power transmission - Description ________________________ 12
E. Vibration damper and coupling shaft _____________________ 18
F. Service tools ___________________________________________ 21
Issue 1 May 2001

5H01.2 Full Powershift Gearbox
A . General
The AG150 and AG250 Full Powershift gearboxes com-
prise forward and rear housings containing seven shafts
and nine clutches. Six speed clutches and three range
clutches. Three clutches must be hydraulically engaged
in order to transmit engine power. These transmissions
are fitted with their own Gerotor hydraulic pump, filter,
pressure regulating valve, lubricating metering valve and
nine proportional solenoid valves to engage the clutches.
These transmissions use an oil tank that is common to
the gearbox and axle assembly. The gearbox is coupled
to the engine via a splined coupling shaft situated in the
transmission and a damper located on the engine fly-
wheel.
Fig. 1
B . Characteristics
The AG150 and AG250 Full Powershift gearboxes have
the following characteristics:
- 18 forward speeds
- 6 or 8 reverse speeds depending on the specifications
in each country
- constant meshing, helicoidal gears
- ball and roller bearings to eliminate all vibration
- common axle / gearbox oil tank
- hydraulically controlled multi-plate clutches
- electro-hydraulic gear changes
- 100% modulated gear changes
- adaptation to speed of movement
- reverse shuttle
- compact design in a 2-part housing
- housing also acts as the tractor chassis between the
engine and rear axle unit
- pressure lubrication of all clutches
- self-controlled hydraulic pump
- vibration damper in the engine flywheel
- electronically protected.
Issue 1 May 2001

C . Transmission (Figs. 2 to 7)
Parts list
(1) Forward transmission housing
(2) Rear transmission housing
(3) Location of the first stage shaft
(4) Location of the second stage shaft
(5) Location of the third stage shaft
(6) Location of the fourth stage shaft
(7) Location of the fifth stage shaft
(8) Location of the sixth stage shaft
(9) Location of the seventh stage shaft
(10) Input shaft and seal
(11) 260 psi (18 bar) pressure regulating valve
(12) Clutch 2 proportional solenoid valve
(13) Clutch A proportional solenoid valve
(14) Clutch R proportional solenoid valve
(15) Clutch B proportional solenoid valve
(16) Clutch 1 proportional solenoid valve
(17) Clutch C proportional solenoid valve
(18) Clutch L proportional solenoid valve
(19) (AG 150) clutch M proportional solenoid valve
(AG 250) clutch H proportional solenoid valve
(20) (AG 150) clutch H proportional solenoid valve
(AG 250) clutch M proportional solenoid valve
(21) 130 psi (9 bar) pump pressure switch
(22) Engine speed sensor
(23) Forward speed sensor
(24) Calibration sensor
(25) Temperature sensor
(26) Clutch hydraulic test port - 7/16” plugs
(27) Lubricating pressure test port - 9/16” plugs
(28) Pump hydraulic test ports - wide plugs
(29) IN port (inlet) of the pump from the tank
(30) Free return to housing port
(31) Pump pressure outlet port
(32) Pump pressure inlet port to forward housing
(33) Oil outlet port towards oil cooler and lubricating Fig. 2
relief-valve
(34) Return port for oil from oil cooler
(35) Gearbox serial and model number identification Fig. 3
plate
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Issue 21 May 2002

2001
Overall view
15
26
27
21
26
13
24
17
16
Fig. 3
1
11
12
Fig. 4
14 26 Fig. 5
18 Fig. 6
28
Parts list Fig. 7

27
Fig. 2
Issue 2
1 May 2002
2001
Front view
4 10 3 5 6
3RD
2ND 4TH
19
11
7TH
6TH
5TH
1 9 8 7 18
Parts list
Fig. 2 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 3
Issue 1 May 2001


Top view
26 27 14 26 27 21 1
16 26
11 12
17 19
24 13
15 2
Fig. 2
Fig. 3
Fig. 5
Fig. 6
Parts list Fig. 7
Fig. 4
Issue 1 May 2001

Right-hand view
29 13 12 27
2 35 13 23 20 19 1
Parts list
Fig. 2 Fig. 3 Fig. 4 Fig. 6 Fig. 7

Fig. 5
Issue 1 May 2001

Left-hand view
25 16 27 14 15 24 17 32 22 31
1 18 34 33 11 2
Parts list
Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 7 Fig. 6
Issue 1 May 2001

Bottom view
26 27 26 28 26 28
Parts list Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7
Issue 1 May 2001

Diagram showing the meshing

of AG 150 pinions
5TH STAGE
74T L 40T
4TH STAGE
70T
C 71T
1 62T
42T 70T
B 71T
R 62T 3RD STAGE
42T
A 71T
2 48T 2ND STAGE
INPUT 32T 1ST STAGE PTO OUTPUT
48T
H 72T 6TH STAGE OUTPUT
65T
M 40T 7TH STAGE
Fig. 8
Issue 1 May 2001

Diagram showing the meshing of

AG 250 pinions
80T L 44T 5TH STAGE
80T
C 82T
1 76T 4TH STAGE
3RD STAGE
48T 60T
B 82T
R 76T
48T
A 82T
2 59T 2ND STAGE
INPUT 38T 1ST STAGE PTO OUTPUT
53T
H 81T
6TH STAGE OUTPUT
75T
M 47T 7TH STAGE
Fig. 9
Issue 1 May 2001


Thanks to this configuration, the various clutches supply
D . Power transmission – Descrip- six forward ratios and three reverse ratios to the trans-
tion mission, in accordance with the input clutches (1, 2 or R)
or output clutches (A, B or C) selected. The output from
The engine power is transmitted to the 1st stage shaft that
speed clutches directs the power to the clutch of the
drives the shafts of the 2nd, 3rd and 4th stages. The 1st
selected range (L, M or H), thus providing 18 forward
stage shaft also drives the Gerotor hydraulic pump for the
speeds and 8 reverse speeds. In the North American
gearbox and acts as the PTO input shaft. The shafts of
market, the electronic control does not permit the engag-
the 2nd and 4th stages act as forward speeds with the
ing of the two highest speeds. Other international mar-
various ratios of input speed, while the shaft of the 3rd
kets may authorise these reverse speeds in relation to
stage acts as reverse with a single input speed ratio. This
the legislation in force in their countries (Figs. 10 to 14).
allows to obtain forward and reverse speeds. When
clutch 1, 2 or R is engaged, it locks the clutch housing to
the corresponding shaft. Each clutch housing is fitted
with a pinion that meshes with the other shafts (all
having the same ratio), permitting the power to enter via
a clutch (1, 2 or R) and to exit via another clutch (A, B or
C) and another shaft.
SPEED CLUTCHES AG15O AG250 POWER TRANSMISSION

RATIO RATIO ROUTE (Fig. 10)
F1 1-A-L 10,241 10,227 A-C-E-F-G-I-H-J-K-L-M-P
F2 2-A-L 7,929 7,940 A-B-I-H-J-K-L-M-P
F3 1-B-L 6,145 6,136 A-C-E-F-J-K-L-M-P
F4 1-A-M 5,397 5,386 A-C-E-F-I-O-Q-P
F5 2-B-L 4,757 4,764 A-B-G-F-J-K-L-M-P
F6 2-A-M 4,179 4,181 A-B-I-O-Q-P
F7 1-C-L 3,687 3,682 A-C-K-L-M-P
F8 1-B-M 3,238 3,231 A-C-E-F-H-I-O-Q-P
F9 2-C-L 2,854 2,858 A-B-G-F-E-K-L-M-P
F10 2-B-M 2,507 2,509 A-B-G-F-H-I-O-Q-P
F11 1-A-H 2,214 2,208 A-C-E-F-G-I-O-N
F12 1-C-M 1,943 1,939 A-C-K-J-H-I-O-Q-P
F13 2-A-H 1,714 1,714 A-B-I-O-N
F14 2-C-M 1,504 1,505 A-B-G-F-E-K-J-H-I-O-Q-P
F15 1-B-H 1,329 1,325 A-C-E-F-H-I-O-N
F16 2-B-H 1,029 1,029 A-B-G-F-H-I-O-N
F17 1-C-H 0,797 0,795 A-C-K-J-H-I-O-N
F18 2-C-H 0,617 0,617 A-B-G-F-E-K-J-H-I-O-N
R1 R-A-L 10,241 10,227 A-D-F-G-I-H-J-K-L-M-P
R2 R-B-L 6,145 6,136 A-D-J-K-L-M-P
R3 R-B-M 5,397 5,386 A-D-F-G-I-O-Q-P
R4 R-C-L 3,687 3,682 A-D-F-E-K-L-M-P
R5 R-B-M 3,238 3,231 A-D-H-I-O-Q-P
R6 R-A-H 2,214 2,208 A-D-F-G-I-O-N
R7 R-C-M 1,934 1,939 A-D-F-E-K-J-H-I-O-Q-P
Issue 1 May 2001

Power transmission route
L L M 5TH STAGE
K C E 1 C 4TH STAGE
J H B F R D 3RD STAGE
I A G 2 B 2ND STAGE
INPUT A 1ST STAGE PTO OUTPUT
N H P 6TH STAGE OUTPUT
O M Q 7TH STAGE
Fig. 10
Issue 1 May 2001


F1 speed (1st forward)
L 5TH STAGE
4TH STAGE
C 1
B R 3RD STAGE
A 2 2ND STAGE
INPUT 1ST STAGE PTO OUTPUT
H 6TH STAGE OUTPUT
M 7TH STAGE
Fig. 11
Issue 1 May 2001


R4 speed (4th reverse)
L 5TH STAGE
C 1 4TH STAGE
B R 3RD STAGE
A 2 2ND STAGE
ENTREE 1ST STAGE PTO OUTPUT
H 6TH STAGE OUTPUT
M 7TH STAGE
Fig. 12
Issue 1 May 2001


F14 speed (14th forward)
L 5TH STAGE
4TH STAGE
C 1
B R 3rd STAGE
A 2 2nd STAGE
INPUT 1st STAGE PTO OUTPUT
H 6TH STAGE SORTIE
M 7TH STAGE
Fig. 13
Issue 1 May 2001


F18 speed (18th forward)
L 5TH STAGE
C 1 4TH STAGE
B R 3RD STAGE
A 2 2ND STAGE
INPUT 1ST STAGE 1ST STAGE
H 6TH STAGE OUTPUT
M 7TH STAGE
Fig. 14
Issue 1 May 2001

E . Vibration damper and coupling

shafts (Figs. 15 - 16)
Parts list
(36) Engine flywheel
(37) LUK damper
(38) Bearing
(39) Coupling shaft
(40) Spring
(41) Input shaft seal
(42) 1st stage shaft
(43) Bolt
Tightening torque
- M10 bolt (43): 68 – 92 Nm.
Reminder
For additional information (see section 3B01).
Fig. 15
Fig. 16
Issue 1 May 2001

AG 150
40 43 37 39
41
42
36 38
A : Valmet engine flywheel

B : Perkins engine flywheel
Issue 1 May 2001


AG 250
40 43 37 39
41
A 42
36 38
A and C : Valmet engine flywheel Parts list Fig. 15 Fig. 16
Issue 1 May 2001

(51) ATP 3020 - Bearing fit-in sleeves

F . Service tools (52) ATP 3020-1 - Fit-in grip
(53) ATP 3020-2 - Adaptor bush for AG150 gearbox bea-
ATP 3015 - AG150 / AG250 - Tool kit (Fig. 17)
rings
(45) ATP 3016 - Set of metric lifting rings
(54) ATP 3020-4 - Adaptor bush for AG250 gearbox bea-
(46) ATP 3017 - Pinion block lifting tool
rings
(47) ATP 3018-1 - Pump pressure test adaptor
(55) ATP 3021 - Sling for clutch train
(48) ATP 3018-2 - Clutch pressure test adaptor
(56) ATP 3022 - Set of guide studs "
(49) ATP 3018-3 -Lubricating pressure test adaptor
(50) ATP 3019 - Pinion block fitting plate
47 49
45
48
52
51
53
46
54
55
56
50
Fig. 17
Issue 1 May 2001


ATP 3030 – Set of transmission pinion ex-
tractors also designed for the previous se-
ries of Full Powershift gearboxes (Fig. 18)
(57) ATP 3030-1 Main pinion extracting sleeve
(58) ATP 3030-2 Pinion extracting sleeve
(64) ATP 3030-8 Main pinion extracting sleeve
57
64
58 59 60
61 62 63
Fig. 18
Issue 1 May 2001

ATP 3002 – Clutch spring compression tool

sold in previous tool kits (Fig. 19)
Other recommended tools
1. MFN-20001: Quick-disconnect coupling adaptor kit
for hydraulic tests
2. Pinion extractor with a range of 255 mm (10 inch)
minimum
Fig. 19
Issue 1 May 2001

Full Powershift Gearbox 5I01.1
5I01 Transmission hydraulic circuit
CONTENTS
A. Characteristics __________________________________________ 2
B. General ________________________________________________ 3
C. Hydraulic circuit diagram ________________________________ 4
D. Gearbox oil filter ________________________________________ 6
E. Oil cooler thermostatic valve _____________________________ 8
F. Pressure regulating-valve ________________________________ 10
G. Proportional solenoid valve ______________________________ 11
H. Pump and pressure circuit _______________________________ 12
I. Pump disassembly ______________________________________ 13
J. Pump reassembly _______________________________________ 14
K. Clutch circuit ___________________________________________ 15
L. Lubricating circuit ______________________________________ 16
Issue 1 May 2001

5I01.2 Full Powershift Gearbox
Issue 1 May 2001

A . Characteristics - Transmission hydraulic circuit

Hydraulic characteristics at 2200 rpm at 60° C (140° F)
1. Clutch pressure regulating-valve ........................................................ 17.2 - 19 bar (250 - 270 psi)
2. Lubricating pressure regulating-valve ................................................. 6.2 - 9.3 bar (90 -140 psi)
3. Filter by-pass valve – Differential pressure ......................................... 3.1 - 3.7 bar (45 - 54 psi)
4. Oil cooler thermostatic valve opens at ............................................... 71° C (160° F)
5. Oil cooler thermostatic valve fully open at ......................................... 85° C (185° F)
6. Gerotor pump flow rate ...................................................................... 94.5 l/min (25 gpm min)
7. Lubricating oil flow rate thru oil cooler at 85° C (185° F) ..................... 75.7 l/min (20 gpm min)
8. Lubricating oil flow rate by-passing oil cooler at 60° C (140° F) .......... 75.7 l/min (20 gpm min)
9. Gearbox oil filter ................................................................................. 15 microns
Issue 1 May 2001


Lubricating circuit
B . General After having supplied the clutches, the oil supplied by the
Clutch pressure circuit pump passes through the oil cooler, or bypasses it via the
The Full Powershift AG150 and AG250 transmissions are thermostatic valve, and is used to lubricate the clutches.
fitted with their own Gerotor type toothed rotor hydraulic The cooled lubricating oil is thus supplied to the gearbox
pump mounted at the rear of the transmission. The pump to lubricate the shafts, clutches and bearings. All the oil
is driven at engine speed by the first stage shaft. When supplied to the bearings is metered by a calibrated port
the engine is running the pump supplies the pressure and located in the bore of the bearings and by three channels
flow rate to activate the clutches and lubricate the drilled in the clutch shafts. When the pump provides
transmission. The oil is sucked through a strainer located sufficient oil for the lubricating circuit, the pressure rises
in the intermediate housing. The pump discharges oil until the relief-valve opens and the excess returns to the
through the gearbox filter and by priority supplies the tank.
clutch solenoid valves and the pressure regulating-valve.
Once the necessary pressure and flow rate for the clutch
supply is supplied, the pressure regulating-valve opens.
It maintains the operating pressure in the clutches. Three
solenoids are then simultaneously activated to engage
the three clutches and transmit the power from the
engine to the transmission. To obtain the various speeds,
it is possible to activate a combination of any three of the
nine solenoids. Once the required volume of oil to engage
the clutches is attained and the pressure regulating-valve
is open, the oil flows through the lubricating circuit via the
pressure regulating-valve and the thermostatic valve.
Proportional solenoid valves

The oil reaches each extremity of the proportional sole-
noid valves and the volume of oil that supplies each
clutch via a solenoid valve is controlled at clutch level by
an electrical signal emitted by the transmission calcula-
tor (TC), this modulates the gear changes.
Each solenoid valve is linked to the oil return. When the
TC cuts the supply to the solenoid valve, the oil contained
in the clutch returns to the tank.
Issue 1 May 2001

C . Hydraulic circuit diagram

Parts list (Fig. 1)
(1) Tank
(2) Suction strainer (250 µ)
(3) Suction pipe
(4) Gerotor - toothed rotor pump 14 14
2ND STAGE
3RD STAGE
(5) Pump discharge pipe
4TH STAGE
6TH STAGE
(6) Main oil filter for the gearbox
(7) Gearbox oil filter by-pass
(8) Oil cooler
(9) Oil cooler by-pass
(10) Lubricating relief-valve
5TH STAGE
7TH STAGE
(11) Clutch pressure regulating-valve (17 bar)
(12) Proportional solenoid valve
(13) Lubricating pressure pipe
(14) Lubricating port
(15) "A" clutch supply pipe
(16) "2" clutch supply pipe "1" "R" "2"
(17) Clutch return port
(18) Lubricating oil return port from relief-valve
A : Clutch "A" "C" "B" "A" "H" "M"

B : Clutch "B"
C : Clutch "C" "L"
12
H : Clutch "H"
L : Clutch "L"
M : Clutch "M"
"M"
"H"
"C"
"A"
R : Clutch "R"
"L"
"R"
"1"
"2"
"B"
1 : Clutch "1" 8 6 5 17
INLET
2 : Clutch "2"
4
Legend
Low pressure (17 bar)
Lubrication
3
Suction
Return
13 15 16 13 11 18 10 9 7 1
Fig. 1
Issue 1 May 2001

D . Oil filter (Fig. 2)

22 19
29
28
27
26
25 21
24
23
22
20
(6) Filter element

(7) By-pass (24) By-pass seat
(19) Filter head (25) O’ring
(20) Filter bowl (26) By-pass outlet to lubrication
(21) Oil inlet port (27) O’ring
(22) Oil outlet port (28) By-pass spring
(23) O’ring (29) O’ring Fig. 2
Issue 1 May 2001

Oil filter – Oil flow Oil filtered under pressure flows into the chamber con-
Coming from the Gerotor pump, the oil enters the head taining the by-pass valve spring and enables the spring
of the filter unit. It flows from the outside of the filter to keep the valve closed. If the filter becomes blocked,
element to the inside. Filtered oil from the centre of the the pressure on the outside of the filter element increases
filter element then flows out through a separate channel while it drops in the centre of the filter element. The
in the head of the filter unit to supply the transmission. If pressure of the oil on the outside of the filter element then
the filter is blocked, a by-pass valve opens and channels exceeds that of the by-pass valve spring and the valve
non-filtered oil to the lubricating circuit. The by-pass therefore opens. The by-pass valve opens when the
valve operates on the pressure differential existing be- pressure differential equals 3.1 - 3.7 bar (45 - 54 psi) (Fig.
tween the filtered oil and non-filtered oil. The differential 3).
pressure is controlled by the by-pass valve spring.
Fig. 3
Issue 1 May 2001

E . Thermostatic valve (Fig. 4)

(9) Thermostatic valve
(30) "IN" oil inlet port
(31) "OUT" oil outlet to oil cooler
(32) "OUT" oil outlet to tank
(33) Housing towards oil cooler
(34) Housing towards tank
(35) O'ring
(36) Support bolts. Tighten to a torque of 6.7 Nm
(37) Spring
(38) Guide and spring seal
(39) Thermic element
(40) Guide washer
(41) Screw adjustment. Smear the screw with Loctite
290. Tighten until contact, then add an additional
quarter turn.
31 41
33 40
39 36
30 35
35 9
37 38
34 36
32
Fig. 4
Issue 1 May 2001

Thermostatic valve – Oil flow

When the transmission oil temperature is less than 71°C,
the thermostatic valve closes so that oil cannot flow
through the oil cooler. When the oil temperature reaches
85°C, the thermostatic valve is fully open and oil flows
to the oil cooler (Fig. 5).
CLOSED TO OIL COOLER OPEN TO OIL COOLER
INLET INLET
GEARBOX GEARBOX
Fig. 5
Issue 1 May 2001

F . Pressure regulating-valve (Fig. 6)

(11) Gearbox pressure regulating-valve
(42) Return port to tank
(43) Return oil pressure - Outlet to lubrication
(44) Pump inlet pressure
(45) Plug
(46) O'ring
(47) Shims
(48) Outer spring
(49) Inner spring
(50) O'ring
(51) O'ring
(52) Washer
(53) Regulating spool
(54) O'ring
(55) Plug
45 49 50 51 53 55
46 47 48 52 51 54
11 42 43 44
Fig. 6
Issue 1 May 2001

G . Proportional solenoid valve (Fig.

7)
(12) Proportional solenoid valve (cannot be repaired)
(56) Aluminium nut - 1.7 to 2.8 Nm
(57) Washer 56
(58) Solenoid
(59) O'ring
(60) O'ring
(61) O'ring 57
(62) Clutch return oil port
(63) Clutch outlet oil pressure
(64) Pump inlet pressure
58
12
59
60 62
63
61
64
Fig. 7
Issue 1 May 2001

H . Pump and pressure circuit
The AG150 and AG250 transmissions have a fully inte- 4

grated hydraulic circuit. The pump (4) is located at the
rear of the transmission (Fig. 8). It is driven by the first
stage shaft that runs at engine speed. The Gerotor pump
has two inlet ports in order to reduce vibration within the
hydraulic circuit. It can be removed by uncoupling the
tractor between the gearbox and the intermediate hous-
ing (see section 2C01). The inlet and outlet ports of the
pump are fixed to the rear housing of the gearbox and oil
tightness is provided by O'rings. The suction and dis-
charge channels are moulded into the rear housing of the
gearbox. The right-hand channels are suction and the
left-hand channels are discharge.
Fig. 8
During repair operations, check pump wear between the
external bush and the housing, axial clearance and the
splines. Replace the pump if it is damaged. Consult
figures 8 - 9 and § 1 for pump disassembly.
The pressure regulating-valve (11) (Fig. 10) controls the

pressure in the circuit used to activate the clutches. The
condition of the regulating-valve can be determined by
carrying out a pressure test (see section 9N01).
The pressure must be uniform across the whole engine

speed range, though it may vary slightly. The pressure
must be between 17.2 and 19 bars. The pressure test
can be carried out by removing the wide plug (28) (see
sections 5H01 and 9N01). Use the ATP 3018-1 service
tool in a wide plug on the forward housing. The pressure
regulating-valve has the form of a repairable cartridge
and it must be checked for any deposits, scratches or Fig. 9
friction points. Replace the O"rings on the cartridge each
time that it is removed from the transmission (Fig. 6 and
10).
11
Fig. 10
Issue 1 May 2001

I . Disassembling the pump

The Gerotor pump is bolted to the rear housing of the
gearbox. It can be removed by taking out the six retaining
bolts after uncoupling the tractor between the gearbox
and the centre housing. Remove the two bolts that hold
together the pump body and cover and separate the
halves (Fig. 8 - 9).
Measurement of wear on pump compo-

nents
· Maximum acceptable wear between the external rim of
the bush and the housing: 0.51 mm (Fig. 11).
· Between the tip of the internal star and the external
bush: 0.18 mm (Fig. 12).
Lateral clearance of two components in relation to the Fig. 11

housing: 0.1 mm (Fig. 13).
Examine the surface condition ace of the two compo-

nents. Replace them where necessary.
Maintain the relative positions of components in relation

to each other, in order to avoid producing new wear areas
due to accidental offset.
Fig. 12
Fig. 13
Issue 1 May 2001

J . Pump reassembly
Reassemble the pump and fasten the cover on to the
body with the two bolts. Tighten to a torque of 24 Nm.
Lubricate the pump with transmission oil and fit the two
O'rings smeared with miscible grease into the pump
body. Fit the pump on to the rear housing of the gearbox.
Fix it in place with the six bolts removed previously.

Tighten the bolts to a torque of 24 Nm (Fig. 14 - 15).
Fig. 14
Fig. 15
Issue 1 May 2001

K . Clutch circuit
The oil flow in the clutch piston chamber is controlled by 56
the proportional solenoid valves (12) and they them-
selves are controlled by the transmission control unit
(TC). The oil is metered in the clutch pistons by the
proportional solenoid valves, in relation to the electrical 12
signal received by transmission control. The hydraulic
spools of the proportional solenoid valves cannot be
repaired, except for the O'rings and the solenoid. The
solenoid is fixed to the spool by an aluminium nut (56)
and mustd be tightened to a torque of 1.7 - 2.8 Nm ma-
ximum.
Fig. 16
Each clutch is fitted with a control channel located near

the solenoid valve concerned.
Each control channel is identified by a number or letter

moulded into the housing (Fig. 17) and corresponding to
the clutch. All the channels are closed by a small 7/16”
plug.
Use ATP 3018-2 adaptors (see section 5H01) to check

the pressure. To correctly carry out a check on a gear
ratio, check the pressure in all three clutches concerned
at the same time.
Fig. 17
56
12
Fig. 18
Issue 1 May 2001

L . Lubricating circuit
The gearbox lubricating oil is supplied by the Gerotor
pump via the pressure regulating-valve. Lubricating oil
pressure is maintained by the pump flow and by the
lubricating relief-valve. The lubricating relief-valve (10) is
located at the bottom of the threaded port provided for the 10
oil cooler connector on the left hand side of the transmis-
sion (Fig. 19). The lubricating oil supplies each transmis-
sion shaft, lubricates the clutch plates, shafts and
bearings. To test the lubricating pressure, use test
connector ATP 3018-3. Screw the test connector into one
of the medium-sized plugs (27) (see section 5H01).
The lubricating relief-valve (10) (Fig. 21) may be replaced

either by screw tapping the interior of the valve and
removing it with the aid of an inertia extractor, or when Fig. 19
the gearbox is disassembled by driving it out from the
interior using a suitable fixture (Fig. 20).
A drilled aperture in the shaft provides lubrication for the

forward bearing while a port at the end of the shaft
provides lubrication for the rear bearing (Fig. 22).
10
Fig. 20
10
Fig. 21 Fig. 22
Issue 1 May 2001

Full Powershift Gearbox 5J01.1
5J01 Transmission - Repair
Contents
A. Disassembling the gearbox ______________________________ 2
B. Removing the front housing _____________________________ 3
C. Removing clutches and transmission shafts ______________ 4
D. Replacing the input shaft seal ____________________________ 6
E. Inspecting and repairing the housing _____________________ 7
F. Reassembling the gearbox _______________________________ 8
G. Overhauling a speed clutch train _________________________ 10
H. Input shaft - First stage shaft _____________________________ 23
I. Repairing the range clutch shaft __________________________ 24
Issue 1 May 2001

5J01.2 Full Powershift Gearbox

- Separate the tractor between the gearbox and the
- Separate the gearbox from the engine (see section
2B01). 4
A . Disassembling the gearbox

- Take off the Gerotor pump (4) from the gearbox and PTO
shaft from the rear of the gearbox. The Gerotor pump (4)
is fixed to the rear housing of the gearbox by six bolts.
Slide the pump and shaft apart to separate them. Keep
the O’rings between the pump and the rear housing
(Fig. 1).
- Remove the engine speed sensors (22), forward speed Fig. 1
sensor (23) and the calibration sensor (24) from the
gearbox in order to avoid damage to them when
separating the housings (Fig. 2).
- Remove the hydraulic supply pipes, the output connec-
tions to the oil cooler and the pressure regulating-valve 24
(11) from the front housing of the gearbox in order to gain
access to the housing bolts (Fig. 3).
- Place a wooden plank of the correct thickness on the
ground. Provide enough space in order to be able to
reach the top of the gearbox with workshop crane or a
suitably adapted lifting tackle.
- In order to protect the mating faces from scratching or
damage, before removing the front housing, position
the gearbox vertically as shown in Fig. 5 using a
suitable sling and lifting rings ATP 3016 (Fig. 4), the rear
face being placed on the wooden plank.
Fig. 2
11
Fig. 3 Fig. 4
Issue 1 May 2001

B . Removing the front housing

Raise the front housing after having removed the bolts
(Fig. 5).
Note: Adjust the lifting sling in such a way that the

front housing remains horizontal during the sepa-
rating operation. The shafts will be withdrawn more
easily from the housing if the latter is shaken lightly
as it is lifted.
Note: Take care that the transmission shafts remain

in the rear housing and are not lifted at the same time
as the front housing. Lightly shake the front housing
when it is lifted to avoid bending the shafts (Fig. 6).
Fig. 5
Fig. 6
Issue 1 May 2001

C . Removing clutches and trans- 1

mission shafts
Clean the work area and prepare shaft support plate (ATP
3019) on which the work will be carried out (Fig. 7). The
workshop must be accessible by a workshop crane or
suitable lifting tackle.
Position 1 - AG 150 gearbox

Stands (1) screwed directly into the plate (Fig. 8)
Position 2 - AG 250 gearbox
Stands (1) screwed into the bushes (Fig. 8)
- Remove the seal rings from all shafts to avoid damag-

ing them before installing the shaft-lifting tool.
- Install lifting tool (AP 3017) on the shafts and fix each
Fig. 7
shaft to the tool with the supplied locking devices.
Place the lifting ring of the tool in the correct position
(Fig. 11).
- Position 1 for the AG 150 gearbox (Fig. 9) 1 2
- Position 2 for the AG 250 gearbox (Fig. 10)
Fig. 8
1 2
Fig. 9 Fig. 10
Issue 1 May 2001

- With a workshop crane or suitable lifting tackle and a

chain attached to the lifting ring of the tool (Fig. 11).
- Gently raise, while lightly shaking the shafts so that the
bearings leave the bores of the rear housing. Take care
not to lift the rear housing at the same time in order to
avoid bending the shafts.
- Once the block of shafts has been removed, take off the
plastic guard from the forward pinions (Fig. 12).
- lace the tool and shafts in a single block on the
workbench.
- Position the block of removed shafts on the previously
prepared support (ATP 3019) (Fig. 13).
- Remove the shaft lifting tool after having positioned the
shafts on the support. Take care not to knock over the
block of shafts or clutches when removing the lifting
tool.
- Mark the location of the shafts in order to understand Fig. 11
how to reassemble them.
- The shafts may be removed one by one from the
support to carry out even greater levels of disassembly.
- For the repair of clutches and shafts, see § G and I.
Fig. 12
Fig. 13
Issue 1 May 2001

D . Replacing the input shaft seal

41
Replacing the seal only without disassem-
bling the gearbox
- Separate the tractor between the engine and gearbox
(see section 2B01).
- Take out, by sliding them, the input shaft and the spring
from the gearbox.
Note: Never try to separate the tractor between the
front and rear gearbox housings - this will result in
serious damage.
- Take out the input shaft seal (41) through the front
housing of the gearbox using a suitable extractor (Fig.
14).
- Fit a new seal using an insertion sleeve.
- Take care that the new seal is correctly aligned so that
it does not leak. Lubricate the seal lip with miscible Fig. 14
grease.
- Reassemble in reverse order using the guide studs to
align the gearbox with the engine (see section 2B01). 41 1
Replacing the seal while disassembling the

gearbox
- When the front housing (1) has been removed, take out
the old seal (41) (Fig. 15).
- Fit the new seal using a suitable insertion sleeve, taking
care that it is correctly aligned so that it does not leak.
Lubricate the seal lip with miscible grease.
Fig. 15
Issue 1 May 2001

E . Inspecting and repairing the hous-

ing 10
Inspecting the housing

- Examine all the bearing bores of the front and rear
housings to ensure that they are not damaged. Replace
or repair any damaged bores.
- Examine all wear rings for damage and replace where
necessary (Fig. 16).
Replacing seal wear rings

All the seal bores in the front housing contain rings (Fig.
16). The latter may be replaced if they are damaged. The
location of the holes in the rings is not very important
since the bores have annular grooves beneath all the Fig. 16
bushes. By using an extractor with two or three jaws and
fitted with an inertia device (Fig. 17), hook the front edge
of the ring and extract it. Fit a new ring leaving the
chamfer on the outside to guide the seal. Fit the new bush
by pressing the insertion sleeve against the housing (Fig.
18).
Lubricating relief-valve
If the previous tests have shown that the lubricating
relief-valve is defective (10) (Fig. 16), it may be removed
from the interior at this time. It may also be removed
from outside the housing by taking off the oil cooler piping
and connection. Screw tap the inside of the valve (10)
(Fig. 26) and use an inertia extractor to remove it.
Fig. 17
Fig. 18
Issue 1 May 2001

F . Reassembling the gearbox

- After cleaning the housings and refitting the shafts and
clutches, place the rear face of the rear housing on the
suitably sized plank of wood.
- Install the pinion block lifting tool (ATP 3017) on the
shafts in supporting tool (ATP 3019) (Fig. 19). Take care
that each shaft is locked to the lifting tool. With a
workshop crane or suitable lifting tackle, move the
block of pinions towards the rear housing (Fig. 20).
- Fit the plastic guard on the pinion block (Fig. 21). Slowly
lower the pinion block into the rear housing taking care
that guard remains in place (Fig. 22). When the pinion
block approaches its original position, take care that all
the bearings are correctly placed in their respective
bores. Once the shafts begin to slide into their bores,
lightly shake the pinion block so that the bearings slide Fig. 19
into the bores. Take care that all the shafts attain their
original position. Remove the pinion block lifting tool
(Fig. 23).
Fig. 20
Fig. 21 Fig. 22
Issue 1 May 2001

- Before fitting the seals on the shafts. Reshape each

seal ring by holding it and joining both ends and
compressing them so that the ends overlap (Fig. 24).
Fit the seals on the shafts and centre them in the
grooves. Apply miscible grease on the outside of the
seal to maintain them more easily in the groove. Check
that all the seals are correctly placed on each shaft.
- Using lifting rings (ATP 3016) fitted to the front housing,
lift the housing to a horizontal position to place it above
the shafts of the rear housing (Fig. 25).
- Clean and degrease the front and rear housing flanges.
Use Loctite 518 to seal the front and rear housings.
- Fit the guide studs (ATP 3022) into the rear housing to
facilitate the installation of the front housing.
- Lower the front housing onto the rear housing. Lightly
shake the front housing shafts, taking care that it is
perfectly horizontal when it is lowered. This avoids Fig. 23
damaging the seal rings when lowering the housing.
- Fit the 16 x 140 mm retaining bolts in the housing and
tighten them one by one to a torque of 68 Nm. Then
tighten to 135 Nm. Finally tighten to 217 Nm.
- Install the pressure regulating-valve (11), oil cooler pipe
connectors and the speed and calibration sensors in
the housings (Fig. 26).
Fig. 24
10
11
Fig. 25 Fig. 26
Issue 1 May 2001

G . Overhauling a speed clutch train

General
- All speed clutch trains are disassembled in the same
manner.
- All speed clutch trains are composed of two clutch
packs.
- The sets of speed clutches are identified thus:
. clutches A and 2 - 2nd stage shaft
. clutches B and R - 3rd stage shaft
. clutches C and 1 - 4th stage shaft
- For more details on the fitting of each shaft, see the
paragraphs relating to each shaft (Fig. 38, 39 and 40).
Disassembly
- Using a clutch train sling (ATP 3021), remove the speed
clutch to be repaired from the pinion block support tool. Fig. 27
Place the clutch train on a clean workbench and turn the
groove of the seal ring upwards (Fig. 27).
Note: Take care that the gear train is properly
supported to avoid it toppling and damaging the
pinions.
- Install a split bearing extractor (OEM 4175 or equiva-
lent) on the bearing (18) or (22). The split bearing
extractor must be fitted so that its flat surface is turned
towards the pinion. Tighten the tightening bolts of the
extractor until the bearing begins to extract (Fig. 28).
- Hook the pinion extractor below the split bearing extrac-
tor and extract the bearing from the shaft by pulling (Fig.
29).
- Remove the circlip (17) or (21) from the shaft.
- Place the extractor (ATP 3030) (Fig. 30) on the pinion
and tighten the bolt. To be able to remove the pinion
from the shaft, the extractor must be tightened around
the external diameter of the pinion (4) or (5). In some Fig. 28
cases, the main sleeve is necessary and must be fitted
beneath the pinion. Place the extractor by hooking it
beneath the sleeve and extract the pinion (4) and (5) and
the bearing (16) or (20) from the shaft by pulling (Fig. 31).
Note: To select the extraction sleeve that matches
the pinion, see the pages relating to the clutch
trains (pages 14 to 19).
Note: DO NOT USE THE EXTRACTOR WITHOUT AN
EXTRACTION SLEEVE TO REMOVE THE PINIONS -
THIS MAY DAMAGE THE TEETH OF THE PINIONS.
THE TEETH ARE HARDENED AND MAY SHATTER
LIKE GLASS. THE PINIONS MUST BE EXTRACTED
BY EFFECTING A TIGHTENING ON THE EXTERNAL
WALL OF THE PINION.
- Remove circlip (14), closing plate (13), thrust plates and
friction plates.
- Fit a suitable extractor on the bearing of the inside pinion
(15) (19) and remove the latter from the shaft.
Fig. 29
Issue
Issue21 May
May2002
2001
- Place the clutch train in a press. Fit tool ATP 3002 on the
Belleville washers (10). Compress the washers, re-
move the circlip (12) and release the pressure on the
washers (Fig. 32).
- Remove the clutch train from the press and remove the
locking washer from circlip (11) and the Belleville
washers (10).
- Remove the oil seal washer (9) that lies between the
Belleville washers (10) and the clutch piston (6) (Fig. 33).
Fig. 30
Fig. 31
6 9 10
Fig. 32 Fig. 33
Issue 1 May 2001


- Once the Belleville washers are removed, inject
compressed air into the clutch oil supply channel near
the seal ring on the shaft (24) or (25) (Fig. 34). This will 1
eject the piston from the clutch housing (1) (Fig. 35).
- Disassemble the opposite end of the shaft in the same
manner.
Note: The best method to maintain the shaft in a
vertical position is to have a 3” (76 mm) diameter
hole in the workbench to recieve the shaft. 24 25
Inspecting components
Belleville washers
Check for:
- Cracks
- Wear on contact points
Piston, seals and piston bores Fig. 34

Check for:
- Seal hardening, cracking, nicks, etc.
- Piston seal groove: dents, burs, chipping, etc.
- Piston bores: chipping, dents, burs (Fig. 36). 6
Thrust plates and clutch discs

Check for:
- Buckling, heat discoloration, surface and spline wear
Nominal dimensions
- Thrust plates ……… 1.78 mm
- Discs……………… 2.79 mm
When refitting previously used clutch discs and thrust

plates, it is the piston travel that determines whether they
should be replaced (Fig. 37). 1
Fig. 35
Fig. 36 Fig. 37
Issue 1 May 2001

Inspection of components
Pinions
Check for:
- Pitting, flaking, ripples, broken teeth, cracks, bore wear
due to bearing creep, spline wear.
Bearings
Check for:
- Pitting, denting, grooving, cracks in the groove, wear
due to creep on internal and external rims.
Circlips and grooves

Check that circlips and grooves are in good condition.
Note: Circlips with rounded and square edges. The
square edge must always retain the load.
Shafts
Check for:
- Wear on splines, cracks, surface wear due to creep.
Check that seal ring grooves are square edged and
without burs, etc. That oil channels are not blocked; that
all port and stop plugs are correctly in place; that there
is no spline wear or cracking in the clutch housings; that
circlip slots are square edged.
Issue 1 May 2001

2nd stage shaft
26 24
25
17 18
16 4
26 15
13 2
14 2nd STAGE 26
A
A
11 6
12 7
10 25
9 1
2 2
8 26
24 3
19
21 26
23 5
22 20
Fig. 38
Issue 1 May 2001

2nd stage shaft (Fig. 38) 2nd stage shaft (Fig. 38)
AG 150 transmission AG 250 transmission
(1) 2nd stage shaft pinion - 71 teeth (1) 2nd stage shaft pinion - 82 teeth
(2) "A" clutch linings - 10 thrust plates and discs (2) "A" clutch linings - 10 thrust plates and discs
(3) "2" clutch linings - 10 thrust plates and discs (3) "2" clutch linings - 10 thrust plates and discs
(4) "A" clutch hub pinion - 42 teeth (4) "A" clutch hub pinion - 48 teeth
Use ATP 3030-1 and ATP 3030-3 sleeves to extract Use ATP 3030-1 and ATP 3030-6 sleeves to extract
the pinion the pinion
(5) "2" clutch hub pinion - 48 teeth (5) "2" clutch hub pinion - 59 teeth
Use ATP 3030-1 and ATP 3030-6 sleeves to extract Use only ATP 3030-1 sleeve to extract the pinion
the pinion (6) Clutch piston
(6) Clutch piston (7) Piston external seal - "D" bush type seal
(7) Piston external seal - "D" bush type seal (8) Piston internal seal - O'ring
(8) Piston internal seal - O'ring (9) Oil seal washer
(9) Oil seal washer (10) Belleville washers - 6
(10) Belleville washers - 6 (11) Circlip holding washer
(11) Circlip holding washer (12) Circlip
(12) Circlip (13) Closing plate
(13) Closing plate (14) Clutch lining circlip
(14) Clutch lining circlip (15) "A" clutch internal pinion hub ball bearing
(15) "A" clutch internal pinion hub ball bearing (16) "A" clutch external pinion hub ball bearing
(16) "A" clutch external pinion hub ball bearing (17) Circlip
(17) Circlip (18) Forward shaft roller bearing
(18) Forward shaft roller bearing (19) "2" clutch internal pinion hub ball bearing
(19) "2" clutch internal pinion hub ball bearing (20) "2" clutch external pinion hub ball bearing
(20) "2" clutch external pinion hub ball bearing (21) Circlip
(21) Circlip (22) Rear shaft ball bearing
(22) Rear shaft ball bearing (23) Lubricating port
(23) Lubricating port (24) "2" clutch pressurized oil channel
(24) "2" clutch pressurized oil channel (25) "A" clutch pressurized oil channel
(25) "A" clutch pressurized oil channel (26) Pressurized oil channel
(26) Pressurized oil channel
Instructions
Instructions (15) The ball bearing may be installed in either position.
(15) The ball bearing may be installed in either position. (18) The roller bearing must be installed with the bearing
(18) The roller bearing must be installed with the bearing circlip facing the centre of the shaft.
circlip facing the centre of the shaft. (22) The SH2 designation bearing must be installed
here. The SH2 bearing is a hardened bearing with
twice the normal life span.
Issue 1 May 2001

3rd stage shaft

26 24
18 25
26 17
15 16
13 4
14 27
11 28
12 B 26
B
10 2
9 6
8 7
R
R
24 1
19 25
rd
3 STAGE
5 3
20 26
21 22
23 Fig. 39
Issue 1 May 2001

3rd stage shaft (Fig. 39) 3rd stage shaft (Fig. 39)
(1) 3rd stage shaft pinion - 71 teeth (1) 3rd stage shaft pinion - 82 teeth
(2) "B" clutch linings - 10 thrust plates and discs (2) "B" clutch linings - 10 thrust plates and discs
(3) "R" clutch linings - 10 thrust plates and discs (3) "R" clutch linings - 10 thrust plates and discs
(4) "B" clutch hub pinion - 42 teeth (4) "B" clutch hub pinion - 48 teeth
Use only ATP 3030-1 to extract the pinion Use ATP 3030-1 and ATP 3030-6 sleeves to extract
(5) "R" clutch hub pinion - 62 teeth the pinion
Use only ATP 3030-1 to extract the pinion (5) "R" clutch hub pinion - 76 teeth
(6) Clutch piston Use only ATP 3030-8 to extract the pinion
(7) Piston external seal - "D" bush type seal (6) Clutch piston
(8) Piston internal seal - O'ring (7) Piston external seal - "D" bush type seal
(9) Oil seal washer (8) Piston internal seal - O'ring
(10) Belleville washers - 6 (9) Oil seal washer
(11) Circlip holding washer (10) Belleville washers - 6
(12) Circlip (11) Circlip holding washer
(13) Closing plate (12) Circlip
(14) Clutch lining circlip (13) Closing plate
(15) "B" clutch internal pinion hub ball bearing (14) Clutch lining circlip
(16) "B" clutch external pinion hub ball bearing (15) "B" clutch internal pinion hub ball bearing
(17) Circlip (16) "B" clutch external pinion hub ball bearing
(18) Front shaft roller bearing (17) Circlip
(19) "R" clutch internal pinion hub ball bearing (18) Forward shaft roller bearing
(20) "R" clutch external pinion hub ball bearing (19) "R" clutch internal pinion hub ball bearing
(21) Circlip (20) "R" clutch external pinion hub ball bearing
(22) Rear shaft ball bearing (21) Circlip
(23) Lubricating port (22) Rear shaft ball bearing
(24) "R" clutch pressurized oil channel (23) Lubricating port
(25) "B" clutch pressurized oil channel (24) "R" clutch pressurized oil channel
(26) Pressurized oil channel (25) "B" clutch pressurized oil channel
(27) Pinion - 70 teeth (26) Pressurized oil channel
(28) Circlip (27) Pinion - 60 teeth
(28) Circlip
Instructions
(18) The roller bearing must be installed with the bearing Instructions
circlip facing the centre of the shaft. (16) The SH2 designation bearing must be installed
(18) The roller bearing must be installed with the bearing
circlip facing the centre of the shaft.
Issue 1 May 2001

4th stage shaft
26 24
25
17 18
16 4
26 15
13 2
14 26
C
11 C 6
12 7
10 25
9 1
8 1 1 26
24 3
4th STAGE
19 26
20 23
21 22
Fig. 40
Issue 1 May 2001

4th stage shaft (Fig. 40) 4th stage shaft (Fig. 40)
(1) 4th stage shaft pinion - 71 teeth (1) 4th stage shaft pinion - 82 teeth
(2) "C" clutch linings - 10 thrust plates and discs (2) "C" clutch linings - 10 thrust plates and discs
(3) "1" clutch linings - 10 thrust plates and discs (3) "1" clutch linings - 10 thrust plates and discs
(4) "C" clutch hub pinion - 70 teeth (4) "C" clutch hub pinion - 80 teeth
Use only ATP 3030-1 to extract the pinion Use only ATP 3030-8 to extract the pinion
(5) "1" clutch hub pinion - 62 teeth (5) "1" clutch hub pinion - 76 teeth
Use only ATP 3030-1 to extract the pinion Use only ATP 3030-1 to extract the pinion
(6) Clutch piston (6) Clutch piston
(7) Piston external seal - “D” bush type seal (7) Piston external seal - "D" bush type seal
(8) Piston internal seal - O-ring (8) Piston internal seal - O'ring
(9) Oil seal washer (9) Oil seal washer
(10) Belleville washers - 6 (10) Belleville washers - 6
(11) Circlip holding washer (11) Circlip holding washer
(12) Circlip (12) Circlip
(13) Closing plate (13) Closing plate
(14) Clutch lining circlip (14) Clutch lining circlip
(15) "C" clutch internal pinion hub ball bearing (15) "C" clutch internal pinion hub ball bearing
(16) "C" clutch external pinion hub ball bearing (16) "C" clutch external pinion hub ball bearing
(18) Forward shaft roller bearing (18) Forward shaft roller bearing
(19) "R" clutch internal pinion hub ball bearing (19) "1" clutch internal pinion hub ball bearing
(20) "R" clutch external pinion hub ball bearing (20) "1" clutch external pinion hub ball bearing
(22) Rear shaft ball bearing (22) Rear shaft ball bearing - hardened bearing
(23) Lubricating port (23) Lubricating port
(24) "1" clutch pressurized oil channel (24) "1" clutch pressurized oil channel
(25) "B" clutch pressurized oil channel (25) "C" clutch pressurized oil channel
(26) Pressurized oil channel (26) Pressurized oil channel
Instructions Instructions
(16) The roller bearing must be installed with a circlip in (15) The SH2 designation bearing must be installed
the bearing located towards the front of the shaft here. The SH2 bearing is a hardened bearing with
(18) The roller bearing must be installed with the bearing twice the normal life span.
circlip facing the centre of the shaft. (16) The roller bearing must be installed with a circlip in
the bearing located towards the front of the shaft.
circlip facing the centre of the shaft.
(22) The SH2 designation bearing must be installed
Issue 1 May 2001


Reassembling the speed clutch train
Place the clutch train vertically on the bench. Refit the
internal and external seals (7) (8) on piston (6). Smear the
piston seals and clutch-housing bore with transmission
oil. Fit the piston (6) with the pockets and grooves on the
outside (Fig. 41).
6
Fit an oil seal washer (9). All the clutch oil seal washers
are identical (Fig. 42).
Reassemble the Belleville washers (10). The diameter of

the first Belleville washer must be in contact with the oil
seal washer. The second Belleville washer must be in
contact with the external diameter of the first washer.
Alternate the Belleville washers until they are all installed
(Fig. 42).
(6) Piston Fig. 41
(9) Washer - oil stop
(12) Circlip holding washer and circlip.
Place the clutch train on a press. Using tool ATP 3002

compress the Belleville washers and fit a holding washer 6 12
(11) and a circlip (12) (Fig. 43).
Before assembly, lubricate the thrust plates and discs

with transmission oil. Alternate 10 thrust plates with 10 C
discs, beginning with a thrust plate on the piston. Fit the
closing plate (13) and circlip (14) (Fig. 44).
9 10
Fig. 42
Fig. 43 Fig. 44
Issue 1 May 2001

Measuring piston travel

- Using a depth gauge, measure distance (A) from the
end of the piston to the edge of the clutch housing.
- Inject compressed air at 4.8 bars into the piston supply
channel to compress the Belleville washers.
- Measure distance (B) from the end of the piston to the
edge of the clutch housing (Fig. 45).
- The difference between these two measurements, A -
B, equals the piston travel.
Piston travel
- The piston travel can be adjusted by selecting or
exchanging intermediate plates since their thickness
varies.
. With new thrust plates and discs:
Piston travel - 1.3 - 3.8 mm Fig. 45
. With used thrust plates and discs:
Piston travel - 1.8 - 5.5 mm
Issue 1 May 2001


Reassembling clutch bearings
Note: Certain bearings used in the clutches and
shafts require installing in the correct direction. See
the legend, page 14 -19, relating to each of the shafts
for instructions on the repair of clutch trains.
- Reassemble bearing (15) or (19) the nearest to the

clutch linings, using the ATP 3020 sleeve (Fig. 46 - 47).
- Reassemble the pinion with the clutch hub (4) or (5) in
the discs or thrust plates and above the bearing (15) or
(19). The pinion is slid over the bearing. Turn and lightly
shake the pinion until all the splines of the discs and
thrust plates are engaged and bearing (15) or (19) is at
the bottom of the bore of the pinion (Fig. 48)
- Reassemble the external pinion hub bearing (16) or (20)
on the shaft and push it into the pinion hub. Fit the circlip
(17) or (21) on the shaft (Fig. 49). Fig. 46
- Place the extractor on the pinion (4) or (5), pull the pinion
and bearing (16) or (20) against circlip (17) or (21) to
eliminate any lateral load being placed on the bearings.
The pinion hub must move longitudinally.
- Fit the shaft bearing (18) or (22) on the shaft and push
it into its emplacement.
- Repeat the procedure for each end of the shaft and for 15
all the other speed clutch shafts.
Fig. 47
16
4
Fig. 48 Fig. 49
Issue 1 May 2001

H . Input shaft - 1st stage shaft (Fig.

50)
AG 150 transmission 3
(1) 1st stage shaft - 32 teeth
(2) At the rear - roller bearing
(3) At the front - ball bearing
Instructions
(2) Install the roller bearing with the bearing circlip facing
the pinion.
AG 250 transmission
(1) 1st stage shaft - 38 teeth
(2) At the rear - roller bearing
(3) At the front - ball bearing
Instructions
(2) Install the roller bearing with the circlip facing the
pinion.
Repairing the first stage shaft

- Remove the clutch train support tool required to reach
and extract the input shaft.
- Check for damage to the input shaft (1) and bearings (2) 1
and (3) and replace where necessary.
- Place the split bearing extractor (OEM 4175 or equiva-
lent) on the bearing. Use the appropriate extractor to
hook the bearings and remove them from the input
shaft.
1st STAGE
- Push new bearings (2) and (3) into their emplacement
using an appropriate sleeve tool.
- Replace the input shaft (1) in the support tool and
replace the clutch trains in the reverse order of their
removal.
PTO
Fig. 50
Issue 1 May 2001

I . Repairing the range clutch shaft
General
- All gear range clutch trains are dismantled in the same
way.
- All the gear trains possess a clutch.
- The gear range clutch trains (Fig. 51) are identified as L
follows:
"L" clutch - 5th stage shaft
M
"H" clutch - 6th stage shaft H
"M" clutch - 7th stage shaft
- For more details on the assembly of each shaft, see the
sections concerning each shaft following this section,
pages 28 - 33.
Fig. 51
Disassembly
- Using a sling for the clutch train, remove the range
clutch shaft to be repaired from the support tool (ATP
3021). Place the shaft on a clean workbench and turn
the grooves of the seal rings upwards.
Note. Take care that the shaft is properly supported
to avoid toppling and damage to the pinions.
- Install a suitable split bearing extractor (OEM 4175 or
equivalent) on the first bearing (16) or (17). The split
bearing extractor must be placed in such a manner that
its flat surface is turned towards the pinion. Tighten the
extractor bolts until the bearing begins to extract from
the 7th stage shaft.
- Hook the pinion extractor beneath the split bearing
extractor and remove the bearing from the shaft by
pulling (Fig. 52). Remove the circlips (18) (19) or (20)
from the shaft (Fig. 53).
Fig. 52
20
Fig. 53
Issue 1 May 2001

- Place the pinion extractor sleeve (ATP 3030) on the

pinion and tighten the bolts. To be able to extract the
pinion from the shaft, the extractor sleeve must be
tightened around the external diameter of the pinion (3).
In certain cases, use of the main sleeve is specified and
must be fitted beneath the pinion. Hook the pinion
extractor beneath the extractor sleeve and remove the
pinion (3) and bearing (14) from the shaft by pulling
upwards (Figs. 54, 55 and 56).
Note: To select the extractor sleeve suited to the
pinions, see the pages relating to the shafts, pages
28 - 33.
Note: DO NOT ATTEMPT TO USE THE PINION

EXTRACTOR TO EXTRACT PINIONS WITHOUT EX-
TRACTOR SLEEVES - THIS CAN DAMAGE THE
TEETH OF THE PINIONS. THE TEETH ARE BRITTLE Fig. 54
AND MAY SHATTER LIKE GLASS. THE PINIONS
MUST BE EXTRACTED BY TIGHTENING AROUND
THE EXTERNAL WALL OF THE PINION.
- Take off circlip (12) and closing plate (11), the thrust
plates, clutch discs and clutch housing.
- Place a suitable pinion extractor on the internal pinion
bearing (13) and remove it from the shaft (Fig. 57).
Fig. 55
12
13 11
Fig. 56 Fig. 57
Issue 1 May 2001


- Place the clutch train in a press. Place tool ATP 3002 on
the Belleville washers (8). Compress the washers,
remove circlip (10) and release the pressure on the
washers (Fig. 58).
- Remove the clutch train from the press and take off the
holding washer of circlip (9) and Belleville washers (8) 1
from the clutch (Fig. 59).
- Remove the oil seal washer (7) located between the
Belleville washers (8) and the clutch piston (4) (Fig. 59
and 61).
- Once all the Belleville washers are removed, feed
compressed air into the clutch pressurized oil channel,
near shaft seal ring (22). This will eject the piston (4)
from the clutch housing (1) (Fig. 60).
- Disassemble the opposite end of the shaft in the same
manner.
Note: The best method of supporting the shaft is to Fig. 58
have a 76 mm diameter hole in the workbench to
receive the shaft.
8
- Compress the Belleville washers and remove the
circlip using tool ATP 3002 (Fig. 58). 9
- Take off the washing retaining the circlip, the Belleville
washers and the oil seal washer (Fig. 59). 10
- Remove the clutch piston (Fig. 60 and 61).
Fig. 59
Fig. 60 Fig. 61
Issue 1 May 2001

Inspecting components
Belleville washers
Check for:
- Cracks
- Wear on contact points
Piston, seals and piston bores

Check for:
- Seal: hardening, cracks, nicks, etc.
- Piston seal groove: dents, burs, undercutting, etc.
- Piston bores: undercutting, dents, burs (Fig. 62)
Thrust plates and clutch discs

Check for:
- Buckling, heat discolouring, surface and spline wear.
- Nominal dimensions:
. thrust plates: 1.90 mm Fig. 62
. friction plates: 2.79 mm
- During the refitting of previously used thrust plates and
clutch discs, the piston travel determines whether they
should be replaced or not (Fig. 63)
Pinions
Check for:
- Pitting, flaking, rippling, broken teeth, cracks, bore
wear due to bearing creep, spline wear.
Bearings
Check for:
- Pitting, dents, grooves, cracks in the groove, wear due
to creep on the internal and external rims.
Circlips and grooves

Check that:
- The edges of grooves and slots are square. The edges
of the circlips are square and that the springiness is Fig. 63
adequate.
Note: Circlips having one chamfered edge and one
square edge - the square edge must always bear the
load.
Shafts
Check for:
- Spline wear, cracking, surface wear due to creep; that
grooves of seal rings have square edges, no burs, etc.;
that oil channels are not blocked; that all the stop plugs
and port plugs are in place; that there is no spline wear
or cracking on the clutch housings; that the circlip
grooves and slots are square.
Issue 1 May 2001

5th stage shaft
23 22
4 16
1 22
6 5
8 L 7
L
2 10
9 12
15 11
13 23
5th STAGE
14 3
19 18
24 17
Fig. 64
Issue 1 May 2001

(1) 5th stage pinion shaft - 74 teeth (1) 5th stage pinion shaft - 80 teeth
(2) "L" clutch linings - 10 thrust plates and discs (2) "L" clutch linings - 10 thrust plates and discs
(3) Pinion "L" clutch hub - 40 teeth. (3) Pinion "L" clutch hub - 44 teeth.
Use extractor sleeves ATP 3030-1 and ATP 3030- Use extractor sleeves ATP 3030-1 and ATP 3030-
10 to removethe pinion. 12 to remove the pinion.
(5) External piston seal - type "D" bush seal (5) External piston seal - type "D" bush seal
(6) Internal piston seal - O’ring (6) Internal piston seal - O’ring
(9) Circlip retaining washer (9) Circlip retaining washer
(13) Protected ball bearing of "L"clutch internal pinion (13) Protected ball bearing of "L" clutch internal pinion
hub hub
(14) Ball bearing of "L"clutch external pinion hub (14) Ball bearing of "L" clutch external pinion hub
(15) Clutch lubricating oil regulation O’ring (15) Clutch lubricating oil regulation O’ring
(16) Forward shaft ball bearing (16) Forward shaft ball bearing - hardened bearing
(17) Rear shaft roller bearing (17) Rear shaft roller bearing
(22) "L" clutch pressurized oil channel (22) "L" clutch pressurized oil channel
(13) The protected ball bearing must be installed with (13) The protected ball bearing must be installed with
the protective device facing the clutch linings. the protective device facing the clutch linings.
(17) The roller bearing must be installed with the bearing (16) The SH2 bearing must be installed here. The SH2
circlip facing the centre of the shaft bearing is a hardened bearing providing twice the
normal life span.
circlip facing the centre of the shaft
Issue 1 May 2001

6th stage shaft
23 22
21 16
14 20
13 3
11 23
9 12
H H
10 15
2 4
8 5
6th STAGE
1 6
7 23
22 17
24
Fig. 65
Issue 1 May 2001

(2) "H" clutch linings - 10 thrust plates and discs (2) "H" clutch linings - 10 thrust plates and discs
(3) Pinion - "H" clutch hub - 48 teeth. (3) Pinion "H" clutch hub - 53 teeth.
155 to remove the pinion. 16 to remove the pinion.
(13) Protected ball bearing of "H" clutch internal pinion (13) Protected ball bearing of "H" clutch internal pinion
hub hub
(14) Ball bearing of "H" clutch external pinion hub (14) Ball bearing of "H" clutch external pinion hub
(17) Rear shaft roller bearing (17) Rear shaft roller bearing - hardened bearing
(21) Distance piece sleeve (21) Distance piece sleeve
(22) "H" clutch pressurized oil channel (22) "H" clutch pressurized oil channel
(16) The SH2 bearing must be installed here. The SH2
bearing is a hardened bearing providing twice the
normal life span.
normal life span.
Issue 1 May 2001

7th stage shaft
23 22
16 23
6 22
4 1
5 7
10 2
M
11 8
12 9
3 15
7th STAGE
14 13
18 23
24 17
Fig. 66
Issue 1 May 2001

(2) "M" clutch linings - 10 thrust plates and discs (2) "M" clutch linings - 10 thrust plates and discs
(3) Pinion "M" clutch hub - 40 teeth. (3) Pinion "M" clutch hub - 47 teeth.
10 to remove the pinion. 13 to remove the pinion.
(13) Protected ball bearing of "M" clutch internal pinion (13) Protected ball bearing of "M" clutch internal pinion
hub hub
(14) Ball bearing of "M" clutch external pinion hub (14) Ball bearing of "M" clutch external pinion hub
(17) Rear shaft roller bearing (17) Rear shaft roller bearing - hardened bearing
(22) "M" clutch pressurized oil channel (22) "M" clutch pressurized oil channel
normal lifetime
normal lifetime
Issue 1 May 2001


Assembling range clutches
- Place the clutch train vertically on the workbench. Fit
the internal and external seals (5) and (6) on the piston
(4). Smear the piston seals and clutch-housing bore
with transmission oil. Fit piston (4) with the reinforce-
ments and depressions facing outside (Fig. 67).
- Fit an oil seal washer (7). All the clutch oil seal washers
of the range are identical. 4
- Fit a Belleville washer (8). The first washer closest to
the piston must touch the internal rim of the washer.
The second Belleville washer must touch the external
rim of the first washer. Alternate Belleville washers
until they are all installed (Fig. 68).
(4) Piston
(7) Oil seal washer
(10) Circlip Fig. 67
4 10
7 8
Fig. 68
Issue 1 May 2001

- Place the clutch train in a press. Using tool ATP 3002,

compress the Belleville washers and fit retaining washer
(9) and a circlip (10) (Fig. 69).
- Lubricate the thrust plates and discs with transmission
oil as they are installed. Begin with the thrust plate
closest to the piston and alternate until the 10 thrust
plates and 10 friction disks are installed. Place the
splined clutch closing plate (11) on the outside and fit
circlip (12) (Fig. 70).
Fig. 69
Fig. 70
Issue 1 May 2001


Measuring piston travel
- Using slide callipers fitted with a depth gauge, measure
distance A from the piston to the edge of the clutch
housing.
- Inject 4.8 bar compressed air in the oil channel to
compress the Belleville washers. Measure distance B
from the piston to the edge of the clutch housing (Fig.
71).
- The difference between these two measurements, A -
B equals the piston travel.
Piston travel
- The piston travel can be adjusted by selecting or
exchanging thrust plates since their thickness varies.
. With new clutch discs and thrust plates
Piston travel: 1.3 to 3.8 mm
. With used clutch discs and thrust plates Fig. 71
Piston travel: 1.8 to 5.5 mm
Issue 1 May 2001

Reassembling clutch range bearings

Note: Certain bearings used in the clutches and on
the shafts are directional and must be installed in
the correct direction. See the legend relating to each
shaft for instructions about the clutch train to be
repaired, pages 28 - 33.
- Push bearing (13) the closest to the clutch linings, on to 13
the shaft using a compression tool (ATP 3020). Fit the
bearing with the protective device facing the clutch
lining (Fig. 72).
- Fit the oil regulation o’ring (15) on clutch hub (3) and
lubricate the o’ring (Fig. 73).
- Install the pinion with the clutch hub (3) (Fig. 74) in the
discs and thrust plates, over the bearing. The pinion
being placed above the bearing. Turn the pinion and
shake lightly so that all the splines of the discs and
thrust plates are correctly engaged and so that the Fig. 72
bearing thrusts against the bottom of the pinion bore.
Note: When fitting the hub, ensure that the oil
regulation O’ring (15) is not pinched when it passes
the closing plate (11). The O’ring must be posi-
tioned so that it is loose on the clutch hub.
15
Fig. 73
Fig. 74
Issue 1 May 2001


- Fit external pinion hub bearing (14) (Fig. 75) on the shaft
using a compression tool (ATP 3020) and push it into the
pinion hub. Fit a circlip (19) or (18) on the shaft of the fifth
or seventh stage, or a sleeve (21) and a circlip (20) on
the sixth stage shaft. 14
- Place an extraction sleeve (ATP 3030) on the pinion, pull
the pinion and the bearing upwards against the circlip to
avoid any lateral load on the bearings. The hub of the
pinion must move longitudinally.
- Place the bearings on the shaft (16) (17) and push them
home using a compression tool (ATP 3020).
Note: Bearing (17) of the fifth stage clutch train is
a roller bearing and must be installed so that the
bearing circlip faces the clutch.
- Repeat the procedure at each end of the shaft and for
all the speed clutch shafts.
Fig. 75
Issue 1 May 2001

Heavy Duty Gearbox - 5K01.1

Creeper unit
5 K01 Creeper unit
CONTENTS
- General _____________________________________________ 2
- Operation ___________________________________________ 3
A. Removing and refitting the unit _______________________ 7
B. Disassembling, reassembling and adjusting the selector 9
C. Disassembling and reassembling the epicyclical reducer 12
D. Control adjustment __________________________________ 13
Issue 1 May 2001

5K01.2 Heavy Duty Gearbox -

Creeper unit
General
The 8210 - 8220 - 8240 and 8250 fitted with a Heavy Duty
gearbox may also be fitted, depending on the options,
with a creeper gear reducer unit.
This reducer unit (24) consists of a simple epicyclical 24

gear train comprising a planetary carrier and a crown
and placed at the rear of the gearbox (Fig. 1).
The link fitted to the front right-hand side of the interme-

diate housing operates the control fork of the reducer via
a cable linked to a lever located in the tractor cab.
The coupler can only be activated when the tractor is 22

halted.
Fig. 1
Issue 1 May 2001


Creeper unit
Operation (Fig. 2)
The coupler (29) is connected by splines to the drive
pinion (9). Moving the control lever towards the "Snail"
position moves the coupler to the rear and connects it to
the planetary carrier (20) via the intermediary of the
coupler ring (22) (Fig. 1).
The rotational speed of the drive pinion is one quarter of

that of the output shaft of the gearbox.
In normal gears, when the coupler is moved forward the

output shaft of the gearbox is linked to the drive pinion,
thus ensuring direct transmission.
Lubrication
The lubricating of the epicyclical reducer is carried out by
splashing caused by its moving components.
20 22 9
29
Fig. 2
Issue 1 May 2001


Creeper unit
Parts list
(1) Nut
(2) Ring
(9) Drive pinion
(11) Snap ring
(12) Friction washers
(13) Pins
(14) Friction plates
(15) Planetary gears
(16) Crown ring
(17) Spacers
(18) Needle bearings
(20) Planetary carrier
(21) Snap ring
(22) Coupler ring
(23) Bolt
(24) Planetary carrier assembly (reducer)
(26) Nut
(27) Fork
(28) Selector rail
(29) Link
(35) Locking stud
(36) Spring
(37) Plug
(38) Pin
(39) Index
(40) O’ring
(41) pin
(42) Link
(43) Bolt
(44) Housing
(45) Shim(s)
(46) Splined bearing
(47) Output shaft
(48) Bolt
Fig. 3
Fig. 4
Issue 1 May 2001


Creeper unit
Overall view
11 12 13 14 18 15 17 12 16 14 44 20 21 22
19
23
29
38 45 19 27
B
37
36
35 39 41 40
19 B
F
47 46 48 24 23 2 26 28 27 43 42
Parts list Fig. 4

Fig. 3
Issue 1 May 2001


Creeper unit
Exploded view
26 37
28
36
35 42 43
27 40
41
45
46
47
39
38
11 48
12
19
16
20
21
22
12
44
23
2
29
17 18
14
15
14
13 Parts list Fig. 3 Fig. 4
Issue 1 May 2001


Creeper unit
A . Removing and remounting the
unit
Removing the unit

2. Take off ring (2) and bolt (23) fitted respectively to the
output shaft (47) and the housing (44).
3. Remove the components making up the reducer
assembly (24) on the gearbox.
Remarks
- On gearboxes fitted with a creeper gearbox, bearing
(46) is different from that fitted to the standard ver-
sion.
- Machined splines on its edge connect it to the crown
ring (16).
Refitting
4. Carry out a visual inspection of all components.
5. Lightly smear the faces of the reducer with miscible
grease and fit the friction washers (12) with their tabs
located in the appropriate grooves.
6. Replace the reducer assembly on the output shaft.
Remarks
- a machined area on the external diameter of the
crown ring ensures that the rear cup of the layshaft
of the gearbox stands clear.
- the cutaway part of the housing (44) faces down-
wards.
7. Check the correct positioning of the components and
tighten bolts (23) smeared with Loctite 241 to a torque
of 10 - 14 Nm.
Manually check for the rotation of the gearbox output
shaft.
Final operation
Issue 1 May 2001


Creeper unit
3 12 1
11 4
2 29
3 12
2
37
36
35
26 28
38 19
39 41 45 40 43 42
Fig. 5
Issue 1 May 2001


Creeper unit
Action
B . Disassembling, reassembling and - If the clearance is outside the maximum allowed
adjusting the selector tolerance, determine a new thickness of shims re-
quired. After shimming, check for correct orientation of
Preliminary operations the index and the link. Definitively insert pin (38), fit and
9. Uncouple the tractor between the gearbox and the tighten Allen screw (43).
intermediate housing (see section 2C01). 19. Rearrange the assembly (pinion, coupler, and fork) in
10. Disconnect the control cable fitted to the link (42). the intermediate housing. Carry out operation 15 in
reverse order.
Disassembly (Fig. 5) 20. Immobilize the pinion again. Fit and tighten the bolts
Remark (4) lightly smeared with Loctite 241 to a torque of 72
- To take off the coupler (29), it is necessary to remove - 96 Nm.
drive pinion (1) from the hydraulic pumps. 21. On bearing (11), replace in their correct positions the
spring, lug washer and ring.
11. Remove plug (37), recover spring (36) and locking 22. Refit the selector rail and nut assembly. Adjust the
pin (35). fork (see operation further on).
12. Remove the selector rail assembly (28) and nut (26).
If necessary, break the seal, unscrew and take off Final operations
nut (26). 23. Couple the tractor between the gearbox and the
13. Remove rear ring (2), take off the lug washer (3) and intermediate housing (see section 2C01).
spring (12). 24. Reconnect the control cable and where necessary
14. Immobilize the pinion and remove bolts (4). carry out its adjustment (see § D).
15. Extract pinion (1) from bearing (11) and simultane-
ously take out the assembly (pinion, fork and cou-
pler) through the front of the housing.
16. Remove the control link (42) located on the right-
hand side of the intermediate housing. Drive out pin
(38) and remove index (39). Recover the shim(s) (45)
and remove pin (41) complete with o’ring (40).
Refitting (Fig. 5)
17. Lubricate a new o’ring (40) and place it on pin (41).
18. Place the pin in the chamfered port located on the
exterior of the intermediate housing (19).
Reminder
- To limit the axial clearance, it is recommended to shim
to a tolerance of 0.1 to 0.6 mm.
Shimming
- On the axle, place the approximate thickness of shims
(45). Fit index (39) and partially place the pin (38). Refit
the link (42) and bolt (43).
- Manually evaluate the clearance.
Remark
- The adjustment principle consists of obtaining the
minimum clearance between the various compo-
nents.
Issue 1 May 2001


Creeper unit
29
F1
19
F2 37
36
F3 F4
A 35
G2
19
B 26 28 27
X1
A
X2
Fig. 6
Issue 1 May 2001


Creeper unit
Adjustment (Fig. 6)
- Fit locking stud (35), spring (36) and plug (37). Partially
tighten the plug.
- Place coupler (29) in the F1 “creeper gear” position, the
rear face thrusting against the M60 nut (1).
- In F2, maintain the fork thrust against the coupler.
- In F3, turn the selector rail (28) in nut (26) so as to place
in contact the oblique side of groove G2 with locking pin
(35) while simultaneously holding nut (26) against spot-
face B of the intermediate housing (19).
- Using a depth gauge, measure distance X1 between
the front face of the selector rail and face A of the
housing.
- In F2, maintain the fork thrust against the coupler.
- In F4, turn the selector rail in the nut so as to place the
other oblique face of groove G2 in contact with the
locking stud while maintaining nut (26) as previously.
- Measure distance X2 in the same way as X1.
- Determine the X adjustment position using the follow-
ing formula:
X = (X1 + X2) 2
- Provisionally position the selector rail (28) at dimension
X.
- Place the coupler (29) in the "direct drive" position;
manually check the locking of the control and the
clearance between the fork and the coupler. Take care
also that the coupler is not in contact with the hydraulic
pumps drive pinion.
- If this check is satisfactory, take out plug (37), the
spring and the locking pin.
- Degrease the threads of the selector rail and those in nut
(26).
- Lightly smear the nut threads with Loctite, tighten the
nut and definitively position the selector rail, in accord-
ance with the previously calculated dimension X.
- Lock the nut by bending its collar into the machined slot
on the selector rail.
- Replace the locking assembly. Tighten plug (37) to 50
- 70 Nm.
Issue 1 May 2001


Creeper unit
33. Refit pins (13), correctly orienting them to corre-
C . Disassembling and reassembling spond with snap ring (11).
the epicyclical reducer 34. Place the snap ring. Manually check the axial clear-
ance and rotation of each planetary gear.
Disassembly (Fig. 7) 35. Lightly smear the faces of the reducer with miscible
25. Remove the unit (see § A) grease and fit the friction washers (12), with their
26. Take off the circlip (11). lugs lodged in the appropriate grooves.
27. Remove the friction washers (12). 36. Refit the unit (see § A).
28. Drive out the pins (13)
29. Remove the planetary gears (15) from the planetary
carrier (20) taking care not to lose the needles (18),
the spacers (17) and friction plates (14).
Remark
- The coupler ring (22) is inserted into the planetary
carrier using a press. The snap ring (21) ensures
additional locking of the various components.
Reassembly (Fig. 7)
30. Inspect and clean all components. Replace any
defective parts.
31. Fit each planetary gear with two rows of needles
smeared with miscible grease and separated by a
spacer.
32. Replace the planetary gears and position the friction
plates (14).
11
12
20
21
22
12
18
13
17
14
24 15
14
Fig. 7
Issue 1 May 2001


Creeper unit
D . Control adjustment
On lever "A" (Fig. 8) C
37. Place control lever “A” in the “Snail” position.
38. Screw clevis (1) flush with the threaded part of the 1
cable (6). 7
39. Mount clevis (1) on lever "A" with clip (7). Tighten nut
(2). 6
40. Tighten nut (3) on the knurled sheath end (5). A
41. Fit the knurled sheath end and Grower washer onto
4
the support piece. Tighten nut (4) while checking that
the cable is not pinched. 2
3
On link "B" (Fig. 9) 5

42. Place link "B" in the "creeper gearbox" position Fig. 8
(coupler (29) engaging the splines of the planetary
gear carrier (20) (Fig. 2) and with the fork locked).
43. Screw clevis (9) flush with the threaded adjuster of
the cable (6).
44. Fit the clevis (9) on to link "B" using clip (10). Tighten
nut (11).
45. Adjust the stop (12) using nut (13) on support (8)
while checking that link "B" is still correctly locked.
46. Tighten nut (14) and check that the cable is not
pinched.
47. Check the operation and locking of the control in the
"direct drive" position.
14 8
13
12
11
10
B
9 Fig. 9
Issue 1 May 2001

6 . REAR AXLE
Contents
6 A01 DESCRIPTION
6 B01 STANDARD TRUMPET HOUSINGS
6 B02 TRUMPET HOUSINGS WITH SEALED COMPARTMENT
6 B03 TRUMPET HOUSINGS WITH COMPOSITE DRIVE UNIT
6 B04 TRUMPET HOUSINGS WITH DOUBLE DRIVE UNIT
6 C01 HANDBRAKE UNIT AND CONTROL LINK
6 D01 DIFFERENTIAL WITH STANDARD BEVEL GEAR AND HYDROMECHANICAL
LOCK
6 D02 DIFFERENTIAL WITH STANDARD BEVEL GEAR AND MULTIDISC LOCK
6 D03 DIFFERENTIAL WITH HYPOID BEVEL GEAR AND MULTIDISC LOCK
6 E01 BRAKE PISTONS AND SEALS
6 F01 PARK LOCK
6 G01 LIFT CYLINDER SUPPORTS
6 H01 CREEPER UNIT
6 I01 BRACKETS AND AUTOMATIC HOOK
6 J01 REAR HITCH MECHANISM
Issue 1 May 2001

Rear Axle - Description 6A01.1
6A01 Description
CONTENTS
A. General ________________________________________________ 2
B. Layout of main components _____________________________ 2
Issue 1 May 2001

6A01.2 Rear Axle - Description
A . General B . Layout of the main components

The rear axle is made up of five main housings: (Fig. 1 and 2)
- The intermediate housing comprising:
Inside: (2) Centre housing
. the drive pinion (see sections 6D01, 6D02 or 6D03
(3) PTO housing
according to the version)
(4) Bevel gear (crownwheel and drive pinion)
. the hand brake unit (see section 6C01)
(5) Handbrake unit
. the hydraulic pump pinion (see sections 9G01 - 9G02
(6) Creeper gearbox (if fitted)
depending on the hydraulic equipment)
(7) PTO clutch and drive pinion(s)
. the 4 WD clutch (see section 8A01)
(8) 540 / 1000 rpm pinions
. the Park Lock system (if fitted) (see section 6F01)
(9) 4 WD clutch
. the PTO clutch transmission shaft.
(10) Park Lock unit
Outside: (11) Hydraulic pump drive pinion
. the right-hand and left-hand side covers (see sections
(12) Removable 540 / 1000 rpm shaft (Fig. 1)
9G01 - 9G02 and 9H01 depending on the hydraulic
equipment). Fig. 1
- The centre housing containing:
Inside: Fig. 2
. the drive pinion crownwheel and differential (see
sections 6D01 - 6D02 or 6D03 depending on the
version)
. the PTO brake (see section 7F01)
Outside:
. the two trumpet housings (see sections 6B01 and
6B04).
- The PTO housing containing:

. in the upper part, the clutch and double pinion driving
the 540 / 1000 rpm pinions (see section 7F01).
. in the lower part, the removable 540 or 1000 rpm shaft
depending on the desired speed and the 540 / 1000
rpm pinions (see respective sections 7A01 and 7E01).
- The left and right trumpet housings acting as the

housing for the rear wheel drive system.
Issue 1 May 2001

Centre housing assembly
8200 SERIES TRACTORS (longitudinal section)
Rear Axle - Description 6A01.3
Version with standard bevel gear - 8210 - 8220 - 8240 and 8250 tractors
Remark: On tractors fitted with Heavy Duty transmission, the drive unit (6) is fitted to the rear of the gearbox.
11 4 7
12
6 10 9 5 2 8
Issue 1 May 2001

6A01.4 Rear Axle - Description
Centre housing assembly Version with hypoid bevel gear - 8250 to 8280 tractors
(longitudinal section) Remark: On a hypoid bevel gear, the axial line of the drive pinion is not common with the centre of the
crownwheel.
4 7
11
6 10 9 5 2 8
Parts list Fig. 1

Fig. 2
Issue 1 May 2001

Rear Axle - Standard trumpets 6B01.1
6B01 Standard trumpets
CONTENTS
- General ________________________________________________ 2
A. Removing and refitting the trumpet assembly _____________ 5
B. Removing and refitting the crownwheel and brake plate ___ 7
C. Removing and disassembling the planetary carrier ________ 8
D. Reassembling and refitting the planetary carrier ___________ 9
E. Replacing the axle shaft bearings ________________________ 10
F. Shimming the axle shaft bearings ________________________ 12
G. Replacing a wheel stud on the flange shaft _______________ 13
Issue 1 May 2001

6B01.2 Rear Axle - Standard trumpets

Parts list
General (1) Washer
8210 tractors are fitted with standard trumpet housings; (2) Plain axle shaft
also known has Heavy Duty "HD". (2) Wheel flange
They may be fitted either with a plain axle shaft or with (5) 3-lipped seal
a flanged axle shaft. (6) Cage
The flanged axle shaft type of trumpet housing is offered (7) Bearing cone
as an option on 8220 series tractors. (8) Bearing cup
(9) Threaded plug
(10) Trumpet housing
Description (11) Seal
The trumpet housings support the left and right-hand axle (12) Bearing cup
shafts and contain the final drive unit that receives the (13) Bearing cone
rotation from the differential assembly. Both trumpet (14) Pins
housings are symmetrical and fitted on either side of the (15) Crownwheel
centre housing. (16) Tab washer
(17) Spacer
(18) Bolt
(19) Circlip
Construction (20) Planetary gear pin
The axle shaft (2), depending on the version, is supported
(21) Washer
by two taper roller bearings comprising bearing cups (8)
(22) Planetary gear
(12) and cones (7) (13) fitted opposing each other.
The oil tightness of the drive unit compartment is pro-
(24) Spacer
vided by a lip seal (11).
The oil tightness of the crownwheel is ensured by two
(26) Shim(s)
beads of silicone (Silicomet type).
(27) Lock washer
The lip seal (5) protects the external bearing. The plan-
(28) Bolt
etary carrier (25) engages with the axle shaft (2) by
(29) Sun gear
means of splines and contains three planetary gears (22)
(30) Brake plate
that engage with the crownwheel (15) and the sun gear
(34) Ring (straight axle shaft)
(29).
(35) Brake disc
The crownwheel placed between the trumpet housing
(39) Bolt
(10) and the brake plate (30) is centred by pins (14).
(40) Bolt
The sun gear (29) drives the brake disc (35).
The pre-loading of the taper roller bearings is obtained by
shim(s) (26) placed at the end of the shaft between Fig. 1
washers (1) (27).
The axle shaft (2), depending on version and planetary
carrier (25) are held by washer (27) and bolt (28). Fig. 2
The brake plate (30) possesses a port "O" providing
lubrication for the brakes (see section 6E01).
Issue 1 May 2001

Rear axle - Standard trumpets 6B01.3 Overall view
14
20 mm D
B
6 C
39 39 0 39 5 2 10 11 16 25 19 20 21 24 15 22 23
21
6 7 8 35
39 2
40
29
39 34 5 9 A
39
17
18
8 mm
39 39 39 25
12 13 1 26 27 28 25 39 30
19
P1 = 0,02 / 0,12 mm
Parts list Fig. 2
Fig. 1
Issue 1 May 2001

6B01.4 Rear axle - Standard trumpets
Exploded view
14
16
15
13
12
11
10
9
8 35
7 30
6
29
5 28
27
26
1
17
18
19
21
23
24
23 40
39
22
21
25
20
Parts list Fig. 1

Fig. 2
Issue 1 May 2001

Remark
A . Removing and refitting the trum- The piston of brake "P" remains in the housing (1) (Fig. 3).
pet housing assembly
Removal Important:
2. Immobilize the tractor. Take off the wheel concerned. - Take care not to press the concerned brake pedal,
Position an axle stand. or fix a piston retaining tool on the centre housing
3. Remove the cab fixing bolts and the stabilizer support. (see section 6E01).
4. Take out the lift ram pin.
5. Support the trumpet housings with an appropriate
support and an adapted trolley jack
6. Take out bolts (39) excluding bolt (40) (Fig. 3).
7. Separate the centre housing, the trumpet housing
assembly, crownwheel (15) and brake plate (30). The
sun gear (29) and brake disc (35) remaining on the
housing (Fig. 3).
Note: If necessary, take out the sun gear and the
brake disc.
15 30
35
29
39 40
35 1
Fig. 3
Issue 1 May 2001


Refitting
8. Clean the mating faces of trumpet and centre
housings. Remove any remaining traces of sealing
compound. Dry the parts.
9. Place a bead of silicone sealing compound (Silicomet 1
type) in angle "D" of the centre housing (1) (Fig. 4).
Reminder: The diameter of the bead must be uni-
form, of small section and without joins.
10. Introduce the sun gear shaft (29) into the differential.
Refit the brake disc (35) while checking that it slides
freely on the splines of the shaft. D
11. Support the trumpet housing with the equipment
used to remove it. If necessary, screw two guide
studs on to the centre housing. Engage the trumpet
housing. Turn the axle shaft and push the trumpet
housing until it makes contact with the centre
housing. Fig. 4
12. If used, remove the guide studs. Smear the bolts (39)
with a sealing compound such as "Plastex" or
"Hylomar" and tighten them to a torque of 220 -
300 Nm.
13. Replace the various components around the trumpet
housing. Refit the wheel and tighten the studs or
wheel nuts to the correct torque depending on the
version (see section 2G01).
14. Top up the oil level in the housings and check it in the
transparent tube located on the left-hand side of the
centre housing.
15. Check the lift ram operation. Carry out a road test of
the brake circuit. Check the oil tightness of the
trumpet housing and hydraulic unions.
Issue 1 May 2001

B . Removing and refitting the brake

plate and crownwheel assembly
30
Removal
16. Remove the trumpet housing assembly (see § A). C
17. If possible, place the trumpet housing on an appro-
priate stand (plain axle) (Fig. 6) or on the flange
(flanged axle) with the sun gear (29) upwards.
Remove bolts (40).
18. Free and take off the brake plate (30) and the
crownwheel (15).
B
Refitting
19. Clean the mating faces of the trumpet housing, 10
crownwheel and brake plate with solvent. Remove Fig. 5
all traces of previous sealing compound. Dry the
parts.
20. Place a bead of sealing compound (Silicomet type)
in angles "B" and "C" located on the trumpet housing
(10) and the brake plate (30) according to the arrows 29
in Fig. 5.
21. Refit the crownwheel and the brake plate. Fit and
tighten the bolts (40) to 100 - 300 Nm.
22. Refit the trumpet housing (see § A).
Fig. 6
Issue 1 May 2001

C . Removing and disassembling

the planetary carrier
Removal
23. Remove the trumpet housing (see § A).
24. Free and take off the brake plate assembly (30) and
crownwheel (15) (see § B).
25. Immobilise the axle shaft and planetary carrier.
26. Take off bolts (28), washers (1) (27), and the shim(s)
(26). Remove the planetary carrier assembly (25)
(Fig. 7).
28 27
Disassembly
27. Remove the bolts (18) and spacer (17). Remove 26
snap ring (19) by opening its two ends (Fig. 8).
28. Drive out and remove the pins (20). Take out the
friction washers (21) and the planetary gears (22)
from the planetary carrier. Recover the two ranks of 25 1
needle bearings (23) separated by spacer (24).
16
17 18
F F
25 17
40
19
18
Fig. 8 Fig. 7
Issue 1 May 2001

D . Reassembling and refitting the

planetary carrier
Reassembly
29. In the planetary gears, fit the needle bearings (23)
previously coated lightly with miscible grease.
30. Refit the planetary gears. Carry out operation 28 (§ C)
in reverse order. Place the spacer (17). Lightly smear
bolts (18) with Loctite 270 (Fig. 8) and tighten to a
torque of 34 - 50 Nm.
Refitting
31. Check for the presence of the tab washer (16). Refit
the planetary carrier assembly (25) (Fig. 7). If neces-
sary, shim the bearings (see § F).
32. Immobilise the axle shaft and the planetary carrier.
Fit washers (1) (27) with the shim(s) (26) between
them. Fit bolt (28) previously lightly smeared with
Loctite 270 or equivalent, and tighten to the following
torque:
- 270 - 440 Nm : flanged axle shaft, Ø 82 mm.
- 340 - 500 Nm : straight axle shaft, Ø 95 mm.
33. Refit the brake plate assembly (30) and crownwheel
(15) (see § B).
34. Refit the trumpet housing (see § A).
Issue 1 May 2001

E . Replacing the axle shaft bearings

35. Remove:
- trumpet housing assembly (see § A). 12
- brake plate assembly (30) and crownwheel (see
§ B).
- planetary carrier assembly (see § C).
Disassembly 8 mm
36. Take off tab washer (16) and shaft assembly (2). 2
37. On the shaft: 11
- remove bearing cone (13)
- extract bearing cone (7) and seal (5).
38. Using an extractor or a locally manufactured tool,
Fig. 9
remove the bearing cups (8) (12) and cage (6).
Remark: During the replacement of the bearings, the
replacement of seal (11) is also recommended.
Reassembly
parts found to be defective.
Positioning the seal (11)

40. Smear the external diameter of the seal with Loctite
542 and insert it 8 mm from the shoulder of bearing
cup (12) (Fig. 9), with the lip of the seal turned
towards the drive unit.
Special point
If a circumferential groove appears on the shaft (2)
at seal (11) location, offset the new seal slightly so
that the lip runs on a different section of the shaft.
Remark: Bush (34) is sealed with Loctite 648 and
force fitted on to shaft (2) (Fig. 1).
41. Insert:
- bearing cups (8) (12) thrust against their respective
shoulders
- cage (6) according to Fig. 10
- bearing cone (7), lubricated, and thrust against the
shoulder on shaft (2), depending on the version.
Issue 1 May 2001

Positioning the three-lipped seal (5)

42. Insert the new seal, respecting the direction of
assembly and with the seal thrust against bearing
cone (7) (Fig. 10).
43. Moderately grease the cone and seal lips (5) (11) (BP 5 6
Agricharge grease or equivalent).
44. Protect the lip seal (11) by temporarily masking the
splines on the axle shaft with a flexible protection.
Introduce the prepared shaft into the trumpet hous-
ing fitted with its seal and its cups, and with the lips 7
of the seal (5) turned outwards. 20 mm
Fit cone (13) and replace the tab washer (16).
Final operations
45. Refit the planetary carrier (25) assembly.
46. Carry out shimming of the bearings (see § F). Fig. 10
47. Refit the brake plate assembly (30) and crownwheel
(see § B).
48. Temporarily replace plug (9) with a grease nipple.
Partially fill cavity "A" (Fig. 11) of the trumpet housing
with grease (BP Agricharge or equivalent). Remove
the grease nipple. Screw in the plug.
49. Refit the trumpet housing assembly (see § A).
A 9
Fig. 11
Issue 1 May 2001

F . Shimming the axle shaft bearings

Components concerned by the shimming
The axle shaft (2), the taper roller bearings (7) (8) (12) (13),
the trumpet housing, tab washer (16) and planetary
carrier (25).
27
Remark
The pre-loaded shimming of taper roller bearings on the 1
axle shaft is carried out via the shim(s) (26) placed
between washers (1) (27) (Fig. 12).
Reminder
To carry out the correct shimming of the bearings, place
the trumpet housing in a vertical position (Fig. 12).
Preparation 26
50. With the bearing cone (13), tab washer (16), plan- P1 =
etary carrier (25) and washer (1) already fitted, place 0,02 / 0,12 mm
a thickness of shims (26) greater than the space
between washer (1) and the thrust face of the
washer (27) on the planetary carrier (Fig. 13), so as
to obtain a provisional clearance of approximately
0.10 mm to 0.15 mm, in order to carry out the final
shimming with pre-loading (see further on). 2
51. Place washer (27). Provisionally tighten bolt (28).
Fig. 12
Issue 1 May 2001

Shimming (Fig. 13)

52. Press hard on the planetary carrier and simultane-
G . Replacing a wheel stud on the
ously turn the trumpet housing several times. axle flange
53. Place a dial gauge on the planetary carrier, the index
58. Drive out the defective stud
positioned towards its centre.
59. Clean the new stud and its lodging in the hub.
60. Smear the ridges of the stud with Loctite 270 or
55. Using two appropriate levers, move the planetary
equivalent and insert it using a bronze drift and an
carrier upwards.
appropriate hammer.
56. In relation to the clearance "J" measured, remove a
shim (26) thickness to obtain pre-loading of:
P1 = 0.02 mm to 0.12 mm (Fig. 12)
according: J – (0.02 to 0.12).
57. Definitively fit washer (27) and bolt (28) previously
lightly smeared with Loctite 270 or equivalent, and
tighten in accordance with the torque indicated in
operation 32 (see § D).
28 27
26
25
16
13
Fig. 13
Issue 1 May 2001

Issue 1 May 2001

Rear axle -Trumpets with sealed compartment 6B02.1
6B02 Trumpets with sealed compartment
Contents
- General ________________________________________________ 2
B. Removing and refitting the compartment and crownwheel

assembly _______________________________________________ 7
C. Replacing compartment seals ____________________________ 8
D. Removing and refitting the planetary carrier _______________ 9
E. Reassembling and refitting the planetary carrier ___________ 9
F. Replacing the axle shaft bearings ________________________ 10
G. Shimming the axle shaft bearings ________________________ 12
H. Service tools ___________________________________________ 14

6B02.2 Rear axle -Trumpets with sealed compartment

Parts list
General (2) Straight axle shaft
The 8220 tractors can be fitted with trumpets containing (5) Three-lipped seal
a sealed compartment, these are also known as "HDE" (6) Cage
or Heavy Duty Etanche. (7) Bearing cone
The 8240 and 8250 tractors are fitted with Optimised (8) Bearing cup
Heavy Duty trumpets with sealed compartment called (9) Threaded plug
"HDEO". (10) Trumpet
HDEO trumpets have a crownwheel and sun gears that (11) Seal
have been carbon nitrided: this is a special heat treat- (12) Bearing cup
ment that makes them resistant to "pitting." (13) Bearing cone
A final honing ensures the optimum bearing of the teeth (14) Pins
as a function of the high loads borne by the epicyclic gear. (15) Crownwheel
(16) Tab washer
The trumpets bear the right and left hand side axle shafts (17) Spacer
and contain the final drive units that transmit the rotation (18) Bolt
from the differential assembly. The trumpets are sym- (19) Circlip
metrical and mounted either side of the centre housing. (20) Planetary gear pin
The final drive unit is lodged in a sealed compartment (21) Washer
isolated from the centre housing and containing oil with (22) Planetary gear
SAE 85W140 viscosity grade. (23) Needle bearings
(24) Spacer
Construction (26) Shim(s)
The axle shaft (2) is supported by two opposing taper (27) Lock washer
roller bearings comprising cups (8) (12) and cones (7) (28) Bolt
(13). (29) Sun gear
The oil tightness of the final drive unit compartment is (30) Brake plate (compartment)
ensured by lip seal (11) and compartment (30) fitted with (31) Seals
seals (31) mounted back-to-back. The oil tightness of the (32) Splined hub
crownwheel (15) is provided by two beads of silicone (33) Snap ring
(Silicomet type). (35) Brake disc
The three lipped seal (5) protects the outer bearing. The (38) Tube
planetary carrier (25) engages with the axle shaft (2) via (39) Bolt
splines, it is made up of three planetary gears (22) that (40) Bolt
engage with the crownwheel (15) and the sun gear (29). (41) Filler plug
The crownwheel is placed between the trumpet (10) and (42) Oil level plug
compartment (30) and is centred via pins (14). The (43) Magnetic drain plug
compartment (30) equally serves as the brake plate.
The sun gear (29) drives the brake disc (35) through a Fig. 1
splined hub (32) held in place by a snap ring (33).
The pre-loading of the taper roller bearings is provided by Fig. 2
shim(s) (26) placed at the end of the shaft.
Axle shaft (2) and planetary carrier (25) are held in place
by washer (27) and bolt (28).
The compartment (30) possesses a port "O" providing for
lubrication of the brakes (see section 6E01).
The tube (38) linked to the breather tube screwed on the
left hand-side lifting support allows atmospheric pres-
sure to be maintained in the trumpet.
Issue 1
2 December
May 2000
2002
Overall view
Rear axle - Trumpets with sealed compartment 6B02.3

30 "O"
14
20 mm
D
B
C
10 16 25 19 38 20 21 23 24 15 22 21 35
39 39 O 39
6 5 2
30
41 6 7 8
31
31
39
40
29
42
33
39
32
2 A 9 5
8 mm 31
25 17 18
39 39 39 39 11 12 13 26 27 28 25 39 30
19 P1 = 0,02 - 0,12 mm
43
Fig. 1
Parts list Fig. 2

Issue 1 May 2001
6B02.4 Rear axle - Trumpets with sealed compartment
Exploded view
14
2 38
16
15
13
12
11
10 35
9 32
8 30
7 41
6 43
5 28
27
26
17
18
33
19
31
31
42
29
21 41
23
24
23 40
39
22
21 42
25
20
Issue 1 May 2001

7. Separate the trumpet assembly with the sun gear (29)

A . Removing and refitting the trum- from the centre housing, the compartment assembly
pet assembly (30) with its markings (31) to (33) and the crownwheel
(15) (Fig. 3).
Removal Remark
1. Drain the centre housing. - Brake piston "P" remains in the housing (1) (Fig. 3)
Remarks
- The oil used for the mechanical and hydraulic com-
ponents of the transmission and that used for lubri- Important
cating the moving parts in the trumpet housings are
not the same, their viscosities differ.
- Take care not to press the brake pedal concerned,
- If the oils are not to be changed, they must not be
or fix a piston retaining tool on to the centre
mixed when drained.
housing (see section 6E01).
2. Immobilise the tractor. Take off the wheel. Position an
axle stand.
3. Remove the cab fixing bolts and the stabiliser support.
4. Take out the axle from the lift ram.
5. Support the trumpet with an appropriate support and
a suitable trolley jack.
6. Remove bolts (39) excluding bolt (40).
15 30 29
39 40
35 1
Fig. 3
Issue 1 May 2001


Refitting
8. Clean the mating faces of the trumpet and centre
housings. Remove any traces of previous sealing
9. Place a bead of silicone sealing compound (Silicomet 1
type) in angle "D" of the centre housing (1) (Fig. 4).
Reminder
- The diameter of the bead must be uniform, of small
section and without joins.
10. Replace the brake disc (35) checking that it slides
freely on the hub splines.
11. Support the trumpet using the equipment used when D
removing it. If necessary, screw two gui-de studs
into the centre housing. Engage the trumpet. Turn the
axle shaft and push the trumpet until it makes
contact with the housing.
12. Remove the guide studs if used. Smear the bolts (39) Fig. 4
with an oil tightness product ("Plastex" or "Hylomar")
13. Refit the remaining components around the trumpet.
Refit the wheel and tighten the wheel nuts or studs
section 2G01).
14. Top up the oil level and check using it in the
transparent tube located on the left-hand-side of the
centre housing.
Remark
- In addition, check the oil level in the final drive unit.
15. Check the operation of the lift ram.
Road test the brake circuit.
Check the oil tightness of the trumpet, the hydraulic
unions and plugs.
Issue 1 May 2001

B . Removing and refitting the com-

partment and crownwheel assem-
bly
Removal 33
16. Remove the trumpet assembly (see § A) and drain 32
the drive unit concerned.
30
17. If possible, place the trumpet in a vertical position,
the sun gear (29) at the top (Fig. 6). Remove bolt (40),
snap ring (33) and hub (32).
Unstick and remove compartment (30) having previ- 15
ously place a flexible protection over the splines of
the sun gear (29).
Remove the sun gear. Release and remove the 28 29
crownwheel (15) (Fig. 5).
26 27
25
16
29
F
F
40
Fig. 6 Fig. 5
Issue 1 May 2001


Refitting
18. Clean the mating surfaces of the trumpet, the
crownwheel and compartment with solvent. Re-
move all traces of the previous sealing compound. 30
Dry the components.
19. Seal angles B and C located on the trumpet (10) and C
the compartment (30) with a Silicone sealing com-
pound (Silicomet type) according to the arrows
shown in Fig. 7.
20. Refit the sun gear. Place protector 3376885M1,
compartment (30), hub (32), snap ring (33). Replace
and tighten bolt (40) to 100 - 130 Nm.
21. Refit the trumpet (see § A) and top up and check the B
oil level of the drive unit concerned.
10
Fig. 7
30 31
C . Replacing compartment seals
Disassembly
22. Remove the trumpet assembly (see § A).
23. Remove the compartment assembly (30) and the
crownwheel (see § B).
24. Extract the seals (31).
Reassembly
25. Using an appropriate assembly, insert the first new
seal (31) against the shoulder of compartment (30) 31
with the second seal back to back, employing the
same method (Fig. 8). Fig. 8
26. Refit the compartment assembly (30) and crown-
wheel (see § B). Refit the trumpet assembly (see §
A).
Issue 1 May 2001

D . Removing and refitting the plan-

17 18
etary carrier
Removal
28. Remove the compartment assembly (30) and
crownwheel (see § B). 25 17
30. Take out bolt (28), washer (27), shim(s) (26).
Remove the planetary carrier assembly (25) (Fig. 5).
19
Disassembly
31. Take out bolt (18) and spacer (17). Remove snap ring
18
(19) by opening its two extremities (Fig. 9).
32. Drive out and remove the pins (20). Take off the Fig. 9
friction washers (21) and the planetary gears. Re-
cover the needle bearings that are arranged in two
rows separated by a spacer (24).
E . Reassembling and refitting the

planetary carrier
Reassembly
33. In the planetary gears, fit the needle bearings (23)
previously coated lightly with miscible grease.
34. Refit the planetary gears. Carry out operation 32 in
reverse order (§ D). Place the spacer (17). Smear bolt
(18) with Loctite 270 (Fig. 9) and tighten to a torque
of 34 - 50 Nm.
Refitting
35. Check for the presence of washer (16). Refit the
planetary carrier assembly (25) (Fig. 5). If neces-
sary, carry out shimming of the bearings (see § G).
Place the shim(s) (26) and washer (27). Fit and
tighten bolt (28), lightly smeared with Loctite 270 or
equivalent, to a torque of 340 - 500 Nm.
37. Refit the compartment assembly (30) and crown-
wheel (see § B). Refit the trumpet assembly (see §
A).
Issue 1 May 2001

F . Replacing the axle shaft bearings

12
38. Remove:
- the trumpet assembly (see § A).
- the compartment assembly (30) and crownwheel
(see § B).
- the planetary carrier assembly (25) (see § D).
Disassembly
39. Take off washer (16) and the shaft assembly (2) 8 mm
(bearing cone (13) moves freely on the shaft).
40. Take off bearing cone (13). Extract bearing cone (7)
and seal (5) from the shaft. 11
41. Using an extractor or a locally manufactured tool, 2
take off the bearing cups (8) (12) and cage (6).
Remark Fig. 10
- When replacing the bearings, it is recommended
that the seal (11) is also replaced.
Reassembly
parts found to be defective. 5 6
Positioning seal (11)

43. Smear the external diameter of the seal with Loctite
542 and insert it 8 mm from the shoulder of bearing
cup (12) (Fig. 10), the lip turned to face the drive unit. 20 mm
Special point
- If a circumferential groove is present on shaft (2) at 7
the location of seal (11), offset the new seal slightly
so that it operates on a different section of the shaft.
44. Insert:
- cups (8) (12) thrust against their respective shoul-
ders. Fig. 11
- cage (6) according to Fig. 11.
- cone (7) previously lubricated and thrust against
the shoulder on shaft (2).
Issue 1 May 2001

Positioning the three-lipped seal (5)

45. Insert the new seal thrust against bearing cone (7)
and respect the assembly direction (Fig. 11).
46. Moderately grease the cone, seal lips (5) (11) (BP
Agricharge grease or equivalent).
47. Protect the seal lip (11) by temporarily masking the
splines on the axle shaft with a flexible protection.
Introduce the prepared shaft into the trumpet fitted
with its seal and cups while directing the seal lips
towards the exterior.
Fit cone (13) and refit the tab washer (16).
Final operations
48. Refit the planetary carrier assembly (25).
49. Carry out shimming of the bearings (see § G). A 9
50. Refit the compartment assembly (30) and crown- Fig. 12
wheel (see § B).
51. Temporarily replace plug (9) by a grease nipple.
Partially fill cavity A (Fig. 12) of the trumpet with
grease (BP Agricharge or equivalent). Remove the
grease nipple. Screw in the plug.
52. Refit the trumpet assembly (see § A).
Issue 1 May 2001

G . Shimming the axle shaft bea-

rings
Components concerned by shimming
- The axle shaft (2), taper roller bearings (7) (8) (12) (13), 27
the trumpet, tab washer (16) and planetary carrier (25).
Remark
- The pre-loading shimming of the taper roller bearings on
the axle shaft is carried out via shims (26) placed
between the shaft (2) end and washer (27) (Fig. 13).
Reminder
- To carry out the shimming of the bearings correctly, 26
place the trumpet in a vertical position (Fig. 13). P1 =
0,02 - 012 mm
Preparation
- The bearing cone (13), tab washer (16) and planetary
carrier (25) being fitted, place a thickness of shims (26) 2
greater than the space between the end of the axle shaft
(2) and the washer (27) thrust face on the planetary
carrier (Fig. 14), to obtain a provisional clearance of
approximately 0.10 mm to 0.15 mm, in order to be able
to carry out definitive shimming and pre-loading (see
further on).
Fig. 13
Issue 1 May 2001

Shimming (Fig. 14)

54. Press hard on the planetary carrier while simultane-
ously turning the trumpet several turns.
55. Place a dial gauge on the planetary carrier with the
index positioned towards its centre.
57. Using appropriate levers move the planetary carrier
vertically.
58. In relation to the clearance "J" measured, remove a
thickness of shims (26) to obtain the pre-loading:
P1 = 0.02 mm to 0.12 mm (Fig. 13) according to
J - (0.02 to 0.12)
59. Definitively fit washer (27) and bolt (28) previously
smeared with Loctite 270 or equivalent, tighten to
the torque indicated in operation 36 (see § E).
28 27
26
25
16
13
Fig. 14
Issue 1 May 2001

H . Service tools
1. Tool available in the AGCO network
- 3376885 M1 - Oil seal protector (Fig. 15).
Fig. 15
2. Locally manufactured tool

- Cone and pusher for inserting snap ring (33) (Fig. 16).
85 30
35
R10 20
ø18
ø32,6 +0,1
+0,3
ø51-0-0,2
ø47-0-0,3
ø41
5
45
R10
180
30
ø51,2 +0,3
+0,1
ø61
ø71
0,5 x 45˚
Fig. 16
Issue 1 May 2001

Rear axle - Trumpets with composite drive unit 6B03.1
6B03 Trumpets with composite drive unit
Contents
- General ________________________________________________ 3
B. Removing and refitting the spacer and crownwheel

assembly _______________________________________________ 11
C. Replacing spacer seals __________________________________ 12
D. Replacing the cassette seal ______________________________ 13
E. Removing and disassembling the planetary carrier ________ 14
F. Reassembling and refitting the planetary carrier ___________ 15
G. Shimming the planetary gear ____________________________ 16
H. Replacing the axle shaft bearings ________________________ 17
I. Shimming the axle shaft bearings ________________________ 18
J. Service tools ___________________________________________ 20
Issue 1 May 2001

6B03.2 Rear axle - Trumpets with composite drive unit
Issue 1 May 2001

General Kinematics (Fig. 2)

The differential assembly drives the sun gear shaft (29)
The 8250 tractors are fitted with trumpets having a that in turn transmits the movement to the axle shaft (2)
composite drive unit, as are the 8240 tractors, depending via double planetary gears (22), crownwheel (15) and
on options. planetary carrier (25).
It is a classical kinematics train: the movement enters
Description the sun gear shaft and is output to the planetary carrier.
The trumpets support the left-hand and right-hand side
axle shafts and contain the final drive unit that transmits
the rotation from the differential assembly. The trumpets
are symmetrical and fitted on either side of the centre
housing.
Construction
The axle shaft (2) is supported by two taper roller bea-
rings comprised of cups (8) (12) and cones (7) (13)
mounted opposing each other.
The oil tightness of the final drive unit is provided by lip
seals (31) fitted back-to-back and o’rings (4). The cas-
sette seal (3) protects the external bearing comprising
cup (8) and cone (7).
The planetary carrier (25) is separated from the centre
housing by a spacer (30) that also serves as the brake
plate.
The compartment containing the final drive unit contains
SAE 85W140 viscosity oil and is different from that used
in the transmission.
Axial and radial drilled holes in pin (20) permit lubrication
of the needle bearings (23) in the double sun gears.
The planetary carrier drives the axle shaft (2) via splines
and has three double pinions (22). The axial clearance of
these pinions is provided by shim(s) placed on pin (20)
against the 17-teeth pinion.
Shims (26) placed at the end of the axle shaft allow a pre-
loading of the taper roller bearings. Shaft (2) and planetary
carrier (25) are held by washers (27) and bolt (28).
The reduction crown (15) squeezed between the trumpet
(10) and spacer (30) is centred by pin (14). Spacer (30) is
positioned by pin (5) on the centre housing. The rotation
of the differential is transmitted to the double sun gears
via a planetary gear shaft on which snap ring (33) retains
hub (32) driving the brake disc (35).
The compartment of spacer (30) possesses a port "O"
that provides for lubrication of the brakes (see section
6E01). Tube (38) linked to the breather tube screwed on
to the left-hand lift support allows atmospheric pressure
to be maintained in the trumpet.
Issue 1 May 2001


Parts list
(1) Bush
(2) Straight shaft
(3) Cassette seal
(4) O’rings
(5) Locating pin
(6) Shim(s)
(7) Bearing cone
(8) Bearing cup
(9) Washer
(10) Trumpet
(11) Nut
(12) Bearing cup
(13) Bearing cone
(14) Pin
(15) Crownwheel
(16) Tab washer
(17) Spacer
(18) Bolt
(19) Circlip
(20) Planetary gear pin
(21) Washer
(22) Double planetary gear
(24) Spacer
(26) Shim(s)
(27) Lock washer
(28) Bolt
(29) Sun gear
(30) Spacer (brake plate)
(31) Seals
(32) Splined hub
(33) Snap ring
(34) Stud
(35) Brake disc Fig. 1
(36) Studs
(37) Stud
(38) Tube Fig. 2
(40) Bolt
(41) Plug (filler and level)
(43) Magnetic drain plug
Fig. 3
Issue 1 May 2001

Overall view
30
14 5
31 31
"O" 35
9 11 36 4 15 4 30
D 19 20 38 6 23 24 15 22 23 21
2 1 7 8 10 16
29
40
33
40
32
31
3 13 12 11 9 27 28 25 30
26
9 11 34 9 11 37
17 18 41
P1 =
0,02 - 0,12 mm
25
30
43
19
Fig. 1

Issue 1 May 2001
Exploded view
2
29
16
4
15
22
14
4
13
12
15 10
8
7
1
30
25 3
41
29
28
27
26 35
33
25
32
19
31
5
9
43 11
36
40 40
2
21
22
23
17
24
18
20
9 11 34 9 11 37
6
Parts list Fig. 1 Fig. 3 Fig. 2 Parts list Fig. 1 Fig. 2 Fig. 3
Issue 1 May 2001

A . Removing and refitting the trum-

pet assembly 1
Removal
Remarks
- The oil used for the mechanical and hydraulic com-
ponents of the transmission and that used for the
lubrication of the moving parts of the trumpet are not
of the same type and their viscosity is different.
- If the oils are not to be changed, they must not be
mixed when drained. 2
2. Immobilise the tractor. Take off the wheel. Position an
axle stand.
3. Remove the cab fixing bolts and the stabiliser support.
Note: If necessary slightly raise the side of the cab Fig. 4
concerned, check that nothing blocks its lifting.
Position an axle stand.
4. Drive out the holding snap ring (1) (Fig. 4). Push the
lower axle (2) of the lift ram outwards and remove it.
Issue 1 May 2001


5. Support the trumpet using appropriate support and
trolley jack.
6. Remove the nuts (11) and washers (9) but exclude
bolt (40).
7. Separate the centre housing, the trumpet assembly
from the sun gear (29), the spacer assembly (30)
bearing the markings (31) to (33) - (35) and crownwheel
(15) (Fig. 5).
Remarks
- The brake piston "P" remains in the housing (1)
(Fig. 5).
Important
- Take care not to press the brake pedal concerned or fix

a piston retaining tool to the centre housing (see section
6E01).
29
15 30
40 9 11
40 P
35 1
Fig. 5
Issue 1 May 2001

Refitting
Special points
- The threaded studs (34) (36) (37) screwed into the
centre housing have different lengths and their threads
must be lightly smeared with Loctite 270 or equivalent
before fitting (Fig. 6).
Important
- Place the studs in the housing, respecting their length

and locations in accordance with Fig. 1 :
. (34) : Ø 16 mm - L 335 mm
. (36) : Ø 16 mm - L 353 mm
. (37) : Ø 16 mm - L 363 mm
8. Clean the mating faces of the trumpet and centre Fig. 6

housing. Remove all traces of previous sealing
9. Place a bead of sealing compound (Silicomet type)
in angle "D" of the centre housing (1) (Figs. 7 and 9).
Reminder
- The diameter of the bead must be uniform, of small
section and without joins. 1
10. Refit the brake disc (35) while checking that it slides
freely on the splines of the hub (32). Check for the
presence of the locating pin (5) (Fig. 8).
11. Support the trumpet with the aid of the equipment
used when removing it.
12. Engage the trumpet on the original studs. Turn the
axle shaft and push the trumpet until it mates with
the housing. D
13. Place a washer (9) on each stud. Screw on the nuts
and tighten to a torque of 247 - 253 Nm.
Fig. 7
35 32
5
Fig. 8
Issue 1 May 2001


14. Replace the components surrounding the trumpet. Fig. 9
Refit the wheel and tighten the bolts and nuts to the
correct torque depending on the version (see section
2G01).
Tightening torques
- cab fixing bolts (silent bloc): 200 - 260 Nm. Loctite
270 or equivalent.
15. Top up the oil level of the housings and check using
the transparent tube located on the left-hand side of
the centre housing.
Remark
- Equally, check the level of oil in the drive unit con-
cerned.
16. Check the operation of the lift control. Carry out a
road test of the brake circuit. Check the oil tightness
of the trumpet, hydraulic unions and plugs.
Issue 1 May 2001

B . Removal and refitting the spacer

and crownwheel assembly
33
Removal
17. Remove the trumpet assembly (see § A) and drain 32
the drive unit concerned. 30
the sun gear (29) at the top (Fig. 11). Remove bolts
(40), snap ring (33) and hub (32). Unstick and remove
the spacer (30) having previously placed a flexible
protection on the splines of the sun gear (29).
Take off the sun gear.
Remove the planetary carrier assembly (see § E). 29
Unstick and remove the crownwheel (15) (Fig. 10).
19. Discard the o’rings (4) (Fig. 1).
28
27
15
26
16
25
29
40 F
F
40
Fig. 11 Fig. 10
Issue 1 May 2001


Refitting
20. Clean the mating faces of the trumpet, crownwheel
and spacer with solvent. Dry the parts.
21. Position new crownwheel o’rings (4) according to 30
the arrows in angles B and C (Fig. 12) between the
trumpet (10) and compartment (30).
22. Replace the trumpet assembly (see § F) and the sun
gear. Fit protector ref. 3376885M1, the spacer (30), C
hub (32), snap ring (33). Fit and tighten the bolts (40)
23. Replace the trumpet assembly (see § A) and top up
and check the drive unit oil level.
4
10
B
Fig. 12
C . Replacing the spacer seals

Disassembly 30 31
25. Remove the spacer assembly (30) and crownwheel
(see § B).
26. Extract the seals (31).
Reassembly
27. Using a suitable fixture, insert the first new seal (31)
against the shoulder of the spacer (30) (Fig. 13) and
the second seal back-to-back using the same method.
28. Refit the spacer assembly (30) and the crownwheel
31
(see § B).
29. Refit the trumpet assembly (see § A). Fig. 13
Issue 1 May 2001

D . Replacing the cassette seal

3
30. Partially drain the concerned drive unit.
31. Chock the front wheels. Remove the rear wheel (see
section 2G01). Place an axle stand beneath the trum-
pet.
Removal
Special points
- The 8240 (depending on options) and 8250 tractors may
be fitted with axle shafts of 95 mm or 110 mm
diameter.
- Whatever the diameter of the shaft, the reference
number for bush (1) and cassette seal (3) (Fig. 14 - 15) 1
remains identical. Fig. 14
- If necessary, smear the bore of the bush with Loctite
648 or its equivalent and slide it on to the shaft flush with
the thrust face of bearing cone (7) (Fig. 15).
32. Using a locally manufactured tool, extract the cas- 1 3

sette seal (3), without damaging the trumpet or the
external diameter of the bush (1) (Fig. 14).
Refitting
33. Clean the location of the seal on the trumpet and
bush (1).
34. Lightly smear the external diameter of the seal with
Loctite 648 or its equivalent and moderately lubricate
its internal diameter with transmission oil.
35. Insert the seal using tool ref. 3378151M1 (see § J).
Wipe off all remaining traces of Loctite.
Remark 7
- The design of the tool determines the position of the
cassette seal in the trumpet. Fig. 15
Final operations
36. Refit the wheel and tighten the wheel studs or nuts
depending on the version (see section 2G01).
37. Top up and check the oil level in the drive unit.
38. Road test. Check the oil tightness of the cassette
seal.
Issue 1 May 2001

E . Removing and dissassembling of

the planetary carrier 18
Removal 17
40. Remove the hub (32), spacer (30) and the sun gear
shaft (29) (see § B).
42. Take out bolt (28), washer (27) and the shim(s) (26).
Remove the planetary carrier assembly (25) (Fig. 10)
using an appropriate sling.
43. Take out the crownwheel (see § B).
Disassembly
44. Take out bolt (18) and spacer (17) (Fig. 16). Fig. 16
Take off the circlip (19) by opening its extremities
(Fig. 17).
45. Drive out and remove the pins (20).
Remove the friction washers (21), shim(s) (6) and
planetary gears (22).
Recover the two rows of needle bearings (23) sepa-
rated by spacer (24) (Fig. 18).
19
Fig. 17
23
24
23
20
6
21
22
Fig. 18
Issue 1 May 2001

F . Reassembling and refitting the

planetary carrier
O
Reassembly
46. Clean and check the components. Replace any O
47. Coat the needle bearings (23) with miscible grease.
20
In each of the planetary gears (22), place two rows
of needle bearings separated by spacer (24).
48. If necessary, carry out axial shimming of the pla- 19
netary gears (see § G), otherwise continue with the
reassembly operation.
49. Place the planetary gear (22) in the planetary carrier
(25) with the 17 teeth pinion facing the circlip (19).
Place washers (21) and shim(s) (6).
50. Engage the three pins (20) and turn the lubricating
Fig. 19
ports "O" towards the circlip (19) (Fig. 19).
51. Push again on the three pins and open the circlip.
52. Tap lightly and alternately on the pins to ensure that
the circlip correctly fits in the groove of the planetary
carrier (Fig. 19). 17 18
53. Place spacer (17), fit and tighten bolt (18) previously
lightly smeared with Loctite 270 or its equivalent and
tighten to a torque of 34 - 50 Nm (Fig. 20).
54. Manually check the rotation of the planetary gears.
17
Refitting
55. Refit the crownwheel (see § B).
56. Check for the presence of washer (16). Refit the
planetary carrier assembly (25) (Fig. 10) turning the
19
marks stamped on each planetary gear to the posi-
tion shown in Fig. 21.
If necessary, carry out shimming of the axle shaft 18
bearings (see § I). Otherwise, continue the refitting Fig. 20
operation.
Remark
- Each planetary gear carries a punched mark on the
29 teeth pinion. These marks indicate the align-
ment of two teeth belonging to their respective 22
pinions (17 and 29 teeth). The marks must point
towards the centre of the planetary carrier.
57. Immobilise the axle shaft and the planetary carrier.
Place the shim(s) (26) and washer (27). Fit and
tighten bolt (28) previously lightly smeared with Loc-
tite 270 or equivalent and tighten to a torque of 340
- 500 Nm.
58. Refit the sun gear shaft (29), spacer (30) and hub (32)
(see § B).
59. Refit the trumpet assembly (see § A) and top up and
check the oil level in the drive unit concerned.
Fig. 21
Issue 1 May 2001

G . Shimming the planetary gear

Principle
- The planetary carrier (25) comprises three double pin-
ions (22) also known as planetary gears. The axial
clearance of these pinions is obtained via shim(s) (6)
placed on pin (20) against the 17 teeth pinion.
Preparation
60. Place the planetary gears (22), the 17-teeth pinion
facing the circlip (19).
Place washers (21) against the 29 teeth pinion and
average thickness provisional shim(s) (6) against
the 17 teeth pinion.
61. Engage the three pins (20), turning the lubricating
ports towards the circlip (19). Fig. 22
Shimming
20 6
62. Using a feeler gauge (Fig. 22) determine the thick-
ness of the definitive shim(s) (6) to be fitted so as to
obtain a clearance of between 0.15 mm and 0.6 mm
on each planetary gear.
Note: Where possible shim to the minimum
tolerance.
63. Slightly retract the pins (20) and place the shim(s) (6)
(Fig. 23) whose thickness was previously deter-
mined.
Reminder
- The thickest shim must be placed against the row
of needle bearings.
64. Refit the pins. Fit circlip (19). Position the spacer (17)
and tighten bolt (18), previously lightly smeared with
Loctite, to a torque of 34 - 50 Nm. Fig. 23
Issue 1 May 2001

H . Replacing the axle shaft bearings

65. Remove:
- the trumpet assembly (see § A)
- the spacer assembly (30) (see § B)
- the planetary carrier (25)
- the crownwheel (see § B)
Disassembly
66. Take off washer (16) and shaft assembly (2).
Remark
- The bearing cone (13) runs free on the shaft.
67. Remove the bearing cone (13). Extract bearing cone
(7).
68. Drive out the cassette seal (3).
69. Using an extractor or locally manufactured tool,
remove bearing cups (8) (12).
Reassembly
71. Insert:
- bearing cups (8) (12) thrusting against their respec-
tive shoulders
- bearing cone (7) previously lubricated with trans-
mission oil and thrusting against the shoulder on
the shaft.
72. Introduce the prepared shaft into the trumpet fitted
with its cups.
73. Assemble cone (13) and refit tab washer (16).
Final operations
74. Place the crownwheel (see § B). Refit the planetary
carrier assembly (25) (see § F) and carry out shim-
ming of the bearings (see § I).
75. Refit the spacer assembly (30) (see § B).
77. Insert a new cassette seal (see § D).
section 2G01).
79. Top up and check the oil level in the housings and
check the level in the transparent tube located on the
left-hand side of the centre housing.
In addition, top up and check the oil level of the drive
unit concerned.
Issue 1 May 2001

I . Shimming the axle shaft bearings

- The axle shaft (2), taper roller bearings (7) (8) (12) (13), P1 =
the trumpet and tab washer (16). 0,02 - 0,12 mm
Remark 27 26
- The shimming for pre-loading of the taper roller bearings
on the axle shaft is carried out using shim(s) (26) placed
between the end of shaft (2) and washer (27) (Fig. 24).
Reminder
- To carry out the correct shimming of the bearings, place
the trumpet in a vertical position (Fig. 24).
Preparation
80. With bearing cone (13), tab washer (16) and plan-
etary carrier (25) fitted, place a thickness of shim(s)
(26) greater than the space between the end of the
axle shaft (2) and the thrust face of washer (27) on
the planetary carrier (Fig. 25) to obtain a provisional
clearance of approximately 0.10 mm to 0.15 mm, in
order to carry out definitive shimming (see further
on).
Fig. 24
Issue 1 May 2001

Shimming (Fig. 25)

82. Press hard on the planetary carrier while simultane-
ously turning the trumpet several times.
83. Place a dial gauge on the planetary carrier (Fig. 25 -
26), the index positioned close to the axis of the
trumpet.
85. Using appropriate levers, move the planetary carrier
vertically (Fig. 26).
86. In relation to the clearance "J", remove a thickness
of shim(s) (26) necessary to obtain a pre-loading of:
P1 = 0.02 mm to 0.12 mm (Fig. 24) according to :
J - (0.02 to 0.012)
87. Definitively fit washer (27) and tighten bolt (28)
previously lightly smeared with Loctite 270 or its
equivalent, according to the torque shown in opera-
tion 57 (see § F). Fig. 26
28 27
26
25
16
13
Fig. 25
Issue 1 May 2001

J . Service tools
- 3376885M1 - Spacer (30) seal protector (Fig. 27).
- 3378151M1 - Cassette seal (3) insertion tool (Fig.
28).
Fig. 27
Fig. 28
Issue 1 May 2001

2. locally manufactured tools

- Cone and pusher for inserting snap ring (33) (Fig. 29).
85 30
35
R10 20
ø18
ø32,6 +0,1
+0,3
ø51-0-0,2
ø47-0-0,3
ø41
5
45
R10
180
30
ø51,2 +0,3
+0,1
ø61
ø71
0,5 x 45˚
Fig. 29
Issue 1 May 2001

Issue 1 May 2001

Rear axle - Trumpets with double reduction 6B04.1
6B04 Trumpets with double reduction
Contents
- General ________________________________________________ 3
B. Removing and refitting brake plate, crownwheels, spacer

and epicyclic reducer gears ______________________________ 11
C. Replacing the cassette seal ______________________________ 14
D. Disassembling and reassembling the planetary gears ______ 15
E. Replacing the axle shaft bearings ________________________ 16
F. Shimming the axle shaft bearings ________________________ 17
G. Service tools ___________________________________________ 19
Issue 1 May 2001

6B04.2 Rear axle - Trumpets with double reduction
20 31
47 44
24 18
15
51
25
Fig. 1
Issue 1 May 2001

Operation
General Special point
8260 and 8280 tractors are fitted with trumpets contain- - In order to maintain an operational clearance between
ing two epicyclic gear trains, also known as double the planetary gears, the sun gears and crownwheels,
reductions. the secondary sun gear (51) ‘floats’ on ball bearings (19)
These drive units allow for a higher reduction ratio and (49).
lower transmission torque.
They are housed in a compartment and are comprised of
the trumpet, two primary crownwheels (47) and two Kinematics (Fig. 1)
secondary crownwheels (15) and a spacer (48). The Primary epicyclic gear train
brake plate (30) partially closes the drive unit compart- - The primary planetary carrier (24) is integral via splines
ment. with the secondary sun gear (51) and comprises three
planetary gears (20) that engage with crownwheel (47)
Construction and primary sun gear (44) splined onto input shaft (31).
The axle shaft is supported by two bearings comprising
cups (8) (12) and bearing cones (7) (13) mounted in Secondary epicyclic gear train
opposition to each other. The input shafts (31) are of - The secondary planetary carrier (25) integral via splines
different lengths ; the long shaft is fitted in the left hand with axle shaft (2) possesses six planetary gears (18)
side trumpet. The crownwheels, spacer and brake plate in constant engagement with crownwheel (15) and
are positioned by pins (14). The pre-loading of the taper secondary sun gear (51). It receives movement coming
roller bearings is provided by shim(s) (26) placed at the from the primary epicyclic gear train to then transmit it
end of the axle shaft. Shaft (2) and planetary carrier (25) to axle shaft (2).
are held by washer (27) and bolt (28).
The oil tightness between the trumpet, crownwheels,
spacer and brake plate is provided by silicone seals
(Silicomet type).
The cassette seal (3) protects the outer bearing compris-
ing cup (8) and cone (7).
The oil splash lubrication for the mechanical assemblies
is provided by transmission oil coming from the shared
oil tank formed by the intermediate housing and the
centre housing. The centre housing is linked to the lower
part of the trumpet by an external transfer pipe. The brake
plate contains a port "O" (Fig. 2) allowing lubrication and
cooling of the discs by a flow of oil coming from the
booster circuit. The transmission oil within the trumpet is
kept at the correct level via an oblique pipe (56). This pipe
is located in the drive unit compartment and communi-
cates with the external transfer pipe.
The inner chamber of the trumpet is maintained at
atmospheric pressure by a breather pipe screwed onto
the left lift ram support. This breather pipe also ensures
the venting of the shared oil tank.
The input shaft (31) drives brake discs (35) via a splined
hub (32) held by snap ring (33).
Issue 1 May 2001


Parts list (50) Washer
(1) Bush (51) Secondary sun gear
(2) Straight shaft (52) O’ring
(3) Cassette seal (53) O’rings
(4) Thrust washer (54) Transfer tube
(5) Locating pin (55) Cup plug
(6) Circlip (56) Oblique pipe
(7) Bearing cone (57) Locating pin
(8) Bearing cup
(9) Washer
(10) Trumpet
Fig. 2
(11) Nut
(12) Bearing cup Fig. 3
(13) Bearing cone
(14) Pins
(15) Secondary crownwheel
(16) Tab washer
(17) Stop ring
(18) Secondary planetary gears
(19) Ball bearing
(20) Primary planetary gears
(21) Circlip
(22) Roller bearing
(23) Roller bearing
(24) Primary planetary carrier
(25) Secondary planetary carrier
(26) Shim(s)
(27) Lock washer
(28) Bolt
(29) Circlip
(30) Brake plate
(31) Input shaft
(32) Splined hub
(33) Snap ring
(34) Studs
(35) Brake discs
(36) Stud
(37) Studs
(38) Intermediary plate
(39) Drilled stop pin
(40) Bolt
(41) Stop pin
(42) Circlip
(43) Magnetic drain plug
(44) Primary sun gear
(45) Circlip
(46) Washer
(47) Primary crownwheel
(48) Spacer
(49) Ball bearing
Issue 1 May 2001

Rear axle - Trumpets with double reduction 6B04.5 Overall view
14 14 5
30 39 41
0
30
10 15 48 47 30
25 17 23 18 17 29 24 20 22 29
57
50
49
31
33
32
35 2
38
4
2 1 3 7 8 10 12 13
51 26 27 28 19 46 21 45 44 42 31
16 11 9 34 36 37
P1 = 0,02 / 0,12 mm
43 52 Parts list Fig. 3 Fig. 2
Issue 1 May 2001

6B04.6 Rear axle - Trumpet s with double reduction

29 50
2
Exploded view 17 6
18 48
23
17
49
56 4
52
25
16 43
13
12
15
8
7 14
1
53 42
9 11 34 3
44
40 54
53
55
29
10 20
22
40
40
21
46
28
9 11 36 19
27
31
26 47
51
39
14
45
9 11 37
24
41
41
53 54 53 5 33
32
35
38
35
30 Parts list Fig. 2 Fig. 3
Issue 1 May 2001

A . Removing and refitting the trum-

pet assembly
Removal
1. Drain the centre housing and the oil trapped in the
trumpet that is being removed.
Remark
- The drain plug (43) of the trumpet is located behind
the transfer tube (54) (Fig. 4).
2. Immobilise the tractor. Take off the wheel. Place an
axle stand beneath the centre housing.
54 43
Fig. 4
15 48 47 30
35
32
31
11
40
9
P
40
39 41
38
30 1
Fig. 5
Issue 1 May 2001


3. Remove the bolt (1) holding the cab and if necessary
also take out bolt (2) from the rear support above the
trumpet (Fig. 6). 1
4. If necessary, slightly raise the side of the cab and
check that there is no interference with nearby ele-
ments. Chock the cab using a suitably adapted axle
stand.
5. Remove bolts (1) and the stabiliser support (2) (Fig. 7).
Take off circlip (1) and remove the lower pin (2) of the
lift ram (Fig. 8). Using a strap, pull the ram away from
the trumpet.
6. Position a suitable support beneath the trumpet.
7. Remove nuts (11) and washers (9) without taking out
bolts (40).
Remark
- These bolts serve to hold the crownwheel, spacer
2
and brake plate assembly on the trumpet.
Fig. 6
8. Unstick and separate the trumpet assembly complete
with the input shaft (31), brake plate (30), crownwheel
(15) (17) and spacer (48) from the centre housing.
Recover the brake discs (35), the intermediate plate 1
(38) and the stop pins (39) (41) (Fig. 5).
Remark
- Brake piston ‘P’ remains in the housing (1) (Fig. 5).
Important
- Take care not to press the brake pedal concerned, or fit

a piston retainer tool on the centre housing (see section
6E01).
9. Remove the transfer tube (54) and discard the O’rings

(53). 2
Fig. 7
2 1
Fig. 8
Issue 1 May 2001

Refitting
Special points
- The studs (34) (36) (37), screwed into the centre
housing are of different lengths. Before fitting, their
threads must be lightly smeared with Loctite 270 or
equivalent (Fig. 9).
Important
- Place the studs in the housing, respecting their length

and location, according to Fig. 3:
. (34): Ø 16 mm - L 363 mm
. (36): Ø 16 mm - L 378 mm
. (37): Ø 16 mm - L 388 mm
10. Clean the site of the silicone seal on brake plate (30) Fig. 9
and the centre housing.
Check that all previous traces of sealing compound
have been removed. Properly dry the components.
11. Coat angle "D" of the centre housing (1) (Figs. 10 -11)
with a sealing compound (Silicomet type).
Reminder
1
- The diameter of the bead (seal) must be uniform,
small section and without joins.
12. Check that discs (35) slide normally on the hub (32).
Check that the stop pins (39) (41) are free in:
- the drilled holes of piston"P" and the intermediate
plate (38) (Fig. 5)
- the recesses of the brake plate (30) and the centre
housing (1) (Fig. 5).
13. Check for the presence of locating pin (5) on the D
centre housing.
14. Check that port "O" on the brake plate (30) is not
obstructed (Fig. 2).
15. Check for the presence of the radial drilled holes on Fig. 10
the intermediate plate (38).
16. On the trumpet, fit plate (38) by placing either side of
it a brake disc (35) on hub (32) and position the stop
pins (39) (41) (Fig. 5).
Remark
- The drilled pin is fitted in the upper recess of the
brake plate.
Fig. 11
Issue 1 May 2001


17. Fit new o’rings (53) smeared with miscible grease
onto the transfer pipe (54). Introduce the pipe into the
trumpet port.
18. With the help of a second operator and the support
equipment used for removal, engage the trumpet on
the studs. Turn the axle shaft and push the trumpet
until it mates with the centre housing. Check that the
end of the transfer tube (54) as well as the stop pins
(39) (41) are correctly positioned in their respective
grooves in the housing.
Place washers (9). Fit and tighten nuts (11) to a
torque of 247 - 253 Nm. Remove the support from
beneath the trumpet. Refit the lift ram. Replace the
stabiliser support and tighten the bolts to 480 - 640
Nm.
19. Refit the various elements that surround the trum-
pet. Refit the wheel and tighten the nuts or studs to
the correct torque depending on the version (see
section 2G01).
Tightening torque
- Cab fixing bolt (silent bloc): 200 - 260 Nm, Loctite
270 or equivalent.
20. Top up the oil level in the housings and check on the
transparent tube located on the left-hand side of the
centre housing.
21. Check the operation of the lift system. Carry out a
road test of the brake circuit.
22. Check the oil tightness of:
- the trumpet
- the O’rings (53) located on transfer tube (54).
Issue 1 May 2001

B . Removing and refitting brake

plate, crownwheels, spacer and
epicyclic reducer gears (Fig. 12) 42 33
Removal
23. Remove the trumpet assembly (see § A). 30 32
the input shaft (31) at the top (Fig. 13).
25. Remove the bolts (40). Unstick and remove the
brake plate (30). 31
44
26. If necessary, take off snap ring (33) and hub (32).
27. Disengage circlip (42) from its groove and remove
the primary sun gear (44). 21 46
28. Disengage circlip (21), take off washer (46) and
remove the input shaft (31) fitted with ball bearing 19 47
race (19).
29. Take off circlip (45). Take out the primary planetary
20 45
carrier (24). Remove the planetary gears (20) (see §
D).
30. Unstick and remove the primary crownwheel (47). 28 24
31. Immobilise the planetary carrier (25). Take off bolts
(28). Remove holding washer (27) and shims (26). 31
27
51
32. Disengage the secondary sun gear (51). Remove the
thrust washer (4).
49 48
6 26
18 25
15
16
31
40 40
F
40
Fig. 13 Fig. 12
Issue 1 May 2001


33. Take out the secondary planetary carrier (25). Re-
move the planetary gears (18) (see § D).
34. If necessary, extract bearing (19) from the input
shaft (31).
35. Unstick and remove the secondary crownwheel (15)
(see special points below).
Special points
- The reason for the secondary crownwheel (15) are
the large forces exerted, and its heat treatment is
different compared to that of the primary crownwheel
(47).
- In order to identify the crownwheels and avoid their
incorrect fitting, the perimeter of the secondary
crownwheel has two diametrically opposed ma-
chined flats "M" (Fig. 14).
- This crownwheel also possesses an additional
locating pin (57) (Fig. 2).
M
Refitting
36. Clean the components. Replace any parts found to 15
be defective. Remove all traces of previous sealing
compound in the internal angles of the trumpet, on
the crownwheels (15) (47), the spacer (48) and the
brake plate (30).
Special points
- If the replacement of the oblique pipe (56) is
necessary, lightly smear the end concerned with
Loctite 648 or its equivalent and introduce it into the
trumpet, the oblique profile turned towards bearing
(12) (13) (Fig. 15).
- The bearing cup plug (55) fitted at the end of the
channel (see exploded view) must likewise be
smeared with Loctite 542 or equivalent before in-
sertion.
37. Check for the presence of the tab washer (16). Fig. 14
38. Refit the secondary planetary carrier (25).
39. Refit the thrust washer (4) as in the overall view.
Refit the secondary sun gear (51) comprising ball
bearing (49), washer (50) and circlip (6).
40. Place pin (14) and the locating pin (57) in their res- 56
pective grooves located on the trumpet.
12 13
Fig. 15
Issue 1 May 2001

41. Coat the inner angle "B" of trumpet (10) with a

silicone sealing compound (Silicomet type) (Fig. 16).
Reminders
- The diameter of the bead (seal) must be uniform,
small in section and without joins. 30
- This fitting information also holds true for all later
sealing operations. E
42. Position the secondary crownwheel (15), with the
flats "M" (Fig. 14) along the horizontal axis of the 48 A
tractor.
43. If necessary, reassemble the secondary planetary C
gears (18) with bearings (23) and stop rings (17). 15
44. Refit the secondary planetary gears correctly posi-
B
tioned on the planetary carrier (25). Fit circlips (29)
(see § D). 10
45. Place the shim(s) (26) removed during disassembly
and refit the holding washer (27). Immobilise the Fig. 16
planetary carrier. Smear bolts (28) with Loctite 242
46. Coat the internal angles "A" and "C" of spacer (48) 56. Coat the internal angle "E" of the brake plate (30) with
with a silicone sealing compound (Silicomet type) a silicone sealing compound (Silicomet type) (Fig.
(Fig. 16). 16).
47. Position the spacer on the secondary crownwheel 57. Position the brake plate on the primary crownwheel
(15). (47).
48. Place the second pin (14) in its groove in the spacer. 58. Fit bolts (40) and tighten them to a torque of 90 - 120
49. If necessary, refit the primary planetary gears (20) Nm.
correctly positioned with bearings (22) on the corre- 59. Slide hub (32) onto shaft (31). Using suitable pliers,
sponding planetary carrier. Fit the circlips (29) (see § fit the snap ring (33).
D). 60. Refit the trumpet assembly (see § A).
50. Position the primary crownwheel (47) on the spacer
(48).
51. Slide the primary planetary carrier (47) onto the
secondary sun gear. Turn the planetary gears to
facilitate their engagement.
52. Fit circlip (45).
53. If disassembled, insert the ball bearing race (19) on
the input shaft (31).
54. Engage shaft (31) fitted with its bearing in the
secondary sun gear (51). Place washer (46) and
circlip (21).
55. Slide the primary sun gear (44) correctly oriented
(Fig. 2) on to shaft (31). Fit circlip (42).
Issue 1 May 2001

C . Replacing the cassette seal

3
61. Partially drain the trumpet concerned.
62. Chock the front wheels. Remove the rear wheel (see
section 2G01). Place an axle stand beneath the
trumpet.
Removal
Special points
- Model 8260 to 8280 tractors are fitted with axle shaft
with a diameter of 110 mm. The shape of this shaft is
different from that of the same diameter fitted to 8240
tractors (depending on option) and the 8250 fitted with 1
composite drive unit.
- Bush (1) (Fig. 17) has a larger bore and is referenced in Fig. 17
the spare parts catalogue.
- The cassette seal (3) (Fig. 17) retains the same charac-
teristics as that fitted to trumpets with composite drive
unit.
- The bore of the bush is smeared with Loctite 648 or 3
equivalent. The bush is placed on the shaft flush with
the thrust face of the bearing cone (7) (Fig. 18).
1
63. Using a locally manufactured tool, extract the cas-
sette seal (3) without leaving any marks on the
trumpet or external diameter of the bush (1) (Fig. 17).
Refitting
64. Clean the groove of the seal on the trumpet and the
bush (1).
65. Lightly smear the external diameter of the seal with 7
Loctite 648 or equivalent and moderately lubricate its
internal diameter with transmission oil. Fig. 18
66. Using service tool ref. 3378151M1 (see § G), insert
the seal. Wipe away any remaining traces of Loctite.
Remark
- The design of the service tool determines the
position of the cassette seal in its groove in the
trumpet.
Final operations
section 2G01).
68. Top up the oil level in the housings and check it on
the transparent tube located on the left-hand side of
the centre housing.
69. Road test. Check the oil tightness of the cassette
seal.
Issue 1 May 2001


the planetary gears
18
Disassembly
70. Remove the trumpet assembly (see § A) and the
epicyclic reducer gears (see § B).
20 23
Primary planetary carrier (24) (Fig. 20)
71. Note visually the shape of the planetary gears (20)
and roller bearings (22) (Fig. 19). Take off the circlips
(29). Remove the three planetary gears.
D
Secondary planetary carrier (25) (Fig. 20).
72. Note visually the shape of the planetary gears (28) D
and roller bearings (23) (Fig. 9). Take off the circlips
(29). Remore the six planetary gears. 22
Fig. 19
Reassembly
73. Check the components. Replace any parts found to
be defective.
74. Fit the planetary gears with their roller bearings and
respective snap rings. Refit the planetary gears on
the corresponding planetary carrier by turning the
clearance "D" on the bearings (Fig. 19) towards throat
"C" of the reducer gears (Fig. 20).
75. Fit the circlips (29) (Fig. 20)
76. Manually check the rotation of each planetary gear.
77. Refit the epicyclic reducer gears (see § B) and the
trumpet assembly (see § A).
25 24
29
C 20
18 29
Fig. 20
Issue 1 May 2001

E . Replacing the axle shaft bearings

79. Remove the brake plate, crownwheels, spacer and
epicyclic reducer gears (see § B).
Disassembly
80. Take off washer (16) and shaft assembly (2).
Remark
- The bearing cone (13) is free on the shaft.
81. Remove cone (13). Extract bearing cone (7).
82. Drive out the cassette seal (3).
83. Using an extractor or a locally manufactured tool,
remove the bearing cups (8) (12).
Reassembly
85. Lubricate the bores of the cups (8) (12) with trans-
mission oil.
86. Insert the cups into their respective bores thrusting
against the shoulder.
87. Lubricate the bore of the bearing cone (7) and insert
it so as to mate with the shoulder on shaft (2).
88. Lubricate the bearing cup (8).
89. Introduce the prepared shaft into the trumpet fitted
with its cups.
90. Lubricate and fit the bearing cone (13) and the tab
washer (16).
Final operations
91. Refit the secondary planetary carrier (25), thrust
washer (4), secondary sun gear (51) comprising
bearing (49), washer (50) and the circlip (6).
92. Carry out shimming of the bearings (see § F).
93. Complete the refitting of the epicyclic reducer gear,
spacer, crownwheels and brake plate (see § B).
95. Insert a new cassette seal (see § C).
section 2G01).
97. Top up the level of the housings and check the oil
level on the transparent tube located on the left hand
side of the centre housing.
Issue 1 May 2001

F . Shimming the axle shaft bearings

- Axle shaft (2), taper roller bearings (7) (8) and (12) (13),
trumpet, tab washer (16), secondary planetary carrier
(25), washer (4), ball bearing race (49).
Remark
- The pre-loaded shimming of the taper roller bearings of
the axle shaft is carried out using shim(s) (26) placed
between the end of the shaft (2) and washer (27) (Fig.
22).
Reminder
Fig. 21
- To carry out the correct shimming of the bearings, place
the trumpet in a vertical position (Fig. 21).
P1 =
0,02 / 0,12 mm
27 26
Fig. 22
Issue 1 May 2001

Preparation
98. Check for the presence of bearing cone (13), the tab
washer (16), the planetary carrier (25) and the
secondary sun gear (51) (Fig. 24).
Shimming (Fig. 24)

99. Press hard on the secondary sun gear while simul-
taneously turning the trumpet several times in
order to seat the bearing cones and cups.
100. Using an appropriate depth gauge (Fig. 23), meas-
ure distance "E" between side "A" of the ball bearing
race (49) and side "B" at the end of shaft (2).
101. Determine the thickness of shim(s) (26) to be fitted
to obtain a pre-loading of P1 = 0.02 to 0.12 mm
(Fig. 2), according to :
E - (0.02 to 0.12)
102. Place the previously selected shims on the end of Fig. 23
the shaft. Fit washer (27) on ball bearing race (49).
Smear bolts (28) with Loctite 242 or equivalent and
tighten them to a torque of 100 - 130 Nm.
A B E
51
49
2
25
16
13
Fig. 24
Issue 1 May 2001

G . Service tools
- 3378151M1 - Fitting tools for rear shaft's cassette
seal (Ø 110) (Fig. 25)
Fig. 25
Issue 1 May 2001

Issue 1 May 2001

Rear axle - Handbrake unit and control link 6C01.1
6C01 Handbrake unit and control link
Contents
- General ________________________________________________ 2
- Operation ______________________________________________ 2
A. Disassembling and reassembling the handbrake unit ______ 5
B. Disassembling, reassembling and adjusting the controls ___ 7
C. Disassembling, reassembling the lever and replacing the

cable ___________________________________________________ 9
Issue 1 May 2001

6C01.2 Rear axle - Handbrake unit and control link

Parts list
General (1) O’ring
The mechanical control assembly of the handbrake is (2) Bolt
fitted on drive pinion (9) located on the intermediate hou- (3) Link
sing. (4) Holding plate
(5) Bolt
It consists of a mechanism (16) placed between six (6) Intermediate plates
discs (14) that are integral with the drive pinion and four (7) Housing
intermediary plates (6). (8) Bolt
(9) Drive pinion
The mechanism housed in a unit (15) fixed to the rear (10) Friction ring
bearing carrier is composed of two cast-iron plates held (11) Pin
by springs and separated by ball bearings lodged in (12) Oil seal
raceways. (13) Bearing carrier
(14) Disks
It is operated via a rod (23) fitted on relay pin (26) by (15) Housing
means of relay cam (22) which is in contact with rod (19), (16) Spreader mechanism
itself thrusting against a second cam (31) integral via (17) Bolt
splines with pin (11) controlled by link (3). (18) Washer
(19) Rod
Remarks (20) Pin
- Depending on the type of tractor, the lubrication of the (21) Adjuster nut
handbrake discs is ensured by an oil mist coming from (22) Cam
a central channel and radial drilled holes machined into (23) Link
the drive pinion (see section 6D01, 6D02 or 6D03 (24) Clevis
depending on the version). (25) Pin
- This centre oil channel also serves to lubricate a needle (26) Pin
bearing on those tractors fitted with a creeper unit (see (27) Friction rings
section 6H01 depending on the version). (28) Special bolt
(29) Mecanindus pin
(30) Set screw
(31) Cam
(32) Spring
(33) O’ring
(34) Lever
Operation (35) Nuts
When the handbrake lever is pulled upwards, the cable (36) Grower washer
acts upon link (3) integral with pin (11) via splines. (37) Cable
Pin (11) pivots and turns cam (31) that pushes rod (19) to (38) Ratchet
thrust against a relay cam (22) that turns freely on pin (39) Quadrant
(26), thus causing the spreading of mechanism (16) by (40) Clevis
way of threaded link pin (23). (41) Rod
When the handbrake lever is in the off position, the link (42) Shouldered washer
(3) returns to its initial position by means of spring (32). (43) Washer
The adjuster nut of the mechanism is accessible via a (44) Push-button
plug screwed on to the top of the intermediary housing. (45) Spring
The oil tightness of housing (7) is provided by seal (12)
and that of pin (11) by o’ring (1). Fig. 1
Fig. 2
Issue 1 May 2001

Overall view
7 19 30 31 7 4
K K
K-K
6 16 14 13 2
L 5
LOCTITE 510
15 9
L
3
8 2 1 17 18 3 19 7
32
M
11
27 22 33 28 12 21
2 22
7 20
M
26 29 10 31 23
24
25
M-M
L-L Fig. 1
Parts list Fig. 2

Issue 1 May 2001
Exploded view 8200 SERIES TRACTORS
34
8
13
14
16
35 5 3
14
36 15
35
21
20
37
23 25
24 33
29
4
28 27
22
5
27
4
26
38 39
17
18
32
40
12
41
42 11
45
43 2
44
30
7 10 31 30 19
Issue 1 May 2001


the handbrake unit 15
Remark
- To carry out operations on the handbrake mechanism
comprising discs (14), intermediate plates (6) and T
mechanism (16), it is necessary to uncouple the tractor 14 5
and remove the intermediate housing as well as the
drive pinion. C
16
5
1. Uncouple the tractor between the gearbox and the 13
intermediate housing (see section 2C01). 6
2. Separate the intermediate housing from the centre 8
housing (see section 2D01). Fig. 3
3. Remove the creeper unit (if fitted) (see section 6H01).
If necessary, remove the sleeve and ratchet of the
Park Lock (depending on equipment) and the bearing
assembly / hydraulic pump drive pinion.
4. Remove the drive pinion and handbrake unit (see
section 6D01, 6D02 or 6D03 depending on the ver-
sion).
Disassembly
5. Remove circlip (5)
6. Loosen and remove bolts (8)
Separate the housings (13) (15).
7. Place the drive pinion on the workbench, the bevel
gear at the bottom.
8. Remove the discs, intermediate plates and the brake
mechanism.
Reassembly
9. Clean and check the components. Replace any parts
found to be defective or buckled.
Check that the central channel and radial drilled holes
of the drive pinion (depending on versions) are not
obstructed.
Check also, the oil discharge ports located at the base
of the handbrake unit housing.
Issue 1 May 2001


10. Place carrier (13) on the bearing cone of the drive
pinion, with the cup previously lubricated.
11. Correctly orient control"C". Refit mechanism (16) by
placing it between discs (14) and the intermediate
plates (6) as shown in the overall view. Correctly
position stops "T".
12. Assemble the handbrake unit (15) on bearing carrier
(13).
13. Fit bolts (8) previously lightly smeared with Loctite
270 or its equivalent and tighten to a torque of 120 -
160 Nm.
Final operations
15. Refit the drive pinion unit and handbrake (see
section 6D01, 6D02 or 6D03 depending on the ver-
sion).
16. Turn and fit axle (25) to mechanism (16) so as to
clear it easily. Fit the washer and a new split pin.
Adjust the control (see § B).
17. Refit the bearing / hydraulic pump drive pinion
assembly, the ratchet and the Park Lock sleeve
(depending on equipment). Fit the creeper unit (if
fitted).
18. Reassemble the intermediate housing and centre
housing (see section 2D01).
20. Check the correct operation of all the controls.
21. Check all the functions (mechanical and electrical)
of the handbrake lever.
22. Road test.
23. Check the oil tightness of the mating faces and the
hydraulic unions.
Issue 1 May 2001

B . Disassembling, reassembling and

adjusting the controls
Disassembly 27 22
24. Remove the entire unit (7) and rod (19). If necessary,
take out each component in the unit.
F F
Remark
- To take out pin (26) and cam (22), it is necessary to
uncouple the tractor between the gearbox and the
Reassembly
25. Reverse the order of the previous operations and
respect the following special points.
Fig. 4
Special points
On unit (7)
- Insert friction bush (10) using a locally manufactured
drift.
- Insert oil seal (12) in contact with unit (7) using a
suitable fixture. After inserting, lubricate the seal.
- lightly smear with Loctite 241 the Philips head bolt (30)
of cam (31).
- lightly smear with Loctite 510 the mating face of unit (7)
and the intermediate housing.
- Tighten bolts (2) to a torque of 25 - 35 Nm and bolt (17)
Note: During assembly, do not forget o’ring (1) that
provides oil tightness between pin (11) and the link
(3).
On cam (22)
- Insert the friction bush (27) flush with face ‘F’ (Fig. 4).
- Lightly smear bolt (28) with Loctite 542 (solely on an
assembly without an o’ring) and tighten to a torque of
25 – 35 Nm.
On cam (31)
- Moderately tighten set screw (30) smeared with Loctite
241.
On the brake mechanism (16)

- Fit pin (25) in such a manner as to provide clearance.
- Lightly smear the thread of link rod (23) with Loctite 270
and tighten it in clevis (24).
Issue 1 May 2001


Adjustment
- With cam (31) in contact with unit (7) (Fig. 5) via the port
located above the intermediate housing, act on nut (21)
in order to obtain a clearance "J" of 1.2 mm to 1.3 mm
between the discs, intermediate plates and mecha- 7 31
nism (Fig. 7).
26. Position link (3) on pin (11) to obtain a dimension of
225 mm to 250 mm between the centre of the cable
and cable holder (4) (position A - Fig. 6) by checking
that cam (31) is in contact with the housing (7).
27. Check that the travel of the link (3) falls between 30
mm and 45 mm with a force of 10 - 25 daN exerted
at the point where the cable is fixed (position B -
Fig. 6).
Remarks
- To adjust the tractor handbrake, take off the wheel Fig. 5
concerned and slightly tilt the cab to the left , taking care
not to damage any of the components attached to it.
Position an axle stand. 225 - 250 mm
- Remove the plug located above the intermediate hous-
ing.
- Using a locally manufactured short spanner, adjust nut 30 - 45 mm
(21) in order to obtain the travel stated in operation 27.
- After adjustment, check the free movement of the
tractor with the handbrake in the off position. 4
A B
Reminder
- Tightening torque for wheel nuts or studs (see section
2G01).
11 3
Fig. 6
J = 1,2 / 1,3 mm
Fig. 7
Issue 1 May 2001

C . Disassembling, reassembling the

lever and replacing the cable
Disassembling the handbrake lever (Fig. 9)
28. Disconnect the electrical connector (1) to the switch
and the handbrake cable (37) (Fig. 8).
29. Unscrew the push-button (44). 3
30. Recover washers (42) (43) and spring (45).
31. Remove the clevis assembly (40) and rod (41).
Note: If necessary, separate the rod and clevis. 1
32. Replace the quadrant (39) and ratchet (38) (Fig. 9).
37
Reassembly
33. Refit the lever. Reverse the disassembly operations.
34. Check the correct operation of the lever (see opera- Fig. 8
tion 37). If necessary, adjust the handbrake (see
§ B).
Replacing the cable

Removal 42 39
35. Disconnect the endsof the cable and sheath (Fig. 8).
Remove the cable.
44 43 45 41 40 38
Fig. 9
Issue 1 May 2001


Refitting
Note: If necessary, before refitting the new cable,
hold it vertically and inject a few drops of Vaseline 35 1 35 4
oil between the cable and sheath. Wait for several
moments for the oil to descend the length of the
cable.
36. Carry out the fitting of the cable on its respective
fixing points.
Remark
- Take care to place the lock washer (1) between
nuts (35) on cable holder (4) (Fig. 10) located above
the intermediate housing. This assembly avoids
any kinking of the cable during handbrake opera-
tion.
37. Check the following points to ensure correct opera-
tion of the handbrake lever:
- put the handbrake on, its initial travel should be Fig. 10
approximately 10 to 13 clicks of the ratchet with a
force of around 10 - 25 daN exerted at the point of
cable connection.
- the signal lamp on the dashboard should light.
- release the handbrake. The assembly should return
to the handbrake off position.
- the assembly should operate freely without any
"hard" points or sticking.
- in the handbrake off position, the dashboard light
must go out.
Reminder
- On tractors fitted with a Full Powershift gearbox, first
disengage the speed control of the Park Lock in order to
get the dashboard light to go out when the handbrake is
in the off position.
Issue 21
Issue May 2002
May 2001
Rear axle - Differential 6D01.1
6D01 Differential with standard bevel gear and

hydromechanical lock
Contents
- General ________________________________________________ 2
A. Removing and refitting the left-hand differential lock

carrier, disassembling and reassembling the
lock assembly __________________________________________ 5
B. Removing and refitting the right-hand differential

lock carrier _____________________________________________ 8
C. Removing and refitting the differential unit assembly ______ 9
D. Removing and refitting the planetary gears and sun

gears and disassembling and reassembling the
crownwheel ____________________________________________ 11
E. Adjusting and checking the backlash _____________________ 13
F. Shimming the differential unit ___________________________ 15
G. Removing and refitting the drive pinion ___________________ 18
H. Adjusting the position and shimming the drive pinion _____ 21
I. Service tools ___________________________________________ 25
Issue 1 May 2001

6D01.2 Rear axle - Differential

The differential assembly is formed by two halves
General holding four planetary gears and two sun gears. The drive
Reminder pinion, which bears the 4 WD drive pinion (17) (if fitted),
The 8210 - 8220 - 8240 and 8250 tractors are equipped is located in the intermediate housing. The adjustment of
with an identical centre housing. The intermediate hous- its position is carried out by shims (12) fitted between the
ing differs depending on the type of gearbox. differential lock carriers, the bearings (13) and the hou-
sing. The pre-loading of the bearings is obtained by
shim(s) (3) fitted between the bearing cone (1) and the
thrust washer (4). The pre-loading via shimming of the
Specifications
differential assembly is carried out via the intermediary
- Model 8210 – 8220 – 8240 and 8250 tractors
of a deflector (55) (equally serving as an adjustment
. Heavy Duty gearbox
shim) placed between bearing cup (57) and the left-hand
. narrow intermediate housing
differential lock carrier (38).
- Model 8210 – 8220 and 8240 tractors
. AG 150 Full Powershift gearbox
Backlash between the drive pinion and the crownwheel
. wide intermediate housing
is obtained by using shims (59) inserted between cup
- Model 8250 tractors
(32) and the differential half-housing (23).
. AG 250 Full Powershift gearbox
. wide intermediate housing (hypoid version)
Differential lock
Model 8210 - 8220 - 8240 and 8250 tractors are fitted with Arrangement and operation
a standard bevel gear and either a multidisc or hydro- - The left-hand differential lock carrier houses the diffe-
mechanical differential lock (depending on version). rential lock mechanism
- The system consists of a piston (58) and a mobile dog
In this section, we shall limit our description to the hydro- (48) integral via splines with the input sun gear in the
mechanical version. For the multidisc version, see sec- left-hand side trumpet housing.
tion 6D02. - The piston acts upon the mobile dog when the 17 bar
hydraulic circuit is pressurized via the solenoid valve
fitted to the right-hand cover. The piston moves and
pushes the mobile dog while compressing spring (47).
- The front teeth of the mobile dog engage with a fixed
Construction
dog (46) integral with the differential half-housing (23).
The bevel gear, its rotation provided by the gearbox
In this position, the input sun gears of the right-hand and
output shaft, drives the rear axle.
left-hand trumpets then turn at the same speed. When
The helical drive pinion is supported by two taper roller
the pressure is released, the mobile dog returns to its
bearings mounted in opposition.
initial position under the action of the spring.
The bearing cone (7) is force fitted on the drive pinion, and
cups (2) (10) are likewise force fitted into the interme-
diate housing (19) and bearing carrier (13). The bearing
cone (1), mounted free on the drive pinion, allows to fit
shims (3) required for shimming. The crownwheel is
fastened to the differential housing by rivets. The diffe-
rential assembly rotates on two taper roller bearings
supported by two lateral carriers centred by bushes (25)
(40) and fixed by bolts to the housing.
Issue 1 May 2001

Overall view

A B
Parts list (53) Finger
(1) Bearing cone (54) Bearing cone 55 46
(2) Bearing cup (55) Deflector (shim)
(3) Shim(s) (57) Bearing cone
50 57 59
(4) Thrust washer (58) Piston
(5) Circlip (59) Shim(s)
(61) Shouldered bush 52
(6) Intermediat plates (handbrake)
(7) Bearing cone
(8) Bolt Fig. 1 58
(9) Drive pinion
(10) Bearing cup 51 20
(11) Bolt Fig. 2 19 2 3 4 5 6
(12) Shim(s)
49 48 47 54 61 35
(13) Bearing carrier Fig. 3
(14) Discs
(15) Handbrake unit
(16) Mechanism 44 45
(17) 4 WD drive pinion (if fitted)
(18) Nut 8 43 22
(20) Deflector 42 23
(22) Crownwheel 7
(23) Differential half-housing 1 41 24
(24) Rivets 9
(25) Centring bush 34 34
(26) Bolt 18
(27) Right-hand carrier
40 25
(28) Spherical washer
(29) Planetary gear 16
(30) Sun gear 39 26
(31) Bearing cone 17
(32) Bearing cup 37 30
(33) Brace 10
(34) O’rings A B
(35) Shouldered bush 11
(36) Fixed coupler 31
(37) O’ring
13
(38) Left-hand carrier 27
(39) Bolt
(40) Centring bush 53 32
12
(41) Bolt
(42) Transfer tube
(43) O’ring 14
15
(44) Union
(45) Centre housing 38 29
15
(46) Fixed dog
(47) Spring 28
(48) Mobile dog
(49) Friction washer 33
(50) O’ring
(51) O’ring 36 23
(52) Circlip
Parts list Fig. 2 Fig. 3 Fig. 1 Parts list Fig. 1 Fig. 3 Fig. 2
Issue 1 May 2001

Exploded view
33
30
35 28
22
23
20 23
59
32
31 61
34
29
24 4
25 7 3
27 10 2
26 11 1
13
12
18
44
57
54
41 43
46 38
34 42
50
58
51 37
52
49
48 39
47
55
40
53

Fig. 3
Issue 1 May 2001

A . Removing and refitting the left-

hand differential lock carrier, disas-
sembling and reassembling the lock
assembly
Remark
It is possible to gain access to the following differential
lock components by removing only the left-hand trumpet
housing:
- differential lock carrier (38)
- piston (58)
- seals (50) (51)
- spring (47)
- mobile dog (48) 44
Fig. 4
Removing the left-hand differential lock car-
rier (38)
1. Remove the left-hand trumpet housing (see section
6B01, 6B02 or 6B03 depending on the version).
2. Disconnect the hydraulic feed pipe.
Unscrew union (44) and raise the transfer pipe (42)
(Fig. 4 - 5).
3. Remove the brake piston (see section 6E01)
4. Alternatively, unscrew bolts (39) on the differential
lock carrier. Place two diametrically opposed guide
studs "G" on the housing. Progressively extract the
differential lock carrier through the tapped holes and
two bolts "V" (Fig. 6) in order to progressively release
the spring (47).
5. Remove the differential lock carrier and recover the
spring, the mobile dog, the friction washer, possibly
42
cup (57) and deflector (55) (shim).
Fig. 5
V
39
V
Fig. 6
Issue 1 May 2001


Refitting
6. Check for the presence of centring bush (40), the
correct positioning of deflector (55) (shim) and cup
(57) in accordance with Fig. 7.
7. Fit new o’rings (34) (37).
8. Place the friction washer (49) and spring (47) on the
mobile dog. Fit the assembly in the piston. Slide the
differential lock carrier onto the guide studs "G"
previously fitted into the housing (Fig. 6) by position-
ing the hydraulic port of the differential lock upwards
and holding the spring in position.
9. Alternately and uniformly tighten the four bolts (39)
to a torque of 100 - 130 Nm. Remove the guide studs.
Fit and tighten the other bolts to the same torque.
10. Fit transfer pipe (42) and connection (44).
11. Refit the brake piston (see section 6E01).
12. Check the oil tightness of seal (34) on differential 57 55
lock carrier (38) (see section 6E01).
13. Refit the left-hand trumpet (see section 6B01, 6B02
or 6B03 depending on the version).
40
Fig. 7
58
Fig. 8
Issue 1 May 2001

Disassembling the lock assembly (Fig. 9)

14. Remove the differential lock carrier (see § A).
15. Take out cup (57). Note the orientation of the deflec-
tor (55) (shim) and remove the differential lock
carrier.
16. Take off circlip (52).
17. Drive out piston (58) from the differential lock carrier
using a compressed air jet (Fig. 8).
18. Take off the o’rings (37) (50) and (51).
19. If necessary, unscrew the finger (53).
53 52
Reassembly
20. Check and clean the components. Replace any
parts found to be defective. 50 58
21. If finger (53) has been removed, lightly smear with
Loctite 221 then refit and tighten it in the differential
lock carrier (38).
51
22. Coat the o’rings (50) (51) with miscible grease, in
order to place them correctly in the bottom of their
respective grooves.
23. Using a plastic hammer, insert the piston (58) into 57
the differential lock carrier (38) (Fig. 10) while res-
pecting the location of the finger (53).
24. Fit circlip (52), deflector (55) (shim) while respecting
its orientation (Fig. 7). Place bearing cup (57). 55
25. Refit the differential lock carrier on to the centre
housing (see § A).
26. Test the oil tightness of the seals (50) (51) and 37
differential lock carrier (38) mounted on the locking
piston.
Reminder
- If the piston (58), seals (50) (51) or carrier (38) have
been disassembled, it is recommended to carry
out an hydraulic test of the whole hydraulic assem-
bly and of the transfer tube after reassembly. Fig. 9
58
38
Fig. 10
Issue 1 May 2001


Hydraulic test
- Use a pressure gauge that has previously been tested
for pressure tightness (Fig. 11).
- Supply the circuit with compressed air up to around 5
bar, in order to check the reaction of the piston. Adjust
the pressure to approximately 0.3 bar. Carry out the
hydraulic test.
- Close the valve. For approximately 1 minute, no drop in
pressure must be observed on the pressure gauge.
27. When the test is completed, remove the pressure

gauge and fit the original pressure pipe.
28. Refit the trumpet housing (see section 6B01, 6B02
44
Fig. 11
B . Removing and refitting the right-

27
hand differential lock carrier
Remarks 25
- The access to the right-hand differential lock carrier
(27) is similar to that of the left-hand differential lock
carrier (38).
- In order to maintain the crownwheel assembly in
position, it is recommended to screw two diametri-
cally opposed guide studs "G" into the tapped holes
holding the differential lock carrier on to the housing,
with their ends abutting against the differential half-
housing (23). 34
Removal Fig. 12
29. Remove bolts (26).
30. Using the two ‘V’ bolts in the tapped holes of the
carrier, extract the latter from the housing and
remove it, as described in the procedure used for the
left-hand carrier (Fig. 6).
Refitting
31. Check for the presence of centring pin (25) and O’ring
(34) (Fig. 12).
32. Uniformly and alternately, tighten the four bolts (26)
to a torque of 100 - 130 Nm. Take out the guide studs.
33. Check the oil tightness of seal (34) on carrier (27)
(see section 6E01)
Issue 1 May 2001

C . Removing and refitting the differ-

ential unit assembly
36
Preparation for removal
34. Split the tractor between the intermediate housing
and the centre housing (see section 2D01).
35. If necessary, separate the PTO housing from the
centre housing (see section 2E01).
36. Remove the trumpet housings (see section 6B01,
6B02 or 6B03 depending on the version).
37. Take off union (44) and raise the transfer tube (42)
(Fig. 4 - 5). Unscrew the ground speed sensor to
avoid interference with the crownwheel.
38. Remove the brake pistons (see section 6E01).
39. Place and tighten sling ref. 3378116M1, (see § I) in
position 1 (this position corresponds to a differential
assembly with a hydromechanical differential lock Fig. 13
and a rear axle with a Full Powershift or Heavy Duty
gearbox). Using the sling, hold the differential as-
sembly in the axis of the left and right-hand carriers
(27) (38).
Removing the differential unit

40. Remove bolts (26) (39) from the differential lock
carriers and fit the guide bolts "G" in accordance with
Figure 6.
Extract and remove the differential lock carriers
using the tapped holes and the two bolts "V" as
shown in Figure 6.
Recover the differential lock spring (47) fitted in the
left-hand differential lock carrier (38).
41. Remove the o’rings (34).
42. Take out the lock assembly and the differential (36)
from the centre housing (Fig. 13).
Refitting
Note: Since space is limited around the differential
unit, it is vital to fit the auxiliary spool valve and lift
control valve the oil return pipe in the housing (45)
before refitting the unit..
43. Using the sling, introduce the differential assembly
into the centre housing and hold it in the axis of the
trumpets.
44. Refit the left and right-hand side differential lock
carriers (see § B and A).
45. After fitting the differential lock carriers, manually
check the rotation of the differential assembly.
Issue
Issue21 May 2002
December 2000

46. Refit the brake pistons (see section 6E01).
Special point
- If the carrier (1) of the ground speed sensor (2) has been 1 3
removed, position the carrier previously lightly smeared
with Loctite 510 or its equivalent, with the offset of the
sensor turned towards the longitudinal axis of the
centre housing as shown in Fig. 14. Tighten the bolts (3)
previously lightly smeared with Loctite 542 to a torque
of 25 - 35 Nm.
Remarks
- The end of the sensor must always be placed above the
teeth of the differential crownwheel. 2
- Fit and adjust the ground speed sensor lightly smeared
with Loctite 577 (Sensor Sealing or equivalent).
Fig. 14
Final operations
47. Refit the trumpet housings (see section 6B01, 6B02
48. If the PTO housing has been removed, assemble it
with the centre housing (see section 2E01).
49. Couple the tractor between the intermediate housing
50. Check the correct operation of all the controls (me-
chanical, hydraulic and electronic).
51. Carry out a road test. Check the oil tightness of the
mating faces and hydraulic unions.

D . Removing and refitting the plan-

etary gears and sun gears and dis-
assembling and reassembling the
crownwheel
46
52. Remove the differential unit (see operations 34 to
42).
53. Remove the fixed dog (46) (Fig. 15).
Removal
54. Separate the differential half-housings (23) (Fig. 15).
Note: These components both bear the same 23
number. They must always be fitted as pairs.
Fig. 15
55. Remove the sun gears (30), planetary gears (29),
washers (28) and the differential brace (33) (Fig.
15A).
56. If necessary, drive cup (32) off the differential half-
housing (23), recover the shim(s) (59). Extract and 29 33 61
discard the deflector (20).
35 30 28
Fig. 15A
Issue 1 May 2001


Disassembling the crownwheel
- The replacement of the crownwheel automatically
requires replacement of the drive pinion.
- Both parts bear the same number. 24
- They must always be fitted as pairs.
- The original factory parts are assembled using rivets
- During repairs, these rivets are replaced by nuts and
bolts and are referenced in the spare parts catalogue.
57. Centre punch each rivet (24) (on toothed side of

crownwheel). Using a 5 mm drill, drill out the rivets
to a depth of 12 mm (Fig. 16). Carry out a second
drilling operation using a 12 mm drill to the same
depth. Drive out the rivets using an appropriate drift
(Fig. 17).
Fig. 16
Refitting the crownwheel
58. Clean the mating faces of the new crownwheel (22)
and differential half-housing (23) as well as their nuts
and bolts.
59. Lightly smear the first few threads of the bolts with
Loctite 270 and place them in the crownwheel and
housing.
60. Tighten the nuts to a torque of 150 - 200 Nm.
Refitting planetary gears and sun gears

Special points
- If replacement of the friction bushes (35) (61) is neces-
sary, insert the new bushes lightly smeared with
Loctite 638 or equivalent, using a suitable fixture.
- Check after insertion that the lubricating ports have not
been blocked by Loctite.
- If necessary, insert deflector (20) and cup (32) (see
Fig. 17
operation 66).
61. Refit the planetary gears and sun gears. Carry out
operations 54 to 55 in reverse order.
62. Refit the fixed dog (46).
63. Lightly smear bolts (41) with Loctite 270 or its
equivalent and tighten them to a torque of 130 Nm.
64. Refit the differential assembly (see operations 43 to
45) and the brake pistons (see section 6E01).
Final operations
65. Finish the refitting of the different assemblies. Carry
out operations 47 to 51.
Issue 1 May 2001

66. Place the previously selected shim(s) (59) in the bore

E . Adjusting and checking the back- of the half-housing (23). Insert the deflector (20) and
lash cup (32) (Fig. 18).
Remarks
Reminder - The deflector serves as a guide for centring the
- The backlash between the crownwheel and drive pinion shims. It is inserted using the cup and an appropri-
ensures reliability of the bevel gear and the correct ate locally manufactured tool. This method allows
operation of the assembly. This clearance must be the deflector to rest against the cup both during and
checked after: after its insertion.
. adjusting the bevel gear distance - When the operation is completed, check that the
. shimming the differential unit. cup is thrusting on the shim(s) and in contact with
the deflector.
Disassembly 67. Refit the right-hand differential lock carrier and shim
- Using an appropriate extractor, remove cup (32) and the differential unit (see § F).
Pre-adjustment
- The thickness of the shim(s) "E" required to obtain the
correct backlash is calculated as follows: E = Dc + 0.10
mm
E: thickness of shim(s) (59) to be fitted
Dc: crownwheel offset
Remark
- The Dc (example shown: -0.40) engraved on the exter-
nal diameter of the crownwheel (Fig. 18) after the
pairing number and letter (39 K) may range between 0
and -0.60 mm.
Special point
- When calculating "E" do not take the negative sign pre-
ceding the Dc into consideration (Fig. 18).
59 32
20 40
K - 0,
39
23
Fig. 18
Issue 1 May 2001


Checking
- Couple and provisionally fix the intermediate housing to
the centre housing using several diametrically opposed
bolts tightened to a torque of 540 - 680 Nm.
- With the PTO housing taken off, through the rear
opening of the centre housing (45), place the index of a
dial gauge half way across the length of a tooth of the
crownwheel (Fig. 19).
- Check that the backlash is between 0.15 mm and 0.45
mm. Carry out this check at three points around the
crownwheel.
Important
- If the backlash is incorrect, the adjustment principle is
to reduce or increase the thickness of shim(s) (59).
- In this case, select and fit a different thickness of
shim(s). Carry out the shimming of the differential unit Fig. 19
again in order to obtain the pre-loading of bearings (31)
(32) and (54) (57).
- Check a second time, the backlash between the drive
pinion and the crownwheel.
- When the final adjustment has been obtained, go on
with the refitting operations.
Issue 1 May 2001

F . Shimming the differential unit

Note: If the centre housing (45), crownwheel (see § 3378117 M1
D), taper roller bearings and carriers (27) (28) have
been replaced, the differential unit must be shimmed.
Check beforehand that the shim(s) (59) used for the
backlash (see § E) are fitted in the half-housing (23)
and cup (32).
Shimming preparation
68. Place the differential assembly previously fitted
with bearing cone (54) in the housing using sling ref.
3378116M1 (see § I). Screw two diametrically op-
posed guide studs into the centre housing.
Assembly of the right-hand differential lock Fig. 20

carrier
- Insert the carrier (27) fitted with a new o’ring (34) using
four bolts (26). Remove the guide studs. Finish refitting
the four bolts and tighten to a torque of 100 - 130 Nm.
69. At the location of the left-hand side differential lock

carrier, place tool ref. 3378117M1 (see § I), adapted
for the standard differential unit with hydromechanical
differential lock. Using two bolts, fix the tool onto the
housing (Fig. 20).
70. Tighten the centre bolt to 10 Nm (Fig. 20).
Note: Turn the crownwheel several times to seat
the cones correctly in the cups. Check the tight-
ening torque of the centre bolt again.
Issue 1 May 2001


Dimension to be measured on the housing (45) (Fig.
21 - 22) 3378117 M1
71. Using an appropriate depth gauge, measure dimen-
sion "B" and determine dimension "C" between
bearing cup (57) and the seating face of the carrier
(38) on the housing (Fig. 22):
C = B - 10 mm (10 mm is the thickness of tool, ref.
3378117M1).
Dimension to be measured on differential lock car-

rier (38) (Fig. 23)
72. Using appropriate tools (depth gauge, calliper, rule)
so as order to carry out the measurement under the
best conditions, measure dimension "Y".
57
Fig. 21
38
3378117M1
Y
57
57
45
38
Fig. 23 Fig. 22
Issue 1 May 2001

73. Calculate distance "E" (Fig. 24) between the seating

faces of bearing cup (57) and carrier (38):
E=C–Y E
74. Fill in space "E" with a deflector (shim) of a thickness 55 38 57
shown in the following table, so as to obtain a P2 pre-
loading of 0.05 mm to 0.15 mm (Fig. 24).
Final operations
75. Remove the tool and the bearing cup (57).
76. On differential lock carrier (38), check for the pre-
sence of centring bush (40) and place the deflector
(55) (shim) determined in operation 74 and cup (57)
in accordance with Figure 7.
77. Insert the carrier. Carry out operations 7 to 9.
78. After fitting the differential lock carriers, manually
check the rotation of the differential assembly.
P2 =
0,05 / 0,15 mm
Fig. 24
Reference No. of punch E (mm)

marks (dots)
57
187 689 M1 0 0,73 - 0,78
892 173 M1 1 0,864 - 0,914
892 172 M1 2 0,991 - 1,041
Punch
892 171 M1 3 1,118 - 1,168 marks
892 170 M1 4 1,245 - 1,295 (dots)
191 124 M1 5 1,37 - 1,42
191 125 M1 6 1,49 - 1,54
521 401 M1 7 0,61 - 0,66
Issue 1 May 2001

G . Removing and refitting the drive

pinion 18
79. Uncouple the tractor between the intermediate hous-
ing and the centre housing (see section 2D01).
80. Remove the creeper unit (if fitted) (see section
6H01). Free the ratchet of the Park Lock transmis-
sion lock (if fitted) (see section 6F01).
81. Locate the position of and take out the sleeve linking 3378119M1
the drive pinion and the lower shaft. 3378118M1
82. Remove the hydraulic pump bearing / drive pinion
assembly.
Removing the drive pinion Fig. 25

83. Disconnect control pin (25) of the handbrake mecha-
nism (see overall view, section 6C01).
84. Release and immobilise nut (18) using spanner, ref.
3378118M1 (see § I). Place special socket, ref.
3378119M1 (see § I), on the end of the drive pinion 11
(Fig. 25) and turn it clockwise. G
85. Remove bearing cone (1), shims (3) and thrust
washer (4).
86. Take out two diametrically opposed bolts (11) on 13 V
bearing carrier (13). In their place screw two guide
studs "G" (Fig. 26) into the tapped holes.87. 11
Extract carrier (13) using two bolts "V" of sufficient
length (Fig. 26) placed in the tapped holes.
88. Take off the carrier (13) assembly / unit (15), shims V G
(12) and 4 WD pinion (17) (if fitted). Visually note the
position of the components.
89. Remove circlip (5). Unscrew and remove bolts (8).
Separate the carrier (13) and the unit (15) (see
section 6C01).90. Remove the discs (14), the Fig. 26
intermediate plates (6) and the handbrake mecha-
nism (16) (see section 6C01).
91. If necessary, extract the bearing cups (2) (10) and
cone (7) on the drive pinion.
Issue 1 May 2001

Refitting the drive pinion

Note: If the drive pinion (see § D – Disassembly of the
crownwheel), taper roller bearings (7) (10) (1) (2),
bearing carrier (13), thrust washer (4) and intermedi-
ate housing (19) have been replaced, it is essential to
adjust the position of the drive pinion (bevel dis-
tance) and then shim the taper roller bearings see §
H).
93. If bearing cone (7) has been disassembled, force fit
it to thrust against the drive pinion and cup (10) in
contact with bearing carrier (13), using a press and
an appropriate fixture.
94. Lubricate the taper roller bearings (7) (10) with
transmission oil.
95. Refit mechanism (16), the intermediate plates (6)
and discs (14). Assemble unit (15) and carrier (13)
(see section 6C01).
the tapped bolt holes (11).
97. Position and slide the shims (12) on to the guide
studs.
98. Check that the 4 WD drive pinion (17) (if fitted) is
oriented as shown in the overall view. Correctly
position the carrier assembly (13) and unit (15) on
the guide studs. Turn the drive pinion so as to
engage the splines in pinion (17). Continue to push
the unit assembly until it reaches its inserted
position.
99. Use the remaining bolts (11) and insert uniformly
and alternately the carrier assembly (13) and unit
(15). Remove the guide studs. Lightly smear bolts
(11) with Loctite 270 and tighten them to a torque
of 100 - 130 Nm.
100. Check that carrier (13) is in contact with shims (12).
101. It is essential to place thrust washer (4) against
shoulder "E" of the drive pinion (Fig. 30). Slide on
shims (3). Lubricate the bearing cone (1) with
transmission oil and fit it on to the drive pinion in
contact with the shims.
102. Degrease the threads of nut (18) as well as those
on the drive pinion.
Issue 1 May 2001


103. Lightly smear the threads of the nut with Loctite
270 or its equivalent and immobilise it using span-
ner, ref. 3378118M1. Using socket, ref. 3378119M1,
turn the drive pinion anti clockwise and tighten it to
a torque of 200 - 250 Nm.
Important: Take care to correctly position the
torque wrench. Remove the tool. Manually
check the rotation of the drive pinion. Lock the
nut by bending the lock washer into the grooves
of the pinion without breaking it, using an
appropriate tool.
104. Fit pin (25) into the handbrake mechanism, cor-
rectly positioned to provide clearance. Place the
washer and retaining pin. Adjust the control (see
section 6C01).
Final operations
105. Refit the hydraulic pump bearing / drive pinion
assembly.
106. Refit the ratchet and locking sleeve of the Park
Lock transmission (if fitted). Refit the creeper
gearbox reducer gear (if fitted). Adjust the fork (see
section 6H01).
107. Re-couple the tractor between the intermediate
housing and the centre housing (see section 2D01).
Note: If the crownwheel and drive pinion have
been replaced, check the backlash (see § E).
108. Check the operation of all the controls.
110. Check the oil tightness of the mating surfaces.
111. Check the oil tightness of the hydraulic unions.
Issue 1 May 2001

H . Removing and refitting the drive

pinion
Reminder
- It is essential to adjust the position of the drive pinion
before carrying out shimming of the taper roller bearings
(7) (10) and (1) (2). Under no circumstances, this
adjustment must be modified without readjusting the
shimming of the drive pinion bearings.
112. Using a press, force fit cup (10) thrust against
bearing carrier (13).
Using a suitable fixture, insert cup (2) to thrust
against housing (19). Screw in two diametrically
opposed guide studs into the tapped bolt holes (11).
Fit the carrier alone without shims (12). Alterna-
tively and progressively, tighten the four bolts (11)
Check that carrier (13) is in contact with the
intermediate housing (19).
113. Using a press and an appropriate fixture, force fit
cone (7) to thrust against the drive pinion.
transmission oil.
115. Temporarily fit the drive pinion without shims (3)
but with thrust washer (4) placed between the
bearing cone (1) and nut (18)
116. Pre-tighten the nut to a torque of 30 - 50 Nm using
wrench, ref. 3378118M1 and socket, ref.
3378119M1 (Figs. 33 -34, § I) taking care to cor-
rectly position the torque wrench.
117. Turn the drive pinion several times to correctly seat
the bearing cones in the cups. Check again the
correct pre-tightening of nut (18).
Issue 1 May 2001


Adjusting the position of drive pinion
The thickness of shims (12) required to position the drive
pinion is calculated as follows:
E = Z – (X + Y) where:
E: Is the thickness of shims (12) to be fitted, tolerance

± 0.05 mm.
Z: Is the nominal dimension between the rear face of
the intermediate housing (19) and the axis of the
differential crownwheel (22) (Fig. 27).
Note: This dimension is stamped inside the
housing in the horizontal axis of the differential
unit (Fig. 28).
Y: Is the nominal dimension of the positioning of the
drive pinion = 139.00 (Fig. 28).
X: Is the dimension measured between the endof the
drive pinion and the rear face of the intermediate
housing (Fig. 29).
Note: The drive pinion and the crownwheel are
matched pairs with a number and letter engraved
on each component.
Z
19 X
Y
18
39 K 22
39 K
11
13
19 E 12
Fig. 27
Issue 1 May 2001

Procedure (Operations 118 to 119)

118. Using a depth gauge, measure dimension X (Fig.
29).
119. After having taken the measurement, use the
formula to determine E, the thickness of the shim(s)
(12) to be fitted in order to correctly position the
drive pinion.
Checks
- Temporarily refit the assembly fitted with the
previously determined shims and measure di-
mension X again.
- Check that X + Y does in fact equal Z.
120. Remove the drive pinion and bearing carrier (13).
121. On bearing carrier (13), refit the mechanism, the
intermediate plates, the discs and unit (15). Refit
the assembly on the intermediate housing (19).
Carry out operations 94 to 100 again. Fig. 28
Reminder
- Carry out the shimming of the drive pinion taper
roller bearings.
Fig. 29
Issue 1 May 2001


Shimming taper roller bearings (7) (10) and
(1) (2) of the drive pinion
122. On the drive pinion, slide the thickness of shims (3)
required to obtain a provisional clearance of 0.10
mm to 0.15 mm maximum, in order to prepare P1 18 1 3 4
shimming.
Note: The thrust washer (4) must be placed
against shoulder E of the drive pinion (Fig. 30).
123. Lubricate bearing cup (2). Fit bearing cone (1).
124. Using wrench, ref. 3378118M1and socket, ref.
3378119M1, temporarily tighten nut (18) to a torque
of 30 - 50 Nm.
125. Place the index of the dial gauge on the tapered end E
of the pinion (Fig. 30).
126. Pull strongly on the pinion via the front of the P1 0,04 / 0,10 mm
intermediate housing while alternately turning the
pinion left and right to correctly seat the bearing
cones in their cups.
127. With the assistance of another operative, set the
dial gauge to zero.
128. Repeat operation 126 but this time pushing. 18 1 7
129. In relation to the clearance measured, select a new
thickness of shims (3) in order to obtain pre-loading
(Fig. 30):
P1 = 0.04 mm to 0.10 mm
130. Loosen and take off nut (18).
131. Slide the shims (3) selected during operation 129
between thrust washer (4) (see note, operation
122) and bearing cone (1).
of the drive pinion. Fit and definitively tighten the 10
nut, its threads previously lightly smeared with
Loctite 270, to a torque of 200 - 250 Nm. 11
133. Manually check the rotation of the drive pinion.
134. Lock the nut by bending its lock washer into the 2 13 12
grooves of the pinion without breaking it, using an
appropriate tool.
Fig. 30
Issue 1 May 2001

I . Service tools
- 3378116M1 – Differential unit sling (Fig. 31)
- 3378117M1 – Shimming tool (Fig. 32)
- 3378118M1 – Locking wrench for drive pinion nut
(Fig. 33)
- 3378119M1 – Drive pinion tightening socket (Fig.
34).
Fig. 31
Fig. 32
Fig. 33 Fig. 34
Issue 1 May 2001

6D02 Differential with standard bevel gear

and multidisc lock
Contents
- General ________________________________________________ 2
A. Removing and refitting the carriers _______________________ 5
B. Removal and refitting the differential unit assembly _______ 7
C. Removal and refitting the multidisc lock __________________ 10
D. Removal and refitting the planetary gears and sun

crownwheel ____________________________________________ 12
E. Adjusting and checking the backlash _____________________ 14
H. Adjusting and shimming the drive pinion _________________ 21
I. Service tools ___________________________________________ 24
Issue 1 May 2001


thrust washer (4). The pre-loading via shimming of the
General differential assembly is carried out via shims (55) placed
Reminder between bearing cone (54) and the left-hand carrier (38).
The 8210 - 8220 - 8240 and 8250 tractors are equipped Backlash of the drive pinion and the crownwheel is
with an identical centre housing. The intermediate hous- obtained by using shims (59) inserted between cup (32)
ing differs depending on the type of gearbox. and the differential half-housing (23).
Specifications Differential lock

- Model 8210 - 8220 - 8240 and 8250 tractors The multidisc lock system, located on the left-hand side
. Heavy Duty gearbox of half-housing (23), comprises:
. narrow intermediate housing - a unit (46) housing the discs (49) and intermediate
- Model 8210 - 8220 and 8240 tractors plates (48),
. AG 150 Full Powershift gearbox - a hub (53) integral via splines with the left-hand trumpet
. wide intermediate housing input sun gear,
- Model 8250 tractors - a cover (52) made up by piston assembly (58) and
. AG 250 Full Powershift gearbox supported by taper roller bearings (54) (57).
. wide intermediate housing (hypoid version) The piston chamber lodged in the cover communicates
with a channel in the left-hand carrier, allowing (17 bar)
low pressure to act upon the piston. Two seal rings (56)
Model 8210 - 8220 - 8240 and 8250 tractors are fitted with ensure the oil tightness of the circuit.
a standard bevel gear and either a multidisc or hydro-
mechanical differential lock (depending on version).
Operation
In this section, we shall limit our description to the multi- Clutched position
disc version. For the hydromechanical version, see When the differential lock solenoid valve is activated, the
section 6D01. pressure flows through the channels of carrier (38) and
cover (52) and enters piston chamber (58). The piston
compresses the intermediate plates (48) and discs (49)
Construction integral respectively via stops and splines in lock unit
The bevel gear, moved in rotation by the gearbox output (46) and hub (53).
shaft, drives the rear axle. In this ‘clutched’ position, the input sun gears of the right-
The helical drive pinion is supported by two taper roller hand and left-hand trumpets turn at the same speeds.
The bearing cone (7) is force fitted on the drive pinion, and Declutched position
cups (2) (10) are likewise force fitted into the interme- When the pressure is cut, the piston returns, the discs
diate housing (19) and bearing carrier (13). The bearing and intermediate plates are no longer compressed and
cone (1), mounted free on the drive pinion, allows to fit allow the sun gears and planetary gears to carry out their
shims (3) required for shimming. differential function.
The crownwheel is fastened to the differential housing by
rivets. The differential assembly rotates on two taper
roller bearings supported by two lateral carriers centred
by bushes (25) (40) and fixed by bolts to the housing.
The differential assembly is formed by two halves
holding four planetary gears and two sun gears. The drive
pinion, which bears the 4 WD drive pinion (17) (if fitted),
is located in the intermediate housing. The adjustment of
its position is carried out by shims (12) fitted between the
differential lock carriers, the bearings (13) and the hous-
ing. The pre-loading of the bearings is obtained by
shim(s) (3) fitted between the bearing cone (1) and the
Issue 1 May 2001

Overall view

A B
Parts list (54) Bearing cone

(1) Bearing cone (55) Shims
(2) Bearing cup (56) Seal ring 60 41 59
(3) Shim(s) (57) Bearing cup
(4) Thrust washer (58) Piston
(5) Circlip (59) Shim(s)
(6) Intermediate plates (handbrake) (60) Rivet
(7) Bearing cone (61) Shouldered bush
(8) Bolt 21 20
(9) Drive pinion Fig. 1 Fig. 2 Fig. 3
(10) Bearing cup
(11) Bolt 56 57 61 35
(12) Shim(s) 19 2 3 4 5 6
(13) Bearing carrier
(14) Discs
44 45
(15) Handbrake unit
(16) Mechanism
(17) 4 WD drive pinion (if fitted) 43 22
(18) Nut
8 42 23
(20) Deflector
(22) Crownwheel 7 52 24
(23) Differential half-housing
(24) Rivets 1 34 A 34
(25) Centring bush 9
(26) Bolt 40 25
(27) Right-hand carrier 18
(28) Spherical washer 39 26
(30) Sun gear
37 B 30
(31) Bearing cone
(32) Bearing cup 17
(33) Brace 54
(34) O’rings 11
(35) Shouldered bush 53 31
(36) Fixed dog 10
(37) O’ring 55 27
(38) Left-hand carrier 13
(39) Bolt 51 32
(40) Centring bush
(41) Bolt 12 58 35
(42) Transfer tube
(43) O’ring 38 29
14
15
(44) Union
(45) Centre housing
15 48 28
(46) Differential lock disc unit
(47) Bolt
(48) Intermediate plates (differential lock) 50 33
Fig. 2 Fig. 3 Fig. 1
Parts list
(49) Discs
(50) O’ring 49 46 47 36 23
(51) O’ring
(52) Cover
(53) Hub Parts list Fig. 1 Fig. 3 Fig. 2
Issue 1 May 2001

Exploded view
33
30
35 28
22
23
20 23
59
32
31 61
34
29
24 4
25 7 3
27 10 2
26 11 1
13
12
18 53
48
49
41 44
46
47 43
42
56
37
54
50 39
58
38
51
40
34
55 Fig. 1
57
52
Parts list Fig. 2
Fig. 3
Issue 1 May 2001

A . Removing and refitting the car-

riers
Left-hand carrier
Note: It is possible to carry out maintenance on
carrier (38) and seal rings (56) of the differential lock
by removing only the left-hand trumpet housing.
Removal
2. Take off union (44) and raise the transfer tube (42) (Fig.
4). 42
3. Remove the brake piston (see section 6E01).
4. Remove bolts (39) from the left-hand carrier as shown
in Figure 5. Place two diametrically opposed guide
studs "G" on the housing, their ends resting against
cover (52) of the lock unit.
5. Extract the carrier through the tapped holes and using
two bolts "V" (Fig. 5), take it off and recover cone (54)
and shim(s) (55).
Note: The guide studs "G" hold and centre the
differential assembly (36) in the housing (Fig. 6).
Do not unscrew the guide studs in order not to
throw off centre the assembly and damage the
seal rings (56) during refitting of the carrier.
44
Fig. 4
36
G V
52 V
G
Fig. 5 Fig. 6
Issue 1 May 2001


Refitting
6. Check for the presence of centring bush (40), the
correct positioning of shim(s) (55) and bearing cone
(54).
7. Check that the seal rings (56) are not damaged and
that they turn normally in their grooves. After this
check, remove the seal rings and coat them with
miscible grease, so that they remain at the bottom
of the groove when refitting the carrier.
8. Fit new O’rings (34) (37).
9. Slide the carrier onto the guide studs "G" (Fig. 5) and
alternately and uniformly tighten the four bolts (39) to
a torque of 100 - 130 Nm. Remove the guide studs.
10. Position the transfer tube (42) in carrier (38).
11. Screw in and position union (44).
(see section 6E01).
14. Refit the left-hand trumpet housing (see section
Right-hand carrier
Note: The access to the right-hand carrier (27) is
similar to that of the left-hand carrier (38).
Removal
- Take out bolts (26) and place diametrically opposed
guide studs in the housing, their end resting against the
half-housing (23).
- Extract and remove the carriers by inserting the two
bolts "V" through the tapped holes and take it off.
Refitting
- Check for the presence of the centring pin (25) and
O’ring (34).
- Tighten uniformly and alternately the four bolts (26) to
a torque of 100 - 130 Nm. Remove the guide studs. Fit
and tighten the other bolts to the same torque.
- Check the oil tightness of seal (34) on carrier (27) (see
section 6E01).
Issue 1 May 2001

B . Removal and refitting the diffe-

rential unit assembly 36
Preparation for fitting
17. Remove the trumpet housings (see section 6B01,
6B02 or 6B03 depending on the version).
(Fig. 4). Unscrew the ground speed sensor to avoid
interference with the crownwheel.
19. Remove the brake pistons (see section 6E01).20.
Place and tighten sling ref. 3378116M1, (see § I) in
position 1 (this position corresponds to a differential Fig. 7
assembly with a multidisc differential lock on the
rear axle with a Full Powershift or Heavy Duty
gearbox). Using the sling, hold the differential as-
sembly in the axis of the left and right-hand carriers
(27) (38).

21. Remove bolts (26) (39) from the differential lock
carriers and fit the guide bolts "G" in accordance with
Figure 5.
Extract and remove the carriers by inserting the two
bolts "V" through the tapped holes as shown in Figu-
re 5.
Recover the cone (54) and shims (55) of carrier (38).
22. Remove the O’rings (34).
23. Take out the differential lock assembly (36) from the
centre housing (Fig. 7).
Refitting
unit, it is vital to fit the auxiliary spool valve and lift
control valve return pipe in the housing (45) before
refitting the unit..
In order not to damage the seal rings (56), it is
necessary to correctly align the differential assem-
bly along the axis of the centre housing before
inserting carriers (27) (38).
trumpet housings.
Issue 1 May 2001


Assembling the right-hand carrier (27)
the centre housing. Check for the presence of cen-
tring bush (25). Lubricate and fit a new O’ring (34) 25
(Fig. 8). Insert the carrier using the four bolts (26)
uniformly and alternately tightened to a torque of 100
- 130 Nm. Tighten the other bolts to the same torque.
Assembling the left-hand carrier (38)

26. Slide bearing cone (54) on to tool, ref. 3378117M1
(see § I), adapted for the standard differential with
multidisc lock. Using the tool, centre the differential
assembly in the housing by manually turning the 27 34
central bolt clockwise until it encounters resistance.
two holes in the centre housing, their ends thrusting
against cover (52) of the lock unit. This method
allows the centring of the differential assembly to be 56
retained after removing tool ref. 3378117M1, so as
to later provide a correct fitting of the left-hand carrier
(38) without damaging the seal rings (56). Remove 40 38
the tool and recover the bearing cone (54).
28. Check for the presence of centring bush (40) and fit
a new O’ring (34) on to carrier (38) (Fig. 8).
29. Check that the seal rings (56) have not been dama-
ged and that they turn normally in their grooves. After
this check, remove the seal rings (Fig. 8) and coat
them with miscible grease so that they remain at the
bottom of the groove during refitting of the carrier.
30. Place shim(s) (55) and slide the bearing cone (54) on
carrier (38). Insert the carrier into the housing using
the four bolts (39) uniformly and alternately tightened 34
to a torque of 100 - 130 Nm. Tighten the other bolts
to the same torque.
31. After fitting the carriers, manually check the rotation Fig. 8
of the differential assembly.
32. Refit the brake pistons (see section 6E01), the
transfer tube (42) and union (44).
Issue 1 May 2001

Special point
- If the carrier (1) of the ground speed sensor (2) has been
with Loctite 510 or its equivalent, with the offset of the 1 3
sensor turned towards the longitudinal axis of the
centre housing as shown in Fig. 14. Tighten the bolts (3)
previously lightly smeared with Loctite 542 to a torque
of 25 - 35 Nm.
Remarks
teeth of the crownwheel of the differential.
- Fit and adjust the ground speed sensor lightly smeared 2
Fig. 9
Final operations
33. Refit the trumpet housings (see section 6B01, 6B02
36. Check the correct operation of all controls (mechani-
cal, hydraulic and electronic).
Issue 1 May 2001

C . Removing and refitting the multi-

50 52 57 51
disc lock
23).
48 53 58 49
Removal (Fig. 10)
39. Place the differential unit with the lock turned up-
wards.
40. Loosen and take out bolts (47).
41. Take off the cover (52), discs (49), intermediate pla-
tes (48) and hub (53).
42. Remove bolts (41) and lock unit (46).
43. Gently tap the cover (52) on a wooden block to re- 47 41 46
move the piston (58). Take off O’rings (50) (51). Fig. 10
44. If necessary, drive out cup (57).
On the left-hand carrier (38)

45. Remove the seal rings (56) and O’ring (37).
Reassembly
Note: If unit (46), cover (52) and carrier (38) have been
removed, it is mandatory to carry out shimming of
the differential unit (see § F) and to check the
backlash between the drive pinion and the
crownwheel (see § E).
47. Check that the hydraulic channels in cover (52) are
not obstructed.
48. Lubricate and fit new O’rings (50) (51) on piston (58).
49. Insert the piston by tapping around its rim with a
plastic hammer. Check that there are no seal frag-
ments after insertion.
50. Position unit (46). Lightly smear bolts (41) with
Loctite 270 and tighten them to a torque of 130 Nm.
51. Place hub (53). Assemble the intermediate plates
(48) and discs (49) as shown in Figure 10.
Issue 1 May 2001

52. Position cover (52) fitted with piston (58). Fit bolts
(47) lightly smeared with Loctite 270 and tighten to
53. Manually check that the discs and intermediate
plates are not constrained in any way.
54. Refit the differential unit (see operations 24 to 31) and
the brake pistons (see section 6E01)
Fit and adjust the forward speed sensor lightly smeared
with Loctite 577 (Sensor Sealing or its equivalent).
Refit the transfer tube (42) and union (44).
Final operations
55. Complete the refitting of the various assemblies,
carry out operations 33 to 37.
Issue 1 May 2001

D . Removing and refitting the plane-

tary gears and sun gears and disas- 46 23
semblying and reassembling the
crownwheel 30 29
33 30
23).
57. Remove the locking system and unit (46) (see § C).
61 35
Removal
58. Separate the half-housings (23) (Fig.11).
Note: These components both bear the same 29 28
number. They must be fitted as pairs. Fig. 11
59. Remove the sun gears (30) fitted with friction bushes
(35) (61), the planetary gears (29), washers (28) and
differential brace (33) (Fig. 11).
60. If necessary, drive cup (32) off the half-housing (23)
and recover the shim(s) (59). Extract and discard
deflector (20). 24

The replacement of the crownwheel automatically re-
quires replacement of the drive pinion.
Both parts bear the same number and they must always
be fitted as pairs.
The original factory parts are assembled using rivets.
During repairs, these rivets are replaced by nuts and bolts
and are referenced in the spare parts catalogue.
61. Centre punch each rivet (24) (on toothed side of
crownwheel). Using a 5 mm drill, drill out the rivets
to a depth of 12 mm (Fig. 12). Carry out a second Fig. 12
drilling using a 12 mm drill to the same depth. Drive
out the rivets using an appropriate drift (Fig. 13).
Fig. 13
Issue 1 May 2001


and differential half-housing (23) as well as their nuts
and bolts.
63. Lightly smear the first few threads of the bolts with
Loctite 270 and place them in the crownwheel and
housing.
64. Tighten the nuts to a torque of 150 - 200 Nm.

Special points
- If the friction bushes (35) (61) have been replaced,
insert the new bushes lightly smeared with Loctite 638
or equivalent, using a suitable fixture.
Note: If necessary, insert the deflector (20) and cup

(32) (see operation 70).
65. Refit the planetary gears and sun gears. Carry out
operations 58 and 59 in reverse order.
66. Lightly smear bolts (41) with Loctite 270 or its
equivalent and tighten them to a torque of 130 Nm.
67. Refit the hub, the intermediate plates, discs and
cover (see § C).
68. Refit the differential unit (see operations 24 to 31) and
the brake pistons (see section 6E01).
Final operations
Issue 1 May 2001

E . Adjusting and checking the back-

lash
Reminder
The backlash between the crownwheel and drive pinion
ensures reliability of the bevel gear and the correct
operation of the assembly. This clearance must be che-
cked after:
- adjusting the bevel gear distance
- shimming the differential unit.
Disassembly
- Using an appropriate extractor, remove cup (32) and
Pre-adjustment Fig. 14
- The thickness of the shim(s) E required to obtain the
correct backlash is calculated as follows:
E = Dc + 0.10 mm
E: thickness of shim(s) (59) to be fitted
Dc: crownwheel offset
Remark
nal diameter of the crownwheel (Fig. 14A) after the
pairing number and letter ( 39 K) may range between 0
and -0.60 mm.
Special point
- When calculating E do not take the negative sign
preceding the Dc into consideration (Fig. 14A).
70. Place the previously selected shim(s) (59) in the bore

of the half-housing (23). Insert the deflector (20) and
cup (32) (Fig. 14A).
59 32
20 40
K - 0,
39
23
Fig. 14A
Issue 1 May 2001

Remarks
- The deflector serves as a guide for centring the shims.
It is inserted using the cup and an appropriate locally
manufactured tool. This method allows the deflector to
rest against the cup both during and after its insertion.
- When the operation is completed, check that the cup is
thrusting on the shim(s) and in contact with the deflec-
tor.
71. Refit and shim the differential unit (see § B and F).
Checking
- Couple and temporarily fix the intermediate housing to
bolts tightened to a torque of 540 – 680 Nm.
- Check that the backlash is between 0.15 mm and 0.45
crownwheel.
Important
In this case, select and fit a different thickness of
shim(s).
Carry out the shimming of the differential unit again in
order to obtain the pre-loading of bearings (31) (32) and
(54) (57).
Check a second time the backlash between the drive
- When the final adjustment has been obtained, go on
Issue 1 May 2001


Note: If the centre housing (45), crownwheel (see § 3378117 M1
been replaced, carry out shimming of the differential
unit. Check beforehand that the shim(s) (59) used for
the backlash (see § E) are fitted in the half-housing
(23) and cup (32).
72. Place the differential assembly previously fitted
with bearing cone (54) in the housing using sling ref.
3378116M1 (see § I). Screw two diametrically op-
posed guide studs into the centre housing. Insert
carrier (27) fitted with a new O’ring (34) using four
bolts (26). Remove the guide studs. Complete the
refitting of the other bolts and tighten to a torque of Fig. 15
100 - 130 Nm.
73. Remove bearing cone (54) and shim(s) (55) from
carrier (38).
74. Slide bearing cone (54) on tool, ref. 3378117M1 (see
§ I), adapted for the standard differential unit with 3378117 M1
multidisc lock. Using two bolts, fix the tool onto the
housing (Fig. 15).

16 - 17)
sion "B" and determine dimension "C" between bea-
ring cup (54) and the thrust face of the carrier (38) on
the housing (Fig. 17):
C = B – 10 mm Fig. 16
(10 mm is the thickness of tool, ref. 3378117M1).
38 57
B 54
3378117 M1
45
Fig. 17
Issue 1 May 2001

Dimension to be measured on carrier (38) (Fig. 18)

77. Measure dimension "Y" using an appropriate depth
gauge and rule.
78. Calculate distance "E" between the thrust faces of
bearing cup (54) and carrier (38): 54 38 45
E=C–Y
Fill in space "E" with a thickness of shims (55).
79. In space "E", add additional shims between 0.05 mm
and 0.15 mm, so as to obtain a P2 (Fig. 19):
P2 = 0.05 mm to 0.15 mm
Y
Final operations
80. Remove the tool and bearing cup (54).
81. On carrier (38), place the shims determined in ope-
ration 79. Centre the differential assembly, carry out
operations 26 and 27. Insert the carrier, carry out
operations 28 to 31. Fig. 18
P2 = 0,05/0,15 mm
Fig. 19
Issue 1 May 2001


pinion 18
6H01).
Free the ratchet of the Park Lock transmission lock
(if fitted) (see section 6F01). 3378119M1
84. Locate the position of and take out the sleeve linking 3378118M1
the drive pinion and the lower shaft.
assembly.
Fig. 20
Removing the drive pinion
87. Release and immobilise nut (18) using wrench, ref.
3378118M1 (see § I). Place special socket ref. 11
3378119M1 (see § I), on the end of the drive pinion G
(Fig. 20) and turn it clockwise.
88. Remove bearing cone (1), shims (3) and thrust wa-
sher (4). 13 V
89. Take out two diametrically opposed bolts (11) on
bearing carrier (13). In their place screw two guide
11
studs "G" (Fig. 21) into the tapped holes. Remove the
other bolts.
90. Extract carrier (13) using two bolts "V" of sufficient V G
length (Fig. 21) placed in the tapped holes.
91. Take off the carrier (13) assembly / unit (15), shims
(12) and 4 WD pinion (17) (if fitted). Visually note the
position of the components.
92. Remove circlip (5). Unscrew and remove bolts (8). Fig. 21
section 6C01).
93. Remove the discs (14), the intermediate plates (6)
and the handbrake mechanism (16) (see section
6C01).
cone (7) from the drive pinion.
Issue 1 May 2001


crownwheel), the taper roller bearings (7) (10) (1) (2),
bearing carrier (13), thrust washer (4) and interme-
diate housing (19) have been replaced, it is essential
to adjust the position of the drive pinion (bevel
distance) and then shim the taper roller bearings see
§ H).
96. If bearing cone (7) has been disassembled, insert
transmission oil.
(see section 6C01).
100. Position and slide shims (12) on to the guide studs.
the guide studs. Turn the drive pinion so as to
position.
of 100 - 130 Nm.
Issue 1 May 2001


270 or its equivalent and immobilise it using wrench,
ref. 3378118M1. Using socket, ref. 3378119M1,
turn the drive pinion anti clockwise and tighten it to
nut by bending the lock washer into the grooves
appropriate tool.
section 6C01).
Final operations
assembly.
Lock transmission (if fitted). Refit the creeper unit
(if fitted). Adjust the fork (see section 6H01).
110. Re-couple the tractor between the intermediate
housing and the centre housing (see section 2D01).
Note: If the crownwheel and drive pinion have
been replaced, check the backlash (see § E).
Issue 1 May 2001


H . Adjusting and shimming the drive but with thrust washer (4) placed between the
pinion bearing cone (1) and nut (18)
Reminder: It is essential to adjust the position of the wrench ref. 3378118M1 and socket, ref. 3378119M1
drive pinion before carrying out shimming of the (Figs. 27 - 28, § I) taking care to correctly position
taper roller bearings (7) (10) and (1) (2). Under no the torque wrench.
circumstances should this adjustment be modified 120. Turn the drive pinion several times to correctly seat
without readjusting the shimming of the drive pi- the bearing cones in the cups. Check again the
nion bearings. correct pre-tightening of nut (18).
115. Using a press, insert cup (10) thrust against bearing
carrier (13). Using a suitable fixture, insert cup (2)
to thrust against housing (19). Screw in two dia-
metrically opposed guide studs into the tapped bolt
holes (11). Fit the carrier alone without shims (12).
Alternatively and progressively, tighten the four
bolts (11) to a torque of 100 - 130 Nm.
Check that carrier (13) is in contact with the
intermediate housing (19).
116. Using a press and an appropriate fixture, insert
transmission oil.
Z
19 X
Y
18
39 K 22
39 K
11
13
19 E 12 Fig. 22
Issue 1 May 2001


Adjusting the position of the drive pinion
E : Is the thickness of shims (12) to be fitted, tolerance
± 0.05 mm.
Z : Is the nominal dimension between the rear face of
Note: This dimension is stamped inside the housing
in the horizontal axis of the differential unit (Fig. 22A).
Y : Is the nominal dimension of the positioning of the
drive pinion = 139.00
X : Is the dimension measured between the end of the
housing (Fig. 23).
Note: The drive pinion and the crownwheel are Fig. 22A
matched pairs with a number and letter engraved on
each component.
Fig. 23
Procedure (Operations 121 and 122)

121. Using a depth gauge, measure dimension "X" (Fig.
23).
formula to determine "E", the thickness of the
shim(s) (12) to be fitted in order to correctly position
the drive pinion.
X
Checks
- Temporarily refit the assembly fitted with the previ-
ously determined shims and measure dimension "X"
again. Check that X + Y does in fact equal Z.

the assembly on the intermediate housing (19).
Carry out operations 97 to 103.
Reminder
- Carry out shimming of the drive pinion taper roller
bearings.
Issue 1 May 2001


required to obtain a provisional clearance of 0.10
mm to 0.15 mm maximum, in order to prepare P1 18 1 3 4
shimming.
against shoulder "E" of the drive pinion (Fig.
24).
127. Using wrench, ref. 3378118M1and socket, ref.
of 30 - 50 Nm. E
128. Place the index of the dial gauge on the tapered end
of the pinion (Fig. 24).
P1 =
129. Pull strongly on the pinion via the front of the
0,04 / 0,10 mm
130. With the assistance of another operator, set the dial
gauge to zero.
131. Repeat operation 129 but this time pushing. 18 1 7
(Fig. 24):
P1 = 0.04 mm to 0.10 mm
135. Degrease the threads of nut (18) as well as those 10
of the drive pinion. Fit and definitively tighten the
nut, its threads previously lightly smeared with 11
Loctite 270, to a torque of 200 - 250 Nm.
136. Manually check the rotation of the drive pinion. 2 13 12
137. Lock the nut by bending its lock washer into the
grooves of the pinion without breaking it, using an
appropriate tool.
Fig. 24
Issue 1 May 2001

I . Service tools
(Fig. 27)
28).
Fig. 25
Fig. 26
Fig. 27 Fig. 28
Issue 1 May 2001

6D03 Differential with hypoid bevel gear and

multidisc lock
Contents
- General ________________________________________________ 2
A. Removing and refitting the carriers _______________________ 5
B. Removing and refitting the differential unit assembly ______ 7
C. Removing and refitting the multidisc lock ________________ 10
D. Removing and refitting the planetary gears and sun

crownwheel ____________________________________________ 11
E. Adjusting and checking the multidisc ____________________ 13
H. Adjusting and shimming the drive pinion _________________ 21
I. Service tools ___________________________________________ 25
Issue 1 May 2001


Backlash of the drive pinion and the crownwheel is
General obtained by using shims (29) inserted between cup (28)
and the differential half-housing (21).
Reminder
The 8260 to 8280 tractors is equipped with a centre
housing identical to that mounted on the 8210, 8220,
8240 and 8250 tractors. They are fitted with an AG250 Differential lock
Full Powershift gearbox and have a wide intermediate The multidisc lock system comprises:
housing in which the axial position of the drive pinion has - a unit (21) housing the discs (56) and intermediate
been redesigned for the fitting of a hypoid bevel gear. plates (55).
- a hub (33) integral via splines with the left-hand trumpet
input sun gear.
- a cover (50) made up by piston assembly (52) and
Construction
supported by taper roller bearings (46) (47).
The bevel gear, moved in rotation by the gearbox output
The piston chamber lodged in the cover communicates
shaft, drives the rear axle.
with a channel in the left-hand carrier (40), allowing (17
The helical drive pinion is supported by two taper roller
bar) low pressure to act upon the piston. Two seal rings
(49) ensure the oil tightness of the circuit.
The bearing cone (7) is force fitted on the drive pinion, and
cups (2) (10) are likewise force fitted into the interme-
diate housing (19) and bearing support (13). The bearing
cone (1), mounted free on the drive pinion, allows to fit Operation
the shims (3) required for shimming. Clutched position
The crownwheel is fastened to the differential housing by When the differential lock solenoid valve is activated, the
bolts. The differential assembly rotates on two taper pressure flows through the channels in left-hand carrier
roller bearings supported by two lateral carriers centred (40) and cover (50) on unit (21) and enters piston chamber
by bushes (23) and fixed by bolts to the housing. (52). The piston compresses the intermediate plates (55)
The differential assembly is formed by two halves and discs (56) integral respectively via stops and splines
holding four planetary gears (31) and two sun gears (32) in lock unit (21) and hub (33).
(33). The left-hand side sun gear also serves as the hub In this ‘clutched’ position, the input sun gears of the right-
for the differential lock discs (56). The planetary gears hand and left-hand trumpets turn at the same speeds.
turn on four half shafts (35) housed in the unit and the
differential yoke (34). They are held in place by pins and Declutched position
bolts. When the pressure is cut, the piston returns, the discs
The lubrication of the planetary gears is carried out by and intermediate plates are no longer compressed and
axial and radial channels drilled in the half shafts. allow the sun gears and planetary gears to carry out their
The sun gears, left-hand carrier (40), cover (50) and the differential function.
differential yoke contain drilled lubrication channels al-
lowing transmission oil to reach bushes (36) (37), discs
(56) and the differential lock system. The drive pinion,
which bears the 4 WD drive pinion (17), is located in the
intermediate housing. The adjustment of its position is
carried out by shims (12) fitted between the bearing
carrier (13) and the housing. The pre-loading of the
bearings is obtained by shim(s) (3) fitted between the
bearing cone (1) and the thrust washer (4). The pre-
loading via shimming of the differential assembly is
carried out via shim(s) (48) placed between bearing cone
(46) and the left-hand carrier (40).
Issue 1 May 2001

Rear axle - Differential 6D03.3 Overall view
A B
Parts list (53) O’ring 58 50 29 21
(1) Bearing cone (54) O’ring
(2) Bearing cup (55) Intermediate plates (differential lock) 51
(3) Shim(s) (56) Discs
(4) Thrust washer (57) Lubricating pipe 46 59 32 23
(5) Circlip (58) Rivet
(6) Intermediate plates (handbrake) (59) Rivet
48
(7) Bearing cone
(8) Bolt
(9) Drive pinion Fig. 1 Fig. 2 Fig. 3 49 37 36
(10) Bearing cup 20
(11) Bolt
50 45 44 43 41
(12) Shim(s) 22
(13) Bearing carrier
(14) Discs 51 21
(15) Handbrake unit 19 2 3 4 5 14 12 13
(16) Mechanism 26 26
(17) 4 WD drive pinion
(18) Nut
11 23 23
(20) Crownwheel
(21) Unit 24 24
(22) Bolts
(23) Centring bushes 7
42 29
(24) Bolts
(25) Right-hand carrier 9 47
(26) O’rings 32
(27) Bearing cone
(28) Bearing cup 57 46 36
1
(29) Shim(s) A B
(30) Spherical washer 49 34
(32) Right sun gear 37 27
(33) Left sun gear 16
(34) Differential yoke
(35) Planetary gear half shafts 48 28
17
(36) Shouldered bush
(37) Shouldered bush 10 25
(39) Bolt 54
(40) Left-hand carrier 8 31
(41) Transfer tube
(42) O’ring 6 40 30
(43) O’ring
(44) Union 15 35
(45) Centre housing 52
(46) Bearing cone
(47) Bearing cup
(48) Shim(s)
53 56 55 33 39 38
(49) Seal rings
(50) Cover Parts list Fig. 2 Fig. 3 Fig. 2
(51) Bolt Fig. 1
(52) Piston
Issue 1 May 2001


Exploded view
34 35 37
31
30
32
36
21
29 33
28
27 30
26
25
24 31
39
9
20
38
12
4
3
7 2
22 10 1
23 8 18
11 13
33
56
55
42 44
40
26
49 43
48
46 41
47
50 24
53
52 23
51
54
Fig. 3
Issue 1 May 2001

A . Removing and refitting the car-

riers
Left-hand carrier
Note: It is possible to carry out maintenance on
carrier (40) and seal rings (49) of the differential lock
by removing only the left-hand trumpet housing.
Removal
6B04).
2. Take off union (44) (Fig. 4) and raise the transfer tube
(41) (Fig. 5).
3. Remove the brake piston (see section 6E01)
4. Remove bolts (24) on from the left-hand carrier. Place 44
two diametrically opposed guide studs "G" on the
housing as shown in Figure 6, their ends pushing Fig. 4
against cover (50) of the lock unit.
5. Extract the carrier by inserting two bolts "V" through
the tapped holes (Fig. 6); take it off and recover cone
(46) and shim(s) (48).
Note: The guide studs "G" hold and centre the
differential assembly in the housing (Fig. 7). Do
not unscrew the guide studs. This may throw off
centre the assembly and damage the seal rings
(49) during refitting of the carrier.
41
Fig. 5
G
V
50
V
50 G
Fig. 6 Fig. 7
Issue 1 May 2001


Refitting
6. Check for the presence of centring bush (23) on the
housing, the shim(s) (48) and bearing cone (46).
7. Check that the seal rings (49) are not damaged and
that they turn normally in their grooves. After this
check, remove the seal rings and coat them with
miscible grease, so that they remain at the bottom
of the groove during refitting of the carrier.
8. Fit new O’rings (26) (42).
9. Slide the carrier onto the guide studs"G" (Fig. 6) and
alternately and uniformly tighten the four bolts (24) to
a torque of 100 - 130 Nm. Remove the guide studs.
10. Position the transfer tube (41) in carrier (40).
11. Screw in and position union (44).
(see section 6E01).
14. Refit the left-hand trumpet housing (see section
6B04).
Right-hand carrier
Note: The access to the right-hand carrier (25) is
similar to that of the left-hand carrier (40).
Removal
- Take out bolts (24) and place diametrically opposed
guide studs "G" in the housing, their ends thrust against
the half-housing (21).
- Extract the carrier by inserting two bolts "V" through the
tapped holes and remove it.
Refitting
- Check for the presence of the centring pin (23) on the
housing and O’ring (26).
- Tighten uniformly and alternately the four bolts (24) to
a torque of 100 - 130 Nm. Remove the guide studs. Fit
and tighten the other bolts to the same torque.
- Check the oil tightness of seal (26) on carrier (25) (see
section 6E01).
Issue 1 May 2001

B . Removing and refitting the diffe-

rential unit assembly
Preparation for fitting
17. Remove the trumpet housings (see section 6B04).
(Fig. 5). Unscrew the ground speed sensor to avoid
interference with the crownwheel.
19. Remove the brake pistons (see section 6E01).
20. Place and tighten sling ref. 3378116M1, (see § I) in
position 2 (this position corresponds to a differential
assembly with a multidisc differential lock on the
rear axle with an AG250 Full Powershift gearbox). Fig. 8
Using the sling, hold the differential assembly in the
axis of the left and right-hand carriers (25) (40).

21. Remove bolts (24) from the carriers and fit the guide
bolts "G" in accordance with Figure 6.
Extract and remove the carriers by inserting two bolts "V"
through the tapped holes as shown in Figure 6.
Recover the cone (46) and shims (48) from carrier
(40).
22. Remove the O’rings (26).
23. Take out the differential assembly from the centre
housing (Fig. 8).
Refitting
unit, it is essential to fit the auxiliary spool valve and
lift control valve return pipe in the housing (45)
before refitting the unit.
In order not to damage the seal rings (49), it is
necessary to correctly align the differential assem-
bly along the axis of the centre housing before
inserting carriers (25) (40).
trumpet housings.
Issue 1 May 2001


Assembling the right-hand carrier (25)
25. Screw two diametrically opposed guide studs into 25
the centre housing. Check for the presence of cen-
tring bush (23). Lubricate and fit a new O’ring (26)
(Fig. 9). Insert the carrier (25) using the four bolts (24) 23
uniformly and alternately tightened to a torque of 100
– 130 Nm. Tighten the other bolts to the same torque.
Assembling the left-hand carrier (40)

26. Slide bearing cone (46) on to tool, ref. 3378117M1
(see § I), adapted for the differential with hypoid
bevel gear and multidisc lock. Using the tool, centre
the differential assembly in the housing by manually
turning the central bolt clockwise until it encounters 26
resistance.
27. Screw two diametrically opposed guide studs into Fig. 9
two holes in the centre housing, their ends thrusting
against cover (50) of the differential lock. This method
allows the centring of the differential assembly to be
retained after removal of tool ref. 3378117M1, in
order to later provide a correct fitting of the left-hand 49 40
carrier (40) without damaging the seal rings (49).
Remove the tool and recover the bearing cone (46).
28. Check for the presence of centring bush (23) in the
housing and fit a new O’ring (26) on to carrier (40)
(Fig. 10).
29. Check that the seal rings (49) have not been dam-
aged and that they turn normally in their grooves.
After this check, remove the seal rings (Fig. 10) and
coat them with miscible grease so that they remain
at the bottom of the groove during refitting of the
carrier.
30. Place shim(s) (48) and slide the bearing cone (46) on
23 26
carrier (40).
31. Insert the carrier into the housing using the four bolts Fig. 10
(24) uniformly and alternately tightened to a torque of
100 - 130 Nm. Tighten the other bolts to the same
torque.
Issue 1 May 2001

32. After fitting the carriers, manually check the rotation

of the differential assembly.
33. Refit the brake pistons (see section 6E01).
1 2
Special points
- If the carrier (1) of the ground speed sensor (2) has been
with Loctite 510, with the offset of the sensor turned
towards the longitudinal axis of the centre housing as
shown in Fig. 11.
- Tighten the bolts (3) previously lightly smeared with
Loctite 542 to a torque of 25 - 35 Nm.
Remarks 3
teeth of the crownwheel of the differential.
Fig. 11
- Fit and adjust the ground speed sensor lightly smeared
34. Refit transfer tube (41) and union (44).
Final operations
35. Refit the trumpet housings (see section 6B04).
38. Check the correct operation of all controls (mechani-
cal, hydraulic and electronic).
Issue 1 May 2001

C . Removing and refitting the multi-

disc lock 47 51
23). 50
Removal (Fig. 12) 52 53

41. Place the differential unit with the lock turned up-
wards.
42. Loosen and take out bolts (51).
43. Take off the cover (50).
54 56
44. Separate the discs (56) and intermediate plates (55)
from the left-hand sun gear (33).
45. Gently tap the cover (50) on a wooden block to
remove the piston (52). Remove O’rings (53) (54). 33 55
46. If necessary, drive out cup (47).
On the left-hand carrier (40)

47. Remove the seal rings (49) and O’ring (42).
Reassembly
Note: If unit (21), cover (50) and carrier (40) have been
replaced, it is mandatory to carry out shimming of
the differential unit (see § F) and to check the Fig. 12
backlash between the drive pinion and the
crownwheel (see § E).
56. Refit the differential unit assembly (see operations
24 to 31) and the brake pistons (see section 6E01)
57. Adjust the forward speed sensor (see special points
49. Check that the hydraulic channel in cover (50) is not
and remarks, § B). Refit the transfer tube (41) and
obstructed.
union (44).
50. Lubricate and fit new O’rings (53) (54) on piston (52).
51. Insert the piston by tapping around its rim with a
plastic hammer.
52. Check that there are no seal fragments after inser- Final operation
tion. 58. Complete the refitting of the various assemblies,
53. Assemble the intermediate plates (55) and discs carry out operations 35 to 39.
(56) as shown in the overall view.
54. Position cover (50) fitted with piston (52). Fit bolts
(51) lightly smeared with Loctite 270 and tighten to
55. Manually check that the discs and intermediate
plates are not constrained in any way.
Issue 1 May 2001

D . Removing and refitting the plane-

tary gears and sun gears and disas- 34 33 35
sembling and reassembling the
crownwheel 21 39
59. Remove the differential unit assembly (see opera-
tions 15 to 23).
60. Remove the locking system (see § C).
Removal
61. Remove the left-hand sun gear (33).
62. To remove the half shafts (35), it is necessary to
31 36 32 28 29
disassemble the crownwheel (see below).
64. Take out pins (38) from unit (21).
65. Push on a half shaft in the direction of the arrow to 34 30 39
drive out the opposite half shaft. Repeat the opera-
tion for the remaining half shafts. Recover the 31 38
spherical washers (30). Remove the planetary gears
(31).
66. Remove the differential yoke and the right-hand sun 35
gear (32).
67. If necessary, drive cup (28) off the unit (21) and
recover the shim(s) (29).

The replacement of the crownwheel automatically re-
quires replacement of the drive pinion. 39 21
Both parts bear the same number and they must always
be fitted as pairs.
68. Remove bolts (22) (Fig. 14). Fig. 13

Important 22
- During repairs, use the bolts referenced in the spare
parts catalogue.
and unit (21) as well as bolts (22).
the tapped holes of the crownwheel. Assemble the
crownwheel on the unit.
71. Smear the first few threads of the bolts with Loctite
270 and screw them into the crownwheel. Remove
the guide studs.
72. Tighten and lock the nuts at a torque of 240 - 320 Nm.
Fig. 14
Issue 1 May 2001


Note: If necessary, place shim(s) (29) and insert cup
(28) in unit (21).
Special points
- If replacement of the friction bushes (36) (37) is neces-
sary, insert the new bushes lightly smeared with
Loctite 638 using a suitable fixture.
73. Refit the right-hand sun gear (32) in the friction bush
(36). Refit the differential yoke (34) as shown in the
overall view.
74. Check that the central channels and radial drilled
passages in the half shafts (35) are not obstructed.
75. Assemble planetary gears (31), friction washers (30)
and the half shafts, with the holes turned towards
bolt (39) as shown in the overall view.
76. Position the shafts. Fit and tighten bolts (39) lightly
smeared with Loctite 270 and tighten them to a
77. Manually check the rotation of the planetary gears
and the right-hand sun gear (32).
78. Refit the crownwheel (see § D).
Refit the intermediate plates, discs and cover (see §
C).
Refit the differential unit assembly (see operations
24 to 31) and the brake pistons (see section 6E01).
79. Fit and adjust the forward speed sensor (see special
points and remarks, § B). Refit the transfer tube (41)
and union (44).
Final operation
Issue 1 May 2001

Special point
E . Adjusting and checking the multi- When calculating ‘E’ do not take the negative sign
disc preceding the Dc into consideration (Fig. 15).
Note: The backlash between the crownwheel and
81. Place the previously selected shim(s) in the bore of
drive pinion ensures reliability of the bevel gear and
the unit (21). Insert bearing cup (28) and check that
the correct operation of the assembly.
it is in contact with the shims.
This backlash must be checked after:
82. Refit and shim the differential unit (see § B and F
- adjusting the bevel gear distance
respectively).
- shimming the differential unit.
Disassembly
Using an appropriate extractor, remove cup (28).
Pre-adjustment
The thickness of the shim(s) "E" required to obtain the
correct backlash is calculated as follows:
E = Dc + 0.10 mm
where:
E : thickness of shim(s) (29) to be fitted
Dc : crownwheel offset
Remark
nal diameter of the crownwheel (Fig. 15) after the
pairing number and letter (31 A) may range between 0
and -0.60 mm.
29 28
21
10
A - 0,
31
Fig. 15
Issue 1 May 2001


Checks
- Couple and temporarily fix the intermediate housing to
bolts tightened to a torque of 540 – 680 Nm.
- Check that the multidisc is between 0.15 mm and 0.45
crownwheel.
- In this case, select and fit a different thickness of
shim(s). Carry out the shimming of the differential unit
again in order to obtain the pre-loading of bearings (27)
(28) and (46) (47).
Fig. 16
- Check a second time the backlash between the drive
83. When the final adjustment has been obtained, go on

Issue 1 May 2001


3378117M1
Note: If the centre housing (45), crownwheel (see §
been replaced, carry out shimming of the differential
unit.
Check beforehand that the shim(s) (29) used for
providing the multidisc (see § E) are fitted between
unit (21) and cup (28).
84. Place the differential assembly in the housing using
sling ref. 3378116M1 (see § I). Screw two diametri-
cally opposed guide studs into the centre housing.
Insert carrier (25) fitted with a new O’ring (26) using
four bolts (24). Remove the guide studs. Complete Fig. 17
the refitting of the other bolts and tighten to a torque
of 100 - 130 Nm.
85. Remove bearing cone (46) and shim(s) (48) from
carrier (40).
86. Slide bearing cone (46) on tool, ref. 3378117M1 (see
§ I), adapted for the hypoid differential unit with
multidisc lock. Using two bolts, fix the tool onto the
housing (Fig. 17).
Issue 1 May 2001


18 - 19)
sion "B" at two opposed points (work out average of 40
the two measurements) and determine dimension
"C" between bearing cup (46) and the thrust face of
the carrier (40) on the housing (Fig. 18):
C = B – 10 mm
(10 mm is the thickness of tool, ref. 3378117M1).
3378117M1
45 46 47
Fig. 18
3378117M1
Fig. 19
Issue 1 May 2001

Dimension to be measured on carrier (40) (Fig. 20)

89. Measure dimension "Y" using an appropriate depth
gauge and rule.
90. Calculate distance "E" between the thrust faces of
45 40 46
bearing cup (46) and carrier (40):
E=C–Y
Fill in space "E" with a thickness of shims (48).
91. In space "E", add additional shims between 0.05 mm
and 0.15 mm, in order to obtain P2 (Fig. 21):
P2 = 0.05 mm to 0.15 mm
Y
Final operations
92. Remove the tool and bearing cup (46).
93. On carrier (40), place the shims determined in
operation 91. Centre the differential assembly, carry
out operations 26 and 27. Insert the carrier, carry out
Fig. 20
operations 28 to 31.
46

pinion
ing and the centre housing (see section 2D01). 40
6H01).
96. Free the ratchet of the Park Lock transmission lock
(if fitted) (see section 6F01).
97. Locate the position of and take out the sleeve linking
the drive pinion and the lower shaft.
assembly.
E
P2 = 0,05 / 0,15 mm
Fig. 21
Issue 1 May 2001


1 57
100. Remove bolt (1). Take off pipe (57) located at the
taper end of the drive pinion (Fig. 22).
101. Release and immobilise nut (18) using wrench, ref.
3378118M1 (see § I). Place special socket, ref.
3378119M1 (see § I), on the end of the drive pinion
(Fig. 23) and turn clockwise.
102. Remove bearing cone (1), shims (3) and thrust
washer (4).
103. Take out two diametrically opposed bolts (11) on
bearing carrier (13). In their place, screw two guide
studs "G" (Fig. 24) into the tapped holes. Finishing
removing the other bolts.
104. Extract carrier (13) using two bolts "V" of sufficient
length (Fig. 24) placed in the tapped holes. Fig. 22
105. Take off the carrier (13) assembly / unit (15), shims
(12) and 4 WD pinion (17). Visually note the position
of the components.
106. Remove circlip (5). Unscrew and remove bolts (8).
section 6C01). 18
107. Remove the discs (14), the intermediate plates (6)
and handbrake mechanism (16) (see section 6C01).
cone (7) on the drive pinion.
3378118M1
3378119M1
Fig. 23
11 V
11
G
G
Fig. 24
Issue 1 May 2001


crownwheel), taper roller bearings (7) (10) (1) (2),
bearing carrier (13), thrust washer (4) and intermedi-
ate housing (19) have been replaced, it is essential to
adjust the position of the drive pinion (bevel dis-
tance) and then shim the taper roller bearings (see §
H).
110. If bearing cone (7) has been disassembled, insert
transmission oil.
(see section 6C01).
114. Position and slide shims (12) on to the guide studs.
the guide studs. Turn the drive pinion in order to
position.
of 100 - 130 Nm.
Issue 1 May 2001


270 (or its equivalent) and immobilise it using
wrench, ref. 3378118M1 (Fig. 25). Using socket, 18
ref. 3378119M1 (Fig. 25), turn the drive pinion anti
clockwise and tighten it to a torque of 200 - 250 Nm.
337811
nut by bending the lock washer into the grooves 8M1
appropriate tool.
section 6C01).
3378119M1
Fig. 25
Final operations
assembly.
Lock transmission.
124. Refit the creeper unit (if fitted). Adjust the fork (see
section 6H01).
125. Couple the tractor between the intermediate hous-
Note: If replacement of the crownwheel and
drive pinion has been carried out, check the
backlash (see § E).
Issue 1 May 2001

H . Adjusting the position and shim-

ming the drive pinion
Reminder
- It is essential to adjust the position of the drive pinion
before carrying out shimming of the taper roller bearings
(7) (10) and (1) (2). Under no circumstances should this
adjustment be modified without readjusting the shim-
ming of the drive pinion bearings.
130. Using a press, insert cup (10) thrust against bearing
carrier (13).
Using a suitable fixture, insert cup (2) to thrust
against housing (19). Screw in two diametrically
opposed guide studs into the tapped holes (11). Fit
the carrier alone without shims (12). Alternatively
and progressively, tighten the four bolts (11) to a
torque of 100 -130 Nm. Check that carrier (13) is in
contact with the intermediate housing (19).
transmission oil.
but with thrust washer (4) placed between the
bearing cone (1) and nut (18).
wrench, ref. 3378118M1 and socket, ref.
3378119M1 (Figs. 33 - 34, § I) taking care to cor-
rectly position the torque wrench.
135. Turn the drive pinion several times to correctly seat
the bearing cones in the cups. Check the correct
pre-tightening of nut (18) again.
Issue 2
1 May 2002
2001

Adjusting the drive pinion position
E : Is the thickness of shims (12) to be fitted, tolerance
± 0.05 mm.
Z : Is the nominal dimension between the rear face of
Note: This dimension is stamped inside the
housing in the horizontal axis of the differential
unit (Fig. 27).
Y : Is the nominal dimension of the positioning of the
drive pinion = 139.00
X : Is the dimension measured between the end of the
housing (Fig. 28).
Note: The drive pinion and the crownwheel are
matched pairs and have a number and letter
engraved on each component.
Z
19
X
Y
31 A
18 20
31 A
13 11
19
E
12
Fig. 26
Issue 1 May 2001

Procedure (Operations 136 and 137)

136. Using a depth gauge, measure dimension "X" (Fig.
28).
formula to determine "E", the thickness of the
shim(s) (12) to be fitted in order to correctly position
the drive pinion.
Checks
- Temporarily reassemble the assembly fitted with
the previously determined shims and measure
dimension "X" again.
- Check that X + Y does in fact equal Z.

the assembly on the intermediate housing (19). Fig. 27
Reminder
- Carry out shimming of the drive pinion taper roller
bearings.
Fig. 28
Issue 1 May 2001


required to obtain a provisional clearance of 0.10 18 1 3 4
mm to 0.15 mm maximum, in order to prepare P1
shimming.
against shoulder ‘E’ of the drive pinion (Fig. 29).
142. Using wrench, ref. 3378118M1 and socket, ref.
E
of 30 - 50 Nm.
143. Place the index of the dial gauge on the tapered end
of the pinion (Figs. 29 - 30). P1 =
144. Pull strongly on the pinion via the front of the 0,04 / 0,10 mm
145. With the assistance of another operator, set the dial
gauge to zero. 18 1 7
146. Repeat operation 144 but this time pushing.
(Fig. 29):
P1 = 0.04 mm to 0.10 mm
10
of the drive pinion. Fit and definitively tighten the
nut, its threads previously lightly smeared with 11
Loctite 270, to a torque of 200 - 250 Nm. 2 13 12
151. Manually check the rotation of the drive pinion.
152. Lock the nut by bending its lock washer into the
grooves of the pinion without breaking it, using an Fig. 29
appropriate tool.
Fig. 30
Issue 1 May 2001

I . Service tools
(Fig. 33)
34).
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Issue 1 May 2001

Rear axle - Brake pistons and seals 6E01.1
6E01 Brake pistons and seals
Contents
- General ________________________________________________ 2
A. Disassembly ____________________________________________ 6
B. Reassembly ____________________________________________ 8
C. Service tools ___________________________________________ 11
Issue 1 May 2001

6E01.2 Rear axle - Brake pistons and seals

Parts list
General (1) Centre housing
The brake pistons (2) are housed in two cavities formed (2) Piston
by the centre housing and the differential carrier, concen- (3) O’ring
tric with the thrust face of each trumpet housing. The (4) O’ring
brake pistons are guided by three locating pins (6) force (5) O’ring
fitted into the centre housing and have an annular face (6) Stop pin
that is submitted to pressure from the master cylinder. (7) Pin
The other face has a larger surface area and acts upon a (32) Hub
disc that is integral via splines with the input sun gear of (35) Disc(s)
the trumpet housing and on the wall of a compartment (38) Intermediate plate
that also serves as the brake plate. This compartment is (39) Stop pin (drilled)
centred by locating pins that are force fitted into the (41) Stop pin
trumpet housing which may or not be oil tight depending
on the type of assembly.
The oil tightness of the pistons is provided by O’rings Identification of ports
fitted into the grooves of the centre housing and the O : Disc lubricating port
differential carriers. Two other seals placed in the angle P : Pressure from master cylinders
of each carrier stop the pressure in the piston chamber
from communicating with the interior of the centre
housing. Fig. 1
The shape of the pistons differs according to the options
and the type of trumpet housing.
Fig. 2
Each piston is controlled by a master cylinder the oil level
of which is maintained by a residual oil flow from the
lubricating circuit. Fig. 3
When the brake is released, a minimum clearance is
provided between the piston and the disc. The brakes are
self-adjusting and maintain a constant brake pedal posi- Fig. 4
tion.
When they are not in use, the discs are lubricated by an Fig. 5
oil flow from the lubricating circuit on the right-hand
cover. This oil also serves to cool the discs when they are
used.
Remark
On tractors fitted with trumpet housings with double
drive unit, the brake pistons (2) are fitted in the same
cylinders as previously mentioned. They are guided by
three stop pins (39) (41) mounted free in the housing. Pin
(39) fitted in the upper part of the housing has a drilled
central port to allow pressure venting from the trumpet
housing into the rear axle and breather pipe. The pistons
act upon a two-disc system (35) running in an oil bath and
integral via splines with hub (32) and the trumpet housing
input shaft. The discs are separated by an intermediate
plate (38) that is guided by the previously mentioned
pins.
During braking, the double-disc system is thrust against
the centre brake plate by pin (7) on the centre housing.
Issue 1 May 2001

Overall view
Assembly with standard trumpet housing Assembly with sealed compartment trumpet housing
P
P
O O 1
35
3 2
4
35
2
32
6
6
Parts list Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 1 Parts list Fig. 1 Fig. 3 Fig. 4 Fig. 5 Fig. 2
Issue 1 May 2001


Overall view
Assembly with trumpet housing fitted with composite drive unit Assembly with trumpet housing fitted with double drive unit
P P
O 3 O 1
3
2
4
2
35 35
32
32
38
5
5
6 41
Parts list Fig. 1 Fig. 2 Fig. 4 Fig. 5 Fig. 3

Issue 1 May 2001

Exploded view
Single disc
2
6
35
39
Double disc
7
3
4
2
41
32
35
38
35
Issue 1 May 2001

A . Disassembly
1. Remove the trumpet housing(s) concerned (see sec-
tion 6B01, 6B02, 6B03 or 6B04 depending on the
version). 3
2. Remove the master cylinder brake supply pipe from
the union above the centre housing. Progressively
drive out piston (2) from housing (1) using a com-
pressed air jet connected to the union (3) (Fig. 6).
1 2
Fig. 6
Issue 1 May 2001

3. Remove the O’rings (3) (4) fitted on the housing and

differential carriers respectively (Fig. 7).
Remarks
- The seals (3) (4) not being mounted on the brake 4
piston, their movement and wear is limited.
- The O’rings (5) fitted between the differential carriers
and the centre housing (Fig. 1 - 4) ensure the oil tight-
ness of the piston chambers.
4. If necessary, remove the differential carrier(s) to
replace the previously mentioned O’rings (see section
6D01, 6D02 or 6D03 depending on the version).
3
Reminder
- If the spacer acting as the brake plate has to be repla-
ced, consult the section concerning the relevant trum-
pet housing type (6B01, 6B02, 6B03 or 6B04).
Fig. 7
Issue 1 May 2001

B . Reassembly
found to be defective.
6. If removed, refit the differential carrier(s) with a new 6
seal (see section 6D01, 6D02, or 6D03 depending on
the version).
V
1
Checks before reassembly
- Remove the O’rings (3) (4) (Fig. 9) and place the piston
in the housing.
- Check that the piston slides freely in its bore and that 6
there are no stiff spots on stop pins (6) (39) or (41) (de- V
pending on the version) (Fig. 8 and 9).
39
41 41
V
Fig. 8
Issue 1 May 2001

7. When the check is completed, definitively fit the new

seals previously lubricated with transmission oil (Fig.
7) and position the piston on the stop pins (Fig. 8), tur-
ning the more numerous lubricating ports upwards. 6
Reminder
- To avoid damaging the seals, place the piston in its
bore using a locally manufactured tool (see § C) and
with the aid of two bolts "V" of a suitable length that
are alternatively and progressively tightened (Fig. 8).
4 3
6
6
39 4
41
41 3
Fig. 9
Issue 1 May 2001


8. Remove the tool. If necessary, complete the fitting
by alternatively tapping on the face of the piston
using a plastic hammer. Check that there are no
fragments of O’rings after fitting.
Hydraulic test (Fig. 10)

Positioning of seals
Remarks
3
- Use a pressure gauge that has previously been checked
for pressure tightness and fit the piston retainer tool
onto the housing (see § C and Fig. 10).
- Using compressed air, pressurize the circuit to approxi-
mately 5 bar.
- Disconnect the pressure gauge and push the piston
back using a plastic hammer.
- Repeat the above operation several times.
Tests
- Pressurize the circuit again to a pressure of approxi-
mately 0.3 bar.
- Close the pressure relief-valve.
- Over a period of one minute, no drop in pressure should
be seen on the pressure gauge.
- After the test, remove the pressure gauge and take off
the retainer tool.
3
Final operations
9. Refit the trumpet housing(s) (see section 6B01,
10. Purge the main brake system (see section 9I01).
11. Carry out a road test of the brake circuit.
12. Check the oil tightness of:
- trumpet housing seals (silicone)
- brake lubricating pipes Fig. 10
Issue 1 May 2001

C . Service tools
Locally manufactured tools 340
- Brake piston fitting tool (Fig. 11) 215
a : rubber or plastic
30
2 Ø 13
2 mini
20
a
Fig. 11
Issue 1 May 2001

Rear axle - Park lock 6F01.1
6F01 Park lock
Contents
- General ________________________________________________ 2
A. Unlocking the system and positioning the special bolt _____ 5
B. Removing and refitting the sleeve ________________________ 6
C. Disassembling the control _______________________________ 7
D. Reassembling the control ________________________________ 8
Issue 1 May 2001

6F01.2 Rear axle - Park lock
General
The Park lock system, fitted inside the centre housing,
comprises a ratchet (17) and a toothed sleeved (15),
integral via splines with the drive pinion and the lower
shaft connected to the gearbox.
This system is activated by a control unit (3) attached to
the right-hand side of the housing and through a spring-
loaded control rod.
The Park lock is only fitted to transmissions equipped
with a Full Powershift gearbox.
Operation
Engaged position (speed control in position P)
- When the tractor is halted with the engine running, the
Park lock provides a mechanical locking of the trans-
mission. In the engaged position, the solenoid valve (7)
is not activated and the system functions in a purely
mechanical manner.
- Spring (10) pushes piston (1) towards unit (3). The
control rod (11) screwed into the piston drives the links
(13) that engage ratchet (17) in the toothed sleeve (15),
thus locking the lower transmission shaftline.
- With the engine halted, the Park lock is engaged auto-
matically.
Disengaged position (hydraulic activation)

- When the speed control is placed in the P or N position,
the electronic unit (TC) controls solenoid valve (7) that
supplies control unit (3) which disengages the Park
lock. The pressure in the piston chamber (1), acting
upon the front face of the piston, compresses spring
(10) and frees ratchet (17) from the toothed sleeve (15).
- The electronic unit (TC) is informed through the position
of switch (19) (see section 11).
Issue 1 May 2001

Overall view
Parts list Key to letters
(1) Piston D : Disengaged position
(2) O’ring 23
E : Engaged position
(3) Control unit
6 9 3 8 1 10 11 13 15 12 17 16 18
(4) Bolt
(5) O’ring Fig. 1
(6) Special bolt
(7) Solenoid valve
(8) O’ring Fig. 2
(9) Nut
(10) Spring
(11) Control rod
(12) Split pin bolt 19
(13) Links
(15) Toothed sleeve
(16) Pin and washer E
(17) Ratchet F
(18) Seal(s)
(19) Switch D
(20) O’ring
(23) Non-return valve
Version without Park lock F

5 2
(24) Plug
(25) Plug 20
(26) Threaded plug
4 7 24 18
View along F
25 26
Parts list Fig. 2

Fig. 1
Issue 1 May 2001

Exploded view
19
18
16
17
16
12
13
13
11
10
1
8
23
6
5
20
3
2
9
7
Issue 1 May 2001

A . Unlocking the system and posi-

tioning the special bolt
Special point 15
- The Park lock system must be unlocked before carrying
out certain maintenance operations on the tractor or
when the hydraulic or electronic circuits of the Park lock
system fail.
Unlocking 17
1. Take off nut (9) and turn the special bolt (6) (Fig. 3)
clockwise until piston (1) comes into contact with the 10
11
shoulder of the housing.
Action obtained Fig. 4

- During this operation, the control rod (11) is moved to
the right and compresses the spring (10) freeing ratchet
(17) from the toothed sleeve (15) (Figs. 3 - 4). Test
3. Check the correct operation of the transmission lock.
Restoring the initial position of the special

bolt
Reminder
- After any intervention on the special bolt (6), it is
important to restore it in its initial position, i.e. com-
pletely unscrewed and locked at a torque of 40 - 50 Nm
in order to ensure both the correct operation of the Park
lock system and oil tightness of its control unit (3).
2. Using wrenches, hold the bolt in the previously stated

position and tighten nut (9) against the unit housing to
9 6 11
1 10 15
11 17
11 11
Fig. 3
Issue 1 May 2001

B . Removing and refitting the sleeve

Removal
5. Disengage the Park lock system (see § A) and remo-
ve the creeper drive unit (if fitted, see section 6H01).
6. Visually locate the position of the sleeve and remove
it.
If necessary, take out the snap ring located inside it.
Refitting
defective parts.
8. If previously removed, replace the snap ring.
9. Check that the sleeve slides easily on the drive
pinion and on the lower shaft coming from the
gearbox. Place the sleeve in its final position on the
drive pinion, the long part turned towards the pinion.
Refit the creeper unit (if fitted, see section 6H01).
Final operations
10. Couple the tractor between the gearbox and the inter-
mediate housing (see section 2C01).
11. Place the special bolt (6) in its initial position (see §
A).
Issue 1 May 2001

C . Disassembling the control

12. Immobilise the tractor. Chock the front wheels. 4
13. Chock between the frame and the front axle.
14. Remove the rear wheels or place them in the wide
track position. If the wheels are removed, position 3
axle stands.
15. Remove the left and right-hand hydraulic covers (see
section 9G01, 9G02, 9H01 depending on the hydrau-
lic equipment).
16. Disconnect solenoid valve (7) fitted on the Park lock
unit (3).
6 9
Disassembly
17. Remove two diametrically opposed bolts (4) and Fig. 5
screw instead two sufficiently long M6 x 100 threaded
rods, fitted with nuts and washers, to make contact
with unit (3) (Fig. 5).
18. Remove the two other bolts.
19. Loosen nut (9) and turn the special bolt (6) (Fig. 5)
several turns clockwise to slightly free the lower pin
bolt (12) (Fig. 1).
20. Through the opening of the right-hand side cover,
take out the pin and remove the bolt.
21. Progressively and alternately unscrew the wing nuts 10
"E" on the two threaded rods in order to release the
spring (10) (Fig. 6).
22. Remove unit (3), piston (1) fitted with O’ring (8), rod
(11) and spring (10).
23. Recover the O’rings (2) (20).
E
24. Through the opening of the left-hand side cover,
remove the pin from bolt (16) and thus remove 9
ratchet (17). Fig. 6
25. If necessary, remove the switch (19) fitted with its
seal (18).
Issue 1 May 2001

D . Reassembling the control

27. Refit the ratchet. Carry out operation 24 in reverse
R
order.
Special point
- Limit the axial clearance of pin bolt (16) to the 1
maximum (tolerance 0 mm to 2 mm), by if possible
placing a washer on the pin bolt between the
housing and the pin. 11
28. If fitted, screw piston (1) on to rod (11) with its
threads lightly smeared with Loctite 270 and tighten
to a torque of 50 - 70 Nm. Using a punch, mark the
external face of piston (1) and rod (11) with two
diametrically opposed marks (Fig. 7).
29. Replace and lubricate the O’rings (2) (8) (20). In the Fig. 7
opening of the intermediate housing, position piston
(1) with rod (11) (Fig. 7) and spring (10) by aligning the Torques
hole of the shaft with the two links (13). - Switch (19): 20 Nm
30. Use unit (3) to push on piston (1) and compress - Bolts (4): 10 - 14 Nm
spring (10) by using the threaded rods, washers and - Solenoid spool valve (7): 18 - 20 Nm
wing nuts used for disassembly. - Knurled nut (solenoid valve): 3 - 4 Nm or manual tighte-
31. Fit pin (12) with its retaining pin turned towards the ning
front.
32. Fit and tighten the two bolts (4) to a torque of 10 - 14 Remark
Nm.
- The letter "R" (Fig. 7) indicates the unit (3) oil return port.
33. Remove the nuts, washers and threaded rods.
34. Fit the other two bolts and tighten to the previously
indicated torque.
Final operations
35. Refit the right- and left-hand side covers (see section
9G01, 9G02 and 9H01).
36. Reconnect solenoid valve (7).
37. Remove the axle stands (if used) refit the wheels or
place them in their initial position. Carry out the
tightening of nuts and bolts to their indicated torque
(see section 2G01).38. Check the correct op-
eration of the dashboard indicator lamp and the
display of the letters P and N in relation to the speed
control.
39. Check the oil tightness of the control unit (3).
Issue 1 May 2001

Rear axle - Lift cylinder supports 6G01.1
6G01 Lift cylinder supports
CONTENTS
- General ________________________________________________ 3
A. Cylinder attaching parts _________________________________ 7
B. Preliminary operations __________________________________ 8
C. Removing and refitting the shaft _________________________ 9
D. Disassembling and reassembling the supports ____________ 10
F. Service tools ___________________________________________ 11
Issue 1 May 2001

6G01.2 Rear axle - Lift cylinder supports
Issue 1 May 2001

Remarks
General - In both assembly configurations, an O’ring (19) be-
The lift shaft (7) fits into supports (2) (16) fitted to the tween the housing and the support provides oil tight-
centre housing. The lift shaft is splined at its ends and ness for channel "C".
operates the arms (5) (15). - Tractors also exist without hydraulic lift. In this case, a
The arm (5) is positioned by locating pin (4) inserted into plate covers the location of the supports (2) (16).
cam (8), itself integral with the shaft via splines. The
shaft drives the cam that informs the ELC calculator of The lower and lateral supports (1) of drawbars (7) are
the arm position via sensor (11). positioned by locating pins (3) and retained by bolts (4) on
Each support is positioned by two locating pins (13) force to the centre housing (Fig. 1).
fitted into the centre housing. Each support is fitted with a draft sensor (8) held by
Oil tightness of the bearings including friction bushes (10) locking plate (2), spacers (6) and bolts (5) (Fig. 1).
is provided by seals (1) (3) inserted in both sides of the A guard (9) fixed to supports (1) protects the sensor
support. harness (Fig. 1).
Special point Tightening torques

Two types of assemblies are possible on the left- - Bolts (4) on supports (1) (Fig. 1): 480 - 640 Nm, Loctite
hand support (Fig. 2) 270
Assembly 1 - Bolts (5): 50 Nm, Loctite 270.
- On support (16), a channel "C" and a port "O", linked to
the trumpet housings by external pipes, provide for air
venting in the centre housing and trumpet housings via
breather pipe (18).
Assembly 2
- On support (16), air venting in the centre and trumpet
housings is solely ensured by channel "C" and breather
(18).
- A plug (30) blocks the unused port.
5 3
9 4
2
8 1
Fig. 1
Issue 1 May 2001


Parts list
(1) Seal
(2) Right-hand support
(3) Seal
(4) Locating pin
(5) Right-hand side lift arm
(6) Bolts and washers
(7) Shaft
(8) Cam
(9) Bolts and washers
(10) Friction bushes
(11) Position sensor
(12) Nut
(13) Locating pins
(14) Grease nipples
(15) Left-hand side lift arm
(16) Left-hand side support
(17) Grooved spacer
(18) Breather pipe
(30) Plug
(31) O’ring
Assembly types (Fig. 2)

Assembly 1
- Tractors fitted with Heavy Duty trumpet housings with
sealed compartment or composite drive units.
Assembly 2
- Tractors fitted with standard or double drive unit trum-
pet housings.
Issue 1 May 2001

Overall view
Right-hand support
1 2 3 4 5 14 2
10 7
9 11
A
8 13 12
Left-hand support
32 16
18
6 15 3 16 1 14
13
7 10
B C
Assembly 1
19
A
17
30
31
Parts list Fig. 3 Assembly 2 Fig. 2
Issue 1 May 2001

Exploded view
31
30
O
7
1
32
18
16 8
10
3
3
9
17
6
10
2
4
1 14
12 13
11
19
15
29
Parts list
Fig. 2
Fig. 3
Issue 1 May 2001

Lift cylinder upper and lower attaching points Lift cylinder upper and lower attaching points
A . Cylinder attaching points 8210 - 8220 - 8240 and 8250 tractors 8260 to 8280 tractors
Layout of components
(20) Upper pins
(21) Retaining pins
(22) Cylinders
(23) Washers
(24) Grease nipples 20 21 20 21
(25) Snap rings
(26) Washers
(27) Lower pins
(28) Circlips
(29) Friction bushes
24 22 24 23
Fig. 4
23 29 23 29
22
24 22 26 24
27 26 28 25
28 25 27
Parts list Fig. 4
Issue 1 May 2001


B . Preliminary operations
1. Immobilise the tractor. Chock the front wheels. 2 1
2. If necessary, chock between the fcylindere and the
front axle. Remove the rear wheels or place them in
the wide track position. Position axle stands as
required. Remove the rear silent block bolts and
slightly tilt the cab forwards, checking that nothing
hinders this or touches the forward face of the cab.
Remarks
- Access to the right-hand side support is difficult
since one of the four retaining bolts is masked by the
high-pressure pipe (1) of the lift control and auxiliary
spool valves (Fig. 5)
- To remove the support, disconnect this pipe that runs
from the manifold on one hand, and the priority
blocks on the other (depending on options). Fig. 5
3. Disassemble union (2) (Fig. 5).
4. Remove the position sensor (11).
5. Take out the upper pins (20) from cylinders (22) and the
lift rod pins (Fig. 4).
Issue 1 May 2001

C . Removing and refitting the shaft

3 16 1 7
(7)
Removal
6. Take off breather pipe (18). Disconnect and remove
the union screwed into port "O" on support (16)
(depending on the assembly type, see Fig. 2).
7. Take out bolts (9) on each support. Using straps,
sling together the pin, supports and lifting arm and
remove them.
8. Recover the O’ring (19).
9. Take out bolts (6). Remove the lift arms, noting their
direction for reassembly. If necessary, extract bushes
(29) (Fig. 3). 3378123M1
10. Remove the cam (8) and grooved spacer (17).
11. Note the position of the supports (2) (16) and sepa- Fig. 6
rate them from the shaft.
23. Fit the washers on bolts (9) the threads lightly smea-
red with Loctite 270. Tighten to a torque of 240 -320
Nm.
Refitting 24. Check that none of the channels in support (16) are
12. Clean and check the components. Replace any obstructed. In the case of an Assembly 2 type (Fig.
parts found to be defective. 2), refit the plug (30) fitted with seal (31).
13. Use protector, ref. 3378123M1 (see § F). Slide sup- On an Assembly 1 type, fit the hydraulic union and
port (16) onto shaft (7) (Fig. 6) in the position pre- reconnect the pipe (see operation 6).
viously noted in operation 11. Proceed in the same On each type of assembly, check the cleanliness of
way with support (2). breather pipe (18) and screw it fitted with O’ring (32)
14. Check for the presence of locating pin (4) on cam (8). onto the left-hand side support.
15. On shaft (7), insert grooved spacer (17) and cam (8) 25. Manually check the axial clearance and the rotation
in contact with their respective supports (2) (16). of the shaft.
16. If necessary, replace friction bushes (29) using pin
(20) as an insertion tool.
17. Mark the position of locating pin (4) with a line of
paint on cam (8) and arm (5).
18. Lightly coat the splined ends of the shaft with Anti-
seize grease or its equivalent.
19. Refit the lift arms with the paint mark made previ-
ously on the arm (5) aligned with that on cam (8) and
side "A" of the arm flush with side "B" of the pin (see
Fig. 2).
20. Assemble the washers and bolts (6) the threads
lightly smeared with Loctite 270. Tighten to a torque
of 240 - 320 Nm.
21. Check for the presence of locating pins (13) inserted
into the centre housing at the location of each
support and O’ring (19) on the left-hand side support.
22. Using straps, correctly sling the assembly of pin,
supports and lift arm and position them on locating
pins (13).
Issue 1 May 2001


the supports (2) (16)
Disassembly
26. On each support, remove seals (1) (3) and grease
nipples (14).
Note: The reference for bush (10) is not found in
the spare parts catalogue. If it is worn or dam-
aged, replace the support.
Reassembly
27. Lightly smear the external diameter of seals (1) (3)
with Loctite 542 and insert them using service tool,
ref. 3378124M1, with the lip turned towards the
outside of the support (see § F).
28. Fit the grease nipples (14).
29. Refit the upper cylinder pins fitted with grease
nipples (24) respecting the location of washer (23).
30. Fit and adjust the position sensor (see section 11 -
Electronics).
31. Refit union (2) on the manifold and reconnect the high
pressure pipe (1) from the auxiliary and lift control
spool valves that was disassembled in operation 3.
32. If needed, place the cab on its rear supports. Tighten
the bolts previously lightly smeared with Loctite 270
to a torque of 200 - 260 Nm. Refit the wheels or place
them in their initial position. Remove the axle stands
(if used). Tighten all nuts and bolts to their correct
torque (see section 2G01).
33. Using a grease gun, grease the supports (2) (16), and
pins (20) (27).
34. Check the lift control operation. Check the oil tight-
ness of pipe (1) and union (2) (Fig. 5).
Issue 1 May 2001

F . Service tools
- 3378123M1 – Protector (Fig. 7)
- 3378124M1 – Seal insertion tools (Fig. 8).
Fig. 7
Fig. 8
Issue 1 May 2001

Rear axle - Creeper 6H01.1
6H01 Creeper
CONTENTS
- General ________________________________________________ 2
- Operation ______________________________________________ 2
A. Removing and refitting the unit __________________________ 5
B. Disassembling, reassembling and adjusting the selection

mechanism _____________________________________________ 7
C. Disassembling and reassembling the epicyclical reducer

gear ____________________________________________________ 11
D. Adjusting the control ____________________________________ 12
Issue 1 May 2001

6H01.2 Rear axle - Creeper

Operation (Fig. 1)
General The coupler (29) is integral via splines with the layshaft
All tractors in the 8200 range fitted with an AG150 or (30). The moving of the control lever to the "Snail" position
AG250 Full Powershift gearbox may be fitted, according moves the coupler rearwards and locks it to the planetary
to options, with a creeper. carrier (20) via coupler ring (22). The speed of the output
shaft is 1/4 of that of the input shaft.
This reducer unit (24) comprises a simple epicyclical
gear train having a planetary carrier and crownwheel
mounted at the front of the intermediate housing (19) Lubrication
(Fig. 1). The lubrication of the mechanical components of the
epicyclical reducer gear is ensured by an oil splash. The
It is controlled by a lever on the right-hand side console drive pinion and the layshaft (30) have an axial drilled
in the cab that is linked via a cable to a link fitted on the channel, this allows flow "D" from the right-hand side
front right-hand side of the intermediate housing. This link hydraulic cover to lubricate needle bearing (34) (Fig. 1).
moves the coupler control fork. The bearing supports the layshaft and permits a differ-
ence in rotation of the shafts when in the "Creeper"
The coupler, fitted with straight teeth, must only be position.
engaged when the tractor is stationary.
19 20 22 30 29 D
24
34
Fig. 1
Issue 1 May 2001


Overall view
Parts list
(1) Snap ring
(2) Connecting shaft
(3) Bolts
(4) Sleeve 26 28 27 36 37 35 16 17 18 14 26 25 27 28
(5) Support
(6) Snap ring
15
(7) Bearing carrier
(8) Circlip
(9) Circlip 14
(10) Ball bearing E
(11) Snap ring
(12) Friction washer 12
(13) Pin
(14) Friction plates
(15) Sun gears 11
(16) Crownwheel 13
(17) Spacers
(18) Roller bearings
(19) Intermediate housing A 12
(21) Snap ring 45
20
(22) Coupler ring A
(23) Bolts
(24) Planetary carrier assembly (reducer gear) 22
(25) Locating pin
(26) Nut B
(27) Fork 9 21
(28) Guide rod
(29) Coupler
(30) Layshaft 8 44
(31) Snap ring
(32) Sleeve
(33) Snap ring 19 40 38 41 39 4 1 2 10 23
(34) Needle bearing
(35) Locking stud
(36) Spring B 7
(37) Plug
(38) Pin 24
(39) Finger 3
(41) Pin 5
(42) Link Fig. 3
(43) Bolt
(44) Housing 43 42 6 19 34 29 30 31 32 33
(45) Shim(s) Fig. 4
Parts list
Fig. 3
Fig. 2 Fig. 4 Parts list Fig. 2 Fig. 4 Fig. 3
Issue 1 May 2001


Exploded view
3
1 5
6 8
9
4
7 10
2
11
12
16
25
45 20
42
12
44
23
26 43
38
40
18
28
41
35
36 17
39 14
37
15
27 14
13
19
21
22
29
31
34
30
32
33
Fig. 4
Issue 1 May 2001

A . Removing and refitting the unit

2. Remove the sleeve (4).
Removal
3. Remove bolts (3). Remove the shaft (2) and unit (24)
assembly.
Note: The locating pins (25) are force fitted into
the intermediate housing (19).
Refitting
4. Check for the presence of the locating pins on the
5. Screw two guide studs of suitable length in the place
of two bolts (3).
6. Place coupler (29) in contact with snap ring (31).
7. Refit shaft (2) and unit (24) assembly turning the
machined recess "E" on support (5) towards the
adjusting nut (26) on guide rod (28) (Fig. 3). Turn shaft
(2) several turns to engage the exterior splines of
coupler ring (22) in those of coupler (29).
8. Alternately and uniformly tighten bolts (3) lightly
smeared with Loctite 241 to a torque of 90 - 120 Nm.
Issue 1 May 2001

26 28 27 36 37 35
26 27 28 29 30 31 19
34
A
45
40 38 41 39 43 42
Fig. 5
Issue 1 May 2001

22. Fit the shaft, coupler and fork in the intermediate

B . Disassembling, reassembling and housing.
adjusting the selection mechanism 23. Refit the guide rod and nut assembly.
24. Refit the unit (24) (See § A).
Preliminary operations Adjust the fork (see subsequent operations).
10. Remove unit (24) (see § A).
11. Disconnect the control cable fitted to link (42).
Final operations
Disassembly (Fig. 5) intermediate housing (see section 2C01).
12. Remove plug (37). Recover spring (36) and locking 26. Connect the control cable and adjust it if necessary
stud (35). (see § D).
13. Remove the Allen screw (43). Remove the link (42)
and pin (41) fitted with seal (40) and finger (39).
Recover the shim(s) (45). Drive out pin (38) linking
the pin and the finger.
14. Disengage the guide rod (28) from the fork (27) and
15. If necessary, loosen, unscrew and discard nut (26).
16. Remove the fork, coupler and shaft (30) fitted with
needle bearing (34).
17. Remove snap ring (31).
18. If necessary, extract the bearing.
Refitting
20. If fitted, using an appropriate fixture, insert bearing
(34) thrust against the shoulder on layshaft (30) and
check that the needle bearing turns normally. Place
snap ring (31).
21. Lubricate a new seal (40) and fit it on pin (41). Enter
the pin through the chamfered port of the intermedi-
ate housing (19).
Reminder
- To limit axial clearance of the pin, it is recom-
mended to carry out shimming with a tolerance of
0.1 mm to 0.6 mm.
Shimming
- On the pin, place an approximate thickness of
shim(s) (45). Fit finger (39) and partially fit pin (39).
Reassemble the link (42) and bolt (43).
- Manually evaluate the existing clearance.
Remark
- The adjustment principle consists in obtaining a
minimum clearance between the various parts.
Action
- If the clearance is outside the maximum stated
tolerance, determine a new thickness of shim(s).
After shimming, check for the correct orientation of
the finger and the link. Definitively insert pin (38), fit
and tighten Allen screw (43).
Issue 1 May 2001

A 37
27
35
36
X2
X1 26 28
19 F4 F3
G1
F2
29
2 F1
Fig. 6
Issue 1 May 2001

Adjustment (Fig. 6)
- Fit the locking stud (35), spring (36) and plug (38).
Partially tighten the plug.
- Position coupler (29) in accordance with F1, its forward
face thrust against shaft (2).
- Maintain the fork thrust against the coupler in accord-
ance with F2. Turn the guide rod (28) in nut (25)
according to F3 so as to place in contact the oblique
face of groove G1 with locking stud (35) while simulta-
neously holding nut (26) against spot-faced face B of
- Using a depth gauge, measure X1 between the forward
face of the guide rod and face A of the intermediate
housing (19).
- Hold the fork thrust against the coupler in accordance
with F2.
- Turn the guide rod in the nut in accordance with F4 so
as to place the other oblique face of groove G1 in
contact with the locking stud while holding nut (26) as
previously.
- Measure X2 in the same manner as X1.
- Determine the position of adjustment X using the
following formula:
X = (X1 + X2) : 2
- Provisionally position guide rod (28) to dimension X.
- Place coupler (29) in the "Creeper unit" position. Manu-
ally check for locking of the control and the clearance
between the fork and the coupler.
- If this check is satisfactory, remove unit (24), plug (37),
the spring and the locking stud.
- Grease the threads of the guide rod and the threads of
nut (26).
- Tighten the nut, previously lightly smeared with Loctite
frein filet faibe, and definitively position the guide rod
according to the previously calculated dimension X.
- Lock the nut by bending its collar into the machined
groove of the guide rod.
- Reassemble the locking mechanism. Tighten plug (37)
to a torque of 50 - 70 Nm. Refit unit (24) (see § A).
Issue 1 May 2001

13 12 20 22 21 44 23
14
24
18
17
16 15 14 12 11 10 9 8 7 6 5
Fig. 7
Issue 1 May 2001

C . Disassembling and reassembling Final operations

the epicyclical reducer gear (Fig. 7) 42. If disassembled, insert bearing (10) on shaft (2)
using an appropriate fixture.
Preliminary operations 43. Fit circlips (8) (9) and snap ring (6).
27. Remove unit (24) (see § A). 44. Assemble supports (5) (7).
28. Take out bolts (23). Remove housing (44). 45. Engage reducer gear (20) on shaft (2).
29. Disengage reducer gear (20) from shaft (2). Remove 46. Refit the crownwheel (16).
crownwheel (16). 47. Position housing (44), with the cut out turned down-
30. Separate supports (5) (7). ward.
31. If necessary, take off snap ring (6) and circlips (8) (9). 48. Assemble and tighten bolts (23) previously lightly
Extract bearing (10). smeared with Loctite 241 and tighten to a torque of
10 - 14 Nm.
49. Refit unit (24) (see § A).
Disassembly
32. Remove the friction washers (12)
33. Take off circlip (11)
34. Drive out pins (13).
35. Remove sun gears (15) taking care not to lose the
needle bearings (18), spacers (17) and the friction
plates (14).
Remark
- The coupler ring (22) is fitted in the planetary carrier
using a press. Snap ring (21) provides additional
locking of the various parts.
Reassembly
36. Check and clean the components. Replace any
37. Fit each sun gear (15) with both needle bearings (18)
and spacer (17) smeared with miscible grease.
38. Refit the sun gears and position the friction plates
(14). Refit pins (13) correctly turning the spot-face for
the fitting of snap ring (11).
39. Fit the snap ring.
40. Manually check the axial clearance and rotation of
each sun gear.
41. Lightly smear the faces of the reducer gear with
miscible grease and fit the friction washers (12),
with the tabs lodged in the appropriate grooves.
Issue 1 May 2001

D . Adjusting the control

C
On lever "A" (Fig. 8)
50. Place control lever "A" in the "Snail" position.
51. Screw yoke (1) flush with the end of the threaded part 1
of the cable (6). 7
52. Fit the yoke (1) on to lever "A" with clip (7). Tighten
nut (2). 6
53. Tighten nut (3) against sheath end (5). A
54. Fit the sheath end and Grower washer on to the 4
support. Tighten nut (4) checking that the cable is not
pinched. 2
3
On link "B" (Fig. 9) 5

55. Place link "B" in the "Creeper" position (coupler (29)
locked by splines to planetary carrier (20) (Fig. 1) fork Fig. 8
locked).
56. Screw yoke (9) flush with the threaded part of cable
(6).
57. Assemble yoke (9) on to link "B" using clip (10).
Tighten nut (11).
58. Adjust stop (12) using nut (13) on support (8) while
checking that link "B" is still correctly locked.
59. Tighten nut (14) and check that the cable is not
pinched.
60. Check for correct operation and locking of the control
in the “Direct drive” position.
A
14
13 8 A
12
C
6
11 C
10
9 B
Fig. 9
Issue 1 May 2001

Rear axle - Brackets and automatic hook 6I01.1
6I01 Brackets and automatic hook
CONTENTS
- General ________________________________________________ 2
A. Identifying the brackets, yokes, swinging drawbars and

automatic hook _________________________________________ 2
B. Adjusting the rods and automatic hook control ___________ 4
C. Operating principle of the Dromone retractable hook ______ 6
Issue 1 May 2001

6I01.2 Rear axle - Brackets and automatic hook
General
The 8200 tractors can be fitted either with an automatic
hook or a bracket according to the models shown in § A
and depending upon the country and options.
A . Identifying the brackets, yokes,

swinging drawbars and automatic
hook (Fig. 1)
Brackets
a : brackets for standard swinging drawbar
b : brackets for swinging drawbar with roller
c : brackets with short ladder with a stud for attaching
the trailer eye-bolt
d : brackets with long ladder
Yokes
e : Lemoine standard yoke
f : Cramer automatic yoke
Swinging drawbars
g : standard swinging drawbars
h : swinging drawbar with roller
Hook
i : Dromone automatic hook
Tightening torques for bolts

- (1) : 480 - 640 Nm (Loctite 270, automatic hook only)
- (1) (2) (3) : 480 - 640 Nm
- (4) : 100 - 130 Nm
Issue 1 May 2001

1 2
2 1
b h
4
1
1
3
2 i
2
f
2 4
d
3 e
1
Fig. 1
Issue 1 May 2001


B . Adjusting the rods and automatic
hook control
Adjusting the rods
1. On the bracket, disconnect the lower yokes of the rods
and the control cable.
3. With the assistance of another operator, operate the
interior or exterior lift control (depending on option) so
that the lift arms are in the maximum high position
(continuous pumping).
4. Compress the lower part of the hook along the axis of
the tractor as indicated by F (Fig. 2), using a trolley jack
and to obtain a dimension X of 3.5 mm to 6.5 mm
between the top of the main bracket and the top of the
mobile plate (Fig. 2).
5. Adjust the length of the rods by turning their square F
section (1) so as to engage the yokes (2) on pins (3)
of the bracket (Fig. 2).
6. Fit the pins.
7. Remove the jack.
8. Reconnect the control.
X 3
Fig. 2
Fig. 3
Issue 1 May 2001

Adjusting the control

On the lever (Fig. 4)
10. Place the "L" lever in the "Neutral" position.
11. Screw yoke (1) flush with the threaded end of cable
(2). 1 4
12. Assemble the yoke on the lever using clip (3).
Tighten nut (4). 2
13. Adjust the sheath end (5) on bracket (6) with an equal
length of thread showing on each side of the nuts (7)
L
(8).
5
Note: Check that the cable is not pinched.
8
On the automatic hook (Fig. 5)
14. Screw yoke (1) flush with the threaded end of the 6
cable (2). 7
3
15. Fit the yoke on link B using clip (3) and ensure that L
the link is in the locked position. Tighten nut (4).
16. Assemble the sheath end (5) in bracket (6) and
tighten nuts (7) (8) so that there is no play in cable (2)
and the cable is not pinched.
Note: During adjustment, take care that link B
remains locked.
Fig. 4
7
2
4
3
B
1
Fig. 5
Issue 1 May 2001

C . Operating principle of the

1
Dromone retractable hook
Construction (Fig. 6)
- The automatic hook assembly comprises a main bracket
(1) fixed to the centre housing, a mobile plate (2) that
can be raised or lowered by the lift control and a
retractable hook (3) operated by a double acting hydrau-
lic cylinder (4).
2
Operation (Fig. 8)
Plate lowered 4
- When the manual valve (1) is opened and the auxiliary
lever No. 1 (Fig. 7) located on the console is operated, 3
the high pressure passing through the unions (2) con- Fig. 6
nected to quick-disconnect couplings A and B of the
spool valve concerned supplies the double acting cyl-
inder (4) integral with the retractable hook (3).
- The hook can then extend and retract to connect a
trailer, depending on the position the auxiliary lever is
placed in. 3
2
Plate raised
- In this configuration, the locking safety of the retract-
able hook is provided when it is at maximum retraction, 1
with plate (2) (Fig. 6) previously raised and engaged.
- The principle is two mechanical locks located at the
rear of the main bracket. When the previously stated
conditions exist, the lock bolts enter their respective
recesses in the retractable hook and prohibit any further
movement.
On placing in the safety position, the locks must
produce a clack that is audible by the operator during
maximum retraction of the hook.
Note: During retraction of the hook, the operator in
the driving seat should check that the gear and
handbrake levers are in the neutral position. This
facilitates the coupling of a trailer.
Fig. 7
Issue 1 May 2001


- When valve (1) is closed, the cylinder is hydraulically
isolated from the auxiliary spool valve and thus permits
normal use of the spool valve.
B
Reminder
- Periodically grease the safety lock mechanism and the
mobile plate control cable.
Checking on the safety locking

A
- Open the valve and check that the lock is correctly
engaging, by placing the auxiliary spool valve lever
concerned in both positions. 2
- The hook must not extend beyond the plate. If it does,
seek the cause of the problem.
4 3
Fig. 8
Issue 1 May 2001

Rear axle - Rear hitch mechanism 6J01.1
6J01 Rear hitch mechanism
CONTENTS
A. General ________________________________________________ 2
B. Description of the hitch mechanism ______________________ 2
C. Disassembling and reassembling a lift cylinder ____________ 5
Issue 1 May 2001

6J01.2 Rear axle - Rear hitch mechanism
A . General
On 8200 tractors, the hitch comprises several compo-
nents that are, depending on the options and the country:
- a hook or ball joint 3-point hitch
- two lower bars with ball joints, automatic hook or
telescopic links (depending on version)
- two levelling units
- two tube or thrust type blades
- a perforated bar
B . Description of the hitch mecha-

nism
a : 3-point hitch bars (Fig. 4)
b : levelling units (Fig.3)
c : ball joint lower bars
d : lower links with automatic hooks (Fig. 1)
e : lower links with telescopic end-pieces
f : tube type (Fig. 6) or thrust type blades (Fig. 5)
g : perforated bar (Fig. 2)
Special point
- For the adjustment of tube type blades, refer to Opera-
tor Instructions Book.
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Issue 1 May 2001

b
f
c
Parts list
e
Parts list
Fig. 1
g
f
IMPORTANT
Improper positionning
of stabilizers may
cause damage. See
Operator Instruction
Book.
VOIR MANUEL D'UTILISATION
Fig. 2 Fig. 4 SEE OPERATOR INSTRUCTION BOOK

VEDRE LIBRETO D'USO
SIEME BETRIEBS AMLEITUNG
VER MANUAL DEL OPERATOR
SE INSTRUKSIONS BOKEN FOR JUSTERING
Fig. 6
Parts list Parts list
Parts list
Issue 1 May 2001
6J01.4 Rear axle - Rear hitch mechanism
Issue 1 May 2001

C . Disassembling and reassembling

a lift cylinder
Remark O 1
On 8200 tractors, there are two models of lift cylinders
depending on the type of tractor:
- 8210 - 8220 - 8240 - 8250 tractors
. Ø 95 mm cylinders
- 8260 to 8280 tractors
. Ø 105 mm cylinders
1. Run the engine and lower the lower bars to their
maximum using the ELC.
2. Disconnect the feed hose, remove the cylinder and 3
empty it of oil.
2
3. Remove the 90° union (1) fitted with its O’ring. 4
4. Push the cylinder ram (5) until snap ring (4) is visible
in port O of the union.
5. Introduce a screwdriver in this port and while turning
the cylinder ram push the snap ring into the V-shaped
recess. 5
6. Remove the ram and seal (4). Drive off scraper seal
(2) and oil seal (3) (systematically discard these three 4
parts).
5
Reassembly
Special point
- Carefully clean all components. Replace any parts that
are scratched or bowed. In cases of seizing up or Fig. 7
serious scratching, replace the cylinder and ram.
7. Dry all components using compressed air. Final operations

8. Lubricate the assembly with clean transmission oil. 10. Lubricate the upper and lower pins with anti-seize
9. Proceed with assembly of the cylinder. Carry out grease and refit them. Reconnect the feed hose.
operations 3 to 6 in reverse order. 11. Run the engine. Using the ELC, raise the lower hitch
Special points bars into the high position and vice versa.
- New seals and snap rings must always be fitted. 12. Check that the hitch is operating correctly and that
- Use an appropriate fixture to force fit the parts there are no oil leaks around either cylinder or ram.
without damaging the seals.
- Fit the ram into the cylinder with care.
Issue 1 May 2001

7 . POWER TAKE-OFF
Contents
7 A01 PRESENTATION OF THE POWER TAKE-OFF
7 B01 DRIVE PINIONS - BEARINGS - LAYSHAFT
7 C01 REMOVABLE SHAFT
7 D01 SHIFTABLE PTO SHAFT
7 E01 1000 RPM POWER TAKE-OFF SHAFT
7 F01 CLUTCH AND BRAKE
Issue 1 May 2001

Power Take-off - Description 7A01.1
7A01 Description of the Power Take-off
CONTENTS
A. General ________________________________________________ 2
B. Overall views ___________________________________________ 4
Issue 1 May 2001

7A01.2 Power Take-off - Description

Type "b" (Fig. 4)
A . General - the clutch unit is integral via splines with two pinions
Description that are constantly engaged with the 540 / 1000 rpm or
750 / 1000 rpm pinions that rotate the power take-off
The power take-off housing, fitted to the rear of the centre
output shaft when the coupler is either moved for-
housing, houses all mechanical components of the rear
wards, to the 540 / 1000 rpm position, or rearwards to
power take-off on the 8200 series tractors.
the 1000 rpm position, depending on the speed re-
The power take-off is independent of the transmission.
quired.
On tractors fitted with a Heavy Duty gearbox, the input
shaft is integral via splines with the vibration damper
Type "c" (Fig. 5)
fixed to the engine flywheel. It transmits the engine
- the clutch unit is integral via splines with a single pinion
speed to the power take-off multi-disc clutch via a
that is constantly engaged with the 1000 rpm pinion that
shaftline comprising two layshafts.
rotates the power take-off output shaft.
The first layshaft is linked by splines to the engine input
Remark
shaft and, at the front, to the hydraulic pump drive pinion.
- In the type "c", a spacer replaces the 540 or 750 rpm
The second layshaft is splined at the front on the
drive pinion. The coupler is integral via splines with the
hydraulic pump drive pinion and at the rear on the power
1000 rpm drive pinion. It is held in place by a snap ring
take-off clutch.
located on the hub. This hub is itself immobilised by
On tractors fitted with an AG150 or AG250 Full Powershift
another snap ring fitted on the output shaft.
gearboxes, the engine speed is transmitted to the power
take-off clutch by a shaftline comprising four shafts.
The first shaft is likewise driven via the vibration damper
When the clutch is disengaged and the control button in
fitted to the engine flywheel. The second shaft, passing
the cab is placed in the "PTO brake" position, the 17 bar
through the gearbox, is linked to the third shaft by a
pressure acts upon piston (1) and it enters in contact with
sleeve and drives the hydraulic pump drive pinion. As in
the outside edge of unit (6) and thus brakes its rotation
the version mentioned above, the last shaft is splined at
(Fig. 1).
the front on the hydraulic pump drive pinion and at the rear
on the power take-off clutch.
Types of power take-off available

"a" : with long or short removable shaft - 540 / 1000 rpm
or with an option of 750 / 1000 rpm
"b" : with a jaw coupler and short or long shaft with disc
- 540 / 1000 rpm or 750 / 1000 rpm
"c" : with fixed coupler and shaft with disc - 1000 rpm
Type "a" (Fig. 3)

- the clutch unit is integral via splines with a double pinion Section EE
that is constantly engaged with the 540 / 1000 rpm or
750 / 1000 rpm pinions that rotate the 1000 rpm shaft
or the 750 rpm shaft at the required speed.
1
Fig. 1
Issue 1 May 2001

Construction
The clutch, located on the upper shaftline, is supported
by two taper roller bearings. The bearing cups are fitted
in two carriers fixed to the power take-off housing and the
bearing cones are positioned on two spans inside the
clutch housing.
The front bearing cone is force fitted on:

- the clutch unit (type "a" PTO)
- the 540 or 750 rpm pinion drive pinion (type "b" PTO)
- the spacer (type "c" PTO)
The rear bearing cone is mounted free on all types. The

bearing clearance is adjusted by means of shims placed
between the two carriers.
The lower shaftline comprises: Fig. 2

- A unit fixed by bolts on the rear of the centre housing,
in which a roller bearing (type "a" PTO) is fitted.
On the other types, this bearing is force fitted, preceded
by an oil deflector, in the centre housing.
- A rear bearing comprising two taper roller bearings;
their clearance is adjusted by shims placed between
the power take-off housing and the bearing.
On the type "a" power take-off, the previously stated
bearings are fitted on a sleeve integral with the power
take-off output shaft.
- A cassette seal provides oil tightness for the bearing.
Depending on the type of power take-off, the type of tool

that is to be driven and the recommended rotational
speed, the output shafts (Fig. 2) (removable or with
interchangeable end-piece) may be of different lengths
and have 6, 20 or 21 splines.
Issue 1 May 2001

7A01.4 Power Take-off - Description
B . Overall views
Type "a"
E E
Fig. 3
Issue 1 May 2001

Type "b"
Fig. 4
Type "c"
Fig. 5
Issue 1 May 2001

Power take-off - Driving pinions- Bearings - Layshaft 7B01.1
7B01 Driving pinions - Bearings - Layshaft
CONTENTS
- General ________________________________________________ 2
A. Removing and refitting the driving pinion, bearings and

layshaft ________________________________________________ 5
B. Shimming ______________________________________________ 7
Issue 1 May 2001

7B01.2 Power take-off - Driving pinions- Bearings - Layshaft

Parts list
General (1) Circlip
On tractors in the 8200 series, the layshaft, clutch, (2) Bearing cone
bearings and driving pinion form the upper shaft line of the (3) Bearing cup
rear power take-off. (4) Cover
(5) Shims
The upper shaftline passes through the intermediate and (6) Unit housing
centre housings to then transmit the engine speed to the (7) Bearing cone
driving pinions located in the rear housing. (8) Bearing cup
(9) Driving pinion
The layshaft is supported at the front by a bearing block (10) Spacer
mounted on two ball bearings housed in the bore of the (11) Driving pinion(s)
intermediate housing and at the rear by the clutch (12) Circlip
assembly (15) in which the driving pinions are integral via (27) Bolt
splines. (28) Layshaft
On unit (23), the cups (3) (8) are free mounted in their
respective bores. The bearing cone (7) is mounted free on Fig. 1
the splined part of the clutch. Depending on the type of
power take-off, the bearing cone (2) is force fitted on:
Fig. 2
- the clutch unit (15)
- the pinion (9)
- the spacer (10)
Identification of the assemblies corresponding to the

types of power take-off available
"a" : removable shaft
"b" : jaw coupler
"c" : 1000 rpm
Issue 1 May 2001

Overall view
Front bearing with

Full Powershift gearbox 3 4 5 27 7
23
1 12 28 2 11 6 8
9 11
15
23
28
Parts list
Front bearing with 10 11
Heavy Duty gearbox
Fig. 2 Fig. 1
Issue 1 May 2001

Exploded view
15
23
2
3
27
4
b 5
11
6
8
7
9
2
11
10
2
11
Issue 1 May 2001

Remark
- Uncouple the power take-off housing from the centre
housing (see section 2E01) to carry out maintenance on 4
the following components:
- driving pinion(s)
- unit housing (6)
- cover (4)
- bearings (2) (3) and (7) (8)
A . Removing and refitting the dri-

ving pinion, bearings and layshaft 11 6 5 27
Special points (Fig. 1) Fig. 3

- If the layshaft (28) mounted on tractors fitted with Full
Powershift transmission has to be replaced, it is abso-
lutely necessary to remove the left-hand side hydraulic
cover (see section 9H01) to gain access to circlip (1), 4
since this will not pass through the hole provided in the
wall of the intermediate housing. Before removing the
shaft, visually note its profile in order to later pass the " D"
crownwheel of the bevel gear through.
- On tractors fitted with Heavy Duty transmission, the
layshaft does not has a circlip (1).
Removal
1. Remove and separate the clutch (15) and unit (23)
assembly (see section 7F01, § B ).
Assembly "a" (Fig. 2 - 3) 11 6

2. Extract bearing cone (2) from the clutch unit and
remove it. Take off bolts (27), cover (4) and shim(s) Fig. 4
(5).
3. Take out the driving pinion (11) from unit (6).
4. Disassemble the cups (3) (8) (as required).
Assembly "b" (Fig. 2 - 4)

5. Remove pinion (9) and bearing cone (2). Take out cup
(3) from the cover (4).
6. Remove the cover and shim(s) (5).
7. Take out cup (8) from unit (6). Extract cone (2) (as
required).
Assembly "c" (Fig. 2)

- On this type of assembly, the method is similar to that
used for assembly "b" type.
Issue 1 May 2001


Refitting
Reminder
- If maintenance has been carried out on one of the
components stated at the beginning of this section, it is
important to carry out shimming of the bearings (2) (3)
and (7) (8) (see § B).
Assembly "a"
8. If disassembled, place cups (3) and (8) in cover (4)
and unit (6) respectively.
9. Refit the driving pinion (11), the shim(s) (5) (if
adjustment is not necessary), the cover (4) and the
bolts (27) on unit (6).
bearing cone (2) into the clutch housing.
Assembly "b"
11. If disassembled, place cups (3) and (8) in cover (4)
and unit (6) respectively.
12. Position pinion (11) in unit (6), the long offset "D"turned
to face cover (4) (Fig. 1 - 4).
13. Refit the shim(s) (5) (if adjustment is not necessary),
the cover (4) and bolts (27) on unit (6).
bearing cone (2) in pinion (9).
Assembly "c"
- In this type of assembly, assemble the components
using the assembly principle used in the “b” type
assembly.
15. Reassemble and refit clutch (15) and unit (23) as-
sembly (see section 7F01, § B).
Issue 1 May 2001

B . Shimming
J1 = 0 / 0,10mm
16. Assemble clutch (15) with unit (23) (see section
7F01, § B ).
17. Fasten the cover (4) and the unit housing (6) with four 23
bolts (27) and nuts (14) that should be supplied
locally (Figs. 5 - 6). Hold the assembly (23) in a vice
fitted with soft jaws (Fig. 5).
Shimming (Fig. 5 – 6) a
18. Place the index of a dial gauge on the end of the
sleeve (10).
19. Pull hard on the clutch unit while turning it alterna-
tively left and right in order to correctly seat the cones
in the cups.
21. Repeat operation 19, but this time by pushing.
22. According to the provisional clearance measured on J1 = 0 / 0,10mm
the dial gauge, determine a new thickness of shim(s)
(5) to obtain a definitive clearance (Fig. 6): 4 5 27
J1 = 0 to 0.10 mm.
14
23
J1 = 0 / 0,10mm
14 6 4
10 14 23 27
Fig. 5 Fig. 6
Issue 1 May 2001

Power take-off - Removable shaft 7C01.1
7C01 Removable shaft
CONTENTS
- General ________________________________________________ 2
A. Disassembling and reassembling 540 - 1000 rpm

or 750 - 1000 rpm pinions ________________________________ 5
B. Disassembling and reassembling the front bearing block ___ 5
C. Disassembling and reassembling the bearings ____________ 6
D. Removing and refitting the shaft and replacing the

oil seal _________________________________________________ 7
E. Shimming ______________________________________________ 8
F. Service tools ___________________________________________ 9
Issue 1 May 2001

7C01.2 Power take-off - Removable shaft

Part list
General (1) Front bearing
On 8200 series tractors, the driven pinions (7) (18) are (2) Bearing cup
fitted on the power take-off shaft located on the lower (3) Bearing cone
rear housing. (4) Castellated washer
(5) Serrated sleeve
These pinions are constantly engaged with the driving (6) Snap ring
pinion(s) (depending on version) and driven by the upper (7) 540 or 750 rpm driven pinion
shaftline where the engine speed is transmitted by the (8) Bearing cone
power take-off clutch. (9) Protector
(10) Friction washer
At the front, the removable shaft (12) turns on a roller (11) Bolt
bearing (24) inserted into a fixed bearing block on the rear (12) Shaft
of the centre housing. (13) Bolt
(14) Cassette seal
At the rear, the shaft is supported by a splined sleeve (5) (15) O'ring
that turns in taper roller bearings. (16) Circlip
(17) Circlip
Washer (4) is integral via a tab with sleeve (5) which itself (18) 1000 rpm driven pinion
is integral with shaft (12) via splines. The sleeve is (19) O'ring
serrated all around its outside edge and transmits speed (20) Friction washer
information to the onboard electronic system via the (21) Bearing cup
sensor located on the right-hand side of the rear housing. (22) Bearing
(23) Shim(s)
An oil splash from the centre housing along with a central (24) Roller bearing
port and radial channels drilled in the shaft provide
lubrication of the: Fig. 1
- friction washers (10)
- taper roller bearings.
Fig. 2
In the 540 rpm or 750 rpm (optional) configurations, the
shaft (12) is integral with pinion (7) via splines. Pinion (18)
is an idling gear that runs on the hubs of pinion (7) and
sleeve (5).
In the 1000 rpm configuration, the shaft (12) is integral

with pinion (18) via splines. Pinion (7) is an idling gear that
runs on the hub of pinion (18) and the front bearing.
The oil tightness of the rear bearing is provided by

cassette seal (14) and O’ring (15).
Bearing clearance is adjusted by shim(s) (23) placed

between the rear housing and bearing (22).
Issue 1 May 2001

Overall view
10 2
11 23
22
21
12
24 1 20 7 10 18 17 16 15 14 13 6 19 9 5
540 / 750
1000
Issue 1 May 2001


Exploded view
540 / 750
1
1000
24 7
10
18
10
11
20
17
2
3
4
8
21
16
14
23
15
22
13
12
6
5 Parts list
19
12 Fig. 1
Fig. 2
Issue 1 May 2001

Special point
- The removal and refitting of the power take-off housing
is necessary for all maintenance operations on the the front bearing block (1)
layshaft apart from the removal of bearing (22), the
replacement of seals (14) (15) and shaft (12). The centre Disassembly
housing must be drained either partially or completely 11. Uncouple the power take-off housing from the centre
depending on the operation and must be brought up to housing (see section 2E01 and carry out operation 2,
level again after the maintenance. § A).
12. Take out bolts (11). Remove the front bearing block
(1).
13. Where necessary, note the manner in which bearing
(24) is assembled and then extract it from the
bearing block.

Reassembly
pinions 540 - 1000 rpm or 750 - 1000 14. Clean and check the components. Replace any
rpm parts found to be defective.
15. If disassembled, position bearing (24) using an
Remark appropriate insertion drift, with the rounded cage
- The 540 - 1000 rpm and 750 - 1000 rpm versions have holding the rollers turned to face the forward end of
the same assembly configuration. The only difference shaft (12).
is that the 540 rpm and 750 rpm pinions have a different 16. Refit bearing block (1). Fit and tighten bolts (11) with
number of teeth. their threads lightly smeared with Loctite 241 and
tighten to a torque of 27 - 35 Nm. Carry out operation
Disassembly 9 § A.
1. Uncouple the power take-off housing from the centre 17. Couple the power take-off housing to the centre
housing (see section 2E01). housing (see section 2E01).
2. Recover the friction washer (20).
3. Remove snap ring (6) and support driven pinions (7)
(18).
4. Pull shaft (12). Remove the pinions. Recover the
friction washer (10).
Reassembly
parts found to be defective. Check that the oil
channels in shaft (12) are not obstructed. Check that
the interior of sleeve (5) is clean and free of burrs.
Lubricate and fit a new O’ring (19).
6. Assemble driven pinions (7) (18) and friction wash-
ers (10) smeared with miscible grease and placed
according to the overall view. Maintain the pinions
inserted and thrust against sleeve (5).
7. Engage shaft (12) against the shoulder of the sleeve.
8. Fit snap ring (6).
9. Smear friction washer (20) with miscible grease and
apply it against bearing (24).
10. Couple the PTO housing to the centre housing (see
section 2E01).
Issue 1 May 2001


the bearings
Disassembly
18. Uncouple the power take-off housing from the centre
19. Take out the bolt from the lower sensor and remove
it. Disassemble the pinions and the shaft (see § A).
20. Take out bolts (13), remove bearing block assembly
(22) comprising sleeve (5), oil seal (14), O’rings (15)
(19), shim(s) (23), bearing cup (21), bearing cones (3)
(8) and castellated washer (4).
21. Take off bearing cup (2).
22. On sleeve (5), remove circlip (17). Remove bearing
cone (3), castellated washer (4), bearing cone (8)
and circlip (16).
Reassembly
Special point
- If the power take-off housing, bearing block (22), taper
roller bearings (2) (3) (8) (21) or castellated washer (4)
had to be replaced, the bearings must be shimmed
again (see § E).

channels in shaft (12) are not obstructed.
24. On sleeve (5), place circlip (16), bearing cones (3) (8)
separated by castellated washer (4). Fit circlip (17).
25. Refit cup (2), sleeve (5) assembled, cup (21), bearing
block (22) with shim(s) (23) according to the method
described in operations 39, 41 and 42 § D, as well as,
after lubrication, O’rings (15) (19). Fit and tighten
bolts (13) to a torque of 72 - 96 Nm.
26. Refit the 540 - 1000 rpm or 750 - 1000 rpm pinions
and shaft (12) (see § A).
27. Couple the power take-off to the centre housing (see
section 2E01).
28. Refit the sensor, O’ring and bolt
Issue 1 May 2001

40. Hold the shaft (12) pushed forwards, as described in

D . Removing and refitting the shaft operation 35.
and replacing the oil seal 41. Alternatively and uniformly screw two bolts and
washers on the threaded rods so as to insert the
Removing the shaft bearing parallel with the face of the housing.
29. Partially drain the centre housing in order to avoid oil 42. Remove the threaded rods. Fit and tighten the initial
from running through the shaft bore, or raise the rear bolts (13) to 72 - 96 Nm.
axle of the tractor (after chocking the front wheels). 43. Top up the oil level in the housings and check it on
30. Remove O’ring (6). Take out shaft (12). Take off the transparent tube mounted on the left-side of the
O’ring (19). centre housing.
Refitting
31. Check that the interior of sleeve (5) is clean and free
of burrs. Lubricate and fit a new O’ring.
32. Check that the channel in the shaft is not obstructed.
Clean and then engage the shaft thrust up against the
shoulder on sleeve (5). Refit snap ring (6).
33. Remove the trolley jack.
Replacing the oil seal (14) on rear bearing

block (22)
Removal
34. Partially drain the centre housing.
35. Take out bolts (13), remove bearing block (22) while
holding the shaft (12) pushed forwards in order not to
displace sleeve (5) on pinion (18). Take off seal (15).
Recover the shim(s) (23).
36. Note the direction of assembly of seal (14) and then
extract it.
Reassembly
38. If necessary, before fitting seal (14), see note § E.
Lightly smear the external diameter of seal (14) with
Loctite 542. Using a press and tool ref. 3378115M1,
insert the cassette seal into the bearing block (22)
with its lip turned to face taper roller bearing (8) (21).
39. Screw two diametrically opposed threaded rods (Ø
10 x 150, length approximately 50 mm) in place of
bolts (13). Check that sleeve (5) is free from burrs.
Lubricate the internal diameter of cassette seal (14)
with transmission oil. Refit the bearing block fitted
with lubricated seal (15) and the shims (23) removed
during disassembly.
Issue 1 May 2001

E . Shimming (Fig. 3 - 4)
Note: Carry out the shimming of bearings (2) (3) and
(8) (21) before fitting seal (14).
44. Using a depth gauge, measure dimension A on the 2

power take-off housing. B
45. Place the sleeve prepared in operation 24, the bear-
ing cups and bearing block (22) thrust against a
locally manufactured support.
46. With the help of an operator, apply strong continuous 22
pressure around the rim of the cup (2). At the same
time, alternately turn the sleeve left and right in order
to correctly seat the bearing cones in their cups.
Measure dimension B at two opposing points. Take
the average of the two measurements.
47. Apply the formula B - A. Place a thickness of shim(s)
(23) in order to provide a clearance of:
J1 = 0.05 mm to 0.15 mm.
J1 = 0,05
8 21 23
/ 0,15
2 3 8 21 5
Fig. 3 Fig. 4
Issue 1 May 2001

F . Service Tools
- 3378115M1 - Insertion tool for cassette seal (14) on
power take-off bearing block (Fig. 5).
Fig. 5
Issue 1 May 2001

Power take-off - Shiftable PTO shaft 7D01.1
7D01 Shiftable PTO shaft
SOMMAIRE
- General ________________________________________________ 2
A. Disassembling and reassembling 540 / 1000 rpm or

750 / 1000 rpm pinions, fork and bearing __________________ 5
B. Removing, refitting and disassembling, reassembling

the rear bearing block, oil seal and shaft bearings _________ 6
C. Shimming ______________________________________________ 7
D. Long shaft version ______________________________________ 7
E. Adjusting the control ____________________________________ 8
F. Service tools ___________________________________________ 9
Issue 1 May 2001

7D01.2 Power take-off - Shiftable PTO shaft

Parts list
General (1) Locking ring
On tractors in the 8200 series, the driven pinions (7) (18) (2) Circlip
are fitted on the power take-off shaft located at the lower (3) Bearing cone
part of the rear housing. (4) Castellated washer
(5) Interchangeable end piece (shaft with disc)
These pinions are constantly engaged with the driving (6) Bolt
pinions driven by the upper shaftline where the engine (7) 540 or 750 rpm driven pinion
speed is transmitted via the power take-off clutch. (8) Bearing cone
(9) Protector
The power take-off shaft is supported at the front by a (10) Coupler
roller bearing (24) that is force fitted into the centre (11) Hub
housing. It is free fitted in bearing cones (3) and (8) of the (12) Shaft
rear bearing block (22). (13) Bolt
(14) Cassette seal
Hub (11) of the coupler is integral with shaft (12) via (15) O’ring
splines. The pinions (7) (18) drive the shaft when coupler (16) Circlip
(10) is moved either forwards (540 or 750 rpm), or (17) Circlip
rearward (1000 rpm). When one of the pinions (7) (18) (18) 1000 rpm driven pinion
transmits movement to the lower layshaft, the other (19) Bearing cup
pinion is passive and idles on its shaft. (20) Splined washer
(21) Bearing cup
A fork (31) fitted on pin (28) allows selection of the (22) Bearing block
required speed (540 - 750 - or 1000 rpm). This fork may (23) Shim(s)
be controlled by an external lever located on the right- (24) Roller bearing
hand side of the housing or via a cable operated by a lever (25) Oil deflector
placed inside the cab. (26) Locking ring
(27) O’ring
The oil tightness of the rear bearing block is ensured by (28) Pin
cassette seal (14) and O’ring (15). (29) Pads
(30) Set screw
Bearing clearance is adjusted by shim(s) (23) inserted (31) Fork
between the rear housing and bearing block (22). (32) O’ring
(33) Control link Fig. 1
The castellated washer (4), via its rotation, transmits (34) Bolt
information to the sensor (output speed of shaft (12)) and (35) Locating pin
(36) Plug Fig. 2
equally serves as a spacer for bearing cones (3) (8).
Identifying the controls (Fig. 1 - 2)

Lubricating the pinions A : External control
Lubrication is ensured by the transmission oil. The oil B : Internal control via cable and lever
splashed and held in deflector (25) lubricates roller
bearing (24) and taper roller bearings (3) (19) (8) (21) via
the shaft (12) which is fitted with an axial channel and
drilled radial ports.
Issue 1 May 2001

Overall view
26 1 19 3 4 21 23 8 22
14 12 6 5 9
25 24 2 20 7 11 10 18 17 16 15 13 33 34
540 / 750 1000
A
FRONT REAR
1000 540 / 750
1000 540 / 750
FRONT REAR
33
B
34 27 28 29 30 31 29 32 33
Parts list
27 36 Fig. 2
Fig. 1
Issue 1 May 2001

Exploded view
33
25 32
24 28
2 31 A
20 30
27
29
10
7
26
11
540 / 750
B 36
1
18 1000
17
19
3
4
8 13
21 12
16 35
14
23
15
22
Issue 1 May 2001

Special points
- The removal of the power take-off housing is necessary
for all maintenance concerning the lower layshaft line,
except for the disassembly of the interchangeable shaft 7
(5).
18
- The centre housing must be drained during mainte-
nance and refilled afterwards.

540 - 1000 rpm or 750 - 1000 rpm 1
pinions, fork and bearing (24)
Preliminary operation Fig. 3
1. Uncouple the power take-off housing from the centre
11. Lubricate the ring (1) of pinion (18) (Fig. 3). Slide the
pinion on to shaft (12).
Disassembling pinions and fork 12. Assemble the locking ring (1).
2. Take off circlip (2) and splined washer (20). 13. Assemble the hub assembly (11), coupler (10) and
3. Remove the clutch (15), unit (23) and pinion (7) fork (31) assembly with the pads (29) smeared with
assembly (see section 7F01 § B). miscible grease. Fit new O’rings (27) (32) on pin (28)
4. Take out set screw (30). Remove pin (28), link (33) and slide it through the bores of the power take-off
and the fork fitted with its pads (29). housing.
5. Take off the locking ring (26), hub (11) and coupler 14. Position the fork. Fit and tighten the set screw (30)
(10); locking ring (1) and driven pinion (18). previously lightly smeared with Loctite 241. Fit ring
6. Take off and discard the O’rings (27) (32) on pin (28). (26).
15. Lubricate ring (1) of pinion (7) (Fig. 3).
16. Slide pinion (7) on to shaft (12). Refit the clutch (15)
Disassembling bearing (24) and unit (23) assembly (see section 7F01 § B).
7. Where necessary, note the direction of bearing (24) Place washer (20) and fit circlip (2).
and then extract it from the centre housing using an 17. Manually check the rotation of the mechanical as-
inertia tool. Remove deflector (25). semblies.
18. Assemble link (33). Tighten bolt (34).
19. Using either the external control or the control lo-
Reassembling the bearing cated inside the cab, check that coupler (10) en-
8. Clean the components. Replace any parts found to gages correctly on the 540 - 1000 rpm or 750 - 1000
be defective. Check that the oil channels in shaft (12) rpm pinions.
are not obstructed.
9. Position deflector (25) in the bore of the centre
housing in accordance with Fig. 1. Final operation
10. Using an appropriate insertion drift, fit bearing (24) 20. Couple the power take-off housing to the centre
with the rounded cage facing the front end of shaft housing (see section 2E01).
(12) and thrust against the deflector.
Reassembling pinions and fork

Note: if the locking ring (1) (not referenced in the
spare parts catalogue) is worn, replace the pinions
(7) (18) (Fig. 3). The rings are bored and brought to the
correct dimension after insertion.
Issue 1 May 2001


31. Lubricate the internal diameter of seal (14) with
B . Removing, refitting and disas- transmission oil. Insert shaft (12) in the seal of
sembling, reassembling the rear bearing block (22).
32. Place circlip (16), refit cup (21), bearing cone (8),
bearing block, oil seal and shaft bea castellated washer (4) and bearing cone (3). Fit
rings circlip (17).
Removing the bearing block

21. Disassemble the 540 - 1000 rpm or 750 - 1000 rpm Refitting the bearing block
pinions (see § A). 33. Refit cup (19) and shaft (12) previously assembled
22. Take out the sensor (shaft output speed (12)) located with bearing block (22), the bearings and O’ring (15)
on the right-hand side of the housing. and place in the bore of the power take-off housing.
23. Remove bolts (13), pull on the interchangeable end 34. Place and tighten bolts (13) to a torque of 72 - 96 Nm.
piece (5) and take out the bearing block assembly 35. Refit the 540 - 1000 rpm or 750 - 1000 rpm pinions
(22) comprising: and fork (see § A).
- oil seal (14) 36. Couple the power take-off housing and the centre
- O’ring (15) housing (see section 2E01).
- shim(s) (23) 37. Refit the sensor fitted with its O’ring.
- bearing cups (3) (8) 38. If the interchangeable end-piece (5) has been disas-
- castellated washer (4) sembled, check for the presence of locating pin (35).
24. Take cup (19) out of the housing. Refit the end-piece. Lightly smear the threads of bolt
(6) with Loctite 241 and tighten it to a torque of 120
- 140 Nm.
Disassembling the rear bearing block, oil
seal and shaft bearings
25. Take off circlip (17), remove the bearing cone (3),
castellated washer (4), cone (8), cup (21) and circlip
(16).
26. Separate bearing block (22) from shaft (12).
27. Extract cassette seal (14) and take off O’ring (15).
28. If needed, take out bolts (6) and remove the inter-
changeable end-piece (5) (Fig. 1).
Reassembly
Special point
- If the power take-off housing, bearing block (22),
bearings (3) (19) (8) (21) or castellated washer (4) has
been replaced, carry out shimming of the bearings (see
§ C).

30. Before assembly of seal (14), see note § C.
Lightly smear the external diameter of the seal with
Loctite 542. Using a press and tool, ref. 3378115M1
(see § F), insert the cassette seal into bearing block
(22) with the lip turned to face bearing cone (8).
Issue 1 May 2001

C . Shimming (Fig. 4 – 5)
Note: The shimming of bearings (3) (19) (8) (21) must
be carried out before fitting seal (14).
19
39. Using a depth gauge, measure dimension A on the B
power take-off housing.
40. On shaft (12) fit: bearing block (22), circlip (16), cup 22
(21), cone (8), castellated washer (4), cone (3) and
circlip (17).
41. Place the shaft and bearing block (22) assembly in
thrust on a suitable fixture. Using another operator,
press hard on the rim of cup (19) in a continuous
manner. At the same time, turn the shaft left and
right to seat the cones in their cups. Measure
dimension B at two diametrically opposed points.
Use the average of the two measurements.
42. Apply the formula: B - A
Place a thickness of shim(s) (23) to obtain a clear-
ance (Fig. 5) of:
J1 = 0.05 mm to 0.15 mm
A
D . Long shaft version

- The removal of the long shaft is identical to the inter-
changeable end-piece version.
- The long shaft is centred by a locating pin (35) and fixed
by bolts (6) to shaft (12) (Fig. 6).
Fig. 4
6 J1 = 0,05 23
/ 0,15
35
12
Fig. 6 Fig. 5
Issue 1 May 2001

E . Adjusting the control

On lever L (Fig. 8). L
43. Place control lever L located inside the cab in the
1000 rpm position (Fig. 7).
44. Screw yoke (1) flush with the threaded end of the
cable (6).
45. Mount the yoke on the lever using clip (7). Tighten nut
(2).
46. Position nut (3) on the threaded sheath end (5).
47. Fit the threaded sheath end on the bracket. Tighten
nut (4) and check that the cable is not constrained in
any way.
On link B (Fig. 8) Fig. 7

48. Turn link B towards the front of the tractor in the 1000
rpm position.
49. Screw yoke (9) flush with the threaded part of cable
(6).
50. Fit yoke (9) on link B using clip (10). Tighten nut (11).
51. Adjust the threaded sheath end (12) on bracket (8)
using nut (13), taking care that link B does not move.
52. Tighten nut (14) while checking that the cable is not
constrained.
53. Check the operation of the control lever in the
position 540 or 750 rpm.
L
1
7 6
4
12
14
13 8
11 6
B
10 9
Fig. 8
Issue 1 May 2001

F . Service tools
- 3378115M1 – Tool for fitting cassette seal (14) on
the power take-off bearing block (Fig. 9).
Fig. 9
Issue 1 May 2001

Power take-off - 1000 rpm shaft 7E01.1
7E01 1000 rpm power take-off shaft
CONTENTS
- General ________________________________________________ 2
A. Disassembling and reassembling 1000 rpm pinion

and bearing _____________________________________________ 5
B. Removing, refitting and disassembling, reassembling

the rear bearing block, oil seal and shaft bearings _________ 6
C. Shimming ______________________________________________ 7
D. Long shaft version ______________________________________ 7
E. Service tools ___________________________________________ 8
Issue 1 May 2001

7E01.2 Power take-off - 1000 rpm shaft

Parts list
General (1) Locking ring
Certain types of tractors in the 8200 series may be fitted (2) Circlip
with a 1000 rpm power take-off. (3) Bearing cone
(4) Castellated washer
The driven pinion (18) is fitted on the power take-off shaft (5) Interchangeable end-piece (shaft with disc)
located at the lower part of the rear housing. (6) Bolt
(8) Bearing cone
This pinion is constantly engaged with the driving pinion (9) Protector
driven by the upper shaft line where the engine speed is (10) Coupler
transmitted via the power take-off clutch. (11) Hub
(12) Shaft
The power take-off shaft is supported at the front by a (13) Bolt
roller bearing (24) that is force fitted into the centre (14) Cassette seal
housing. It is mounted free in the bearing cones (3) (8) of (15) O’ring
the rear bearing block (22). (16) Circlip
(17) Circlip
The hub (11) is integral with shaft (12) via splines. (18) 1000 rpm driven pinion
Rotation is transmitted to the driven pinion (18) via the (19) Bearing cup
coupler (10). This coupler is held in position permanently (21) Bearing cup
by circlip (2). (22) Bearing block
(23) Shim(s)
The oil tightness of the rear block is provided by cassette (24) Roller bearing
seal (14) and O’ring (15). (25) Oil deflector
(26) Locking ring
The clearance of the bearings is adjusted by shim(s) (23) (35) Locating pin
inserted between the rear housing and bearing block (22). (36) Plugs
During rotation, the serrated washer (4) transmits infor- Fig. 1

mation to the output shaft speed sensor (12) and equally
serves as a spacer between bearing cones (3) and (8).
Fig. 2
Lubrication
Lubrication is provided by the transmission oil. The
projected oil is held in deflector (25) and lubricates roller
bearing (24) and bearing cones (3) (19) (8) (21) via the
intermediary of shaft (12) that contains an axial channel
and radial drilled ports.
Issue 1 May 2001

Overall view
2 1 19 3 4 21 23 8 22
14 12
25 24 26 11 10 18 17 16 15 13
1000
36 6 5 9
Issue 1 May 2001


Exploded view
25
24
2
26
11
10
1
18
1000
36
17
19
3
4
8 13
21 12
16 35
14
23
15
22
Issue 1 May 2001

Special points
- The removal of the power take-off housing is necessary
for all maintenance operations on the lower shaftline,
apart from the disassembly of the interchangeable 18
shaft (5).
- The centre housing must be drained and then brought
back up to level after the maintenance operation.
1
A . Disassembling and reassem-
blying 1000 rpm pinion and bearing Fig. 3
(24)
Preliminary operation Reassembling the pinion
1. Uncouple the power take-off housing from the centre Note: if the locking ring (1) (not referenced in the
housing (see section 2E01). spare part catalogue) is worn, replace pinion (18)
(Fig. 3). The ring is bored to the correct dimension
after insertion.
Disassembling the pinion
2. Take off locking ring (26). Slide hub (11) and coupler 8. Lubricate locking ring (1) of pinion (18) (Fig. 3). Slide
(10) along shaft (12). Take off pinion (18). the pinion on the shaft (12).
9. Fit locking ring (1)
10. Fit the hub assembly (11) and coupler (10).
Disassembling the pinion 11. Check for the presence of circlip (2) and fit locking
3. Where necessary, visually locate the direction that ring (26).
bearing (24) is fitted and then extract it from the centre 12. Check the presence of plugs (36) Figs. 1 - 2).
housing using an inertia tool.
4. Remove the deflector (25).
Final operation
13. Couple the power take-off housing to the centre
Reassembling the bearing housing (see section 2E01).
5. Clean the components. Replace any parts found to be
defective. Check that the channels in shaft (12) are not
obstructed.
6. Position deflector (25) in the bore of the centre housing
in accordance with Fig. 1.
7. Using an appropriate insertion tool, fit bearing (24)
thrust against the deflector, with the rounded part of
the cage turned towards the front end of the shaft (12).
Issue 1 May 2001


24. Lubricate the inside diameter of seal (14) with
B . Removing, refitting and disas- transmission oil. Insert shaft (12) in the seal of
sembling, reassembling the rear bearing block (22).
25. Fit circlip (16), refit cup (21), bearing cone (8),
bearing block, oil seal and shaft bea castellatedwasher (4), bearing cone (3). Fit circlip
rings (17).
Removing the bearing block
14. Disassemble the 1000 rpm pinion (see § A).
15. Take out the speed sensor (output shaft (12) speed
Refitting the bearing block
sensor) located on the right-hand side of the housing.
26. In the bore of the power take-off housing, refit cup
16. Remove bolts (13), pull on the interchangeable end-
(19) and shaft (12) previously assembled on bearing
piece (5) and take out the bearing block assembly
block (22), along with the bearings and o’ring (15).
(22) comprising:
27. Place and tighten bolts (13) to a torque of 72 - 96 Nm.
- oil seal (14)
28. Refit the 1000 rpm pinion (see § A).
- O’ring (15)
- shim(s) (23)
- cups (19) (21)
30. Refit the sensor with its o’ring.
- bearing cones (3) (8)
31. If removing of the interchangeable end-piece (5) is
- castellated washer (4)
necessary, check for the presence of locating pin
17. Take cup (19) out of the housing.
(35). Refit the end-piece. Lightly smear the threads
of bolts (6) with Loctite 241 and tighten them to a
Disassembling the rear bearing, oil seal and
shaft bearings
18. Take off circlip (17), remove bearing cone (3), castel-
lated (4), bearing cone (8), bearing cup (21) and
circlip (16).
19. Separate bearing block (22) from shaft (12).
20. Where necessary, take out bolts (6) and remove the
interchangeable end-piece (5) (Fig. 1).
Reassembly
Special point
- If replacement is necessary of the power take-off
housing, bearing block (22), bearings (3) (19) (8) (21) or
castellated washer (4), carry out shimming of the
bearings (see § C).

23. Before fitting seal (14), see note § C. Lightly smear
the external diameter of the seal with Loctite 542.
Using a press and tool, ref. 3378115M1 (see § F),
insert the cassette seal in bearing block (22) with its
lip turned to face bearing cone (8).
Issue 1 May 2001

C . Shimming (Figs. 4 - 5)
Note: The shimming of bearings (3) (19) (8) (21) must
be carried out before fitting seal (14).
19
32. Using a depth gauge, measure dimension A on the
power take-off housing. B
33. On shaft (12), fit: bearing block (22), circlip (16), cup
(21), cone (8), castellated washer (4), cone (3) and 22
circlip (17).
34. Place the shaft and bearing block assembly (22) to
thrust against a locally manufactured fixture. Using
another operator, apply strong pressure around the
rim of cup (19) in a sustained manner. At the same
time turn the shaft alternately left and right in order
to correctly seat the bearings in their cups. Measure
dimension B at two diametrically opposed points.
Calculate the average of the two measurements.
35. Use the formula: B - A.
Place a thickness of shims (23) to obtain a clearance of:
J1 = 0.05 mm to 0.15 mm
D . Long shaft version

- The removal of the long shaft is identical to that of the
interchangeable end-piece.
- The long shaft is centred by locating pin (35) and fixed
by bolts (6) on shaft (12) (Fig. 6).
Fig. 4
6 J1 = 0,05 / 23
0, 15
35
12
Fig. 6 Fig. 5
Issue 1 May 2001

E . Service tools
- 3378115M1 - Tool for inserting cassette seal (14) on
the power take-off shaft (Fig. 7)
Fig. 7
Issue 1 May 2001

Power take-off - Clutch and brake 7F01.1
7F01 Clutch and brake
CONTENTS
A. General ________________________________________________ 3
B. Removing and refitting the clutch ________________________ 7
C. Disassembling and reassembling the clutch _______________ 9
D. Service tools ___________________________________________ 11
Issue 1 May 2001

7F01.2 Power take-off - Clutch and brake
Issue 1 May 2001

Power take-off brake (Fig. 1)

A . General - When the supply to the PTO clutch is halted, spring (8)
On the 8200 series tractors, the PTO clutch is fitted in the pushes piston (19) against unit (6).
rear housing and driven by the upper shaftline (see - The pressure is then directed towards the PTO brake
section 7A01, § A). and moves piston (1) which presses against the exter-
nal periphery of unit (6) thus braking the driving pinion
Depending upon the type of tractor, the clutch contains (11) or (9) (if fitted) (Figs. 4 - 5) that is integral with the
a different number of clutch plates and intermediate clutch housing via splines.
plates. - A channel communicating with piston chamber (1)
- 8210 - 8220 tractors provides lubrication to the rim of unit (6) and the forward
. 5 clutch plates, 5 intermediate plates face of the piston during its travel.
- 8240 - 8250 tractors - The cylinder of piston (1) (Fig. 1) is positioned on the
. 6 clutch plates, 6 intermediate plates centre housing by Mecanindus pins.
- 8260 - 8280 tractors
. 7 clutch plates, 7 intermediate plates
The clutch assembly comprises:

- a clutch unit (6) supported by two taper roller bearings
- a sleeve (10) centred by a ring in the rear housing and
by a ball bearing (13) inserted in hub (1). It has two
lubricating channels:
- a central channel for the bearings
- an axial channel for piston (19)
- a hub (1) supporting the clutch plates (4)
- a cover (2) that receives the intermediate plates.
Operation
Clutched position
- The clutch is supplied via the power take-off proportional
solenoid valve by the 17 bar hydraulic circuit located on
the right-hand side cover and by an external pipe con-
nected to the rear housing of the power take-off.
- Oil enters unit (6) via channels a, c and chamber b (Fig.
2). It pushes piston (19) that then compresses clutch
plates (4) against the intermediary plates (3). The latter
are integral with cover (2) via tabs and bolts (16). Clutch
plates (4) are integral with hub (1) via splines. The
movement is transmitted to driving pinions (11) (9) (Fig.
4 - 5), depending on the type of power take-off, via shaft
(28) housed in hub (1). 1
- In the clutched position, the brake piston (1) of the
power take-off located in the centre housing is at rest
and this frees clutch unit (6) (Fig. 1) allowing the 540- 8 19
rpm – 1000 rpm pinions to turn freely. When the clutch
is engaged, oil from the lubricating circuit coming from
channel d cools and lubricates the clutch plates (Fig. 2). 6
Fig. 1
Issue 1 May 2001


Parts list (Fig. 2 - 3)
(1) Drive hub
(2) Cover
(4) Clutch plates
(5) Progressivity washer
(6) Clutch housing
(7) Valve
(8) Spring
(9) O’ring
(10) Sleeve
(11) Bolt
(12) Chamfered washer
(13) Ball bearing
(14) Circlip
(15) Clutch assembly
(16) Bolt
(17) Spring seat
(18) O’ring
(19) Piston
(20) Support
(21) O’ring
(22) Seal rings
(28) Intermediate shaft
(29) Reducer
(30) Threaded plug
(31) Deflector
Fig. 2
Fig. 3
Issue 1 May 2001

Overall view Exploded view
15
1 2 3 4 5 6 7 8 9 10 30
3
4
c a a d
11 1
12
31
13
b
14
e 17
8
20
5
19
21 18
10 9
29
30
28 11 12 13 14 17 16 31 19 18 20 21 29 22 7
15
22
Parts list Fig. 3
Fig. 2 16 Parts list Fig. 2
Fig. 3
Issue 1 May 2001

16 ± 0,1 mm
27 15 22 23 27 25
15 23
28 5 6
11
12
24 26
20 7 10 18 10
Fig. 4 Fig. 6
1 15 9 23 27 16 ± 0,1mm
15 22 23 27 25
5
28
11
20
24 26
2 7 Fig. 5 Fig. 7
Issue 1 May 2001

B . Removing and refitting the clutch

22
1. Remove the power take-off housing (see section
2E01).
22
Remove the sensor located on the upper right-hand
side of the power take-off housing.
Removal
Power take-off with removable shaft (Fig. 4)
2. Recover the friction washer (20).
3. Take off snap ring (6), support the driven pinions
(7) (18).
Pull on shaft (12). Remove the pinions. Recover the
friction washers (10).
4. Take out bolts (27). Fig. 8
5. Remove the clutch (15) and unit (23) assembly.
Power take-off with jaw coupler (Fig. 5)

6. Take off circlip (2) and splined washer (20).
8. Disengage the clutch (15), unit (23) and pinion (7) 25 26 24
assembly.
1000 rpm power take-off

Remark
- To remove the clutch on this type of power take-off, no
operations need be carried out on the lower shaftline.
9. Remove the seal rings (22) (Fig. 8).

10. Using a press, an "S" support and service tool, ref.
3378135M1 (see § D), moderately compress the
Belleville washer (24) until the recess of snap ring
(26) groove can be reached. Remove the snap ring
and washer (25) while noting their positioning for
later reassembly, then the Belleville washer.
P
Separation of the assembly (15) (23)
11. Separate the clutch (15) and unit (23) assembly (Fig.
6 - 7, depending on the type of power take-off).
Remove the bolts (27).
Check
12. Check that the hydraulic channels in the power take-
off housing are not obstructed.
S
Fig. 9
Issue 1 May 2001


Special point
- If disassembled, using an appropriate insertion drift,
position ring (5) (Fig. 10) according to the dimension 16
mm ± 0.1 mm measured between the thrust face of the
power take-off housing and the end of ring (5) (Fig. 4 or
5) and in such a manner that the machined groove on 5
the outside of the ring matches the 17 bar channel of the
power take-off housing.
Reassembling assembly (15) (23)

13. Place bolts (27) on unit (23). Assemble clutch (15)
and unit (23) (Fig. 6 or 7).
14. Fit a new Belleville washer (24) respecting its as-
sembly direction, then fit washer (25) turning the
countersinking towards snap ring (26).
15. Slide the new snap ring (a new snap ring must be
fitted) on sleeve (10) opening its diameter to the Fig. 10
minimum.
16. Compress the washer as in operation 10. Fit and
correctly position the snap ring in the countersunk Power take-off with jaw coupler (Fig. 5)
washer (25). 23. With the help of another operator, refit the assembly
17. Place the seal rings (22) in their grooves and hook (clutch (15) and unit (23) accompanied by pinion (7)).
their ends (Fig. 8). After assembly, check that they 24. Tighten bolts (27) to a torque of 50 - 70 Nm.
rotate freely. 25. Place washer (20) and assemble circlip (2). On each
type of power take-off, manually check the rotation
of the mechanical assembly.
Refitting
Remark Final operations
- In order to facilitate the refitting of the clutch assembly, 26. Lightly smear the threads of the upper sensor with
tilt the power take-off housing, with the inside face Loctite 577 (Sensor Sealing or equivalent). Assem-
turned upwards. ble and adjust the sensor:
- screw the sensor fully home without forcing it until
18. Lubricate the seal rings with transmission oil it touches the driving pinion,
- unscrew the sensor by ¾ turn
Power take-off with removable shaft (Fig. 4) - moderately tighten the lock nut.
19. Lightly smear the threads of bolts (27) with Loctite 27. Couple the power take-off housing to the centre
242 or equivalent and tighten them to a torque of 50 housing (see section 2E01).
- 70 Nm. Assemble the clutch (15) and unit (23) Test the clutch and its brake.
assembly.
20. Refit the driven pinions (7) (18) with friction washers
(10) lightly smeared with miscible grease.
21. Engage shaft (12) in the rear bearing block and
pinions (7) (18). Reassemble snap ring (6).
22. Position friction washer (20), previously lightly
smeared with miscible grease.
Issue 1 May 2001


the clutch
Preliminary operation 1
28. Remove and separate the clutch (15) and unit (23)
(see § B).
11 12
8
Disassembly
29. Tighten unit (6) in a vice fitted with soft jaw protec-
tors.
30. Take out bolts (16). Separate the unit from the cover (2).
Remove clutch plates (4) and intermediate plates (3).
31. Using a locally manufactured tool (see § D), hold the
hub (1). Take out bolts (11) and washer (12). Release
spring (8) (Fig. 11). Remove the tool.
Fig. 11
32. Remove the drive hub (1), spring seat (17), spring (8),
support (20) and progressivity washer (5).
33. Where necessary, take off circlip (14) and extract
bearing (13).
34. Using a compressed air jet, drive out piston (19) and
take off the O’rings (9) (18) (21).
Reassembly
Remarks
- Valve (7) is crimped in unit (6). The restrictor (29) is
placed in sleeve (10). The bearing cone E is force fitted
(Fig. 2). The sleeve (10), previously lightly smeared
with Loctite 648, is fitted by press.
- If disassembly was necessary, on reassembly check
that the 17 bar and lubrication channels are not ob-
structed by Loctite. Threaded plug (30) is lightly smeared

36. Replace and lubricate the O’rings (9) (18) (21).
37. Lubricate sleeve (10) and piston (19) and insert it in
unit (6) by tapping it moderately around the rim with
a plastic hammer.
38. If disassembled, insert bearing (13) in hub (1). Fit
circlip (14).
39. Refit progressivity washer (5) in accordance with the
overall view, support (20), spring (8), spring seat (17)
and drive hub (1).
Issue 1 May 2001


40. Compress the spring using the previously used tool,
fit washer (12) and bolt (11) (Fig. 11) lightly smeared
with Loctite 241. Tighten to a torque of 24 - 28 Nm.
1
41. Assemble the intermediate plates on hub (1), placing
the tabs T between the drilled holes V and alternating
them with previously lubricated clutch plates (Fig.
12).
Remark
- Depending on the type of tractor, the number of
clutch plates and intermediate plates differs. T
42. Position cover (2). Fit bolts (16) the threads lightly
smeared with Loctite 242 and tighten to a torque of
25.5 - 34.5 Nm.
43. Manually check that the hub turns freely.
V
Fig. 12
Final operations
44. Reconstitute and refit the clutch assembly (15) (23)
(see § B).
Issue 1 May 2001

D . Service tools
- 3378135M1 - Belleville washer (24) compression
sleeve (Fig. 13).
Fig. 13
Locally manufactured tool

- Clutch spring holding tool (Fig. 14)
5
+ 0,2
21 146,25 -
Ø8
170
170
= =
25
+ 0,5
1 x 45 ˚ Ø 58 0
Ø 92
64
M6 M6
Fig. 14
Issue 1 May 2001

8 . FRONT AXLE
Contents
8 A01 GENERALITY - CARRARO FRONT AXLE
8 B01 DANA FINAL DRIVE UNITS
8 B02 ZF FINAL DRIVE UNITS

8 B03 CARRARO FINAL DRIVE UNITS
8 C01 DANA DIFFERENTIAL
8 C02 ZF DIFFERENTIAL
8 C03 CARRARO DIFFERENTIAL

8 D01 2 WD FRONT AXLE
8 E01 STEERING COLUMN
8 F01 BEARINGS AND TRANSMISSION SHAFTS (DANA FRONT AXLE)

8 F02 BEARINGS AND TRANSMISSION SHAFTS (ZF FRONT AXLE)
8 F03 BEARINGS AND TRANSMISSION SHAFTS (CARRARO FRONT AXLE)
8 G01 4WD CLUTCH
8 G02 CARRARO SUSPENSION

8 I01 CARRARO TROUBLESHOOTING
Issue 2 May 2002

Front axle - Generality 8A01.1
8A01 Generality - Carraro front axle
CONTENTS
A. General description _________________________________________ 2
B. Safety instructions __________________________________________ 14
Issue 2 May 2002

8A01.2 Front axle - Generality
Parts list
A. General description (1) Wheel hub group
(2) Axle beam group
The axle described in this manual, designed and manu-
(3) Differential group
factured following the customer’s requests, consists of
(4) Arms unit
a beam casing, housing the differential in the middle and
(5) Epicyclic reduction gear
a wheel hub unit at each end.
(6) Steering cylinder group
The differential, type “Limited Slip”, is supported by two
(7) Differential support group
bearings mounted on a suitable structure allowing the
(8) Pinion group
bevel gear set to be adjusted.
(9) Suspension cylinder group
The ring bevel gear is adjusted by means of two ring nuts
located opposite each other.
The position of the bevel pinion, supported by two
bearings, is adjusted by inserting adjusting shims.
The wheel hubs containing the epicyclic reduction gears
are supported by two tapered roller bearings and are
powered by a hydraulically-operated steering unit.
The axle is equipped with hydropneumatic shock-ab-
sorbing suspension system (Carraro patent), electroni-
cally controlled, ensuring the constant contact of the
tyres with the ground in any operating conditions.
Fig. 1
Issue 2 May 2002

1 2 3
4 9
6 Parts list Fig. 1
Issue 2 May 2002

Issue 2 May 2002

Overall dimensions
All values given in the following table are in millimeters.
A = 2145 F = Ø 335 K = 260 ± 45
B = 548 G = M22 x 1.5 L = 66
C = Ø 380 H = 454 M = 160
D = Ø 280.8 I = 90 N = 348
E = 1900 J = 183 O = 508
A .
B .
C .
D .
E
.
G
3
.8 9
1 9
F 0
1 9
.4 2
1 9
H
1 2
9 8
. 9
7
2
7 3
6 . 9
4
8
I
L 2 .3 1
2
7 1
K .
I
J 6 .8 8
6
1 2
. .
M N
.
O
Fig. 2
Issue 2 May 2002

The product identification

The Carraro front axle is designed by an identification
plate (Fig. 3) riveted on the axle housing.
Part list
(1) Axle type
(2) Carraro S/N
(3) Carraro N°
(4) Customer reference
(5) Total ratio
(6) Input rotation
(7) Differential type
(8) Differential oil type
(9) Differential oil quantity
(10) Epicyclic reduction gear oil type
(11) Epicyclic reduction gear oil quantity
1 2
3 4 5
6 7
8 9
10 11
Fig. 3
Issue 2 May 2002

Technical features
Axle model 20.29 S 20.43 S
Tractor 8210/40 8250
DESCRIPTION VALUES
20.29 S 20.43 S
Bevel gear reduction 3,00 / 1 3,00 / 1
Epicyclic reduction 6,923 / 1 6,923 / 1
Total reduction 20,769 / 1 20,769 / 1
Dry weight 596 kg 616 kg
Input rotation Reverse clock wise
Differential type With multidisc clutch in oil bath hydraulically
control
O
Steering angle Maxi 55° -2
O
Toe in A -2
Oil specification SAE 85W- 140 EP
To comply
API GL4 – GL5
respectively
MIL-L-2105
and
MIL-L-2105D
Differential oil capacity 8,5 Liters
Gear box epicyclic oil capacity 1,3 + 1,3 liters 1,3 + 1,3 liters
Differential looking engaged feed pressure 20 bar
Grease POLYMER 400/L
DIN = KHER1R
ISO-I-XMR-XM2
Bevel gear set backlash 0,18+0,23 mm
Pinion bearing « P » pull (Measured D=39.9 mm P = 9,2 + 13,7 daN
without seal)
Total pinion ring gear bearing pull « T » (measured T = (P+9,2) + (P+10,7) daN
D=37,9 mm)
Issue 2 May 2002

Sealing compounds and adhesives
A1
B2
A1
B1
B1
B1
B1
Fig. 4
A1 = Loctite 510 ● B2 = Loctite 270 ●
A2 = Loctite 573 ❍ C1 = Loctite 405 ❍
A3 = Loctite 518 ❍ C2 = Loctite 496 ❍
B1 = Loctite 542 ● C3 = Loctite 638 ❍
Apply on the contact surface

Apply on bolt screws / on pins
Issue 2 May 2002

Tightening torques
All tightening torques are referenced in the following
table.
Tightening torques for 20.29 Sand 20.43 S(Fig.5 - 6)
NR. DESCRIPTION T HREAD Nm
1 Wheel hub stud bolt M18x69 70
2 Planetary gear retaining screw M10x50 79
3 Wheel carrier retaining screw M14x65 230
4 Magnetic plug M30x2 60
5 Planetary gear carrier retaining screw M8x20 25
6 Pad retaining screw M10x25 10
7 Differential box/Crown wheel retaining screw M10x30 70
8 Oil breather M10x1 10
9 Steering arm ball joint retaining nut M20x1.5 220
10 King pin retaining screw M14x35 190
11 Oil fill plug M24x1.5 60
12 Stop steering bolt nut M16 150
13 Cover retaining screw M10x30 60
14 Greaser M6x1 8
15 Ball joint 300
16 Steering cylinder flange retaining screw M12x45 120
17 Flange retaining screw M10x60 57
18 Steering arm retaining nut M24x10 250

Arms lower pin retaining screw
19 M14x120 190
(potentiometer)
20 Potentiometer retaining screw M4x12 3
21 Potentiometer cover retaining screw M8x25 13
22 Half-collar retaining screw M14x75 266
23 Differential support retaining screw M12x33 169
24 Shock-absorber cover retaining screw M10x35 60
25 Arms lower pin bearing retaining screw M14x120 190
26 Arms upper pin retaining screw M14x100 190
27 Greaser M6x1 8
28 Differential support retaining screw M12x55 169
Issue 2 May 2002

4
5 B
7
D E 9
A C
6
11 B C E
A D 12
10
13
14
15
F
18
16
17
Fig. 5
Issue 2 May 2002

22
19
20 21 Sez.A.A
24
Sez.B.B
23
25
Sez.C.C
26
Sez.D.D
28
Sez.E.E Sez.F.F
27
Fig. 6
Issue 2 May 2002

Filling and checks Routine checks

Specific description Position In the axle, lubricant should be flush with control plug (1)
Differential oil filling and plug 1 and (3). If not, make up level with the same oil. If leakage
level or any other factor determining fall in the oil level is found,
2 then it is advisable to check immediately, in order to
Oil breather
avoid damages to the machanical parts. Loosen and
Fill/drain and level plug of 3
remove the drain plug for oil draining (4) and (3).
epicyclic reduction gear oil
Differential oil drain plug 4
Greasing points 5
2
1
4 3
5
5
5
5
Fig. 7
Issue 2 May 2002

General checks
1. Before draining the oil, loosen the breather to release
possible internal pressure, then tighten the plug with
a torque wrench to the prescribed torque (see § A)
(Fig.8)
Drain the oil from the appropriate plug, then tighten the
plug with a torque wrench to the prescribed torque
(see section A01 §A).
2. Before draining the oil, always loosen the breather to
release possible internal pressure.
Check oil level and top up if necessary (Fig.9)
Tighten the plug with a torque wrench to the pre-
scribed torque (see § A).
3. Before draining the oil, position the wheel hub so that
the filer cap is in the highest point, then loosen the plug
to release possible internal pressure.
Position the wheel hub so that the filer cap is on the Fig. 8
centre line of the horizontal axis (Fig.10)
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the pre-
scribed torque (see § A).
Fig. 9
Fig. 10
Issue 2 May 2002

The product is used for any other purpose different from

B. Safety instructions the one foreseen, than Carraro Spa declines any re-
sponsibility.
Important In this case all consequences will be at the customer’s
Before proceeding with any operations please read this expense.
chapter very carefully
Safety precautions Safety maintenance rules

- Correct use and repair of axles and of their components
1. Operate in a clean and dry environment.
is very important for safety and reliability.
2. Do not lubricate, handle or adjust the group underway.
- Recommendations and all described procedures given
3. Keep off your hands, feet and clothing from moving
in this manual have been experimented and hence are
parts.
effective operational methods. Please follow every
4. Be always prepared for fires. Keep the extinguisher
procedure. Use the text as well as the illustrations.
and the first aid kit within reach.
- Certain procedures show use of special tools, designed
5. Keep the phone numbers of a doctor, of an ambu-
so that the operations can be carried out in a clear and
lance, of a hospital and of the fire department within
correct manner.
reach near the telephone set.
- Special tools must be used when a particular operation
6. Wear suitable clothing and protections as overalls,
is being carried out.
safety gloves and ear safety devices.
- It is impossible to advice every working method or
7. Use suitable ear protections, like ear plugs, to keep
know all possible methodologies for carrying it out or to
out noise and prevent injury to the ears.
predict risky consequences of each operation. Hence,
A prolonged exposure to noise can damage your
performing procedures or using instruments which
hearing.
have not been advised could be dangerous for the
8. The operator must be very careful with the equipment.
operator/mechanic as well as the vehicle.
Do not use headphones to listen music while you are
working on the product or on the group.
Danger : Safety goggles must be worn while carry-
ing out every assembling or disassembling opera-
tions. Residual risk elimination
- Risk of squashing and shearing due to the presence of
- Observe safety instructions, accident prevention rules moving parts.
and all general safety regulations in each and every step Warning :
at work. - Carry out all maintenance operations when the
- Before going ahead with maintenance or repair work machine is stationary.
ensure that all the tools, the supporting bench, stands,
levers, extractors and spanners are in good condition so - Risk due to inhalation of poison gases that can be
that the work can be carried out easily. produced by heating the varnishes during any welding.
- Risks to various parts and components will also be Warning :
reduced in this way and working condition for the - Use work stations equipped with dust and fume
operator will also be safer. discharging systems.
- Carraro Spa declines any responsibility in case of an - Let the fumes disperse for at least 15 minutes,
accident or damage resulting due to changes made before welding or reheating, or working on the
arbitrarily on product. group again.
Issue 2 May 2002

- Risk of fire due to the solvents used and to the oil in the
axle.
Warning :
- Keep off any heat sources from the working area.
- When solvents or paint removers are used, they
should be removed with soap and water, before
welding.
- Remove any containers of solvent, paint remover
or any other inflammable products from the work-
ing area.
- Risk due to fall, drop or violent ejection of objects or oil

from the axle.
sWarning :
- These residual risks and the suitable relative
procedures to eliminate them completely are
pointed out, in detail, in the assembly and disas-
sembly procedures. During maintenance, follow
carefully all the safety procedures indicated in the
manual.
Issue 2 May 2002

Front axle - Dana final drive units 8B01.1
8B01 Dana final drive units
CONTENTS
- General ________________________________________________ 2
A. Layout of the main components __________________________ 5
B. Removing and disassembling the planetary carrier, sun gear

and crownwheel ________________________________________ 7
C. Reassembling and refitting the planetary carrier, crownwheel

and sun gear ___________________________________________ 9
D. Disassembling and reassembling the wheel hub __________ 10
E. Replacing a wheel stud __________________________________ 12
F. Disassembling, reassembling and shimming the swivel

housing ________________________________________________ 12
G. Removing and refitting the universal drive shaft ___________ 15
H. Service tools ___________________________________________ 17
Issue 1 May 2001

8B01.2 Front axle - Dana final drive units

Parts list
General (1) Wheel stud
Types of final drive unit available according (2) Locating pin
(3) Wheel hub
to tractor type: (4) Circlip
- 8210 - 8220 tractors
(5) Swivel housing
. Dana final drive unit (AG 155H front axle)
(6) Cup plug
- 8240 tractors
(7) Threaded plug
. Dana final drive unit (AG 155H front axle or optional AG
(8) Bolt
200H)
(9) Shim(s)
- 8250 and 8260 tractors
(10) Cover
. Dana final drive unit (AG 200H front axle)
(11) Bearing cone
(12) Bearing cup
The 8270 and 8280 tractors are fitted with a ZF front axle
(13) Front axle housing
with final drive unit of the same type (see section 8B02).
(14) Universal drive shaft
(15) Bush
A plate riveted on the axle housing indicates the type and
(16) Seal
serial number.
(17) Protection bush
(18) Seal
The final drive unit assembly comprises a swivel hous-
(19) Grease nipple
ing (5) that is articulated on the front axle housing via two
(20) Cover
swivel pins (21). The wheel hub (3) turns on two taper
(21) Swivel pin
roller bearings whose cups (25) are force fitted in the hub.
(22) Seal
The bearing cones (24) are likewise force fitted.
(23) Cassette seal
(24) Bearing cone
The taper roller bearings (24) (25) are not adjustable. The
(25) Bearing cup
parts are produced with machined tolerances that require
(26) Plug
neither shimming nor adjustment.
(27) Seal
(28) Crownwheel carrier
The movement from the differential is transmitted to the
(29) Snap ring
wheel hub via the universal drive shaft assembly (14),
(30) Bushes
the sun gear (39), the planetary gears (42) and crownwheel
(31) Crownwheel
(31). The crownwheel is retained on the crownwheel
(32) Nut
carrier (28) by two snap rings (29). The splined rear end
(33) Stop
of the sun gear (39) is inserted in the universal drive shaft
(34) Washer
(14). The crownwheel carrier is force fitted on the swivel
(35) Circlip
housing (5). It is integral with the splines of the housing
and locked by central nut (32).
(37) Friction washers
(38) Stop
For greater efficiency, the oil seals are fitted with double
(39) Sun gear
lips. Fig. 1
(40) Planetary gear pin
(41) Needles
Oil tightness is ensured at the hub / housing by cassette
(42) Planetary gear
seal (23) and at the universal drive shaft / axle housing
(43) Bolt
Fig. 2
by seal (16) and protection bush (17). It is ensured at the
(48) Set screw
drive unit / swivel housing by seal (22) and at the swivel
bearings in the unit and by seals (18).
(49) Nut Fig. 3
(50) Compound needle bearings
(51) O’ring
(52) Countersunk screw
Fig. 4
Issue 1 May 2001

Overall view
AG155H AG200H
1 2 3 4 5 7 6 8 9 10 11 12 13 14 15 40 42 50 2 4
43
42
41
40
39
37
38
36
35
34
33
32
26 27 51 52
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
Parts list Fig. 2 Fig. 3 Fig. 4 Fig. 1

Parts list Fig. 1 Fig. 3 Fig. 4
Fig. 2
Issue 1 May 2001


Exploded view
23
1
AG 155H
3
25
24
29
19 8 10
28
24 29
9
25 31
26 32
49 48 22 12
30 11
27
4
18 2
37
21 40
41
42
13 33 37
38
34
15 36
35
16 5 43
39
17
23 1
21
3
18 51 AG 200H
24
19 11 25
24 29
12 25 28
29
20 2 31
32
8
4
40
34 42
14
35
50
39
52
38
36 26
6 27
Fig. 3
Issue 1 May 2001

A . Layout of main components
42 39 31 3
AG 155H
36
28
41
32
24 24 23 5
25
25
36 50 42 39 31 51
35 34 22 21 14 13
AG 200H

Fig. 4
Issue 1 May 2001

Issue 1 May 2001


the planetary carrier, sun gear and
crownwheel
Remark
- The procedure is identical on both AG 155H and AG
200H front axles.
32
1. Chock the rear wheels. Put the handbrake on.
Reminder
- The 4 WD clutch is mechanically engaged when
the tractor is stationary and the engine turned off.
Raise both front wheels in order to freely turn the
hub of the wheel concerned. Fig. 5
2. Position axle stands.
3. Take off the wheel concerned.
4. Drain the final drive unit.
Removing the planetary carrier

AG 155H final drive unit
5. Remove the bolts (43).
6. Release and remove the planetary carrier (36) and
stop (38) assembly.
7. Remove the sun gear (39). 32
AG 200H final drive unit

8. Remove screws (52)
9. Remove the planetary carrier (36) and stop (38)
assembly.
10. Remove the sun gear (39).
Special point Fig. 6
- In order not to damage the threads on the swivel
housing (5), unlock nut (32) correctly.
All types of final drive units

11. Loosen and take off nut (32) (Fig. 5, AG 155H front
axle or Fig. 6, AG 200H front axle) using the socket
ref. 3378028M1 (see § H).
12. Place a sling on the wheel hub (3).
Issue 1 May 2001


13. Remove the hub, the crownwheel carrier (28) and
crownwheel (31) (Fig. 7, AG 155H front axle or Fig. 8,
AG 200H front axle) using extractor ref. 33780381M1 28 31
and sleeve ref. 3378122M1 (see § H).
Remark
- Smear the cone and thread of the tool with graphite
grease in order to avoid unnecessary friction during
extraction.
14. Remove snap rings (29). Separate the crownwheel
(31) from the crownwheel carrier.
Disassembling the planetary carrier 3

15. Place the planetary carrier (36) on a workbench.
AG 155H final drive unit (Fig. 9) Fig. 7

16. Take off circlips (4) and the locating pins (2). Take out
the planetary gear pins (40) using a locally supplied
bolt. Recover the friction washers.
28 31
AG 200H drive unit (Fig. 10)
17. Take off circlips (4) and locating pins (2). Take out the
planetary gear pins (40) using the above described
procedure.
Fig. 8
4 2 40 42 4 2 36
42
36 E 40
Fig. 9 Fig. 10
Issue 1 May 2001

AG 155H drive unit

C . Reassembling and refitting the 33. Lightly smear the mating face of the planetary carrier
planetary carrier, crownwheel and with Loctite 510 or its equivalent.
sun gear 34. Check for the presence of stop (38) in the planetary
carrier.
18. Clean and inspect the components. Replace any 35. Refit the planetary carrier.
parts found to be defective. 36. Fit and tighten the bolts (43) to a torque of 70 - 85 Nm.
AG 155H final drive unit AG 200H drive unit

19. In each planetary gear (42), place the needles coated 37. Lubricate O’ring (51) and position it in the groove
with bearing grease. concerned in the hub.
20. Fit the prepared planetary gears in the planetary 38. Check for the presence of stop (38) in the planetary
carrier (36). carrier.
21. Centre the planetary gears and friction washers. 39. Refit the planetary carrier.
Position and fit the pins (40) with the notches facing 40. Fit and tighten the countersunk screw to a torque of
notches E on the planetary carrier (Fig. 9). Fit pins (2) 40 - 50 Nm.
and circlips (4).
22. Manually check the axial clearance and rotation of
each planetary gear. Final operations
41. Turn the hub of the wheel in order to place the filler
plug in the horizontal axis of the final drive unit. The
AG 200H final drive unit same port is used for both filling and checking the oil
23. In each planetary gear (42), place the compound level of the drive unit.
needle bearings (50) coated with bearing grease. Screw in plug (26) fitted with its seal (27).
24. Fit the prepared planetary gears in the planetary 42. Refit the wheel. Remove the axle stands and the
carrier. trolley jack.
25. Centre the planetary gears. Reminder
Position and fit the pins (40) with the holes facing Wheel nut tightening torque: 640 - 680 Nm.
notches E on the planetary carrier (Fig. 10). Fit 43. Remove the wheel chocks and take off the hand-
circlips (4). brake.
26. Manually check the axial clearance and rotation of 44. Carry out a road test. Check the oil tightness of the
each planetary gear. planetary carrier mating face and the filler plug.
All types of drive units

27. Assemble the crownwheel (31) on the crownwheel
carrier (28). Fit snap rings (29) correctly positioned in
their respective grooves.
28. Prepare the refitting of the hub. Carry out operations
49 and 50 again, then insert the hub assembly (3) and
crownwheel carrier (28) fitted with crownwheel (31).
29. Manually check the rotation of the hub.
30. Fit and tighten nut (32) previously lightly smeared
with Loctite 270 or its equivalent. Tighten to a torque
of 400 - 450 Nm.
31. Lock the nut, by bending its collar without breaking
it, into the notch on the swivel housing using an
appropriate punch.
32. Fit the sun gear (39).
Issue 1 May 2001

D . Disassembling and reassembling Fig. 11

the wheel hub 28 B
Disassembly
45. Remove the planetary carrier (36), the wheel hub (3)
and the crownwheel carrier (28) (see § B).
46. If necessary, extract bearing cones (24) and remove
bearing cups (25) from the hub. If the bearings are to
be re-used, take care to match the correct cones and
cups.
Reassembly
parts found to be defective. 3
Assembling bearings (24) (25)

Cups and cones re-used
48. Insert the previously carefully matched cups and
cones on their respective shoulders machined on the 28
wheel hub, swivel housing and crownwheel carrier.
3
New cups and cones
Special points
- The bearing cones and cups must be of a special type
(width tolerance 0.1 mm instead of 0.2 mm). The
shimming of the bearings is determined in relation to
the machined tolerances of swivel housing (5), hub (3)
and crownwheel carrier (28).
- The above components may be replaced individually.
Remark
- If the rotation of the hub (3) is not correct after fitting,
seek out the defective component(s) that are causing
the problem. B
Fig. 12
49. To correctly guide hub (3) onto the cassette seal (23),
insert the crownwheel carrier (28) according to the
method described in operation 50.
Issue 1 May 2001

50. Lubricate the splines of swivel housing (5). Using

three or four flanges “B” (supplied locally) that are
screwed into the threaded holes on the hub, block
the planetary carrier (28) and hub (3) (Fig. 11, AG155H G
3
front axle or Fig. 12, AG 200H front axle). Insert the
crownwheel carrier / hub assembly, using tool ref.
3378039M1, until the crownwheel carrier makes
contact with the housing.
Remark
- Tighten tool A (see § H) thrust against the swivel
housing. Smear nut D and its thrust face with D
graphite grease (Figs. 13 or 14).
51. Manually check the rotation of hub (3).
52. Clean the nut threads on the housing. Lightly smear
nut (32 with Loctite 270 or its equivalent and tighten
to a torque of 400 - 450 Nm. 28
G
53. Lock the nut by bending its collar, without breaking Fig. 13
it, into the groove on the housing.
54. Refit the sun gear (39).
55. Refit the planetary carrier (see § C).
28 3
D
Fig. 14
Issue 1 May 2001

E . Replacing a wheel stud

56. Chock the rear wheels. Put on the handbrake.
57. Lift the side of the tractor concerned using a trolley
jack. Position an axle stand and disassemble the
front wheel.
58. Drive out the defective stud.
59. Lightly smear the serrated area with Loctite 270 and
insert it using an appropriate bronze drift and ham-
mer.
60. Refit the wheel. Remove the axle stand and jack.
Tighten the nuts to the same torque as shown in
operation 42.
F . Disassembling, reassembling and

shimming the swivel housing
Disassembly
61. Remove the planetary carrier (see § B).
62. Disassemble the sun gear (39) and wheel hub (see
§ D).
63. If necessary, remove seal (23) using a suitable
extractor or a locally manufactured tool. Remove
circlip (35) and washer (34). Take off the retaining pin
and nut of the steering ball joint. Extract the ball joint.
64. Using an appropriate sling place a sling on swivel
housing (5).
65. Take out bolts (8). Remove cover (20) and bearing
cup (12). Extract the lower swivel pin (21) (Fig. 15)
using tool MF451B and adaptor MF451B3 (see § H). Fig. . 15
66. Take out bolts (8) and remove cover (10). Remove
the shims (9), cup (12), and extract the upper swivel
pin (21) in the same way as the lower one (Fig. 15).
67. If necessary, extract cones (11) from the swivel
pins.
68. Remove housing (5).
69. If necessary, take off seal (22) and drive off the
bushes (30).
70. If necessary, remove the drive shaft. Take off
protection bush (17), seal (16) and extract bush (15).
Issue 1 May 2001

Reassembly
72. If disassembled, insert bush (15) and seal (16) so as
to thrust against the shoulder of housing (13). Lubri-
cate seal (16). Refit the universal drive shaft. Intro-
duce a guide into the filler hole in order to align the
left-hand side drive shaft with the differential.
73. If disassembled, insert bushes (30) and a new
lubricated seal (22) thrusting against the shoulder of
housing (5). 18
74. Replace seals (18) turning the lips as shown in
Fig. 16.
Remark
21
- The turning lock stops (Fig. 17) are adjusted by set
screw (48), depending on the amount of turning
lock required. Refer to the table below. After adjust- Fig. 16
ment, lock by tightening nut (49).
Dimension X Turning lock angle
77 mm 35°
63 mm 40°
34 mm 50° AG 155H
75. If disassembled, insert cones (11) thrusting against
swivel pins (21).
76. Refit housing (5). Position the upper swivel pin (21)
in order to align the unit assembly with housing (13).
Insert the swivel pin while checking that the lip of
seal (18) is correctly positioned.
77. Fit cup (12), shim(s) (9) removed during disassem-
bly, and cover (10). Fit and tighten bolts (8) uniformly X
and alternately.
78. Fit the lower pin (21) smeared with Anti-seize grease
while checking that the lip of seal (18) is correctly
positioned. Place cup (12) and cover (20). Fit and
tighten bolts (8) (115 - 140 Nm) in the same way as 49 48
described in operation 77.
Important
- Check that the swivel pins (21) are fully in contact
with the housing.
79. Once the pins have been inserted, provisionally
AG 200H
remove shim(s) (9). Refit cover (10) and tighten the
bolts to a torque of 115 - 140 Nm. Inspect and if
required carry out P1 shimming.
Fig. 17
Issue 1 May 2001


P1 shimming (Fig. 19)
80. Using a dial gauge, measure the axial clearance by
vertically moving the housing with a lever (Fig. 18).
81. Fill the clearance measured with a corresponding
thickness of shims (9). Then to definitively obtain P1,
add additional shims of a thickness of 0.15 mm to
0.25 mm (0.15 mm to 0.25 mm being the pre-load
value that is required).
82. Take out bolts (8), remove cover (10). Fit the shims
(9) that were defined in operation 81. Refit the cover.
Tighten bolts (8) to a torque of 115 - 140 Nm.
83. Continue the reassembly operations. With a grease
gun, grease bearings (11) (12).
84. Smear the rim of seal (23) with Loctite 542 (Fig. 20)
and lubricate the lips. Insert the seal (Fig. 20) using
tool ref. 3378039M1, and bush ref. 3378056M1 or
3378057M1 depending on the type of final drive unit. Fig. 18
Note: Tool A (see § H) must be fully screwed in.
Seal (23) is not thrust against the shoulder; it is
the bush that determines its position. Smear nut
D (see § H) and its thrust face with graphite
grease. P1
For information purposes: the position of seal (23) is
11.5 mm from face F (Fig. 20A).
85. Refit the steering ball-joint. Tighten the nut to a torque
of 140 - 155 Nm. Lock the nut with a new pin. Refit
9
the wheel hub (see § D).
86. Place washer (34) and circlip (35). Refit the sun gear
(39).
Fig. 19
Fig. 20A
11,5
F
542
Fig. 20
Issue 1 May 2001

G . Removing and refitting the uni-

1 2
versal drive shaft
Removal
88. Remove the planetary carrier (see § B).
89. Remove the sun gear (39), circlip (35) and washer
(34). Extract the steering ball-joint.
90. To remove the swivel housing (5) and hub (3)
assembly, apply the same procedure as that used
for removing the pins (21)and described in § F.
91. Remove the universal drive shaft (14).
Disassembly of the shaft universal joint (Fig.

21) 3
92. Hold the external section (1) of the transmission
shaft in a vice fitted with soft jaw protectors. Fig. 21
93. Remove the four circlips (3) at each end of the
universal joint.
94. Using a plastic hammer drive out the central yoke
(2) downwards, until the sleeve of the bearing is 1
visible.
95. Hold the bearing sleeve in a vice, tap the yoke, and
drive it out.
96. Remove the opposite bearing sleeve in the same
way and remove the external section of the shaft.
97. Turn the shaft assembly through 90°, then repeat
operations 94 to 96 to free the universal joint from
the shaft.
98. Tighten the internal section of the transmission
shaft in a vice and repeat operations 93 to 97. If
necessary, drive out the cup plug (6) (Fig. 1 - 2).
Reassembly of the universal-joint

Fig. 22
universal joint assembly including the spiders, oil
seals, bearings, sleeves and circlips.
If disassembled, lightly smear the cup plug (6) with
Loctite 270 and insert it into the internal section of
the drive shaft but foresee the assembly of the sun
gear (39).
100. Coat the needle bearings with bearing grease and
ensure that they are all present in the sleeves.
101. Position the universal joint (1) in the yoke and push
it as far as possible to one side (Fig. 22) so that the
end of the spider acts as a guide for fitting the
sleeve with the needle bearings.
Issue 1 May 2001


102. Press the sleeve (1) into the yoke quite deeply and
hold the spider (Fig. 23) in order to fit the circlip.
103. Assemble the other sleeves and spider in the same 1
way.
Refitting
104. Refit the drive shaft. Introduce a guide through the
housing filler aperture (13) to align the left-hand
drive shaft with the differential while holding the
overhanging part.
105. Replace the seals (18). Turn the lips of seals as
shown in Fig. 16. Insert the cones (11) to thrust
against swivel pins (21). Refit the swivel housing
and wheel hub assembly. Position the upper swivel
pin (21) in order to align the housing assembly with
housing (13). Insert the pin while checking that the Fig. 23
lip of seal (18) is correctly positioned.
106. Fit cup (12), shims (9) and cover (10). Fit and tighten
bolts (8) uniformly and alternately to a torque of
115 - 140 Nm.
107. Fit the lower swivel pin (21) smeared with Anti-
Seize grease and while checking that the lip of seal
(18) is correctly positioned. Place cup (12) and
cover (20). Fit and tighten bolts (8) to a torque of
115 - 140 Nm in the same way as in operation 106.
Important
- Check that swivel pin (21) is fully in contact with
housing (13).
108. Using a grease gun, grease bearings (11) (12).
109. Reassemble the steering ball-joint. Tighten the nut
to a torque of 140 - 155 Nm and lock it using a new
pin.
110. Check for the presence of friction washer (33).
Place washer (34) and circlip (35). Fit the sun gear
(39).
Special point
- washer (33) is fixed on swivel housing (5) using
Loctite 270 or its equivalent.
Issue 1 May 2001

H . Service tools
- MF451B - Swivel pin extractor (Fig. 24)
- MF451B-3 - Adaptor for extractor M18 (Fig. 24)
- 3378028M1 - Socket for crownwheel carrier nut

(Fig. 25)
- 3378038M1 - Crownwheel carrier extractor (Fig. 26)
Fig. 24
Fig. 25
Fig. 26
AG 155H
AG 200H
Issue 1 May 2001


- 3378039M1 - Insertion tool for crownwheel carrier
and seal (Fig. 27)
- 3378056M1(*) - Insertion bush for AG 155H front

axle seal (23) (Fig. 28)
- 3378057M1(*) - Insertion bush for AG 200H front

axle seal (23) (Fig. 28)
- 3378122M1 - Sleeve (Fig. 29)
(*) Remark: These bushes must be used with the basic

tool ref. 3378039M1. A
Fig. 27
Fig. 28
Fig. 29
Issue 1 May 2001

Front axle - ZF final drive units 8B02.1
8 B02 ZF final drive units
CONTENTS
- General ________________________________________________ 2
A. Removing and refitting the planetary carrier, sun gear,

crownwheel and wheel hub _____________________________ 5
B. Disassembling and reassembling the planetary carrier _____ 7
C. Replacing the lip seal and wheel hub bearings ____________ 8
D. Adjusting the rotational torque of the wheel hub __________ 9
E. Shimming the planetary carrier __________________________ 10
F. Disassembling and reassembling the swivel housing ______ 11
G. Replacing the seal and transmission bushes ______________ 14
H. Removing and refitting - disassembling and

reassembling the universal drive shaft ____________________ 15
I. Replacing a wheel stud __________________________________ 16
J. Service tools ___________________________________________ 17
Issue 1 May 2001

8B02.2 Front axle - ZF final drive units

(28) Seal
General (29) Bush
The 8270 and 8280 tractors are fitted with an APL 5052 (30) Spindle
front axle. A plate riveted on the rear right-hand side of the (31) Bolt
main housing indicates the serial number and type, as (32) Seal
well as certain front axle specifications. (33) Bearing cone
(34) Wheel hub
The final drive unit assembly is fitted on a swivel housing (35) Stud
(13) that is articulated on the main housing (1) via two (36) Bearing cup
swivel pins (16). Two taper roller bearings (33) (36) and (37) Bearing cup
(37) (38) fitted in the wheel hub (34) ensure the rotation (38) Bearing cone
of the latter. (39) Snap ring
(40) Crownwheel carrier
The movement from the front differential is transmitted (41) Crownwheel
to the wheel hub via universal drive shaft (12), sun gear (42) Castellated nuts
(45) and crownwheel (41). The latter is retained by snap (43) Stop
ring (39) on planetary carrier (40). (44) Tab washer
(45) Sun gear
Oil tightness is ensured at the final drive unit by a lip seal (46) Snap ring
(32) and at the universal drive shaft / main housing by (47) Tab washer
seal (9). (48) Shim
Oil tightness is ensured at spindle (30) and universal (50) Bolt
drive shaft (12) by seal (28) and at swivel bearings in (51) Planetary gear pin
housing (13) by O’ring (7). (52) Snap ring
(53) Bearing cup plug
(54) Seal
(55) Plug
Parts list (56) Friction washer
(1) Axle housing (57) Washer
(2) Breather (58) Planetary gear
(4) Bearing cone (59) Needle bearing
(5) Bearing cup
(6) Deflectors
(7) O’ring
(8) Bush
Fig. 1
(9) Seal
(10) Dust cover
(12) Universal drive shaft
(13) Swivel housing
(14) Steering lock adjustment screw
(15) Nut
(16) Swivel pin
(17) Shims
(18) Arm
(19) Mecanindus pin dia. 12
(20) Mecanindus pin dia. 20
(21) Bolt
(22) Grease nipple
(23) Lower cover
(24) Bolt
(25) 45º grease nipple
(27) Dust cover
Issue 1 May 2001

Exploded view
12
27
2 7 28
29
6
31
4 5
30
32
8 9 10 36
33
34
21
1 5 4 37
38
19 39 35
6
20 40
7
41
18
42
22
44
17 45
46
16 47
48
49
14 13 50
15
43
55
56
23 57 54
16 58
59
24 17 57 53
56
25 51 Fig. 1
52
Parts list
Issue 1 May 2001

Issue 1 May 2001

A . Removing and refitting the pla-

netary carrier, sun gear, crownwheel
and wheel hub
Reminder
- The 4WD clutch is mechanically engaged when the V
tractor is stationary and the engine turned off. Raise
both front wheels so as to freely turn the hub of the
wheel concerned.
2. Place axle stands beneath the front axle. T
4. Drain the final drive unit. 50
Special point
- The drain port machined into the planetary carrier Fig. 2
(49) is aligned with a moulded cavity on wheel hub
(34), in order to allow for the correct evacuation of the
lubricating oil when draining. For this reason, the
position of the planetary carrier on the hub must be
located by two opposing paint marks T before
disassembly (Fig. 2). 34
Removal
5. Remove bolts (50) and separate the planetary carrier
assembly from the hub using two extractor bolts “V”,
ref. 5870 204 016 (Fig. 2 and § J).
6. Take off snap ring (46), sun gear (45) and tab washer
(44).
7. Correctly unlock the two castellated nuts (42) and
successively unscrew them using socket, ref.
5870 401 082 (see § J). Discard the retainer (43).
8. Extract the wheel hub (34), crownwheel carrier (40)
and crownwheel (41). Remove the assembly using a
lifting device (Fig. 3). Where necessary, match and Fig. 3
keep together bearing cones (33) (38) and bearing
cups (36) (37).
Danger
- Request the assistance of another operator and take

care when removing the hub.
9. If required, remove snap ring (39) and separate

crownwheel (41) from the crownwheel carrier (40).
Issue 1 May 2001


Refitting
Note: If the crownwheel has previously been sepa-
rated from the crownwheel carrier, fit the two to-
gether and fit the snap ring (39).
10. If required, replace lip seal (32) that provides oil
tightness for the wheel hub (see § C).
11. Refit the wheel hub, the crownwheel carrier and
crownwheel, using the same safety precautions and
method as when removing it.
12. Adjust the rotational torque of the wheel hub (see
§ D).
13. Check or carry out shimming of the planetary carrier
(see § E).
14. Lightly smear the mating face of the planetary carrier
with the hub with Loctite 510 or its equivalent, taking
care that it does not enter the tapped holes.
the hub.
16. Check for the presence of tab washer (47) in the
cavity in the planetary carrier.
17. Position the planetary carrier according to the paint
marks made during its removal.
18. Fit bolts (50) and tighten to a torque of 190 - 220 Nm.
Final operations
19. Turn the wheel hub in order to fit the oil filler plug in
the horizontal axis of the drive unit. Top up the oil
level using an oil with a viscosity grade of 80W/90
and check the oil level through the same port. Screw
in plug (55) fitted with its seal (54).
20. Refit the wheel. Remove the axle stands and trolley
jack. Tighten the wheel nuts to a torque of 575 Nm.
21. Remove the chocks and release the handbrake.
22. Carry out a road test. Check for the oil tightness of
the mating face of the planetary carrier and the drain
and filling plugs.
Issue 1 May 2001


the planetary carrier P
51
23. Remove the planetary carrier (see § A).
Disassembly
24. Place the planetary carrier in a press fitted with an
appropriate fixture.
25. Extract pins (51) from the planetary carrier (49),
pulling outwards as shown by “P” (Fig. 4)
Remark
- Each pin is fitted with a snap ring (52). 49
26. Recover the friction washers (56), washers (57) and
needle bearings (59) from each bearing. Fig. 4
Reassembly
51
28. In the planetary gears (58), arrange the needle
bearings coated with bearing grease. Place a washer
(57) on either side of each planetary gear.
29. Position the friction washers (56), with each tab
located in the groove of the planetary carrier. Slide
the pre-assembled planetary gears between the
friction washers.
30. Check for the presence of snap ring (52) on the
planetary gear pins. Centre the planetary gears and
friction washers. Position and insert the pins (51)
thrusting against the planetary carrier via its external
face (Fig. 5) using the same equipment that was
used for their removal.
Fig. 5
31. Manually check the axial clearance and the free
rotation of each planetary gear.
Final operation
32. Refit the planetary carrier (see § A).
Issue 1 May 2001

C . Replacing the lip seal and wheel

hub bearings
33. Remove the wheel hub (see § A).
Replacing the seal (32)

Disassembly
34. Locate the position of the seal and extract it using a
local method.
Reassembly
35. Inspect and clean the seal location. Check for any
shock or scratching that could affect the oil tightness
of the hub.
36. Insert the new seal in the hub into the previously
noted position using an insertion tool made up from
centring bush, ref. 5870 905 005, drift, ref. 5870 055
073 and handle, ref. 5870 260 002 (see § J).
37. Lubricate the lips of the seal.
Replacing the bearings

Disassembly
38. Extract seal (32) and discard it (see previous opera-
tions).
39. Extract the bearing cups from the wheel hub (34)
using a local method.
Discard the cones (33) (38) and bearing cups (36)
(37).
Reassembly
40. Clean and visually check that the cone and cup
locations are free from burs. Lubricate the bearings.
41. Insert new cups on the shoulders of the hub using a
press and an appropriate fixture.
Final operations
42. Refit the wheel hub (see § A).
43. Adjust the hub rotational torque (see § D).
44. Check or carry out the shimming of the planetary
carrier (see § E).
Issue 1 May 2001

D . Adjusting the rotational torque

of the wheel hub
Remark
- This adjustment is carried out during the replacement of
the taper roller bearings or the wheel hub.
34
Adjustment
45. Fit internal nut (42) and tighten it using socket, ref.
5870 401 082 (see § J), so as to obtain a rotational
torque of:
- 7 to 13 Nm for new bearings
- 3.5 to 6.5 Nm for re-used bearings
Remark
- The rotational torque is checked using a spring
balance and a wire wrapped around the circumfer- Fig. 6
ence of hub (34) (Fig. 6).
46. Place the retainer (43). Screw and lock the external
nut (42) using the socket applied in operation 45.
Special point
- Retainer (43) is fitted between two nuts (42). By
means of two tabs lodged in the grooves on spindle
(30) it stops any rotation of the internal adjusting nut
during the tightening of the external locking nut.
47. Using an appropriate tool, lock nut (42) by bending
the retainer (43), without breaking it, into one of the
six notches on each nut.
Issue 1 May 2001

E . Shimming the planetary carrier

12 34
Remark
- The shimming of the planetary carrier consists of
obtaining a J1 clearance of 0.3 to 0.5 mm between the
end of the universal drive shaft (12) and the bottom of
the planetary carrier (49).
48. Fit the tab washer (44) with its tabs positioned in the
notches on spindle (30).
49. Slide the sun gear (45) on to the end of universal drive
shaft and fit snap ring (46).
Shimming Fig. 7
Important
- Push hard on the universal drive shaft in order that the
sun gear thrusts against the spindle.
On the wheel hub (34) (Fig. 7)

50. Measure dimension A between the thrust face of the
planetary carrier on the hub and the end of the
universal drive shaft (12).
On the planetary carrier (49) (Fig. 8)

51. Measure dimension B between the thrust face of the
planetary carrier and the tab washer (47).
52. Determine J1 using the formula: B - A 49
Remark
- If J1 is between 0.30 and 0.50 mm, the shimming
47
is correct. Otherwise, extract cup plug (53). Re-
lease and drive off tab washer (47) to add or remove
shims (48) in order to obtain the correct J1 clear- Fig. 8
ance.
Final operation
53. After carrying out the shimming, refit:
- the previously selected shims
- the thrust washer, its rim lightly smeared with
Loctite
- a new cup plug, its circumference lightly smeared
with Loctite 542 or its equivalent.
Issue 1 May 2001

F . Disassembling and reassembling

the swivel housing 2
Preliminary operation 1
54. Remove the wheel hub (see § A). 3
Disassembly
55. Remove pin (1). Unscrew nut (2) and extract the ball
joint (3) from swivel housing (13) (Fig. 9).
56. Unscrew the nut and extract the ram ball joint (see
section 9F02).
57. Take out bolts (31) and take off the spindle (30). 13
58. Remove the universal drive shaft (12).
59. Take off grease nipples (22) (25) located on the upper
and lower swivel pins (16).
60. Take out bolts (21) (24). Remove arm (18) and the Fig. 9
lower cover (23).
61. With the assistance of another operator, hold the
swivel housing.
62. Remove the swivel pins (16) from the housing (13)
using an inertia extractor (Fig. 10 - 11) beginning with
the lower swivel pin.
Note: If necessary, match shims (17) with their 16
respective swivel pin.
63. Separate the bearing cones (4), deflectors (6) and
O’rings (7) from the swivel pins. If needed, extract
the bearing cups (5) inserted in axle housing (1) and
match them with their respective cones (4).
13
Fig. 10
13
Fig. 11
Issue 1 May 2001


Reassembly
65. Insert bearing cups (5) in the axle housing (1) using 16
66. Assemble on each swivel pin (16):
- a new O’ring (7)
- a correctly positioned deflector (6)
- a bearing cone (4) 1 13
67. With the assistance of another operator, refit the
swivel housing (13).
68. Position the pre-assembled upper swivel pin (16) in
order to align swivel housing (13) and axle housing
(1) (Fig. 12).
69. Replace the shim (17) removed during disassembly.
Check for the presence of the Mecanindus pins (19)
(20) and check that their slots are diametrically Fig. 12
opposed. Fit arm (18) by partially fixing it with two
bolts (21).
70. Assemble the pre-assembled lower swivel pin (16).
Place shim (17) removed during disassembly and fit
cover (23). Assemble and tighten bolts (24) to a
torque of 190 Nm.
71. Fit all the bolts (21) and tighten to a torque of 190 Nm.
72. Turn swivel housing (13) several times from one
stop to the other in order to seat the cones in their 13
cups (Fig. 13).
73. Using a torque wrench fitted with a dial and an
appropriate fixture that respects the axis of the
swivel pins (Fig. 13), check that the resistance of
bearings (4) (5) is between 21 and 28 Nm. Other-
wise, carry out adjustments.
Fig. 13
Issue 1 May 2001

Adjustment
- The adjustment principle consists of adding or remov-
ing shims (17) on the lower or upper swivel pins in order
to obtain the previously stated bearing resistance. 31
74. Refit the universal drive shaft (12)

Note: Introduce a guide through the housing
filler hole (1) in order to align the right-hand side
transmission with the differential.
75. Fit spindle (30). Lightly smear the threads of bolts 30
(31) with Loctite 241 and tighten them to a torque of
295 Nm (Fig. 14).
76. Fit the grease nipples. Using a grease gun, lubricate
bearings (4) (5) on the upper and lower swivel pins.
Note: A 45º grease nipple is fitted on the lower
swivel pin.
77. Insert the steering ram ball joint and tighten the nut
Fig. 14
to a torque of 440 Nm.
78. Insert the ball joint of the steering rod and tighten the
nut to a torque of 290 Nm. Lock it using a new pin.
Final operations
79. Refit the wheel hub (see § A).
80. Adjust the steering lock stops.
Note: On the APL 5052 axle, the maximum al-
lowed steering lock is 50º.
Remark
- The steering lock stops are located on the upper
part of each swivel housing.
Issue 1 May 2001

G . Replacing the seal and transmis- Fig. 15
sion bushes
1
81. Extract the steering ball joints and the coupling bar
(see § F).
82. If only the dust covers (10), seal (9) or bush (8) on
axle housing (1) are to be replaced, integrally remove
swivel housing (13) and the final drive unit (Fig. 15).
Danger 8
- With the assistance of another operator, carefully carry 9

out the removal operation taking into account the risks
13 10
posed by a sudden tilting of the housing and the heavy
weight of the assembly.
Reminders
Reminder - For the replacement of the dust covers (27), seal (28)
- The removal of the lower and upper swivel pins is and bush (29) on spindle (30), in addition remove the
carried out in the same way as the disassembly of the planetary carrier and sun gear (see § A) as well as the
swivel housing alone (see § F). universal drive shaft.
83. Using a suitable sling, hold and remove the entire - Then use the same method as described in operations
drive unit assembly as well as the universal drive 84 and 85 for disassembly and then operations 86 to 89
shaft (Fig. 15). for reassembly.
Disassembly (Fig. 15) Final operation

84. Locate the position of dust covers (10) and seal (9) 90. Refit the entire final drive unit assembly (Fig. 15 and
and drive them off the axle housing (1). § F) using the same safety precautions taken during
85. Carry out the same operation for bush (8). its removal.
Reassembly
86. Clean the components. Check that the seal and bush
carriers are free of scratches and dents.
87. Lightly smear the rim of the bush with Loctite 620 or
its equivalent and insert it into the axle housing using
the service tool made up from drift, ref. 5870 058 026
and handle, ref. 5870 260 002 (see § J) in accor-
dance with the position marked during disassembly.
88. Insert the seal and the dust covers using a service
tool made up from drift, ref. 5870 055 006 and handle,
ref. 5870 260 002 (see § J).
89. Lubricate the lip of the seal.
Issue 1 May 2001

H . Removing and refitting - disas-

sembling and reassembling the uni- 12
versal drive shaft
Removal
91. To gain access to the universal drive shaft, it is
necessary to:
- remove the upper and lower swivel pins and
remove the housing assembled with the final drive
unit (see § G).
- remove the planetary carrier and the sun gear (see 1
§ A). 2
1
Disassembling the seal of the universal drive

shaft (Fig. 16 - 17) Fig. 16
92. Hold the external section (12) of the universal drive
shaft in a vice fitted with soft jaws.
93. Remove the grease nipples and four circlips (3) at the
ends of the universal joint. 12 2
94. Using a soft hammer, drive the centre yoke (2)
downwards until the bearing sleeve is visible.
96. Remove the opposite bearing sleeve in the same
way and remove the protruding section of the shaft.
97. Turn the whole shaft through 90º, then repeat the
operations 94 to 96 to disengage the universal joint
from the shaft.
98. Tighten the internal section of the universal drive
shaft in the vice and repeat operations 93 to 97.
Fig. 17
Issue 1 May 2001


Reassembling the universal drive shaft
entire universal joint including the spider, seals, 1
bearings, sleeves and circlips.
100. Smear the needle bearings with bearing grease and
ensure that they are all in the sleeves.
101. Position the universal joint (1) in the yoke and push
it as far as possible to one side (Fig. 18) so that the
end of the spider serves as a guide for refitting the
sleeve with the needle bearings.
102. Push the sleeve (1) deep into the yoke while holding
the spider (Fig. 19) in order to fit the circlip.
103. Assemble the other sleeves and spider in the same
way and refit the grease nipples. Using a grease
gun, lubricate the spider.
Special point
- A 45º grease nipple is fitted on the external spider.
Fig. 18
Reassembling
104. Refit the universal drive shaft, carry out operation
91 in reverse order. 1
I . Replacing a wheel stud

105. Chock the rear wheels. Apply the handbrake.
106. Lift the side concerned with a jack. Take off the
front wheel and position an axle stand. Fig. 19
107. Drive out the defective stud.
108. Fit a new stud in the hub flange with its serrated
area lightly smeared with Loctite 270.
109. Refit the wheel and remove the axle stand and
jack. Tighten the wheel nuts to a torque of 575 Nm.
Issue 1 May 2001

J . Service tools
- 5870 401 082 - Socket for crownwheel carrier nuts
(Fig. 20)
- 5870 204 016 - Crownwheel carrier extraction bolt
(Fig. 21)
- 5870 260 002 - Handle (Fig. 22)
Fig. 20
Fig. 21
Fig. 22
Issue 1 May 2001


- 5870 905 053* - Centring bush (Fig. 23)
- 5870 055 006** - Insertion drift for seal and dust
5870 905 004
cover (Fig. 24)
- 5870 058 026** - Insertion drift for bushes (Fig. 25)
5870 055 073
- 5870 055 073** - Insertion drift for seal (Fig. 23)
Remarks
* Bush, ref. 5870 905 005 must be used with drift, ref.
5870 055 073
** Insertion drifts, ref. 5870 055 006, 5870 058 026
and 5870 055 073 must be used with handle, ref.
5870 260 002
Fig. 23
Fig. 24
Fig. 25
Issue 1 May 2001

Front axle - Carraro final drive units 8B03.1
8B03 Carraro final drive units
CONTENTS
- General _______________________________________________ 2
A. Steering cylinder group disassembly ____________________ 2
B. Epicyclic reduction gear disassembly ____________________ 3
C. Wheel hub group disassembly __________________________ 4
D. Axle beam group disassembly __________________________ 8
E. Axle beam group assembly _____________________________ 9
F. Wheel hub group assembly _____________________________ 10
G. Epicyclic reduction gear assembly _______________________ 15
H. Toe-in adjustement _____________________________________ 16
I. Steering angle adjustment ______________________________ 18
J. Service tools __________________________________________ 19
Issue 1 May 2002

8B03.2 Front axle - Carraro final drive units
General
Some of the pictures of that manual may not show
exactly your axle, but the process is the same.
A. Steering cylinder group

disassembly
Fig. 1
Reminder
- The 4 WD clutch is mechanically engaged when
the tractor is stationnary and the engine turned off.
Raise the both front wheels in order to freely turn
the hub of the wheel concerned.
2. Positions axle stands.
4. Drain the final drive unit.
Steerring cylinder group disassembly

5. Unloose the guide rod locknut of some turns till it is
on a level with the threaded pin (Fig.1)
6. Beat on the nut with a hammer in order to disjoin the
guide rod from the swivel housing (Fig.2)
Note : this is a destructive operation for the nut.
Fig. 2
To disassembly the steering cylinder group, see
section 9K02.
Issue 1 May 2002

B. Epicyclic reduction gear disas-

sembly
7. Before draining the oil, position the wheel hub with the
plug on the upper part and loosen it of some turns in
order to eliminate any possible inner pressure, then
remove it completely. Turn the wheel hub upside-
down till the hole is in the lowest point.
Drain the oil completely (Fig.3)
8. Unscrew and remove both fastening screws of the
planetary carrier with a wrench (Fig.4)
Remove the planetary carrier from the wheel hub.
Position the planetary carrier on a workbench and
check its wear conditions.
9. To carry out any possible replacements of the plan-
etary gears: Fig. 3
- remove the fastening scews on every planetary
gear;
- remove the washers;
- take the planetary gears out of the pins
- collect the needle bearings, checking their condi-
tions
- remove the thrust washers (Fig.5)
Note : With new planetary gears is advisable to
assembly new roller bearings.
Fig. 4
20.29 S
20.43 S
Fig. 5
Issue 1 May 2002

C. Wheel hub group disassembly

Before disassembling the wheel hub, it is advisable to
secure it with a belt or a rope on a hoist or any other
supporting device, in order to avoid its accidental fall that
could damage either the operator or the wheel hub group.
10. Insert a lever between the swivel housing and the

axle beam and fit it into the double U-joint. With the
lever push the double U-joint in the direction of the
final drive to make easier the lock ring removal
(Fig.6).
Remove and throw out the lock ring (Fig.6A).
Remove and throw out the washers (Fig6B).
Remove and throw out the two thrust washers
(Fig6C).
Fig. 6
Fig. 6A
Fig. 6B Fig. 6B
Issue 1 May 2002

11. Unscrew and remove the fastening screws from the

wheel carrier group (Fig.7)
12. In order to remove the wheel carrier group from its
housing, screw at least two of the just removed
screws in the threaded extraction holes (Fig.8A).
Check that the scews don't touch the catches A.
Danger
- Don't use these two screws for the assembly of
the wheel carrier.
Fig. 7
Fig. 8a
A Fig. 8A
Issue 1 May 2002

13. Extract and remove the wheel carrier together with

the epicyclic ring gear.
Remove the steel lock ring and disjoin the wheel
carrier from the epicyclic ring gear. Check the wear
conditions of the components (Fig.9). Only if neces-
sary, remove the centering bushes of the hub lock
ring gear with a hammer and the special tool code
CA715027 (see § J)
14. Remove the wheel hub, using levers and a hammer
to facilitate the operation (Fig.10)
Note : Collect the bearing cone.
15. Position the wheel hub on a flat surface and take the
seal ring A out with a lever.
Note : This is a destructive operation for the seal
ring.
Take the bearing cups B out, on both sides of the
hub, using a hammer and a suitable drift.
Fig. 9
Remove the bearing cone from the swivel housing
end, using a suitable extractor.
Remove the O-Ring C from the wheel hub (Fig.11).
Fig. 10
Fig. 11
Issue 1 May 2002

16. Unscrew and remove the fastening screws from the

upper and lower king pin (Fig.12)
Danger
- Before removing the king pins, secure the swivel
housing with a belt or a rope to a hoist or any other
supporting device.
Remove the king pins.
Note : Collect the belleville washers.
17. Remove the swivel housing from the axle beam and
from the short shaft of the U-Joint (Fig.13)
Position the swivel housing on a flat surface and
take the seal ring out with a lever (Fig.14)
ring.
18. Turn the swivel housing and take the bush out, using
a drift and a hammer (Fig.14A) Fig. 12
Fig. 13
Fig. 14 Fig. 14A
Issue 1 May 2002

D. Axle beam group disassembly

19. Remove the U-Joint from the axle beam (Fig.15)
20. Take the seal ring A out of the axle beam with a lever.
Remove the cup springs C from the king pin housings
in the axle beam.
ring.
Remove the bush B from the beam with a suitable
extractor (Fig.16)
Note : Examine the bush before the removal and
replace it only if the wear conditions require
this.
21. Take the upper D and lower E bushes out of the king
pin housings F and out of king pin with a suitable
extractor (Fig.17).
Fig. 15
B
A
C
A
Fig. 16
Fig. 17
Issue 1 May 2002

E. Axle beam group assembly

22. Assemble the upper king pin bush on the axle beam
with the special tool CA715034 (see § J) and a
hammer.
Insert the cup of the ball bearing on the lower part of
the axle beam with the special tool CA715035 (see
§ J) and a hammer (Fig.18)
Note : To make the assembly easier, it is advis-
able to cool the cup of the ball bearing at a
temperature lower than 100°C. That operation is
possible by fully immersing the arms pins in
liquid nitrogen. To buy or rent liquid nitrogen,
contact the "Air liquide" society.
Warning : Wear safety gloves.
23. Assemble the bush on the axle beam with the
Fig. 18
special tool code CA119055 (see § J) and a hammer.
Assemble the seal ring on the beam with the special
tool code CA 715097 (see § J) and a hammer (Fig.19)
Fill ¾ of the seal ring cavity with grease.
24. Lubricate the bush and the seal ring lip.
Insert the U-Joint inside the axle beam (Fig.20)
Warning : Be careful not to damage the seal.
Fig. 19
Fig. 20
Issue 1 May 2002

F. Wheel hub group assembly

25. Force the bush into the swivel housing with the
special tool code CA 715108 (see § J) and a
hammer or a press.
Assemble the seal ring on the swivel housing with
the special tool code CA 715097 (see § J) and a
hammer (Fig.21)
Fill ¾ of the gasket cavity with grease.
26. Position the lower king pin on a workbench and
assemble the cone of the spherical joint with the
special tool code CA715035 (see § J) under a press.
Grease well the king pin housings with specific
grease (see section 8A01 § A).
Position the Belleville washers on the king pin
housings (Fig.22)
27. Danger : Secure the swivel housing group with Fig. 21
a rope.
Lubricate the seal ring lip and protect the splined end
of the axle shaft by winding it with thin adhesive tape
to avoid damage to the seal ring. After assembly,
remove completely the adhesive tape.
Assemble the swivel housing on the axle beam.
Assemble the two king pins, the upper and the
lower, and tighten the retaining screws with dy-
namometric wrench to the requested torque (see
section 8A01 § A) (Fig.23)
Note : Make sure that the Belleville washers
remain in their position.
Fig. 22
Fig. 23
Issue 1 May 2002

28. The special operation “Set Right” of the bearings

does not require specific registrations of preloading
or backlash. Anyway, before assembling new com-
ponents check the indicated dimensions (Fig.24)
A= 08.450 to 08.500
B= 54.775 to 54.825
C= 23.070 to 23.172
29. Position the wheel hub on a workbench and force
both cups of the taper roller bearings in position with
the special tool code CA715026 (see § J) under a
press or with a hammer (Fig.25)
Insert the seal ring into the wheel hub with the
30. Assemble the cone of the taper roller bearing on the
swivel housing end.
Assemble the wheel hub on the swivel housing and
fit the other cone of the taper roller bearing in position
Fig. 24
(Fig.26)
31. Position the wheel carrier on a workbench and force
the bushes to the carrier surface level with the
special tool code CA715027 (see § J).
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins (Fig.26A).
Fig. 25
Fig. 26 Fig. 26A
Issue 1 May 2002

32. Preassemble the wheel carrier-epicyclic ring gear

group with the special locking ring X shown in figure
(Fig.27)
33. Assemble the wheel carrier group on the wheel hub
using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub (Fig.28)
Danger
- Don't use the two screws you took to remove the
wheel carrier group from its housing (see operation
12).
34. Force all the hub dowel bushes completely with the
Assemble the wheel carrier fastening screws and X
tighten to the requested torque (see section 8A01 §
Fig. 27
A) (Fig.29).
Fig. 28
Fig. 29
Issue 1 May 2002

35. Insert a lever between the swivel houing and the

axle beam and fit it into the double U-joint. With the
lever push the double U-joint in the direction of the
final drive to make easier the lock ring insertion
(Fig.30).
Insert the two new thrust washerson the halfshaft
(Fig.31).
Warning : Check the correct insertion between
the bushings (Fig.31A).
Fig. 30
Fig. 31
Fig.31A
Issue 1 May 2002

Insert the new washer ref. CA 142017 with the lock

ring seat towards the external side (Fig.31B).
Side the new lock ring ref. CA 142018. Pay attention
not to damage the lock ring during the assembling
(Fig.31C).
Push the double U-joint thoroughly and check the
lock ring is correctly fitted in its seat (Fig.31D).
Fig. 31B
Fig. 31C
Fig. 31D
Issue 1 May 2002

G. Epicyclic reduction gear assem-

bly
36. Collect all the components of the epicyclic reduction
gear (Fig.32)
37. Position the planetary carrier on a workbench.
Insert the lower thrust washer, the planetary gear,
the needle bearings and the two upper thrust washer
in the planetary carrier pins (Fig.33)
Note : Check correct positioning of lower thrust
washer in the lock pin. assemble the retaining
screw, then tighten the screws with dynano-
metric wrench to the requested torque.
38. Assemble a new O-ring on the wheel hub.
Assemble the epicyclic reduction gear on the wheel
hub (Fig.34)
Fig. 32
Screw in the fastening screws and tighten with
dynamometric wrench to the requested torque (see
section 8A01 § A).
Fig. 33
Fig. 34
Issue 1 May 2002

H . Toe-in adjustement
39. Put two equal one-meter-long linear bars on the
wheel sides and lock them with two nuts on the
wheel hub stud bolt (Fig. 35)
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.
40. Measure the distance in mm M between the bars
ends with a tapeline (Fig. 36)
Note : Keep the minimum value, swinging the
measurement point.
41. Check that the difference of the measurements E
between the wheel hubs diameters ends is within
the requested tolerance range (see Toe-in in sec. 50 cm 50 cm
8A01 § A) (Fig. 37) Fig. 35
The prescribed value 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 lenght of the bar and flange
diameter :
- toe-in (see section 8A01 § A) = E 0-2
- measurement difference = M0-5
Fig. 36
E0-2
A
.
M0-5
M
Fig. 37
Issue 1 May 2002

42. If toe-in is uncorrect, operate with two wrenches on

the guide rods screwing in and out the two joint tie
rods equally till the toe-in is within the requested
tolerance (Fig. 38)
43. After adjusting, screw in the lock nuts of the guide
rods to the requested tightening torque (see section
8A01 § A) (Fig. 39)
Fig. 38
Fig. 39
Issue 1 May 2002

J. Steering angle adjustment

44. Use the same bars assembled for the toe-in adjust-
ment 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 maxi-
mum steering (Fig. 40)
45. Adjust a goniometer to the requested angle (see
section 8A01 § A) and position it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the goniometer (Fig. 41)
46. Adjust the steering mechanical retainer, screwing in
or out the special screws (Fig. 42), locking them with
a locknut to the requested tightening torque (see
section 8A01 §A)
Steer completely towards the other side and repeat
the same operations. Fig. 40
Fig. 41
Fig. 42
Issue 1 May 2002

K. Service tools
- CA 119055 - Bush driver (Fig. 43)
- CA 715097 - Oil seal driver (Fig. 44)
Fig. 43
Fig. 44
Fig. 45
Issue 1 May 2002

- CA 715026 - Bearing cone driver (Fig. 46)

Fig. 46
Fig. 47
Fig. 48
Issue 1 May 2002

- CA 715035 - Driver for king pin bush (Fig. 49)

Fig. 49
Fig. 50
Issue 1 May 2002

Front axle - Dana differential 8C01.1
8C01 Dana differential
CONTENTS
- General ________________________________________________ 2
A. Splitting front axle / frame _______________________________ 5
B. Removing swivel housings, wheel hub and drive shafts ___ 5
C. Removing the differential housing assembly ______________ 5
D. Disassembling the differential ____________________________ 6
E. Removing the differential lock ___________________________ 7
F. Removing the crownwheel and drive pinion ______________ 7
G. Refitting the drive pinion and crownwheel ________________ 9
H. Reassembling the differential lock ________________________ 12
I. Piston leak test _________________________________________ 14
J. Refitting the differential housing assembly ________________ 14
K. Refitting swivel housings, wheel hub and drive shafts _____ 14
L. Assembling front axle / frame ____________________________ 14
M. Service tools ___________________________________________ 15
Issue 1 May 2001

8C01.2 Front axle - Dana differential

(10) Washer
General (11) Shim(s)
Whatever the type of front axle installed on 8200 series (12) Bearing cup
tractors (AG 155H or AG 200H), the operating principles (13) Bearing cone
and maintenance procedures remain similar. (14) Bolt
- 8210 - 8220 - 8240 tractors (15) Cover
. AG 155H type (16) Half-housing
- 8240 (optional) - 8250 - 8260 tractors (17) Planetary gear
. AG 200H type (18) Spherical washer
(19) Planetary gear pins
Note however that the splined end of the drive pinion is (20) Bolts
different on AG 200H front axles. This amendment (21) Sun gear
allows for a semi-rigid link between plate (45) and the (22) Bolt
drive shaft. (23) Lock washer
(24) Splined nut
The 8270 and 8280 tractors have a ZF front axle fitted with (25) Washer
a bevel gear of the same type (see section 8C02). (26) Half-housing
(27) Crownwheel
The bevel gear assembly containing the differential lock (28) Shim(s)
mechanism is fitted in a housing (35) that has two half- (29) O’ring
bearings held by bolts (42). (30) Nut
(31) Seal
The drive pinion is placed at the rear of the housing on two (32) Bearing cone
opposing taper roller bearings. Its adjustment is carried (33) Bearing cup
out via shim(s) (28) located behind the leading bearing. (34) Shim
The preloading of the bearings is obtained via shim(s) (35) Housing
(34) placed between bearing cone (32) and the shoulder (36) Deflector
of the drive pinion. (37) Bearing cup
The oil tightness is provided by seal (31) and O’ring (29) (38) Bearing cone
fitted on the drive pinion. (39) Drive pinion
(40) Mobile coupler
The adjustment of the crownwheel / drive pinion is (41) Half-bearing
obtained via shim(s) (11) placed behind bearing cup (12). (42) Bearing block bolt
(43) Centring bush
The preloading of the housing and crownwheel assembly (44) Wear ring
is carried out via splined nut (24). (45) Plate
(46) Washer
A plate riveted on the right-hand side of the housing
indicates the type and serial number of the front axle.
Fig. 1
Parts list Fig. 2

(1) Snap ring
(2) Tab washer
(3) O’ring Fig. 3
(4) Piston
(5) Friction washer
(6) Spring
(7) Locating pin
(8) O’ring
(9) Guiding washer
Issue 1 May 2001

Overall view
AG 155H AG200H
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
4 21
3 22
2 23
1 24
47 39
38
40 25
37
39 26
35
38 27
44 28
37 28 42
42 34 33
36 44
32 29
35 22 43
22 43 31
34 23
23 45
24
33 32 31 30 29 24 46
41
41 30 Fig. 2
Fig. 1
Parts list Fig. 2 Fig. 3 Parts list Fig. 1 Fig. 3

Issue 1 May 2001

Exploded view
31
32
33
36
44
30
35
46
45
29
36
30
31
29
24 32
12 33
13 44
41 35
23
34
20 28
22 37
43 38
42
13
34
12
28 AG 200H
37
38
26
39
3
2
25 11 1
10
27 21 9
6
AG 155H 18 40
19 5
8
16
4
15 7
17
14 Fig. 3
Issue 1 May 2001

A . Splitting front axle / frame

1. Drain the axle housing.
2. Split the axle and its bearing from the front frame (see 1 35
section 8F01).
B . Removing swivel housings,

wheel hub and drive shafts
Fig. 3A
Danger
- With the help of another operator, carefully carry out the

removal operation while taking into account the risks of
any unexpected tilting of the housing with its conse-
quent weight.
3. Extract the steering ball joints.

4. Using a suitable sling, hold, then remove the swivel
housing assembly (see section 8B01 § F).
C . Removing the differential hous-

ing assembly
5. Remove the swivel housing, wheel hub and drive
shaft assembly (see § B). Remove the bolts holding
the steering ram and remove it.
6. Take out bolts (1) (Fig. 3A).
7. Release and remove the differential housing assem-
bly (35) (Fig. 3A). If necessary, remove the deflector
(36).
Issue 1 May 2001

D . Disassembling the differential

8. Place housing (35) in a vice fitted with soft jaws 24
(Fig. 4) 42
9. Remove bolt (22) and its lock washer (23) (Fig. 4). 35
10. Remove the splined nut (24) using a special locally
manufactured wrench (see § M).
23
11. Take out the four bolts (42), remove the half-bearing
(41) (Fig. 4).
Danger
27
- Carefully take off the half-bearing on the differential
lock control side, since spring (6) has been com-
pressed during assembly. The washer (10) re- 41 22
mains in housing (35).
12. Remove the entire differential assembly with bear- Fig. 4
ing cones (13) and cups (12) (Fig. 5). Separate the
cups and cones. Remove shim(s) (11).
Remark
- If the bearings are to be reused, take care to match
12
the original cups and cones.
13. If necessary, extract the two cones (13).
14. Place the differential assembly in a vice fitted with
soft jaws. Remove bolts (20) and disassemble the
crownwheel (27).
15. Before disassembly, mark the position of half-
housings (16) (26) and cover (15). So that they can
be matched at reassembly. Remove bolts(14) and
separate the half-housings (16) and cover (15).
16. Remove the sun gear (21) and the washer (25).
17. Separate the two pins (19), the planetary gears (17)
and the spherical washers (18) (Fig. 6).
13
Fig. 5
20 25 21 19 16 15
14
26
18 17
Fig. 6
Issue 1 May 2001

E . Removing the differential lock

(Fig. 7) 9 4
18. Using tool ref. MF471 correctly centred (see § M),
compress spring (6) until washer (10) is released.
6 5
19. Remove washer (10).
20. Progressively, release the spring (6).
21. Remove the tool. 40 2
22. Remove the spring guiding washer (9).
23. Remove the spring (6).
24. Disassemble the snap ring (1) of coupler (40). 10 1
25. Remove the mobile coupler (40), friction washer (5)
and tab washer (2).
26. Remove piston (4). 8 3
27. Take off the O’rings (3) (8).
Fig. 7
F . Removing the crownwheel and

drive pinion
Removing the crownwheel
Reminder
- The replacement of the crownwheel (27) necessarily
requires replacement of the drive pinion (39). Both the
crownwheel and drive pinion have the same number
engraved on them and they must be fitted as matched
pairs.
28. Take out bolts (20) and remove the crownwheel (27).
Issue 1 May 2001


29. Unlock nut (30).
AG 155H front axles

30. Unscrew the drive pinion clockwise (Fig. 9) using F
wrench ref. 3378051M1 (Fig. 8) and a locally manu-
factured special sleeve “C” (Fig. 8) (see § M).
AG 200H front axles C

31. Unscrew the drive pinion clockwise using wrench F
ref. 3378275M1 and flange ref. 33782267M1, (Fig.
8A and § M).
32. Take out of the housing the drive pinion, cone (38),
shim (34) and O’ring (29) assembly.
33. Separate the drive pinion, seal (29), shim (34).
34. Extract cone (38) from the drive pinion.
35. Extract cup (37) and remove shims (28). Fig. 8
36. Extract seal (31). Remove cone (32) and drive off cup
(33).
Fig. 8A
Fig. 9
Issue 1 May 2001

G . Refitting the drive pinion and F

crownwheel
37. Before reassembly, clean and inspect all compo-
nents and replace any parts found to be defective. d
C
Check that the oil channel of the differential lock is
not obstructed.
Refitting the drive pinion 35 SP

38. Adjust the position of the drive pinion (Fig. 10). The
thickness of shims necessary to correctly position 28
the drive pinion is calculated using the following 37
formula:
SP = C - E - (d ± r)
SP : Thickness of shims necessary (28) E 38
C : Distance measured between thrust face of cup Fig. 10
(37) on housing (35) and machined face F.
d : Nominal distance of positioning drive pinion on
axles:
- AG 155H= 133.5 ± 0.10
- AG200H = 139 ± 0.10
E : Thickness of bearing (37) (38).
r : Actual dimension marked on drive pinion
(Fig. 11). This value may be either positive or
negative (add or deduct from nominal dimen- +
9-
13
0,1
sion d).
0
Procedure
39. Measure dimensions C and E using a depth gauge.
Note: Take care to correctly seat cone (38) in cup
(37). r
40. When the dimensions are measured, apply the
formula in order to determine the thickness of the
shims required. Fig. 11
41. Insert the cone thrusting against the shoulder on the
drive pinion using a press and a suitable fixture
(Fig. 12).
42. Place the previously calculated thickness of shim(s)
(28) in the housing.
43. Insert cup (37) using an appropriate fixture.
44. Carry out the shimming of bearings (32) (33) (37)
(38).
39
38
Fig. 12
Issue 1 May 2001


Method
45. Place the prepared drive pinion in the housing (35) SP1
thrusting against the cylindrical sleeve M as shown
34
in Fig. 13. Turn the housing several turns while
applying a strong pressure to correctly seat cone (38)
in cup (37).
37
sion F in accordance with the formula A - B (Fig. 13). A B
47. Press hard on cup (33) while turning it alternately left
38
and right in order to correctly seat cone (32). Meas-
F
ure dimension G (Fig. 13). M
48. Determine thickness SP1 of shim (34) (Fig. 13) using
35
the formula: 33
(G + F) – 0.05 (0.05 mm being the preload value).
49. Place cup (33) thrusting against the housing.
50. Slide the shim(s) (34) determined during operation 48 32
G
on to the drive pinion. Fit cone (32) and seal (29) Fig. 13
previously lubricated (Fig. 14).
51. Grease seal (31) and insert it home in the shoulder
using a locally manufactured tool (see § M).
52. AG 155H front axles
- Assemble nut (30) lock it using wrench ref. 29 32
3378051M1. Using a special sleeve and a torque
wrench, turn the drive pinion then tighten to a torque
of 450 - 500 Nm (Fig. 15).
AG 200H front axles 34
- Assemble nut (30) and lock it with wrench ref.
3378275M1 and flange ref. 3378276M1, then tighten
to a torque of 450 - 500 Nm (Fig. 15).
53. Check the rotation torque of the drive pinion.
Fig. 14
AG 155H
30
AG 200H
Fig. 15
Issue 1 May 2001

Method
54. On AG 155H front axles, turn the drive pinion several
turns using a dial torque wrench and the special
sleeve (Fig. 16) on AG 200H front axles use wrench
ref. 3378275M1. Check that the rotation torque of the
drive pinion is between 2 to 4 Nm.

Special point
- When repairing, use the bolts referenced in the spare
parts catalogue.
55. Clean the mating faces of the new crownwheel and

housing. Degrease the new bolts and lightly smear
with Loctite 270 or equivalent and screw them into
the crownwheel. Fig. 16
Tighten all the bolts to a torque of 140 - 155 Nm.
Issue 1 May 2001

H . Reassembling the differential lock Fig. 17
56. Assemble the friction washer (5) on the mobile

coupler (40). Slide the assembly into piston (4). Fit
tab washer (2) and position snap ring (1) in the groove
of the mobile coupler. 13
57. In the housing without its seals, fit the piston (4) with
the mobile coupler (40).
Note: The pin (7) is force fitted into the piston.
Check that both the piston and pin slide freely in 26
the housing. Once this check has been carried
out, remove the piston and mobile coupler.
58. Fit new O’rings (3) (8). Position the piston with the
mobile coupler then insert it by hitting around its rim
with a plastic hammer.
59. Position spring (6) and washer (9), with the shoulder
of the washer facing the spring. Place the assembly
under tension using tool MF 471 until washer (10)
slides freely in the groove of the housing.
60. Carefully loosen the tool so that the spring does not
escape.
61. Insert cone (13), if disassembled, on half-housing
(26) using a press or appropriate fixture (Fig. 17).
62. Insert the other cone (13), if disassembled, in cover
(15).
63. Assemble half-housing (16) in cover (15) (with cou-
pler teeth) with regard to the marks made during
disassembly.
64. Position washer (25) on sun gear (21), place the
assembly in half-housing (16), while locating the
washer tab in one of the holes on the half-housing.
65. Place the four planetary gears (17) and four spherical
washers (18) on the two pins (19) then place the
assemblies in half-housing (16) inserting the washer
(18) tabs into the holes on the half-housing (16)
(Fig. 6).
66. Place the other washer (25) on the other sun gear
(21). Fit the assembly in half-housing (26) while
respecting the position of the washer (25) tab.
67. Position half-housing assembly (26) on half-housing
(16) with regard to the marks made during disas-
sembly.
Issue 1 May 2001

68. Join together half-housings (16) (26) and cover (15).

Fit bolts (14) previously lightly smeared with Loctite
270. Tighten to a torque of 82 - 90 Nm. 24
Position crownwheel (27) on half-housing (26). Smear
bolts (20) with Loctite 270 and tighten to a torque of
140 - 155 Nm. 27
69. Position cups (12) on their cones (13).
70. Place shim(s) (11) on washer (10).
71. Place the crownwheel assembly in housing (35)
(Fig. 5). Check for the presence of centring bushes
(43). Position the half-bearings (41).
Moderately tighten bolts (42) so that cups (12) can
move freely.
72. Place the housing horizontally in a vice fitted with
soft jaws, the crownwheel facing upwards (Fig. 18).
73. Place a depth gauge. Tighten nut (24) (Fig. 18) and
turn the crownwheel several times while pushing
Fig. 18
down vigorously on it in order to correctly seat the
bearing cones in their cups. Retighten the nut in order
to remove axial clearance.
Fig. 19
74. Tighten nut (24) by three additional notches to obtain
the correct preload value.
75. Check the clearance between the teeth of the
crownwheel and drive pinion using a dial gauge 27
(Fig. 19). Take three measurements at equidistant
points. Calculate the average of the three measure-
ments, to obtain a clearance of 0.18 mm - 0.23 mm.
If the value is too high, reduce the thickness of
shim(s) (11); if the value is too low, increase the
shim thickness until the correct clearance is ob-
tained.
76. Remove one by one bolts (42) and smear them with
Loctite 270 then definitively tighten them to a torque
of 115 - 127 Nm.
77. Refit lock washer (23) on bolt (22) previously lightly
smeared with Loctite 270 and tighten to a torque of
16 - 25 Nm. Lock nut (24) by bending the tab into its
corresponding slot.
Issue 1 May 2001

I . Piston leak test K . Refitting swivel housings, wheel

78. Fit a pressure gauge fitted with an airtight valve on hub and drive shafts
to the supply side union of the differential lock.
79. Feed compressed air at approximately 5 bar into the
Danger
circuit and check for the movement of piston (4).
Bring the pressure down to 0.3 bar and close the
- Reminder: With the assistance of another operator,
valve. No drop in pressure should be noted on the
carefully carry out the refitting operation.
pressure gauge for approximately 1 minute.
80. Remove the pressure gauge and valve.
86. Using suitable slings raise, hold and then refit the
swivel housing assembly (see section 8B01, § F).
J . Refitting swivel housings, wheel L . Assembling front axle / frame

hub and drive shafts 87. Couple the axle and its bearings to the front frame
81. Clean and inspect the components. Replace any (see section 8F01).
parts found to be defective. 88. Top-up the oil level in the front axle housing oil level
82. Check for the presence of bushes (47) on the axle and then check the levels in the drive units.
housing. 89. Carry out a road test of the front axle and the
83. Smear the mating face of the differential housing differential lock control.
with the axle with a sealing compound such as 90. Check the oil tightness:
Loctite 510 or its equivalent, and screw in two - of the seals and differential housing mating face,
diametrically opposed guide studs. - of the hydraulic unions.
Refit the housing assembly (35) (Fig. 3A).
84. Take out the guide studs. Fit and tighten bolts (1)
(Fig. 3A):
- AG 155H front axles: 125 - 140 Nm.
- AG 200H front axles: 215 - 235 Nm
Refit the swivel housings, wheel hubs and drive
shafts (see § K).
85. Refit the steering ram. Smear the bolts with Loctite
270 and tighten to a torque of 180 - 200 Nm.
Issue 1 May 2001

M . Service tools
- MF 471 - Differential lock spring compression tool
(Fig. 20)
- 3378051M1 - AG 155H front axles - Drive pinion nut

wrench (Fig. 21)
- 3378275M1 - AG 200H front axles - “C” wrench for

drive pinion nut (Fig. 22)
- 3378276M1 - AG 200H front axles - “B” flange for

drive pinion plate (Fig. 22)
Fig. 20
Fig. 21
Fig. 22
Issue 1 May 2001


2. Locally manufactured tools
- Special wrench for splined nut (Fig. 23)
H M12
5
14
H M8
10
20
13 74
100
Fig. 23
- Special sleeve for tightening and rotation torque

of drive pinion - AG 155H front axles (Fig. 24).
H M18
H M8
3714416M2
Fig. 24
- Oil tightness bush insertion drift (Fig. 25)
R=
85
+0,5
0
Ø 91,8
Ø 50
Ø 37,60
Ø72
30
22 1 x 45
25
94
107
Fig. 25
Issue 1 May 2001

Front axle - ZF differential 8C02.1
8C02 ZF differential
CONTENTS
- General ________________________________________________ 2
A. Splitting front axle / frame _______________________________ 5
B. Removing the swivel housings ___________________________ 5
C. Removing the axle nose _________________________________ 5
D. Removing and refitting - disassembling and

reassembling the differential housing and crownwheel ____ 6
E. Shimming the differential housing and adjusting

the backlash ____________________________________________ 11
F. Removing and refitting the drive pinion, adjusting

the bevel gear distance and shimming the bearings _______ 13
G. Refitting the axle nose __________________________________ 19
H. Refitting the swivel housings ____________________________ 19
I. Assembling front axle / frame ____________________________ 19
J. Service tools ___________________________________________ 20
Issue 1 May 2001

8C02.2 Front axle - ZF differential

(15) Ring
General (16) Bolt
The 8270 and 8280 tractors are fitted with an APL 5052 (17) Half-housing
front axle. This axle does not have a hydraulic differential (18) Half-bearing
lock similar to the “conventional” front axles. (19) Crownwheel
(20) Drive pinion
This front axle is fitted with an limited slippage system (21) Bearing cup
which consists of friction disks (35) and intermediate (22) Bearing cone
plates (36) integral with the left and right-hand side output (23) Shim (bevel gear)
sun gears (34) and the half-housings of the differential (24) Planetary gear pin
(17) (37). (25) Planetary gear
(26) Dust cover
This type of differential does not have a total self-locking (27) Spherical washer
function. (28) Plate
(29) Washer
The crownwheel / drive pinion assembly is fitted in (30) Nut
housing (7) and comprises two split bearings (18) held by (31) Level plug and seal
bolts. The drive pinion, located at the rear of the housing, (32) Drain plug and seal
bears on two taper roller bearings. Its position is adjusted (33) Bolt
by shim (23) inserted between the housing and the (34) Sun gear
bearing cup (21). The pre-loading of the bearings is (35) Friction disks
obtained by shim (9) placed between the shoulder of the (36) Intermediate plates
drive pinion and bearing cone (11). (37) Half-housing
(38) Washer
Both the pre-loading of the differential housing assembly (39) Bolt
and the drive pinion backlash is adjusted by castellated (40) Bolt
nuts (4) fitted on either side of the differential housing. (41) Tab washer
(42) Bolt
The housing oil tightness is provided by a lip seal (12)
fitted in flange (13). Fig. 1
Parts list (Fig. 1)

(1) Axle housing
(2) Breather
(3) Split pin
(4) Castellated nut
(5) Bearing cup
(6) Bearing cone
(7) Housing
(8) Bush
(9) Shim
(10) Bearing cup
(11) Bearing cone
(12) Lip seal
(13) Flange
(14) Bolt
Issue 1 May 2001

Front axle - ZF differential 8C02.3 Exploded view
15
42
13
12 14
3 10 11
9
4 8
5 6 7
27
25
5 6
24
18 30
29
28
16
27
26
25
24
40 4
17
36
23
21 22
20
2
27 34
19 25
41
25
27 35
31 36
37
33 34 38
39
35
1
32 41 Fig. 1
Parts list
Issue 1 May 2001

Issue 1 May 2001

A . Splitting front axle / frame

1. Drain the axle housing (1)
2. Split the axle and its main support bearings (see
section 8F02).
B . Removing the swivel housings

Danger
- Using a suitable sling, hold and then remove the entire

swivel housing assembly accompanied by the univer- Fig. 2
sal drive shaft (Fig. 2).
3. Take off:
- the swivel pin grease nipples
- the arm on the upper swivel pin
- the cover on the lower swivel pin
Note: Visually note the location of the shims and
bearing cones.
1
Remark
- A 45º grease nipple is fitted on the lower swivel pin.
Reminder
- Take care not to damage the seals and dust covers
T
fitted on the axle housing when the removing the
universal drive shaft.
Fig. 3
C . Removing the axle nose

4. Take out bolts (33). Mark the position of the differential
housing on the axle housing (1) by two opposing paint
marks “T” (Fig. 3) in order to later refit the assembly
in its original position.
Lift and remove the housing using an appropriate
fixture (Fig. 3).
Issue 1 May 2001

D . Removing and refitting - disas-

sembling and reassembling the dif-
ferential housing and crownwheel
Removal (Fig. 4)
5. Mark the position of the half-bearings (18) on the
housing (7) using two opposing paint marks “T” so
as to be able to replace them in their original
positions on reassembly.
6. Take off and discard the two split pins (3). Unscrew 1
the castellated nuts (4) using a suitable locally 1
manufactured tool.
7. Cut and remove the steel wire “F” that locks bolts F
(40). Take out the bolts fitted with their washers. T
8. Remove the half-bearings and bearing cups (5). Take
out the differential housing from the housing (7) (Fig.
5)
Remark 40 3 40
- If they are to be re-used, match the cups and cones
together.
18
Refitting
Reminder
- The bearing cups and cones must be lubricated with oil 7
having an 80W/90 viscosity grade before assembly.
1
1
9. Place the differential housing in the housing with the
bearing cones. 4
10. Position the half-bearings in accordance with the
previously made marks.
11. Fit bolts (40) equipped with their washers and tighten
them to a torque of 150 Nm.
12. Lock the bolts by tying them in pairs using new steel
wire. Twist the ends of the wire together correctly. Fig. 4
13. Carry out the shimming of the differential housing
bearing cones and cups (6) (5) (see § E).
14. Adjust the crownwheel and drive pinion backlash
(see § E).
Fig. 5
Issue 1 May 2001

Disassembling the differential housing

15. Place the differential housing on a workbench with
the crownwheel (19) turned downwards (Fig. 6). 37
16. Mark the position of the differential half-housings
(17) (37) with two opposing paint marks (Fig. 6). 17
17. Remove the bolts fitted with their washers.
18. Separate the half-housings while holding the upper
sun gear (34) (Fig. 7) comprising:
- the disks
- the intermediate plates
19
- the tab washer
19. One by one, separate the disks (35), the intermedi-
ate plates (36) and tab washer (41) from the sun gear
(34) while visually noting their location (Fig. 8).
20. Take apart the planetary gear pins (24), the planetary
gears (25) and spherical tab washers (27) (Fig. 9).
21. Take out the lower sun gear (34) and one-by-one Fig. 6
remove the disks, intermediate plates and half-
housing (17) tab washer and visually note their
location.
22. If required, extract the bearing cones from each half-
housing using a locally manufactured tool.
34
Fig. 7
Fig. 9
25
35 36 41
34
24 27 24
Fig. 8
Issue 1 May 2001


Reminder
- The replacement of the crownwheel necessarily re-
quires replacement of the drive pinion. Both parts have
the same number engraved on them.
- They must be fitted as matched pairs.
16
23. Take out bolts (16) (Fig. 10) and extract the crown-
wheel from the half-housing (17).
Reassembling the crownwheel

Important: During repairs, use new bolts referenced
in the Spare Parts catalogue.
24. Clean the mating faces of the new crownwheel and
half-housing. Check that there is no traces of shock.
25. Using an oven only, heat the crownwheel to a tem- Fig. 10
perature of 95º C and insert it thrusting against the
half-housing.
26. Degrease the new bolts and lightly smear the threads
with Loctite 270 or its equivalent and screw them 34
into the crownwheel. Tighten all the bolts to a torque
of 190 Nm.
36 41
Reassembling the differential housing

- If disassembled, insert the new or re-used bearing
cones on the shoulder of each half-housing.
35
Reassembling the differential limited slip lock
Important: The friction disks (35), intermediate plates
(36) and tab washers (41) must be replaced.
27. Pile and alternate four disks (35), five intermediate
plates (36) and one tab washer (41) on the lower sun
gear (Fig. 11) beginning with the tab washer (41) Fig. 11
which has a greater thickness than the friction disks.
Special point
- The shiny face of the tab washer must face the sun
gear.
Issue 1 May 2001

28. Return the previously assembled sun gear to the

Fig. 12
half-housing (17).
29. Assemble the four planetary gears (25), the four 25 27 24
spherical washers (27) on the two pins (24) then
place the assembly in the half-housing by placing
tabs “E” of each spherical washer in contact with
the half-housing (17) in accordance with Fig. 12.
30. Pile and alternate the friction disks, intermediate
plates and tab washer on the upper sun gear (34)
(Fig. 13) according to the procedure described in
operation 27.
31. Return the previously assembled sun gear to the
half-housing (37).
32. Check that the tabs of the spherical washers (27) are
in contact with the half-housing (17).
33. Place the half-housing (37) according to the paint 24 17
E
marks made during the disassembly of half-housing
(17) while holding manually the upper sun gear and
pile of friction disks, intermediate plates and thrust
washer.
34. Provisionally fit four diametrically opposed bolts (39)
with their washers and tighten to a torque of 120 Nm.
36 35
41
34
Fig. 13
Issue 1 May 2001


Adjusting the differential lock
Principle
- In order for the limited slip differential housing to func- 41
tion correctly there must be a space of 0.1 to 0.2 mm
between the friction disks and the intermediate plates.
For this, carry out the following adjustment. 37
Adjustment
Remark
- The adjustment is carried out on each sun gear.
34
Sun gear opposite the crownwheel
35. Place the index of a dial gauge on tab washer (41)
which is accessible via one of the four ports ma-
chined in the half-housing (37) (Fig. 14). Fig. 14
36. Set the needle of the dial gauge to zero.
37. Manually apply pressure from top to bottom or vice
versa on the sun gear (34) through the lateral re-
cesses in the half-housing (Fig. 14) and calculate the
gap after reading the dial gauge.
Note: If the gap is between 0.1 mm and 0.2 mm
the adjustment is correct. Otherwise, replace
17
the intermediate plates (36) by thicker or thinner
plates in order to obtain the previously stated
clearance. 34 41
Remark
- There are three thicknesses of intermediate plates
referenced in the Spare Parts catalogue:
. 1.8 mm
. 1.9 mm
. 2 mm
38. Use the previously mentioned method for the sun
gear on the crownwheel side (Fig. 15)
Remark Fig. 15
- The half-housing (17) does not have lateral reces-
ses. Manually access the sun gear via the central
bore.
39. When the adjustment phase is completed, take out
the four bolts and washers that were provisionally
tightened and then fit all the bolts (39), with their
threads lightly smeared with Loctite 242 or its
equivalent. Tighten the bolts to a torque of 120 Nm.
40. Manually check for the rotation of the sun gears
using a locally manufactured tool matching the
splines on the sun gears.
Issue 1 May 2001

E . Shimming the differential hou-

sing and adjusting the backlash
Note: If replacement is necessary of the housing (7), 17
bevel gear and drive pinion (see § F), carry out a
shimming of the differential housing and an adjust-
ment of the backlash.

41. Refit the differential housing in the housing (see § D).
42. Place the axle nose vertically on an appropriate
fixture.
Shimming the differential housing

43. Install a dial gauge, the index touching the machined Fig. 16
end of the half-housing (17) (Fig. 16).
Important: Before carrying out shimming, check
that the crownwheel does not overload the drive
pinion.
44. Using two diametrically opposed levers, exert an
axial pressure on the differential housing first front-
ward then rearwards in order to correctly seat the
cones (6) in bearing cups (5).
45. Screw down the castellated nut (4) facing the
crownwheel to remove the axial clearance at the
differential housing. During the operation, check for
the correct rotation of the assembly.
46. After removing the clearance, turn the previously
mentioned nut by two additional notches in order to
apply the correct pre-loading on bearings (5) (6).
Issue 1 May 2001


Adjusting the backlash
Reminder
- the adjustment of backlash is carried out after shim-
ming the differential housing. It ensures the reliability
and correct operation of the bevel gear.
Adjustment
47. Place the index of a dial gauge half way down a tooth 19
on the crownwheel (19) (Fig. 17).
48. Move the differential housing towards the drive
pinion by successively screwing and unscrewing
nuts (4) (Fig. 17) by the same amount.
49. With care, move the crownwheel forward and back-
ward without actually turning the drive pinion in order 4
to read the value of the backlash on the dial gauge
(Fig. 17).
Fig. 17
Important
50. Carry out three measurements at three equidistant
points on the crownwheel and calculate the average
of the three readings, so as to obtain a backlash 291 / 0,18
corresponding to the decimal number stamped on
the rim of the crownwheel (Fig. 18) within a tolerance
of ± 10%.
Example: 291 / 0.18
291/0,18
- 291 = matching set number
- 0.18 = correct value of backlash
51. When the correct backlash has been obtained, fit
and bend the new pins (3) in order to immobilise the
castellated nuts (4).
Notes:
- If the notch of the nut is not aligned with the
hole of the half-bearing pin, continue tighten-
ing until the next notch.
- Manually check for the rotation of the differen-
tial housing. Fig. 18
Issue 1 May 2001

Checking the bearing of the crownwheel on the

drive pinion
52. Using a marker product, mark the teeth of the
crownwheel (19) at three equidistant points (Fig. 19). 19
53. Turn the crownwheel several times and visually
check the traces of the crownwheel on the drive
pinion.
Note: If the traces are doubtful, check or adjust
the backlash and/or bevel gear distance again.
Fig. 19
F . Removing and refitting the drive

pinion, adjusting the bevel gear dis-
tance and shimming the bearings
54. Remove the axle nose (see § C) and take out the
differential housing (see § D).
Removal
Reminder
- Re-used bearing cups and cones must be matched
pairs.
55. Loosen and take off nut (30) using a standard socket
and holding clamp ref. 5870 240 002 (see § J) from
plate (28).
56. Remove the plate and recover washer (29).
57. Take out bolts (14) and remove ring (15).
58. Take out bolts (42) and extract flange (13).
59. Force off the drive pinion fitted with bearing cone (22)
using a press and take it out through the rear of the
housing.
60. Recover shim (9) and extract bearing cone (22) using
a locally manufactured tool.
61. Extract the bearing cups (10) (21) from the housing
and recover shim (23) that positions the drive pinion.
62. Drive the lip seal (12) off the flange (13).
Issue 1 May 2001

18
b
d
A
SP
23
7
22
21
e
Fig. 22
18 18
Fig. 23
Issue 1 May 2001

Refitting
63. Clean the components. Replace any parts found to
be defective.
64. Lightly smear the external diameter of seal (12) with
Loctite 640 or its equivalent and insert it to within 8
mm from the external edge of flange (13) (Fig. 20)
using tool, ref. 5870 055 017 and handle, ref. 5870 13
260 002 (see § J).
Adjusting the bevel gear distance

Important 12
- If the crownwheel and drive pinion must be replaced,
both parts must be replaced together. They are matched
pairs with a number (e.g. 291) engraved both on the
front face of the drive pinion (Fig. 21) and on the rim of
the crownwheel (Fig. 18). Fig. 20
Reminders
- As with the backlash, the adjustment of the bevel gear
distance is of firts importance. It ensures the reliability
and the correct operation of the drive / crownwheel
assembly.
- It is essential to first adjust the bevel gear distance and
then carry out the shimming of the drive pinion.
291
Remark d
- The adjustment of the bevel gear distance is carried out
using a service tool made up from rod ref. 5870 500 001
and two bushes ref. 5870 500 010, held by the two half-
bearings (18) (see Fig. 22 - 23 and § J).
Fig. 21
Issue 1 May 2001


Adjustment (Fig. 22)
Note: The thickness of shim(s) necessary to cor-
rectly position the drive pinion is calculated using
the following formula:
SP = A – (b + d + e)
SP : Thickness of shim(s) (23) to be fitted
A : Dimension measured between the housing (7)
mating face and the top of the measurement
axis
b : Radius of measurement axis
d : The nominal positioning dimension stamped
into front face of drive pinion (Fig. 21).
Caution: do not confuse the positioning dimen-
sion with the matched pairs numbering
e : Thickness of bearings (21) (22)
r : Possible correction factor (e.g. –0.05) engraved
on the forward face of the drive pinion (Fig. 21).
Special point
- In the given example, the negative “r” value is sub-
tracted from the nominal dimension “d”.
Procedure
65. Measure dimension of A using tools, ref. 5870 500
001 and 5870 500 010 (see § J) and in accordance
with Fig. 22 and 23.
66. Measure dimension “e” of bearing (21) (22) using a
depth gauge (Fig. 22).
Special point
- Take care to correctly seat bearing cone (22) in cup
(21).
67. After having taken the measurements, use the
previously stated formula to calculate the thickness
of shim(s) required.
bearing cone (22) against the shoulder of the drive
pinion.
69. Place the previously calculated thickness of shim(s)
(23) in the housing. Insert the bearing cups (21) (10)
using a press and an appropriate fixture.
70. Lubricate the bearing cones and cups and carry out
the shimming of the drive pinion.
71. Install the pre-assembled drive pinion in the housing.
Issue 1 May 2001

Shimming the drive pinion bearings

Remarks
- The shimming of the drive pinion bearings requires G
calibrated ring ref. 5870 340 010 (see § J).
- This ring has three mecanindus pins “G” fitted in ope-
ning holes 120° apart (Fig. 24).
- Before using the calibrated ring, push the three pins as
far out as they will go without losing them.
- The function of this tool is to measure the space bet-
ween the shoulder of the drive pinion and the inner ring
of bearing cone (22) after tightening to a preset tighten-
ing torque.
- The shim (9) to fit, will therefore be equal to the gap
measured, in order to provide the correct pre-loading of
the drive pinion bearings. G
G
72. Slide the previously mentioned tool on to drive pinion
(20), with pins G thrusting against the shoulder of the
pinion (Fig. 25).
73. Using an oven, only heat the inner ring of bearing 3
30˚ x
cone (22) to 95° C. Slide the bearing rapidly on to the 12
0˚
drive pinion in contact with the tool.
74. Provisionally fit the plate (28), washer (29) and nut
(30) after having lubricated the threads of the drive
pinion. Tighten nut (30) to a torque of:
- 2 Nm to 3 Nm for new bearings
- 1.5 Nm to 2 Nm for re-used bearings
Note: Turn the drive pinion several times and
check the tightening torque.
75. Take off the nut, washer and plate.
76. Drive off the drive pinion using a press and take it out
through the rear of the housing. X
77. Recover the tool.
78. Measure dimension “X” on the tool in accordance
with Fig. 24. The thickness of the shim is equivalent
to measurement “X”. Fig. 24
Reminder
- Measurement “X” is obtained by forcing the meca-
nindus pins into the disc of the tool applying the
preset torque.
20
Fig. 25
Issue 1 May 2001


79. Refit the drive pinion in the housing then slide on
shim (9) as determined in operation 78, with chamfer
C facing the drive pinion.
80. Using an oven, only heat the inner ring of bearing
cone (11) to 95° C and definitively slide the bearing
against the shim.
81. Lubricate the lips of seal (12). Lightly smear the 30 28
mating face of flange (13) with housing (7) with
Loctite 510 or its equivalent. Fit the flange. Tighten
bolts (42).
82. Fit ring (15) and tighten bolts (14).
83. Refit plate (28) and washer (29).
84. Degrease the threads of the drive pinion and the nut.
Smear the threads of the nut with Loctite 270 or its
equivalent and tighten to a torque of 350 Nm using a
standard socket and the flange used during removal. 29
Fig. 26
Final operation
85. Refit the differential housing (see § D) and the axle
nose (see § G).
Fig. 27
Issue 1 May 2001

G . Refitting the axle nose I . Assembling front axle / frame

86. Clean the mating faces on differential housing (7) 95. Assemble the front axle and bearings with the main
and axle housing (1). stand (see section 8F02).
87. Smear the mating face of the differential housing 96. Top up the oil level in the front axle housing and
with Loctite 510 or its equivalent, taking care that it check the oil level in drive units.
does not enter the tapped holes. 97. Carry out a road test of the front axle and the
88. Screw two diametrically opposed guide studs into differential lock with limited slippage.
the axle housing (optional). 98. Check for the oil lightness of the mating face of the
89. Refit the housing using an appropriate fixture and differential housing and plate. (28).
position it according to the marks made when
removing it.
90. Fit and tighten bolts (33) to a torque of 190 Nm.
H . Refitting the swivel housings
Danger
- Carefully carry out the refitting operation with the assis-

tance of another operator.
91. Using a sling, refit the entire assembly of each

swivel housing, taking care not to damage the dust
cover and lip seal when introducing the universal
drive shaft into the axle housing.
92. Fit:
- the bearing cones and shims in their initial location
- the cover on the lower swivel pin
- the arm on the upper swivel pin
93. Tighten the cover and arm bolts to 190 Nm.
94. Fit the grease nipples taking into account the remark
in § B. Using a grease gun, moderately lubricate the
swivel pin bearings.
Issue 1 May 2001

J . Service tools
- 5870 055 017 - Insertion drift for lip seal (Fig. 28).
- 5870 240 002 - Holding clamp for the drive pinion
plate (Fig. 29).
- 5870 260 002 - Handle for the insertion drift for the
lip seal (Fig. 30).
Fig. 28
Fig. 29
Fig. 30
Issue 1 May 2001

- 5870 500 001 - Rod for bevel gear adjustment tool

(Fig. 31).
- 5870 500 010 - Bevel gear adjustment rings (Fig. 31).
- 5870 340 010 - Drive pinion calibration ring (Fig. 32).
Fig. 31
Fig. 32
Issue 1 May 2001

Front axle - Carraro differential 8C03.1
8 C03 Carraro differential
CONTENTS
- General _______________________________________________ 2
A. Splitting front axle / frame ______________________________ 2
B. Removing swivel housings, wheel hub and drive shafts ___ 2
C. Disassembling the differential support group ____________ 3
D. Pinion group disassembly ______________________________ 6
E. Differential group disassembly __________________________ 8
F. Pinion group assembly _________________________________ 10
G. Differential group assembly _____________________________ 14
H. Differential carrier group assembly _______________________ 16
I. Service tools __________________________________________ 22
Issue 1 May 2002

8C03.2 Front axle - Carraro differential
General
Some of the following pictures may not show exactly
your axle, but the process is the same.
A. Splitting front axle / frame

1. Drain the axle housing.
2. Split the axle and its bearing from the front frame (see
section 8F02).
B. Removing swivel housings,

wheel hub and drive shafts
With the help of another operator, carefully carry out the
removal operation while taking into account the risks of
any unexpected tilting of the housing with its conse-
quences weight.
3. Extract the steering ball joints.
4. Using a suitable sling, hold, then remove the swivel
housing assembly (see section 8B02)
Issue 1 May 2002

C. Disassembling the differential

support group
5. Remove the fastening screw B and the nut from the
flange A (Fig. 1).
Take the flange out, then collect the seal ring C.
Note : This is a destructive operation for the seal A
ring.
6. Loosen and remove the screws on the differential
support.
Remove the differential carrier (Fig. 2).
C
Warning : Support the differential carrier with a
rope or other appropriate means. B
7. Loosen and remove the screws A to take out the two
ring nut retainers B (Fig. 3).
Fig. 1
Fig. 2
A
B
Fig. 3
Issue 1 May 2002

8. Before removing the bolts, mark both half-collars

and the differential carrier with permanent reference
marks to avoid inverting them during re-assembly.
Mark the area between the ring nuts and the differ-
ential carrier as well (Fig. 4).
9. Unscrew the adjuster ring nuts using tools CA119030
(see § I) and CA119049 (see § I) (Fig.5).
Note : The two ring nuts are different, so take
note of their position with regard to the bevel
crown gear.
10. Remove the 4 screws A and remove both half-
collars B.
Check that the bushes C remain in their housings
(Fig.6).
Fig. 4
Fig. 5
Fig. 6
Issue 1 May 2002

11. Take out the differential case.

Remove and collect from ring gear side, the spacer
E with its seal rings D assembled, the washer F and
the cup bearings, which are removed together with
D
the differential case (Fig. 7).
D
Warning : Don’t mismatch the cup bearings if
they are not to be replaced.
12. Collect the washer G and the O-Ring H from the E
bearing seat on the ring gear side (Fig. 8). F
Fig. 7
G
H
Fig. 8
Issue 1 May 2002

D. Pinion group disassembly

13. Fit the differential carrier in a vise.
Unscrew the lock nut using special tools CA119099
(see § I) and CA715022 (see § I) (Fig.9)
Note : This operation will irretrievably damage
the ring nut.
14. Remove the ring nut A and collect its retaining
washer B (Fig.10).
15. Tap the shaft with a soft hammer to remove the
bevel pinion C.
Warning : Take care not to drop the pinion.
Collect the washers, the collapsible spacer D and
the inner cone E of the tapered roller bearing (Fig. 11).
Fig. 9
B
A
Fig. 10
E
D
Fig. 11
Issue 1 May 2002

16. Place the differential carrier on a flat surface as

shown in the figure and remove the outer cups of the
taper roller bearing using a drift and a hammer (Fig.
12).
17. To remove the inner cone of the tapered roller bearing
of the pinion, use a standard extractor.
Collect the bearing cone and the underlying shim.
18. Check all pinion components for wear (Fig. 13).
The ring nut and the collapsible spacer must be
replaced when reassembling the unit (Fig. 14).
Fig. 12
Fig. 13
Fig. 14
Issue 1 May 2002

E. Differential group disassembly

19. Collect the differential and close it in a clamp.
Unscrew the fastening screws and remove the
bevel gear crown (Fig. 15).
Warning : This will make both differential half
boxes free, so take care not to drop the internal
components.
20. Disassemble the cover A from the differential box C
then remove the piston B (Fig. 16).
Collect the O-Rings from the cover and from the
differential lock piston (inner and outer housings).
21. Disassemble the plates, drive-plates and planetary
gear D from the differential box (Fig. 17).
Note : Separate, carefully clean and examine the
removed components, checking their wear and
operating conditions. Fig. 15
Fig. 16
Fig. 17
Issue 1 May 2002

22. Using a thin punch, pull out the three locking pins in
order to take out the short and the long pins (Fig. 18).
23. Disassemble the planetary carrier and collect all the
components inside the differential box: sun gears,
thrust washers, spider, planetary gear (Fig. 19).
Note: Check the operating and wear conditions
of all the components.
24. Take the bearings out of the differential half boxes
and from the cover, using a three-hold extractor (Fig.
20).
Fig. 18
Fig. 19
Fig. 20
Issue 1 May 2002

F. Pinion group assembly

25. Place the differential support on a workbench.
Fit the outer cups of the new bearings using the
special drifts, ref. CA119225 (see § I) and CA715092
(see § I), a hammer and the drift CA119033 for final
positioning (Fig. 21).
26. In order to measure the distance, use the kit consist-
ing of the special tools called “false pinion” CA119202
and “false differential box” CA119182 and CA119228
(see § I) (Fig. 22).
27. Insert the false pinion with CA119202 , together with
its bearings and its ring nut, in the just mounted
housings for the bearings.
Tighten without exceeding, till the backlash is elimi-
nated.
Install special tools CA119182 and CA119228 (see Fig. 21
§ I) to the differential group supports and screw in the
half collar bolts (Fig. 23);
Note : For all special tools here above advised,
see section C02 §I.
Fig. 22
Fig. 23
Issue 1 May 2002

28. Assembly diagram of the tools code CA119182 (see

§ I) and CA119228 on the bearing differential carrier
seats.
Use a depth gauge to measure distance V (distance
between the axis of the differential bearings and the B
point at which the pinion head is supported, or base
of the bearing) (Fig. 24)
29. In order to determine the necessary thickness S
between the pinion and the bearing, subtract the
value V, stamped on the pinion head (V=requested
conical distance), from the measured value B (Fig.
25) :
S=B-V
30. Select the thickness S from the range of available
shims, and fit to shaft under the pinion head.
Note : take care to assemble correctly.
Fig. 24
SHIM RANGE
Thickness 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
Q.ty
31. Once you have chosen and inserted the suitable

shim with the chamfer against the gear, force the
bearing into the pinion shaft end with special tool
CA715004 (see § I) under a press, making sure that
it is well set.
Insert the shims and a new elastic spacer (Fig. 26).
Note : use always a new elastic spacer.
Fig. 25
Fig. 26
Issue 1 May 2002

32. Insert the bevel pinion unit into the differential hous-
ing (from the internal side) and install the assembly
(with the bevel pinion oriented downwards) on a
hydraulic press equipped with a pressure gauge in
order to read the press fit pressure.
Insert a suitable shim between the bevel pinion and
the press bench so as to exert an opposing force to
the bearing press fit pressure.
Insert the second bearing cone at the pinion end
(Fig. 27), then the tool CA715004 (see § I).
Press fit the bearing until the load in the press jack
reaches 3 tons as a maximum.
Remove the press assembly.
33. Insert a ring nut washer and screw a new lock ring
nut on the pinion end (Fig. 28).
34. Screw the ring nut in, using the wrench for ring nut
(CA119099) (see § I) and for pinion retainer CA715022
(see § I) (Fig. 29). Fig. 27
Warning : The torque setting is given by the
preloading measurement on bearings. Tighten
the ring nut gradually.
Note :
- If the tightening is excessive, the elastic spacer
must be replaced and the procedure repeated.
- When you check the preloading, it is advisable
to beat slightly both pinion ends with a soft
hammer, so as to help setting the bearings.
Fig. 28
Fig. 29
Issue 1 May 2002

35. Carry out the torque measurement P of the pinion

taper roller bearings, using a dynamometer whose
cord is wound on the end of pinion spline.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed (Fig.
30).
Warning : All torques must be measured with-
out the seal ring.
P = 1,82 to 2,72 Nm
Record the value, since it will be used in opera-
tion 50.
36. Once the requested torque value is achieved, caulk
the ring nut, using a hammer and a chisel (Fig. 31).
Fig. 30
Fig. 31
Issue 1 May 2002

G. Differential group assembly

37. Assemble the cones of the new taper roller bearings
on the half boxes, using the special tool code
CA715093 (see § I) and a hammer (Fig. 32).
38. Position a half box on a workbench and assemble all
its inner components (thrust washer, planetary gears,
sun gears, thrust washers, spider), as shown in
figure.
Insert the short pins and the long pin in their housings,
constraining appropriately the planetary gears and
the spider (Fig. 33).
39. Lock the just assembled pins inserting the relative
lock pins in the holes on the box and on the pins.
Rotate the pins by hand, in order to align the locking
pins holes to those on the box.(Fig. 34).
Note : Insert completely the lock pins. Fig. 32
Fig. 33
Fig. 34
Issue 1 May 2002

40. Position all the inner components into the box sun
gear, discs and counterdiscs (Fig. 35).
41. Position new O-Rings well lubricate in the relative
housings on the piston and on the differential box
cover.
Insert the piston and assemble the cover in the
differential box (Fig. 36).
42. Position the bevel crown gear on the cover, apply
Loctite 270 on the threads and fix the whole, tight-
ening the screws to the requested torque (see
section 8A01 §A) (Fig. 37).
Fig. 35
Fig. 36
Fig. 37
Issue 1 May 2002

H. Differential carrier group assem-

bly
43. Assemble the outer cups of the taper roller bearings
on both differential box bearings and on the bevel
gear side: the washer and the spacer with new seal
rings already assembled with a light grease layer
(Fig. 38).
44. Before positioning the differential box on the differen-
tial carrier, insert a new O-ring B and the washer A
in the bearing seat, at the bevel crown side, on the
hydraulic oil hole.
Position the complete differential box on the differen-
tial carrier (Fig. 39).
Warning : Take care not to invert the outer cups
of the taper roller bearings and check the right
side of the bevel crown assembly. Fig. 38
45. Move the differential group so to place the bevel
crown gear on the pinion.
Note :
- The insertion of a scriber (or equivalent) through
the oil inlet port will make the positioning of the A
B
housing easier.
Check that all bushes E are in their housings and
position both half collars D on their seats using the
previously traced reference marks.
Lock both collars with their fastening bolts C (Fig.
40).
Fig. 39
Fig. 40
Issue 1 May 2002

46. Assemble and tighten both adjustment ring nuts in

the differential support with special tools CA119030
(see § I) and CA119149 (see § I), till the backlash is
eliminated and the differential bearings are slightly
preloaded.
Note : The 2 ring nuts are different, so take care
not to invert their position with regard to the
bevel crown gear.
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 (Fig. 41).
47. Position a magnetic-base dial gauge on the differen-
tial carrier, so that the feeler stylus touches the
surface of one tooth of the crown gear with a 90°
angle (Fig. 42).
Lock the pinion and move the crown gear alterna-
tively and note the pinion-ring gear backlash, meas-
ured with the comparator. Fig. 41
Repeat the operation on 2 or more points (teeth),
rotating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range :
0.18 to 0.23 mm
Carry out the adjustment by operating on the 2 ring
nuts with the appropriate tools CA119030 (see § I)
and CA119149 (see § I) (Fig. 43).
Fig. 42
Fig. 43
Issue 1 May 2002

48. Adjust the ring nuts, remembering that:

- if the measured backlash is less than the given
tolerance range, unscrew the ring nut on the bevel
crown gear side and screw in the opposite one by
the same measure;
- if the measured backlash is greater than the given
tolerance range, unscrew the ring nut on the side
opposite to the bevel crown gear, and screw in the
other one by the same measure.
49. 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.
50. Once the pinion-ring gear backlash has been estab-
lished, measure the total torque T of the bearings
(pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion Fig. 44
splined end. The measured value should be within
the following range:
T = (P + 1,82) ÷ (P + 2,12) Nm
where P is the effectively measured pinion torque
((see § F, operation 36)..
Warning : All torques must be measured with-
out seal ring.
If the measurement is not within the requested
range, check well the assembly of each component
and operate on the adjusting ring nuts of the differen-
tial support:
- if the total torque is less than the given range, screw
in both ring nuts by the same measure, keeping the
pinion-ring gear backlash value unchanged;
- if the total torque is greater than the given range,
unscrew both ring nuts by the same measure,
keeping the pinion-ring gear backlash value un-
changed. Fig. 45
Fig. 45
Issue 1 May 2002

Generic information
51. To test the marks of the bevel gear teeth, paint the
ring gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides (Fig. 47).
52. OK = Correct contact
If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
- Z : Excessive contact on the tooth tip
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
order to adjust the backlash.
- X : Excessive contact at the tooth base
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
order to adjust the backlash (Fig. 48)
53. Movements to correct : Fig. 47
1 move the pinion for type X contact adjustment
2 move the pinion for type Z contact adjustment
(Fig. 49). Z
OK
Fig. 48
Fig. 49
Issue 1 May 2002

54. Once all the adjustment operations have been com-

pleted, fit the adjuster ring nut retainers and their
respective screws, tightening them to the requested
torque (see section 8A01 § A) with a dynamometric
wrench (Fig. 50).
Warning : The ring nut and the relative locking
plate from the crown side are different from
them on the opposite differential box side; turn
the ring nuts slightly in order to align them to
the related retainer.
55. Tighten the bolts of both half collars to the requested
torque (see section 8A01 § A) with a dynamometric
wrench (Fig. 51).
56. Before matching 2 surfaces, make sure they are
perfectly clean. Degrease and clean them with
appropriate detergents.
Spread a film of Loctite 510 on the contact surface
between the axle beam and the differential carrier. Fig. 50
Position the differential carrier on the axle housing,
and tighten the retaining screws to the requested
torque (see section 8A01 § A) (Fig. 52).
Fig. 51
Fig. 52
Issue 1 May 2002

57. Assemble a new well lubricated seal ring C on the

pinion end, using the special tool CA119148, then
assemble the flange A.
Fit the flange fastening screws B with the relative
nuts on the flange.
Tighten screws and nuts with dynamometric wrench
to the requested torque (see section 8A01 § A) (Fig.
53).
A
C
B
Fig. 53
Issue 1 May 2002

I. Service tools
- CA 119030 - Ring nut wrench (Fig. 54)
- CA 119099 - Pinion lock nut wrench (Fig. 55)
Fig. 54
Fig. 55
Fig. 56
Issue 1 May 2002

- CA 119149 - Ring nut wrench (Fig. 57)

- CA 119182 - False differential box (Fig. 58)
- CA 119202 - False pinion (Fig. 59)
Fig. 57
Fig. 58
Fig. 59
Issue 1 May 2002

- CA 119225 - Bearing cup driver (Fig. 60)

- CA 119228 - False differential box (Fig. 61)
Fig. 60
Fig. 61
Fig. 62
Issue 1 May 2002

- CA 715022 - Pinion shaft lock wrench (Fig. 63)

Fig. 63
Fig. 64
Fig. 65
Issue 1 May 2002

Front axle - 2 WD front axle 8D01.1
8 D01 2 WD front axle
CONTENTS
- General _____________________________________________ 2
A. Removing and refitting the steering arm ball joint ______ 5
B. Removing and refitting the hub, axle spindle and

extending arm _______________________________________ 5
C. Removing and refitting the steering ram _______________ 7
D. Removing and refitting the front axle __________________ 8
E. Adjusting the wheel alignment ________________________ 10
F. Adjusting the track ___________________________________ 10
G. Service tools ________________________________________ 11
Issue 1 May 2001

8D01.2 Front axle - 2 WD front axle

(31) Washers
General (32) Nuts
Tractors in the 8200 series, except the 8270 and 8280, (33) Sleeve
may be fitted with a 2 WD front axle. (34) Bolt
(35) Steering rod
The front axle is made up by the following assemblies: (36) Bolt
- a cast-iron support identical to the 4 WD version, its (37) Nuts
lower rear part having a bearing supporting the 2nd (38) Sleeve
removable swivel pin, (39) Pin
- a front bearing fixed to the cast-iron support and holding (40) Washer
the 1st swivel pin, (41) Nut
- a swivel beam, holding the arms, (42) Ball joint
- two extending arms, (43) Pin
- two axle spindle assemblies mounted into the bores of (44) Nut
the extending arms, (45) Ball joint
- a double-acting hydraulic ram linked to the axle spin- (46) Support
dles by two links. (47) Bush
(48) Thrust washer
(49) O’ring
(50) O’ring
Parts list
(51) Nut
(1) Nut
(52) Lock nut
(2) Washer
(53) Bushes
(3) Bearing cone
(54) Grease nipple
(4) Spindle
(55) Plug
(5) Bearing cup
(6) Guard
(7) Grease nipple
(8) Nut
Fig. 1
(9) Axle
(10) Steering arm Fig. 2
(11) Bush
(12) Extending arm
(13) Seal
(14) Bearing cone
(15) Hub
(16) Bearing cup
(17) Cover
(18) Rivet
(19) Nut
(20) Washer
(22) Sealing ring
(23) Bearing cone
(24) Bearing cup
(25) Sealing ring
(26) Lock washer
(27) Spacers
(28) Bolt
(29) Hydraulic ram
(30) Bolt
Issue 1 May 2001

Overall view

8 28 29
28 8 9 21 10 19 20 22 11
12
5 15 16
A
17
27 27 DETAIL A
55
18
12 24
26
25 23 45 46 47 53 51 54
13 4 6 14 3 2 1
DETAIL B
29 32 31 30 34 32 31 37 38 37 42 10
29
B
39
41 40 44
C
DETAIL C
19 10
43 48 49 9 50 52
28 8 33 35 36 Parts list Fig. 2 Fig. 1
Issue 1 May 2001


Exploded view
53
52
50
8 48
47
39
9 41
24 40
54
23 28 19 51
27 20 10
49 29
25 21
46 45
22
44 30
11 43
31
7
12
32
4
34
37
13 33
35
14 26
5 1 36
15 18
38
16
3 42
2 17
Issue 1 May 2001

Removing the axle spindle

A . Removing and refitting the stee- 21. Remove nut (19) and washer (20). Extract ball joint
ring arm ball joint (42) from steering arm (10). Remove the steering
arm and Belleville washers (21).
Removal 22. Take out axle spindle (4) from extending arm (12).
1. Chock the rear wheels and put on the handbrake. 23. Separate bearing cone (23) from the spindle.
2. Raise the wheel concerned using a jack. Remove 24. Extract the sealing rings (25) and (22) from the
pin (39), nut (41) and washer (40). extending arm (12).
3. Extract the ball joint (42) from the steering arm (10). 25. Extract bush (11) and cup (24) from extending arm
4. Loosen nuts (37), turn sleeve (38) to separate the ball (12). Removing the extending arm.
joint (42) from steering rod (35). 26. Remove bolts (28) and nuts (8)
27. Extract extending arm (12) from axle (9) and remove
grease nipple (7).
Refitting
parts found to be defective. Refitting the extending arm
6. Fit the ball joint (42) into the steering arm (10). 28. Clean and inspect the components. Replace any
7. Couple sleeve (38), steering rod (35) and ball joint parts found to be defective.
(42). 29. Assemble and fit extending arm (12) in axle (9) using
8. Place washer (40) and tighten nut (41) to a torque of bolts (28) and nuts (8) placed in their adapted
108 - 122 Nm, then lock it using a new pin (39). locations. Tighten to a torque of 400 - 600 Nm.
9. Remove the jack.
10. Remove the chocks and take off the handbrake.
11. Adjust the wheel alignment (see § E). Refitting the axle spindle
30. Using a drift, insert bush (11) home against the
shoulder in extending arm (12).
31. Using an appropriate fixture, position the sealing ring
(22) home against the shoulder in the extending arm,
the lip facing outwards in order to prevent the seal
B . Removing and refitting the hub, from moving in case of excessive greasing of the
axle spindle and extending arm extending arm.
32. Insert the guard (6) on the axle spindle (4).
Preliminary operations 33. Position bearing cup (24) in the extending arm.
12. Chock the rear wheels and put on the handbrake. 34. Insert the sealing ring (25) in the extending arm, the
13. Raise the front of the tractor using a jack placed in the lip turned outwards for the same reason as explained
axle axis and then position axle stands. in operation 31.
14. Remove the wheel concerned. 35. Insert bearing cone (23) on axle spindle (4), then
introduce the axle spindle into the extending arm.
Removing the hub 36. Position the Belleville washers (21), the steering arm
15. Extract cover (17). (10) and washer (20). Smear nut (19) with Loctite 241
Unlock and loosen nut (1), remove lock washer (26) and tighten to a torque of 550 - 580 Nm.
and washer (2).
16. Remove bearing cone (3).
17. Take hub (15) off the spindle (4).
18. Extract the seal (13) and remove cone (14).
19. Extract cups (5) (16).
20. Remove the guard (6).
Issue 1 May 2001


Refitting the hub
37. Using as press or appropriate fixture, insert cups (5)
(16) home against the shoulder in the hub (15).
38. Smear cone (14) with bearing grease and place it in 13
cup (5).
39. Using an appropriate fixture, insert the seal (13) in its
housing thrust against the shoulder, the lip facing
outwards (Fig. 3) in order to prevent the seal from
moving in case of excessive greasing of the hub
bearings.
40. Fill the cavity of the hub (15) with bearing grease.
41. Fit the hub on to the axle spindle (4).
42. Smear cone (3) with bearing grease, place it on the
axle spindle in contact with cup (16).
43. Position washer (2), lock washer (26) and nut (1).
After tightening the nut to a torque of 81 Nm, loosen
it by 1/12 to 1/6 of a turn to obtain a clearance of Fig. 3
between 0 mm and 0.13 mm.
44. Bend the tab of the lock washer (26) to lock nut (1).
45. Check that the hub turns smoothly.
46. Fill the cavity of hub (15) (on the nut side) with
bearing grease.
47. Close the hub using cover (17).
48. Insert rivet (18) in the cover hole. Fit grease nipple
(7).
Final operations
49. Refit the wheel and remove the axle stands. Tighten
the wheel nuts to a torque of 140 - 200 Nm. Grease
the extending arms (12).
51. Adjust the wheel alignment (see § E).
Issue 1 May 2001

C . Removing and refitting the stee-

ring ram
Removal
52. Chock the rear wheels and put on the handbrake.
Raise the front of the tractor with a jack placed in the
axis of the front axle.
53. Disconnect the hoses on the rams after marking
their position.
54. Loosen nuts (37), turn sleeves (38) to separate the
ball joints (42) from the steering rods (35).
55. Remove pin (43) and nut (44). Extract the ball joint
(45) from support (46).
56. Remove the steering ram assembly.
57. Unscrew ball joint (45) (if necessary).
58. Disassemble nuts (32), washers (31) and bolts (30),
separate the sleeves (33) fitted with steering rods
(35).
Refitting
60. Assemble sleeves (33) fitted with steering rods (35)
on the ram. Fit bolts (30), washers (31) and tighten
nuts (32).
61. Screw ball joint (45) (if removed) on to the steering
ram.
62. Refit the ram assembly on to the support (46).
63. Tighten nut (44) of the ball joint to a torque of 100 -
120 Nm and fit pin (43).
64. Couple sleeves (38) to the steering rods (35) and ball
joints (42).
65. Remove the jack. Take away the chocks and re-
lease the handbrake.
67. Check the wheel alignment (see § E).
68. Check the oil tightness of the hydraulic ram unions.
Issue 1 May 2001

D . Removing and refitting the front

axle
Removal
70. Raise the front of the tractor with a jack positioned
in the axis of the front axle.
71. Position an axle stand beneath the lower part of the 1
engine sump.
72. Remove the front wheels.
73. Remove bolts (28) and nuts (8).
74. Take off nuts (32), washers (31) and bolts (30).
75. Remove the assemblies (1) (Fig. 4).
76. Remove pin (43), nut (44), extract ball joint (45) from
support (46), push the ram (29) away from the axle
(9). Fig. 4
77. Place slings on the axle beam (Fig. 5).
Fig. 5
Issue 1 May 2001

78. Take out bolts (1), grease nipple (3). Remove the
front bearing (2) and washer (4) (Fig. 6).
79. Remove the front axle by sliding it out of its rear
bearing (5) and washer (6) (Fig. 6).
80. Take off lock nut (52), nut (51) with its seal (50),
remove support (46). The bush (47), thrust washer
(48) and O’ring (49) remain on support (46). 1
81. If necessary, extract bushes (53) from the axle
beam. 2
Refitting 3 5
7
83. If necessary, insert bushes (53) using a locally
manufactured drift (see § G).
84. Check for the presence of bush (47) and thrust 4 6
washer (48). Replace O’ring (49) and refit support Fig. 6
(46).
85. Tighten nut (51) fitted with O’ring (50) on support
(46), then loosen it in order to obtain an axial
clearance of 0.05 mm to 0.25 mm. ø 895
86. Using a pin wrench, tighten lock nut (52) to a torque
of 120 - 150 Nm. Check that the support swivels A A'
freely.
87. Place slings on the axle beam, position washer (6)
(the chamfer facing the axle) (Fig. 6). Insert the axle
in support (5).
88. Position washer (4) (the chamfer facing the axle) A'
(Fig. 6). Fit the front bearing (2) in order to obtain the A
minimum clearance between washers and axle.
89. Smear bolts (1) with Loctite 270 (Fig. 6). Tighten to
a torque of 520 - 640 Nm. Remove the slings. D L
90. Fit grease nipples (3) and (7) (Fig. 6).
91. Refit the hydraulic ram assembly (29) on support
(46). Tighten nut (44) to a torque of 100 - 120 Nm and B
fit the pin (43). B' Fig. 7
92. Grease the bearings (2) and (5) (Fig. 6) and support
(46).
93. Grease the steering rods (35) using molybdenum
sulphide grease. Refit assemblies (1) (Fig. 4). Fit
nuts (8) and bolts (28). Tighten to a torque of 400 -
600 Nm.
94. Fit bolts (30), washers (31) and nuts (32). Tighten to
95. Refit the front wheels, remove the axle stand.
Tighten the wheel nuts to a torque of 140 - 200 Nm.
97. Check the wheel alignment (see § E).
Issue 1 May 2001

E . Adjusting the wheel alignment

98. Place the steering in the central position. The
adjustment is carried out by acting upon sleeves 28 8
(38) in order to obtain a wheel alignment of 0 mm
to 14 mm.
This toe-in is measured from points A, A’ and B, B’
and is determined by a 895 mm diameter circle
traced on the sides of the tyres (Fig. 7).
It is obtained from the difference of the two values
L and D.
Note. If the toe-in is measured on a diameter
other than 895 mm, correct the values accord-
ingly. Once the adjustment has been carried
out, tighten nuts (37) to a torque of 45 - 55 Nm. 34 32
Fig. 8
F . Adjusting the wheel track

99. Raise the front of the tractor using a jack positioned
in the axis of the front axle.
100. Remove bolts (28) (34), nuts (8) (32) (Fig. 8).
101. Place the extending arms in the required position.
102. Fit bolts (28), tighten to a torque of 400 - 600 Nm.
103. Place the steering rods (35) in relation to the
position of the extended arms.
Fit bolts (34), washers (31), nuts (32), tighten to a
torque of 75 - 81 Nm. 28
Note: When the tractor is used in the widest
track position, spacers (27) must be used for
fitting the 3rd bolt (28) (Fig. 29).
27
Fig. 9
Issue 1 May 2001

G . Service tools
Locally manufactured tools
- Bush insertion drift (Fig. 10)
(a) Knurling
(b) Chamfer
(b) 2 x 45˚ (a) (b) 2 x 45˚

Ø 34,90
Ø 37,90
Ø 45
5
40 40
180
Fig. 10
Issue 1 May 2001

Front axle - Steering column 8E01.1
8 E01 Steering column
CONTENTS
- General ___________________________________________________ 2
- Operation _________________________________________________ 2
A. Removing and refitting the steering column __________________ 5
B. Disassembling and reassembling of the control lever assembly 5
C. Removing and refitting the notched lever and rack ____________ 6
D. Removing and refitting the locking mechanism _______________ 6
E. Replacing the shafts and bearings ___________________________ 7
F. Replacing the guide bushes _________________________________ 7
Issue 1 May 2001

8E01.2 Front axle - Steering column

Parts list
General (1) Retaining washer
The steering column assembly consists of two parts: (2) Retaining washer
- a lower fixed part comprising a tube and fixing base- (3) Spring
plate, (4) Control lever assembly
- an upper mobile part comprising a tube and a welded (5) Adjusting screw
yoke as well as a housing containing the steering wheel (6) Bolt
height and tilt adjustment mechanisms. (7) Spring
(8) Elbowed lever
(9) Notched lever
(10) Rack
(11) Pin
(12) Upper shaft
(13) Retaining washer
(14) Pin
(15) Arm
(16) Lock plate
(17) Springs
(18) Pin
(19) Pin
(20) Housing
(21) Mobile column
Operation (22) Bearings
(23) Circlip
Height adjustment (24) Bolt
When the control lever (4) is moved upwards, the rod T (25) Stop
causes the elbowed lever (8) to swivel and lower arm (26) Bush
(15), which is hinged on pin (14). The lock plate (16), on (27) Bush
which presses the adjusting screw (5) integral with the (28) Fixed column
arm, is released and allows the upper part of the steering (29) Lower shaft
column to move. (30) Bushes
Spring (3) returns lever (4) to its initial position. (31) Circlip
Stop (25) limits the movement of both parts. (32) Seal
Fig. 1
Tilt adjustment
When control lever (4) is moved downwards, it presses Fig. 2
against the rod T which in turn pushes against the end of
the notched lever (9) and frees it from the rack (10), thus
allowing tilt the housing (20).
The two return springs (17) facilitate the positioning of the
steering wheel.
Adjusting screw (5) allows the meshing of the teeth of
the rack (10) and notched lever (9) to be adjusted.
Issue 1 May 2001

Overall view
12 4
4 23 32
17 22
20 17
19 18 20
2 10 2 6
6 11 T 10
T 7 1 9
9 8 27 7
1 15 8
3 24 21 15
28 25 3
26 21 16 13
28 5 28 14
30 5
31 26
29
Fig. 1
Parts list Fig. 2
Issue 1 May 2001

Exploded view Fig. 2
Parts list Fig. 1

32
23
22
20
8 4
12
3
2
27
17
T 7
1
28 6
19
10
29
18
30 14 11
21 9
15
26 24 25 16 13 5
Issue 1 May 2001

A . Removing and refitting the stee-

ring column 3
Removal 1
1. Using the lever located under the right-hand side of
the steering wheel, pull the steering column as far as
possible towards the driver.
2. Remove the steering wheel and the dashboard
covering.
3. Disconnect the connectors (Fig. 3): 2
- light switch (1)
2
- Dynashift lever A B C D (3) (Heavy Duty gearbox)
or reverse shuttle and left hand gear shift (Full
Powershift gearbox).
4. Remove the bolts (2) which attach the column base
onto the cab support (Fig. 3).
5. Remove the assembly by tilting it in order to take out Fig. 3
the base through the dashboard support.
Refitting
6. Check the operation in all steering column positions.
7. Lightly smear the splines of shaft (29) with Loctite
Anti-Seize grease or its equivalent.
8. Carry out operations 2 to 5 in reverse order.
Note: Tighten the steering wheel nut to a torque
of 57 - 78 Nm.
9. Check the correct operation of the electrical equip-
ment.

the control lever assembly
Disassembly
10. Remove the steering column. Carry out operations 1
to 5.
11. Take off the half-housings around the steering
column.
12. Remove and discard the retaining washers (1) (2).
Disassemble spring (3), lever (4) with its dust cover
and lever (8).
Reassembly
13. Refit the levers (4) (8) and spring (3). Replace the
retaining washers (1) (2).
14. Adjust lever (4), with the rod T in contact with the
notched lever (9), by using adjusting screw (5) (3
mm Allen key).
15. Reverse operation 11 and carry out operations 6 to 9.
Issue 1 May 2001

C . Removing and refitting the not-

ched lever and rack
4
Removal
to 5.
17. Take off the half-housings around the steering co-
lumn.
18. Remove and discard the retaining washers (1) (2).
Remove spring (3) and lever (4) complete with its 10
dust cover.
19. Compress spring (7) by pressing notched lever (9).
Remove bolts (6). Take out bolts (6). Remove the
rack (10).
20. Drive out pin (11). Remove the notched lever (9) and
spring (7).
Fig. 4
Refitting
21. Carry out operation 20 in reverse order. Refitting
22. Compress spring (7). Position rack (10) in accord- 30. Carry out operation 29 in reverse order.
ance with Fig. 4 in order to avoid interference with 31. Place pin (14). Replace the retaining washer (13).
lever (4). Fit and tighten bolts (6) lightly smeared with 32. Fit and adjust screw (5), lever (4), the rod T in contact
Loctite 241. with notched lever (9).
23. Refit lever (4), with the rod T and spring (3). Replace 33. Carry out operation 27 in reverse order and then carry
the retaining washers (1) (2). out operations 6 to 9.
24. Adjust lever (4) with the rod T in contact with the
notched lever (9), using adjusting screw (5) (3 mm
Allen key).
25. Carry out operation 17 in reverse order and then carry
D . Removing and refitting the lock-

ing mechanism
Disassembly
to 5 again.
27. Take off the half-housings around the steering col-
umn.
28. Take off adjusting screw (5) (3 mm Allen key). Take
off and discard retaining washer (13). Drive out pin
(14).
29. Remove arm (15) and lock plate (16).
Issue 1 May 2001

E . Replacing the shafts and bea- F . Replacing the guide bushes (26)
rings (27) (30)
Disassembly Disassembly
34. Remove the steering column. Carry out operations 1 52. Remove the steering column. Carry out operations 1
to 5. to 5.
35. Take off the half-housings around the steering col- 53. Remove the half-housings from around the steering
umn. column.
36. Slide the dust cover off the control lever (4). 54. Loosen screw (5) (3 mm Allen key). Remove the
37. Compress spring (7) by pushing on the notched lever lock plate (16).
(9). 55. Remove bolt (24) from stop (25).
38. Remove springs (17). 56. Extract bush (26).
39. Extract pin (18). Drive out pins (18) (19). 57. Uncouple the mobile column (21) from fixed column
40. Separate housing (20) from the mobile column (21). (28).
41. Take off circlip (23). Separate the upper shaft (12) 58. Extract bush (27)
from housing (20).
mobile column (21).
43. Extract bearings (22) from housing (20). Reassembly
59. Position bush (27).
60. Place stop (25) in the groove on fixed column (28).
Reassembly 61. Assemble the mobile column (21) with fixed column
44. Insert bearings (22) in housing (20) using an appro- (28).
priate fixture. 62. Fit bolt (24) loose it in order to locate bush (26). When
45. Assemble the upper shaft (12) on bearings (22). Fit the bush is correctly located, moderately tighten the
circlip (23). bolt. Check that the mobile column (21) slides freely.
46. Assemble the lower shaft (29) complete with bushes 63. Refit the lock plate (16). Adjust lever (4) and the rod
(30) and circlip (31) on the fixed column (28). T in contact with notched lever (9) by using adjusting
Note: Deform the tube of the column using a screw (5).
punch in order to lock bushes (30). 64. Reverse the order of operation 53 and then carry out
47. Assemble housing (20) and mobile column (21). Fit operations 6 to 9.
pins (18) (19). Insert pin (18).
48. Refit springs (17).
49. Compress spring (7). Position rack (10) in accord-
ance with Fig. 4 in order to avoid interference with
lever (4). Fit and tighten bolts (6) lightly smeared with
Loctite 241.
50. Adjust lever (4), with the rod T in contact with
notched lever (9) by using adjusting screw (5) (3 mm
Allen key).
51. Carry out operation 35 in reverse order and then carry
Issue 1 May 2001

Front axle - Bearings and transmission shafts 8F01.1
8 F01 Bearings and transmission shafts

(Dana front axles)
CONTENTS
- General ________________________________________________ 2
A. Removing and refitting the bearings ______________________ 6
B. Replacing bushes and seal _______________________________ 9
C. 2WD version ____________________________________________ 10
Issue 1 May 2001

8F01.2 Front axle - Bearings and transmission shafts
General
On 8200 series tractors, the bearings supporting the
AG155H front axle are attached on the frame the same
way as the AG200H front axles.
The transmission shaft (1) is housed in a guard (2)

located beneath the tractor (Fig. 1). Each of its ends is
respectively linked by sleeves (3) to the 4WD gearbox
and to the front axle housing. The central part of the
transmission shaft is supported in a bearing (6) contained
in a support (5) fixed on to the lower part of the engine.
Parts list
(1) Bolt
(2) Front bearing
(6) Rear bearing
(8) Seal
(9) Seal
(10) Bush
(11) Seal
(12) Bolt
(13) Bolt
(14) Bush
(15) Main support
(52) Axle housing
Fig. 1
Fig. 2
Fig. 3
Issue 1 May 2001

1
AG 155H 2
6
3
AG 200H 4
Issue 1 May 2001

Overall view
15
AG 155H
1 10 11 13
A 14
A
4
B
4 9 52 7 8 12 6
AG 200H
A B
Issue 1 May 2001

Exploded view
15
1
2
14
10
11
6
12
13
Issue 1 May 2001

A . Removing and refitting the bea-

rings
Removal
2. Disconnect the two hoses to the front axle differen-
tial lock fitted on to the guard. Remove the guard and
the transmission shaft.
3. Raise the front of the tractor using an appropriate
jack positioned in the axis of the axle housing.
Position an axle stand under the lower cranckcase
(Fig. 4). Take off the wheels. 2
4. Disconnect the hoses on the steering ram and mark
their locations.
5. Sling the front axle using straps (Fig. 4). 1
6. Take off grease nipple (3) and bolts (1). Remove
bearing (2) (Fig. 5), washer (4) and seal (9).
Fig. 4
2 3
Fig. 5
Issue 1 May 2001

7. Take out bolts (12) (13). Remove the front axle with
bearing (6) (AG 155H front axle - Fig. 6 or AG 200H
front axle - Fig. 7).
8. Separate the front axle bearing. Remove washer (7)
and seal (8).
Refitting
9. Replace seal (8). Position washer (7), the chamfer
facing the axle housing (52) (Fig. 2). Assemble
bearing (6) on the front axle.
10. Sling the axle and bearing assembly and fit it in
place. Provisionally fit bolts (12) (13).
11. Replace seal (9). Position washer (4), the chamfer
facing housing (52) (Fig. 2). Refit bearing (2). Provi- 6 12 5 13
sionally fit bolts (1).
Fig. 6
12
4 13
Fig. 7
Issue 1 May 2001


12. Remove and refit, one by one, bolts (12) (13), lightly
smeared with Loctite 270. Definitively tighten them
to a torque of:
- (12): 260 - 320 Nm
- (13): 560 - 640 Nm
13. Apply bearing (2) to washer (4) in order to obtain the
minimum clearance possible. Definitively tighten
bolts (1) previously lightly smeared with Loctite 270
and tighten to a torque of 520 - 640 Nm.
14. Fit the grease nipples to the bearings (2) (6).
15. Reconnect the steering ram hoses. Smear the two
transmission shaft sleeves with Anti-Seize grease
or its equivalent. Fit the dust covers. Refit the
transmission shaft and sleeves on to the 4WD unit
and front axle.
- AG 155H front axles
. fit the bolts with a seal and tighten them on to the
sleeves previously lightly smeared with Loctite
241 or its equivalent.
- AG 200H front axles
. lightly smear bolts (4) with Loctite 241 or its
equivalent and tighten them to a torque of 61 -
81 Nm (Fig. 7).
16. Refit the guard. Reconnect both the hoses located on
either side of the front differential lock supply pipe.
Refit the wheels and tighten the wheel nuts to a
17. Using a grease gun, grease friction bushes (10) (14).
Issue 1 May 2001

B . Replacing bushes and seal

Disassembly
18. After removing the bearings, extract seal (11) and
the worn bushes (10) (14). 2
Refitting
19. Clean the components. Using a press and an appro-
priate fixture, insert bushes (10) (14) in their respec- F
tive holders, flush with face F (Fig. 8), and with orifice
O facing upward and aligned with the grease chan-
nel.
Using an appropriate fixture, insert seal (11) thrust 14
against the shoulder of the bearing (6). Refit the
bearings.
F 6
10 11
Fig. 8
O
O
Fig. 9 Fig. 10
Issue 1 May 2001

C . 2 WD version
On tractors equipped with the 2 WD version, the same
method as that used for the 4WD version is applied.
Special points
- Raise the front of the tractor using a jack positioned in
the axis of the front axle and position axle stands.
- Insert plug (55), its rim previously lightly smeared with
Loctite 542 (Fig. 11).
- The O’ring (11) ensures oil tightness of the 2nd axle
pivot.
- Tightening torque for wheel nuts or studs:140 - 200 Nm.
- Using a grease gun, grease the friction bushes (10) (14).
5 12 13
2 14 4 9 11 10 6 55
Parts list
(3) - (5) Grease nipples
(11) O’ring
(55) Plug Fig. 11
Issue 1 May 2001


(ZF front axles)
CONTENTS
- General ________________________________________________ 2
A. Disassembling and reassembling 4WD transmission shafts

and universal joint spiders _______________________________ 6
B. Removing and refitting the bearing stands ________________ 8
C. Replacing the bushes and seal ___________________________ 10
Issue 1 May 2001

General
On 8270 and 8280 tractors, the front bearings, located on
the cast-iron stand, support the two pivots of the ZF axle.
The 4WD transmission shaftline comprises two shafts,

the straight shaft (1) and the universal shaft (1A) (Fig. 1).
They are linked to the 4WD and the front axle housing (52)
by splined sleeve (3) and the universal joint spiders (9).
This transmission line is supported by bearing (6) and
bearing block (5) fitted beneath the lower housing at the
rear of the engine.
Issue 1 May 2001

Front axle - Bearings and transmission shafts 8F02.3 Overall view
3 1 2 6 2A 4 52
1A
9
7
9
5
A 8
Fig. 1

Issue 1 May 2001

Parts list (Figs. 2 - 3) Overall view
(1) Bolt
(2) Front bearing 15 12
(3) Mecanindus locating pin
(4) Washer
(6) Rear bearing
(8) Seal
(9) Seal
(10) Bush
(11) Seal
(12) Bolt
(14) Bush
(15) Main bearing stand
(16) Bolt
(17) Grease nipples
(18) Grease nipples
(19) Cover
(20) Stop washer
(21) Locating pins
(22) Washer
(23) Nuts
(52) Axle housing
1
Fig. 1
21
Fig. 2
Fig. 3
2 22
18 6
17
9 52 23 3 4 8
Fig. 2
Issue 1 May 2001

Exploded view
12
15
21
17
2
14
20
19 6
18
11
10
1
17
8
16
Issue 1 May 2001


4WD transmission shafts and uni-
versal joint spiders
Universal shaft
1. Chock the front wheels and put on the handbrake.
2. Remove the front guard (2A) (Fig. 1).
3. Remove universal shaft (1A) with its spiders (Figs. 1
and 4).
Reassembly (Fig. 1)
Remark 1A
- The universal shaft and spiders form a complete as-
sembly referenced in the spare parts catalogue.
Fig. 4
4. Refit the shaft.
5. Raise the front wheels (optional). Fix the spiders on
sleeve (4) and plate (7) using bolts (8) previously
lightly smeared with Loctite 241 or its equivalent and
tightened to a torque of 61 - 81 Nm.
6. Using a grease gun, grease sleeve (4).
7. Refit the front guard (2A).
Issue 1 May 2001

Straight shaft
8. Remove the front guard and the universal shaft and 1 6 1
carry out operations 1 to 3.
9. Remove the rear guard (2).
10. Spread apart the rubber protectors on sleeve (3).
Take out the bolt located in the centre of the sleeve
and slide the latter along straight shaft (1) towards
the front of the tractor.
11. Uncouple and remove the shaft, sleeve (3) and
bearing (5) assembly.
V
Reassembly (Fig. 1)
12. Inspect the components. Replace any parts found to 5
be defective.
13. Refit the shaft and sleeve assembly. Assemble the Fig. 5
central bearing in accordance with Fig. 5.
14. Tighten the bolts of bearing (5) and the central bolt of
sleeve (3).
15. Position the straight shaft.
Remark
- The rotating shaft turns bearing (6) located in
bearing (5) by means of bolts V (Fig. 5).
16. Lightly smear bolts V with Loctite 542 or its equiva-
lent and tighten them in order to obtain a space
between the rear end of the shaft and the central bolt
on sleeve (3) (Fig. 1, detail A).
17. Place the rubber protectors on the sleeve.
18. Using a grease gun, grease sleeve (3).
19. Refit guard (2).
20. Refit the universal shaft (1A) and refit the front guard
(2A). Carry out operations 4 to 7 again.
Issue 1 May 2001

B . Removing and refitting the bea-

rings
21. Remove the front weights and centre weights (if
fitted). Immobilise the tractor by putting on the
handbrake and placing chocks on either side of the
rear wheels, as shown in Fig. 7.
Removal
22. Remove the front guard and disassemble the univer-
sal shaft (1A) (see § A).
23. Raise the front of the tractor using an appropriate 2 17
jack positioned in the axis of the axle housing. Take
off the wheels. Position an axle stand under the
lower part of the engine sump (Fig. 7).
Fig. 6
24. Locate the hose unions and disconnect them from
the steering rams.
25. Sling the front axle using appropriate straps (Fig. 7).
Fig. 7
Issue 1 May 2001

26. Take off grease nipple (17) (Fig. 6). Remove bolts (1)
(Fig. 8), the bearing stand (2) and seal (9) (Fig. 2).
27. Unscrew nuts (23) and recover the washers (22)
(Fig. 9).
28. Remove the front axle with bearing stand (6). 1
29. Separate the bearing stand from the front axle.
Recover seal (8) and washer (4) (Fig. 2).
Remark
- The Mecanindus pin (3) is force fitted in housing
(52) (Fig. 2).
Refitting (Fig. 2)
30. Slide washer (4) on the axle pivot with the hole facing
the Mecanindus pin (3).
31. Position new seals (8) (9) on the axle pivots turning
the lip towards their respective stands. Fig. 8
32. Sling the front axle. Refit the front axle and stands
assembly.
33. Place the stands on the main stand. Fig. 9
Fit the bolts and washers and tighten the nuts (23) 22 23
lightly smeared with Loctite 270 or its equivalent to
34. Push bearing stand (2) towards axle housing (52) in
order to obtain the minimum clearance possible
between the bearing stands and housing.
35. Fit the washers and tighten bolts (1) previously
lightly smeared with Loctite 270 or its equivalent to
36. Check for the presence of grease nipples on cover
(19) and on each bearing.
37. Reconnect the hoses to the steering ram.
38. Refit the wheels. Remove the axle stand. Tighten
the wheel nuts to a torque of 640 - 680 Nm. Refit the 6
centre weight and front weights (depending on op-
tions).
39. Refit the universal shaft and guard (see § A).
Final operations
40. Remove the chocks and take off the handbrake.
41. Using a grease gun, grease bushes (10) (14) in the
bearing stands.
Issue 1 May 2001

C . Replacing bushes and seal

20
42. Remove the bearing stands (see § B).
F
Disassembly
Front bearing (Fig. 10)
43. Take out bolts (16), remove cover (19) and stop
washer (20). Extract and discard bush (14) of bearing
stand (2).
Rear bearing (Fig. 11)

14 2
44. Mark the position of the dust seal (11). Extract and
discard the latter as well as bush (10).
2
Reassembly
parts found to be defective. Check that the grease
channels are not obstructed.
16
19
Front bearing
Fig. 10
10
11
10
Rear bearing Fig. 11
Issue 1 May 2001

Rear bearing (Fig. 12)

46. Using a press and an appropriate fixture, insert bush
(10) home against the shoulder of bearing stand (6), O 6
with the oblong ports O facing upwards and commu-
nicating with the bearing lubricating channel.
47. Using a press and an appropriate fixture, insert the
dust seal (11) in the correct direction, abutting
against the shoulder of bearing stand (6).
10
Front bearing (Fig. 13)
48. Using a press and an appropriate fixture, insert bush
(14) flush with face F of bearing stand (2) (Fig. 10) and
with the oblong ports facing upwards and communi-
cating with the lubricating channel of bearing stand
(2). 11
49. Refit the stop washer (20).
Remark
- The stop washer has ridges that allow the passage
of grease for the lubrication of the bearing block.
50. Fit cover (19) on bearing block holder (2) and tighten
bolts (16) to a torque of 90 - 120 Nm (Fig. 10).
Final operation
51. Refit the bearing stands (see § B).
Front bearing
Fig. 12
2 14
20
Rear bearing Fig. 13
Issue 1 May 2001


(Carraro front axle)
CONTENTS
- General ________________________________________________ 2
A. Disassembling and reassembling the 4WD transmission

shafts and the universal joint spiders _____________________ 6
B. Removing and refitting the front bearing support and the

front axle _______________________________________________ 8
C. Replacing the friction rings and seal ______________________ 14
Issue 1 May 2002

General
8210 - 8220 - 8240 and 8250 series tractors are equipped
with a Carraro fixed or suspension front axle. It is fitted
on a new frame which integrates the second axle pivot
bearing. The first axle pivot bearing, of conventional type,
can therefore be disassembled.
This frame can also be fitted with a Dana front axle. In

this case, the front axle must be supported by two
specific bearings (front bearing (2) and rear bearing (6)) to
be attached under the frame (Fig. 1).
The 4 WD transmission line is constituted by two shafts:

- straight shaft
- universal drive shaft.
These shafts are linked respectively to the 4 WD arrange-

ment on the centre housing and to the nose of the front axle,
via a splined sleeve and universal joint spiders (Fig. 2).
This transmission line is supported by the bearing and the

cast-iron unit fitted at the front under the axle housing.
The rotating assembly is protected by two guards (2) (2A)
(Fig. 2).
2 6
Parts list (Fig.2)
(1) Straight shaft
(1A) Universal drive shaft
(2) Rear guard
(2A) Front guard
(3) Serrated shaft
(4) Nut and bolt
(5) Support
(6) Ball bearing Fig. 1
(7) Dust cover nut
(8) Spiders
(9) Yoke
(10) Sleeve
(11) Castellated locknut
(15) Front frame
(19) Flanges
(20) Shoulder screw
Issue 1 May 2002


Overall view
A : Full Powershift
B : Dynashift
15
20 19
1A
4 3
7
10 11
5
8
6
9
8
2
19 20
1
A
2A
Parts list Fig. 1
Issue 1 May 2002

Parts list (Figs. 3 - 4)
(1) Bolt
(2) Front bearing
(3)
(4)
Unions
Washers
(5) Lubricating pipe
(6) Rear bearing
(8) Seal Overall view
(9) Seal
(10) Bush
(11) Seal
(12) Bolt
(14) Bush
(15) Main bearing stand
(16) Bolt Fig 3
(17) Grease nipples
(18) Grease nipple(s) 15 L
(19) Flanges Fig 4
(20) Stop washer
(52) Axle housing
1
Parts list
2
9 A
16
Version with suspension front axle
L1
7
2
A
10 6 8 6
1 1
L1 L
14 11
7
A L
52
4
Fig 4 52 19 20
Fig. 2
Version with fixed front axle
Issue 1 May 2002

3
17
8
3
6
5
15
10
16
9
2
3 11
12
18
14
Parts list
Fig 1
Issue 1 May 2002


the 4WD transmission shafts and
the universal joint spiders
Universal drive shaft (Fig. 2)
Disassembly
1. Chock the rear wheels and put the handbrake on.
2. Remove the guards (2) (2A).
3. Unscrew the dust cover nut (7).
4. Remove the bolts (20) and flanges (19) (Fig. 5).
5. Spread the universal drive shaft (1A) and universal
joint spider (8) assembly apart from the nose of the
axle. Remove the shaft (Fig. 2 and 5).
Remark 1A 19 20 8
- If there is not enough room to push the universal joint
backwards, disassemble the central bearing and Fig. 5
straight shaft (1).
Reminder 7. Smear the front splines of the straight shaft with
- It is possible to replace the universal joint spiders. molybdenum sulphide grease or its equivalent. Refit
Their reference is indicated in the spare parts cata- the universal drive shaft (1A).
logue. 8. Fix the front universal joint spider (8) on the plate of
the axle nose using flanges (19) and shoulder screws
(20) lightly smeared with Loctite 241 or its equivalent
Reassembly and tighten them to a torque of 34 - 41 Nm.
Check points 9. Moderately tighten the dust cover nut (7).
- If the universal joint spiders must be replaced, carefully 10. Using a grease gun, grease sleeve (10) and refit the
check the condition of the universal joint end yokes. guards (2) (2A)(Fig.2).
Remove any traces of impact or deformations. Clean
the groove of each circlip correctly. After assembly
check that the circlips are properly placed in their
respective grooves.
Remark
- If necessary, to facilitate the coupling of the universal
joint to the nose of the axle, raise the front wheels using
a jack having sufficient lifting capacity and positioned
along the axis of the axle housing.
6. Replace the dust cover nut (7) if necessary.

Note: Use a locally made conical tool to refit the
dust cover nut (7) on the shaft (1).
Issue 1 May 2002

Straight shaft and bearing (Fig. 2)

Disassembly
11. Remove the guards (2) (2A) and the universal drive
shaft assembly. Carry out operations 1 to 5.
12. Remove the nut and bolt (4) and slide the sleeve (3)
towards the front of the straight shaft.
13. Remove the central bearing assembly (5), bearing
(6) and the straight shaft (1) (Fig. 6).
14. Separate support (5) from the bearing (6).
15. Unscrew the castellated nut (11) using a suitable
wrench.
16. Remove the bearing from the straight shaft (1).
Reassembly 5 6 1
17. Check the components. Replace any parts found to
be defective. Fig. 6
18. Fit bearing (6) on the straight shaft with the offset
turned rearwards. Tighten the nut with a suitable
wrench.
19. Assemble support (5) on the bearing (6). Tighten the
bolts.
20. Refit the central bearing assembly, refit bearing (6)
and straight shaft (1).
21. Smear the rear splines of the straight shaft (1) with
molybdenum sulphide grease or equivalent.
22. Slide the sleeve (3) towards the rear of the straight
shaft. Fit abolt (4) and tighten the nut.
23. Refit the universal drive shaft assembly.
Issue 1 May 2002

B . Removing and refitting the front

bearing support and front axle 1
Fixed or suspension front axles 11

24. Remove the front weights (if fitted). Immobilise the
tractor. Put on the handbrake. Place safety chocks
on either side of the rear wheels as shown in Fig. 9.
Remark
- The belly weight (1) (where fitted) (Fig. 8) is attached
under the front frame and may hinder the removal of
bearing (2) support.
Danger Fig. 7
- The belly weight weighs between 300 and 420 kg

(approximately), depending on the option. The removal
operation must be carried out carefully with the help of
an operator and using a suitable lifting tool.
To remove the belly weight, proceed as follows:
. remove the inside elements at the lower part of the
grille
. maintain the weight using the above-mentioned tool
. remove the screws (2) (Fig. 8)
. carefully remove the weight from the tractor.
Reminder
- Some tractors may be fitted with a front power take off.
In this case, it will be necessary to remove it in order
to uncouple the front axle from the frame.
1 1
Fig. 8 Fig. 9
Issue 1 May 2002

Suspension front axle

Removing the hydraulic unit
25. Remove guard (14) (Fig. 3)
Special point
- It is important to unscrew bleed screw (1) to lower
the pressure in the hydraulic unit (11) (Fig. 7) before
carrying out any operations on the hydraulic pipes.
26. Locate the Load Sensing (LS) hydraulic pipes (2), 3
Return (3), and Pressure (4) connections linked to the
hydraulic unit (11) (Fig. 10) and remove them.
27. Locate and remove the hose pipes (1) (2) connected
to the suspension ram (Fig. 11).
28. Locate and separate the connectors linked to the
hydraulic unit electronic device, which are mounted: 2
- at the front left-hand side of the tractor beneath the
frame 4 11
- inside the nose assembly Fig. 10
29. On the hydraulic unit, locate and disconnect:
- the solenoid valve (1) located at the front of the
hydraulic unit, green connector (Fig. 12)
- the remaining solenoid valve (2), black connector
(Fig. 12).
30. Remove the hydraulic unit with the aid of another
operator or a locally-made fixture fitted to the head of
a trolley jack. 1
Fig. 11
Fig. 12
Issue 1 May 2002

Suspension and fixed front axles

Removing the support (2) and the front axle
31. Remove guard (2) (2A) (see § A).
32. Raise the tractor along the axis of the front axle
housing using a jack that has sufficient lifting capa-
city. Remove the front wheels.
33. Remove the front wheels.
Danger
- Place a fixed axle stand under the lower engine

housing.
34. Locate the connections of the hoses for the steering
and separate them from the cylinder.
35. Disconnect the front differential lock hose.
36. Sling the front axle using suitable straps (Fig. 9).
37. Take out bolts (1) (Fig. 3).
38. Pull the front axle assembly complete with bearing
support (2) frontwards along the axis of the axle
(position 1) and remove the front axle (position 2)
(Fig. 3 - 9).
39. Note the characteristics, location and position of the
chamfered washers (4) (7) and remove them (Fig. 3).
Remark
- On 8210 to 8250 series tractors, which are equipped
with a fixed front axle, the two washers 3785074M1
(4 mm thick each) fitted on the first axle pivot now
are replaced by a single washer 3785924M1
(8 mm thick) from the serial number K179009 on.
Fixed front axles Suspension front axles

(Fig. 3) (Fig. 3)
Types Washers (4) Washers (7) Washers (4) (7)

of 3785924M1 3785074M1 3785075M1
tractors
Inside Ø Outside Ø Inside Ø Outside Ø Inside Ø Outside Ø
8210 - 8220
60 mm 90 mm 60 mm 110 mm 70 mm 115 mm
8240 - 8250
Issue 1 May 2002

Refitting
Check points
40. Clean all components and check the condition of:
- the pivot pin at each end
- the chamfered washers (4) (7)
- the friction rings (10) (16)
- the seal (9)
Fixed front axles

41. Slide a chamfered washer (7) slightly smeared with
bearing grease on to the rear end of the pivot, the
chamfer turned towards the front axle (Fig. 3).
42. Slide the washer (4), 3785924 M1, slightly smeared
with bearing grease, onto the front end of the pivot
pin (Fig. 3).
Suspension front axles

43. Slide the washers (7) respectively slightly smeared
with bearing grease onto the front and rear ends of
the pivot pin, the chamfer turned towards the front
axle (Fig. 3).
Fixed and suspension front axles

44. Sling the front axle (Fig. 9). Moderately grease the
ends of the pivot pin and mount the support (2) at the
front of the axle pivot.
Remarks
- Before refitting the front axle assembly, check that
there is no excess grease in the cavity of the
second axle pivot on the front frame.
- During refitting of the front axle assembly, any such
excess grease will be compressed making entry of
the axle pivot into its bearing difficult.
45. Refit the front axle and support (2) assembly.
46. Push the assembly hard until it abuts against the
second axle pivot.
47. Thrust the support (2) against the front axle assem-
bly in such a way as to eliminate the clearance
between supports and axle housing to the maxi-
mum.
Issue 1 May 2002

48. Fit the screws lightly smeared with Loctite 270 or Fixed and suspension front axles
equivalent and tighten to a torque of 520 - 640 Nm. 50. Reconnect the hoses (using marks made during
Check points disassembly)
- Check that the front face of the pivot pin (1) is - of the steering ram
almost flush with the front edge F of the bearing - of the front differential lock
support (2) (Fig. 13). 51. Refit the wheels. Remove the axle stand and take
49. Check for the presence of the grease nipple on: away the jack. Tighten the nuts to a torque of 640 -
Fixed front axles 680 Nm.
- the right-hand side and above the front frame 52. Refit the belly weight. Tighten bolts (2) to a torque of
(second axle pivot) 420 - 560 Nm (Fig. 8), after smearing lightly the
- support (2) (first axle pivot) threads with Loctite 270 or equivalent. Refit the front
Suspension front axles weights (depending on equipment).
- the right-hand side and above the front frame 53. Refit the universal drive shaft and the guards (see § A).
(second axle pivot)
- the left-hand support of the hydraulic unit (first axle
pivot)
Fig. 13
Issue 1 May 2002

Suspension front axles

Refitting of the hydraulic unit
54. Refit the hydraulic unit using the same method used
when removing it.
55. Reconnect the solenoid valves and the electronic
device connectors (according to marks made).
56. Reconnect the hoses to the suspension cylinder
(according to marks made).
57. Reconnect the hydraulic pipes, Pressure (4), Return
(3) and LS (2) to the hydraulic unit (according to
marks made) (Fig. 10).
Reminder
- Check that bleed screw (1) (Fig. 7) is properly
closed with a view of the future putting into service
of the tractor.
58. Refit guard (14).
Final operations
59. Remove the safety chocks and release the hand-
brake.
60. Using a grease gun, grease the friction rings (10) (16)
of the axle pivots.
Issue 1 May 2002

C . Replacing the friction rings and

seal 16
Front bearing (first axle pivot, Fig. 3)
Disassembly
61. Remove only bearing support (2) (see § B).
62. Extract and discard ring (16).
63. Drive out and discard seal (9).
Reassembly
found to be defective. Check that the grease chan-
nels in the support are not obstructed.
2
65. Using a press and a suitable fixture, insert a correctly
positioned seal (9) and ring (16) flush with face F of Fig. 14
support (2) (Fig. 14 - 15), the grease hole T in
communication with the channel (Fig. 16).
16
Fig. 15
Fig. 16
9
Issue 1 May 2002

Rear bearing (second axle pivot, Fig. 3)

Remark
- To operate on bush (10) of the second axle pivot, it is
first necessary to take off the first axle pivot and the
front axle (see § B).
Disassembly
66. Drive out bush (10) using a locally-made tool.
Note: The circlip (6) and plug (8) are not consi-
dered as normally wearing parts, therefore their
replacement is unlikely.
Reassembly
67. Using a locally-made drift, insert bush (10) into the
10 15
frame (15) flush with chamfer C (Fig. 17 - 18).
Fig. 17
Remark
- Bush (10) does not have a grease port. The grease is
led inwards by an axial channel L1 and a radially drilled
hole at the rear end of the pivot axis (Fig. 3).
Fig. 18
10
C
15 15
Issue 1 May 2002

Front axle - 4 WD clutch 8G01.1
8G01 4 WD clutch
CONTENTS
- General ________________________________________________ 3
B. Removing, refitting the clutch assembly and shaft _________ 7
C. Disassembling, reassembling and shimming the clutch ____ 9
D. Shimming the shaft _____________________________________ 11
Issue 1 May 2002

8G01.2 Front axle - 4 WD clutch
Issue 1 May 2002

Operation
General Declutched position
On 8200 series tractors, the clutch assembly on the front - The 4 WD solenoid valve, fitted on the right-hand side
axle is fitted in the lower part of the intermediate housing. hydraulic cover and controlled by the tractor’s elec-
A cover beneath the housing gives access to the clutch, tronic system, supplies the interior of the shaft with 17-
which comprises: bar pressure via channel “A” (Fig. 1). The pressure is
- a shaft (2) rotating in two taper roller bearings (8) (9) and maintained by seal rings (32). Piston (39) moves in hub
(4) (16) fitted in the bore of the housing (30) and draws clutch cover (23) thus compressing the
- a hydraulic clutch assembly integral with the rotating Belleville washers (26) and freeing the plates (36). The
shaft bell-shaped gear (10) then idles on the shaft.
- a bell-shaped gear (10) driving clutch plates (36) and
centred on the shaft by a friction bush (6) Clutched position
- When the pressure is cut-off, the Belleville washers
The bell-shaped helical gear (10) is constantly meshed (26) push the clutch cover (23), mating the clutch plates
with the driving pinion (17) that is integral via splines with with the bell-shaped gear (10) and thus allowing for the
the drive pinion. rotation of shaft (2).
The shaft is shimmed to provide an operating clearance Lubrication

of 0 mm to 0.1 mm using shim(s) (18) placed between - The oil from the lubricating circuit arrives via reducer
the seal holder (20) and bearing cup (4). union (22) and lubricates the clutch plates (36) via the
transfer pipe (21) and channel “B” drilled in shaft (2)
The clutch assembly (15) is shimmed to obtain a clear- (Fig. 1).
ance of 0.9 mm to 1.1 mm between circlip (34) and
shim(s) (35) in the declutched position (solenoid valve
activated).
A bush (7) held by transfer pipe (28) supplies the clutch

with 17 bar pressure via union (27).
The oil tightness of the shaft is ensured by a lip seal (1)

and a dust seal (41), and the oil tightness of the housing
by an O’ring (19).
Depending on the type of tractor, the clutch possesses

a different number of clutch plates and intermediate
plates. This leads to minor differences in the following
components:
- drive shaft (2)
- bell-shaped gear (10)
- cover plate (29)
- hub (30)
8210 - 8220 - 8240 tractors

- 6 clutch plates - 5 intermediate plates
8240 - 8250 tractors
8260 - 8280 tractors
Issue 1 May 2002


Part list
(1) Lip seal
(2) 4 WD drive shaft
(3) Circlip
(4) Bearing cup
(5) Circlip
(6) Bush
(7) Bush
(8) Bearing cup
(9) Bearing cone
(10) Bell-shaped gear
(11) Cover
(12) Bolt
(13) Plug
(14) Seal
(15) Clutch assembly
(16) Bearing cone
(17) Driving pinion
(18) Shim(s)
(19) O’ring
(20) Seal holder
(21) Transfer pipe (lubrication)
(22) Restrictor union and seal
(23) Clutch cover
(24) O’ring
(25) O’ring
(27) Union and seal
(28) Transfer pipe (17 bar)
(29) Cover plate
(30) Hub
(31) O’ring
(32) Seal rings
(33) Circlip
(34) Circlip
(35) Shim(s)
(36) Clutch friction plates
(37) Intermediate clutch plates Fig 1
(38) Circlip
(39) Piston
(40) O’ring Fig 2
(41) Dust seal
Issue 1 May 2002

Front axle - 4 WD clutch 8G01.5 Overall view
G 1 19 18 16 17 5
41
20 4
F-F
21 22 23 30 27
B A F F
28
29
13 14 33 15 11
A
B
O 12
31
40
34
6 7
35
39
9 T 32
38 24 25 26 36 37 10 8 Parts list
Fig 2
Fig. 1
Issue 1 May 2002

Exploded view
5
17
7
33
8
6
11 29
37
12
28
13
31
9
14 10
25 34
35
36
38
32
23 2
26 16
30 19
39 1
24 20
40 41
21
Parts list
4
18
Fig 1 3
Fig. 2
Issue 1 May 2002

Stripping the shaft

A . Preliminary operations 13. Take off oil seal rings (32).
1. Immobilise the tractor. Chock the rear wheels. Put 14. Extract bearing cone (16) using a press and appropri-
on the handbrake. ate fixture.
2. On tractors fitted with an AG 155H or AG 200H front
axle, disconnect the front differential control piping
(block off the piping). Remove the transmission Reassembling the shaft
shaft. 15. Ensure that channels "A"and "B" (Fig. 1) are not
3. Drain the intermediate housing. obstructed. Check for the presence of the rivets at
4. Remove bolts (12). Release and remove cover (11). each end of the shaft.
16. Insert bearing cone (16) thrust against the shoulder
on shaft (2).
17. Place the oil seal rings (32) in the grooves of the
shaft. Hook their ends. Ensure that they turn freely.
B . Removing, refitting the clutch

assembly and shaft
Special points
- Bush (7) is held solely by transfer pipe (28). If removal
of only the transfer pipe is necessary, check that the
bush has not accidentally been moved.
- This bush has a drilled hole "T" (Fig. 1) that is turned
downwards and allows for pressure-relief of the bear-
ing.
Removal
5. Take off circlip (3).
6. Wrap the splined section of shaft (2) with a flexible
protective tape. Take out dust seal (41). Extract the
seal holder (20) fitted with its seal (1) using two
locally manufactured hooks placed in internal groove
"G" of the seal holder (Fig. 1). Extract seal (1).
7. Take out O’ring (19).
8. Remove the shim(s) (18) and bearing cup (4).
9. Take out the shaft assembly (2) fitted with bearing
cone (16) while holding the clutch (15) and the bell-
shaped gear (10) assembly.
10. Remove the clutch assembly, the bell-shaped gear
and bearing cone (9).
11. Extract cup (8). Remove circlip (33).
Note: To carry out maintenance on driving pin-
ion (17), remove the entire unit assembly with
drive pinion (see section 6D01, 6D02 or 6D03
according to the version).
12. Remove the 4 WD clutch 17 bar supply pipe, union
(27) and transfer pipe (28) using circlip pliers. Take
off bush (7). Remove O’ring (31).
Issue 1 May 2002


Refitting the clutch assembly and shaft
19. Position bush (7) fitted with a new O’ring (31), with
port "O" of the bush facing the transfer pipe (28) and
hole "T" positioned facing downwards (Fig. 1). Insert
the pipe. Screw on union (27) fitted with its seal.
Replace the clutch pressure supply pipe.
20. Refit circlip (33). Insert cup (8).
21. Smear bearing cone (9) with miscible grease and
place it in cup (8).
Note: If the intermediate housing, shaft (2),
bearings (8) (9) and (4) (16), seal holder (20) and
circlips (3) (33) have been replaced, carry out J2
shimming, see § D.
22. Refit the clutch (15) and the bell-shaped gear (10)
assembly.
23. Hold the clutch assembly and bell-shaped pinion.
Engage shaft (2) fitted with bearing cone (16) and
lubricated seal rings (32), in the clutch assembly,
bearing cone (9) and bush (7).
24. Place cup (4). Lightly coat shim(s) (18) with miscible
grease and stick them against the cup.
25. Using a press and an appropriate fixture, insert lip
seal (1) in the seal holder (20).
26. Fit O’ring (19).
27. Protect the splined section of shaft (2). Insert the
seal holder fitted with seal (1) previously lubricated,
using a locally manufactured sleeve. Remove the
protection material.
Issue 1 May 2002

C . Disassembling, reassembling and

shimming the clutch
Disassembly
29. Remove the clutch assembly (see § B).
34
30. Separate the bell-shaped gear (10) from the clutch
assembly (15). 35
31. Take off circlip (38). Remove piston (39).
32. Take off the O’rings (24) (40).
33. Using a press and an appropriate fixture, compress
the Belleville washers (26) (Fig. 3).
26
34. Take off circlip (34), the shim(s) (35) (Fig. 3).
35. Remove the fixture. Take off cover plate (29), clutch
plates (36) and intermediate plates (37).
36. Separate hub (30) from clutch cover (23).
37. Take off O’ring (25).
Fig. 3
38. Remove the Belleville washers (26).
Reassembly
39. Inspect and clean the components. Replace any
parts found to be defective. Check that channels "A" 26 23
and "B" (Fig. 1) are not obstructed.
40. Position the Belleville washers (26) in the clutch
cover (23) (Fig. 4).
41. Lubricate and fit O’ring (25) on hub (30).
42. Position hub (30) in clutch cover (23) and thrusting
against the Belleville washers.
43. Place the clutch friction plates (36) aligning the tabs,
the intermediate plates (37) and fit the cover plate
(29).
Reminder
- Depending upon the options, cover (29), the number
of clutch plates and intermediate plates differ.
Fig. 4
Issue 1 May 2002


Shimming the clutch
J1 shimming
44. Using a press and an appropriate fixture (Fig. 5),
apply a load of 2000 daN so as to fully compress the
Belleville washers (26).
45. Fit circlip (34). Using a set of feeler gauges, measure
the gap X (Fig. 6), between cover plate (29) and
circlip (34). Select a thickness of shim(s) (35) to
provide a clearance of:
J1 = 0.9 mm to 1.1 mm (Fig. 6).
46. Remove circlip (34).
47. Position the shim(s) selected in operation 45 be- 26
tween the cover plate and the circlip.
Important: Fit the splined shim on the circlip
side.
48. Refit the circlip.
49. Lubricate and fit the O’rings (24) (40) on piston (39) Fig. 5
and refit it.
51. Couple clutch assembly (15) and bell-shaped gear
(10).
Note: Bush (6) is force fitted in the bell-shaped J1 = 0,9 / 1,1 mm 34
gear and then rebored.
52. Refit the clutch assembly (15) and bell-shaped gear
(10). Carry out operations 21 to 28 § B. 35
34
29
X
Fig. 6
Issue 1 May 2002

D . Shimming the shaft

J2 = 0 / 0,10 mm
Reminder 2
- Since the 4 WD clutch is mechanically engaged when
stationary by the Belleville washers and through the link
with the rear axle drive pinion, it is impossible to turn the
driving shaft (2).
Action
- To carry out J2 shimming, provisionally fit bearing cone
(9), shaft (2) fitted with taper roller bearing (16) without
fitting the clutch (15), bell-shaped gear (10) and shim(s)
(18) assembly. Fit bearing cup (4), seal holder (20) and
circlip (3).
J2 shimming
Fig. 7
53. Place the index of a dial gauge on the end of shaft (2)
(Fig. 7).
54. Since access is limited around the shaft, pull hard 64. Refit the transmission shaft.
using vice grip pliers, and alternatively turning it left 65. On tractors fitted with an AG 155H or AG 200H front
and right in order to correctly seat the cones and axle, reconnect the differential lock control piping.
cups. 66. Remove the chocks from the wheels. Carry out a
55. Set the dial gauge to zero. road test the 4 WD clutch.
56. Repeat operation 54, this time while pushing. 67. Check the oil tightness of:
57. In relation to the clearance measured, select a shim - the cover (11) mating face beneath the intermedi-
(18) thickness to provide a clearance of: ate housing
J2 = 0 mm to 0.1 mm (Fig. 7) - the hydraulic unions
58. Remove circlip (3), seal holder (20), shaft (2) and the
bearings.
59. Definitively fit the clutch (15), bell-shaped gear (10)
and shaft (2) assembly. Carry out operations 21 to 28
§ B.
60. Clean cover (11) and its mating face on the housing.
61. Smear the cover mating face with Loctite 510 or its
equivalent.
62. Refit the inspection cover. Tighten the bolts (12) to a
63. Refill the housings and check the oil level on the
transparent tube on the left-hand side of the centre
housing.
Issue 1 May 2002

Front axle - Carraro supension 8G02.1
8G02 Carraro suspension
CONTENTS
A. Arms unit disassembly _________________________________ 2
B. Arms unit assembly ____________________________________ 5
C. Service tools __________________________________________ 14
Issue 1 May 2002

8G02.2 Front axle - Carraro suspension
A. Arms unit disassembly

1. Secure the arms with a suitable lifting system in order
to prevent any unwished movement.
A
Unscrew the nut A and remove the conic pin B.
B
Remove the pivot pin C, if needed, beating with a
rubber hammer or other tender material.
Danger
C
- Arms are very heavy, then they could move and
harm the operator.
2. Remove the upper arms pin covers D on front and
back side of the arms, unscrewing the relative fastenig
screws F.
Collect the seal rings and the shims, where they are
present. Fig. 1
All dismantelled parts needs to be marked at their
position.
Remove the bearing G and the fastening ring H from
every pin.
3. Remove the arms pin fastening screws I and extract
the pins J with a suitable extractor, using the special
threaded hole in the pin. H
Warning : This operation set the arms free.
Note : D
- To make the extraction easier, there is a possibil-
F
ity to heat the arm pins housing until a limit of
+100°C. G
- This is a destructive operation for the seal rings.
Danger
- if the upper and lower arms aren’t correctly
supported, they could move harming the opera-
tor. Fig. 2
J
I
Fig. 3
Issue 1 May 2002

4. Remove the upper arms, using a suitable lifting

system.
Note : The type of washers placed on each side of
suspension cylinder's ball joint have been changed
for the following front axle serial number
- Model 20.19S : n° 1000230
- Model 20.19S : n° 1000132
K
Danger
- the lower arms could rotate harming the opera- K
tor.
Collect the seal rings and the shims, where they are
present.
If needed replace the shock-absorber pads K remov-
ing the relative screws.
5. Remove the lower arms pin covers and the sensor Fig. 4
plate E, unsrewing the relative fastening screws F
(Fig. 5). Collect the rubber washer on the sensor side
(see section 11G01 §B).
6. Remove the bearings fastening screws L from the
arms pin, collecting the relative thrust washer M and
the shims N, where they are present.
Note : The thrust washer on the sensor pin has a
particular shape and it could not be confused with
the other ones.
To reach the fastening screw on the sensor side,
positioning ring needs to be removed from the thrust
washer (see section 11G01 §B).
Note : This is a destructive operation for the seals.
Remove the bearings O and the seal rings P.
E Fig. 5
P
N
L
O
M
Fig. 6
Issue 1 May 2002

7. Extract the arms pins Q with a suitable extractor,

using the special threaded hole in the pin.
Warning : His operation set the lower arms free.
Remove the lower arms from the axle body.
Danger
- if the lower arms aren’t supported correctly they

could fall harming the operator. Q
8. In order to disassemble the lower cover T remove the
fastening screws. Remove the cylinder from the axle
beam.
Remove the O-Ring U from the cylinder and seal ring
R from its housing in the axle beam.
Only if needed replace the bush S, removing them
with a suitable extractor.
Fig. 7
Fig. 8
Issue 1 May 2002

B
B. Arms unit assembly
9. Insert the bush A in the suspension cylinder housing, A
applying Loctite 510 on the retaining rabbet.
Assemble the seal ring B on the axle beam and a
new O-Ring C, with few grease, in the housing on the
bottom of the suspension cylinder D.
Insert the lubricate cylinder in the axle beam. D
10. Assemble the lower cover E on the bottom of axle
beam and tighten the relative retaining screws tight-
ening them to the requested torque (see section C
8A01 § A) with dynamometric wrench.
Note : Before assembling the cover check the
correct position of the O-Ring on the cylinder
bottom.
Place the lower arms on the axle beam and align the
pins housing inserting the special tool CA715350 Fig. 9
(see § C) G in the housing from the opposite side of
that the pin assembly.
11. Insert the arms pins H in their housings on every arm
and in the beam until the end is reached using the
special tool CA715353 (see § C).
Note :
- To make the assembly easier, it is advisable to
cool the arms pins at a temperature lower than
-100°C.
- That operation is possible by fully immersing
the arms pins in liquid nitrogen.
- To buy or rent liquid nitrogen, contact the "Air
liquide" society.
Warning : Wear safety gloves. E
Note : The arms pins housing can be heated at a
maximum of +100°C.
Fig. 10
Fig. 11
Issue 1 May 2002

12. Assemble the seal ring (I) on every pin in the lower
arms housings using the special tool CA715352 (see
§ C) code with a hammer.
Insert the conical bearing (J) using the special tool
CA715349 (see § C).
Assemble a reference spacer R (on the pinion side)
of appropriate dimension (shim R= 1 mm) and the
thrust washer K with the fastening screw L (Fig.12).
Warning : The spacer must have the outer diam- I
eter lower than the inner one of the bearing. R
Note : The thrust washer on the sensor pin has L
a particular shape and it must not be confused
with the other pins ones.
J
K
Adjust the conical bearings moving the arms and
tighten the fastening screws with a dynamometric
wrench to the requested torque (see section 8A01 §
A).
13. Warning : verify the bearings assembly position Fig. 12
on the pins arms.
On the lower pins : the bearing must be inserted
with the cup on the inner side (in the arm housing)
and the cone on the outer one (on the pin).
On the upper pins : the bearing must be inserted
with the cone in the inner side (on the pin) and the cup
on the outer one (on the arm housing) (Fig.13).
14. Position a magnetic-base dial gauge on the axle
beam so that the feeler touches the lower arm side
surface and then zero the gauge.
Position a lever between the arm and the axle beam,
drive the arm till end of stroke from both side and
measure the backlash with the dial gauge. Repeat
this operation several times, so to find an average
value X (Fig.13).
15. In order to determine the necessary thickness S to
give preloading to the bearing, substract the meas-
ured value X and the prescribed one from the known Fig. 13
reference shim value R
S = (R - X) - V
V = 0.05 to 0.15 mm
Choose among the available shims a quantity in a
way to reach the previously determinated value S.
Shim range
Thickness 0.1 0.2 0.5
Quantity - - -
Fig. 14
Issue 1 May 2002

16. Remove the fastening screws L from the pinion side

and the reference shim R.
Insert the shims S between the thrust K and the
conical bearing J (Fig.15).
Warning : It is necessary to insert all the shims
and only on the pinion side.
Reassemble the fastening screws then tighten
them with a dynamometric wrench to the requested
J
torque (see section 8A01 § A). K
Repeat the described procedures also on the other L
lower arm.
17. Place the upper arms on a workbench, using a
suitable lifting system.
S
Danger
- the arms are heavy, it is necessary to handle Fig. 15

them with extreme attention in order to avoid
operator harm.
If needed replace the shock-absorber pad (P), screw-
ing its fastening screws with dynamometric wrench
to the requested torque (see section A01 §A) (Fig.16)
Fig. 16
Issue 1 May 2002

18. Assemble the two bushes Q on the pivot pin housings

on the fork arm using the special tools CA715347 for
the 20.22 S and 20.19 S models, CA715385 for the
20.29 S model (see § C) and a hammer. U
T
Note : To make the assembly easier, it is neces- T
sary to cool the bushes at a temperature lower U R
than -100°C. Q
Insert the seal rings R using the CA715383 (see § C).
Insert the spacers T from the inner side fork, using Q
R
the special tool CA715384 (see § C) and the relative
O-Ring U in the spacer housings (Fig.17).
19. Place the spacer Z in the other arm pivot pin housing
using the special tools CA715384(see § C) and the
relative O-Ring V.
In the opposite side insert the false thrust washer W
in the spacer housing with the special tool
CA715381(see § C) (Fig.18). Fig. 17
Note : Verify that the false thrust washer posi-
tion remains correct during the arms assembly,
then the thrust washer will be replaced with ZV
shims, after the spacer backlash is measured.
20. With the help of a suitable lifting system, place the
upper arms on the axle beam couple them with the
lower arms.
Insert the pins arms F in their housings on each arm W
until the end is reached using the special tool
CA715353 (see § C) (Fig.19).
Note : To make the assembly easier, it is neces-
sary to cool the arms pins at a temperature lower
than -100°C.
Assemble the fastening screws E, applying Loctite
542 on the threads, then tighten them with dynamo-
metric wrench to the requested torque (see section
8A01 §A). Fig. 18
F
E
Fig. 19
Issue 1 May 2002

21. Assemble the seal ring H on every arms pin using the
special tool CA715351(see § C).
Insert the conical bearing (I) using the special tool
CA715349 (see § C).
Warning :
- Check the bearings assembly position on the
pins arms, as defined at sequence 5.
Assemble the cover J with the relative fastening I
screws K (Fig.20). J
Note : Do not insert any spacers under the cover.
Adjust the conical bearings moving the arms and
tighten the fastening screws with dynamometric H
wrench to the requested torque (see section 8A01 § K
A).
22. Position a magnetic-base dial gauge on the upper
arm so that the feeler touches the upper arm side
surface and then zero the gauge.
Position a lever between the upper arm and the lower Fig. 20
arm, drive the arm till end of stroke from both side
and measure the backlash with the dial gauge X
between the bearings and the relative housings.
Repeat this operation several times, so to find an
average value (Fig.21).
give preloading to the bearing, add the measured
value Y to the prescribed value V :
S=X+V
V = 0.05 to 0.15 mm
Shim range
Thickness 0.1 0.2 0.5
Quantity - - -
24. Repeat the described procedures also on the other
upper arm. Fig. 21
Remove the arms pins covers from the pinion side,
insert the shims S and a new O-Ring L and reassem-
ble them, filling the housing in excess with grease,
then screw the relative fastening screws K with a
dynamometric wrench to the requested torque (see
section 8A01 § A).
Disassemble the covers from the pinion opposite
side, fill the housing in excess with grease, then
reassemble them with a new O-Ring L. I
Warning : The shims are added only in the pinion J
side.
Tighten the relative fastening screws K with a S
dynamometric wrench to the requested torque (see L
section 8A01 § A) (Fig.22). K
Fig. 22
Issue 1 May 2002

25. Align arms, suspension cylinder holes and washers

(if they are). Special tool the guide pin CA715382 for
X Y
(see § C) can be used to align them, but needs to be
removed after.
26. Measured the dimensions X and Y with two long
thickness gauges at the same time with the wash-
ers in place.
The length of the gauge needs to be minimum the
outside diameter of the cylinder head.
27. If needed, move some of the positionned shims
(see operation 23) of the upper left arm from the
pinion side to the other side in order to obtain a
minimum play X of 0.10 mm.
If needed, move some of the positionned shims
(see operation 23) of the upper right arm from the
pinion side to the other side in order to obtain a A
minimum play Y of 0.10 mm.
Fig. 23
X Y
Fig. 23A
Issue 1 May 2002

28. Insert the guide pin CA715382 for the 20.29 S model
(see § C) and adjust the components.
Measure the dimension with a thickness gauge X
between the spacer T and the false thrust washer
W. X S
Remove the false thrust, taking away the guide pin
in order to remove the spacers housings on the arms S
(Fig. 24). T W
give backlash to the arms, calculate: D
S=X-V
V = 0.4 to 0.7 mm
Shim range
Thickness 0.1 0.3
Quantity - - Fig. 24 Fig. 24A
30. Insert the just chosen shims S and the spacer D in

the false thrust washer housing, using the special
tool CA715348 (see § C) (Fig. 25).
31. Align arms and suspension cylinder holes, inserting
before the pivot pin P the special tool CA715382 (see
§ C), then drive the pin in the housing (Fig. 26).
Warning : Hold the special tool at the exit from S
the pin housing. D
Stop the pivot pin with the conical pin Q, screwing
the nut R with a dynamometric wrench to the
requested torque (see section 8A01 § A).
Danger
- if the upper and lower arms aren’t correctly

supported, they could move harming the op-
erator. Fig. 25
32. Remove the fastening screws of all the lower arms
pins and erassamble then applying Loctite 542 on
the threads, then ligthen them with a dynanometric R Q
wrench to the requested torque (see section 8A01 §
A).
Fig. 26
Issue 1 May 2002

33. Insert the seal ring M on the sensor pin thrust washer
with the special tool CA715345 (see § C) and new O-
Rings in the relative housing on the pins arms covers
O and on the sensor plate N.
Assemble arms pin covers and the sensor plate,
filling their housing in excess with grease, then
screw the relative fastening screws to the requested
torque (see section 8A01§A) (Fig. 27).
34. Measure the distance Xac in the Closed Axle posi-
tion from the pin centre to the differential support, M
choosing a well precise datum-point P (Fig. 28). N
35. Lift completly the arms and measure the distance
Xaa in the Opened Axle position, from the pivot pin
centre to the chosen datum-point P (Fig. 29).
Warning : Lift gradually the arms untill the end O
of strokes is reached, surpasse this position
damage suspension cylinder.
Check that the suspension cylinder stroke C fall Fig. 27
within the prescribed range, substracting between
C = Xaa - Xac
C = 88 to 89 mm
Xac
P
Fig. 28
Xaa
Fig. 29
Issue 1 May 2002

36. If the suspension cylinder stroke C fall out the

prescribed range, measure the backlash X between
the upper arms in the shims inserting point, in
Opened Axle position (Fig. 30).
give the correct end of stroke position to the arms
add the measured value X to the value prescribed
V:
S=X+V X
V = 0.3 mm
Shim range
Thickness 0.05 0.10 0.20 2.00
Quantity - - - -
38. Lower the axle upper arms (Closed Axle position) Fig. 30
and assemble the chosen shims with the relative
fastening screw.
Lift again the axle until the end is reached (Opened
Axle) in order to settle the arms, then come back to
the starting position (Closed Axle).
Check that the suspension cylinder stroke (C fall
within the prescribed range (Fig. 31).
Fig. 31
Issue 1 May 2002

C. Service tools
- CA 715382 - Driver rod (Fig. 32)
Fig. 32
Fig. 33
Fig. 34
Issue 1 May 2002


- CA 715384 - Spacer driver (Fig. 36)
- CA 715349 - Bearing driver (Fig. 37)
Fig. 35
Fig. 36
Fig. 37
Issue 1 May 2002

- CA 715350 - Driver kit (Fig. 38)

Fig. 38
Fig. 39
Fig. 40
Issue 1 May 2002

- CA 715353 - Pin driver (Fig. 41)

- CA 715381 - False thrust washer (Fig. 42)
- CA 715384 - Space driver (Fig. 43)
Fig. 41
Fig. 42
Fig.43
Issue 1 May 2002

Front axle - Carraro troubleshooting 8I01.1
8I01 Carraro troubleshooting
CONTENTS
- Generality __________________________________________________ 2
A. Troubleshooting ____________________________________________ 4
B. Axle problem and diagnosis _________________________________ 6
Issue 1 May 2002

8I01.2 Front axle - Carraro troubleshooting
Generality
The following table presents you some possible problems
and their causes. Refer you to the number of the cause
to know its remedy.
Possible causes
Problems
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration, front tyre resistance, ¨ ¨ ¨ ¨ ¨

halshaft breakage
Wheel vibration, front tyre resistance,

halshaft breakage ¨ ¨ ¨ ¨ ¨
No differential action, jamming while ¨ ¨ ¨ ¨

steering
Bruit excessif de la transmission ¨ ¨ ¨ ¨ ¨ ¨ ¨ ¨
Uneven wear of tyre ¨ ¨ ¨ ¨ ¨ ¨ ¨ ¨
Friction noise ¨ ¨ ¨ ¨ ¨ ¨ ¨
Vibration during forward drice, ¨ ¨

intermittent noise
1. Incorrect installation / defective axle

Correct installation or repair or replace the differential
in case it does not survive any one of the test phases.
2. Overloading/ incorrect weight distribution

Remove excessive weight and redistribute load, fol-
lowing instructions related to the vehicle.
3. Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial
wheel slipping when force is applied.The other tyre
with bigger radius will have to support all the work.
Replace the tyre or adjust pressure to have same
radius on both tyre.
4. Broken halfshaft
It is not advisable to operate the vehicle with a broken
halfshaft. It is acceptable to move the vehicle (engine
off unloaded) a few meters away only.
Issue 1 May 2002

5. Bent halfshaft
Replace halfshaft.
6. Blocked differential
Abnormal functioning of the differential or breakage/
blockage of command device. Verify assembly and
all components.
Vehicles with wide steering angle may proceed with
kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to
minimum and decelerate when the vehicle begins to
kick.
7. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.
8. Spoiled or worn out axle parts

Check the condition of ring gear, pinion gear, bear-
ings etc. Replace when ever necessary.
9. Contamination in the axle box or incorrect as-

sembly of parts
Look for foreign particles. Check assembly of the
various parts of the axle.
10. Incorrect adjustment of bevel gear set: Parts of

the transmission worn out (transmission gears, U
joints, etc.)
Replace or adjust as required.
11. Incorrect use of the product

See the vehicle producer‘s instructions once again.
Issue 1 May 2002

A. Troubleshooting
PROBLEM CAUSE REMEDY
Ring gear tooth broken at the 1. Excessive gear load Replace bevel gear set
outer side compared to the one foreseen Follow carefully the
2. Incorrect gear adjustment recommended operations for
(excessive backlash) the adjustment of bevel gear
3. Pinion nut loosened set backlash
Ring gear tooth broken side 1. Load bump Replace bevel gear set
2. Incorrect gear adjustment Follow carefully the
(insufficient backlash) recommended operations for
3. Pinion nut loosened the adjustment of bevel gear
set backlash.
Pinion or ring gear teeth or 1. Insufficient lubrication Replace bevel gear set.
worn 2. Contaminated oil Follow carefully the
3. Incorrect lubrication or recommended operations for
depleted additives the adjustment of bevel gear
4. Worn out pinion bearings set backlash.
that cause an incorrect pinion Use correct lubricants, fill up to
axle backlash and wrong the right levels and replace
contact between pinion and according to the
ring. recommended program.
Overheated ring and pinion 1. Prolong ed functioning at Replace bevel gear set.
teeth. See if gear teeth have high temperatures Use proper lubrication, fill up to
faded 2. Incorrect lubrication right level and replace at
3. Low oil level recommended 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,
3. Excessive use to the right level and replace at
4. Normal wear out recommended intervals
5. Pinion nut loosened
Issue 1 May 2002

Oil leakage form gaskets and 1. Prolonged functioning at Replace the gasket or seal and
seals high temperature of the oil matching surface if damaged.
2. Oil gasket assembled Use correct lubrication and
incorrectly replace at recommended
3. Seal lip damaged intervals.
4. Contaminated oil
Excessive wearing out of input 1. Exhaustive use Replace the flange.

flange spline 2. Pinion nut loosened Check that the pinion spline is
3. Pinion axle backlash not 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 2. Continuos overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage 1. Crash load of differential Check and/or replace other
components differential components.
Side gear spline worn out. Excessive use Replace differential gear group.
Replace all scratched washers Replace halfshaft if required
(Excessive backlash)
Thrust washer surface worn 1. Insufficient lubrication Use correct lubrication and fill
out or scratched. 2. Incorrect lubrication up to 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 Check pinion axial backlash.
backlash Use proper lubrication, fill up to
3. Insufficient lubrication right level and replace at
4. Contaminated oil recommended intervals.
Bent or broken halfshaft Vehicle intensively operated or Replace

overloaded
Halfshaft broken at wheel side 1. Wheel support loosened Replace

2. Beam body bent Check that wheel support is
not worn out or wrongly
adjusted.
Issue 1 May 2002

B. Axle problem and diagnosis
PROBLEM CAUSE RECOMMENDED REPAIR
Noise while driving 1. Excessive backlash between 1. Adjust

pinion and ring gear
2. Worn out pinion and gear 2. Replace
ring
3. Worn out pinion bearings 3. Replace
4. Pinion bearings loosened 4. Adjust
5. Excessive axial pinion 5. Adjust
backlash
6. Worn out differential 6. Replace
bearings
7. Differential bearings 7. Adjust
loosened
8. Ring gear out of roundness 8. Replace
9. Low lubricant level 9. Oil level
10. Poor or wrong lubricant 10. Replace
11. Bent halfshaft 11. Replace
Noise while driving in neutral 1. Noise coming from axle are 1. Replace or adjust (see
usually heard when vehicle above)
moves in neutral gear but are
not loud.
2. Incorrect backlash between 2. Replace
pinion and ring (sound heard
while decelerating disappears
while increasing the speed)
3. Pinion or input flange worn 3. Adjust
out
Intermittent noise 1. Ring gear damaged 1. Replace bevel gear set

2. Differential box bolts 2. Tighten to torque
loosened
Constant noise 1. Ring gear teeth or pinion 1. Replace bevel gear set
damaged
2. Worn out bearings 2. Replace
3.Pinion spline worn out 3. Replace
4. Bent halfshaft 4. Replace
Noise while seering 1. Worn out differential gears 1. Replace

2. Worn out differential box or 2. Replace
spider
3. Differential thrust washers 3. Replace
worn out
4. Half shaft spline worn out 4. Replace
Issue 1 May 2002

9 . HYDRAULICS
Contents
9 A01 DESCRIPTION OF THE 110 L/MIN CIRCUIT

9 A02 DESCRIPTION OF THE 150 L/MIN CIRCUIT
9 B01 PRIORITY BLOCKS WITH TRAILER BRAKING
9 C01 PRIORITY BLOCKS WITHOUT TRAILER BRAKING
9 D01 AUXILIARY SPOOL VALVES
9 E01 LIFT CONTROL SPOOL VALVE
9 F01 HYDROSTATIC STEERING FOR 2WD AND 4WD FRONT AXLES - AG155H /
AG200H
9 F02 HYDROSTATIC STEERING FOR 4WD FRONT AXLES - APL5052
9 G01 RIGHT-HAND COVER 110 L/MIN LOAD SENSING
9 G02 150 L/MIN RIGHT-HAND COVER
9H01 LEFT-HAND COVER 110 L/MIN AND 150 L/MIN LOAD SENSING
9 I01 BRAKE AND CLUTCH MASTER CYLINDERS CIRCUIT AND BLEEDING
9 J01 CLUTCH CONTROL VALVE
9 K01 POWER SHUTTLE CONTROL UNIT
9 K02 HYDRAULIC CONTROL UNIT - SUSPENDED FRONT AXLE
9 L01 DYNASHIFT CONTROL
9 M01 OIL DECONTAMINATION
9 N01 HYDRAULIC TESTS
Issue 2 May 2002

Hydraulics - Description of the 110 l/min circuit 9A01.1
9 A01 Description of the 110 l/min circuit
CONTENTS
A. General ________________________________________________ 3
B. Principle _______________________________________________ 4
C. Centre housing lubricating circuit ________________________ 4
D. Layout of components in AG 150 - AG 250 Full Powershift

Heavy Duty gearboxes ___________________________________ 6
E. Diagrams _______________________________________________ 20
Issue 1
2 December
May 2000
2002
9A01.2 Hydraulics - Description of the 110 l/min circuit

The controller takes into account the pilot signal corre-

A . General sponding to the function requiring the highest pressure.
The hydraulic circuit is of the closed centre type and is
equipped with controlled pressure and flowrate. It con- Component characteristics
sists of two separate high and low pressure circuits, Suction strainer (37)
supplied by a variable displacement pump having a - Type .................................... cartridge
maximum flowrate of 45 cm3 per revolution. The variable - Filtration threshold ................ 150 µ
displacement pump is fed by a booster pump.
Booster pump (38)
Both pumps are driven by a pinion fitted on the upper - Trademark ........................... Rexroth Sigma
shaftline of the PTO located in the intermediate housing. - Capacity .............................. 60 cm3 per revolution
- Output .................................. 165 l/min at 2200 rpm
The booster pump fitted on the left-hand cover sucks oil
through a suction strainer to feed the common tank Main filter (13)
formed by the centre housing, the intermediate housing - Filtration threshold ................ 15 µ
and the gearbox. The booster pump oil flow is then - With differential pressure
directed to the right-hand hydraulic cover where it passes bypass ................................. 3,5 bar
through the main filter before flowing to the variable - With differential pressure
displacement pump and then to the oil manifold of the switch .................................. 2,4 bar
centre housing to supply the following components:
- the trumpet housings Safety valve (26)
- the PTO clutch - Calibration ............................ 22 bar
- the hydraulic pump drive bearing - Fitted on the low pressure circuit
- the 4WD unit
- the handbrake mechanism Safety valve (25)
- the creeper unit (if fitted) - Calibration ............................ 5 bar
- No slave device used ........... supplies booster pump
The variable displacement pump supplies either one or - Switch ................................. 5 bar (clogging indi-
two priority blocks, depending on the options, these are cator placed on main
fitted on the right-hand side hydraulic cover: filter)
- one block for tractors without hydraulic trailer braking Opens .................................. 3 bar
- two blocks for tractors with hydraulic trailer braking. Closes ................................. 2 bar
Fitted in parallel to filter
The first block supplies: Linked to signal lamp on dashboard
- as its first priority, the steering system,
- as its second priority, the 17 bar rear axle hydraulic Variable displacement pump (48)
circuit, the auxiliary spool valves and the lift control - Trademark ........................... Brueninghaus
valve. - Type .................................... Axial pistons
- Variable capacity ................. 0 to 45 cm3 per
If a second block is fitted, it shares the priority between revolution
the steering system and the trailer braking. - Output .................................. 0 to 105 l/min
at 2200 rpm
Once the first priorities have been met, the remaining oil - Min. pressure ....................... 22 bar
flow becomes available to the auxiliary spool valves and - Max. pressure ..................... 200 bar
the lift control valve. - Internal lubrication with return to housing
All the pilot signals from the various high pressure valves
are directed to the priority block(s) to then be retransmitted
to the variable displacement pump controller.
Issue 1 May 2001

B . Principle
The purpose of the closed centre hydraulic system is to
limit the power absorbed by the engine. If no hydraulic
slave device is actuated, no flow is discharged by the
variable displacement pump.
When a function is activated, the pump only supplies the

output required for that function.
Note: If the housing is drained, or if the main filter is

replaced or any servicing operation carried results in
the air intake into the system, it is essential to prime
the hydraulic circuit. Disconnect the connector to
the fuel injection pump. Activate the engine starter
motor in consecutive bursts until the (red) booster
pressure signal lamp on the dashboard goes out.
C . Centre housing lubricating circuit

Parts list (Fig. 1)
A :
Trumpet housing lubrication
B :
Centre housing lubricating manifold
C :
Pump bearing lubrication
D :
General supply from booster circuit
E :
PTO clutch lubrication
F :
Lubrication for handbrake mechanism and creeper
unit (if fitted)
G : Transfer pipe for trumpet housings with double
drive unit
Issue 1 May 2001

A B
C
E D
G
Fig. 1
Issue 12
Issue May 2000
December 2002

(53) Pump drive pinion bearing
D . Layout of components in AG 150 (54) Park Lock control
- AG 250 Full Powershift and Heavy (55) Park Lock solenoid valve
Duty gearboxes (62) Priority blocks with trailer braking
(63) Trailer brake valve
Full Powershift gearbox (Figs. 2 - 3) (64) Trailer brake coupler
Parts list (65) High pressure spool valve
(1) Tank
(2) Brake master cylinders Note: for Full Powershift hydraulics, see section 5I01.
(3) Servo brake
(4) Gearbox proportional
to solenoid
(12) valves Fig. 2
(13) Main filter (15 u)
(14) Suction strainer (250 u)
(15) Pump Fig. 3
(16) Variable displacement pump regulator
(17) Load Sensing diagnostic connector
(18) Solenoid valves: PTO, PTO brake, differential
to lock (front, rear)
(21) and 4WD
(22) Steering priority spool valve High pressure
(23) 17 bar pressure spool valve
(24) High pressure diagnostic connector Low pressure
(25) 5 bar safety valve
(26) 22 bar safety valve Lubrication
(27) Priority block without trailer braking
(28) Right-hand cover Suction
(29) Booster pump pressure diagnostic connector
(30) Low pressure diagnostics connector Return
(31) Discharge pressure limiter
(32) Lift rams Brakes
(33) Couplers
(34) PTO brake Pilot flow
(35) PTO clutch
(36) Auxiliary spool valves
(38) Booster pump
(39) Centre housing lubricating manifold
(40) 4WD clutch
(41) Lift control valve
(42) Rear differential lock
(43) Left-hand cover
(44) 3-way filter
(46) Gearbox pressure regulating valve (17 bar)
(47) Hydrostatic steering spool valve (Orbitrol)
(48) Variable displacement pump
(50) Front differential lock (except ZF front axle)
(51) Steering rams
(52) Oil cooler

Full Powershift gearbox - Dana front axle - Without trailer brake
52
51 1
50 2
49 3
4 12
47 58
46 15
45 13
44 54 55
53 14
43 16 17
38 18 21
37
40 22 23 65
39 24 29 30
42 48
32 27
41 25 26 28
36 33 35 34 33 32 31
Issue 1 May 2001

Full Powershift gearbox - ZF front axle - With trailer brake
52 51
51 1
49 3
4 12
47 58
46 15
45 13
44 54 55
53 14
43 16 17
38 22 23 65
37 62 63
40 18 21
39 24 29 30
42 48
32 27
41 25 26 28
36 33 35 34 33 64 32 31
Issue 1 May 2001

Right-hand side
14
A A
(A) Ports and suction pipe of the Gerotor pump

(B) Return port (Orbitrol and braking assistance)
(C) Intermediate housing
(D) Gearbox
Fig. 4
Issue 1
2 December
May 2000
2002
Left-hand side
4 12 45 E
15
52
44
46
49
F (E) Engine speed sensor

(F) Tank and master cylinders of brake and clutch
(Heavy Duty gearbox only)
Fig. 5

Heavy Duty gearbox (Fig. 6 - 7 - 7A)

Parts list with mechanical with Power
reverse shuttle shuttle
(Fig. 7) (Fig. 7A)
(1) Tank • •
(2) Brake master cylinders • •
(3) Servo brake • •
(4) Engine clutch • -
(4) Power shuttle - •
(5) Control valve (clutch and Dynashift) • -
(5) Control unit with Power shuttle - •
(6) Clutch diagnostics connector • -
(6) Front and rear clutch diagnostics connector - •
(7) Dynashift diagnostics connectors • •
(8) Accumulator for low pressure components • •
(9) Hare/Tortoise solenoid valve • •
(10) Oil cooler • •
(11) Load Sensing diagnostics connector • •
(12) Variable displacement pump controller • •
(13) Main filter (15 µ) • •
(14) Solenoid valves: PTO, PTO brake, differential lock
to (front, rear) • •
(17) and 4WD
(18) Steering priority spool valve • •
(19) 17 bar pressure spool valve • •
(20) High pressure diagnostic connector • •
(21) Booster pressure / lubricating diagnostics connector • •
(22) Low pressure diagnostics connector • •
(23) Priority blocks without trailer braking • •
(24) Right-hand side cover • •
(25) 5 bar safety valve • •
(26) 22 bar safety valve • •
(27) Pressure limiter • •
(28) Lift rams • •
(29) Couplers • •
(30) PTO brake • •
(31) PTO clutch • •
(32) Auxiliary spool valves • •
(33) Lift control valve • •
(34) Rear differential lock • •
(35) Centre housing lubricating manifold • •
(36) 4WD clutch • •
(37) Suction strainer (150 µ) • •
(38) Booster pump • •
(39) Left-hand side cover • •
(40) Pump drive pinion bearing • •
(41) Suction strainer and pipe (clutch(es)) • •
(42) Left and right-hand side brakes • •
(43) Dynashift unit • •
(44) Hydrostatic steering spool valve (Orbitrol) Fig. 6 • •
(45) Clutch master cylinder • •
(46) Front differential lock Fig. 7 • •
(47) Steering ram • •
Fig. 7A
(48) Variable displacement pump • •
(51) Braking assistance accumulator • •

May 2002

Parts list with mechanical with Power
reverse shuttle shuttle
(Fig. 6) (Fig. 6)
(55) Priority blocks with trailer braking • •
(56) Trailer brake valve • •
(57) Trailer brake couplers • •
High pressure
Low pressure
Lubrication
Suction Version with trailer braking
Return
Brakes 1
Pilot flow
2
3
Parts list
Fig. 7
Fig. 7A
55
56
57
Fig. 6
Issue 12 May 2000

December 2002
Parts list Heavy Duty gearbox with mechanical reverse shuttle
Fig. 6
Fig. 7A
10
47
46 1
45 5 6 7
44 51
43 8
42 9
41 13
40 11 12
39 14 17
38 18 19
37 20 21 22
36 48
35 23
34 24 25 26
28 27
33 32 29 31 29 30 28
Fig. 7
2
Issue 1 May 2000
December 2002

Heavy Duty gearbox with low pressure circuit
5 6 7
Parts list Fig. 6 Fig. 7 Fig. 7A
Issue 12 December
May 2000
2002
With mechanical reverse shuttle
C
51 8
1 A 2 B
Fig. 8
With mechanical reverse shuttle
41
Fig. 9
Issue 21 May 2002

December 2000

Mechanical reverse shuttle (Fig. 8) Booster circuit
(1) Hare / Tortoise solenoid valve - The booster hydraulic line feeds the variable
(2) Engine clutch (Pressure Loaded) and Dynashift displacement pump and lubricates the mechanical
control valve elements in the gearbox. Exclusively in the Pressure
(8) Accumulator for low pressure components Loaded version, it also maintains the oil level in the
(51) Accumulator for braking assistance brake and clutch master cylinders.
A : 17 bar supply piping for Hare / Tortoise range and

control valve (clutch and Dynashift)
B : Piping to clutch
C : Hose from clutch master cylinder
17 bar low pressure
Gas
Heavy Duty gearbox

Suction circuit
(41) Suction strainer and pipe (Pressure Loaded clutch)
(Fig. 9).
Low pressure (17 bar)

- The Hare / Tortoise range, Dynashift and engine clutch
(Pressure Loaded) or Power shuttle (depending on
assembly) are fed by the low pressure circuit.
- An accumulator fitted on the supply line allows the oil
flow to be accelerated producing a faster reaction of the
Dynashift pistons.
- Another accumulator of the same type is fitted on the
17 bar line and maintains the pressure to the assistance
mechanism (engine stopped), by means of a non-return
valve mounted upstream.
Cooling
- The transmission oil of the rear axle housing is cooled
by two cooling elements located in the grille at the front
of the tractor and linked to the main 15 micron filter
element via a set of pipes and hoses.
Issue 21 May 2002

December 2000
With low pressure circuit
51 8
1 A 2 B
Fig. 8A
With low pressure circuit
41
Fig. 9A
Issue 1
2 December
May 2000
2002
Issue 2
1 May 2002
December 2000
Low pressure circuit (Fig. 8A)

(1) Hare / Tortoise solenoid valve
(2) Engine clutch and Dynashift control valve
(8) Accumulator for low pressure components
(51) Accumulator for braking assistance
A : 17 bar supply piping for Hare / Tortoise range and

control valve (clutch and Dynashift)
B : Piping to clutch
17 bar low pressure
Gas
Heavy Duty gearbox

Suction circuit
((41) Suction strainer and pipe (Pressure Loaded clutch)
(Fig. 9A).
Issue 12
Issue May 2000
December 2002

(60) Return connector (provision for)
E . Diagrams (61) High pressure connector (provision for)
(62) Priority blocks with trailer braking
Full Powershift gearbox (Fig. 10)
(63) Trailer brake valve
Parts list
(64) Trailer brake coupler
(1) Oil tank (gearbox and centre housing)
(65) High pressure spool valve
(2) Brake master cylinders
(3) Servo brake
Note: for Full Powershift gearbox hydraulics, see
(4)
section 5I01.
to Gearbox proportional solenoid valves
(12)
(13) Main filter (15 µ)
Legend
A : Differential lock
(15) Pump
B : (17 bar) low pressure switch
(16) Variable displacement pump controller
C : 4WD
D : rear PTO
(18) Solenoid valves: PTO brake, differential lock
E : rear PTO brake
to (front, rear)
F : 4WD clutch
(21) and 4WD
G : Pump bearing lubrication
(22) Steering priority spool valve
H : Rear PTO lubrication
I : Trumpets lubrication
(24) High pressure diagnostic connector
J : Creeper unit and handbrake mechanism lubrication
(27) Priority block without trailer braking Fig. 10
(28) Right-hand cover
(30) Low pressure diagnostics connector
(31) Dsicharge pressure limiter
(32) Lift rams
(33) Couplers
(34) PTO brake
(35) PTO clutch
(36) Auxiliary spool valve
(38) Booster pump
(40) 4WD clutch
(43) Left cover
(44) 3-way filter
(51) Steering rams
(52) Oil cooler
(54) Park Lock control
(55) Park Lock solenoid valve
(56) Dual Control or front PTO (if fitted) 17 bar hydraulic
line
(57) Braking assistance non-return valve
(58) Braking assistance accumulator
(59) Load Sensing connector (provision for)
Issue 12 December
May 2000
2002
8200 SERIES TRACTORS Diagram showing Full Powershift gearbox mounted in series
- Load sensing 110 l/min and Dana front axle mounted in series.

27
Yft 41 32
T
T0
150 63 23 17
bar bar
Xdlr
Pdlr Pbf Pbn
Parts list
61
62 22 65
Xbf Xbf P
Paux
26
Xaux P LS T
64 31 24
22 bar
A2
Pfr Pl B2
155 bar 17
51 A
B
16 24
20
230 bar XLS
47 21 A1 36
C B1
22 bar
44 200 bar
18
15 46
25 29 48 D
3,5 bar
250 microns
87/73 P LS
14
15>200 45 cc/tr 19
17 bar
E 30
6 bar 49 60 R
52 58 LS
4 2,4 bar
5 bar 59
15>200
à F
2,4 bar 3,5 bar 28
12 H
G
13
J 56 55 54 57 3
I 87/70
2,8 bar 38 43
60 cc/tr 7
39
Ø 4,4 Ø 4,4 150
37 microns
2 1 Fig. 10
Issue
Issue 2
1 May 2002
December 2000

Full Powershift gearbox (Fig. 11) (59) Load Sensing connector (provision for)
Parts list (60) Return connector (provision for)
(1) Oil tank (gearbox and centre housing) (61) High pressure connector (provision for)
(2) Brake master cylinders (62) Priority blocks with trailer braking
(3) Servo brake (63) Trailer brake valve
(4) Gerabox proportional (64) Trailer brake coupler
to solenoid valves (65) High pressure valve spool
(12) of gearbox
(13) Main filter (15u)
(14) Suction strainer
(15) Pump Note : For Full Powershift hydraulics, see section
(16) Variable displacement pump controller 5I01.
(18) Solenoid valves: PTO brake,
to differential lock (front, rear) Legend
(21) and 4WD A : Differential lock
(22) Steering priority spool valve B : (17 bar) low pressure switch
(23) 17 bar pressure spool valve C : 4WD
(24) High pressure diagnostic connector D : rear PTO
(25) 5 bar safety valve E : rear PTO brake
(26) 22 bar safety valve F : 4WD clutch
(27) Priority block without trailer braking G : Pump bearing lubrication
(28) Right-hand cover H : Rear PTO lubrication
(29) Booster pump pressure diagnostic connector I : Trumpets lubrication
(30) Low pressure diagnostics connector J : Creeper unit and handbrake mechanism lubrication
(32) Lift rams
(37) Suction strainer (150u)
(38) Booster pump
(43) Left-hand cover Fig 11
(44) 3-way filter
(47) Hydrostatic steering spool valve (17 bar)
(51) Steering rams
(52) Oil cooler
(56) Dual control or front PTO hydraulic line (17 bar)
(58) Braking assistance accumulator
Issue 1 May 2000

December 2002
Diagram showing Full Powershift gearbox
8200 SERIES TRACTORS - Load sensing 110 l/min and ZF front axle

27
Yft 41 32
T
T0
150 63 23 17
bar bar
Xdlr
Pdlr Pbf Pbn

Parts list
61
62 22 65
Xbf Xbf P
Paux
26
Xaux P LS T
64 31 24
22 bar
A2
Pfr Pl B2
155 bar 17
51 A
B
16 24
20
230 bar XLS
47 21 A1 36
C B1
22 bar
44 200 bar
18
15 46
25 29 48 D
3,5 bar
250 microns
87/73 P LS
14
15>200 45 cc/tr 19
17 bar
E 30
6 bar 49 60 R
52 58 LS
4 2,4 bar
5 bar 59
15>200
à F
2,4 bar 3,5 bar 28
12 H
G
13
J 56 55 54 57 3
I 87/70
2,8 bar 38 43
60 cc/tr
39
Ø 4,4 Ø 4,4 150
37 microns
2 1 Fig. 11

May 2002

Heavy Duty gearbox (Fig. 6 - 7 - 7A) with mechanical with Power
Parts list with mechanical with Power reverse shuttle shuttle
reverse shuttle shuttle (Fig. 12) (Fig. 13)
(Fig. 12) (Fig. 13) (50) Braking assistance non-return valve • •
(1) Oil tank (gearbox and centre housing) • • (51) Braking assistance accumulator • •
(2) Brake master cylinders • • (52) Load Sensing connector for front axle • -
(3) Servo brake • • with suspension system - •
(4) Engine clutch • - (53) Return connector (provision for) • -
(4) Power shuttle - • (54) High pressure connector for front axle • -
(5) Control valve (clutch and Dynashift) • - with suspension system - •
(5) Control unit with Power shuttle - • (58) 13 bar valve - •
(6) Clutch diagnostics connector • - (59) 17 bar diagnostics connector on control unit - •
(6) Power shuttle front clutch diagnostics connector - •
(6A) Power shuttle rear clutch diagnostics connector • •
(7) Dynashift diagnostics connector • •
(8) Accumulator for low pressure components • • Legend (Fig. 12 – 13)
(9) Hare / Tortoise solenoid valve • •
(10) Oil cooler • • A : Differential lock
(11) Load Sensing diagnostic connector • • B : (17 bar) low pressure switch
(12) Variable displacement pump controller • • C : 4WD
(13) Main filter (15 u) D : Rear PTO
(14) Solenoid valves: PTO brake, • • E : Rear PTO brake
to differential lock (front, F : 4WD clutch
(17) rear) and 4WD • • G : Pump bearing lubrication
(18) Steering priority spool valve • • H : Rear PTO lubrication
(19) 17 bar pressure spool valve • • I : Trumpets lubrication
(20) High pressure diagnostic connector • • K : Line to brake master cylinder booster circuit
(21) Booster / lubrication diagnostics connector • • L : Lubrication to gearbox
(22) Low pressure diagnostics connector • • M: Low pressure accumulator
(23) Priority block without trailer braking • • N : Engine clutch line
(24) Right-hand cover • • O : Line to Dynashift rear piston (clutch C)
(25) 5 bar safety valve • • Q : Line to Dynashift front piston (clutch A)
(26) 22 bar safety valve • • S : Hare/Tortoise mechanism
(27) Pressure limiter • • U : High pressure line to suspension front axle with suspension system
(28) Lift rams • • V : Load Sensing line from suspension front axle with suspension system
(32) Auxilliary spool valve • • W: Baking assistance accumulator
(32A)Electro-hydraulic auxiliary spool valves • • X : Line to front PTO
(33) Lift control valve • • Y : Line to Power shuttle rear clutch
(35) Centre housing lubricating manifold • • Z : Line to Power shuttle front clutch
(37) Suction strainer (150 u) • •
(38) Booster pump • •
(39) Left-hand cover • •
(44) Hydrostatic steering spool valve (Orbitrol) • •
(45) Clutch master cylinder • •
(47) Steering ram • •
(48) Variable displacement pump • Fig 12 •
(49) Dual control or front PTO (if fitted) hydraulic line (17 bar) • •
(50) Braking assistance non-return valve • •
(51) Braking assistance accumulator • Fig 13 •
(52) Load Sensing connector (provision for) • •
(53) Return connector (provision for) • •
(54) High pressure connector (provision for) • •
• •
• •
• •

Diagram showing Heavy Duty gearbox with mechanical reverse shuttle
8200 SERIES TRACTORS - 110l/min Load Sensing, mounted in series

23
33 28
T
T0
19 17
bar
Pbn
Fig 13
Parts list
P LS T
54
18 A2
Xbf P B2
Paux
26
Xaux
27 20
22 bar A1 32
Pl B1
11 A
B
150 bar 12 24
16
47 230 bar XLS
17
P LS
22 bar C
200 bar R
14 S LS
22
44 25 21 48 D
9 52 53
K 87/73
K 45 cc/tr 15
50 51
L E
45
8
5 bar
M 3
2 F 3,4 bar
24 49
13 N 4
G H
15>200 2,4 bar 3,4 bar 10
O
6
11 2,8 bar
35 38 87/70 39 7
I 60 cc/tr Q
Ø 4,4 Ø 4,4 150
37
microns
5 1 Fig. 12
Issue 1 May 2000

December 2002
Issue
Issue11 May 2002
December 2000
Diagram with Heavy Duty gearbox and Power shuttle
8200 SERIES TRACTORS - 110 l/min Load Sensing
23
Yft
T
T0
19
17 bar
62 32A
150 bar
Xdir
32
Pdir
28
54
18 U
Paux
26
Xaux
27 20 12 22 bar
P1
Pfr
60 microns
A 16
33
B
50 bar 11
47 230 bar XLS 17
9
C 52
22 bar V
14
200 bar 22 S 50
25 21 48 D
44
76/65
45cc/tr 15 51
K E Fig 12
8 59
5 bar W
2 L Parts list
3
F 3,4 bar 58 X
49
13 13b
G H 24 Y
15>200 2,4 bar 3,4 bar 4
4 Z
35
2,8 bar 38 10
76/61
50cc/tr
6A 6
I 39 O
37 150 nicrons 7
5
Q
1
7 Fig. 13

May 2002
9A02 Description of the 150 l/min circuit
CONTENTS
A. General ________________________________________________ 2
B. Principle _______________________________________________ 3
C. Centre housing lubricating circuit ________________________ 4
D. Layout of components in AG 150 and AG 250 Full Powershift

gearboxes ______________________________________________ 5
E. Diagram ________________________________________________ 10
Issue 1 May 2001

A . General
All tractors in the 8200 series are fitted with a closed
centre hydraulic circuit with controlled pressure and
flowrate.
Only tractors with a Full Powershift gearbox can be fitted,

depending on options, with a 150 l/min flowrate circuit.
48
It is composed of two separate high and low pressure
circuits, supplied by a variable displacement pump (48)
located on the external face of the right-hand side cover
(Fig. 1). This pump has a maximum output of 60 cm3 per
revolution and is itself fed by a 80 cm3 booster pump.
Both pumps are driven by a pinion fitted on the upper

shaft of the PTO located in the intermediate housing. A Fig. 1
“relay” pinion mounted on a bearing located on the
internal side of the cover, ensures the rotation of the
driven pinion of the variable displacement pump. The first block supplies:
- its first priority, steering system
The booster pump fitted on the left-hand cover sucks oil - its second priority, the 17 bar rear axle hydraulic circuit,
through a suction strainer to feed the common tank the auxiliary spool valves and the lift control valve.
formed by the centre housing, intermediate housing and If a second block is fitted, it shares the first priority
gearbox. The booster flowrate is then directed towards between the steering circuit and the trailer braking.
the right-hand cover and passes through the main filter
before flowing towards the variable displacement pump
and the oil manifold of the centre housing to supply the
following components:
- the trumpet housings
- the PTO clutch
- the hydraulic pump bearing
- the 4WD unit
- the handbrake mechanism
- the creeper unit (if fitted).
The variable displacement pump supplies one or two

priority blocks, depending on options, that are fitted on
the right-hand side cover:
- one block for tractors without hydraulic trailer braking
- two blocks for tractors with hydraulic trailer braking.
Issue 1 May 2001

Once the first priorities have been met, the remaining oil
flow becomes available to the auxiliary spool valves and B . Principle
the lift control valve. The purpose of the closed centre hydraulic system is to
limit the power absorbed by the engine. If no hydraulic
All the pilot signals from the various high pressure valves slave device is actuated, no flow is discharged by the
are directed to the priority block(s) to then be retransmitted variable displacement pump.
to the variable displacement pump controller.
The controller takes into account the pilot signal corres- When a function is activated, the pump only supplies the
ponding to the function requiring the highest pressure. output required for that function.
Note: If the housing is drained, or if the main filter is
replaced or any servicing operation carried results in
Component characteristics the air intake into the system, it is essential to prime
Suction strainer (37) the hydraulic circuit. Disconnect the connector to
- Type: cartridge the fuel injection pump. Activate the engine starter
- Filtration threshold: 150 µ motor in consecutive bursts until the (red) booster
pressure signal lamp on the dashboard goes out.
Booster pump (38)
- Trademark Rexroth Sigma
- Capacity: 80 cm3 per revolution
- Output: 215 l/min at 2200 rpm
Main filter (13)

- Filtration threshold: 15 u
- With differential pressure bypass: 3.5 bar
- With differential pressure switch: 2.4 bar
Safety valve (26)

- Calibration: 22 bar
- fitted on the low pressure circuit
Safety valve (25)

- Calibration: 5 bar
- No slave device used resupplies booster pump
- Switch: 5 bar (clogging indicator placed on main filter)
- Opens: 3 bar
- Closes: 2 bar
Fitted in parallel to filter
Linked to signal lamp on dashboard
Variable displacement pump (48)

- Trademark: Brueninghaus
- Type Axial pistons
- Variable capacity 0 to 60 cm3 per revolution
- Output: 0 to 150 l/min at 2200 rpm
- Min. pressure: 22 bar
- Max. pressure: 200 bar
- Internal lubrication with return to housing
Issue 1 May 2001

C . Centre housing lubricating circuit

Fig. 2
A B
C
E D
G
A: Trumpet housing lubrication

B: Centre housing lubricating manifold
C: Pump bearing lubrication
D: General supply from booster circuit
E: PTO clutch lubrication
F : Handbrake mechanism lubrication and creeper unit
(if fitted)
G : Transfer pipe for trumpets with double drive unit
Issue 1 May 2001

D . Layout of components in AG 150

and AG 250 Full Powershift gear-
boxes
(1) Tank
(2) Brake master cylinders
(3) Servo brake
(4)
to Proportional solenoid valves of gearbox
(12)
(14) Suction strainer (250 µ) 27
(15) Pump
(16) Variable displacement pump controller
(17) Load Sensing diagnostic connector Fig. 3
(18) Solenoid valves: PTO brake, differential lock
to (front, rear) Version without trailer braking
(21) and 4WD
(22) Steering priority spool valve (54) Park Lock control
(23) 17 bar pressure spool valve (55) Park Lock solenoid valve
(24) High pressure diagnostic connector (58) Braking assistance accumulator
(25) 5 bar safety valve (62) Priority blocks with trailer braking
(26) 22 bar safety valve (63) Trailer brake valve
(27) Priority block without trailer braking (64) Trailer brake coupler
(28) Right-hand cover (65) High pressure spool valve
(31) Discharge pressure limiter Remark
(32) Lift rams - For Full Powershift gearbox hydraulics, see section
(33) Couplers 5I01.
(34) PTO brake
(35) PTO clutch
(38) Booster pump
(39) Centre housing lubricating manifold High pressure
(40) 4WD clutch
(41) Lift control valve Low pressure
(42) Rear differential lock
(43) Left-hand.t cover Lubrification
(44) 3-way filter (15 µ)
(45) Temperature probe Suction
(47) Hydrostatic steering spool valve (Orbitrol) Return
(49) Thermostatic valve Brakes
(50) Front differential lock
(51) Steering rams Pilot flow
(52) Oil cooler
(53) Pump drive pinion bearing
Fig. 4 Fig. 5
Issue 1 May 2001

Full Powershift gearbox - Dana front axle with trailer braking
52
51 1
50 2
49 3
4 12
47 58
46 15
45 62 63
44 22 23 65
53 54 55
43 24 25 26
38 27
37 28 31
40 18 21
39 14
42 30
32 13 48
41 16 17
36 33 35 34 33 64 32 29
Issue 1 May 2001

Full Powershift gearbox - ZF front axle with trailer braking
52 51
51 1
49 3
4 12
47 58
46 15
45 62 63
44 22 23 65
53 54 55
43 24 25 26
38 27
37 28 31
40 18 21
39 14
42 30
32 13 48
41 16 17
36 33 35 34 33 64 32 29
Issue 1 May 2001

Right-hand side
14
A A
(A) Port and suction pipe of the Gerotor pump

(B) Return port (Orbitrol and braking assistance)
(C) Intermediate housing
(D) Gearbox
Fig. 6
Issue 1 May 2001

Left-hand side
4 12 45 E
15
52
44
46
49
(E) Engine speed sensor

F (F) Tank and brake master cylinders
Fig. 7
Issue 1 May 2001


E . Diagram (58) Braking assistance accumulator
(59) Load Sensing connector (provision for)
Parts list (60) Return connector (provision for)
(1) Tank (61) High pressure connector (provision for)
(2) Brake master cylinders (62) Priority blocks with trailer braking
(3) Servo brake (63) Trailer brake valve
(4) (64) Trailer brake coupler
to Gearbox proportional solenoid valves (65) High pressure spool valve
(12) (66) Intermediate pinion lubrication
(15) Pump
(16) Variable displacement pump controller Fig. 8
(18) Solenoid valves: PTO, PTO brake, differential lock
to (front, rear)
(21) and 4WD
(22) Steering priority spool valve
(24) High pressure diagnostic connector
(27) Priority block without trailer braking
(28) Right-hand cover
(32) Lift rams
(38) Booster pump
(43) Left cover
(44) 3-way filter (15 µ)
(51) Steering ram(s)
(52) Oil cooler
(56) Dual Control or front PTO (if fitted)17 bar hydraulic
line
Issue 1 May 2001

8200 SERIES TRACTORS Diagram of Full Powershift gearbox
- 150 l/min Load Sensing optional
- A: Dana front axle version
Hydraulics - Description of the 150l/min circuit 9A02.11 - B: ZF front axle version
62 27
Yft 41 32
T
T0
150 63 23 17
bar bar
Xdir Xdir
Pdir Pdir Pbf Pbn
61
22 65
Xbf Xbf P
Paux
26
47 Xaux P LS T
64 31 24
22 bar
B A2
Pfr Pl B2
155 bar 17
51 Diff.lock
Manocontact
16 24
20 BP
230 bar XLS
A
21 A1 36
4 RM B1
22 bar
44 200 bar
18
15 46
25 29 48 66 PDF
3,5 bar
250 microns
87/77 P LS
14
15>200 60 cc/tr 19
17 bar 30
6 bar 49 Frein PDF
60 R
52 58 LS
4 2,4 bar
5 bar 59
4 WD
clutch
15>200
2,4 bar 3,5 bar 28

12 Pump PTO lub.
bearing lub.
13
56 55 54 57 3
Trumpets lub.
2,8 bar 38 87/70 43
80 cc/tr 7
39
Ø 4,4 Ø 4,4 150
37 microns
2 1 Fig. 8
Parts list
Issue 1 May 2001

Hydraulics - Priority blocks 9B01.1
9 B01 Priority blocks with trailer braking
CONTENTS
- General ________________________________________________ 2
A. Identification of ports ___________________________________ 5
B. Operation of spool valves ________________________________ 6
Issue 1 May 2001

9B01.2 Hydraulics - Priority blocks
General
Depending on options, the 8200 Load Sensing series 1
tractors fitted with the 110 l/min or 160 l/min variable
displacement pump, may be fitted with a trailer brake
mechanism.
The hydraulic unit attached on the right-hand side cover
has two priority blocks mounted in series.
The internal block (1) (Fig. 1) ensures priority for the 17 bar
circuit and manifold that supplies the auxiliary spool
valves and lift control valve (see respective sections
9D01 and 9E01).
The external block (4) (Fig. 1) shares priority between the
steering function and trailer braking.
To facilitate access to the trailer-braking device, either 4
remove the rear wheel or place it in its wide track position
(see section 2G01). Fig. 1
Tightening torques
- Bolts V: 25 - 35 Nm. Loctite 542 (Fig. 2 - 3)
- Wheel studs or nuts: see section 2G01
Special points
- Check the oil tightness of the unions and O’rings on
priority blocks fitted against the hydraulic cover.
- If the priority blocks have been replaced, carry out
hydraulic tests (see section 9N01) and check the
operation of the controls.
- Carry out a road test.
Issue 1 May 2001

Load sensing 110 l/min
A D C
G I F K
Fig. 2
Issue 1 May 2001

Load sensing 150 l/min
I G F E
C D
Fig. 3
Issue 1 May 2001

I : 17 bar output
A . Identification of ports (Figs. 2 to J : Plugs
4) K : Pilot flow from brake master cylinders
Note: Drilled port B on cover (2) (see section 9C01,
P.dir (St.pr) : Tiroir priorité direction
Fig. 2) allows the priority blocks to be supplied in
BP (LP) : low pressure spool valve
series.
HP : high pressure spool valve
A :
Supply to steering spool valve (Orbitrol)
C :
Load Sensing (LS) pilot flow to pump controller
D :
Load Sensing (LS) pilot flow from the Orbitrol
E :
To trailer brake connection
F :
Pressure to lift control valve and auxiliary spool
valves
G : LS pilot flow from lift control valve and auxiliary
spool valves
Load Sensing 110 l/min Load Sensing 150 l/min
Bottom view Bottom view
1 2
K
K
F J
4
D
G C
E
I J A
Front view Front view
K
P.dir HP BP
BP HP P.dir
K
2
I
A J E
G
D C F 4
K J 1 K
Top view Top view

Fig. 4
Issue 1 May 2001


Parts list (Fig. 5)
B . Operation of spool valves (4) Priority block
Steering priority spool valve
The control slide moves to the left under the action of
(21) Manifold
spring (5). The flow coming from channel B is by priority
(31) LS signal
directed to the Orbitrol spool valve via channel A. When
the steering in a central position, there is no flow through
this channel. The increasing pressure forces the spool to
P : High pressure
move to the right and compress spring (5) thus allowing
R : Return below oil level
the flow to pass into channel J.
LS : Signal to pump controller via the priority blocks
During operation, a pilot pressure from the Orbitrol arrives
through channel D and pushes the spool valve to the left
thus allowing the flowrate required by the steering to Fig. 5
enter into channel A.
The remaining flow is directed into channel J.
Trailer brake spool valve (6) (Fig. 5)

When the trailer brake is not actuated, the pressure in
channel K is zero and the spool valve allows communi-
cation between the L and R channels.
As soon as the tractor brake is activated, the pressure
existing in channel K moves piston (7), this pushes the
spool valve to the left allowing oil to flow between the J
and L channels.
The increasing pressure in channel L acts on the end of
spool valve (6) and compresses spring (8) to reestablish
the balance, allowing pressure in channel L to be main-
tained in relation to the pressure existing in channel K.
The maintenance of this pressure is obtained by placing
in communication channel L with either channel J or R
port .
Note: As with the ‘no trailer braking’ priority block
(see section 9C01), a flowrate of 0.5 l/min flows
through channel A towards channel D (dynamic
steering) via a drilled hole and a pressure relief valve
mounted in the spool valve (2).
Issue 1 May 2001

B 2 D K
4
A
150 bar 17 bar
5
D
F
J
R
B C
K 17
20
1A
1B
31
L 6 8 7 21
P LS LS
R P R
P
Fig. 5
Parts list
Issue 1 May 2001

Hydraulics - Priority blocks 9C01.1
9 C01 Priority blocks without trailer braking
CONTENTS
- General ________________________________________________ 2
A. Identification of ports ___________________________________ 3
B. Operation ______________________________________________ 6
Issue 1 May 2001

9C01.2 Hydraulics - Priority blocks
General
The priority block (1) (Fig. 1) comprises two spool valves 1
(Fig. 5) and is fitted on the right-hand side hydraulic cover
(2) (Fig. 2). It receives the oil flow coming from the
variable displacement pump. It ensures priority for the
steering circuit and the low-pressure circuit (17 bar). The
oil is then directed to the manifold for use by the auxiliary
spool valves and lift control valve (see respective sec-
tions 9D01 and 9E01).
To facilitate access to the priority block, remove the rear
wheel or place it in its wide track position (see section
2G01).
Tightening torques
- Bolts V: 25 - 35 Nm. Loctite 542 (Figs. 2 to 4).
- Wheel nuts or studs: see section 2G01. Fig. 1
Special points
- Check the oil tightness of all unions and O’rings fitted
between the priority block and the hydraulic cover.
- If the priority block has been replaced, carry out hydrau-
lic tests (see section 9N01) and check the operation of
the controls.
Issue 1 May 2001

A . Identification of ports (Fig. 2 to 4)

A : Supply to steering (Orbitrol)
B : HP supply from variable displacement pump (drilled
port on mating face of priority block and hydraulic
cover) (Fig. 2)
C : Load Sensing (LS) pilot to pump controller
D : Load Sensing (LS) pilot from the Orbitrol
F : Pressure to lift control valve and auxiliary spool
valves
G : LS pilot flow from lift control valve and auxiliary
spool valves
H : Internal channel (Fig. 5) Fig. 2
I : 17 bar output
J : Plug
Fig. 3
HP : high pressure spool valve
LP : low pressure spool valve
Fig. 4
Load Sensing 110 l/min Load Sensing 150 l/min
I G F D C A
1
2 B
Bottom view Bottom view
V V J V
J
HP BP
V HP
BP
V
Front view Front view V
B
2
1
A C D F G I
Top view Fig. 2
Top view

Issue 21 May 2002
2001
Load Sensing 110 l/min
A D C
HP
V
BP
G I F

Fig. 3
Issue 1 May 2001

Load Sensing 150 l/min
I G F
2
Issue 1 2002
May 2001

Parts list
B . Operation (Fig. 5) (1) Priority block
1 priority: Steering
st (17) Lift control valve
The spool valve (2) moves to the left under the action of (20) Auxiliary spool valves
spring (3). (21) Manifold
The oil flow coming from the variable displacement (31) LS signal
pump via channel B (Fig. 2) is by priority directed towards
the Orbitrol spool valve via channel A. P : High pressure
- Steering in neutral position: The steering spool valve R : Return below oil level
(Orbitrol) is closed. The pump pressure moves spool LS : Signal to pump controller via the priority block
valve (2) to the right and the oil flow is directed into
channel H.
- Steering wheel turned: A pilot pressure from the
Orbitrol arrives at port D and pushes the spool valve (2)
to the left, allowing the oil flow to enter into port A and
supply the Orbitrol.
Note: An oil flow of approximately 0.5 l/min flows
through port A towards port D via a drilled hole and
restrictor in spool valve (2). This flowrate causes a
pressure of approximately 6 bars at port D. The line
LS directs this pressure to the pump controller
which is adjusted to 22 bar in order to obtain a
standby pressure of 28 bar.
2nd priority: 17 bar pressure holding valve

The spool valve (4) moves to the left under the action of
spring (5), allowing the oil flow from channel H to be
directed into port I (17 bar low pressure). As soon as the
pressure in this port reaches 17 bar, the spool valve
reaches equilibrium thus allowing the low pressure to be
maintained and the oil flow to be directed towards port F
(lift control and auxiliary spool valves).
When the lift control and auxiliary spool valves are used,
a pilot pressure LS is sent to the block via port G to join
the LS line at port C.
Issue 1 May 2001

2 3 1
A C D
HP
F
D
H BP G
B C
20 17
1A
1B
21 31
LS LS
P
R P R
P
I G F P
4 5
Fig. 5
Issue 1 May 2001

Hydraulics - Auxiliary spool valves 9D01.1
9 D01 Auxiliary spool valves
CONTENTS
- General ________________________________________________ 2
- Operation ______________________________________________ 4
A. Different types of spool valves ___________________________ 7
B. Diagram ________________________________________________ 10
C. Removing and refitting the spool valves __________________ 11
Issue 1 May 2001

9D01.2 Hydraulics - Auxiliary spool valves

Basic assemblies proposed
General - 3 spool valves: e – c – c
The Rexroth MP18 type auxiliary spool valves are fitted - 3 spool valves: a – d – c
on the high flowrate, high-pressure circuit. They are - 3 spool valves: c – c – c
supplied by oil coming from the priority block(s) (depend- - 3 spool valves: b – a – d
ing on options). - 4 spool valves: a – d – c – c
- 4 spool valves: e – c – c – c
If no function is activated, the entire flowrate is sent to - 4 spool valves: c – c – c – c
the spool valves. If certain priorities are being supplied, - 4 spool valves: b – a – d – c
the remaining flowrate is then available to the auxiliary - 4 spool valves: b - e – c – c
spool valves.
Each spool valve is provided with a flowrate regulation

system that is controlled by a knob (1) mounted on a
support fixed to the right wing (Fig. 1). Each coupler is
identified by a coloured plug (black, red, green and yellow
for 4th spool valve) which corresponds to the colour of the
knobs (1).
The main spool of the valve is operated by a cable linked

to a lever located in the cab, except in the case of a spool
valve with Dual Control where the cable is replaced by an
electrical control (this type of spool valve is not dealt with
in this section). The spool directs the oil towards one or
other of the outlet ports. Each outlet port is linked to the
XLS control line of the variable displacement pump
regulator, via the priority block(s).
The tractors are fitted with a basic block comprising three

or four spool valves (depending on options).
Different types of spool valves

- a : 3-position, flowrate regulator, spring return, zero
leak
- b : 3-position, flowrate regulator, spring return, electri-
cal control (Dual Control is not dealt with in this
section)
- c : 4-position, flowrate regulator, automatic return to
neutral, floating position, zero leak 1
- d : 4-position, flowrate regulator, automatic return to
neutral, floating position, no zero leak.
- e : 4-position, flowrate regulator, automatic return to
neutral, floating position, overpressure and supply
valves for hydraulic motors.
Fig. 1
Issue 1 May 2001

Couplers (Fig. 1A)

When the auxiliary spool valve is at rest, a lever system
(1) allows existing pressure to be relieved into the hose
hydraulic pipe (2) linking the spool valve to the coupler
block concerned (3).
By acting on this system, the clean oil under pressure is
directed to the return via a hose and pipe assembly (4)
connected to the upper part of the intermediate housing.
This drop in pressure facilitates the connecting of the
male coupler to the female coupler.
The contaminated oil, coming from the separation of the
couplers, flows through a port placed above a tank (5)
located beneath the coupler blocks, in a flexible and
transparent manner.
5
3
5 4
F
2 1
Fig. 1A
Issue 1 May 2001

Operation (Fig. 5 to 7)
Adjusting the compensated pressure flow
This system comprises:
- the flow control tube (6)
- the compensating spool (7)
- the rod (5)
- the compensator spring (10)
The role of this system is to provide a constant pressure

drop of 4.5 bar (65 psi) in the flow control tube and outlet
port and to limit the flowrate of 9.5 to 114 l/min.
The pressure supplied by the variable displacement

pump arrives via chamber D and enters inside the tube.
This pressure then passes to the right-hand side end of
the spool via a central drilled hole. The pressure in the
inlet chamber E becomes greater by 4.5 bar than the XLS
pilot pressure acting upon the spring. The compensating
spool moves to the left and closes the inlet, thus dropping
the pressure in chamber E and causing movement of the
spool to the right.
This regulation of the compensating spool ensures a

constant drop in pressure in the control tube and the work
port. This pressure drop allows the flowrate to remain
constant whatever the load.
Slot F in the control tube limits the maximum flowrate.

This slot opens or closes the oil flow to the body of the
spool valve when rod (5) is turned. When the tube is in
the minimum position, a slightly open space is formed
and a greater percentage of 4.5 bar pressure acts on the
flowrate control tube. The remainder of the pressure drop
acts upon the main spool. The result of this is to create
a flowrate of 9.5 l/min at the work port. When rod (5) is
turned in the other direction, the opening increases,
generating a lower pressure in the flow control tube and
a greater pressure at the main spool, permitting an
increase in the flowrate in the work port.
Issue 1 May 2001

Position B Return to neutral by spring (Fig. 5)

The main spool (2) is pulled 9.50 mm (0.375 inch) and When the main spool (2) is either pushed or pulled, the
held in position by a trigger mechanism (automatic return pressure-relief housing spring (22) is compressed. As
to neutral version only, Fig. 6 – 7)). It places in commu- soon as the spool is released, it positions itself in the
nication port A and control chamber G with the tank. The neutral position under the action of the spring.
main spool closes chamber G and links pressure port B
to shuttle valve (11) in communication with the spring Valve (23) operating principle (zero leak)
side of the compensating spool. The shuttle valve is also The main spool pulled in the direction of the arrow (Figs.
linked to a second shuttle valve (13) and to the pressure- 5 and 7 – position B) allows the pressure passing through
relief housing (22). The shuttle valve (13) closes to send the spool to open the valve, thus providing for the required
the XLS pilot pressure to the pump regulator. The main feed flow for outlet B.
spool places pressure chamber H and outlet port B in The operation of the valve is identical on all spool valves
communication. fitted with this system.
See below for spool valves fitted with zero leak devices:
Operation principle of valve (23).
Position A
The main spool is pushed 9.50 mm (0.375 inch) and held
in position by the trigger mechanism (automatic return to
neutral version only (Fig. 6 – 7)). It places port B and
control chamber J in communication with the tank. The
main spool closes chamber J and places port A in
communication with the primary shuttle valve linked to
the spring side of the compensating spool. The primary
shuttle valve is also linked to a secondary shuttle valve
(13) and to the pressure-relief housing (22). The second-
ary valve (13) closes to transmit the XLS pilot pressure
to the pump regulator. The main spool permits the flow
to pass from chamber H to outlet port A.
Automatic return to neutral (Figs. 6 – 7)

The pilot pressure acts on valve (25) in the pressure-relief
housing. When the pressure is sufficient, the valve
raises and the pressure moves the piston (26) which
relieves the relief spring and allows the centring spring to
return the spool to the neutral position. When the spool
is in the neutral position, the piston relief pressure flows
to the tank via port K of the pressure relief housing. The
spring then returns the piston to its original position. The
return pressure can be adjusted using screw (27).
The more the spring is compressed, the greater the return
pressure.
Issue 1 May 2001


Description (Fig. 2)
(2) Main spool
(3) Compensating valve
(20) Spool valve 22 2
(22) Return to neutral device housing (automatic or by
spring)
Designation of ports (Fig. 3)

On manifold (21) and spool valve (20)
(15) Return to housing
(30) HP feed from variable displacement pump via the
priority block(s)
(31) LS signal 20 3
A and B outlets to couplers
Fig. 2
Ports foreseen on manifold (21) (Fig. 4)
(1) Return
(30) Pressure
15 1 21 30 1 15
Special points
- Check for the presence of plugs on manifold (21). If 31
necessary, lightly smear them with Loctite 542 before
fitting. 1
- The oil tightness of the auxiliary spool valve return pipe
and the lift control manifold is provided by two O’rings
placed at each end of the collar held in place by manifold
(21). The tube is positioned by a stud lodged in a cavity
in the centre housing.
30
1 1
RL C
31 30 1 15 1
30 1
1
20
21 1 15
B
Fig. 4 Fig. 3
Issue 1 May 2001

A . Different types of spool valves
3-position spool valve - Zero leak with return to neutral by spring
22 23 20 2
J H G
B
LS F D E
10 6 7 3 5
Fig. 6-7 Fig. 8

Fig. 5
Issue 1 May 2001

4-position spool valve - Automatic return to neutral (Kick-out)
26 J H G 20 2
B A
5
K
22 11 10 LS F D E 6 3 7
Fig. 6
4-position spool valve - Automatic return to neutral

(Kick-out) zero leak
27 25 23 B 13 20 2
22 J H G
26 K 10 LS F D E 6 3 7
Fig. 7
Fig. 5 Fig. 8
Issue 1 May 2001

4-position spool valve - Assembly for hydraulic motors
26 20 2
B A
22 10 6 7 3 5
27 25 11 13 Fig. 5
Fig. 6-7
Fig. 8
Issue 1 May 2001

B . Diagram
20
17
P LS
21
31
LS
P R
R
(1) Priority block(s)

(17) Lift control spool valve
(21) Manifold LS
(31) LS signal P
P High pressure
R Return beneath oil level
LS Signal to pump regulator via the priority block(s)
Fig. 9
Issue 1 May 2001

C . Removing and refitting the spool

valves
Important: 9 5
8
When removing the control cables from spool valves, 7
it is essential not to turn the main spool of the valve
6
by half a turn in order to avoid any communication
between the control and pressure channels.
The seals (1) are maintained in the spot faced ports 2
of manifold (21) by a "RL" wide washer and rings "C" 4
(depending on channels) (Fig. 3) in order to ensure 3
the oil tightness of the mating face, when the spool 1
valve is in operation. 21
2
Removal
1. On each spool valve, disconnect the control cables (2) 10 11
and the hose pipes fitted to the spool valve rods (5)
(Fig. 10).
2. Take off the LS hose pipe (9) (Fig. 10). Mark the 9 5
position of the hose pipes connected to the couplers
(Fig. 11).
3. Remove the auxiliary spool valves separately and
disconnect the hose pipes one by one as they are
removed.
4. Note the colour of the connectors and disconnect the
solenoid valves on the lift control spool valve.
Note: The brown connector is connected to the
MoveDown solenoid valve.
5. Take off or move to one side the lift control spool valve 21
from its mating face.
6. Take out bolts (10), remove the support (11) (Fig. 10),
the seals, the wide "RL" washer and rings "C" (Fig. 3). 11 2
10
Refitting
7. Clean the mating faces of the manifold (21) and the
support (11) (Fig. 10). M
A-A
8. Position new seals (1) with the wide "RL" washer and 6 4 8 7
+- 5
rings "C" on the relevant channels of the manifold (21)
(Fig. 3).
9. Refit support (11). Tighten bolts (10) to a torque of 25
- 35 Nm (Fig. 10). A
Before refitting the lift control spool valve, check for M
the presence of the O’rings and washer "R" and rings
"B" (see section 9E01). Tighten the bolts to a torque of
25 - 35 Nm.
A
2
Fig. 10
Issue 1 May 2001


10. Check for the presence of new O’rings (1) (Fig. 3) and
shims (2) (see assembly procedure). Refit the spool
valves. Reconnect:
- the hose pipes of the couplers, respecting their 3B 3A
correct locations
- the LS signal hose on the spool valve block.
11. Check that the flats provided for the fitting of the yoke 2B 2A
on the end of the main spool are parallel to the mating
face of the spool valve.
If this is not so, it is essential to position the flats "M"
1B 1A
of the spool according to Figure 10 and without tur-
ning them a half turn, in order to avoid any abnor-mal
operation of the spool valve.
12. Loosen nut (3) on control cable (2) (Fig. 10). Position
the cable and the yoke (1) on the spool. Fit pin (4) (Fig.
10). Hold the yoke and tighten the nut without turning
the spool. Check that the yoke pin is not constrained
in any way. Adjust the position of the levers in the
cab by acting upon the covers (8) (Fig. 10). After
adjustment, tighten bolts (6) and nut (7) (Fig. 10). 3A 3B 2B
13. Check the operation of the spool valve controls, in
three or four positions, as well as the lift control spool
valve. 2A
14. Check the oil tightness of the seals and hydraulic
unions.
1A
1B
Fig. 11
Issue 1 May 2001

Assembly procedure
To correctly fit the O’rings (1) (Fig. 3) and shims (2) (Fig.
12), the reassembly of each spool valve must be carried
out in a vertical position on the tractor or workbench, in
accordance with Fig. 12.
Important: Shims (2) allow the tightening load to be
distributed among the three studs and not the entire
contact surface of the spool valves. To avoid jam-
ming the spools, it is important to respect the fitting
of the shims and to tighten nuts (3) to a torque of 27
Nm (Fig. 12).
Special point
Tighten studs (1), smeared with Loctite 241, on support
(11) (Fig. 12).
3 2 1 2 2 3
20
11
11 11
Fig. 12
Issue 1 May 2001

9 D02 Bosch auxiliary spool valves
CONTENTS
- General ________________________________________________ 2
- Operation ______________________________________________ 4
A. Layout of components, designation of ports and parts _____ 4
B. Diagram ________________________________________________ 7
C. Removing and refitting the unit - Splitting the spool

valves __________________________________________________ 8
D. Assembly procedure ____________________________________ 13
E. Assembling and adjusting the control cables _____________ 14
Issue 1 May 2002

General
The Bosch SB23 LS proportional auxiliary spool valves
are fitted on the high pressure, high flowrate circuit. As
for the Rexroth auxiliary spool valves, they are fitted to
8200 series tractors. They are juxtaposed at the rear of
the tractor each side of the oil manifold and may form a
unit of two, three or four spool valves (depending on the
option).
The auxiliary spool valve unit also integrates the lift
control spool valve.
The auxiliary spool valves comprise spools and valves.
Certain parts cannot be repaired or replaced by spare
parts.
The spool valves are supplied by oil coming from the
priority block(s). When no other function is engaged, the
entire flowrate is directed to the spool valve. If certain
priorities are being supplied, the remaining flowrate is
then made available to the auxiliary spool valves.
Each spool valve has a flowrate regulation system
controlled by a black, red, green or yellow button (de-
pending on the option) fitted directly to the shaft of the
regulating valve.
The main spool is activated by a cable linked to a lever
located in the cab. The spool directs oil to one or other of
the outlet ports.
Each outlet port is connected to the LS pilot flow line of
the variable displacement pump regulator via the priority
block(s).
The different types of spool valves

- a : 3 positions, flowrate regulation, double acting, zero
leak.
- b : 4 positions, flowrate regulation, double acting, auto-
matic return to neutral (Kick-out) and floating posi-
tion.
- c : 4 positions, flowrate regulation, double acting, zero
leak, automatic return to neutral (Kick-out) and
floating position.
Issue 1 May 2002

Couplers (Fig. 1)
- When the auxiliary spool valve is at rest, a lever system
(1) allows the pressure to be relieved in the hydraulic
hoses (2). These hose pipes link the spool valves to the
couplings concerned (3). By acting on this system, the
clean oil under pressure is directed to the return via a
pipe and hose assembly (4) connected to the upper part
of the intermediate housing.
- This drop in pressure facilitates the connecting of the
male coupler to the female coupler.
- The oil, which may be polluted, coming from the
separation of the couplers, drains into a flexible trans-
parent plastic tank (5) that is located beneath the
coupling unit.
5
3
5 4
F
2 1
Fig. 1
Issue 1 May 2002

Operation (Fig. 2 - 3)
When the spool (1) is pulled, oil penetrates into channel E
P, passes through restrictor C and grooves D. It is then D
directed to channel E, pushes the ball (2) and enters into
chamber F. C
Simultaneously, the ramp on the spool lifts valve (3) and R
oil flows via port B.
The supply of port A is obtained by pushing spool (1). P
Flow regulation is ensured by rod (4) and control spool (5). A
LS
F
N N
B
A . Layout of components, designa-

tion of ports and parts
Layout of components (Fig. 3) N-N
(1) Main spool
(2) Valve
(3) One-way valve
(4) Flowrate regulation control rod
Fig. 2
(5) Flowrate regulation control spool
(6) Unit(s) and locking system.
Designation of ports (Fig. 2 - 4 - 5)

A : Outlet to coupler
B : Outlet to coupler
C : Restrictor
D : Grooves
E : Channels
F : Chamber
P : High pressure supply from variable displacement
pump via the priority block(s) (according to version) R
P2 : High pressure port - Not yet available 3
R : Auxiliary spool valves return 1
R2 : Return port - Not yet available
LS : Load Sensing signal to variable displacement pump
542
regulator via the priority block(s) (according to
version).
R Fig. 4
Issue 1 May 2002

3
1
A
5
N N
B
2
N-N
Fig. 3
Issue 1 May 2002


Designation of components (Fig. 5)
(6) Left-hand side end plate
(14) Right-hand side end plate
(21) Oil manifold
14
241
17
P
21 LS
1
6
R2 P2
241
R P
LS
R
A
1
B
Fig. 5
Issue 1 May 2002

B . Diagram
B A B A B A
F 1.2 F 1.2 F 1.2

2 2 2
0 0 0
1 1 1
20
P
LS
R
B A
F 1.2
2
21 17 0
1
P2
R P 20
P

LS
(20) Auxiliary spool valves P
(21) Manifold 1
P High pressure
P2 High pressure port - Not yet available
R Return below the oil level
LS Signal to the pump regulator via the priority block(s) Fig. 6
Issue 1 May 2002

C . Removing and refitting the unit -

Splitting the spool valves 14
Reminder
- On the mechanically-operated spool valves, discon-
nect the linkage cables while avoiding turning the main
spools a half-turn. This precaution avoids any possible 17
hydraulic leaks between the pilot flow and pressure
channels.
21
Remark (Fig. 7)
- The lift control spool valve (17) is integral with the
auxiliary spool valve unit. It is located between the oil
manifold (21) and the right-hand side end plate (14) or
4th spool valve (1) (if fitted).
1. On each auxiliary spool valve, disconnect the control
cables (2) (Fig. 8) taking the previous reminder into
account. 1
Remark
M = Flat (Fig. 8)
21
Fig. 7
7 2 2 M
A-A
7
8 8
± 5˚
6
3
A A M
4 3 1
4 1
6 Fig. 8
Issue 1 May 2002

2. Disconnect the high pressure pipes (30) and supply to

lift rams (16) as well as the LS hose pipe (9) (Fig. 9).
3. Mark and disconnect the Up (13) / Down (14) solenoid 30
valve harness on lift control spool valve (17) (Fig. 10).
Remark
- The brown connector is connected to the Move
Down solenoid valve.
4. Mark the position of the hose pipes linked to the
couplers and remove them (Fig. 12).
16 9
Fig. 9
14 17
3B 3A
2B 2A
1B 1A
13
Fig. 10
3A
2A
1A 3B
2B
1B
Fig. 12
Issue 1 May 2002


Removing the spool valve unit
5. Remove the bolts (3) and nuts (2) fitted respectively
to the base and upper part of the manifold (21)
(Fig. 11).
6. Lift and separate the spool valve from support (1)
(Fig. 11). Discard the O’ring (3) (Fig. 4).
3
Splitting the spool valve unit
- The spool valve parts are maintained on either side of
the oil manifold (21) by six studs, three of these have
different lengths.
7. Unscrew the nuts on each end plate of the spool valve 3
unit.
8. Remove the spool valves separately without losing 21
the inserted seals.
21
1
Fig. 11
Issue 1 May 2002

Assembling the spool valves unit

Remark
3 5 4
- If the previously mentioned studs are to be replaced,
lightly smear the end of the stud threads with Loctite
241 or equivalent before tightening them into manifold
(21) (Fig. 5). Wipe off any excess Locite after tightening.
9. Clean the mating surface:

- of the manifold (21) without removing the adhesive
shims (1) (inserts) (Fig. 14)
- of the spool valves (auxiliary - lift control)
10. Check for the presence of new seals:
- (3) to (5) in each spot-faced port of the spool valves
(1) (Fig. 13)
- (3) to (6) in each spot-faced port of the manifold (21)
(Fig. 14) 1
11. Assemble the spool valve unit on the workbench Fig. 13
according to the procedure described in § D.
Refitting the spool valve unit

3 5
Special points (Fig. 15)
- The oil return pipe (3) of the auxiliary spool valves and
of the lift control spool valve is positioned by means of 4
a tab in the centre housing and held by support (1).
- The oil tightness of this pipe is provided by fitting two
O’rings (2) either side of the collar. 6
21
4 1 6 21
1
1
2
3
3
Fig. 15 Fig. 14
Issue 1 May 2002


12. Before refitting, check the tightness of studs (2) on
support (1) and replace the O’ring (3) (Fig. 16).
Remark 3 2
- If the studs are to be replaced, lightly smear the short
threaded ends with Loctite 270 or equivalent before
tightening them into the support. Wipe away any
excess Loctite after tightening. 270
13. Refit the spool valve unit on the support. Tighten
bolts (3) to a torque of 50 - 70 Nm and nuts (2) to a
torque of 90 - 120 Nm (Fig. 11).
Final operations
14. Fit the hose pipes linking the spool valves to the 1
couplers.
15. Reconnect the high pressure pipes (30) and the
supply to the lift rams (16) as well as the LS hose Fig. 16
pipe (9) (Fig. 9).
16. Fit and adjust the control cables, see § E.
18. At each spool position, check the operation of:
- the hydraulic system (see section 9N01 - Hydraulic
tests)
- the electronic system (see section 11H01 - Tests).
19. Check the oil tightness of spool valves and hydraulic
unions.
Issue 1 May 2002

D . Assembly procedure
Remark
- To obtain a correct fitting of seals (3) (4) (5) (6)
(Figs. 13 - 14), the assembling of each spool valve (1)
on the manifold (21) must be carried out in a vertical
position on a clean workbench (Fig. 17).
1
Special points
- Adhesive shims, known as inserts, allow a spreading
of tightening forces around the three long studs but not
across the whole contact surface of the various parts.
- To avoid any warping that may lead to a jamming of the
spools, it is important to check for the presence of these
shims and to respect the tightening torque of the nuts: 21
30 - 33 Nm. Fig. 17
Assembly (Fig. 18)

20. After reassembling the spool valve unit, screw nuts
(3) so as to make contact with each end plate, but
without fully tightening them.
21. Place the spool valve unit vertical. Tighten a first
series of nuts to a torque of 30 - 33 Nm. Turn the unit 30/33 Nm
over and complete the assembly by tightening the
second series of nuts to the same torque.
22. Push and pull each spool, using a suitable lever, to
check that they can move freely. 3
Fig. 18
Issue 1 May 2002

E . Assembling and adjusting the

control cables (Fig. 19)
Special points
- The pins (2) are fitted with the threads lightly smeared
2
- The numbers 1 - 4 in the black circles indicate the 3
assembly order for the spool valve levers. 2
- A location is provided on the console for the future 1 1
mounting of a fourth control, which would be placed to
the left of lever 1 (as seen from driving position).
B
- The friction washers (1) should be lightly smeared with 1
molybdenum bisulphide grease before fitting.
- The nuts (3) should be tightened so as to provide a slight
resistance to the levers during operation.
A
4 7
On support (6) and lever (Fig. 19) 6
Note: Depending on the type of spool valve, clevis (4)
may be fitted on link rod A or B. 5
Assembly A: Normal spool valves.
Assembly B: Spool valves with floating position. 8 3
2
23. Pass the cable through the flange plate (9) located at
the rear right-hand side of the cab and then into
stirrup (8).
Note: The hole in stirrup (8) is offset (Fig. 20). To
assemble a spool valve control having floating 1
position, the hole must be turned upwards in
order to ensure a correct alignment of the cable
and its attachment.
24. Screw clevis (4) flush with the threaded cable end of
the cable sheath (7) and mount it on linkage A or B
of the lever concerned. Position clip (5).
Tighten the nut on the clevis while checking that the
cable is not constrained in any way.
4
9
Fig. 19
Issue 1 May 2002

On the spool valves (Fig. 21)

25. Without turning the main spools a half-turn, check
that they are in the neutral position.
26. Screw clevis (1) flush with the threaded end of the
cable sheath (2). Tighten nut (3) and fit pin (4).
27. Partially screw on the cover (8) and fit bolts (6) but
without tightening them.
28. Turn and adjust the cover in order to correctly centre
the control lever in the opening provided in the
console.
29. Fully tighten bolts (6) and tighten nut (7) to a torque
of 20 Nm.
30. Check the operation of the spool valve controls in all
three or four positions, depending on the type.
8 6
Fig. 20
7 2
4 3 1
Fig. 21
Issue 1 May 2002

Hydraulics - Closed centre 9D03.1

Auxiliary spool valves
9 D03 Electro-hydraulic spool valves
CONTENTS
- General ________________________________________________ 2
A. Layout of components and identification of channels

and ports _______________________________________________ 6
B. Diagram ________________________________________________ 9
C. Spool valve assembly ___________________________________ 10
D. Assembly procedure ____________________________________ 13
E. Location of levers on the console and fitting, adjustment

of a control cable _______________________________________ 14
Issue 1 May 2002

9D03.2 Hydraulics - Closed centre

The spool valves consist of both electronic and hydraulic
General components, the latter containing spools and valves.
Description of the components
Some elements cannot be repaired by replacing with
The SB23LS - EHS BOSCH type spool valves that control
spare parts.
the supply to the hydraulic couplers comprise two parts:
The tractors are fitted with a basic block, comprising
A hydraulic part: three to four spool valves (according to options).
- See operation below.
Types of spool valves available
An electro-hydraulic part comprising: . a : electro-hydraulic (Joystick)
- an ON / OFF solenoid valve and a 3-way pressure relief . b : electro-hydraulic (Dual control)
valve located on the left-hand end plate of the distribu- . c : mechanical control (for SB23LS, see section 9D02).
tion block, This spool valve has four positions with automatic
- a pilot valve fitted in the electro-hydraulic unit. return to neutral (Kick-out), is zero leak and provides
lowrate regulation.
This section only deals with the hydraulic part. For the
electronic part, see Chapter 11.
Available assemblies
- 3 spool valves : a + a + c
The SB23LS - EHS electro-hydraulically operated spool
- 3 spool valves : a + a + b
valves are fitted as optional equipment to 8200 series
- 4 spool valves : a + a + c + c
tractors with a closed centre hydraulic circuit. They are
- 4 spool valves : a + a + b + c
supplied with high pressure, high flow rate oil from the
priority blocks.
When no functions are being activated, the entire flowrate Parts list (Fig. 1)
is directed towards the spool valves. When certain (1) Electro-hydraulic auxiliary spool valves
functions are being supplied, the remaining flow then (6) Left-hand end plate with pressure relief valve
remains available to the auxiliary spool valves. (14) Right-hand end plate, LS outlet
The adjustment of the flowrate, expressed as a percen- (21) Oil manifold
tage, may be displayed on the onboard computer
(Datatronic) by the operator (see Operating mode, sec-
tion 11 - Electronics).
Joystick electro-hydraulic spool valves are fitted with a

floating Kick-out position (automatic return to neutral).
The main spool of the spool valve directs oil towards the
outlet ports A or B.
Each outlet port is linked to the LS pilot line of the variable

displacement pump regulating valve via the priority
block(s).
Issue 1 May 2002


Exploded view
M
A
P
LS
R 14
17
A : 3 spool valves
P
B : 4 spool valves
21
M LS
1
P2
R2
6
241
R
Parts list Fig. 1
Issue 1 May 2002


Hydraulic connections between spool Fig. 2
X Y M
valves and couplers (Fig. 2 to 4)
Remark
- Figures 1 to 4 indicate the assembly order of the
auxiliary spool valves.
Legend 3 2 1 VR 5
. M : black, mechanical spool valve
. X : red, Joystick
. Y : green, Joystick
. DC : black, Dual Control M
. VR : lift control spool valve
(5) Support Y
(6) Joystick lever Y
X
DC X Y 6
3 2 1 VR Y
DC
5 Fig. 3
X Y M M
3 2 1 VR 4 M
X M
5 5
Fig. 4
Issue 1 May 2002


Operation of the pressure relief valve
When the ON - OFF solenoid valve (18) located on end
plate (6) is open, the flow from the pump is directed to the
3-way relief valve (3) (Fig. 5). The latter supplies the pilot
valve (5) (Fig. 6) with a pressure of 21 bar to 24 bar via
a pressure balancing valve (Fig. 5). 18
The pilot valve receives a signal from the digital device
(6) and moves the main spool (1) (Fig. 6) in accordance
with information received from the Joystick.
The digital device is informed of the position of the main
spool by a displacement sensor (7) (Fig. 6).
The pilot valve and the digital device are housed in unit
X3
(2) fixed on the base of the spool valve. 3
DMV FP
Electro-hydraulic spool valve (2) (Fig. 6) 6

X3
Parts list
XNA
(1) Main valve spool
(2) Electro-hydraulic unit
(3) Return spring 18
(4) Piston
(5) Pilot valve
(6) Digital electronic system
(7) Displacement sensor
P : Pressure
R : Return
Remark
- Channels P and R are linked to the auxiliary spool
valve. Fig. 5
Operation of the auxiliary spool valve (Fig. FP : Filter

X3 plug Ø 12 x 1.50 : Location of diagnostics
10 - 12) connector.Presence of fuel tank limits access.
When spool (1) is moved electro-hydraulically upwards,
via the pilot valve (5) (Fig. 6), high-pressure oil penetrates
via channel P, passes through restrictor C and grooves D.
It is then directed to channel E, where it pushes ball (2) and
gains access to chamber F. Simultaneously, the ramp on 1 P R 2
the spool raises valve (3) and oil flows via port B.
Port A is supplied by moving spool (1) downwards.
3 5
7 6
Fig. 6
Issue 1 May 2002


A . Layout of components and iden- Fig. 7
tification of channels and ports P

Layout of components (Fig. 10)
(1) Main spool
(2) Valve
(5) Pressure balancing valve
(6) Cover
21 LS
Identification of channels and ports
On oil manifold (21) and the support (1) (Fig. 7 to 9)
P : High pressure supply from the variable displace-
ment pump via the priority block(s) (depending on
version)
R : Return from the auxiliary spool valves (beneath the
oil level)
LS : Signal to the pump regulating valve via the lift Fig. 8
P
control spool valve and the priority block(s) (depen-
ding on version)
21
P
LS
R
R
LS
R
1
3
R Fig. 9
Issue 1 May 2002


3
B
Fig. 10
Issue 1 May 2002


On the auxiliary spool valves (Fig. 11 to 13)
A : Outlet to coupler
B : Outlet to coupler
C : Restrictor
D : Grooves
E : Channel
F : Chamber
P - R and LS : see previous identification on oil manifold A
(21) A
A
B
B
B
Fig. 11
D E
A
LS
B
B A
B A
B A
Fig. 13 Fig. 12
Issue 1 May 2002


B . Diagram
B A B A B A
DMV FP
F F F 1.2
XNA
2 2 2
0 0 0
1 1 1
20
P
LS
R
B A
F 1.2
2
21 17 0
1
P2
R P 20
P
Nomenclature (Fig. 14)

(17) Lift control valve LS
P
(20) Auxiliary spool valves 1
P : High pressure
P2 : Hight pressure port (not yet available)
R : Return beneath the oil level
LS : Signal to the pump regulator via the priority
block(s)
Fig. 14
Issue 1 May 2002


C . Spool valve assembly Fig. 15
Reminder 2
- On tractors where one or more elements of the auxi-
liary spool valves are operated mechanically, take care
to disconnect the link cable(s) without turning the main
spool of the valve a half turn (see section 9D02).
Remark
- The lift control valve (17) is integral with the spool valve
assembly.
1. On the lift control valve (Fig. 16), locate and discon-

nect the solenoid valve harnesses:
- moveUp E1
- moveDown E2 (brown connector)
2. Disconnect:
- the following: high pressure pipe, lift rams feed pipe E2
and LS hose
on mechanically operated spool valves
- control cable (2) (Fig. 15) taking into account the
previous reminder. 18
on Joystick or lever (Dual Control) operated spool
valves (Fig. 16)
- solenoid valve (18) located on the left-hand end
plate (6)
- connector(s) "C" linked to the electro-hydraulic unit(s)
of the spool valve(s), carefully marking their
E1
position(s).
Removal 6 C
Remark Fig. 16
- The spool valve assembly must be removed in full.
- Any operations carried out on the spool valves require
scrupulous cleanliness.
- First correctly clean the spool valves (lift control and
auxiliary), and the areas around them on the tractor,
before removing them.
3. Locate the hose pipe(s) between spool valves and
couplers and disconnect them.
4. Remove the spool valve assembly.
Issue 1 May 2002


Splitting the spool valve assembly on the
workbench
Special point
- The spool valve components are maintained on either 3 5 4 1
side of the oil manifold (21) by six studs, of which 3 are
of a different length.
5. Unscrew the nuts on each end plate of the spool valve

assembly.
6. Remove the spool valves separately taking care not to
lose the seals inserted between the components.
Assembling the spool valve

Remark
- If it is feasible to replace the studs mentioned above, Fig. 17
lightly smear one of their threaded ends with Loctite
241 or equivalent and block them on the manifold (21)
(Fig. 1). Wipe off any excess Loctite if necessary.
7. Clean the mating faces: 3 5

- of the manifold (21) without removing the adhesive
shims (1) (inserts) (Fig. 18)
- of the spool valves (auxiliary - lift control) 4
8. Check the presence of new seals:
- (3) to (5) in each spot-faced port of the spool valves
(1) (Fig. 17) 6
- (3) to (6) in each spot-faced port of the manifold (21)
(Fig. 18)
9. Assemble the spool valve on the workbench, using
the procedure described in § D.
21
4 1 6 21
1
1
Fig. 18
Issue 1 May 2002


Refitting the spool valve assembly
10. Check tightening of the studs (2) on the support (1)
and replace the O'ring (3) (Fig. 19).
3 2
Remark:
- If it is absolutely necessary to replace the studs,
lightly smear the short threads with Loctite 270 or
equivalent, and lock the studs on the support.
270
Wipe off any excess Loctite if necessary.
11. Refit the spool valve assembly on its support.
Tighten the oil manifold (21) on the support (1) as
follows,
- screws: 50 - 70 Nm
- nuts: 90 - 120 Nm
1
Final operations
12. Assemble the hose pipes between the spool valves
and couplers, according to the marks. Fig. 19
13. Reconnect the pipes (high pressure pipe, lift rams
feed pipe and LS hose.
14. Reconnect the MoveUp and MoveDown solenoid
valve connectors in accordance with marks made
during removal.
15. Reconnect:
On the mechanically operated spool valves
- the control cable(s) taking into account the re-
minder in § C
On the Joystick or lever operated spool valves
(Dual Control)
- the connector(s) connected to the electro-hydrau-
lic housing(s) in accordance with marks made
during removal.
- the ON - OFF solenoid valve located on the left-
w
hand end plate.
17. For each spool valve position, check the operation of:
- hydraulic devices (see section 9N01 - tests)
- electronic devices (see section 11)
d
18. Check the oil tightness of the spool valves and
hydraulic unions.
Issue 1 May 2002


D . Assembly procedure
Remark
- To obtain the correct assembly of seals (3) (4) (5) (6)
(Fig. 17 - 18), the reassembly of each spool valve (1)
on the oil manifold (21) must be carried out vertically
on a clean workbench (Fig. 20).
Special point 1
- Adhesive shims also known as “inserts” allow the
tightening load to be distributed among the three studs
and not on the entire contact surface of the spool
valves. To avoid jamming the spools, it is important to
respect the fitting of the shims and to tighten nuts to
Assembly (Fig. 21)

19. After refitting the spool valve assembly, tighten the
nuts (3) in contact with each end plate, without
locking them. 1
20. Place the spool valve assembly in a vertical position.
Tighten a first series of nuts to a torque of 30 - 33
Nm. Turn the assembly over and complete the
assembly process by tightening the second series of
nuts to the same torque.
21. Use a suitable lever to check the mobility of each
spool valve.
21
Fig. 20
30/33 Nm
Fig. 21
Issue 1 May 2002


E . Location of levers on the console
and fitting, adjustment of a control
cable
Location of the lever(s)
Special points (Fig. 23) a 1
- The threads of spindle (2) must be lightly smeared with
Loctite 241 or its equivalent (support side).
- The friction washers (1) are smeared with molybdenum
disulphide grease before assembly.
- The locknut (3) is tightened so as to obtain a slight
resistance on the lever during its manipulation (it being
provisionally separated from its cable).
Remark (Fig. 22)

The figures 1 - 2 and 4 in the black circles indicate the
assembly order for levers on the console depending on b 1
the characteristics of the spool valves:
(1) Control for a mechanical spool valve or fitting of a
Dual Control lever
(2) Control for a second mechanical spool valve
(4) Control for a mechanical spool valve twinned with a
Dual Control lever
a : Three spool valves including one mechanical and

two electro-hydraulic
b : Three spool valves including two electro-hydraulic
and one Dual Control
c : Four spool valves including two mechanical and two c 1 2
electro-hydraulic
d : Four spool valves including one mechanical, two
electro-hydraulic and one Dual Control.
d 4 1
Fig. 22
Issue 1 May 2002


Fitting and adjustment of a control cable
- Figure 23 shows the assembly of a lever for a mechani-
cal spool valve.
- The assembly and adjustment are identical for an 1
additional lever.
3
2
1 A
Reminder
- For the design and operation of the Dual Control lever,
4
see chapter 11 - Electronics
5
8
Assembly and adjustment on the console
(Fig. 23)
Note: For further information, see section 9D02 § E.
22. Pass the cable through the flange (9) located at the
right rear side of the cab and into stirrup (8).
23. Screw yoke (4) flush with the threaded part of the 7
cable (7) and assemble it on link A of the lever
concerned. Position clip (5).
24. Tighten the yoke nut and check that the cable is not
pinched in any way.
Fig. 23
Issue 1 May 2002


Fitting and adjustment on spool valves
(Fig. 24)
25. Check that the main spools of the spool valves are
at the neutral point, without turning them a half turn.
26. Screw yoke (1) flush with the threaded part of the
cable. Tighten nut (3) and fit spindle (4).
27. Partially screw on cover (5) and fit bolts (6) without
tightening them.
28. Turn and adjust the cover to correctly centre the
control lever(s) in the opening provided for them in
the console.
29. Lock bolts (6) while tightening nut (2) to a torque of
20 Nm.
30. Check the operation of the controls in all four posi-
tions.
2 7
4 3 1
Fig. 24
Issue 1 May 2002

Hydraulics - Lift control spool valve 9E01.1
9 E01 Lift control spool valve
CONTENTS
- General ________________________________________________ 2
A. Diagrams _______________________________________________ 4
B. Removing and refitting the spool valve ___________________ 6
C. Neutral position ________________________________________ 8
D. Raise position __________________________________________ 9
E. Lower position _________________________________________ 10
Issue 2 May 2002

9E01.2 Hydraulics - Lift control spool valve
General
21 1 30 15 1
The lift control spool valve is fixed to a manifold provided
with three drilled channels. It is mounted on the centre
housing, in front of the lift control shaft.
The role of the spool valve is to regulate the oil flow, the 31
feed to and return from the lift rams, in relation to signals
transmitted by the electronic linkage control (ELC) calcu-
lator. It has a LS port for the Load Sensing system.
This control port allows the spool valve to transmit
pressure information to the variable displacement pump,
via the priority block(s). 30
Description (Fig. 12 to 14)

The Bosch spool valve comprises two parts:
- Hydraulic part (spool valve) Fig. 1
(2) Spool assembly used during the Lower phase
(4) Control spool
(5) Flowrate adjustment spool
(6) Shock valve 14 30 31 17
(9) Flowrate adjustment spool spring
(10) Control spool spring
(11) Spool assembly spring
(12) Non-return valve holding oil in the rams
13
- Electrical part (solenoid valve) (Fig. 2 - 5)
(13) MoveUp solenoid valve
(14) MoveDown solenoid valve (brown connector)
6
Remarks
- The number of hydraulic ports on the Bosch lift control 15
spool valve varies depending on whether it is assem-
bled with: 16 Fig. 2
. a manifold (21) and Rexroth auxiliary spool valves
(Fig. 1)
. a manifold (21) and Bosch auxiliary spool valves (Fig.
4)
- In all cases, the operating principle remains identical. 1 17 1
- Note the different location on the tractor.
Fig. 3
Issue 2 May 2002

Lift control spool valve with Rexroth auxiliary

spool valves
- The lift control spool valve is fixed on a manifold that 15
has three ports (Fig. 1).
- It is assembled on the centre housing in front of the lift
control shaft. 30
Lift control spool valve with Bosch auxiliary spool 21

valves
- The lift control spool valve is located between the
manifold (21) provided with four ports (Fig. 4) and the
31
right-hand end plate, or the fourth auxiliary spool valve
(if fitted).
- It is integral with the auxiliary spool valve unit at the
rear of the tractor.
15
Fig. 4
Designation of the ports
- On the manifold (21)
. Fig. 1: with Rexroth auxiliary spool valves
. Fig. 4: with Bosch auxiliary spool valves
(15) Return to housing 14 30 31 17
priority block(s)
(31) LS signal
13
- On the lift control spool valve (17)
. Fig. 2 - 3: with Rexroth auxiliary spool valves
. Fig. 5 - 6: with Bosch auxiliary spool valves
(15) Return to housing
(16) HP feed to rams 6
priority block(s)
(31) LS signal
16
Note: To distinguish a hydraulic problem from an Fig. 5
electrical problem, operate the push buttons on
the end of the solenoid valves (13) (14), thus elimi-
nating the effect of the electrical circuit on lift
control.
1 1 15 1
Special points
- The return oil from the lift control spool valve is
directed to the centre housing at the manifold (21)
outlet by a large section pipe the end of which is
beneath the oil level.
- This pipe is also used for the return from the auxiliary
spool valves (see section 9D01 and 9D02).
1 17
Fig. 6
Issue 2 May 2002

A . Diagrams
Layout with Rexroth auxiliary spool valves
17
LS
21
31 LS 31
20 R
P P
R 1
P
P
LS
LS
P
(21) Manifold
(31) LS signal to pump regulator via the priority block(s)
P : High pressure
V : Lift rams
Fig. 7
Issue 2 May 2002
Layout with Bosch auxiliary spool valves
20
P
LS
R
V
21 20
P2 31
R P 17
P

LS P
(20) Auxiliary spool valves 1
(21) Manifold
(31) LS signal to pump regulator via the priority block(s)
P : High pressure
P2 : Secondary high pressure port
V : Lift rams Fig. 8
Issue 2 May 2002

B . Removing and refitting the spool

valve
On the manifold with Rexroth auxiliary spool
valves
Special points 21 1 30 15 1
- Access to the lift control spool valve is limited given the
presence of the neighbouring components. Before re-
moving it, disassemble the auxiliary spool valves. 31
- The seals (1) are maintained in the spot faced ports of
manifold (21) by washer "R" and rings "B" (depending on
the channels) (Fig. 9), in order to provide the correct oil
tightness of the mating face when the lift control
function is activated.
30
Removal
1. Disassemble the auxiliary spool valves (see § C,
section 9D01).
2. Locate the colour of the connector and disconnect
the MoveUp solenoid valves (13) and the MoveDown
solenoid valves (14) (Fig. 10).
3. Using a locally manufactured tool, disassemble the
feed pipes to the rams, connected to union (16)
(Fig. 10).
4. Take out bolts (1) (Fig. 10). Remove the cover (2) and
spool valve (17). R B
5. Take off the seals, washer "R" and rings "B" (Fig. 9).
1 1
Refitting
6. Clean the mating faces of the cover and the spool
valve.
7. Position new seals (1) with washer "R" and rings "B"
on the channels concerned of the manifold (21)
(Fig. 9). Fig. 9
Replace the seals (1) between the spool valve (17)
and the cover (2) (Figs. 3 - 10).
8. Fit and tighten bolts (1) to a torque of 25 - 35 Nm 13 17 1 2 1
(Fig. 10).
9. Definitively tighten union (16) on the ram feed pipes.
10. Reconnect the solenoid valves (according to their
markings) and refit the auxiliary spool valves (see §
C, section 9D01).
12. Check the operation of the lift control system and the
auxiliary spool valves, the oil tightness of all seals
and hydraulic unions.
16 14
Fig. 10
Issue 2 May 2002

On the manifold with Bosch auxiliary spool Fig. 11

valves
Reminder
14
- The lift control spool valve (17) is integral with the
auxiliary spool valve assembly.
17
- It is situated between the manifold (21) and the right-
hand end plate (14) (Fig. 11) or the fourth auxiliary spool
valve (if fitted) (see section 9D02).
- Consequently, it is necessary to remove (and then to 21
refit) the auxiliary spool valve assembly in order to
access to the lift control spool valve for servicing (see
section 9D02).
Issue 2 May 2002


The flowrate adjustment spool (5) is pushed downwards
C . Neutral position by spring (9).
When the engine is not running and the spool valve is in When the engine is running and the spool valve is at rest,
the neutral position, the control spool (4) and the other no pressure information is transmitted to the variable
spools (2) are maintained in position by springs (10) and displacement pump. The LS line communicates with the
(11). return.
11
9
10
6 P
R
LS
Fig. 12
Issue 2 May 2002

As soon as the pressure on valve (12) is greater than that

D . Raise position in the rams, the lift control arms raise.
When the MoveUp solenoid valve (13) is activated, the The LS line communicates with outlet (16) informs the
control spool (4) is moved upwards. regulator of the variable displacement pump. If the
The LS pressure information acting on the upper face of pressure in the rams is too high (shocks received on the
the flowrate regulating spool (5) (spring (9) side) moves lift arms) the valve (6) opens and excess pressure is
the spool downwards the right thus directing the flow to vented to the housing.
the control spool and the non-return valve (12).
The movement of the flowrate regulating spool is damp-
ened by the volume of oil present in chamber "d".
R
P
LS
16
5
V
12
4
13
Fig. 13
Issue 2
1 May 2002
E . Lower position
When the MoveDown solenoid valve (14) is activated to
lower the lift control arms, the spool assembly (2) allows
the flow coming from the rams to enter the return. The LS
pressure information is transmitted to the side of the
flowrate regulating spool (5) (spring (9) side) and to the
variable displacement pump.
14
P
R
LS
Fig. 14
Issue
Issue 12 May 2002
2002
Hydraulics - Hydrostatic steering 9F01.1
9 F01 Hydrostatic steering
CONTENTS
- General ________________________________________________ 2
A. The principle of Load Sensing ____________________________ 2
B. Layout of channels and ports ____________________________ 5
C. Diagram ________________________________________________ 7
D. Neutral position (engine running) ________________________ 8
E. Steering lock (engine running) ___________________________ 10
F. Manual steering (engine stopped) ________________________ 12
G. Disassembling and reassembling the Orbitrol

steering unit ____________________________________________ 14
H. Removing , refitting and disassembling, reassembling

the Dana and Carraro steering rams ______________________ 16
Issue 2 May 2002

9F01.2 Hydraulics - Hydrostatic steering
General A . The principle of Load Sensing

The steering system used on tractors of the 8210 - 8220 Orbitrol steering unit
- 8240 to 8260 series tractors is of the dynamic type The LS port is either placed in communication with the
(constant flow rate of 0.5 l/min - standby pressure of 6 bar closed circuit of the Orbitrol when the steering is in a
(see section 9B01 or 0C01 depending on version)). There neutral position, or placed in communication with the
is no mechanical linkage between the steering wheel pressure supply line as soon as the steering wheel is
and the steering ram. turned.
The Orbitrol type is marked on a plate riveted to the lower
part of the unit (Fig.).
Its control principle is of the ‘Load Sensing’ type. Parts list
The system comprises the following main components: (1) Bolt
- a pressurized oil feed from the priority block(s) supplied (2) Bolt
by the variable displacement pump, (3) O-ring
- an Orbitrol closed centre steering unit, whose capacity (4) Cover plate
differs according to the tractor type, installed in by-pass (5) O-ring
(Orbitrol OSPC 125 LS Dynamic 2WD - Orbitrol OSPC (6) Stator
200 LS Dynamic for 4 WD), (7) Pin
- a double acting ram fitted either on the 4 WD front axle (8) O-ring
or on the 2 WD axle beam. (9) Rotor
(10) Spacer
The Orbitrol unit is supplied via the priority block(s) by the (11) Link shaft
high flow rate circuit. When the steering wheel is turned, (12) Washer
the necessary flow of oil is directed to the corresponding (13) Centring springs
side of the steering ram. The flowrate in excess, not (14) Needle bearing
required by the ram, flows through the return ports to the (15) Bush
selector cover of the Heavy Duty gearbox or to the right- (16) Washer
hand side of the Full Powershift gearbox (according to (17) O'ring
version). (18) Relief-valve
(19) Seal
In the case of an engine breakdown or failure of the hy- (20) Shock valve
draulic pump, the Orbitrol acts as a hand-operated pump (21) Orbitrol unit (distribution valve)
so that the steering can be controlled. (22) Non-return valve
(23) Suction valve
Description of the Orbitrol steering unit (24) Bush
The Orbitrol comprises a selector spool valve, a spring (25) Spool valve
centred supply sleeve and a drive shaft linked to the (26) Non-return valve
steering column. It has five hydraulic ports: (27) Sleeve
- pressure (28) O'ring
- return to the selector cover or to the gearbox (according (29) Distributor plate
to the transmission version)
- two supplies to the steering ram
- Load Sensing
Fig 1
The circuit is protected by a safety valve and two shock
valves as well as two suction valves.
Fig 2
Issue 2 May 2002

Overall view
20 14 16 17 15 13 19 21 7 27
12
24
25
11
26
29
22
28
3 1 10 9 2 6
18
23
Fig 2
Parts list
Fig. 1
Issue 2 May 2002

Exploded view
DANFOSS
OSPC XXX
XXXXXX
2
XXXX
4
1
5
10 29
7
11 28
27
26
25
13
24
12
14
16
15
17
18
21
22
19
23
20
Fig 1 Parts list Fig. 2
Issue 2 May 2002

A Steering ram (1) 2WD axle
B Location of steering column (2) Dana front axle
Hydraulics - Hydrostatic steering 9F01.5 L Supply to left-hand side union of the steering ram (3) Carraro fixed front axle
LS Signal to variable displacement pump via the priority (4) Carraro suspended front axle
block(s)
P High flow rate supply from the variable displace-
ment pump
B . Layout of channels and ports (Fig. 3) R Supply to right-hand side union of the steering ram
T Return to the housing via the selection cover or the
gearbox (depending on transmission version)
L
B
T
T
LS
P
R L
A
A
R
3
L
L R
R P LS
R
1
A
A
L
4
R
L
Fig. 3
Issue 2 May 2002

Issue 2 May 2002

C .Diagram
A
L R
Mechanical links
P B T
LS
BP P
BP Priority block(s) Fig. 4
Issue 2 May 2002

D . Neutral position (engine running)

(Fig. 5)
In this position the spool valve (25) is centred in relation
to the sleeve (27) by the springs (13). The channels P1-
L-R are not supplied.
The oil coming from the variable displacement pump via

channel (2) is directed in priority to the Orbitrol unit via
channel (1).
With the steering in a neutral position, there is no flow in

this channel.
The circuit is closed centre.
Two shock valves (20) and two suction valves (23) are
located in ports L and R of the valve.
The shock valves (20) protect the circuit between the
steering ram and the steering unit from over pressure
caused by mechanical shocks to the front wheels.
The suction valves (23) allow the oil released by the
shock valves (20) to pass from the right-hand channel to
the left-hand channel or vice versa depending on the
movement of the piston inside the steering ram.
Issue 2 May 2002

L R
20
23
25 27
P1
13
T P
12 BP
LS
Inlet channel
BP Priority block(s)
P1 Supply to the metering device Fig. 5
Issue 2 May 2002

E . Steering lock (engine running)

(Fig. 6)
Action on the steering wheel (to the left or right) produces
an angular displacement of the spool valve (25) in relation
to the sleeve (27) and the opening of the closed Orbitrol
circuit.
The pilot flow coming from the Orbitrol enters via channel
(4) thus allowing for the flow required for the metering
device ((stator) (6) and rotor (9)) to pass into channel (1).
The rotor (9) is driven in rotation by the steering wheel and

since the degree of rotation of the rotor (9) is equal to that
of the steering wheel, it forces a directly proportional
quantity of oil towards the steering ram.
Example:
Let us suppose that the steering wheel is turned by 5°.
An angular displacement of 5°of the spool valve (25) is
produced in relation to the sleeve (27).
The rotor (9) is driven in rotation as long as it is supplied.

It drives with it the link shaft (11) (Fig. 1 - 2) and the
sleeve (27).
When the latter have turned 5°, the spool valve (25) and
the sleeve (27) are once again centred by the springs (13).
The rotor ceases to be supplied and stops.
This same reasoning applies to greater angles. The

quantity of oil delivered by the steering unit to the steering
ram is therefore proportional to the rotation angle of the
steering wheel.
The spool valve (25) allows, whether steering lock is

applied to the left or right, to direct oil fed by the metering
device (stator (6) and rotor (9)) to port L or R.
During rotation, the sleeve (27) ensures the synchronous

communication of the cavities in the metering device
with the circuit from the pump, on the one-hand, and the
circuit to the steering ram, on the other hand.
A non-return valve (26) (Fig. 2) is screwed into the supply

port of the steering unit. This one-way valve stops
excessive pressure or blows received by the front
wheels from being transmitted to the pump whenever
steering lock is applied.
If the pressure in the steering circuit is too high, the relief-

valve (18), located in the steering unit, opens and the
excess pressure is released to channel T.
Issue 2 May 2002

L R
13 25 27
9
(R) D
T
T P 6
(L) G
T P
T P
26
18
Inlet channel
Delivery channel
Return channel
Pilot flow channel Fig. 6
Issue 2 May 2002

F . Manual steering (engine stopped)

(Fig. 7)
When the pump is no longer operating or the available
pressure is too low, the rotor (9) is no longer hydraulically
driven. It is no longer power assisted.
In this case, action on the steering wheel compresses

the centring springs (13). The angular clearance between
pin (7) (Fig. 1) and the sleeve (27) is reduced to zero
resulting in mechanical rotation of stator (6) and rotor (9).
The steering distribution valve then operates in the same
way as a hand pump.
The oil returning from steering ram A passes through the

non-return valve (22) and supplies the metering device.
The pressure generated is proportional to the torque

applied to the steering wheel. In such cases where
manual steering is used the effort required to steer is
much greater.
Issue 2 May 2002

L R
13 25 27 9
(R) D
(L) G 6
13 22
T P
BP
LS
Inlet channel
Delivery channel
Return channel Fig. 7
Issue 2 May 2002

G . Disassembling and reassembling

the Orbitrol steering unit (Fig. 1)
Reminder
- If the Orbitrol steering unit is to be replaced, it must be
replaced by a unit having exactly the same
characteristics.
Example: OSPC.200.LSD
OSP ........ Orbitrol steering pump
C ............. Valves incorporated in the steering unit
200 ......... 200 cm3 per rotor rotation
LSD ......... Dynamic Load Sensing (closed centre)
Disassembly
1. Remove the distribution valve from the tractor.
2. Place the distribution valve in a vice fitted with
plastic jaws
3. Take out the bolts (1). Carefully mark the location of
the bolt (2) and then remove it.
4. Remove the cover plate (4), the O'ring (5), the stator
(6) and O'ring (8).
5. Remove the spacer (10), the rotor (9), the distribution
plate (29) and the O'ring (28).
6. Take out the splined link shaft (11).
7. Unscrew the threaded bush and take out the valve
ball from the non-return valve (22).
8. Take out the two axle pins and valve balls from the
suction valves (23) of the distribution valves.
9. Extract the sleeve (27) and spool valve (25) assembly
by pushing it out while checking that the pin (7) lies
along the horizontal axis.
10. Remove the washers (12) (16), the needle bearing
(14) as well as the bush (24) from the sleeve and
spool valve assembly. Remove the pin (7), and the
centring springs (13) by pressing on their ends.
Separate the sleeve (27) from the spool valve (25).
11. Unscrew the plug from the relief-valve (18). Using an
8 mm Allen key, disassemble the threaded bush and
remove the seal, the spring and the valve (the
crimped seat cannot be removed).
12. Unscrew the two plugs from the shock valves (20)
and remove the seals. Using a 6 mm Allen key,
remove the threaded bushes and take out the springs,
the valve balls and their seats (the crimped seats
cannot be removed).
13. Extract the seal (19), the bush (15) and the O'ring (17).
14. Disassemble the non-return valve (26).
Issue 2 May 2002

Reassembly
15. Check and clean all components, replace those
defective. Lubricate with clean transmission oil
before reassembly.
16. Reassemble the non-return valve (26).
17. Fit the seal (19), the O'ring (17) and the bush (15).
18. Place the valve balls and springs in the recesses of
the shock valve (20). Screw in the threaded bushes,
fit the seals and tighten the plugs.
19. Fit the valve and spring in the recesses of the relief-
valve (18), screw in the threaded bush. Fit the seal
and tighten the plug to a torque of 40 - 60 Nm.
20. Insert the spool valve (25) into the sleeve (27).
Position the centring springs (13) according to Fig. 8
and insert the pin (7).
21. Position the bush (24) on the sleeve and spool valve
assembly so that the chamfer facilitates assembly Fig. 8
in the steering unit.
22. Place the washers (12) (16), the chamfer of washer
(12) towards the centring springs (13), by inserting
the needle bearing (14) between them.
23. Fit the sleeve and spool valve assembly in the
steering unit by oscillating it slightly. Check that the
pin (7) is held horizontally. 11 9
24. Place the two valve balls and the two pins in the
recesses of the suction valves (23).
25. Fit the valve ball in the recess of the non-return valve
(22) and screw in the threaded bush.
26. Position the splined link shaft (11).
27. Fit the O'ring (28), the distributor plate (29).
28. Fit the rotor (9) so that the two concave depressions
"C" lie along the axis of the slot in the splined link
shaft (11) (Fig. 9). Refit the spacer (10).
29. Place the O'rings (5) (8) on the stator (6). C
30. While avoiding moving the rotor (9), fit the stator (6).
Then move it so that its fixing holes match with Fig. 9
those of the steering unit.
Note: The rotor (9) and the pin (7) must be in the
position shown in Figure 10.
31. Refit the cover plate (4).
32. Refit the bolt (2) (in the same location as marked
during disassembly) and the bolts (1) fitted with their
9
seals (3). Tighten opposing bolts to a torque of 30 -
35 Nm.
33. Using a test-bench or a suitable fixture, check the
adjustment and correct operation of the steering unit.
34. Refit the steering unit on the tractor.
35. Check the oil tightness of the unions.
Fig. 10
Issue 2 May 2002


Remark
H . Removing, refitting and disas- - If access to the ram fixing bolt (2) in the Dana front axle
sembling, reassembling the Dana seems difficult (Fig. 11):
and Carraro steering rams . lift the front of the tractor with a trolley jack positioned
in the centre of the front axle,
Reminder . remove the front wheels,
- 8210 - 8220 - 8240 and 8250 tractors are now equipped . place an appropriate axle stand beneath the lower
with a Carraro front axle. engine housing,
- 8260 tractors are equipped with a Dana AG200H front . swing the front axle at maximum to high and low
axle with an elevated pivot. positions in order to access the bolts.
36. Immobilise the tractor. Chock the rear wheels. Put
on the handbrake.
4 3 7 2 1
Fig. 11
1
4
3
5
7
2
Fig. 11A
Issue 2 May 2002

Removal (Fig. 11 - 11A)

Carraro front axle
Remark
- To help clear the steering ram on the Carraro front axle,
first remove the mudguard and the front left wheel of
the tractor.
Dana or Carraro front axle

37. Disconnect and block off the feed hoses to the ram,
carefully identifying their positions.
38. Drive out the steering ball joints (1) using an
appropriate extractor.
39. Take out the bolts (2) from the ram and remove it:
- Dana front axle (Fig. 11)
- Carraro front axle (Fig. 11A)
Refitting
40. Refit the ram. Fit and tighten bolts (2) :
- Dana front axle: to a torque of 180 - 200 Nm, the
threads previously smeared with Loctite 270 or
equivalent.
- Carraro axle: to a torque of 120 Nm.
41. Fix the steering ball joints. Tighten bolts (4) :
- Dana front axle: to a torque of 115 - 130 Nm and
block them with new pins (Fig. 11)
- Carraro front axle: to a torque of 220 Nm (Fig. 11A)
42. Reconnect the feed hoses in the positions identified
during disassembly.
43. Mount the wheel(s) and tighten the bolts to a torque
of 640 - 680 Nm.
Refit the mudguard (Carraro front axle).
Issue 21 May 2002


Disassembly (Fig. 12 - 12A)
Rep. Description Dana Carraro 1
(Fig. 12) (Fig. 12A)
(1) Ram assembly X X 2

3
(2) Pack of seals X X 2
4
(3) Guide bushes X - 5
(4) Cylinder X X
(5) Lock ring X -

(6) Piston rod X X
5
(7) Cover - X
Remarks
- The Dana or Carraro front axles are fitted with a double-
acting cylinder, which receives pressure from the 6
Orbitrol spool valve proportional to the rotation of the
steering wheel.
- When one side of the ram is fed, the other is connected
to the return pipes and vice versa.
- Each component can be replaced and is listed in the
spare parts catalogue.
- A pack provides all the seals necessary for carrying out
service operations.
2
44. Remove the steering ram (see previous operations). 2
3
2
Fig. 12
6
2
7
2
2
4
Fig. 12A
Issue 2
1 May 2002
Dana front axle (Fig. 12) Carraro front axle (Fig. 12A)
45. Release and remove the spherical joints (7) (Fig. 11). 60. Lubricate the seals, bushes and cylinder internal
46. Take off the lock rings (5) using an appropriate locally bore with clean transmission oil.
manufactured tool, while simultaneously turning the 61. Fit the seals on the piston rod (6) cylinder (4) and the
guide bushes (3). cover (7) respectively.
47. Take out the piston rod (6) from cylinder (4). 62. Put together the steering ram without damaging the
48. Discard all the seals (sealing ring, O’rings, dust oil tight seals :
guards and lock rings). - by sliding the piston rod fitted with its seals in the
cylinder bore
Carraro front axle (Fig. 12A) - by putting back the cover on the cylinder, with the
49. Release and remove the spherical joints (7) (Fig. pressure inlet facing the right direction.
11A). 63. Tighten and block the spherical joints (7) (Fig. 11A)
50. Separate the cover (7) from the cylinder (4). to the torque of 300 Nm.
51. Take out the piston rod (6) from cylinder.
52. Discard all the seals (sealing ring, O’rings, dust Dana or Carraro front axle
guards and lock rings). 64. Refit the steering ram on the tractor.
65. Check the supply of the ram and its internal oil
tightness (see section 9N01, Hydraulic tests).
Reassembly
53. Clean the components. Replace any parts to be found Final operation
defective. 66. Carry out a road test on the steering system.
Remark
- Check the condition of the internal bore of the
cylinder and the operational parts of the piston rod.
Systematically discard all scratched components
that may compromise the oil tightness of the
steering mechanism.
Dana front axle (Fig. 12)

54. Lubricate the O’rings, bushes and internal bore with
clean transmission oil.
55. Fit the relevant seals on the piston rod (6) and the
guide bushes (3).
56. Slide the piston rod fitted with its seals into the
cylinder bore.
57. Fit the guide bushes at each end of the cylinder,
taking care not to damage the lip of the sealing rings.
58. Position the machined groove of each guide bush
opposite the cylinder groove. Turn the guide bushes
while simultaneously slipping in the lock rings.
59. Tighten and block the spherical joints (7) (Fig. 11) to
a torque of 120 - 150 Nm, the threads previously
smeared with Loctite 270 or equivalent.
2
Issue 1 May 2002
9 F02 Hydrostatic steering for 4WD front axles -

APL5052
CONTENTS
- General ________________________________________________ 3
A. Principle of Load Sensing ________________________________ 4
B. Neutral position (engine running) ________________________ 7
C. Wheel steering lock position (engine running) _____________ 9
D. Manual steering (engine not running) _____________________ 11
E. Disassembling and reassembling the Orbitrol distribution

valve ___________________________________________________ 13
F. Removing and refitting - Disassembling and reassembling

a steering ram __________________________________________ 16
G. Layout of channels and ports ____________________________ 18
Issue 1 May 2001

Issue 1 May 2001

General
The steering system on 8270 and 8280 is of the dynamic
type (constant flowrate of 0.5 l/min, standby pressure of
6 bar) (see section 9B01 or 9C01 depending on the
version). There is no mechanical linkage between the
steering wheel and the steering rams.
Its control principle is of the Load Sensing type. The main
components of the circuit are:
- pressurised oil feed from the priority block(s) (depend-
ing on version) supplied by the variable displacement
pump,
- an Orbitrol steering distribution valve of the closed
centre OSPD.LS 100 - 260 type with twin stator rotors
mounted in by-pass.
- two double acting steering rams connected in parallel
and mounted on the front 4WD axle.
Description of the distribution valve

The Orbitrol houses twin stator rotors having different
capacities and mechanically linked by a drive shaft
connected to the steering column, as well as a supply
sleeve centred by springs and a spool integrated in its
body (19).
It has 5 ports:
- pressure
- return to gearbox
- two steering ram supplies
- Load Sensing.
The circuit is protected by a discharge valve, two shock
valves and two suction valves.
Capacity of the stator rotors

- Stator rotor (27) (28): 100 cm3 / rpm
- Stator rotor (30) (31): 160 cm3 / rpm
The maximum capacity of the Orbitrol is 260 cm3 / rpm.
Operation
The Orbitrol is supplied via the priority block(s) by the high
flowrate circuit that equally supplies the integrated spool
(18) and the twin stator rotors (27) (28) and (30) (31).
When the steering wheel is turned, the necessary oil flow
is directed to the corresponding side of the steering rams.
The excess flow not required by the rams is directed via
the return ports to the right-hand side of the gearbox.
In the case of an engine breakdown or a variable
displacement pump failure, only stator rotor (27) (28) is
active and acts as a hand pump allowing the steering to
still be used.
Issue 1 May 2001

A . Principle of "Load Sensing"

Steering unit
The LS port is placed in communication with the closed
circuit of the Orbitrol when the steering is in a neutral
position, or placed in communication with the pressure
supply line as soon as the wheel is turned.
Parts list
(1) Lip seal
(2) Centring springs
(3) Bush
(4) O’ring
(5) Pin
(6) Sleeve
(7) Spool valve
(8) O’ring
(9) Linkage shaft
(10) O’ring
(11) Plate
(12) O’ring
(13) Plate
(14) O’ring
(15) Spacer
(16) O’ring
(17) O’ring
(18) Integrated spool
(19) Spool body
(20) Seals
(21) O’ring
(22) Washer
(24) Washer
(25) Discharge valve
(26) Block
(27) Rotor (100 cm3)
(28) Stator (100 cm3)
(29) O’ring
(30) Stator (160 cm3)
(31) Rotor (160 cm3)
(32) Plate
(33) Spring
(34) O’ring
(35) Closing plate
(36) Bolts
(37) Shock valves
(39) Spacers Fig. 1
(40) One-way valve
(41) Suction valve
(42) Pin Fig. 2
Issue 1 May 2001

Overall view
1 21
2 22
3 23
4 24
6 25
9 26
10 27
11 28
12 29
13 30
14 31
15 32
16 33
17 34
18 35
19 36
20
Issue 1 May 2001

Exploded view
37
37
1
41
39
4
22
23
24
25 3
5
26
40 6
38
15 8
12 7
28
9 29
10 2
11
27
14
13
31
30
33
16
32
17
19
18
42
34 Parts list
35
20 Fig. 1
36
Fig. 2
Issue 1 May 2001

Two shock valves (37) and two suction valves (41) are
B . Neutral position (engine running) placed in the L and R ports of the distribution valve. The
(Fig. 3) shock valves (37) protect the circuit between the steer-
ing ram and the spool valve from eventual pressure
In this position, the spool valve (7) is centred in relation overloads caused by shocks to the wheels.
to sleeve (6) by springs (2). The P1 – L - R channels are The suction valves allow the oil released by the shock
not supplied. valves to pass from the right-hand channel into the left-
hand channel and vice versa, depending on the move-
The flow coming from the variable displacement pump ment of the piston in the steering ram.
via channel 2 is directed by priority to the Orbitrol
distribution valve via channel 1.
With the steering in the neutral position, there is no flow
through this channel.
37
2 7 6
41 27 31
L R
T P1
25 28 30
40
38
P 12 B
T
LS
B Priority block(s) P1 Supply to metering mechanism (stators (28) (30)

L Supply to steering rams (left-hand lock) and rotors (27) (31))
LS Pilot flow R Supply to steering rams (right-hand lock)
P High flowrate supply from variable displacement T Return to housing
pump
Fig. 3
Issue 1 May 2001

2 7 6 27 31
L R
(R) D
T
T P
25 30
(L) G
40 28
T P
1 B 4
T P
18
LS
Fig. 4
Issue 1 May 2001

C . Wheel steering lock position (en-

gine running) (Fig. 4)
Any action on the steering wheel (left or right) produces
an angular offset of the spool valve (7) and causes the
opening of the closed circuit of the Orbitrol.
A pilot pressure coming from the Orbitrol arrives in

channel 4 and allows the passing into channel 1 of the
flow necessary to the integrated spool (18) and the stator
metering mechanism (stators (28) (30) and rotors (27)
(31)).
The rotors (27) (31) are driven in rotation and force
towards the ram a quantity of oil that is proportional to the
degree of rotation. The rotation of rotors (27) (31) is equal
to that of the steering wheel.
Example: If the steering wheel is turned by 5º an angular

offset of 5º the spool valve (7) is produced in relation to
the sleeve (6).
The rotors (27) (31) are driven in rotation as long as they
are supplied with pressurised oil. They drive the link shaft
(9) and sleeve (6).
When the latter have turned 5º, the spool valve (7) and the
sleeve (6) are once again centred by the springs (2). The
rotors are no longer supplied and stop.
The same principle applies to other steering wheel

angles. The quantity of oil discharged by the steering unit
is therefore proportional to the rotational angle of the
steering wheel. Depending on whether a left-hand or
right-hand lock is applied,the spool valve (7) directs the
oil discharged by the metering mechanism (stator (28)
(30) and rotor (27) (31)) towards the L or R port.
The sleeve (6) ensures, during rotation, a synchronous

communication of the cavities of the metering mecha-
nism with the circuit from the pump, on one hand, and the
circuit going to the rams, on the other.
A one-way valve is screwed into the supply port of the

spool valve.
This one-way valve (40) avoids any excessive pressure

on the wheels from being transmitted to the pump when
the wheels are on steering lock position.
If the pressure in the steering circuit becomes too high,
the discharge valve (25), located inside the spool valve,
is activated and the excess pressure is directed towards
channel T.
Issue 1 May 2001

2 7 6 27 31
L R
(R) D
(L) G 25 28
40
T P B
38 LS
Fig. 5
Issue 1 May 2001

D . Manual steering (engine stopped)

(Fig. 5)
When the pump is no longer providing pressure or when
the pressure is too low, the rotors (27) (31) are no longer
hydraulically driven. There is no power assistance.
In this case, action on the steering wheel compresses

the centring springs (2). The angular clearance between
pin (5) (Fig. 1)a and sleeve (6) is caught up and there is
a mechanical driving of the metering mechanism (stator
(28) and rotor (27)). The spool valve then functions as a
hand pump.
The oil returning from the ram passes through the non-
return valve (38) and supplies the metering mechanism.
The pressure generated is directly proportional to the

torque applied to the steering wheel. The effort therefore
required to turn the wheel in order to steer the tractor is
much greater.
Issue 1 May 2001

T L
L R
P LS
A
A-A
A
40 P R
P T LS
B Priority block(s)
LS Pilot flow
L Supply to the steering rams (left-hand lock)
P P High flowrate supply from the variable
displacement pump
R Supply to the steering rams (right-hand lock)
T Return to housing
Fig. 6
Issue 1 May 2001

E . Disassembling and reassembling

the distribution valve (Orbitrol) (Fig.
1 - 2)
Disassembly
1. Remove the distribution valve from the tractor.
2. Place the distribution valve in a vice fitted with
plastic jaw protectors.
3. Mark the location of bolts (36). Remove the bolts
along with seals (20).
4. Take off the closing plate (35), the O’ring (34), the
body (19), the integral spool (18) and spring (33).
5. Remove the O’ring (17). Locate the position of plate
(32) and remove it.
6. Remove O’ring (16). Remove stator (30) and rotor
(31). Take out the O’ring (14).
7. Locate and remove plate (13).
8. Remove spacer (15), stator (28), rotor (27). Locate
and remove plate (11). Take out O’ring (10).
9. Take out the splined linkage shaft (9).
10. Unscrew the threaded socket and recover the ball
from the non-return valve (38).
11. Take out the two pins and the two balls from the
spool valve suction valves (41).
12. Extract the sleeve assembly (6) and spool valve (7)
by pushing on it and checking that pin (5) lies along
the horizontal axis.
13. Take out washers (22) (24), the needle bearings (23)
and bush (3) from the sleeve / spool valve assembly.
Take out pin (5) and centring springs (2) by pressing
on one of their ends. Separate sleeve (6) from spool
valve (7).
14. Unscrew the plug of the discharge valve (25). Using
an 8 mm Allen key, disassemble the threaded bush
and remove the seal, spring and valve (the inserted
valve seat cannot be removed).
15. Unscrew the two plugs from the shock valves (37),
remove the seals. Using a 6 mm Allen key, disas-
semble the threaded bushes and take out the springs,
the balls and their seats (the inserted valve seats
cannot be removed).
16. Extract the oil tightness seal (1) and O’ring (21).
17. Disassemble the check valve (40).
Issue 1 May 2001


Reassembly
18. Check and clean all components, replace any parts
found to be defective. Lubricate the components
with clean transmission oil before reassembly.
19. Refit the check valve (40).
20. Fit seal (1), O’ring (21) and the bush.
21. Fit the balls and springs in the housings of the shock
valves (37). Screw in the threaded bushes, place the
seals and tighten the plugs.
22. In the housing of the discharge valve (25), place the
valve and spring, screw in the threaded bush. Fit the
seal and tighten the plug to a torque of 40 - 60 Nm.
23. Introduce the spool valve (6) in sleeve (7). Position
the centring springs (2) according to Figure 7 and fit
pin (5).
24. Position bush (3) on the sleeve and spool valve 2
assembly so that the chamfer facilitates assembly Fig. 7
in the spool valve.
25. Place washers (22) (24), with the chamfer of washer
(24) turned towards the centring springs (2) and
placing needle bearing (23) in between them.
26. Assemble the sleeve and spool valve assembly in
the spool valve using a slight oscillatory movement.
Take care that pin (5) is held horizontally. 9 27
27. In the suction valve housings (41), place the two
balls and the two pins. 31
28. In the non-return valve housing (38), place the ball
and screw in the threaded bush.
29. Position the splined linkage shaft (9).
30. Place the O’ring (10), and the distributor plate (11).
31. Fit rotor (27) so that the two cavities "C" lie in the axis
of the slot of splined shaft (9) (Fig. 8).
32. Place the O’rings (12) (29) on the stator (28).
C
33. While avoiding moving the rotor (27), fit the stator
(28). Then turn it so that its fixing holes match those
in the spool valve. Position spacer (15) and plate Fig. 8
(13).
Note: Rotor (27) and pin (5) must be in the
34. Refit rotor (31) on the spacer (15) so that the two
cavities "C" lie in the axis of the slot of splined shaft
(9) (Fig. 8).
Issue 1 May 2001

35. Place O’rings (14) (16) on the stator (30). Fit and
move it so that the fixing holes match those provided
in the spool valve.
Note: Rotor (31) and pin (5) must be in the
27
36. Refit plate (32) in the position noted during disas-
31
sembly.
37. Check that the bore of body (19) and the rim of spool
(18) are free of scratches or burs.
38. Check that the spool moves normally in the body.
39. Slide the spool fitted with its oil tightness compo-
nents into the body. Place O’rings (17) (34) and
spring (33).
40. Refit the closing plate (35). 5
41. Refit the new seals (20) and bolts (36) at the
emplacement noted during disassembly.
42. Alternately tighten the bolts to a torque of 30 - 35 Nm. Fig. 9
43. Using a test bench or an appropriate fixture, check
the adjustment and operation of the spool valve.
Refit the spool valve on the tractor.
44. Check the oil tightness of the unions.
Issue 1 May 2001

F . Removing and refitting – Disas-

2
sembling and reassembling a steer-
ing ram
Removal (Fig. 10 - 11)
45. Disconnect the hoses (2), carefully noting their
positions
46. Loosen and take off nut (4) holding cylinder (3) on the
stub (7) concerned.
47. Repeat the previous operation with the fixing point of
the piston rod.
48. Remove washers (6), spacers (1), carefully noting
their positions.
49. Remove the ram(s) (1). 1
50. If necessary, take out the circlip(s), remove the ball
joint(s) (8). Fig. 10
Refitting (Fig. 11)

51. If removed, replace the ball joint(s). Fit the circlip(s).
52. Refit the ram(s), spacer(s) (1) with the chamfer
facing the ball joint and washers (6).
53. Fit and tighten the nut(s) (4) to a torque of 440 Nm.
Reconnect the hose pipes (2).
54. Using a grease gun and bearing grease, grease the
pins (7).
2 4 5 6 7
1
10 9
3
Fig. 11
Issue 1 May 2001


55. Take off snap ring (14) by turning the oil tight stuffing
box (5) using a locally manufactured pin wrench.
Take out piston rod (15) from cylinder (3). 1
56. Fix the piston rod in a vice using the end intended for
holding the ball joint.
57. Loosen and remove nut (2).
58. Remove piston (4) and take off O’ring (9).
59. Separate the stuffing box (5) from the shaft (15).
60. Remove: 3
- from the piston: oil seal (6), bush (7) and O’ring
(8). 2
- from the oil tight stuffing box: O’ring (10),
washer (11), oil seal (12), oil scraper seal (13).
4
Reassembly (Fig. 12) 5

found to be defective. 6
62. Check that the bore of the cylinder (3) and the rim of 7
the piston (4) are free from scratches and that the oil 8
passage ports in the cylinder are not blocked. 9
63. Carefully refit: 10
- on the stuffing box (5): oil seal (12), scraper seal 11
(13), washer (11) and O’ring (10). 12
64. Lubricate the oil seals, O’rings and oil scraper seal. 13
65. Slide the stuffing box in the correct direction on to the 14
shaft (15) (Fig. 12).
66. Refit with care:
- on piston (4): O’ring (8), bush (7) and oil seal (6).
67. Place a lubricated O’ring (9) against the shoulder of 15
the shaft (15).
68. Slide the piston in the correct direction on to the
screw cut end of shaft (15).
69. Carry out operation 56 again to grip the piston rod.
Fig. 12
70. Discard the used nut (2). Fit and tighten a new nut to
a torque of 405 Nm.
71. Lubricate the bush (7) and the oil seal (6).
72. Slide the shaft assembly (15), stuffing box (5) and
piston (4) into cylinder (3).
73. Position the machined groove of the stuffing box
opposite that of the cylinder.
74. Fit snap ring (14) using the same method as in
operation 55.
75. Refit the ram(s) on to the tractor.
76. Check the operation and the internal oil tightness of
the ram(s) (see section 9N01, Hydraulic Tests).
Issue 1 May 2001

G . Layout of channels and ports
T B L
LS
A
A
P R
R P LS
A A-A
A Steering rams R Supply to steering rams

B Location of the steering column P High pressure from variable displacement pump
LS Pilot pressure from the priority block(s) T Return
Fig. 13
L Supply to steering rams
Issue 1 May 2001

Hydraulics - Right-hand cover 9G01.1
9 G01 Right-hand cover 110 l/min Load Sensing
CONTENTS
- General ________________________________________________ 2
A. Removing and refitting the cover _________________________ 13
B. Description and operation of the variable displacement

pump __________________________________________________ 17
C. Removing and refitting the pump ________________________ 20
D. Adjusting the engine speed sensor (Heavy Duty version) ___ 21
E. Removing and refitting - Disassembling and reassembling

the pump bearing _______________________________________ 22
Issue 1 May 2001

9G01.2 Hydraulics - Right-hand cover
General
39 2 1
The right-hand cover is mounted on the intermediate
housing. It acts as a support for numerous components
and contains the different booster, lubricating and low
flowrate channels and circuits.
On its internal face, the cover contains:

- the variable displacement pump (41) and its drive pinion
(39).
- the safety valve (45) of the low pressure circuit cali-
brated at 22 bar
- the safety valve (44) of the booster circuit and 5 bar
lubricating circuit.
On its external face, the cover is fitted with:

- the main 15 micron filter (27)
Fig. 1
- one or two priority blocks serving different functions of
the low and high flowrate circuits
- the pressure relief-valve (2)
- the regulator (12) of the variable displacement pump
- the 4 solenoid valves (15) to (18) of the low pressure
control functions (depending on options)
- the high and low pressure diagnostic connectors (11)
(48), lubricating booster (29), LS (9)
- the engine speed sensor (25) (depending on options)
- the low pressure (14) and booster (42) switches as well
as the main filter clogging indicator (34).
Description
- The movement transmitted to pinion (1) by the engine,
via shaft (2), drives pinion (39) of the variable displace-
ment pump (41) (Fig. 1).
- The oil coming from the booster pump, located on the
left-hand cover (see section 9H01) is directed towards
the priority blocks through pipe (54) (Fig. 2) via the
variable displacement pump (41), in order to supply the
function requested.
- The pipe (55) (Fig. 2) directs oil coming from the 5 bar
safety valve (44) to the suction manifold fitted on the
booster pump (see section 9H01).
Issue 1 May 2001

53
22
55
VS
52
52 22 54
53 PCV
54 55
(22) Mecanindus pin
(52) O’ring
(53) O’ring
(54) Booster pipe
(55) Safety valve pipe (44)
A : Suction
PCV : To variable displacement pump
VS : 5 bar safety valve (44)
C : Intermediate housing compartment Fig. 2
Issue 1 May 2001


Parts list (45) Safety - valve 22 bar
(1) Bolt (46) Plug or temperature switch (Heavy Duty gearbox)
(2) Pressure relief-valve (47) Pump attachment screw
(3) Supply to Orbitrol (48) LP diagnostics connector
(4) Bolt (49) Rivets
(5) LS pilot flow from the Orbitrol (50) Trailer brake to quick-disconnect coupler
(6) LS pilot flow to the pump regulator
(8) Cover
(9) LS diagnostics connector
Fig. 3
(10) Plugs (depending on version)
(11) HP diagnostic connector
Fig. 3A
(12) Pump regulator
(13) Union (LS)
(14) LP switch (17 bar) Fig. 4
(15) Solenoid valves (PTO, PTO brake,
to differential lock (front and rear if fitted)
(18) and 4WD Fig. 5
(19) Plugs
(20) Park Lock union or plug (depending on assembly)
(21) PTO clutch union Fig. 5A
(23) PTO brake union
(24) 2WD or 4WD differential lock union
(25) Plug or speed sensor (Heavy Duty gearbox)
(26) 4WD union
(27) 15 micron main filter
(28) LP union
(29) Diagnostic connector for booster and lubricating
pressure
(30) Supply to lift control valve manifold and auxiliary
spool valves
(31) LS pilot flow from auxiliary spool valves and lift
control valve
(32) Bolt
(33) Trailer brake valve pilot line
(34) Clogging indicator
(36) Centring pins
(37) Nut
(38) Washer
(39) Pinion
(40) Key
(42) Booster and lubricating pressure switch
(43) Union and pipe to manifold and lubrication (depen-
ding on assembly)
Issue 1 May 2001

External overall view without trailer braking
3 4 5 6 7 8 11 12 13 14 9 19 15
16
17
18
2 21
20
23
HP
1 24
BP
24
28
26
34
31 32 30 47 29 19 48 28 27 25
F
F
Parts list Fig. 3A Fig. 4 Fig. 5 Fig. 5A Fig. 3
Issue 1 May 2001

External overall view with trailer braking
3 4 5 6 7 8 33 11 12 13 14 9 19 15
16
17
18
2 21
20
23
1 HP
24
BP
28
26
34
50 31 32 30 47 29 19 48 28 27 25
F
F
Parts list Fig. 3 Fig. 4 Fig. 5 Fig. 5A Fig. 3A
Issue 1 May 2001

Internal overall view
36 10 49 37 38 39 40 41 8
36
45
49
10
44 34
Heavy Duty
gearbox
43 42
46
Full Powershift
gearbox
Parts list Fig. 3 Fig. 3A Fig. 5 Fig. 5A

Fig. 4
Issue 1 May 2001

Exploded view - Right-hand cover without trailer braking
53
55
7 52
54 41
40
2 36 39
9
8
12
1
47
38
37
44
34
32
42
25 34
27 11
29
48
15 16 17 18 46
8200 version with Heavy Duty gearbox

Parts list
(46) Temperature switch
Fig. 3 Fig. 3A Fig. 4 Fig. 5A Fig. 5
Issue 1 May 2001

Exploded view - Right-hand cover with trailer braking
53
55
7 52
54 41
40
2 36 39
1
47
9
25
38
12 37
44
34
32
46
27 11
29
48
42
15 16 17 18
8200 version with Full Powershift gearbox Parts list

(25) Plug
(46) Plug
Fig. 3 Fig. 3A Fig. 4 Fig. 5 Fig. 5A
Issue 1 May 2001

Identification of ports and channels (Figs. 6 - 7)
Fig. 6
S
HP
GAV
Fig. 7
P S
F
C
F
12 R
C : 22 bar adjusting screw (9) LS diagnostics connector

D : 200 bar adjusting screw (12) Pump regulator
P : HP from variable displacement pump
R : To control piston of variable displacement pump Important: Adjusting screws C and D are factory set.
S : Regulator return Do not modify these settings.
Issue 1 May 2001

Identification of ports and channels (Figs. 8 - 9)

Fig. 8
G
S1
G 8
G
R
Fig. 9
L
S R P G
F 45
G
G
G
44
F : 15 micron main filter (2) Pressure relief-valve

G : Booster (44) 5 bar safety valve
L : Lubrication (45) 22 bar safety valve
P : HP outlet from variable displacement pump
R : To control piston of variable displacement pump
S : Regulator return
S1 : Return from priority block(s)
Issue 1 May 2001

3 4 5 6 12 14 19 15 16 17 18
21
20
1
23
HP
24
BP
28 26
48
27
34 "O" 41
31 32 30 47 28
43 42 46
Fig. 10
Issue 1 May 2001

A . Removing and refitting the cover

Removal (Fig. 10)
1. Immobilise the tractor. Chock the left rear wheel. 1
3. Partially drain the intermediate housing.
4. Remove or place the right rear wheel in the wide track
position. Position axle stand(s) as necessary.
5. Disconnect pipes and hose pipes (3) (5) (6) (20) (21)
(23) (24) (26) (28) (30) (31) (43), solenoid valve electri-
cal harnesses (15) to (18) (depending on version),
switches (14) (42) (34), engine speed sensor (25) and
switch (46) (according to version).
6. Take out bolts (32). Remove the main filter assembly
(27).
7. Take out bolts (4). Remove the priority block(s).
8. Take out bolts (1). Unstick and remove the cover.
Remove the booster pipe (54) and pipe (55) of the 5 bar
safety valve (Fig. 2) (optional).
Special points
- One upper bolt holding the cover may be masked by the
union screwed into regulator (12). Take off the regulator G
in order to facilitate the removal of the cover.
- To disassemble the safety valve (45) of the LP circuit,
compress spring (3) using a screwdriver and remove
circlip (1). Remove parts (2) to (4) (Fig. 12). Check that 54
valve (4) slides freely in its housing.
Fig. 11
Fig. 12
2
45
44
Issue 1 May 2001


Refitting
Note: Check for the presence of the rivets on the
channels provided on the external face of the cover, 36
as well for those (45) on the internal face (Fig. 4).
Also check for the fitting of plugs (10).
9. Clean the mating faces of the housing and the cover.
10. Check for the presence of the two pins (36) (Fig. 13).
11. If it has been removed, insert pipe (55) of the 5 bar
safety valve. Position its end fitted with seal (53) in
the Mecanindus pin (22) located on compartment "C"
of the intermediate housing (Fig. 2).
Place booster pipe (54) fitted with O’ring (52) (Fig. 2),
its slot held by pin (1) (Fig. 11). Lightly smear seal (4) 36
with miscible grease and position it on the collar of
pipe (54) (Fig. 11).
12. Smear the mating face of the housing with a sealing
product (Loctite 510 or equivalent). Place the guide Fig. 13
studs "G" (Fig. 11).
13. Fill pump (41) with transmission oil via port "O"
(Fig. 10).
14. Slide the cover on the guide studs "G" (Fig. 11). Using
a bronze hammer, tap the rim of the cover to engage
pins (36) in the housing. Between the mating faces 3 4
of the cover and housing, check that pipe (55)
(Fig. 2) is correctly positioned on the 5 bar valve (44).
15. Tighten bolts (1) to a torque of 120 - 160 Nm.
Note: If resistance is felt during tightening, do 5
not continue. Move the cover away from the
housing and check the position of pipe (55) on
the 5 bar valve (44) (Fig. 2). Also check for the
rotation of pinion (39).
16. Replace seals (3) to (5) (Fig. 14) and refit the priority
block(s). Tighten bolts (4) smeared with Loctite 542
(Fig. 10) to a torque of 25 - 35 Nm.
17. Reconnect the engine speed sensor (see following
special points). Reconnect the switches, the har-
nesses of the solenoid valves and the hydraulic
pipes. 3 4
18. Raise the tractor, refit the wheel or place it in its initial
position. Remove the axle stands where necessary
and tighten the wheel nuts or studs to the torque
shown in section 2G01. 5
19. Top up the oil level in the housings.
20. Check the operation of the electrical circuits, LP
switches (14), booster (lubrication) switches (42),
clogging switch (34) and the solenoid valves.
21. Check the oil tightness of the cover, the mating
faces and the hydraulic unions.
Fig. 14
Issue 1 May 2001

Special points
- The engine speed sensor (25) is only fitted on 8200
tractors with a Heavy Duty transmission. Before fitting
it, see § D.
- Lightly smear the threads of the booster (lubrication)
switch (42) and low pressure switch (14) with Loctite
542 or its equivalent before fitting them.
Reminder: If replacement of the pump is necessary
(see § C), carry out hydraulic tests (see section 9N01).
Tightening torques
- Solenoid valve spools (15) to (18): 18 - 20 Nm.
- Hexagonal nut (PTO differential solenoid valve) moder-
ate tightening.
- 5 bar valve (44): smear threads with Loctite 241 and
tighten to a torque of 10 - 20 Nm using a locally
manufactured tool.
- Sensor nut (25) (depending on options, Heavy Duty
gearbox only): 10 - 15 Nm.
- Pressure relief-valve (2): 150 Nm.
- Knurled nuts: 4 - 5 Nm.
Issue 1 May 2001

Rotates to the left, shaft facing the operator

G : From variable displacement pump
P : HP outlet to priority block(s)
R : To control piston (10)
8 1 5 9 10
F
+ a
-
41 b 10
P
13
12
4
G
F R
11
6 G
7 3
Fig. 15
Issue 1 May 2001

B . Description and operation of the

variable displacement pump
The variable displacement pump, fitted inside the right-
hand cover, is driven by a pinion fixed by bolts to a
bearing block and located in the intermediate housing
(see § E).
It comprises a body (1) and a cylinder (3) driven by shaft

(13). The cylinder has nine axial pistons (4) thrust on ball
joints (5) that are in contact with plate (6) via the
intermediary of pads (7).
The inclination of the plate is obtained by the balance

between spring (8), pushrod (9) and piston (10) that is
controlled by a regulator receiving the LS pilot pressure
from the HP components via the priority block(s).
Depending on the inclination of the plate, the length of

travel of the axial pistons (4) is modified, thus permitting
the flowrate to adjust to the operating conditions.
The distribution plate (11), behind the cylinder, places in

communication the piston chambers with the suction
and discharge ports of the pump.
The ball joints (5) are drilled to provide lubrication be-
tween the pads (7) and plate (6). The oil is then sent to
the housing via port "O" (Fig. 10).
The pressure relief-valve (2) is screwed into the upper left

of the cover (Fig. 3 or 3A).
Issue 1 May 2001

12
S
R
P LS
10
20
20
21
17
(1) Priority blocks
(10) Piston R
(12) Variable displacement pump regulator
(21) Spool valves (17) (20) manifold Fig. 16
Issue 1 May 2001

Working position – full capacity

When a high flowrate function is activated, for example
an auxiliary spool valve, the pump exits the standby 12 a O XLS C
position and enters the maximum flowrate position. The
flowrate in the spool valve is not slowed enough to allow
the pump pressure to compress the 22 bar spring of spool
a. The pump remains in the maximum flowrate position.
The LS pilot pressure is slightly higher than the pump
pressure, minus 22 bar.
Working position – partial capacity

The partial opening of the spool valve causes an increase
in pressure that results in a LS pilot pressure being sent
to the pump. This pressure pushes spool a, allowing the
pump to be set at full capacity. The pressure of the pump
increases and pushes spool a into its equilibrium position P R b S D
where the pump pressure is greater than 22 bar in
accordance with the LS pilot signal. Fig. 17
If the receiver load increases, the LS pilot pressure
increases on the spring side of the spool a and commu-
nication is set up between ports R and S. The pressure
on piston (10) drops, the spring (8) pushes plate (6) and
increases the pump flowrate in order to finally stabilise
itself in a position where spool a is in an position of 2
equilibrium.
If a higher flowrate is requested, requiring a further
opening of the spool valve. The pressure drops and the
flowrate of the pump increases until it reaches a new
equilibrium. R
Maximum pressure – zero flowrate F

When the pressure at port P reaches 200 bar, spool b is
pushed forwards compressing its spring. The ports P and 1
R are placed in communication and piston (10) is brought
to the zero flowrate position. P F
The regulator (12) (Fig. 17), fitted on cover (8) regulates Fig. 18
the flow of pump pressure according to information
transmitted by the LS signal.
Pressure relief-valve (2) (Fig. 18)
The high pressure flow discharged by the variable dis-
Identification of ports and channels (Fig. 17)
placement pump passes through channel P in the cover
C : 22 bar adjusting screw
(8) (Fig. 8) and is directed towards the priority block(s).
D : 200 bar adjusting screw
The pressure relief-valve calibrated at 230 bar and screwed
O : Decompression port
onto the cover, ensures the safety of the high pressure
P : Pump pressure
circuit. In the case of abnormally high pressure, valve (1)
R : To piston (10)
opens and oil is directed to the housing via the interme-
S : Return
diary of ports R of the relief-valve.
LS : Signal
Important: The adjusting screws C and D are factory
set. Do not modify these settings.
Issue 1 May 2001

C . Removing and refitting the pump

22. Remove the right-hand cover. See § A.
4
Removal 1
23. Remove pump (41) with idler pinion (39).
24. Unscrew nut (37). Remove washer (38). Using an
appropriate extractor, remove the pinion. Recover
key (40).
2
3
Refitting
25. Clean all components. Replace any parts found to be 4
defective. Check that none of the channels in the
cover are obstructed. Fig. 19
26. Check for the presence of the locating pins (4) (Fig.
19).
27. Remplace O'ring (1) to (3) (Fig. 19).
28. Carry out the removal operations in reverse order.
Tighten bolts and nuts to the indicated torque.
Note: Inside the cover, apply a small continuous
bead of Loctite 574 or its equivalent around the
bolt holes (47). Use the same method as used
with the left-hand cover (see section 9H01 § B).
Final operation
29. Refit the right-hand cover (see § A).
Tightening torques
- Nut (37) : 50 - 60 Nm, Loctite 241
- Bolt (47) : 120 - 160 Nm, Loctite 241
- Bolt (4) : 25 - 35 Nm, Loctite 542
- Sensor nut (depending on assembly) : 10 - 15 Nm
Issue 1 May 2001

D . Adjusting the engine speed sen-

sor (Heavy Duty version)
Reminder
- The engine speed sensor (25) is only mounted on 8200
tractors fitted with a Heavy Duty transmission.
Special point
- The threads of the sensor must be lightly smeared with
Loctite 577 or its equivalent before adjustment.
Adjustment
30. Screw the sensor fully home without forcing it. The
end must be in contact with pinion (39) of the variable
displacement pump.
Then unscrew the sensor by three quarters of a turn,
in order to obtain a clearance of 1 mm approximately
between the sensor and the pinion. Tighten the nut
Issue 1 May 2001


Reassembly
E . Removing and refitting – Disas- 41. Clean and check the parts. Replace any compo-
sembly and reassembling the pump nents found to be defective.
bearing 42. Using a press and an appropriate fixture, insert
bearings (6) separated by spacer (5).
Preliminary operations 43. Place circlip (10).
- Place the rear wheels in the wide track position. 44. Refit the bearing block.
- Uncouple the tractor between the gearbox and the 45. Fix the pinion on the bearing block using bolts (4)
intermediate housing (see section 2C01). lightly smeared with Loctite 241 and tighten to a
- Remove the components of the creeper unit (if fitted) torque of 72 - 96 Nm.
that might hinder the removal of the pump drive pinion
(see section 6H01).
- Free the ratchet of the Park Lock (depending on assem- Special point
bly). See section 6F01 and take out the toothed sleeve - The union (9) has a calibrated port “R” to provide a
linking the drive pinion and the shaft, after carefully metered lubrication of the bearings (6).
noting its position.
- Remove pump drive pinion (1) fixed on bearing block
(11) (Fig. 20).
Removal (Fig. 20)

31. Take out plug (8). Using a threaded rod screwed into
the tapped hole, pull on locating pin (7) so as to free
spacer (5).
32. Through the front of the intermediate housing, pull on
bearing block (11) and take it out through the bore.
Refitting (Fig. 20)

33. Check that neither the channel nor drilled holes in the
spacer are blocked.
34. Check for the presence of circlip (12) on the upper
shaft of the power take off (only on tractors fitted
with Heavy Duty gearbox). Refit the bearing block
assembly, carry out operation 32 in reverse order.
35. Position the groove of spacer (5) along the axis of the
port provided for plug (8).
36. Fit the locating pin, inserting the flats in the groove of
the spacer. Tighten the plug.
37. Check that the bearing block assembly is correctly
positioned and that it turns normally.
38. Refit the pinion (1). Tighten bolts (4) lightly smeared
with Loctite 241 to a torque of 72 - 96 Nm.
Disassembling the bearing block (11) (Fig. 20)

39. Remove the bearing block.
40. Take off circlip (10). Extract bearings (6) from the
bearing block. Remove spacer (5).
Issue 1 May 2001

AA
5
A
8 7
9
1 6
4 10
12
11
Fig. 20
Issue 1 May 2001


Final operations
If fitted, refit the ratchet and sleeve of the Park Lock. The
long part of the sleeve must be turned towards the drive
pinion.
- Refit and adjust the elements of the creeper gearbox if
fitted (see section 6H01).
- Couple the tractor between the gearbox and the inter-
mediate housing (see section 2C01).
- Replace the rear wheels in their original position.
Tighten wheel nuts or studs to the torque shown in
section 2G01.
- Check the correct operation of all controls.
- Road test.
- Check the oil tightness of the mating faces and hydrau-
lic unions. 1 11 4
Fig. 21
Special points
- On tractors fitted with the Heavy Duty gearbox, the
profile of the drive bearing block (11) (Figs. 21 – 22) is
different from that fitted to tractors with a Full Powershift
gearbox (Fig. 20). The repair and maintenance opera-
tions however remain the same for both versions.
- If necessary, see section 5K01, creeper unit.
- A sleeve (14) held in position against bush (76) by a
spring (12) and a tab washer (3) provides oil tightness
of the upper shaft line between the gearbox and the
intermediate housing (Fig. 22).
Issue 1 May 2001

Heavy Duty gearbox version
14 3 12
3 12 13 9 R 19
11 5
76 2
13
2 4 1 6 10
(2) Collar (13) Rivets (76) Shouldered bush

(3) Tab washer (14) Sleeve
(12) Spring (19) Intermediate housing Fig. 22
Issue 1 May 2001

Hydraulics - 150 l/min right-hand cover 9G02.1
9 G02 150 l/min right-hand cover
CONTENTS
- General ________________________________________________ 3
B. Description and operation of the variable displacement

pump __________________________________________________ 16
C. Removing and refitting the pump ________________________ 20
D. Disassembling and reassembling - shimming of the idler

pinion __________________________________________________ 22
E. Removing and refitting - Disassembling and reassembling

the pump bearing block _________________________________ 25
Issue 1 May 2001

9G02.2 Hydraulics - 150 l/min right-hand cover
Issue 1 May 2001

Hydraulic routing
General - The oil coming from the booster pump located on the
Certain 8200 tractors may be fitted with a 150 l/min left-hand cover (see section 9H01) flows into the priority
flowrate Load Sensing circuit. block(s) (7) (depending on version) via the main filter
(27) and the variable displacement pump (41) (Fig. 2).
The right-hand side hydraulic cover of this circuit is fitted - The tube (55) (Fig. 3) sends the oil coming from the 5 bar
on the intermediate housing as is the 110 l/min flowrate safety-valve into the suction manifold of the booster
Load Sensing circuit. The cover serves as a support for pump (see section 9H01) when no hydraulic slave
numerous components and contains various channels device is used.
for the booster, lubricating and low flowrate circuits.
On its internal face, the cover contains:

- an idler pinion (82) also known as the "relay" pinion.
- the safety valve (44) of the booster and lubricating
circuit calibrated at 5 bar.
- the safety valve (45) of the low pressure circuit (17 bar).
On its external face, the cover is fitted with:

- the variable displacement pump (41) and its regulator
(12)
- the main 15 micron filter (27)
- one or two priority block(s) (7) (depending on assembly)
serving the various functions of the low and high
flowrate circuits
- the high pressure relief-valve (2) calibrated at 230 bar
- the four solenoid valves (15) to (18) controlling the low
pressure functions (depending on options) one of which
(power take off clutch) is of the proportional type.
- the high and low pressure diagnostics connectors (11)
(48), booster (lubrication) (29) and Load Sensing (9).
- the low pressure (14) and booster (42) switches as well
as the clogging indicator (34) of the main filter (27).
Description
- The engine movement transmitted to pinion (1) by shaft
(2) drives the variable displacement pump pinion via the
"relay" pinion (82) (Fig. 1).
82 1
Fig. 1
Issue 1 May 2001


Parts list (48) Low pressure diagnostic connector
(1) Bolt (49) Rivets
(2) High pressure relief-valve (50) Port to trailer braking quick disconnect coupling
(3) Orbitrol spool valve supply port (51) Transfer pipe
(4) Bolt (56) Composite seal (O’ring and anti-extrusion bush)
(5) Load Sensing control port from Orbitrol spool valve (57) Dust cover
(6) Load Sensing control port to pump regulator (58) Sleeve
(7) Priority block(s) (59) O’ring and dust cover
(8) Cover (60) O’ring and dust cover
(9) Load Sensing diagnostics connector (61) Composite seal (O’ring and anti-extrusion bush)
(10) Return pipe (62) Dust cover
(11) High pressure diagnostic connector (63) Suction manifold and bolt
(12) Pump regulator (64) Discharge manifold and bolt
(13) Load Sensing union (65) Lubricating port for relay pinion
(14) Low pressure (17 bar) switch (66) Port to brake power assistance
(15) Solenoid valves: power take off, power take off (67) Studs
to brake, differential lock front and rear if fitted and (68) Nuts
(18) 4WD (69) Plug
(19) Hydraulic cover assembly (70) Closing plate and seal
(20) Park Lock union (71) Plug
(21) Power take off clutch port (72) Spacer
(22) Mecanindus pin (73) Bolt
(23) Power take off brake (74) Obturator and seal
(24) 2WD or 4WD differential lock port (75) Bolt
(25) O’ring (76) Washer
(26) Port for 4WD union (77) Bearing cone
(27) 15 micron main filter (78) Bearing cup
(28) Low pressure port (79) Shim(s)
(29) Booster pressure and lubricating diagnostic con- (80) Circlips
nector (81) Spacer
(30) Supply port for lift control valve and auxiliary spool (82) Idler pinion
valves via the manifold (83) Pin
(31) Load Sensing control port from auxiliary spool (84) O’ring
valves and lift control valve
(32) Bolt
(33) Control port of trailer brake valve
(35) O’ring
(36) Centring pins Fig. 9
(37) Nut
(38) Washer
(39) Pump pinion Fig. 10
(40) Key
(42) Pressure switch (booster and lubrication)
(43) Port to lubricating manifold located above centre
housing
(46) Plug
(47) Bolt
Issue 1 May 2001

41
BP
27 HP
7
Fig. 2
Issue 1 May 2001

53
22
55
VS
52
52 22 54
53 PCV
C
54 55
(22) Mecanindus pin A : Suction

(52) O’ring PCV : To variable displacement pump (41)
(53) O’ring VS : 5 bar safety valve (44)
(54) Booster pipe C : Intermediate housing compartment
(55) Safety valve (44) pipe
Fig. 3
Issue 1 May 2001

External overall view without trailer braking
F1
16 17 15
18
F.PDF 4RM D.LOCK PDF
21
48 23 24 26 28 31
42 29 43 10 47 1 14
30
F F1
67
68
BP
7
13
HP
12 56 57 9 72 51 41 62 61 8 6 11 5 3
Fig. 4
Issue 1 May 2001


External overall view with trailer braking
F1
16 17 15
18
F.PDF 4RM D.LOCK PDF
21
48 23 24 26 28 31
42 29 43 10 47 1 14 30 50
67
F F1
68
33
BP 7
13
4
HP
12 56 57 9 72 51 41 62 61 8 11 6 5
Fig. 5
Issue 1 May 2001

External overall view
24 26 31 28 23 50 66
21
30
33 P aux X aux 17B

Frein Rem
20
Xdir
Pdir
XLS
5 3
Fig. 6
6 69
67 68 65 1 67 68
67 70
68
32 71
34 27
Fig. 7
Issue 1 May 2001


Internal overall view
36 8
45 36
44
84 41
37
74
38
40
39
68
1 36
67
82
77 78 80 79 80 81 78 77 83 76 75
Fig. 8
Issue 1 May 2001

Hydraulics - 150 l/min right-hand cover

9G02.11
Exploded view
75
76
77
78
80
81
82
80
19
79
52 78
58 39
77
63 83
54
46
38
42
53 37
60 48 55
59 14 67
47 49
25 44
68
40
41
8 1
45
49
9 35 49
84
12 62 7
70
64 61
56
57
51 2
34
32
27
72 71 73 11 74 1 68 67 36
Without trailer braking A
With trailer braking B 4
Fig. 9 Fig. 10
Parts list Fig. 10 Parts list Fig. 9
Issue 1 May 2001

Issue 1 May 2001


1. Immobilise the tractor. Chock the left rear wheel.
4. Disassemble the right rear wheel. Position an axle
stand.
Removing the priority block(s)

5. Proceed with the removal of the priority block(s) by
removing bolts (4) after previously disconnecting
hose pipes (3) (5) (6) (28) (30) (31) (50) (Figs. 4 or 5).
Special point
8
- On tractors fitted with trailer braking, remove the
priority block(s) (7) without disconnecting hose (33) Fig. 11
(Fig. 5). This precaution will avoid bleeding of the
valve pilot circuit when refitting the cover.
Removing the cover (8) (Fig. 11)

6. Disconnect pipes (10) (21) (23) (24) (26) (43), the sole-
noid valve harnesses (15) to (18) (depending on the
version) and switches (14) (34) (42) (Fig. 4, 5 and 7).
7. Take out bolts (32) and remove the main filter assem-
bly (27).
8. Remove bolts (1) and nuts (68).
Reminder
- Check that there is no hydraulic or electrical link that
remains connected between the cover and the
9. Release and remove the cover (see following safety
precaution).
Special point
- Certain nuts and bolts on the cover are difficult to
access. Where necessary, use a locally manufac-
tured wrench.
Issue 1 May 2001

Danger
- The cover and pump together are extremely heavy.

Their removal must be carried out with care using a 1
locally manufactured support that replaces the head of
a trolley jack.
10. After removing the cover, take out pipes (54) (55)
(optional).
Reminder
- The 22 bar safety valve (45) comprises (Fig. 13):
. a circlip (1)
. a stop (2)
. a spring (3)
. a valve (4)
Refitting the cover

Reminder
- Check for the presence of rivets (49) at the end of the
channels located on the external and internal faces of
the cover.
12. Check for the presence of the two centring pins (36)
(Figs. 8 - 14).
13. If removed:
- place seal (53) on pipe (55) (Figs. 3 - 9). Position the
end of the pipe in the Mecanindus pin (22) located
on compartment "C" of the intermediate housing
(Fig. 3).
- place seal (52) on pipe (54) (Figs. 3 - 9). Position the
machined slot of the flange in pin (1) (Fig. 12).
4
Fig. 12
4 3 2 1 36
36
Fig. 13 Fig. 14
Issue 1 May 2001

14. Lightly smear the seal (4) with miscible grease and
stick it to the flange (Fig. 12).
15. Check the location of the pins (67) in the intermediate
housing.
3 4
Remark
- The pins are first lightly smeared with Loctite 241
before fixing them on the housing.
16. Smear the mating face of the housing with Loctite
5
17. With the assistance of another operator and the tool
recommended in the preceding remark "Danger",
refit the cover by aligning its holes with the studs on
the housing.
18. Push the cover progressively while simultaneously
checking between housing and cover mating faces
that the 5 bar safety valve is correctly housed in pipe
(55) (Fig. 3).
19. Tighten bolts (1) and nuts (68) to a torque of 120 -
160 Nm.
3 4
Important
- If there is any resistance, stop tightening and open
the gap between housing and cover to check on the
correct alignment of pipe (55) and the 5 bar valve. 5
20. Refit the main filter assembly (27) and tighten bolts
(32).
21. Reconnect the harnesses to the solenoid valves and
switches. Carry out operation 6 in reverse order.
Refitting the priority block(s)

22. Refit the priority block(s) and check for the presence
of seals (3) (4) (5) (Fig. 15). Tighten bolts (4) previ-
ously smeared with Loctite 542 to a torque of 25 -
35 Nm. Reconnect the pipes or hoses. Carry out
operation 5 in reverse order.
Fig. 15
Final operations
23. Refit the rear wheel. Remove the axle stand. Tighten
the wheel nuts or studs (depending on version) to the
torque shown in section 2G01.
24. Top up the oil levels in the housings and check the
transparent tube on the left-hand side of the centre
housing.
25. Remove the chocks. Start the engine and check:
- the operation of the hydraulic and electrical compo-
nents
- the oil tightness of the mating faces, pipes and
hoses.
Remark
- If the variable displacement pump has been re-
placed, carry out hydraulic tests (see section 9N01).
Issue 1 May 2001


- Depending on the angle of the plate, the travel of the
B . Description and operation of the axial pistons (4) varies and permits the flowrate to be
variable displacement pump adapted to operating requirements.
- The distributor plate (11) at the rear of the cylinder,
Description (Fig. 16) places the piston chambers in communication with the
- The variable displacement pump (41) is fitted on the suction ports and the pump discharge.
external face of the right-hand side cover. It is driven by - The ball joints (2) (5), fitted respectively to the axial
an idler pinion known as the relay pinion that is itself pistons and the inclined plate, are drilled to ensure the
driven by a driving pinion driven by the engine. lubrication of all moving parts. The oil is then directed
- The variable displacement pump comprises a body (1) to a port and an external pipe to lubricate the relay pinion
and a cylinder (3) driven by shaft (13). The cylinder bearings.
contains nine axial pistons thrust against ball joints (5) - The pressure relief-valve is screwed into the lower right
in contact with plate (6) via the pads (7). front of the cover.
- The angle of the plate results from a balance between
spring (9) and piston (10) controlled by a regulator (12)
that receives the LS pilot pressure from the high
pressure components via the priority block(s).
Rotation to the right, shaft facing the operator

G : Booster from left pump
P : HP outlet to the priority block(s)
P1 : HP pressure
R1 : To control piston (10)
S : Return from the regulator
a
41 10
b
P
5 2 9 4 1 8 3
11
13
G
8 12
- + R1 P1
S
6 7 10
F
F
Fig. 16
Issue 1 May 2001

Identification of ports and components (Fig. (1) Priority block(s)

17) (10) Piston
C : 22 bar adjusting screw (12) Variable displacement pump regulator
D : 200 bar adjusting screw (17) Lift control spool valve
P : HP pressure from variable displacement pump (20) Auxiliary spool valves
P1 : HP pressure to regulator (21) Manifold for spool valves (17) (20)
R : Return
R1 : To control piston (variable displacement pump) Important
S : Return from regulator - Screws C and D are factor set.
- Do not modify these settings.
20 21 17
P LS
LS
R PR
1
P
P1 12
R1
S 10 F
R1
C D
P1
S
Fig. 17
Issue 1 May 2001


Working position – full capacity
- When a high flowrate function is activated, for example
an auxiliary spool valve, the pump exits the standby P1 12
position and enters the maximum flowrate position.
The flowrate in the spool valve is not slowed enough to R1
allow the pump pressure to compress the 22 bar spring a
of spool a. The pump remains in the maximum flowrate
b
position. The LS pilot pressure is slightly higher than the
pump pressure, minus 22 bar. O
S
Working position – partial capacity XLS

- The partial opening of the spool valve causes an
increase in pressure that results in a LS pilot pressure D
C
being sent to the pump. This pressure pushes spool a,
allowing the pump to be set at full capacity. The
pressure of the pump increases and pushes spool a into
Fig. 18
its equilibrium position where the pump pressure is
greater than 22 bar in accordance with the LS pilot
signal.
- If the receiver load increases, the LS pilot pressure Identification of ports and channels (Fig. 18)
increases on the spring side of the spool a and commu- C : 22 bar adjusting screw
nication is set up between ports R1 and S. The pressure D : 200 bar adjusting screw
on piston (10) drops, the spring (8) pushes plate (6) and O : Decompression port
increases the pump flowrate in order to finally stabilise P : Pump pressure
itself in a position where spool a is in an position of R : To piston (10)
equilibrium. S : Return
- If a higher flowrate is requested, requiring a further XLS : Signal
opening of the spool valve. The pressure drops and the
flowrate of the pump increases until it reaches a new Important:
equilibrium. - The adjusting screws C and D are factory set.
- Do not modify these settings.
Maximum pressure – zero flowrate

- When the pressure at port P1 reaches 200 bar, spool b
is pushed downwards compressing its spring. The
ports P1 and R1 are placed in communication and piston
(10) is brought to the zero flowrate position.
- The regulator (12) (Fig. 17), fitted on pump (41) regulates
the flow of pump pressure according to information
transmitted by the LS signal.
Issue 1 May 2001

Pressure relief-valve (2) (Fig. 19)

- The high pressure flowrate discharged by the variable P
displacement pump is directed towards the priority F
block(s).
- The pressure relief-valve calibrated at 230 bar and
screwed into the cover, ensures the safety of the high
pressure circuit. In case of any abnormal variation in
pressure, valve (1) raises and the oil is directed to the
housing via ports R in the relief-valve.
F
1 R 2
Fig. 19
Issue 1 May 2001

C . Removing and refitting the pump

27. Remove the right-hand side cover (see § A). 47
A
84
Removal (Fig. 20 - 21)
28. Disconnect any pipes linked to the pump (41). 41 8
29. Take out the obturator (74) along with its seal.
30. Immobilise the pump shaft by blocking pinions (39)
(82) using a bronze drift. R
31. Unscrew nut (37) and recover washer (38).
32. Via the port obturator, introduce an extractor so that
its threaded rods screw into and lock in the threaded 51
holes of the pinion. Operate the extractor and re-
move the pinion from the conical pump shaft.
33. Remove the hydraulic suction A and discharge R Fig. 20
manifolds from the pump. Discard the seals and
recover the transfer pipe (51).
34. Take out bolts (47) and remove the pump from the
cover (8).
35. Discard seal (84).
82
39
40 38
37
74
Fig. 21
Issue 1 May 2001

Refitting
36. Clean and inspect all the parts. Replace any compo- 1
nents found to be defective.
37. Degrease the threads of the pump shaft.
38. Place an new O’ring (84) in the bore of the pump
housing and position key (40) in its slot at the end of
the shaft.
39. Position the pump on the cover by checking the
alignment of the key in the slot on the pinion. Tighten
bolts (47), lightly smeared with Loctite 542 or its
equivalent, to a torque of 200 - 260 Nm.
40. Slide washer (38) onto the shaft.
41. Degrease the threads of nut (37) and lightly smear
them with Loctite 241 or its equivalent, then tighten
42. Manually check the rotation of the pump and check 41
the pinion backlash.
Fig. 22
43. Fit the obturator with a new seal and refit the
assembly in the port in the cover.
44. Replace the hydraulic manifolds and the transfer
pipe fitted with new seals. Fit spacer (72). Tighten
the bolts (Fig. 20) using the torques shown below:
- manifold A : 90 - 120 Nm
- manifold R : 50 - 70 Nm
- spacer (51) : 50 - 70 Nm
Final operation
45. Refit the right-hand side cover (see § A).
Important
- Fill the variable displacement pump (41) with trans-
mission oil via the port of pipe (1) (Fig. 22) before
starting the engine.
Issue 1 May 2001

D . Disassembling, reassembling and

shimming of the idler pinion
Disassembly (Fig. 23) 79 80
46. Remove the variable displacement pump (see § C).
47. Unlock and remove bolts (75). 81 78
48. Take out pin (83) and pinion (82) and pair together the
bearing cones and cups (77) (78) if they are to be re-
77
used. Recover the shim(s) (79) and spacer (81).
49. On the pinion, remove the bearing cups (78) and
circlips (80).
Reassembly
50. Place the bearing cups (78) thrust against the previ-
ously fitted circlips.
51. Reassemble the turning hub of the idler pinion (82) by
assembling the bearing cones (77), spacer (81), the 83 82
shim(s) and pin (83).
Reminder
- If required, carry out the shimming of the idler
pinion (see operations 56 to 64). Otherwise con-
tinue the reassembly operations.
52. Assemble the pinion and pin on the cover.
53. Degrease the threads of bolt (75) and lightly smear
it with Loctite 241 or its equivalent. 75 76
54. Fit washer (76) and tighten the bolt to a torque of 100
- 130 Nm.
55. Manually check the rotation of the pinion.
Fig. 23
Issue 1 May 2001

Preparation for shimming the idler pinion

Parts concerned by shimming (Figs. 24 - 25) 77
- The pinion (82), the circlips (80), the bearing cones and 78
cups (77) (78) and spacer (81). 80
81
Remark
- The clearance of the taper roller bearings is adjusted by
shim(s) (79) placed between the front cone (77) and
spacer (81). (Fig. 24).
Reminder 77
- To carry out the correct shimming of the bearings, place 82 78
the cover in a vice with the pump pinion (39) protruding 83
as shown in Figure 25.
80
79
Fig. 24
J1 = 0,03 / 0,13mm
81
8 75
39 76 79
82
Fig. 25
Issue 1 May 2001


Shimming
56. Place the index of the dial gauge on the pinion (82)
(Fig. 25).
57. Push the pinion strongly downwards, alternatively
turning the pinion left and right in order to correctly
seat the cone in the bearing cup.
59. Repeat the operation, this time pulling on the pinion
instead of pushing.
60. Depending on clearance measured, select a thick-
ness of shim(s) in order to provide a clearance of:
J1 = 0.03 to 0.13 mm (Fig. 25)
Remark:
Wherever possible, shim the bearings to the mini-
mum clearance.
61. Fit the definitive shim(s) selected in operation 60.
62. Degrease the threads of bolt (75) and lightly smear
the threads with Loctite 241 or its equivalent.
63. Fit washer (76) and tighten the bolt to a torque of 100
- 130 Nm.
64. Manually check the rotation of the pinion.
Issue 1 May 2001

E . Removing and refitting - Disas-

sembling and reassembling the 82 4 1
pump bearing block
- Place the rear wheels in the wide track position.
- Uncouple the tractor between the gearbox and the
- Remove the creeper unit components (if fitted, see
section 6H01).
- Free the ratchet of the Park Lock (if fitted, see section
6F01). Take out the toothed sleeve after carefully noting
its position.
Removal Fig. 26
65. Immobilise pinions (1) (82) using a bronze drift. Take
out bolts (4) and extract pinion (1) (Fig. 26).
66. Take out plug (8). Using a threaded rod screwed into
the threaded hole in locating pin (7), pull on it so as
to free spacer (5) (Fig. 27).
67. Through the front opening of the intermediate hous-
ing, pull on the bearing block to disengage it from the
bore of the housing.
Refitting
68. Check that the hydraulic channels and ports of the
spacer are not obstructed.
69. Refit the bearing block. Carry out operation 67 in
reverse order.
70. Place the groove of the spacer in the axis of the port
provided for the plug (8) (Fig. 27).
71. Fit the locating pin, with the flats lodged in the groove
in the spacer. Tighten the plug.
72. Check that the bearing block assembly is correctly
positioned and that it turns normally.
73. Fit pinion (1). Tighten bolts (4) previously smeared
with Loctite 241 or its equivalent to a torque of 72 -
96 Nm (Fig. 26).
Issue 1 May 2001


Disassembly
74. Remove the bearing block.
75. Take off circlip (10). Extract bearings (6) and recover
spacer (5) (Fig. 27).
Reassembly
77. Using a press and an appropriate fixture insert
bearings (6), placing spacer (5) between them.
79. Check for the presence of circlip (12) on the upper
shaft of the power take off (Fig. 27).
80. Refit the bearing block and fit the pinion. Tighten the
bolts to the torque shown in operation 73.
Special point
- The union (9) has a calibrated port for the lubrication of
bearings (6).
Final operations
- If fitted, unclamp the ratchet and position the sleeve of
the Park Lock.
Remark
- The long part of the ratchet must face the drive pinion.
- Refit and adjust the creeper unit components (if fitted,
see section § 6H01).
- Couple the tractor between the gearbox and the
- Replace the wheels in their initial positions. Tighten
the wheel nuts or studs to the torque shown in section
2G01.
- Check the operation of all the controls.
- Check the oil tightness of the mating faces and
hydraulic unions.
Issue 1 May 2001

AA
9 8 7 5
1 10
4
12
11
Fig. 27
Issue 1 May 2001

Hydraulics - Left-hand cover 9H01.1
9 H01 Left-hand cover 110 l/min and

150 l/min Load Sensing
CONTENTS
- General ________________________________________________ 2
B. Removing and refitting the booster pump _________________ 10
C. Replacing pump seals ___________________________________ 11
Issue 1 May 2001

9H01.2 Hydraulics - Left-hand cover
General
12
The left-hand side cover, fitted on the intermediate
housing, forms the support for the following compo- 1
nents:
On its inside face (Figs. 3 - 4)
- the booster pump (2) the capacity of which differs
depending on the hydraulic characteristics as shown in
the table below.
- the suction manifold (4)
2
Load Sensing hydraulic circuit
Booster pump Variable displacement

pump (*)
Fig. 1
60 cm3/rpm 0 à 45 cm3/rpm
80 cm3/rpm 0 à 60 cm3/rpm
(*) see respective sections 9G01 and 9G02
On the outside face

- the 150 micron suction strainer (6) differs through the
size of its filtering surface and depends on the capacity
of the variable displacement pump (96 mm long with
the 60 cm3 pump and 139 mm long with the 80 cm3
version).
Remarks
- The figures given in this section are for the 60 cm3 pump
and its surrounding elements. The construction of the
80 cm3 pump is identical in principle to the former.
- It should be noted however, that the internal pinions as
well as the body of the pump have slightly different
profiles.
Description
Pinion (1) taking its rotation from shaft (2), drives pinion
(12) of the booster pump (Fig. 1). The oil is sucked into
the intermediate housing via the manifold (4). It is then
directed towards the strainer (6) and the booster pump (2)
(Fig. 2) through an internal channel in the cover.
The oil is then discharged towards the variable displace-
ment pump by the booster pipes (3) (54) held by compart-
ment ‘C’ of the intermediate housing (Fig. 2).
The pipe (55) directs the oil coming from the 5 bar safety-
valve towards the suction manifold (4).
Issue 1 May 2001

A
5
C
4 55
25
2
VS
6
54
17 5 26
3 4 25
PCV
26
(25) O’ring
(26) Mecanindus pin
(54) Booster pipe
(55) Safety-valve pipe (see section 9G01 or 9G02 depending on hydraulic characteristics)
A Suction
PCV To the variable displacement pump (see section 9G01 or 9G02 depending on hydraulic characteristics)
VS 5 bar safety-valve
C Compartment of the intermediate housing Fig. 2
Issue 1 May 2001


Parts list
(1) Nut
(2) Booster pump
(3) Booster pipe
(4) Suction manifold
(5) O’ring
(6) Strainer
(7) Studs
(8) Plug
(9) Seal
(10) Bolt
(11) Washer
(12) Pinion
(13) Key
(14) Cover
(15) Nut
(16) Centring pins
(17) O’ring
(18) Gasket
(19) Bolt
(20) Bowl
(21) O’ring
(22) Bolt
(23) O’ring
(24) Locating pins
Fig. 3
Fig. 4
Issue 1 May 2001

Vue d’ensemble
Overal view
17 14 13 12 11 16 3 17 2 10 9
15 7
18
16 4 20
24
23 2 21 7 1 19 4
20
6
22
18
Issue 1 May 2001

Exploded view
16
3
17
2
24
12 23 10
14
9
8
22
24
19
11
13
15
10
6
21
20
18
7
1
Issue 1 May 2001

Identification of channels and ports
2 12
23
24
A
Fig. 5
16
16
A
A : Suction from manifold (4)

B : Strainer (150 microns)
G : Booster supply to the variable displacement pump Fig. 6
Issue 1 May 2001


Removal
1. Take off the wheel on the side concerned. Position
an axle stand.
3. Unscrew the bowl (20). Remove the strainer (6) (Fig. 7)
4. Take off nuts (1) and bolts (10) (19) (Fig. 7).
5. Remove the cover (14) and then the suction mani-
fold (4). If necessary, remove the studs (7) (Figs. 4 and
7).
Refitting
Smear the mating face of the housing with Loctite
7. Replace the O’ring (17) and position the seal (5) on
the suction manifold (4) (Fig. 3).
8. Refit manifold (4), the end fitted with seal (5) inserted
into compartment ‘C’ of the intermediate housing
(Fig. 2). 14 1 7 6 20
9. Lightly smear the face of the gasket (18) on the
suction manifold (4) with Silicomet type silicone.
Spool the gasket over the studs (7), the adhesive
facing the cover. Screw two diametrically opposed
guide studs G on to the intermediate housing (Fig. 8).
10. Check for the presence of the two centring pins (16) 10 19
(Fig. 6).
11. Place a new O’ring (25) on the booster pipe (3). Insert
the pipe, its end positioned in the Mecanindus pin
(26) (Fig. 2).
14 1 7 6 20
Fig. 7
Issue 1 May 2001

12. Spool the cover on to the guide studs G and studs (7)
(Fig. 8). Using a bronze hammer, tap the cover to
engage the pins (16) in the housing.
13. Take out the guide studs G. Fit and alternately and
uniformly tighten the bolts (10) (19) to a torque of 90
- 120 Nm. 7
Note: In case of any resistance felt while tighten-
ing, move the cover away from the housing and
check the position of pipe (3) in the pump port. G
Also turn pinion (12).
14. Fit nuts (1) (Fig. 7) smeared with Loctite 241 and
tighten to a torque of 15 - 20 Nm.
15. If necessary, replace O’ring (21) on bowl (20). Put
the strainer (6) in place and tighten the bowl.
16. Carry out operations 1 and 2 in reverse order.
17. Check the oil tightness of the mating face of the G 4 7 18
cover as well as that of the bowl. Fig. 8
Tightening torques
- Nuts (1): 15 - 20 Nm (Loctite 241)
- Bolts (10) (19): 90 - 120 Nm
- Wheel nuts or studs: see section 2G01
- Bowl (20): moderate tightening.
Issue 1 May 2001

B . Removing and refitting the boos-

ter pump 24 23 C
Remark
- The removal and refitting procedures are the same for
a 60 cm3 or 80 cm3 pump.
18. Take off the cover (see § A).
Removal
19. Remove bolts (22) and pump (2) (Fig. 3). If neces-
sary, remove pinion (12) from the pump. Recover
key (13). Fig. 9
Refitting
20. Clean the mating faces of the pump and cover.
21. Check for the presence of the locating pins (24) (Fig.
9).
22. Inside the cover, apply a bead ‘C’ of Loctite 574 or
its equivalent around the bolt holes (Fig. 9). The dia-
meter of the bead should be small in section so as
to not touch the groove of seal (23). Fit a new seal.
23. If disassembled, replace key (23) and refit pinion
(12). Tighten nut (15) to the torque indicated below.
Position the pump on the centring pins.
24. Fit bolts (22) smeared with Loctite 241 or its equiva-
lent and tighten to a torque of 40 - 50 Nm.
25. Manually check the rotation of the pump.
Final operation
26. Refit the cover (see § A).
Tightening torques
- Nut (15): 50 - 60 Nm (Loctite 241)
- Bolt (22): 40 - 50 Nm (Loctite 241)
Issue 1 May 2001

C . Replacing the pump seals (Fig.

10)
Remark
- Whatever the hydraulic characteristics of the pump, the
operational procedure for the replacement of the seals
remains identical.
27. Remove the left-hand side cover (see § A) and the
booster pump (see § B).
13 3 4 2
17
5 1
6 7
Fig. 10
Issue 1 May 2001


Disassembly
28. Tighten the pump in a vice fitted with plastic jaw
protectors. 1
29. Remove bolt (1) and cover (7) (Fig. 11).
30. Take off circlip (3), seal (4) (Fig. 12) and O’rings (5)
(6) (Fig. 13).
Refitting 7
31. Lubricate seal (4) and insert it using an appropriate
fixture. Place circlip (3).
32. Lightly smear the O’rings (5) (6) with miscible
grease and position them on the cover (7) (Fig. 13).
33. Position the cover (Fig. 14). Fit and tighten bolts (1)
to a torque of 30 - 40 Nm (Fig. 11)
34. Manually check for the free rotation of the pump.
Fig. 11
Final operation
35. Refit the booster pump (see § B) and the left-hand
cover (see § A).
3 4
Fig. 12
5 6
7 5
Fig. 13 Fig. 14
Issue 1 May 2001

Hydraulics - Master cylinders 9I01.1
9 I01 Brake and clutch master cylinders circuit

and bleeding
CONTENTS
- General ________________________________________________ 3
A. Servicing the master cylinders ___________________________ 9
B. Brake master cylinders __________________________________ 9
C. Master cylinder and servobrake assembly _________________ 10
D. Adjusting the servobrake rod ____________________________ 12
E. Adjusting the brake pedals ______________________________ 12
F. Clutch master cylinder - Tractor with mechanical

reverse shuttle __________________________________________ 13
G. Adjusting the clutch pedal - Tractor with mechanical

reverse shuttle __________________________________________ 14
H. Bleeding the main brake circuit __________________________ 15
I. Bleeding the trailer braking circuit _______________________ 17
J. Bleeding the clutch control - Tractor with mechanical

reverse shuttle __________________________________________ 18
2
Issue 1 May 2000
December 2002
9I01.2 Hydraulics - Master cylinders

General
Brake master cylinders
The tank (4) (Fig. 1 - 2) maintains a constant level in the
brake master cylinders through a residual flow of oil 4
coming from:
- either, the output line of the oil cooler via the thermo-
static valve (on tractors with Full Powershift transmis-
sion)
- or, the lubrication line (booster) of the right-hand hydrau-
lic cover (on tractors with Heavy Duty transmission).
On the version without trailer braking, the arrangement is

two single circuit master cylinders (Fig. 1)
On the version with trailer braking, the arrangement is

two double circuit master cylinders (Fig. 2) with a valve
incorporated in the priority blocks (see section 9B01) and
a quick-disconnect coupling located at the rear of the
tractor.
On 8200 tractors, the arrangement is completed by

power assistance reducing the effort required on the
brake pedal.
The servobrakes are supplied from the 17 bar low- Fig. 1

pressure circuit (Fig. 3 - 3A or 4 depending on the
version).
1 4
Fig. 2
Issue 1 May 2001


Characteristics
(1) Accumulator (Fig. 3 - 3A - 4)
- Manufacturer ................................ Olaer Servobrake
- Type .............................................. 1/20 1
- Capacity ........................................ 1 litre
- Gas ............................................... Nitrogen
- Inflation pressure .......................... 9 ± 1bar
To be checked every
six months with
the engine stopped
(2) Non-return valve (Fig. 3 - 3A - 4)
- Manufacturer ................................. Parker
Special point
- During refitting, turn the arrow engraved on the
valve body to match the direction of the fluid flow
(3) Main accumulator (Fig. 3 - 3A) for Dynashift inte-
grated into Heavy Duty transmission 2
Fig. 4
Full Powershift transmission

Servobrake
2 1 3
17 bar low pressure
Gas
Fig. 3
Issue 1 May 2001

Version with Power Shuttle
Servo-rake
2
3
17 bar low pressure
Gas
Fig. 3A
Clutch master cylinder

- Only tractors fitted with Heavy Duty transmission are
equipped with a clutch master cylinder. It is of the
classical type and supplies the engine clutch valve
(Pressure Loaded) that is fitted on the mechanical
reverse shuttle version (Fig. 3). Its oil level is main-
tained constant by the flow passing through hose (1)
(Fig. 2).
Issue 1 May 2001


Parts list (Fig. 5 to 7)
(1) Supply from thermostatic valve (Full Powershift
transmission) or right-hand hydraulic cover (Heavy
Duty transmission).
(3) To clutch master cylinder (Heavy Duty transmis-
sion)
(4) Supply tank
(5) Return from the tank and bleed connector
(6) Pressure balancing junction
(7) Brake pistons supply
(8) Brake assistance return
(9) Servobrake supply
(10) Bleed screw
(11) Right-hand master cylinder
(12) Left-hand master cylinder
(13) Right-hand servobrake
(14) Left-hand servobrake
(15) Trailer brake junction
(16) Hydraulic link
(17) Trailer brake quick-disconnect coupling
(18) Priority blocks with trailer braking
Heavy Duty transmission with power brakes
4 5 5 11 6 13 8 9
3 1
1 12 14 7 10
Fig. 5
Issue 1 May 2001

Full Powershift transmission with power brakes
4 5 5 11 6 13 8 9
2 A
1 12 14 7 10
D C
A : Supply to thermostatic valve from the gearbox C : To gearbox lubrication

B : To oil cooler D : Oil cooler return
Fig. 6
Full Powershift transmission with power brakes and trailer braking
4 5 5 11 6 13 8 9 16 18 17
15
1
2 A 1 12 14 7 10
D C
A : Supply to thermostatic valve from the gearbox C : To gearbox lubrication
B : To oil cooler D : Oil cooler return
Fig. 7
Issue 1 May 2001

D Fig. 8
B C
1 5 2 3 4
D
A B C 3 2
Fig. 8A
E F 6 1 5 4
E A 2 3 5 6
4 16 17 11 1 10 9 T 7 8
Fig. 9
Issue 1 May 2001

A . Servicing the master cylinders

- If disassembly of the master cylinders is necessary,
carefully clean all the parts. Replace any components
found to be scratched or distorted.
- Repair kits for the clutch and brake master cylinders
(tractors with mechanical reverse shuttle only) are
listed in the Spare Parts catalogue.
- After disassembling or replacing the brake master
cylinders, bleed the main brake circuit (see § H).
- Check the adjustment of the servobrake rods and the
pedals (see § D and E).
- After disassembling or replacing the clutch master
cylinder (tractors with mechanical reverse shuttle only),
bleed the circuit (see § J) and adjust the pedal (see § G).
B . Brake master cylinders

Unlatched pedals (Fig. 8)
- The force applied to the pedal is transmitted by rod (8)
(Fig. 9) and moves piston (4) along the bore of the active
master cylinder. Valve (1) closes the supply port, the
balancing valve (3) opens by way of piston (4) and ball
(2) and the oil is directed under pressure towards the
main brake ports C and the pressure balancing junction
D.
- Through the balancing junction, the pressure closes
valve (3) of the passive master cylinder.
Latched pedals (Fig. 8)

Braking and pressure balancing
- The force applied to the pedals is transmitted by the
rods (8) (Fig. 9) and moves the pistons (4) along the
bores of both master cylinders. Both valves (1) close
the supply ports, the two balancing valves (3) open by
way of pistons (4) and balls (2).
- The balancing of pressure is carried out in both master
cylinders via balancing junction D.
- The oil under pressure is directed towards ports C and
C’ of the main brake circuit.
2
Issue 1 May 2000
December 2002

- Pressure acting on the face of the piston (7) produces
C . Master cylinder and servobrake a reaction force due to the effort of the push rod (8). This
assembly equilibrium gives a waiting position for which the
slightest change in force at the pedal turns into an
increase or decrease in pressure until the equilibrium is
Description
newly restored. The machine's amplification factor is
- The servobrake is located between the brake pedal and
the ratio of surfaces of pistons (7) (10) 1/4-4.
the master cylinder. It is fitted at the rear of the master
cylinder and uses pressure from the 17 bar circuit to
Maximum braking position
power assist the master cylinder piston.
- In this position, the groove (2) and hole (3) are entirely
in communication. The spool (6) is thrust up against the
pad (11), and total possible pressure (17 bar) is applied
Identifying ports and ports on master to the rear of the piston (10), and maximum assistance
cylinders (Figs. 8 – 8A) force is obtained. The amplifier thus reaches saturation
A: Control of the trailer braking arrangement and an increase in force on the master cylinder is not
B: Supply of brake master cylinders from tank possible except by pressing the pedal harder.
C: To main brake
D: Pressure balancing valve Servicing
E: Trailer brake pressure chamber - The servobrake does not require servicing. Any defec-
F : Trailer brake valve tive assemblies should be completely replaced.
Identifying ports and channels on the

servobrake (Fig. 9)
A : 17 bar supply
E : To housing return
T : Piston chamber (10)
1 . Functioning of the servobrake (Fig. 9)

Rest position
- Piston (10) is pushed to the right by the action of spring
(16).
- 17 bar pressure enters port A until it reaches groove (2)
where it is stopped by spool (6). The chamber T is
linked to the return E via hole (9), the central channel (5)
and open port (1).
Operating position
- When pressing the brake pedal, a force is applied to
spool (6) via piston (7) and rod (8). The spool (6) is
pushed to the left and closes the link to the tank via
supply port (1). Hole (3) is placed in communication
with groove (2). The oil under pressure arrives in the
supply slot at the rear of the piston (10) via channel (5)
and hole (9) and enters in front of the piston until an
equilibrium is obtained between the resistance of the
master cylinder, via thrust-rod (17) and the force
applied to piston (10).

2 . Functioning of the master cylinders

with trailer braking
Unlatched pedals (Fig. 8A)
Tractor braking and balancing
- The force applied on a pedal and transmitted by rod (17)
(Fig. 9), via the servobrake, moves piston (4) along the
bore of the active cylinder. Valve (1) closes the supply
port, the balancing valve (3) then opens and oil under
pressure is directed towards ports C and D. Through
port D, the pressure closes valve (3) on the passive
master cylinder.
Trailer braking
- The action on piston (4) also produces a movement of
piston (6) and the closing of valve F. The oil contained
in chamber E is directed to chamber E’ of the passive
master cylinder and towards port B’ via the intermedi-
ary of the open valve F’. The valve F and piston (6)
assembly rapidly abuts against the bottom of the
active master cylinder.
- In this position, only the tractor brake is activated, the
trailer is not braked.
Latched pedals (Fig. 8A)

Braking and pressure balancing
- The force applied to both pedals and transmitted by
rods (17) (Fig. 9) through the intermediary of the servo,
moves pistons (4) along the bores of the two master
cylinders. The beginning of the travel of each piston,
while displacing a certain volume of oil, closes the two
F valves. The simultaneous movement of pistons (4)
opens the balancing valves (3) and stops them from
closing again. A balancing of pressures is carried out
in the two master cylinders by way of the communicat-
ing pipe screwed into port D. The oil under pressure is
also directed to tractor braking port C.
Trailer braking
- The continued action of pistons (4) (6) closes valves F
and F’. Chambers E and E’ which are pressurised,
supply the trailer braking valve via ports A and A’.
- In the case of an incident involving the tractor’s braking
circuit, the trailer will remain braked even though the
tractor is not.
- In the case of a failure of the trailer braking valve or its
channels, the tractor will remain braked.
Note: In versions without trailer braking, the mas-
ter cylinder does not have port A, valve F or piston
(6) (Fig. 8)
Issue 1 May 2001

D . Adjusting the servobrake rod

(Fig. 10) 4 J = 0,5 +- 0,25 16 10
1. Measure the position of master cylinder piston (4) in

relation to the flange, dimension A.
Important: When measuring this dimension do not
compress spring (5) (Figs. 8 – 8A).
2. Smear the threads of the push rod nut with Loctite
542.
3. Place the push rod in position in the brake assistance
servo.
4. Measure the position of the end of the push rod (17)
in relation to the flange of the servobrake, dimension A
B. 17
Important: When measuring the dimension take B
care not to compress spring (16) on piston (10). Fig. 10
5. Correct the length of the push rod so as to obtain a
clearance of J = 0.5 ± 0.25 mm between push rod
(17) and piston (4) on the assembly of the master
cylinder and servobrake. 3
6. Proceed in the same manner for the second
servobrake.
1
E . Adjusting the brake pedals (Fig.
11)
7. If disassembled, smear the pins (5) (6) with molyb- 6
denum bisulphide grease. 4
8. Smear the threads of yoke (1) with Loctite 542 and Y
screw it onto rod (8). Fig. 11
9. Fit the return spring (3).
10. Adjust yoke (1) by turning rod (8) so as to obtain the
dimension Y between support (4) and the centre of
pin (6) in the yoke.
Y = 113 ± 0.5 mm without servobrake
Y = 139 ± 0.5 mm with servobrake
11. Proceed in the same way with the second yoke.
Press each pedal ensuring that it goes through its full
travel.
Check that the pedals return freely to their initial
position.
12. Check that the pedal latch functions normally with-
out any hard points.
Issue 1 May 2001

F . Clutch master cylinder - Tractor

with mechanical reverse shuttle
Reminder
- Fitted only on Heavy Duty gearboxes with mechanical
reverse shuttle, see the General section.
Functioning (Fig. 12)

- Force F applied via the pedal moves piston (1) along the
bore of the master cylinder. The oil coming from port A
is directed under pressure to port B and the supply
channel of the clutch control valve.
2 A
B F
1
A Supply from hose pipe (1) (Fig. 2)
B Supply to the clutch valve
(1) Piston
(2) Master cylinder
Fig. 12
Issue 12
Issue May 2000
December 2002
G . Adjusting the clutch pedal - Trac-

tor with mechanical reverse shuttle 8
Remark 7
- If a pedal had to be replaced, during refitting smear the
pins (7) (8) with molybdenum bisulphide grease (Fig. 13). 5
3
6
Adjustment 4
13. Adjust the push rod (3) so as to obtain a movement
of the piston (1) (Fig. 12) of 18.5 mm ± 0.25 mm. 2
Method (Fig. 13)

- Unscrew the stop (6) in order to remove any possible C
constraint. Measure dimension C between the master Fig. 13
cylinder support and the yoke pin, with the pedal in the
clutch engaged position.
- Proceed in the same way, the pedal in contact with stop
(2) (declutched position).
- Calculate the movement of the piston, this is equal to
the difference between the two measurements.
14. After adjustment of the push rod, tighten lock nut (4)
to a torque of 15 - 20 Nm (Fig. 13). Adjust stop nut (6)
to obtain a clearance of 0.5 to 1 mm between it and
the clutch pedal (Fig. 13). Tighten lock nut (5).
Check that the pedal operates normally.
Special point
- Tractors equipped with Full Powershift transmission
are fitted with a pedal known as a manoeuvring pedal.
To adjust it, see section 11 - Electronics.
Issue 2
1 May 2002
December 2000
H . Bleeding the main brake circuit

15. Link the connector (1) of the booster circuit and bleed
connector (2) using hose (3) (Fig. 14) fitted with
female diagnostic connectors, ref. 3582045M1. 4
16. Connect transparent tubes to both the left and right
bleed screws (1) of the centre housing (Fig. 15).
17. Plunge the ends of the two tubes into a container
partially filled with clean transmission oil.
18. Pinch the return hose (5) (Fig. 14) closed using a clip
fitted with suitable jaw protection.
Remark
- Some hose pipes may be difficult to pinch shut due to
their rigid sheath. Consequently, it will be necessary to
disconnect the hose pipe from union (2) and temporarily 2 5
replace it with a plug.
110 l/min
1 3
150 l/min
Fig. 14
Issue 1 May 2001


Bleeding procedure
19. Run the engine at approximately 1300 rpm.
20. Open the bleed screws by one turn and wait 5 mi- 1 1
nutes
Latched pedals
- Press and slowly release the latched brake pedal eight
times over its full travel, until the oil that is released
contains no air bubbles.
Unlatched pedals
- Press and slowly release each unlatched brake pedals
eight times over their full travel, until the oil that is
released contains no air bubbles.
- First close the left bleed screw, then the right-hand one. Fig. 15
- Press hard (60 - 80 kg approximately) on each pedal in
order to position the brake pistons. Check the hardness
and the force required on each pedal. The travel of the
latched pedals must be less than 120 mm using the
previously stated force.
- Stop the engine.
- Remove the hose and unions (3) assembly (Fig. 16) and
the clip fitted to hose (5), see remark in operation 18.
Special point
- If any functional problem appears, carry out the bleed-
ing operation again.
- If the problem persists, check the oil tightness of:
. the circuit
. the master cylinders
. the piston seals. 3
Fig. 16
Issue 1 May 2001

I . Bleeding the trailer braking circuit 110 l/min

Note: If the tractor is fitted with trailer braking, it is
strongly recommended that the main brake and 1
trailer brake are bled simultaneously.
To carry out this bleeding, use the same equipment
and method as described in § H for the bleeding of
the main brake circuit.
Special point
- Open the three bleed screws (main brake (1) (Fig. 15),
trailer brake (1) (Fig. 17 or 19)).
- When the bleeding has been completed, tighten the
bleed screws in the following order: left bleed screw,
right bleed screw and trailer brake bleed screw.
- Check the pressure of trailer braking system (see Fig. 17
section 9N01 - Hydraulic Tests) at the quick-disconnect
(17) (Fig. 18) at the rear of the tractor.
17
Fig. 18
150 l/min
Fig. 19

J . Bleeding the clutch control - Trac-

tor with mechanical reverse shuttle 2
Heavy Duty transmission (mechanical re-

verse shuttle only)
22. Using jaw protection, pinch closed the return hose
(5) (Fig. 14).
Remark
- Certain hose pipes may be difficult to pinch shut
due to their rigid sheath. Consequently, it will be
necessary to disconnect the hose from union (2)
and temporarily replace it with a plug.
23. Slightly unscrew the union (output to control valve)
at the end of the master cylinder so as to expel air
from the master cylinder and pipe. Tighten the union Fig. 20
again.
24. Connect a transparent tube to bleed screw (2) as
shown in Fig. 20.
25. Slightly unscrew the bleed screw and slowly press
the clutch pedal through its full travel. Repeat the
operation several times until the oil flows without
any air bubbles. Close the bleed screw.
26. If necessary, check the adjustment of the clutch
pedal (see § G).
27. Carry out a road test of the clutch.
Issue 2
1 May 2002
December 2000
9 I02 Brake and clutch master cylinders circuit and

bleeding
CONTENTS
- General ________________________________________________ 2
A. Servicing the master cylinders and FTE valve _____________ 6
B. Brake master cylinders __________________________________ 6
C. FTE valve _______________________________________________ 8
D. Adjusting the brake pedals ______________________________ 10
E. Bleeding the main brake circuit __________________________ 11
Issue 1 May 2002

General
The MT645 to MT665 tractors are equipped, in their
standard version, with Meritor brake master cylinders (1)
(Fig. 1 - 2) and provide hydraulic power assistance.
The MT535 model may be fitted with the Meritor master

cylinders as an option.
On the version with trailer braking, the system is com-

pleted by a FTE valve (2) (Fig. 2) providing control of the
trailer brake valve. The latter is incorporated into the
priority blocks (see section 9B01) and a quick-discon- 1
nect coupling located at the rear of the tractor.
The master cylinders are supplied by the 17 bar low-

pressure circuit.
Fig. 1
Fig. 2
Issue 1 May 2002

Characteristics
(1) Accumulator (Fig. 3 - 3A - 4) 4
- Manufacturer ................................ Olaer
- Type .............................................. 1/20 1
- Capacity ........................................ 1 litre
- Gas ............................................... Nitrogen
- Inflation pressure .......................... 9 ± 1bar
To be checked every
six months with
the engine stopped
(2) Non-return valve (Fig. 3 - 3A - 4)
- Manufacturer ................................. Parker
Special point
- During refitting, turn the arrow engraved on the
valve body to match the direction of the fluid flow
(3) Main accumulator (Fig. 3 - 3A) for Dynashift inte-
grated into Heavy Duty transmission 2
Fig. 4
(4) Brake hydraulic power assistance
8200- Version with power shuttle
2
3
17 bar low pressure
Gas
Fig.
Issue 1 May 2002


Parts list (Figs. 5 to 7)
(1) Master cylinder
(2) FTE valve
(3) Brake power assistance return and bleed connector
(4) Brake pistons supply
(5) Brake power assistance supply
(6) Hydraulic link
(7) Trailer brake quick-disconnect coupling
(8) Priority blocks with trailer brake
(9) Bleed screw
Heavy Duty transmission
3 5
1 4 9
Fig. 5
Issue 1 May 2002

3 5
1 4 9
Fig. 6
Full Powershift transmission and trailer braking
12 3 13 5 6 8 7
1 4 9
Fig. 7
Issue 1 May 2002


The oil under pressure (17 bar) present in chamber B also
A . Servicing the master cylinders tends to fill reserve (5) by passing through the bore (11).
and FTE valve
Port C removes any excess oil and directs it to the tank.
Important
- All problems concerning the master cylinders as Note: Under no circumstances should the master
well as the FTE valve (oil tightness, seizure, etc.) cylinder be disassembled; if it is defective it must be
require systematic replacement of the entire com- completely replaced.
ponent.
- After replacement of the brake master cylinders, bleed Parts list (Fig. 8)
the brake circuit (see § E).
(1) Master cylinder assembly
- Check the adjustment of the servo-brake rods and the
(2) Rod
brake pedals (see § D).
(3) Spool
- The master cylinder assembly requires no mainte-
(4) Piston
nance.
(5) Braking circuit reserve supply
(6) Pressure balancing valve
(7) Piston guide bolt
(8) Master cylinder capacity
B . Brake master cylinders (9) Port
(10) Port
(11) Bore
Operation (12) Groove
The force applied to the brake pedal is transmitted by rod (13) Ball plug
(2) and moves the spool (3) in the bore of piston (4).
A: 17 bar constant supply
The 17 bar oil under pressure arriving through port A is B: Chamber in piston (4)
thus applied to the surface of piston (4) through passage C: Return to housing
into chamber B via the groove (12) and ports (10). This D: To main brake or FTE valve (if fitted)
causes the piston (4) to compress the oil (present within
the master cylinder (8)), forcing it towards brake D or the
FTE valve (when fitted).
The bolt (7) guides piston (4) along its movement axis.
Note: Under no circumstances should this bolt be
removed.
When the brake pedal is released, the spool (3) tends to

restore its initial position. The oil under pressure thus no
longer reaches piston (4) and it therefore likewise resumes
its resting position.
The valve (6) allows the pressure between master

cylinder (8) and the tank (5) to be balanced only once the
piston has returned.
The port (9) allows oil to pass in order to maintain a

constant level in the master cylinder.
Issue 1 May 2002

C A
D
2
7 1
9 11 12
D C A
8 6 4 5 10 B 3
Parts list Fig. 8
Issue 1 May 2002


Parts list (Fig. 9)
C. FTE valve (Fig. 9) (1) Spool
(2) Ball
The FTE valve is only present on tractors fitted with a (3) Plunger
trailer braking valve. It provides a logical AND function, (4) Spring
i.e., it allows the passage of oil to the braking valve only
when both brake pedals are activated at the same time. A: To trailer braking valve
B: From right-hand master cylinder
If only one brake pedal is depressed, the trailer braking C: From left-hand master cylinder
valve is not activated. D: To right-hand tractor brake
E: To left-hand tractor brake
B C Fig. 9
C D
E A B
D E
1 4 3 2
A
B C
D E
Issue 1 May 2002

Unlatched pedals (Fig. 10)

- When force is applied to a single brake pedal, the oil
under pressure coming from the master cylinder B B C
moves spool (1) and forces the ball (2) onto the spool
to close off the link between D and A. Because of this,
there is only one direction possible for the oil, from B
towards D.
Latched pedals (Fig. 11)

D E
- When force is applied to both pedals simultaneously,
the spools (1) are thrust against each other and com-
press spring (4). The plunger (3) then forces the balls (2)
apart lifting them from their seats in the spool. Because 1 4 3 2
of this, all the ports are then in direct communication, A
i.e., there is a braking pressure supplied to tractor
brakes D and E and to the braking valve A. Fig. 10
Note: Under no circumstances should this valve be

disassembled, it must be systematically replaced.
B C
D E
1 4 3 2
A
Fig. 11
Issue 1 May 2002

D . Adjusting the brake pedals (Fig.

12) 3
1. If disassembled, lightly smear the pins (5) and (6) with

molybdenum disulphide grease.
2. Lightly smear the threads of yoke (1) with Loctite 542 5
and screw it onto rod (8).
3. Fit the return spring (3). 8
4. Adjust yoke (1) by turning rod (8) so as to obtain during
the maximum pedal travel (top stop to bottom stop) a 1
movement of rod (8) of 30 to 31 mm. This corresponds
to a dimension Y, between bracket (4) and yoke pivot
pin (6):
Y = 132 mm. 6
5. Proceed in the same way with the second yoke. 4
Press each pedal ensuring that it goes through its full Y
travel. Fig. 12
Check that the pedals return freely to their initial
position.
6. Check that the pedal latch functions normally without
any hard points.
Issue 1 May 2002

E . Bleeding the main brake circuit

7. Link the connector (1) of the booster circuit (5 bar)
and bleed connector (2) using hose (3) (Fig. 13) fitted
with female diagnostic connectors, part reference
3582045M1.
8. Connect transparent tubes to both the left and right
bleed screws (1) of the centre housing (Fig. 14) as
well as to the trailer braking valve (if fitted) (Fig. 16
or 18).
Note: The location of the bleeds may differ
slightly on different models. 2 5
9. Plunge the ends of the two tubes into a container
partially filled with clean transmission oil.
10. Pinch the return hose (5) (Fig. 13) closed using a clip
fitted with suitable jaw protection.
Remark
- Some hose pipes may be difficult to pinch shut due to
their rigid sheath. Consequently, it will be necessary to
disconnect the hose pipe from union (2) and temporarily
replace it with a plug. 1
110 l/min
1 3
1 1
150 l/min
Fig. 14 Fig. 13
Issue 1 May 2002


Bleeding procedure
12. Open the three bleed screws by single turn:
- right-hand brake
- left-hand brake
- trailer braking valve (if fitted)
13. Slowly depress the brake pedals several times
14. Continue until bubble free oil is discharged from both
the left- and right-hand bleeds.
15. With the brake pedals fully released, close the left-
and right- hand brake bleeds.
16. If trailer braking is fitted, slowly depress the brake
pedals several times until bubble free oil is dis-
charged from the trailer braking valve bleed. 3
17. With the brake pedals fully released, close the trailer
braking valve bleed.
18. Remove the clip from the booster return hose. Fig. 15
19. Remove the 5 bar pressure connector.
20. The bleeding procedure is now completed.
110 l/min
Fig. 16
Issue 1 May 2002

Special points
- If a there is a problem when operating the brakes, carry
out the bleed sequence a second time. 17
- If the problem still persists:
. check the oil tightness of the circuit and the unions
. check the trailer braking pressure (see section 9L01
or 9L02) on the quick-disconnect coupling (17) (Fig.
17) at the rear of the tractor.
Fig. 17
150 l/min
Fig. 18
Issue 1 May 2002

Hydraulics - Heavy Duty transmission circuit 9J01.1
9 J01 Clutch control valve
CONTENTS
- General ________________________________________________ 2
A. Operating phases of the clutch valve _____________________ 4
B. Disassembling and reassembling the valve ________________ 9
C. Service tools ___________________________________________ 11

9J01.2 Hydraulics - Heavy Duty transmission circuit
General
On 8210 - 8220 - 8240 and 8250 tractors fitted with a
Heavy Duty gearbox, with a mechanical reverse shuttle,
the distribution block (1) (Fig. 1) mounted on the front
right-hand side of the gearbox is formed of two distinct
parts that ensure the control of the clutch and the four
Dynashift ratios.
- The clutch part comprises a series of spools, seals,
a valve and piston. These can be replaced by a kit (Fig.
10) that is found in the Spare Parts catalogue.
- The Dynashift part (see section 9L01).
Role of the control valve

Fitted in the 17 bar circuit, this valve provides the
following functions:
- 17 bar supply to the clutch when the clutch pedal is
released (clutch engaged position).
- modulation of the clutch engagement pressure: 0 to 11
bar (see section 9N01 - Hydraulic Tests).
- starting safety when the tractor is started using external
assistance. To activate the clutch it is necessary to
press the clutch pedal once.
- low pressure starting safety. The clutch disengages
automatically if the pressure drops below 3 bar.
- the ports O (Fig. 2) allow leaks to return to the housing.
Issue
Issue 21 May 2002
December 2000
3 9 1 4
2 8 6 7 5
17 bar low pressure
Gas
(1) Distribution block

(2) 17 bar supply
(3) Accumulator on 17 bar line
(4) Master cylinder hose pipe
(5) Clutch supply pipe
(6) Clutch diagnostics connector
(7) Dynashift front piston diagnostics connector
(8) Dynashift rear piston diagnostics connector
(9) Accumulator for brake assistance
Fig. 1
Issue 1 May 2001


Description
- The valve comprises two spools. The upper spool is
controlled by pressure from the clutch master cylinder
and controls the clutch supply.
- The lower spool, controlled by the inlet pressure,

provides hydraulic safety for the system.
A . Operating phases of the clutch

valve
Neutral position, engine running (Fig. 2)
- If the tractor is started without pressing the clutch
pedal, the pressure rises to 17 bar but all the suction
ports are closed and the clutch is not supplied.
Disengagement before switching the safety-

valve (Fig. 3)
- The main spool (5) is pushed to the rear and com-
presses spring (2) under the effect of piston (19) that is
controlled by the master cylinder. The pressure coming
from the 17 bar circuit passes via the shoulder of the
main spool (5) and begins to act on the front face of
spool (4), the clutch is then linked to the return.
Issue 1 May 2001

P = 17 bar
R = Return
E = Clutch
P R E
Fig. 2
P = 17 bar
R = Return
E = Clutch
P R E
5 19
2
Fig. 3
Issue 1 May 2001

P = 17 bar
R = Return P R E
E = Clutch
Fig. 4
P = 17 bar P R E
R = Return 5 16
E = Clutch
Fig. 5
P = 17 bar
R = Return P R E
5
E = Clutch
Fig. 6
Issue 1 May 2001

Clutch disengagement, switching the safety-

valve (Fig. 4)
- The spool (4) moves to the rear when the pressure is
greater than 12 bar. During full opening, spool (4) allows
communication with the front of the main spool (5).
Clutch engagement, modulation phase (Fig. - From this intermediate position, when the pedal is
5) slightly pressed, the force acting on spring (2) is
- When the pedal is released, the pressure supplying the increased. The spool moves rearwards opening the
clutch is modulated by the position of the main spool communication between the clutch and the return.
(5). - The pressure in the clutch diminishes and the spool
This position is regulated: moves forward to find its equilibrium position.
. at the rear by the 17 bar pressure and spring (2) - The modulation begins after having pressed the pedal
. at the front by the clutch pressure and spring (16) approximately 32 mm. The declutched position is rea-
- When the pedal is slightly released, the spring tension ched 25 mm before the farthest pedal position is rea-
(2) diminishes. The main spool (5) moves forward and ched.
places the 17 bar line in communication with the clutch.
- The pressure in the clutch increases and this pushes
the spool to the rear to find its equilibrium position.
Clutch fully engaged (Fig. 6)

- When the pedal is completely released, spring (2)
pushes spool (5) forwards and causes the full opening
of the 17 bar circuit to the clutch.
Issue 1 May 2001

Overall view
1 2 3 5 8 13 14 15 18 16 19 20 21 11
22
11
10
6 12 17 18 7 10 9
Parts list (12) Spring

(1) Plug (13) Push rod
(2) Spring (14) Circlip
(3) Non-return valve (15) Spring
(4) Safety-valve spool (16) Modulation spring
(5) Main spool (17) Seal quadring
(6) Safety-valve sleeve (18) Guide segments
(7) Valve body (19) Piston
(8) Main spool sleeve (20) Calibrated union
(9) Plugs (21) Modulation limit stop
(10) O’ring (22) Main spool limit stop
(11) Circlip
Fig. 7
Issue 1 May 2001

Exploded view
1
2
5
8
3
20
7
13
22 16
4 21
18
17
18
12
11 15
10 14
9 9
10
11
19
Fig. 8

the valve (Fig. 10)
- To remove the valve, see section 4A01.
Disassembly
1. Using a locally manufactured tool, § C, remove circlip
(11) and take out plug (9) (Fig. 9) from the A assembly.
Using the same method for the B assembly. Remove
the A and B assemblies while visually noting their 9
positions.
2. Unscrew plug (1) and remove the C assembly as in
the previous operation.
11
Fig. 9
Issue 1 May 2001


Reassembly Tightening torques (Fig. 10)
3. Check and clean the parts. Replace any components - Plug (1) smeared with Loctite 542: 50 Nm.
found to be scratched or distorted. Check that valve - Non-return valve (3): 28 - 30 Nm.
(4) and spool (5) spool freely in the sleeves (6) (8).
Before reassembly, lubricate the seals with transmis-
sion oil.
4. Replace o’rings (10) and the assemblies A, B and C
using repair kits. Fit circlips (11).
Note: Before fitting the piston of assembly A,
bend guide segments (18) in a circular manner and
lightly smear them with miscible grease so as to
correctly position them in the grooves of the
piston, the knurled faces turned towards the
valve body.
Remark
- Union (20) is fitted with a calibrated port.
Final operations
5. Refit and bleed the clutch control valve (see sections
4A01 and 9I01 respectively).
6. Check the modulation pressure of the valve (see
section 9N01 - Hydraulic Tests).
C A
20
3 11
1 9
11 10
18
9 10 6 4 5
B
Fig. 10
Issue 1 May 2001

C . Service tools
Tool to be manufactured locally
- Spring compression tool
100
= Ø17 HM8
35
=
75
5
M8
45
60
100
Fig. 11
Issue 1 May 2001

Hydraulics - Power Shuttle 9K01.1

control unit
9 K01 Power Shuttle control unit
CONTENTS
. General ________________________________________________ 2
A. Designation of pipes and components ____________________ 2
B. Removing and refitting the control unit ___________________ 4
C. Location of ports and identifying proportional

solenoid valves _________________________________________ 6
Issue 1 May 2002

9K01.2 Hydraulics - Power Shuttle

control unit
General
The control unit is fixed on the right-hand side at the front
of the gearbox. Its role is to supply:
- the power shuttle proportional solenoid valves with oil
- the Dynashift (see section 5B04).
A filter element (6) (Fig. 1) is located underneath the right-

hand hydraulic cover, upstream of the control unit, to
provide additional filtering of oil going to the proportional
solenoid valves.
A . Designation of pipes and compo-

nents (Fig. 1)
(1) Control unit
(2) 17 bar line - Front clutch
(2A) 17 bar line - Rear clutch
(3) Accumulator (Nitrogen)
(4) Main supply line (17 bar)
(6) 60 micron filter element
(7) 17 bar line - Dynashift to clutch A - B
(8) 17 bar line - Dynashift to clutch C - D
(12) Cover for separate return to gearbox for oil coming
from pipes (2) (2A)
Issue 1 May 2002


control unit
3 1
4 2A 2
12
F
F 8
6 2A 4 2
17 bar low pressure Gas

Fig. 1
Issue 1 May 2002


control unit
10. Tighten the bolts holding the unit to the gearbox to a
B . Removing and refitting the control torque of 42 - 46 Nm, having previously smeared the
unit (1) (Fig.1) threads with Loctite 542.
Note: The cover (12) is positioned on the hydrau-
Preliminary operation lic unit by the two Mecanindus pins G”(Fig. 2).
- Drain the oil from the gearbox. The oil tightness is ensured by:
- application of Loctite 510 or equivalent on the
surface in contact with the unit
Removal - an O’ring (13) fitted between the gearbox hous-
ing and the cover.
Danger 11. Reconnect the pipes and electrical connectors that
were marked during removal.
- If you work on the 17 bar hydraulic circuit immediately Special points
after stopping the engine, release the pressure stored in If the control unit or proportional solenoid valves had
the accumulator or wait a while before working on the to be replaced, carry out hydraulic tests (see section
circuit. 9N01) in order to check:
- the 17 bar pressure of the hydraulic unit
1. Mark and disconnect the connectors on EV1 and EV2 - the front and rear clutch pressures of the power
solenoid valves of the Dynashift (see section 9L01) as shuttle
well as those of the proportional solenoid valves of the - the pressure in the A - B and C - D clutches of the
front and rear clutch of the power shuttle (Fig. 2). Dynashift.
2. Disconnect and remove pipes (2) (2A) (4) connected Then, calibrate the front and rear clutches of the
respectively to the gearbox and accumulator. power shuttle (see Electronics section, chapter 11).
3. Remove the solenoid from the solenoid valve of the 12. Carry out a road test of all hydraulic functions.
Dynashift rear clutch. Unscrew, release and take off 13. Check the oil tightness of hydraulic unions.
cover (12) and the control unit. Discard the O’ring (13)
(Fig. 2).
4. If necessary, empty the internal pipes supplying the
A - B - and C - D clutches of the Dynashift.
Remark:
- The lower pipe has a swan neck.
Refitting
5. Remove all traces of Loctite from the mating surfaces
of the unit and gearbox housing.
6. If removed, position the internal pipes of the Dynashift
clutches in the ports of the input unit.
7. On the unit, replace the O’rings of the previously
mentioned pipes.
8. Lightly smear the mating surface of the unit that
mates with the housing with Loctite 510 or equivalent.
9. Turn the internal pipes of the Dynashift in such a way
that they correctly penetrate the ports of the unit. Refit
the unit.
Issue 1 May 2002


control unit
8 G 2
12 13 8 12
F
G
F1
F
F1 F2
2
Loctite 510
8 2
11 10 F2 9
3 4 5 10 11 7 5 6
7 10
6 11
Fig. 2
Issue 1 May 2002


control unit
C . Location of ports and identifying
proportional solenoid valves 10 11
Location of ports (Fig. 2)
(2) Return to rear clutch housing
(3) Outlet to front clutch
(4) Outlet to rear clutch F
(5) 17 bar supply
(6) Front clutch pressure connector
(7) Rear clutch pressure connector
(8) Return to front clutch housing
(9) 17 bar low pressure pressure connector
(12) Cover
(13) O’ring
P A B C
F
Remark
- Each hydraulic return line from the proportional solenoid Fig. 3
valves is channeled separately, this is done so as to
avoid back pressure between one solenoid valve and
another.
Identification of the proportional solenoid

valves (Fig. 2 - 3)
(10) Rear clutch solenoid valve
(11) Front clutch solenoid valve
Hydraulic part (Fig. 3)

A : Supply ports to front clutch or rear clutch depending
on solenoid valve concerned.
B : Return ports from front clutch or rear clutch depend-
ing on solenoid valve concerned.
P : 17 bar low pressure.
Electrical part (Fig. 3)

C : Connector connection.
Tightening torques
- Body of solenoid valves: 15 to 20 Nm maximum
- Nut on solenoids: 5.4 to 8.1 Nm maximum.
Important: It is imperative to respect the indicated
tightening torques in order to avoid any risk of
deforming the valves and leading to the blocking of
the spool.
Issue 1 May 2002

Hydraulic - All circuits 9K02.1
9K02 Hydraulic control unit - Suspended

front axle
CONTENTS
A. Technical Features __________________________________ 2
B. Description of the hydraulic circuit __________________ 4
C. Disassembly / Assembly of the hydraulic control

unit _______________________________________________ 7
D. Disassembly / Assembly of the steering cylinder ______ 9
Issue 1 Mai 2002

9K02.2 Hydraulic - All circuits
A. Technical Features
DESCRIPTION VALUES
Nominal pressure 250 bar
Hydraulic oil type DIN 51524
Ambient temperature Min -30 °C
Max +90 °C
Temperature of hydraulic oil Min -30 °C
Max +70 °C
Hydraulic connections type ports: P, T, A, B M18x1.5 (ISO6149-1)
Hydraulic connections type port LS M14x1.5 (ISO6149-1)
FILTRATION: maximum permissible NAS 1638 class 10
contamination level of the operating fluid
Tightening torque of valves 25 Nm
Tightening torque of accumulators 200 Nm
Nominal voltage 12 V DC

(1) LS pilot flow
(2) Accumulator KSP1
(3) Accumulator KSP2 2
(4) Accumulator RSP1
(5) Bleed screw
(6) Solenoid valve WV1 3 4
(7) Solenoid valve WV2
(8) Return line
(9) Supply from the pump
(10) Top cylinder supply
(11) Bottom cylinder supply
7 6
Fig. 1
Accumulators pressure and capacity
AXLE TYPE RSP 1 KSP 1 KSP 2
20.19 0,75 litres 1,4 litres 0,75 litres

140 bar 40 bar 40 bar



Issue 1 Mai 2002

Overall dimensions of the hydraulic control unit
10
3
4
11
7 8
Fig. 2
Issue 1 Mai 2002

Neutral position
B . Description of the hydraulic circuit - In low position, chamber A of the cylinder is empty.
The suspension is in contact with two mechanical stops
(1) Front axle suspension cylinder
on the centre beam.
- In high position (fig. 3), the cylinder is maintained in
equilibrium by the accumulators.
(4) Accumulator RSP1
- If the pressure in the cylinder is too high (impact on the
(5) Bleed screw
front axle), the pressure limiter (12) opens and excess
pressure is directed towards the return line.
- If the cylinder position has changed, the position sen-
(8) Suspended front axle
sor value has also changed. If after 3 seconds the sen-
(11) Motor-operated check valve
sor value does not correspond to the calibrated value,
(12) 250 + 20 bar pressure limiter
the calculator feeds the appropriate solenoid valves so
(14) High pressure inlet
as to make these two values identical.
A
4 1 2 3
B
E C
12 11
5
250 + 20 6
bar
7 G
14
Fig. 3
Issue 1 Mai 2002

Raising position (Fig. 3A)

- During the raising phase, solenoid valves WV1 (6) and
WV2 (7) are activated.
- Solenoid valve WV1 sends the oil to the accumulators
(2) (3) and the chamber A of the cylinder.
- When pressure in chamber B reaches 250 bars, oil
returns to the tank through channel C. Channel D also
feeds the accumulator (4).
- Solenoid valve WV2 gives priority to the suspended
front axle in the pilot line F.
4 1 2 3
A
B
E C
12 11
5
6
250 + 20
bar
7 G
14
Fig. 3A
Issue 1 Mai 2002

Lowering position (Fig. 3B)

- During the lowering phase, only the solenoid valve WV2
(7) is fed.
- Oil feeds chamber B of the cylinder through channel E.
The pressure created in the pilot line F gives priority to
the suspended front axle.
- The pressure in the pilot line F also allows the opening
of the check valve (11) so that oil in chamber A returns
to the tank through channel G.
1
4 2 3
A
B
E C
5 12 11
250 + 20 6
bar
7 G
14
Fig. 3B
Issue 1 Mai 2002

C . Disassembly / Assembly of the

hydraulic control unit
The disassembly instructions presume that the unit has
been removed from the vehicle and positioned on a
suitable workbench.
your control unit, but the process is the same.
Disassembly of the hydraulic control unit
Important AV
- Before operate on control unit, open the AV drain

valve, loosening it gradually, to release possible Fig. 4
internal pressure and discharge the accumulators
completely (Fig. 4).
1. Disassemble the accumulators unloosing them with

suitable wrenches (Fig. 5).
Remove the seal rings.
Note : the accumulators have different capacity,
take a note of the assembly position.
2. Unscrew the valve fastening ring nuts A.
Remove the solenoids B from all the group valves.
Remove the valves C unscrewing them with a wrench
and collect all its components.
Check the components conditions in order to identify
those ones who must be replaced.
Fig. 5
A B
C
Fig. 6
Issue 1 Mai 2002

Assembly of the hydraulic control unit

3. Assemble all the components on the valves C.
Insert the solenoid valves in the control unit and screw
them at a torque of 25 Nm
Assemble the solenoids B on the valves locking them
with the relative retaining ring nuts A tightened with
hand (Fig. 7).
4. Install new seal rings on the accumulators connec-
tions. A B
Screw the accumulators at a torque of 25 Nm (Fig.
8) C
Note: The accumulators have different capacity,
respect the correct assembly position.
Fig. 7
Fig. 8
Issue 1 Mai 2002

D . Disassembly / Assembly of the

steering cylinder
Disassembly of the steering cylinder
5. Unloose the guide rod locknut of some turns till it is on
a level with the threaded pin.
6. Beat on the nut with a hammer in order to disjoin the
guide rod from the swivel housing (Fig. 10).
Note: this is a destructive operation for the nut.
7. Remove the guide rod link A by unloosing the tie nut
B with a suitable wrench, then check its conditions.
Unscrew the fastening screws C of the cylinder, then
take the cylinder D out of its housing and, if necessary,
use a rubber hammer (Fig. 11).
Remove only that parts that need to be overhauled
and/or replaced. Fig. 9
8. Detach the cylinder head E from the cylinder case G.
Remove off the cylinder head and the rod F from the
cylinder case.
Remove all the sealings and O-Rings, both from the
cylinder head and the rod (Fig. 12).
Fig. 10
D
B
C F
E
A
Fig. 11 Fig. 12
Issue 1 Mai 2002

Assembly of the steering cylinder

9. Assemble new seal rings: on the cylinder head (A), C
on the piston (B) and on the cylinder body (C) (Fig. 13)
10. Slide pre-assembled rod into the cylinder body (Fig.
14)
11. Fit the O'rings to the ends of the cylinder rod and B
tighten with dynamometric wrench to the requested
torque (see section A01 §A).
Install the O'rings on the central body, with guide A
rods already assembled on the stem.
Note: Install the spacer flange.
Assemble and tighten the steering cylinder fastening
screws with dynamometric wrench to the requested
torque (see section 8A01 §A) (Fig. 15)
Fig.13
Fig. 14
Fig. 15
Issue 1 Mai 2002

12. Align the swivel housings with the axle (parallel

wheel hub).
Screw the link so that the ball joint can be inserted
into the swivel housing arm (Fig. 16)
Note : it is important to unscrew the locking nut
to carry out this operation.
13. Insert the ball joint into its own housing on the swivel
housing (Fig. 17)
Assemble and tighten the lock nut with dynamo-
metric wrench to the requested torque (see section
8A01 §A).
14. Screw in the lock nut of the link only when the toe-
in adjustment has been carried out (Fig. 18)
Fig. 16
Fig. 17
NON
Fig. 18
Issue 1 Mai 2002

Hydraulics - Dynashift control 9L01.1
9 L01 Dynashift control
CONTENTS
- General ________________________________________________ 2
A. Explanation of ratios ____________________________________ 6
B. Checking piston pressures _______________________________ 8
Issue 1 May 2001

9L01.2 Hydraulics - Dynashift control
General
The Dynashift control assembly fitted to 8210 - 8240 and
8250 tractors equipped with the Heavy Duty gearbox
comprises the following three components (Figs. 1 - 1B):
- The control unit (1) mounted on the right-hand side of
the gearbox, constituted by two separate parts
. the first part controls the engine clutch control (Pres-
sure Loaded version) or the front and rear clutches
(Power Shuttle)
. the second part controls the four Dynashift ratios. The
Dynashift part contains two internal channels, A and
B (Fig. 2 - 2A) allowing oil to circulate from one
solenoid valve to another.
- The solenoid valves (2) screwed into the control unit

comprise:
. a lower solenoid valve EV1 with four ports and two
positions
. an upper solenoid valve EV2 with three ports and two
positions.
- The accumulator (3) fitted on the supply line, allows

the oil flow rate to be accelerated to fill the piston 6
chambers of the Dynashift unit when necessary. The
reaction of the pistons is consequently faster.
Trademark : Olaer Fig. 1A
Type : 1/20
Capacity : 1 litre
Gas : Nitrogen On the version with a Mechanical Reverse Shuttle, two
Inflation pressure : 9 ± 1 bar (to be checked with diagnostics connectors (7) (8) (Fig. 1B) can be provision-
specific tools every 6 months, ally fitted to replace the plugs and in order to check the
engine stopped). pressure in the piston chambers (see section 9N01 -
Hydraulic tests).
Note: When the engine is stopped, the accumula-
tor maintains a pressure of 17 bar for a short while. On tractors fitted with a reverse shuttle, the diagnostic
If an immediate maintenance intervention is nec- connectors are fitted during manufacture.
essary, release the pressure or acts on the circuit
with caution. The tube (4) supplies the control unit. The oil return
allowing the piston chambers to be emptied passes
through the gearbox.
On tractors fitted with a reverse shuttle, a filter element

(6) (Fig. 1A) located on the right-hand side hydraulic cover Special point
upstream of the control unit, provides additional filtering - The cross-shaped union (6) is fitted with a restrictor-
for the oil supplying the Dynashift solenoid valves and valve. During reassembly, turn the restrictor to face the
those of the Reverse Shuttle (see section 9K01). 17 bar supply coming from tube (4) (Fig. 1B).
Issue 1 May 2001

Mechanical reverse shuttle version
3 D 1
4 6 2 2
Fig. 1B
8
Reverse shuttle version
3 2 1
4 8
17 bar low pressure

D
Gas
D : Non-return valve
2 Fig. 1
Issue 1 May 2001

Identifying channels and ports
A P
A
B C E
F
EV2
P B
F S A E /T EV1
Control units with Pressure Loaded Tightening torques

clutch - bodies of solenoid valves EV1 and EV2 : 20 Nm
A : Internal channel maximum
B : Internal channel - nuts of solenoid valves: 3 to 4 Nm maximum
C : To “F”
D : Non-return valve Important: The specified tightening torques must
E : Port to front piston absolutely be met in order to avoid any risk of
F : Port to rear piston distortion that may lead to the seizure of the spool
P : Pressure (17 bar) valves.
R : Return
S : Location for rear diagnostics connector
T : Location for front diagnostics connector
EV1 : Solenoid valve 4 x 2
Fig. 2
Issue 1 May 2001

Identifying channels and ports
B C E
EV2
F A R
D
EV1
Control unit with Power Shuttle Tightening torques

A : Internal channel and connecting ports - bodies of solenoid valves EV1 and EV2 : 20 Nm
B : Internal channels and connecting ports maximum
C : To port “F” - nuts of solenoid valves: 3 to 4 Nm maximum
D : Non-return valve
E : Port to front piston Important: The specified tightening torques must
F : Port to rear piston absolutely be met in order to avoid any risk of
P : Pressure (17 bar) distortion that may lead to the seizure of the spool
R : Return valves.
Fig. 2A
Issue 1 May 2001

A . Explanation of ratios
- For a theoretical and mechanical explanation of the
ratios, see section 5B03 or 5B04 (depending on the
version).
EV1+
A ratio (Fig. 2 - 2A - 3) A
The solenoid valve EV1 is supplied, thus allowing oil
under pressure to reach channel A. This channel directs
E
the oil towards the front piston via port E and also
towards solenoid valve EV2. The latter being in the EV2
neutral position, the oil can pass through the slide and
port F towards the rear piston chamber. Both pistons are F
therefore under pressure.
Front Rear Fig. 3

B ratio (Fig. 2 - 2A - 4)
The changing of speeds from A to B is carried out when
both solenoid valves are supplied. The oil flow to the rear
piston is therefore cut off. The rear piston is pushed by
springs, this sends the oil into channel B. This channel
communicates with the housing via the solenoid valve
EV1.
EV1+
EV2+
Front Rear Fig. 4
Issue 1 May 2001

C ratio (Fig. 2 - 2A - 5)
The changing of speeds from B to C is obtained by cutting
off the electrical supply to solenoid valve EV1, while
solenoid valve EV2 is still maintained under voltage. The
channel A is no longer under pressure but linked to the
housing. Consequently, the front piston can return to its
neutral position. Channel B is under pressure. The oil EV1
A
flows to the rear piston via solenoid valve EV2.
EV2+
Front Rear Fig. 5
D ratio (Fig. 2 - 2A - 6)
The D ratio is obtained by cutting off the electrical supply
of EV2. Both pistons are linked to the housing via channel
A.
A EV1
EV2
Front Rear Fig. 6
Issue 1 May 2001

B . Checking piston pressures

Note: After disassembly or replacement of the con-
trol unit, check the pressure in the piston chambers
(see section 9N01 - Hydraulic tests).
Remark
- If the pressures are incorrect, check that the spool
valve is actually moving in the solenoid valve con-
cerned or consult the section on electrical tests.
Issue 1 May 2001

Hydraulics - Oil decontamination 9M01.1
9M01 Oil decontamination
CONTENTS
A. General ________________________________________________ 2
B. Decontamination procedure ______________________________ 3
C. Diagrams _______________________________________________ 7
Issue 1 May 2001

9M01.2 Hydraulics - Oil decontamination
A . General
The correct operation and performance of the hydraulics
system is closely linked to the use of clean transmission
oil.
When maintenance is carried out on the gearbox / axle

assembly (e.g. brake or transmission repairs) this con-
taminates virtually the whole hydraulic circuit.
It is therefore essential to carry out a decontamination

operation after repairs in order to avoid the rapid deterio-
ration of other components in the circuit caused by the
movement of particles carried by the oil.
The contamination of oil can result in:

- seizure or leaks in the steering spool valve (Orbitrol)
- seizure of the spool valves in the solenoid valves
- excessive wear in the hydraulic pump(s).
The aim of oil decontamination is to restore the hydraulic

circuit to a state of cleanliness higher than that before the
repair operation. The particles that cause the greatest
damage are not the largest ones, for these are rapidly
caught in the filter, it is the repeated circulation of small
non-filtered particles that has the greatest abrasive
effect.
Issue 1 May 2001

B . Decontamination procedure
Special point
- The decontamination is carried out in two distinct
phases.
The static phase

Remarks
- This takes place immediately after the repair operation,
without moving the tractor.
- Check that the oil has been replaced after the repair
operation.
- During this phase, no low-pressure components should
be activated.
- The decontamination is carried out by circulating the
contaminated oil to the housing return through filter Fig. 1
elements in order to rapidly remove any particles
suspended in the oil.
Preparation of the tractor (Fig. 3 - 4)

Note: The equipment used for oil decontamination
is two hose pipes of a suitable length fitted with a
female diagnostics connector, ref. 3582045M1 (Fig.
1) on one of the ends.
1. Disconnect the temperature switch (3) (Fig. 3) (Heavy

Duty transmission) and ground it to earth in order to
neutralise its action.
2. Connect the female diagnostics connector of each
hose pipe on the male connectors (1) (2) of the low-
pressure circuit. These connectors are respectively
located on the right-hand side hydraulic cover, on the
clutch valve or the Reverse Shuttle hydraulic control
unit, depending on the version (Fig. 3 - 4).
3. Fasten the other end of the hose pipes without
connectors to the return port R (Fig. 3 - 4).
Issue 1 May 2001


Decontamination
Remark
- The oil temperature must be above 10° C to avoid the B A
opening of the by-pass.
4. Start the engine and run it at 1200 rpm.

5. Allow the engine to run for 15 minutes minimum in
order to filter out the particles in the oil.
Important: Check that the clogging indicator
lamp on the dashboard does not light during the
decontamination operation. If this does happen,
replace the 15-micron filter element and check or
change the suction strainer.
6. After having let the engine run for 15 minutes, stop
the engine and replace the 15-micron filter by a 6-
micron filter.
7. Procure a hose pipe of appropriate strength, fitted at Fig. 2
each end with a male quick-disconnect coupling for
connection to the auxiliary spool valves (Fig. 2).
8. Connect the connectors of the flexible to ports A and
B of the same spool valve (Fig. 2).
9. Start the engine and run it at 1200 rpm.
10. While the engine is running, turn the knurled knob of
the spool valve to maximum flow and alternate the
direction of oil circulation in the spool valve for
approximately 5 minutes (Fig. 2) using the control
lever.
Repeat the operation on the two or three other spool
valves (depending on options).
Reminder
- If the clogging indicator lamp lights on the dashboard,
replace the 6-micron filter element by another of the
same type.
Issue 1 May 2001

Dynamic phase
Remark
- Contrary to the static phase, the dynamic phase uses
all the hydraulic functions of the tractor for 15 minutes
with the engine running:
. lift control
. steering
. power take off
. brakes
. etc.
Preparation of the tractor

11. Remove all the hose pipes used during the static
phase.
Procedure
Reminder
- During decontamination, carefully monitor the dash-
board clogging indicator. If necessary, immediately
replace the 6-micron filter and the suction strainer.
12. Raise and lower the lift arm over the entire travel of
the rams and carry out a rapid alternating raise and
lower cycle.
13. Turn the steering wheel to full lock in both directions
several times.
14. Declutch and allow the clutch in and out 5 or 6 times
using the full travel of the pedal (tractors with Heavy
Duty transmission).
Repeat the same operation again more quickly.
15. Press and release each of the unlatched brake
pedals several times.
16. Repeat the same operation more quickly.
17. Slowly press and release the latched pedals several
times.
18. Repeat the same operation again more quickly.
19. Activate the Dynashift control, located on the left
beneath the steering wheel, moving it from A to D
and vice versa several times.
20. Operate and halt the power take off 4 or 5 times, one
after another.
21. Reconnect the temperature switch.
Issue 1 May 2001


Test
22. Carry out a road test the tractor using various engine
speeds, changing up and down through the ratios for
approximately 15 minutes.
23. When the road test is completed, let the engine run
at 1200 rpm for approximately 15 minutes with the
tractor stationary, in order to eliminate any remaining
particles in the circuit.
Preparing the tractor for service

24. When all these operations have been completed,
prepare the tractor for service by replacing the
suction strainer and the 6-micron filter used for
decontamination with a new and original spare parts
suction strainer and 15-micron filter, as referenced in
the Spare Parts catalogue.
Issue 1 May 2001

C . Diagrams
Parts list R
(1) Decontamination connectors (low pressure)
(2) Decontamination connector on clutch valve or Power
shuttle hydraulic control unit (Heavy Duty transmis-
sion)
(3) Temperature switch (Heavy Duty transmission) 1
(4) Oil decontamination replaceable oil filter element (6 A
micron)
A : Pressure Load ed - Mechanical reverse shuttle

version
B : Reverse shuttle version
2
Fig. 3
5
B
2
1
Parts list Fig. 3
Issue 1 May 2001

Issue 1 May 2001

R
Parts list
(1) Decontamination connectors (low pressure)
(4) Oil decontamination replaceable oil filter ele-
ment (6 micron)
Fig. 4
5
4
Fig. 4
Parts list
Issue 1 May 2001

Hydraulics - Hydraulic tests 9N01.1
9 N01 Hydraulic tests
CONTENTS
A. General ________________________________________________ 2
B. Testing the high pressure 110 l/min circuit _______________ 3
C. Testing the low pressure 110 l/min circuit ________________ 9
D. Testing the high pressure 150 l/min circuit _______________ 21
E. Testing the low pressure 150 l/min circuit ________________ 30
F. Testing the low pressure hydraulic functions of the

Full Powershift gearbox _________________________________ 31
2
Issue 1 May 2000
December 2002
9N01.2 Hydraulics - Hydraulic tests

To carry out the tests indicated in this section, it is
A . General recommended that the following equipment available
through the AGCO network be used:
The 8200 series tractors are fitted with a closed centre - MF 3001: Pressure gauge kit
hydraulic system that provides a flowrate of 110 l/min, - MF 3016: turbine flowmeter - 4 - 160 l/min
depending upon the characteristics of the booster pump - MF 3017: Hose piping assembly for MF 3016 flowmeter
and the variable displacement pump. - 3378174M1: Hose piping kit with diagnostic connec-
tors (Full Powershift gearbox)
The 150 l/min hydraulic system is only fitted as an option - 3582045M1: Diagnostic coupler
on tractors with a Full Powershift transmission. If the above is not available, use equivalent suitable
equipment.
The hydraulic system comprises two separate circuits:
low and high pressure.
Always check the oil flow direction to avoid damag-
ing the flowmeter. In addition, select pressure
Low pressure circuit gauges, hose piping and unions of sufficient capac-
Tractors may be fitted with either Full Powershift or ity and strength.
Heavy Duty gearboxes, with or without Power shuttle.
The Full Powershift gearbox has a specific pump fitted to Values measured during the tests :
the rear of its housing. This discharges oil towards the - maxi flowrate .................. 105 à 115 l/min
low pressure functions of the gearbox and lubricates or 150 l/min (depen-
various mechanical assemblies under pressure. ding on option)
The other 17 bar functions of the rear axle are identical for - mini flowrate ................... 5 l/min
tractors with a Full Powershift or Heavy Duty gearbox. - maxi pressure ................. 200 bar
These are supplied via the priority blocks by the oil flow - mini pressure .................. 0,4 bar
under pressure coming from the variable displacement
pump that is located either in the intermediate housing or
on the outside of the right-hand side hydraulic cover
(depending on options).
High pressure circuit

The design and operating principle of the high pressure
circuit is similar regardless of the type of gearbox that is
fitted.
Before beginning the tests, run the engine in order to bring
the oil temperature up to 80° C minimum (176° F).
To facilitate the increase in oil temperature:

- run the engine at 2000 rpm
- connect a flowmeter to an auxiliary spool valve
- maintain the spool valve activated
- limit the flow through the flowmeter
- as soon as the oil temperature is above 80° C, release
the spool valve and open the flowmeter valve to the
maximum.
Issue 2
1 May 2002
December 2000
B . Testing the high pressure 110 l/ P1

min circuit
The high pressure, 110 l/min circuit supplies the follo-
wing functions:
- steering
- auxiliary spool valves
- lift control
- trailer braking
11 bar
maxi
1. Booster pressure of the variable displace-

ment pump
- Connect a pressure gauge on to the diagnostic connec-
tor located on the right-hand side hydraulic cover (Figs.
1 - 3) and check P1:
Fig. 1
Engine speed P1
(rpm) (bar)
P2
1000 5.2 ± 1
2200 6.3 ± 1
2. Standby pressure and XLS pressure

- Connect a pressure gauge to the diagnostic connector
(Fig. 2 - 3) located: 11 bar
maxi
30 bar
. on the pump controller: XLS pressure = P2
. on the right-hand side hydraulic cover: pump pressure
= P3
Important: Do not activate any high pressure func-
tion such as the steering. This may cause a momen-
P3
tary pressure greater than that the P2 and P3
pressure gauges can withstand. Fig. 2
Engine speed P2 P3
(rpm) (bar) (bar) P3 P2
1000 4 26 ± 1
2200 4 26 ± 1
HP
BP
Note: Pump pressure = XLS pressure + 22 bar ± 1 P1
bar
P3 = P2 + 22 ± 1 bar
Fig. 3
Issue 1 May 2001


3. Maximum flowrate and pressure
- Connect a flowmeter to an auxiliary spool valve (Fig. 4).
Activate and hold the spool valve lever to obtain Q1.
- Connect a pressure gauge on each diagnostics connec-
tor (Fig. 5 - 7) located:
· on the pump controller: XLS pressure = P2
· on the right-hand side hydraulic cover: pump pressure
= P3
- Set the control (1) of the flowrate controller of the
auxiliary spool valve concerned to the maximum flowrate
(Fig. 6).
- Activate the auxiliary spool valve and progressively
close the valve of the flowmeter in order to read the
flowrate and increase the pressure.
Engine Q1 P2 P3
speed
(rpm) (l/min) (bar) (bar)
2200 100±10 110
2200 100±10 130

2200 100±10 P2 = P3 - 22±1 150
2200 100±10 170
2200 100±10 180

2200 0 190 190
Note: If the flowmeter is fitted with a pressure

gauge, the pressure indicated must be taken into
account.
Fig. 4
P2
270 b
270 b
P3
Fig. 5
Issue 1 May 2001

4. Checking the auxiliary spool valve flow- Fig. 6

rate controller
- Connect a flowmeter to a spool valve (Fig. 4) in order 1
to obtain Q2.
- Connect a pressure gauge on each diagnostics con-
nector (Fig. 5 - 7) located:
· on the pump controller: XLS pressure: P2
= P3
Controller Engine P2 P3 Q2
position speed mini
(rpm) (bar) (bar) (l/min)
Maxi 2200 P2 = P3 130 100±10

-22±1 bar
Mini 2200 P2 = P3 35 5±1

-22±1 bar
- Set the control (1) (Fig. 6) of the controller concerned P2

slowly to its minimum stop. Q2 must drop progres-
sively to a flowrate of 5 ± 1 l/min.
If the flowrate is incorrect, see controller operation,
section 9D01.
HP
BP
P3
5. Auxiliary spool valve with automatic re-

turn to neutral
- Connect a flowmeter to an auxiliary spool valve (Fig. 4).
- Connect a pressure gauge to the pump controller (Fig.
7 - 8) to read: XLS pressure = P2. Fig. 7
- Run the engine at 1000 rpm. Activate the spool valve
in the automatic return position, release the lever and
progressively close the valve of the flowmeter until the P2
lever returns to the neutral position. Read the triggering
pressure: P2 = 160 - 185 bar.
- The triggering pressure can be adjusted (see section
9D01).
270 b
Fig. 8
Issue 1 May 2001


6. Lift control
Maximum pressure P2
- Connect a pressure gauge to each diagnostics connec-
· on the pump controller: XLS pressure = P2
= P3
- Run the engine at 1000 rpm.
- Use the external lift control buttons to reach the maxi-
mum lift position
270 b
P2 and P3 = 190 bar. 270 b
Shock valve
- With the engine stopped, disconnect hose supply
piping to the ram (Fig. 10 - 11). P3
- Inject a pressure in the circuit using a calibration pump
(note the opening pressure):
Fig. 9
P4 = 220 – 240 bar.
High pressure
7. Steering
Maximum steering Low pressure
tor (see § 6 and Fig. 9 to 11) and run the engine at 1000 Lubrication
rpm.
- Slowly turn the steering and make sure that P2 and P3 Full Powershift gearbox lubrication (filter
gradually increase: clogged)
P2 = 149 + 2 bar Suction
P3 = 170 + 2 bar
Shock valve Booster

- With the engine stopped, connect a hand calibration
pump to one of the two supply pipes of the steering ram Return
(Fig 10 - 11).
- Inject a pressure using a calibration pump (note the
opening pressure). Brakes
P5 = 225 - 250 bar.
- Apply the same procedure to the second steering ram Pilot flow
supply.
Steering circuit leak

- Place the front wheels on full lock and apply a torque of
4 Nm, measured along the axis of the steering column,
to the steering wheel. The steering wheel must not turn
more than 2 rpm. If it rotates at more than 2 rpm,
disconnect the piping supplying the rams and block off
both ports.
- Apply the same torque to the steering wheel, if it turns
less than 2 rpm, this indicates a leak from the hydraulic
ram.
Issue 1 May 2001

High pressure 110 l/min circuit (Heavy Duty gearbox) High pressure 110 l/min circuit (Full Powershift gearbox)
P5
P5
P3 P2
P3 P2
HP
BP
HP
BP
P4 P4
P4 P4
Fig. 10 Fig. 11
Issue 1 May 2001


High pressure 110 l/min circuit (Full Powershift gearbox)
8. Trailer braking (if fitted)
Maximum pressure
- Connect a pressure gauge to the trailer braking quick- P6
disconnect coupling (Fig. 12) in order to read P6.
- With the brake pedals latched, apply a progressive
pedal pressure.
- The observed pressure must increase gradually and
reach:
P6 = 130 to 150 bar maximum
- If the pressure does not increase gradually, bleed the
brake circuit (see section 9I01).
Flowrate
- Connect a flowmeter, with its load valve fully open, to
the trailer braking quick-disconnect coupling (Fig. 13).
- Connect the return to the manifold union that supports Fig. 12
the auxiliary spool valves.
- Carry out the reading of Q3.
Engine speed P6 Q3
(rpm) (bar) (l/min mini)
1000 0 47 ± 1
2200 0 53 ± 1
- Still connected as indicated, progressively close the

load valve to increase the pressure and read the Q3
flowrate again.
Engine speed P6 Q3
HP 1000 90 25 ± 1
BP
2200 90 26 ± 1
R
Q3
Fig. 13
Issue 1 May 2001

C . Testing the low pressure 110 l/min P7

circuit
On 8200 tractors fitted with a 110 l/min circuit, the rear
axle 17 bar low pressure supplies the following func-
tions:
- Dynashift (*)
- Engine clutch (*)
- Rear power take off clutch
- 4WD clutch 30bar
- Front and rear differential lock

- Hare / Tortoise range (*)
- Power braking assistance
- Front power take off (if fitted)
Note: On tractors fitted with a Full Powershift gear-
box, the functions marked with an asterisk (*) must
not be taken into account. Fig. 14
1. 17 bar circuit P1
(Figs. 14 - 16) located at the front of the right-hand side
hydraulic cover in order to check P7.
- De-clutch (zero pressure in engine clutch) and de-
activate all the low pressure components.
The front axle must be engaged, the pressure is only
used when de-clutching.
11 bar
Place the range lever in the Tortoise position and the maxi
Dynashift lever in position D.

- Engage each function, the pressure must not drop
below 14 bar and must return to its initial level after each
disengagement.
P7 = 17 ± 1 bar
Fig. 15
2. Booster circuit and oil cooler safety

(Fig. 15 - 16) located on the right-hand side hydraulic
cover in order to check P1
Engine speed P1
(rpm) (bar)
1000 5.2 ± 1
2200 6.3 ± 1
2
Issue 1 May 2000
December 2002

Low pressure 110 l/min circuit (Heavy Duty gearbox)
P8 P9
P10
HP
BP
P1 P7 Fig. 16

3. Oil cooler (optional)

- In accordance with Fig. 16, connect a pressure gauge
to the oil cooler inlet to check P8 and to the oil cooler
outlet to check P9.
Engine speed P8 P9
(rpm) (bar) (bar)
1000 2 ± 0.5 1.9 ± 0.5
2200 2.3 ± 0.5 2 ± 0.5
Issue 1 May 2001

Q4
P11 P12
Fig. 18
Issue 1 May 2001

4. Transmission lubricating circuit

a) Pressure test
- Connect a pressure gauge between the union located 1
on the left-hand side of the transmission and the
lubricating pipe leading to the gearbox, to check P10
(Fig. 16).
At 1000 rpm, P10 = 1.5 ± 0.1 bar
Important: If any auxiliary spool valve is activated
(a flowmeter or slave device must be connected to
it), the pressure must not drop below 1 bar for P10.
3
b) Flowrate test 30bar 30bar P11 2
- Connect a flowmeter to the lubricating circuit as shown
in Fig. 18, in order to read Q4 (the union on the box is still P12
accessible despite the tank being fitted).
Important: The flowmeter valve must remain in the
maximum open position until the end of the test in Fig. 17
order not to cut off lubrication to the transmission.
- Check that the pressures are correct according to the

Engine speed Q4 mini following table:
(rpm) (l/min)
1000 17.8 ± 1 Ratio Front Rear EV1 EV2

piston piston voltage voltage
2200 19.9 ± 1 connector (2) connector (3) en en
P11 (bar) P12 (bar) Volt Volt
Important: A 17±1 17±1 12 0

- If an auxiliary spool valve is activated (a flowmeter
or slave device must be connected to it), the B 17±1 0 12 12
pressure must not drop more than 2 l/min.
C 0 17±1 0 12
D 0 0 0 0
- If the pressures are incorrect, check the movement of

5. Pressure of the Servo systems the solenoid valve slide or consult the electrical tests
a) Dynashift section.
- Remove the plugs (1) from the distribution block.
- Screw on two male connectors (2) and (3), ref.
33843871M1, and connect them to the diagnostic
connectors connected to pressure gauges that are able
to withstand approximately 30 bar (Fig. 17 - 18).
- Start the engine.
- Activate the control located on the left-hand side,
beneath the steering wheel, to select each ratio (A, B,
C and D).
Issue 1 May 2001

Q5
P13
P14
Fig. 21
Issue 1 May 2001

b) Clutch
Control circuit
- Connect a pressure gauge to the clutch valve diagnos-
tics connector located on the right-hand side of the
gearbox (Fig. 19 - 21) in order to check P13.
- Operate the pedal to disengage and engage the clutch.
17 bar
Engine speed P13 P13
disengaged engaged 150
(rpm) (bar) (bar)
1000 0 17 ± 1
2200 0 17 ± 1
25 32
Modulation position 0 bar 11 bar
- The clutch valve modulates between 11 bar and 0 bar.
This modulation corresponds to a pedal travel of be-
tween 32 mm ± 1 mm from the high stop position and
25 mm ± 1 mm before the lower stop position of the
pedal (the total travel is 150 mm).
- If the modulation travel is offset in relation to the pedal
travel, it is necessary to bleed the system using the
bleed-valve located on the end of the valve (see section
9I01).
Clutch lubricating circuit P13

- Connect a pressure gauge on the diagnostic connector 30bar
located on the right-hand side of the gearbox (Fig. 20 -
21) in order to check P14.
- Operate the pedal to disengage and engage the clutch:
Engine speed P14 P14

disengaged engaged Fig. 19
(rpm) (bar) (bar)
1000 2 ± 0,1 0,4 ± 0,1
2200 3 ± 0,1 1,2 ± 0,1
Checking the admissible pressure leak on

the clutch supply
- Connect a flowmeter between the valve and the union
on the spacer (Fig. 21) and read Q5. P14
11bar
Engine speed Q5 Q5
declutched clutch in
(rpm) (l/min) (l/min)
1000 0 3 maxi
Fig. 20


Power shuttle
Remark
All 8200 tractors with a Heavy Duty gearbox can be fitted
with a power shuttle.
The rear axle 17 bar low pressure supplies the following
functions:
- Dynashift
- Power shuttle
- Rear PTO clutch
- Power take-off brake
- 4 WD clutch
- front and rear differential lock
- Hare / Tortoise range
- Power braking assistance
- front clutch PTO (if fitted) 3 2
Front view
6. 17 bar circuit
- Connect a pressure gauge to the diagnostics connector
(Fig. 14) located at the front of the right-hand side
hydraulic cover in order to check P7.
- Deactivate all the low pressure components.
- Place the multiple position lever, located to the left
beneath the steering wheel, in neutral position.
- The front axle must be engaged, the pressure is only
used when de-clutching.
- Place the range lever in the Tortoise position and the P11
Dynashift lever in position D. 2
- Engage each function, the pressure must not drop
below 14 bar and must restore its initial position after
each disengagement.
P7 = 17 + 1 bar
Reminder
- The booster, transmission oil cooler safety and trans-
mission lubricating circuits are similar for the Power
shuttle and mechanical reverse shuttle. If necessary,
refer to § C (2 - 3 and 4).
7. Pressure of the Servo systems

a) Dynashift
Checking piston pressure P12 3
- Connect the male connectors (2) (3) to 30 bar capacity
pressure gauges through hoses fitted with diagnostics
connectors (Fig. 22 - 23).
Fig. 23
Issue 2
1 May 2002
December 2000
110 l/min low pressure circuit (Heavy Duty gearbox)
P18
P12
P11
P15
P16 - P17
Fig. 22
2
Issue 1 May 2000
December 2002

Start the engine.
- Activate the multiple position lever located on the left-
hand side, beneath the steering wheel, to select each
ratio (A, B, C and D). 1
- Check that the pressures are correct according to the
following table:
Ratio Front Rear EV1 EV2

piston piston voltage voltage
connector connector (in volts) (in volts)
(2) P11 (bar) (3) P12 (bar)
1
A 17±1 17±1 12 0
B 17±1 0 12 12
C 0 17±1 0 12
D 0 0 0 0
- Advice: If the pressures are incorrect, before you

consider the Dynashift to be partially defective, check
the movement of the solenoid valve spools and the
solenoid power supply.
b) Power shuttle front and rear clutch

Checking control unit pressure supply
- Connect a pressure gauge with a capacity of around 30
bar to the diagnostics connector (1) on the control unit
located to the right-hand in front of the gearbox (Fig. 22- P15
24).
- Check the pressure readings with those of the table
below.
Fig. 24
Engine speed P15
(rpm) (bar)
1000 18 ± 1
2200 18 ± 1
Issue 2
1 May 2002
December 2000
c) Checking clutch lubricating pressure
The checking operation is to be carried out with

an operator in the tractor driving seat.
Remark 2
- The clutch diagnostics connectors (1) (forward ratio)
and (2) (reverse ratio) can be accessed through the
control unit located to the right-hand sode in front of the
gearbox as shown in Fig. 25.
Reminder
The multiple position lever is located on the left-hand
side, beneath the steering wheel: 1
- lever in upward position (forward): green light is on
- lever in downward position (reverse): red light is on
- Connect a 30 bar capacity pressure gauge on each

diagnostics connector (1) (2) (Fig. 22 and 25).
- run the engine at 1000 rpm.
- Activate the lever and select the forward gear, reverse
gear, and neutral. 1
- Check the pressure readings against those given in the
table
P16
Lever Clutch (1) Clutch (2)

position P16 (bar) P17 (bar)
Clutch Clutch Clutch Clutch
engaged disengaged engaged disengaged
Forward 18±1 0 0 0
gear
Neutral 0 0 0 0
Reverse 0 0 18±1 0
gear
P17
Fig. 25
2
Issue 1 May 2000
December 2002

d) Checking clutch lubricating pressure
The checking operation is to be carried out with

1
an operator in the tractor driving seat.
Reminders
- The clutches are lubricated by a gear pump, independ-
ent from the one used for the standard lubricating
system.
- When the front clutch is under load, its internal compo-
nents are lubricated.
- Two valves, mounted on the reverse shuttle front
cover, enable lubrication of the reverse gear system,
when selected.
- Connect a hose fitted with a 11 bar capacity pressure

gauge on the diagnostics connector (1) located to the
right-hand side on the front of the gearbox housing (Fig.
22 and 26).
- Check the test results against the table below. P18
Ratio P18 (bar) P18 (bar)

Ratio engine (rpm) disengaged engaged
Pedal or lever
Forward 1000 1,5 ± 0,1 0,5 ± 0,1

(green
light on) 2200 2 ± 0,1 0,9 ± 0,1
Reverse 1000 1,5 ± 0,1 0,4 ± 0,1

(red
light on) 2200 2 ± 0,1 0,8 ± 0,1
Fig. 26
Issue 2
1 May 2002
December 2000
D . Testing the high pressure 150 l/ P1

min circuit
The high pressure circuit supplies the following func-
tions:
- steering
- auxiliary spool valves
- lift control
- trailer braking
1. Booster pressure of the variable displa-

cement pump
- Connect a pressure gauge on the diagnostic connector
located on the cover (Fig. 27 - 29) and check P1:
Engine speed P1
(rpm) (bar) Fig. 27
1000 5,2 ± 1
Fig. 28
P2
2200 6,3 ± 1
2. Standby pressure and XLS pressure

. on the right-hand cover: pump pressure = P3
Important: Do not activate any high pressure ele-
ments (e.g. steering) in order to avoid a rise in
pressure greater than that the P2 and P3 pressure
gauges can withstand.
Engine speed P2 P3 P3
(rpm) (bar) (bar)
1000 4 26 ± 1
P1
2200 4 26 ± 1
Note: Pump pressure = XLS pressure + 22 bar ± 1

bar
P3 = P2 + 22 ± 1 bar.
P2 P3
Fig. 29
2
Issue 1 May 2000
December 2002

3. Maximum pressure and flowrate
Remark
- The Q1 flowrate is obtained by using a flowmeter
connected to two auxiliary spool valves.
- Connect a flowmeter according to the previous remark

and Fig. 30. Activate and hold the levers of the spool
valves to obtain Q1.
- Connect a flowmeter to each diagnostics connector
located (Fig. 31 - 33):
. on the right-hand cover: pump pressure = P3
Fig. 30
P3
P2
Fig. 31
Issue 2
1 May 2002
December 2000
- Place the control (1) of the flowrate controller of the

auxiliary spool valves concerned to maximum flowrate. Fig. 32
- Simultaneously activate the spool valve levers and 1
progressively close the flowmeter valve to read the
flowrate and increase the pressure.
Engine Q1 P2 P3
speed
(rpm) (l/min) (bar) (bar)
2200 145 ± 10 110

2200 145 ± 10 130
2200 145 ± 10 P2 = P3 - 22±1 150
2200 145 ± 10 170

2200 145 ± 10 180
2200 0 190 190
Note: If the flowmeter is fitted with a pressure

gauge, the pressure indicated must not be taken into
account.
2
Issue 1 May 2000
December 2002

4. Checking the auxiliary spool valves flow
controller
- Connect a flowmeter to a spool valve.
- Connect a pressure gauge to the right-hand cover
(Fig. 31 - 33) to read : P3 pump pressure.
- Increase the engine speed to 2200 rpm and progres-
sively close the flowmeter valve to obtain a P3 pressure
of 130 bar.
- Place the control (1) (Fig. 32) of the flow controller
concerned on the minimum position and note that the
flowrate is 5 ± 1 l/min at a P3 pressure of approximately
35 bar.
If the flowrate is incorrect, see the controller operation,
section 9D01.
P2 P3
Fig. 33
5. Auxiliary spool valve with automatic re-

turn to neutral
- Connect a flowmeter to a spool valve.
- Connect a pressure gauge to the pump controller (Fig.
33 - 34) to read: XLS pressure = P2.
- Run the engine at 1000 rpm. Activate the spool valve in
the return to neutral position, release the lever and
progressively close the valve of the flowmeter until the
lever returns to the neutral position. Read the triggering
pressure:
P2 = 160 - 185 bar
- The triggering pressure can be adjusted (see section
9D01).
P2
Fig. 34
Issue 2
1 May 2002
December 2000
6. Lift control
Maximum pressure
- Connect a pressure gauge on each diagnostics connec- P3
. on the right-hand side hydraulic cover: pump pressure
= P3
- Utilise the external lift control buttons to reach the
maximum high position:
P2 and P3 = 190 bar
Shock valve
- With the engine stopped, disconnect the hose piping
supplying the rams (Fig. 36 - 37). P2
- Inject a pressure in the circuit using a calibration pump Fig. 35
(note the opening pressure):
P4 = 220 - 240 bar
Issue
Issue 12 December
May 2000
2002

7. Steering
Maximum pressure
tor (see § 6, Fig. 35 - 37) and run the engine at 1000 rpm.
- Slowly turn the steering and ensure that P2 and P3
gradually increase:
P2 = 149 ± 2 bar
P3 = 170 ± 2 bar
Shock valve
- With the engine stopped, connect a hand calibration
pump to one of the two supply pipes of the steering ram
(Fig. 36 - 37).
- Inject a pressure using the calibration pump (note the
opening pressure):
P5 = 225 - 250 bar
- Carry out the same procedure with the second ram
supply.
Steering circuit leakage

- Place the front wheels on full lock and apply a torque of
4 Nm to the steering wheel axis. The steering wheel
must not turn more than 2 rpm. If the steering wheel
rotates faster than 2 rpm, disconnect the piping supply-
ing the rams and block off both pipe ports.
- Apply the same torque to the steering wheel, if it rotates
less than 2 rpm, there is a leak from the steering ram.
Issue 2
1 May 2002
December 2000
Dana front axle - High pressure 150 l/min circuit ZF front axle - High pressure 150 l/min circuit
(Full Powershift gearbox) (Full Powershift gearbox)
P5
P5
P2
P3
P2 P3
P4 P4
P4 R P4
R
Q3
Q3
Fig. 31 Fig. 32
Issue 2 May 2002

Issue 2 May 2002

8. Trailer braking (if fitted)

Maximum pressure P6
- Connect a pressure gauge to the trailer brake quick-
disconnect coupling (Fig. 38) in order to read P6.
- With the brake pedals latched, apply a progressive
pressure.
- The pressure that is read must increase gradually and
reach:
P6 = 130 to 150 bar maximum
- If the pressure does not increase gradually, bleed the
brake circuit (see section 9I01).
Flowrate
- Connect a flowmeter, with its load valve open to the
maximum, on to the trailer brake quick-disconnect
coupling (Fig. 36 - 37). Fig. 38
- Connect the return to the manifold union that supports
the auxiliary spool valves.
- Carry out a reading of Q3.
Engine speed P6 Q3
1000 0 47 ± 1
2200 0 53 ± 1
- Still connected as previously described, progressively

close the flowmeter load valve in order to increase the
pressure and read the new Q3 flowrate.
Engine speed P6 Q3
1000 90 25 ± 1
2200 90 26 ± 1
Issue 21 May 2002

December 2000
E . Testing the low pressure 150 l/

min circuit
On 8200 series tractors fitted with a 150 l/min circuit, the
17 bar low pressure of the rear axle supplies the following
functions:
- rear power take clutch
- power take off brake
- 4WD clutch (depending on version)
- front diff lock (if fitted) and rear diff lock
- power braking assistance
- front power take off clutch (if fitted)
Note: The 150 l/min circuit is only available on
tractors fitted with a Full Powershift gearbox.
P7
1. 17 bar circuit Fig. 39
(Fig. 39) located above the right-hand side hydraulic
cover to check P7. P1
- De-activate all low pressure components.
The front axle must be engaged since pressure is used
only when de-clutching.
- Activate each function, the pressure must not drop
below 14 bar and must restore to its initial level when
each component is de-activated.
P7 = 17 ± 1 bar
2. Booster circuit of the variable displace-

ment pump and rear axle lubricating circuit
- The oil used for boosting the variable displacement
pump is also used to lubricate the following functions:
. power take off clutch Fig. 40
. the trumpets (depending on model)
. the handbrake system and mainly the creeper gear-
box (if fitted)
. the 4WD unit
. the hydraulic pump drive bearing block
located on the booster manifold above the right-hand
side hydraulic cover (Fig. 40) in order to check P1.
Engine speed P1
(rpm) (bar)
1000 5,2 ± 1
2200 6,3 ± 1
Issue 11
Issue May 2000
December 2002
F . Testing the low pressure hydrau- Top view

lic functions of the Full Powershift
gearbox 12 13
The Full Powershift gearbox possesses its own hydraulic
supply and clutch lubricating system (see section 5I01).
An inspection plate located beneath the pedals and
bolted to the cab floor allows access to the different plugs
corresponding to the various channels: pump outlet (17
bar), clutch pressure and lubrication (1) (2) (A) (B) (C) and
(R).
- In order not to eliminate the operation of the pressure
switch (17 bar) during the pressure tests, provisionally
screw the pressure switch (13) (red dot) and its relief-
valve at the location of the large plug (12) (Fig. 41). 1 R P1 2
Reconnect the wiring loom to the pressure switch.
- Fit in the port previously used by the pressure switch,
the diagnostics connector and reducer found in kit, ref.
3378174M1, in order to test P1 (Fig. 41).
- Remove the 7/16 plugs. Screw the diagnostic hose
piping provided with kit, ref. 3378174M1, into the
corresponding ports (1) (2) (A) (B) (C) and (R) (Fig. 41)
and the diagnostics connectors into the ports (L) (H) and
(M) (Fig. 42).
C B A
Fig. 41
Bottom view
AG 250 AG 150
M L M L
Fig. 42

May 2002

- Take out the 9/16 plug (14) located on the upper left-side
of the gearbox (Fig. 43). Fit a diagnostic connector in its
location.
- Run the engine to bring the oil up to a temperature of P2 14
80° C minimum (176° F) (see § A).
- Before checking the clutch pressure (see paragraph 3),
check the pump pressure, the operation of the 17 bar
valve and the lubrication pressure in the clutches.
1. Pump pressure and valve operation

and check P1 (Fig. 41).
Engine speed P1
(rpm) (bar)
Fig. 43
1000 18 ± 1
2200 18 ± 1
2. Clutch lubricating pressure

and check P2 (Fig. 43).
Engine speed P2
(rpm) (bar)
1000 0,6 ± 0,2
2200 1,8 ± 0,2
Issue 1 May 2002

December 2000
3. Clutch pressures Note: The reading of the pressures is carried out

Remark inside the cab, with the tractor moving.
For each ratio, selected with the gear shift lever,
three clutches are engaged. The clutch pressure test
is carried out using three pressure gauges of ap-
proximately 30 bar capacity that are moved in rela-
tion to the clutches to be tested (F = Forward and R
= Reverse)
Ratios Clutches
selected engaged
F1 1-A-L
F2 2 - A- L
F3 1-B-L
F4 1-A-M
F5 2-B-L
F6 2-A-M
F7 1-C-L
F8 1-B-M
F9 2-C-L
F10 2-B-M
F11 1-A-H
F12 1-C-M
F13 2-A-H
F14 2-C-M
F15 1-B-H
F16 2-B-H
F17 1-C-H
F18 2-C-H
R1 R-A-L
R2 R-B-L
R3 R-A-M
R4 R-C-L
R5 R-B-M
R6 R-A-H
R7 R-C-M
R8 R-B-H
Issue 1 May 2000

December 2002

- Connect the pressure gauges to the connectors and Note: The value read on each pressure gauge must
diagnostics hose piping of the clutches engaged (Fig. 44) be constant when the clutch is fully engaged.
according to the ratio selected.
- Drive the tractor in this ratio, note and then check the P3 Final operations
to P11 pressures according to the following table: - After carrying out the tests, restore the tractor to the
state prior to the tests (17 bar pressure switch is refitted
Clutch Pressure in its initial location - all connectors and hose piping
removed).
1 P3 = 17 ± 1
2 P4 = 17 ± 1
R P5 = 17 ± 1
A P6 = 17 ± 1
B P7 = 17 ± 1
C P8 = 17 ± 1
L P9 = 17 ± 1
M P10 = 17 ± 1
H P11 = 17 ± 1
Fig. 44
Top view M L
H
1 2
Bottom view
C A of AG250 gearbox
M L
Bottom view
of AG150 gearbox
Issue 11
Issue May 2000
December 2002
10 . ELECTRICAL EQUIPMENT
Contents
10 A01 RISTS ELECTRICAL EQUIPMENT
10 A02 DEUTSCH ELECTRICAL EQUIPMENT
Issue 2 May 2002

Electrical equipment 10A01.1
10 A01 Electrical equipment
CONTENTS
A. General ________________________________________________ 3
B. Dynashift - Cab accessories and engine equipment ________ 8
C. Full Powershift - Engine equipment ______________________ 22
D. Full Powershift - Cab equipment _________________________ 24
E. Lighting layout (except North America) ___________________ 26
F. Direction indicator lamps (except North America) __________ 28
G. Work lights and flashing beacons (except North America) __ 30
H. Dynashift - Full lighting system (North America) ___________ 32
I. Full Powershift - Full lighting system (North America) _____ 34
J. Dynashift - Fuses (except North America) _________________ 36
K. Full Powershift - Fuses (except North America) ____________ 37
L. Dynashift - Fuses (North America) ________________________ 38
M. Full Powershift - Fuses (North America) ___________________ 39
Issue 1 May 2001

10A01.2 Electrical equipment
Issue 1 May 2001

Regulator voltage 14.2 V

A . General Starter
8210 to 8260
The 8200 series of tractors are fitted with a 12-volt
Make Magneti – Marelli
negative ground electrical circuit, charged by a 120 A
Model 2.8 kW
alternator (70 A for platform versions).
Voltage 12 V
The alternator has an integrated rectifier and a charging
Type pre-engaged
regulator. An additional terminal is provided to supply the
electronic tachometer (for Autotronic 2 versions only).
8270 – 8280
The alternator fitted on the right-hand side of the engine
Make Magneti – Marelli
is driven by a belt from the crankshaft pulley.
Model 3.6 kW
The starter motor, fitted on the right-hand side of the
Voltage 12 V
engine, is of the pre-engaged type.
Type pre-engaged
The safety switch, placed under the clutch pedal, supplies
the starter solenoid when the clutch pedal is fully pressed.
+P : + Permanent
The batteries are mounted on a fixed or pivoting carrier
+ AC : + After contact
(depending on the model), behind the right-hand side
Ah : Amp hours
footstep.
Designation of harnesses
Characteristics a : Dashboard harness
Batteries
b : Engine harness
8210 - 8220
c : Console harness
Quantity 2
g : Roof harness
Type Maintenance free
h : Battery cut out harness
Cold start performance 420 A (- 18° C)
i : Rear wiper harness
Reserve capacity at 25 A 120 minutes
j : Lead for battery cut out (radio, clock and roof light
Voltage 12 V
supply)
Capacity 66 Ah
k : Additional tank harness
l : Door switch harness for roof light
8240 to 8280
m : Windscreen washer pump lead
Quantity 2
n : Thermostart lead
Type Maintenance free
o : Batteries harness
Cold start performance 420 A (- 18° C)
p : Interior power socket harness
Reserve capacity at 25 A 180 minutes
r : Roof dashboard lighting harness
Voltage 12 V
s : Roof headlights harness
Capacity 105 Ah
t : Roof dashboard harness (lower part)
u : Roof dashboard harness (upper part)
Alternator
v : Front work lights harness
Cab
w : Front and rear lighting harness
Make Valeo
x : Roof lighting harness
Max. output amperage 120 A
y : Registration plate light harness
Regulator integral
z : Interior 25 A power socket harness
aa : Cigarette lighter harness
ab : Parking brake buzzer harness
Platform
ak : Ground lead (tractor without radiator water level
Make Magneti - Marelli
sensor)
Type A127
Max. output amperage 70 A
Regulator integral
Issue 1 May 2001


Connectors Number Connector Lead colour Tractor
of ways colour
C1 9 (Ritz) or 16 Black circle M - M - M - M - VI - G - G - N

(Deutsch kit)
C2 9 (Ritz) or 16 Black circle RO - M - M - B - R - VI -

(Deutsch kit) with red mark O - BLF
C3 6 Black J - R - M emb. R - R - VI - MC Dynashift
C3 10 Black V-R-N-R-R-N-J-J Full

M emb. R - MC Powershift
C4 6 Black VC - VI - B - VF - MC - N Dynashift
C4 2 Black J-N Full

Powershift
C5 10 Black M-R-J-R-N-O-M-R Dynashift
C5 10 Black RO - S - R - V - M - B - VI Full
Powershift
C6 8 Black B - O - O - G - VI - R - RO - BL
C7 13 Transparent G - BLF - MF - O - VC - J -
G - VI - B - BL - R - M - RO
C8 2 Black BLC - BLF Dynashift

Except
North America
C8 1 Black BLF Dynashift

North America
C8 1 Black V Full
Powershift
C9 9 (Ritz) or 16 Black circle M-M-M-M-V-J-G

(Deutsch kit) with green mark
C10 6 Transparent VF - BE - BLF - VF - R - BLF Except

North America
C10 8 Transparent BLF - BLF - BLF - M - North America

BE - RO - R
C11 10 Grey BL/G - G - S - R - B - Full

RO - R - VI Powershift
C12 2 Transparent M emb. R - N
C13 1 Black R
C14 5 Transparent R - R - R - N - VI
Issue 1 May 2001


of ways colour
C15 10 Black J - R - V - O - BLF - B - R - Full

R - VI - N Powershift
C16 4 Transparent R - G - BE - N
C17 3 Black VI - O - R Standard roof
C17 7 Brown O - O - N - VI High visibility

roof
C18 6 Black G - BL - B - O - N
C19 8 Black O - N - R - RO Except

North America
C19 2 Black O-N North America
C21 3 Black O - RO - RO Except

North America
C21 6 Black VF - VF - VF - M - RO - VI North America
C22 2 Black N-R
C24 4 Black VI - O - RO - R
C25 1 Black RO
C26 1 Black RO
C27 1 Black A Dynashift

Except
North America
C27 1 Black BLC Dynashift

North America
C28 3 Black M-R-V
C29 6 Black O-O-N-N-R Except

North America
C29 3 Black R-N-O North America
C30 13 Transparent G - VF - O - R - G - J - M - R Dynashift

M - B emb. N - J - M - N
C31 13 Transparent O - BLF - J - R - G - B - VI - Dynashift

RO - O - B emb. B
C33 2 Black N-J
C34 2 Black R-N
C37 6 Black R - B - M - G - M - BL Full
Issue 1 May 2001


of ways colour
C42 1 Black VI Except

North America
C43 2 Black M-R Except

North America
C45 3 Black G - VF - J Full

Powershift
C46 2 Transparent B-N Except

North America
C47 3 Transparent M-R-N
C48 2 Black N-N
C50 10 Black R-N-O-M-V-R Dynashift

B - O - RO
C50 10 Grey R - B - RO - R - V Full

BL - O - RO Powershift
C51 3 Black J-R-M Dynashift
C51 10 Black O - BLF - R - J - R - V Full

BLG - RO - S - N Powershift
C52 7 Black V - BL - O - R Dynashift
C52 7 Black B - VI - V - BL - O - RO Full

Powershift
C53 3 Grey and black V-M-B Full

Powershift
C60 8 Black O - R - R - M - I - B - RO - R Except

North America
C60 8 Transparent G - RO - R - O - R - R - M - BE North America
C62 6 Transparent VF - VF - BLF - BLF - BE - R Except

North America
C62 8 Black BLF - BLF - BLF - M North America

R - RO - BE
C63 6 Black G - V - BL - BL - V - R Except

North America
C63 6 Black BL - BL - BL - M - G - RO North America
C64 2 Transparent RO - R Except

North America
C64 1 Transparent RO North America
C65 2 Transparent M-R Except

North America
Issue 1 May 2001


of ways colour
C65 1 Transparent RO North America
C66 4 Black R - RO - B - N Except

North America
C66 3 Black N - RO - R/M North America
C67 4 Black N-M-R-B Except

North America
C67 3 Black N-M-R North America
C68 2x2 Black BL - BL - N - N
C69 2x2 Black BL - BL - N - N
C70 2 Black VF - V Except

North America
C70 2 Black BLF - B North America
C71 2 Black VF - V Except

North America
C71 2 Black BLF - B North America
C72 2 Black N-R
C73 2 Black N-R
C74 1 Round terminal G
C75 6 Black R - R - VI - O - RO - N
C76 6 Black O - VI - R - RO - N - R
C78 2 Black VF - VF
C79 2 Black with VF - VF

green adhesive tape
C80 1 Black VF
C81 2 Transparent VF - N
C82 1 Black G
C83 1 Black G
C84 3 Black N-J-V
Issue 1 May 2001

Colour codes Identification of connectors

B . Dynashift - Cab accessories and A : Silver
engine equipment (Fig. 1 to 7) B : White Connectors Number of ways / Location Tractor
BL : Blue colour
Parts list BE : Beige
1. Starter switch G : Grey
2. Air filter I : Ivory C1 9 (Ritz) or 16 Under bonnet
3. Temperature probe J : Yellow (Deutsch kit) / black circle
4. Water temperature gauge M : Brown
5. Water level detector N : Black C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
5a. Ground to be connected (if no water level detector) O : Orange / black circle with red mark
6. Engine oil pressure switch R : Red
RO : Pink C3 6 / Black Under dashboard left-hand side Dynashift
7. Thermostart
8. Injection pump control solenoid S : Salmon
V : Green C6 8 / Black Under dashboard left-hand side
9. Temperature switch
10. Thermostart solenoid valve VI : Violet
C10 6 / Transparent Under right-hand side cab upright Except
11. Dashboard supply North America
12. Alternator C : Light
13. Lighting switch F : Dark C10 8 / Transparent Under right-hand side cab upright North America
14. Cab relay
15. Air conditioned compressor pressure switch Emb.: end fitting C12 2 / Transparent Under right-hand side cab upright
16. Ventilation unit harness connector
17. Clock C13 1 / Black Behind starter
18. Roof light
C14 5 / Transparent To ELC calculator
19. Door switch
20. Radio harness connector C16 4 / Transparent In heating compartment
21. Starter
22. Batteries C17 3 / Black In heating compartment Standard roof
23. Power socket
24. Cigarette lighter connector C17 7 / Marron In heating compartment High visibility roof
25. Windscreen washer pump
26. Front windscreen wiper switch C18 6 / Black Under dashboard right-hand side
27. Time delay relay
28. Front windscreen wiper motor C24 4 / Black Under right-hand side
29. Rear wiper switch
C25 1 / Black Under dashboard
30. Rear wiper motor
C28 3 / Black In heating compartment
Indicator lamps
T5 : Alternator charge lamp C29 6 / Black Behind power socket Except
T8 : Air filter clogging lamp North America
T10: Engine oil pressure lamp
C29 3 / Black Behind power socket North America
C62 6 / Transparent Under dashboard right-hand side Except

North America
C62 8 / Black Under dashboard right-hand side North America
Issue 1 May 2001

Air filter vacuum sensor

R
2 T8
Temperature probe
3 4
5 5a
Engine oil pressure
6 T10
Fig. 1
Issue 1 May 2001


B . Dynashift - Cab accessories and Colour codes Identification of connectors
A : Silver
BL : Blue colour
C1 9 (Ritz) or 16 Under bonnet
(Deutsch kit) / Black circle
2. Air filter I : Ivory
3. Temperature probe J : Yellow C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
4. Water temperature gauge M : Brown / black circle with red mark
5. Water level detector N : Black
5a. Ground to be connected (if no water level detector) O : Orange C3 6 / Black Under dashboard left-hand side Dynashift
7. Thermostart RO : Pink C6 8 / Black Under dashboard right-hand side
9. Temperature switch V : Green C10 6 / Transparent Under right-hand side cab upright Except
VI : Violet North America
10. Thermostart solenoid valve
11. Dashboard supply C10 8 / Transparent Under right-hand side cab upright North America
13. Lighting switch F : Dark C12 2 / Transparent Under right-hand side cab upright
14. Cab relay
15. Air conditioned compressor pressure switch Emb.: end fitting C13 1 / Black Behind starter
17. Clock C14 5 / Transparent To ELC calculator
18. Roof light
19. Door switch C16 4 / Transparent In heating compartment
20. Radio harness connector
C17 3 / Black In heating compartment Standard roof
21. Starter
22. Batteries C17 7 / Brown In heating compartment High visibility roof
23. Power socket
24. Cigarette lighter connector C18 6 / Black Under dashboard right-hand side
26. Front windscreen wiper switch C24 4 / Black Under right-hand side cab upright
28. Front windscreen wiper motor C25 1/ Black Under dashboard
30. Rear wiper motor C28 3 / Black In heating compartment
C29 6 / Black Behind power socket Except

Indicator lamps North America
T5 : Alternator charge lamp
T8 : Air filter clogging lamp C29 3 / Black Behind power socket North America

North America
C62 8 /Black Under dashboard right-hand side North America
Issue 1 May 2001

Thermostart
1
N
7 R
Injection control and dashboard supply
R
1
8
R
9
11
10
Fig. 2
Issue 1 May 2001


A : Silver
engine equipment (Fig. 1 to 7) B : White
Connectors Number of ways / Location Tractor
colour
BL : Blue
C1 9 (Ritz) or 16 Under bonnet
1. Starter switch G : Grey (Deutsch kit) / Black circle
North America
10. Thermostart solenoid valve VI : Violet
11. Dashboard supply C10 8 / Transparent Under right-hand side cab upright North America
14. Cab relay
18. Roof light
C17 3 / Black In heating compartment Standard roof
21. Starter
22. Batteries C17 7 / Brown In heating compartment High visibility roof
23. Power socket


North America
Issue 1 May 2001

Battery charging
12 T5
1
N
13
14
R
15
16
Fig. 3
Issue 1 May 2001


A : Silver Connectors Number of ways / Location Tractor
engine equipment (Fig. 1 to 7) B : White colour
BL : Blue
G : Grey C1 9 (Ritz) or 16 Under bonnet
1. Starter switch
(Deutsch kit) / Black circle
10. Thermostart solenoid valve VI : Violet North America
11. Dashboard supply
C10 8 / Transparent Under right-hand side cab upright North America
14. Cab relay
18. Roof light
21. Starter C17 3 / Black In heating compartment Standard roof
22. Batteries
C17 7 / Brown In heating compartment High visibility roof
23. Power socket


North America
Issue 1 May 2001

Accessories
1
N
R 13
14
20 17 18
19
Fig. 4
Issue 1 May 2001


A : Silver
BL : Blue colour
1. Starter switch G : Grey C1 9 (Ritz) or 16 Under bonnet
2. Air filter I : Ivory (Deutsch kit) / Black circle
3. Temperature probe J : Yellow
M : Brown C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
4. Water temperature gauge
/ black circle with red mark
12. Alternator C : Light C10 8 / Transparent Under right-hand side cab upright North America.
13. Lighting switch F : Dark
C12 2 / Transparent Under right-hand side cab upright
14. Cab relay
15. Air conditioned compressor pressure switch Emb.: end fitting
C13 1 / Black Behind starter
18. Roof light
22. Batteries
23. Power socket C17 7 / Brown In heating compartment High visibility roof
24. Cigarette lighter connector
C18 6 / Black Under dashboard right-hand side
Indicator lamps C29 6 / Black Behind power socket Except

T5 : Alternator charge lamp North America
T8 : Air filter clogging lamp

North America
Issue 1 May 2001

21
23
30 Amp
22
Cab interior power socket
1
R 13
24
Cigarette lighter
Fig. 5
Issue 1 May 2001


BL : Blue colour
1. Starter switch
I : Ivory (Deutsch kit) / Black circle
2. Air filter
4. Water temperature gauge / black circle with red mark
C : Light C10 8 / Transparent Under right-hand side cab upright North America.
12. Alternator
14. Cab relay
15. Air conditioned compressor pressure switch Emb.: end fitting
18. Roof light
22. Batteries
23. Power socket


North America
Issue 1 May 2001

Front windscreen wiper
14 1
27
25
26
28
Fig. 6
Issue 1 May 2001


BL : Blue colour
1. Starter switch
I : Ivory (Deutsch kit) / Black circle
2. Air filter
4. Water temperature gauge / black circle with red mark
C : Light C10 8 / Transparent Under right-hand side cab upright North America.
12. Alternator
14. Cab relay
15. Air conditioned compressor pressure switch Emb : end fitting
18. Roof light
22. Batteries
23. Power socket


North America
Issue 1 May 2001

Rear wiper
R 13
14
1
29
30
Fig. 7
Issue 1 May 2001


C . Full Powershift – Engine equip- A : Silver
ment (Fig. 8) B : White Connectors Number of ways / Location Tractor
BL : Blue colour
1. Starter switch G : Grey C1 9 (Ritz) or Under bonnet
2. Safety switch I : Ivory 16 (Deutsch kit) / Black circle
3. Batteries J : Yellow
4. Injection pump solenoid M : Brown C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
5. Starter N : Black / black circle with red mark
6. Alternator O : Orange
7. Starter relay R : Red C60 8 / Black Under dashboard left-hand side Except
8. Fuel gauge RO : Pink North America
9. Engine oil pressure gauge S : Salmon
10. Water temperature gauge V : Green C60 8 / Transparent Under dashboard left-hand side North America
11. Tachometer and hourmeter VI : Violet
12. Air filter vacuum sensor
13. Water level sensor C : Light
14. Engine oil pressure sensor F : Dark
15. Temperature probe
16. Fuel level sensor Emb.: end fitting
17. Fuel level sensor (additional tank)
45. Diode and resistor located behind fuse box
Indicator lamps
T8 : Air filter clogging lamp
T10 : Engine oil pressure lamp
T23 : 5 bar booster pressure lamp
T28 : Coolant level lamp
Designation of harnesses
a : Dashboard harness
b : Engine harness
k : Additional tank harness
w : Front and rear lighting harness
Issue 1 May 2001

Fig. 8
Issue 1 May 2001


Designation of harnesses Identification of connectors
D . Full Powershift - Cab equipment a : Dashboard harness
(Fig. 9) b : Engine harness Connectors Number of ways / Location Tractor
c : Console harness colour
h : Battery cut out harness
Parts list
i : Rear wiper harness C1 9 (Ritz) or 16 Under bonnet
1. Starter switch
j : Lead for battery cut out (radio, clock and roof light (Deutsch kit) / Black circle
2. Safety switch
supply)
3. Batteries
l : Door switch harness for roof light C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
6. Alternator
m : Windscreen washer pump lead / black circle with red mark
13. Lighting switch
o : Batteries harness
18. Air conditioned pressure switch
p : Interior power socket harness C3 6 / Black Under dashboard left-hand side Dynashift
19. Air conditioned compressor
20. Cab relay C4 2 / Black Under dashboard left-hand side
u : Roof dashboard harness (upper part)
21. Radio
z : Interior 25 A power socket harness
22. Digital clock C6 8 / Black Under dashboard right-hand side
aa : Cigarette lighter harness
22b Digital clock supply with battery cut out
23. Roof light C8 1 / Black Under bonnet
24. Door switch
25. Water pump C12 2 / Transparent Under cab upright right-hand side
26. Water pump switch
27. Ventilation switch Colour codes C13 1 / Black Behind starter
28. Blower motor A : Silver
29. Air conditioned temperature switch B : White C14 5 / Transparent To ELC calculator
30. Battery cut out BL : Blue
31. Front windscreen wiper motor BE : Beige C16 4 / Transparent In heating compartment
32. Interior power socket G : Grey
33. Console, armrest lighting (roof) I : Ivory C17 3 / Black In heating compartment Standard roof
34. Windscreen washer pump J : Yellow
35. Parking brake switch M : Brown C17 7 / Brown In heating compartment High visibility roof
36. Rear wiper switch N : Black
37. Cigarette lighter O : Orange C18 6 / Black Under dashboard right-hand side
38. Windscreen wiper time delay R : Red
RO : Pink C19 8 / Black Behind radio compartment Except
39. Windscreen wiper switch
S : Salmon North America
41. Parking brake sound signal V : Green
VI : Violet C19 2 / Black Behind radio compartment North America
42. Autotronic2 or DCC / TC batteries supply
C : Light C22 2 / Black Under pneumatic seat

F : Dark
C24 4 / Black Under right-hand side cab upright
Abbreviations Emb.: end fitting C25 1/ Black Under dashboard

CB : 4WD and differential lock switch
CE : Clutch switch C26 1 / Black Under dashboard
GY : To flashing beacon
M : Cab ground terminal block C28 3 / Black In heating compartment
PS : Pneumatic seat (depending on version)
RE : Electronic Linkage C29 6 / Black Behind power socket Except
North America
C33 2 / Black Under Autotronic2 or TC
C34 2 / Black Under Autotronic2 or TC
Issue 1 May 2001

8200 SERIES TRACTORS colour

C48 2 / Black On roof light
C60 8 / Black Under dashboard left-hand side Except

North America
C60 8 / Transparent Under dashboard left-hand side North America
22
Ro. R 24 23
emb.R
+AC
MF 1 21
2 25
O 4
3
G
13 20
6 26
R
R
2
27
30 RE
CB
5
28 19
29 18
3
CE
31
13
1
32
22b 33 39
42
34 M
PS RE 37 38
RE
41
RE 40
35
36 GY
Fig. 9
Issue 1 May 2001


E . Lighting layout (except North A : Silver
America) (Fig. 10) B : White Connectors Number of ways / Location Tractor
BL : Blue colour

1. Starter switch (Deutsch kit) / Black circle
I : Ivory
2. Horn
J : Yellow
3. Front left headlight C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
M : Brown
4. Front right headlight / black circle with red mark
N : Black
5. Right rear tail light / stop light
O : Orange
6. Left rear tail light / stop light C7 13 / Transparent Under dashboard
R : Red
7. Stop light switch
RO : Pink
8. Lighting controller C9 9 (Ritz) or 16 (Deutsch kit) Under bonnet
S : Salmon
9. Roof mounted front left headlight / Black circle with
V : Green
10. Roof mounted front right headlight green mark
VI : Violet
11. Registration plate light
12. Roof mounted headlights switch C10 6 / Transparent Under right-hand side cab upright Except
C : Light
13. Lighting switch North America
F : Dark
14. Front right sidelight
15. Front left sidelight C60 8 / Black Under dashboard left-hand side Except
23. Trailer lighting socket Emb.: end fitting
North America
43. Lighting control unit
North America
C63 6 / Black Under right-hand side cab upright Except

T17 : Headlights on lamp
C64 2 / Transparent Behind rail mounted light Except
North America

North America
C66 4 / Black Behind left tail light Except

North America
C67 4 / Black Behind right tail light Except

North America
C72 2 / Black Behind rear top panel
C73 2 / Black Behind rear top panel
C75 6 / Black Beneath dashboard right-hand side Except

North America
C76 6 / Black Beneath right-hand side cab upright
Issue 1 May 2001

Fig. 10
Issue 1 May 2001


F . Direction indicator lamps (except A : Silver
North America) (Fig. 11) B : White Connectors Number of ways / Location Tractor
BL : Blue colour
C1 9 (Ritz) or Under bonnet
16 (Deutsch kit) / Black circle
16. Rear right indicator lamp I : Ivory
17. Rear left indicator lamp J : Yellow
C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
18. Front right indicator lamp M : Brown
black circle with red mark
19. Front left indicator lamp N : Black
20. Flasher unit O : Orange
21. Emergency lights switch R : Red
North America
23. Trailer lights socket RO : Pink
43. Lighting control unit S : Salmon
V : Green
North America
VI : Violet
C : Light
North America
F : Dark
Indicator lamps C66 4 / Black Behind left tail light Except
Emb: end fitting
T16 : Direction indicator lamp North America
T18 : Direction indicator lamp for second trailer
T19 : Direction indicator lamp for first trailer C67 4 / Black Behind right tail light Except
North America
Issue 1 May 2001

T16 T16 T19 T18

21
20
43 1
16
18
23
17
19
Fig. 11
Issue 1 May 2001


G . Work lights and flashing beacons Colour codes Identification of connectors
A : Silver
(except North America) (Fig. 12) B : White Connectors Number of ways / Location Tractor
BL : Blue colour
G : Grey C1 9 (Ritz) or Under bonnet
13. Lighting switch
I : Ivory 16 (Deutsch kit) / Black circle
22. Rear right wing work light
24. Rear left wing work light J : Yellow
25. Rear roof work lights
N : Black black circle with red mark
26. Front work light on right-hand rail
27. Front roof work lights O : Orange
R : Red C9 9 (Ritz) or 16 (Deutsch kit) Under bonnet
28. Front work light on left-hand rail
RO : Pink black circle with green mark
29. Front work light on right-hand footstep
30. Front work light on left-hand footstep S : Salmon
V : Green C10 6 / Transparent Beneath right-hand side cab upright Except
31. Front and rear work lights switch
VI : Violet North America
32. Flashing beacons
33. Flashing beacon(s) switch
C : Light C16 4 / Transparent In heating compartment
34. Wing and rail work lights switch
34. Footstep work lights switch F : Dark
44. To console lighting
Emb : end fitting North America

North America
C63 6 / Black Beneath right-hand side cab upright Except

North America
C68 2 x 2 / Black Behind left-hand roof light
C69 2 x 2 / Black Behind right-hand roof light
C70 2 / Black Behind rear top panel Except

North America
C71 2 / Black Behind rear top panel Except

North America
C74 1 / Round terminal Behind flashing beacon
C79 2 / Black with green mark Behind right rail light
C80 1 / Black Behind left footstep light
C81 2 / Transparent Behind right footstep light
C82 1 / Black Behind left wing light
C83 1 / Black Behind right wing light
Issue 1 May 2001

13
29
26
35 34 31 31
22
27
25
28
24
30
32 32
44
33
Fig. 12
Issue 1 May 2001


Abbreviations Identification of connectors
H . Dynashift - Full lighting system EA : To rear windscreen wiper switch
(North America) (Fig. 13) Connectors Number of ways / Location Tractor
JC : To fuel gauge
colour
TB : To dashboard
Parts list C1 9 (Ritz) or Under bonnet
1. Starter switch 16 (Deutsch kit) / Black circle
2. Horn
3. Front left headlight Colour codes C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
7. Stop light switch A : Silver black circle with red mark
8. Lighting controller B : White
9. Roof mounted front left headlight BL : Blue C3 6 / Black Under dashboard left-hand side Dynashift
16. Right rear direction indicator lamp BE : Beige
17. Left rear direction indicator lamp G : Grey C6 8 / Black Under dashboard left-hand side
18. Front right direction indicator lamp I : Ivory
19. Front left direction indicator lamp J : Yellow C7 13 / Transparent Under dashboard
20. Flasher unit M : Brown
21. Emergency lights switch N : Black C9 9 (Rits) ou 16 (kit Deutsch) Under bonnet
22. Rear right wing work light O : Orange / Rond noir repère vert
23. Power socket R : Red
24. Rear left wing work light RO : Pink C10 8 / Transparent Under right-hand side cab upright North America
25. Rear roof work light S : Salmon
26. Front right rail light V : Green C16 4 / Transparent In heating compartment
27. Front roof work light VI : Violet
28. Front left rail light C21 6 / Black Under dashboard left-hand side North America
29. Front right footstep work light C : Light
30. Front left footstep work light F : Dark C60 8 / Transparent Under dashboard left-hand side North America
31. Front and rear roof work lights switch
32. Flashing beacon Emb. : end fitting C62 8 / Black Under dashboard right-hand side North America
33. Flashing beacon switch
34. Rear low work lights switch C63 6 / Black Beneath right-hand side cab upright North America
35. Front rail and footstep work lights switch
36. Rear right tail light and direction indicator lamp C64 1/ Transparent Behind rail light North America
37. Rear left tail light and direction indicator lamp Designation of harnesses
43. Lighting control unit a : Dashboard harness C65 1 / Transparent Behind rail light North America
44. To console lighting b: Engine harness
g: Roof harness C66 3 / Black Behind left rear light North America
u: Roof dashboard harness (upper part) C67 3 / Black Behind right rear light North America
Indicator lamps w: Front and rear lighting harness
T16 : Direction indicator lamp x : Roof lighting harness C68 2 x 2 / Black Behind left roof light
T17 : Headlights lamp
T18 : Second trailer direction indicator lamp C69 2 x 2 / Black Behind right roof light
C70 2 / Black Behind rear top panel North America
C71 2 / Black Behind rear top panel North America
C78 2 / Black Behind left rail light
C80 1 / Black Behind left footstep light North America
Issue 1 May 2001


13
43
32 33 EA
20 21
8 T16 T16 T17 T18 35 31 34 1
44
Auto 2
7
18 16
36
25
29
22
4 26
27
23
3 28 2
24
TB
30 JC
25
37
19 17
Fig. 13
Issue 1 May 2001


I . Full lighting system - Full Abbreviations Identification of connectors
EA : To rear wiper switch
Powershift (North America) (Fig. 14) JC : To fuel gauge
colour
TB : To dashboard
Parts list C1 9 (Ritz) or Under bonnet
1. Starter switch 16 (Deutsch kit) / Black circle
2. Horn
3. Front left headlight C2 9 (Ritz) or 16 (Deutsch kit) Under bonnet
4. Front right headlight
Colour codes black circle with red mark
7. Stop light switch
A : Silver
8. Lighting controller C6 8 / Black Under dashboard left-hand side
B : White
13. Lighting switch
BL : Blue
16. Right rear direction indicator lamp C7 13 / Transparent Under dashboard
BE : Beige
17. Left rear direction indicator lamp
G : Grey
18. Front right direction indicator lamp C9 9 (Ritz) or 16 (Deutsch kit) Under bonnet
I : Ivory
19. Front left direction indicator lamp black circle with green mark
J : Yellow
20. Flasher unit
M : Brown
21. Emergency lights switch C10 8 / Transparent Under right-hand side cab upright North America
N : Black
22. Rear right wing work light
O : Orange
23. Power socket C16 4 / Transparent In heating compartment
R : Red
24. Rear left wing work light
RO : Pink
25. Rear roof work light C21 6 / Black Under dashboard left-hand side North America
S : Salmon
26. Front right rail light
V : Green
27. Front roof work light C60 8 / Transparent Under dashboard left-hand side North America
VI : Violet
28. Front left rail light
29. Front right footstep work light C62 8 / Black Under dashboard right-hand side North America
C : Light
30. Front left footstep work light
F : Dark
31. Front and rear roof work lights switch C63 6 / Black Beneath right-hand side cab upright North America
32. Flashing beacon
Emb.: end fitting
33. Flashing beacon switch C64 1 / Transparent Behind rail light North America
34. Rear low work lights switch
35. Front rail and footstep work lights switch C65 1 / Transparent Behind rail light North America
36. Rear right tail light and direction indicator lamp
37. Rear left tail light and direction indicator lamp Designation of harnesses C66 3 / Black Behind left rear light North America
43. Lighting control unit a : Dashboard harness
44. To console lighting b: Engine harness C67 3 / Black Behind right rear light North America
g: Roof harness
t : Roof dashboard harness (lower part) C68 2 x 2 / Black Behind left roof light
u: Roof dashboard harness (upper part)
w: Front and rear lighting harness C69 2 x 2 / Black Behind right roof light
Indicator lamps x : Roof lighting harness
T16 : Direction indicator lamp C70 2 / Black Behind rear top panel North America
T17 : Headlights lamp
T18 : Second trailer direction indicator lamp C71 2 / Black Behind rear top panel North America
C78 2 / Black Behind left rail light
C80 1 / Black Behind left footstep light
Issue 1 May 2001

43
13
32 33 EA
21
20 8 T16 T16 T17 T18 35 31 34
1
44
18 16
36
25
29
22
4 26
27
23
3 2
28 24
TB
30 JC
25
37
19 17
Fig. 14
Issue 1 May 2001


There are also three fuses placed in the battery compart-
J . Dynashift – Fuses (except North America) (Fig. 15) ment:
- a 5 A fuse protects the front power take off (if fitted)
Note: Always replace fuses with fuses of the same amperage - a 7.5 A fuse protects the ELC
- a 15 A fuse protects the Autotronic 2 unit. 19 20 21 22 23 24
Fuse Amperage Functions protected A 3 A fuse located under the ELC console protects the
reference ELC calculator (+ AC).
25
10
25
15
25
15
F1 25 (+P) Front work lights A 30 A fuse located beside the starter, protects the interior
F2 3 (+P) Starter relay power socket.
F3 30 (+P) Cigarette lighter
7.5
7.5
7.5
15
30
10
F4 25 (+AC) Front wiper and washer A 5 A fuse, located on the battery cut out (if fitted) protects
F5 30 (+AC) Cab air conditioning, radio, clock, roof light the clock.
F6 15 (+AC) Rear wiper
F7 10 Seat with pneumatic suspension 13 14 15 16 17 18
F8 5 (+AC) Dynashift control lever
F9 7,5 (+AC) ELC Alternator charge lamp
F10 10 (+AC) Cab relay, 4WD and differential lock switch
F11 15 (+AC) Dashboard (digital display) Injection pump
7 8 9 10 11 12
F12 25 (+AC) Parking brake buzzer Interior power socket, Datatronic, Hare / Tor-
toise, Power take off, ELC switches
F13 15 (+AC) Stop lights
F14 30 (+AC) Stop light switch
7.5
25
10
10
15
5
F15 10 (+AC) Left and right direction indicator lamps
F16 7,5 (+AC) Horn
F17 7,5 Front left sidelight and rear left sidelight, Lighting relay control
F18 7,5 Front right sidelight and rear right sidelight, Registration plate light
25
30
25
30
15
3
Lighting of armrest buttons and switches
F19 25 (+P) Rear work lights
F20 10 Dipped beams
F21 15 (+P) Flashing beacon switches 1 2 3 4 5 6
F22 25 (+P) Emergency lights, additional work lights (if fitted)
F23 15 Headlights
F24 25 Additional work lights (if fitted)
Fig.15
+P = Permanent
+AC = + after contact
Note :
- Fuse F7 : If no fuse, the pneumatic seat function is protected by fuse F12
- Fuse F11: Depending on assembly, it may be 15, 20 or 30 A
- Fuse F21: Depending on assembly, it may be 7.5 or 15 A
Issue 1 May 2001


K . Full Powershift – Fuses (except North America) (Fig. 16) ment:
- a 7.5 A fuse protects the ELC
Note: Always replace fuses with fuses of the same amperage - a 15 A fuse protects the TC. 19 20 21 22 23 24
A 3 A fuse located under the ELC console protects the
Fuse Amperage Functions protected ELC calculator (+ AC).
7,5
30
10
25
15
30
reference
A 30 A fuse located beside the starter, protects the interior
F1 30 (+P) Front work lights power socket.
F2 3 (+P) Starter relay
7.5
7.5
7.5
15
30
10
A 5 A fuse, located on the battery cut out (if fitted) protects
F4 25 (+AC) Front wiper and washer the clock.
F5 30 (+AC) Cab air conditioning; radio; clock; roof light
F7 15 (+AC) Transmission controller 13 14 15 16 17 18
F8 3 (+AC) ELC; Power take off stop
F9 15 (+AC) Park Lock; Clutch switches (top and bottom); Left and right neutral
lever switch.
F10 10 (+AC) Cab relay, 4WD and differential lock switch 7 8 9 10 11 12
F11 30 (+AC) Dashboard (digital display) Injection pump
F12 25 (+AC) Power take off; ELC; Parking brake switch; Interior power socket;
Pneumatic seat suspension; Datatronic
25
10
15
30
15
3
F14 30 (+AC) Stop light switch; DCC braking information
F16 7,5 (+AC) Horn
30
30
25
30
15
3
F17 7,5 (+AC) Front left sidelight and rear left sidelight; Lighting relay control
F18 7,5 (+AC) Front right sidelight and rear right sidelight; Registration plate light;
F19 30 (+P) Rear work lights 1 2 3 4 5 6
F20 10 Dipped beams
F21 7,5 (+P) Flashing beacon switches
F23 15 Headlights
Fig.16
+P = Permanent
Note :
- Depending on assembly, the functions of the Datatronic, ELC and power take off are protected by fuse F10
or fuse F12.
Issue 1 May 2001


L . Dynashift – Fuses (North America) (Fig. 17) ment:
Note: Always replace fuses with fuses of the same amperage - a 7.5 A fuse protects the ELC
- a 15 A fuse protects the Autotronic 2 unit. 19 20 21 22 23 24
Fuse Amperage Functions protected A 3 A fuse located under the ELC console protects the
reference ELC calculator (+ AC).
30
20
25
15
15
10
F1 30 Front work lights A 30 A fuse located beside the starter, protects the interior
F2 3 (+P) Starter relay power socket.
7.5
7.5
7.5
15
10
3
F4 25 (+AC) Front wiper and washer A 5 A fuse, located on the battery cut out (if fitted) protects
F5 30 (+AC) Cab air conditioning, radio, clock, roof light the clock.
F7 10 Seat with pneumatic suspension 13 14 15 16 17 18
F8 5 (+AC) Dynashift control lever
F9 7,5 (+AC) ELC Alternator charge lamp
F11 25 (+AC) Dashboard (digital display) Injection pump 7 8 9 11 12
10
F12 25 (+AC) Parking brake buzzer Interior power socket, Datatronic, Hare /
Tortoise, Power take off, ELC switches
7.5
25
10
10
25
F14 3 (+AC) Stop light switch
5
F16 7,5 (+AC) Horn
F17 7,5 Front left sidelight and rear left sidelight, Lighting relay control
30
F18 7,5 Front right sidelight and rear right sidelight, Registration plate light
30
25
30
15
3
F20 20 Dipped beams
F21 10 (+P) Flashing beacon switches 1 2 3 4 5 6
F23 15 Headlights
Fig.17
+P = Permanent
Note :
- Fuse F7 : If no fuse, the pneumatic seat function is protected by fuse F12
- Fuse F11: Depending on assembly, it may be 15, 20 or 30 A
Issue 1 May 2001


M . Full Powershift – Fuses (North America) (Fig. 18) ment:
Note: Always replace fuses with fuses of the same amperage - a 5 A fuse protects the front power take off (if fitted)
- a 7.5 A fuse protects the ELC
- a 15 A fuse protects the TC. 19 20 21 22 23 24
Fuse Amperage Functions protected
reference A 3 A fuse located under the ELC console protects the
ELC calculator (+ AC).
30
20
25
15
15
10
F1 30 Front work lights
F2 3 (+P) Starter relay A 30 A fuse located beside the starter, protects the interior
F3 30 (+P) Cigarette lighter power socket.
F4 25 (+AC) Front wiper and washer
7.5
7.5
7.5
15
10
A 5 A fuse, located on the battery cut out (if fitted) protects
3
F5 30 (+AC) Cab air conditioning; radio; clock; roof light
F6 15 (+AC) Rear wiper the clock.
F7 15 (+AC) Transmission controller
F8 3 (+AC) ELC; Power take off stop
13 14 15 16 17 18
F9 15 (+AC) Park Lock; Clutch switches (top and bottom); Left and right neutral
lever switch
F11 30 (+AC) Dashboard (digital display) Injection pump 12
7 8 9 10 11
F12 25 (+AC) Power take off; ELC; Parking brake switch; Interior power socket;
Pneumatic seat suspension; Datatronic
25
10
15
30
15
F14 3 (+AC) Stop light switch;
3
DCC braking information
F16 7,5 (+AC) Horn
F17 7,5 (+AC) Front left sidelight and rear left sidelight; Lighting relay control
30
30
25
30
15
3
F18 7,5 (+AC) Front right sidelight and rear right sidelight; Registration plate light;
F20 20 Dipped beams 1 2 3 4 5 6
F21 10 (+P) Flashing beacon switches
F23 15 Headlights
F24 30 Additional work lights (if fitted) Fig.18
+P = Permanent
Note :
- Depending on assembly, the functions of the Datatronic, ELC and power take off are protected by fuse F10
or fuse F12.
Issue 1 May 2001

Electricity 10A02.1
10 A02 Deutsch electrical equipment
CONTENTS
A. General ________________________________________________ 3
B. Engine and cab equipment - Autotronic 3 _________________ 12
C. Engine and cab equipment - Powershift ___________________ 30
D. Lighting equipment - Europe _____________________________ 50
E. Lighting equipment - North America ______________________ 56
F. Location of fuses - Dynashift (Europe) _____________________ 62
G. Location of fuses - Dynashift (North America) _____________ 63
H. Location of fuses - Powershift (Europe) ___________________ 64
I. Location of fuses - Powershift (North America). ____________ 65
Issue 1 May 2002

10A02.2 Electricity
Issue 1 May 2002

Electricity 10A02.3
Description of the Deutsch connector

A . General Since the beginning of January 2001, a new electrical
The 8200 Z1 series tractors are equipped with a 12-volt connection system has been introduced on all tractors
negative ground electrical circuit. The charging is pro- (6200 / 8200). This replaces the former system (Rits).
vided by an 120 amp alternator (80 amp for platform
tractors). The tractors with this new electrical connection system
The alternator contains an integrated rectifier and charge can be recognised by:
regulator. The alternator fitted on the right-hand side of - the reduced number of connectors
the engine is driven by a belt from the crankshaft pulley. - a new fuse box (32 fuse locations)
The starter, fitted on the right-hand side of the motor, is - improved harness protection (ringed sheath)
of the pre-engaged type. - a positive terminal (1) on the cab side
The starter safety switch, placed beneath the clutch - the engine / dashboard junction (2)
pedal, allows the starter solenoid to be activated only - the lighting / dashboard junction (3) fixed on the front of
when the clutch pedal is fully pressed. the cab.
The batteries are mounted on a stable or rotating base
(depending on option) behind the right-hand side foot-
step.
Fig. 1
Issue 1 May 2002

10A02.4 Electricity
Characteristics Colour codes
Battery A : Silver
8210 and 8220 B : White
Quantity 2 BL : Blue
Type Maintenance free BE : Beige
Cold start efficiency 420 A (-18 °C) G : Grey
Reserve capacity at 25 A 120 min I : Ivory
Voltage 12 V J : Yellow
Capacity 66 Ah M : Brown
N : Black
8240 to 8280 O : Orange
Quantity 2 R : Red
Type Maintenance free RO : Pink
Cold start efficiency 505 A (-18 °C) S : Salmon
Reserve capacity at 25 A 180 min V : Green
Voltage 12 V VI : Violet
Capacity 105 Ah
C : Light
Alternator F : Dark
Cab
Make Iskra Emb.: end
Type AAK
Maximum output 120 A
Regulator built-in
Cab (depending on options)

Make Iskra
Type AAK
Maximum output 80 A
Regulator built-in
Starter
8210 to 8280
Make Iskra
Model (3 kW)
Voltage 12 V
Type Pre-engaged
Issue 1 May 2002

Electricity 10A02.5
Identification of connectors CD1 C - Engine harness / dashboard harness junction

Note: One connector may have a different number of - channels: 31
wires in relation to the number of channels. - colour: Black
Example: Connector C3: 6 channels and 5 wires - wires: RO - G - G - R - A - G - R - BLF - R - MF - VI - RO
- M - B - O - V - G - VI - O - B - VC - BLF - J - J - V - G
CD1 M - Engine harness / dashboard harness junction - location: front of the cab
- channels: 31 - for: North America only
- colour: Black
- wires: B - B - B - B - B - B - B - B - B - B - B - B - B
-B- B-B- B-B- B-B- R-M-R CD2 - Lighting harness / dashboard harness junction
- location: front of the cab - channels: 21
- for: Tractors 8210 - 8220 - colour: Black
- wires: R - R - RO - RO - BLF - MC - R - B end N - B end
N - N - RO - I - BLC - RO - O - O
- channels: 31 - for: All countries except North America
- colour: Black
-B- B-B- B-B- B-B- R-M-R CD2 - Lighting harness / dashboard harness junction
- location: front of the cab - channels: 21
- for: Tractors 8240 – 8250 Dynashift - colour: Black
- wires: VF - R - R - G - M - RO - R - VF - BE - BLC - V
- VF - J - O
- channels: 31 - for: North America only
- colour: Black
-B- B-B- B-B- B-B- R-M-R CD3 - Autotronic 3 harness / dashboard harness
- location: front of the cab junction
- for: Tractors 8240 Full Powershift - channels: 47
- colour: Black
- wires: N - MF - M - R - R - J - BLF - VI - V - M - VI - O
CD1 M - Engine harness / dashboard harness junction - B end B - BLC - BLF - J - BLC - J - BLC - J - N - J - VI
- channels: 31 - RO - MF - R - B - N - MF - R - B end N - R - VI - G - VF
- colour: Black - O - R - G - J - J - B - BL - O - BLC - G - R - J
- wires: B - B - B - B - B - B - B - B - B - B - B - B - B - location: on top of Autotronic 3
-B- B-B- B-B- B-B- R-M-R - for: Dynashift tractors all countries
- location: front of the cab
- for: Tractors 8245 to 8280 Full Powershift
C3 - Console / dashboard harness junction
- channels: 6
CD1 C - Engine harness / dashboard harness junction - colour: Black
- channels: 31 - wires: J - M - VI - R - R
- colour: Black - location: under dashboard, left-hand side
- wires: RO - G - G - R - A - G - R - BLF - N - R - R - VI - for: Dynashift tractors all countries
- M - N - R - B - O - V - G - VI - O - B - VC - BLF - J - O
-V-G
- location: front of the cab
- for: all countries except North America
Issue 1 May 2002

10A02.6 Electricity
C3 - Console / dashboard harness junction C11 - Armrest console cab electronics harness junction
- channels: 10 - channels: 10
- colour: Black - colour: White
- wires: VI - V - J - R - R - R- R - J - M - wires: J - G - BL/G - S - VI - R - V - R - B - RO
- location: under dashboard, left-hand side - location: to ELC calculator
- for: Full powershift tractors all countries - for: Full Powershift tractors all countries
C4 - Dashboard harness junction C12 - Rear wiper harness junction

- colour: Black - colour: Black
- wires: VF - B - N - VC - wires: M end - R - N
- location: under dashboard, left-hand side - location: under right upright in cab
- for: tractors all countries - for: tractors all countries
C5 - Armrest / dashboard harness junction C14 - Electronic linkage harness junction

- colour: Black - colour: Transparent
- wires: N - R - N - M - R - M - V - V - M - wires: VI - R - R - N - R
- location: under dashboard, right-hand side - location: to ELC calculator
- for: Dynashift tractors all countries - for: Dynashift tractors all countries
C5 - Armrest / dashboard harness junction C14 - Electronic linkage harness junction

- colour: Grey - colour: Transparent
- wires: N - R - N - M - R - M - V - V - M - wires: R - R - N - R
- location: to ELC calculator - location: to ELC calculator
- for: Full Powershift tractors all countries - for: Full Powershift tractors all countries
C8 - Windscreen washer pump junction C15 - Armrest console cab electronics harness junction
- wires: B - wires: B - O - M - V- M - V
- location: to windscreen washer pump - location: to ELC calculator
- for: tractors all countries - for: Full Powershift tractors all countries
C10 - Roof harness / dashboard junction to roof C16 - Dashboard to roof harness junction
- colour: Transparent - colour: Transparent
- wires: VF - BLF - BLF - VF - BE - R - wires: BE - N - R - G
- location: under right upright in cab - location: in heating compartment
- for: tractors all countries except North America - for: tractors all countries
C10 - Roof harness / dashboard junction to roof

- channels: 8
- colour: Transparent
- wires: BLF - BLF - BLF - R - RO - BE - M
- location: under cab upright, right-hand side
- for: tractors North America only
Issue 1 May 2002

Electricity 10A02.7
C17 - Ventilation unit harness junction C25 - Junction

- wires: O - VI - R - wires: RO
- location: in heating compartment - location: under dashboard
- for: standard tractors all countries - for: tractors all countries
C17 - Ventilation unit harness junction C28 - Rear wiper harness junction
- colour: Brown - colour: Black
- wires: V - O - O - N - wires: M - R - V
- location: in heating compartment - location: in heating compartment
- for: high visibility tractors all countries - for: tractors all countries
C18 - Windscreen wiper harness junction C29 - Power socket harness junction
- wires: G - N - B - BL - O - wires: R - R - N - N - R
- location: in heating compartment - location: behind power socket
C19 - Radio harness junction C36 - Electronic linkage harness junction

- wires: N - O - R - RO - wires: RO - G - B - M - V1
- location: behind radio - location: to ELC calculator
- for: tractors all countries except North America - for: Dynashift tractors all countries
C19 - Radio harness junction C37 - Autotronic 3 / transmission harness junction

- wires: N - O - wires: VF - B - R - I - G - B - J - BLF - N - N - BLC - VC
- location: behind radio - MC - N - O - RO - N - N - J - VI - J - M - R - R - VF
- for: North American tractors only - location: on top of Autotronic 3
- for: Dynashift tractors all countries
C22 - Pneumatic seat junction

- channels: 2 C37 - Transmission harness junction
- colour: Black - channels: 6
- wires: R - N - colour: Black
- location: behind pneumatic seat - wires: BL - M - G - M - B - R
- for: tractors all countries - location: under dashboard
- for: Full Powershift tractors all countries
C24 - Dashboard to roof harness junction

- channels: 4
- colour: Black
- wires: VI - O - RO - R
- location: under cab upright, right-hand side
- for: tractors all countries
Issue 1 May 2002

10A02.8 Electricity
C42 - Cab / console electrical junction C62 - Dashboard harness junction
- wires: B - wires: V - BE - BL - BL - G
- location: to ELC calculator - location: under dashboard, right-hand side
- for: Dynashift tractors all countries - for: platform tractors
C46 - Proportional PTO harness junction C63 - Roof light / dashboard junction
- colour: Transparent - colour: Black
- wires: B - N - wires: G - BLF - VF - VF - BLF
- location: to ELC calculator - location: under cab upright, right-hand side
- for: Dynashift tractors all countries - for: tractors all countries except North America
C47 - Cigarette lighter junction C63 - Roof light / dashboard junction

- colour: Transparent - colour: Black
- wires: MC - R - N - wires: RO - M - BLF - BLF - BLF - G
- location: behind cigarette lighter - location: under cab upright, right-hand side
- for: tractors all countries - for: North American tractors only
C48 - Roof light C64 - Front left travelling light harness junction
- wires: N - wires: RO - R
- location: on roof light - location: behind front left travelling light
- for: tractors all countries - for: tractors all countries except North America
C52- Electronic linkage harness junction C65 - Front right travelling light harness junction
- colour: Grey - colour: Transparent
- wires: R - G - N - J - BL - V - B - R - wires: M - R
- location: to ELC calculator - location: behind front right travelling light
- for: Dynashift tractors all countries - for: tractors all countries except North America
C52- Electronic linkage harness junction C66 - Rear left travelling light harness junction
- colour: Grey - colour: Black
- wires: R - G - N - J - BL - V - B - R - VI - B - wires: RO - R - N - B
- location: to ELC calculator - location: behind rear left travelling light
- for: Full Powershift tractors all countries - for: tractors all countries except North America
C53 - CAN connector

- channels: 3
- colour: Black and grey
- wires: M - B - V
- location: to ELC calculator
Issue 1 May 2002

Electricity 10A02.9
C66 - Rear left travelling light harness junction C70 - Rear left work light harness junction
- wires: R - N - RO - wires: BLF
- location: behind rear left travelling light - location: behind rear left work light
- for: North American tractors only - for: North American tractors only
C67 - Rear right travelling light harness junction C71 - Rear right work light harness junction
- wires: B - N - M - R - wires: VF
- location: behind rear right travelling light - location: behind rear right work light
- for: tractors all countries except North America - for: tractors all countries except North America
C67 - Rear right travelling light harness junction C71 - Rear right work light harness junction
- wires: R - N - M - wires: BLF
- location: behind rear right travelling light - location: behind rear right work light
- for: North American tractors only - for: North American tractors only
C68 - Front left work light harness junction C72 - Registration plate light
- wires: BLF - N - wires: R - N
- location: behind front left work light - location: behind rear roof peak
C69 - Front right work light junction C73 - Registration plate light
- wires: BLF - N - wires: R - N
- location: behind front right work light - location: behind rear roof peak
C70 - Left rear work light harness junction C74 - Flashing beacon junction
- wires: V - wires: G
- location: behind rear left work light - location: behind flashing beacon
- for: tractors all countries except North America - for: tractors all countries
Issue 1 May 2002

10A02.10 Electricity
C75 - Dashboard to roof harness junction C80 - Front left work light on footstep harness
- channels: 6 junction
- wires: O - RO - N - R - VI - R - colour: Black
- location: under cab upright, right-hand side - wires: O
- for: Full Powershift tractors all countries except North - location: behind front left work light on footstep
America - for: tractors all countries except North America
C76 - Dashboard lighting to roof harness junction C80 - Front left work light on footstep harness
- channels: 6 junction
- wires: O - VI - R - RO - N - R - colour: Black
- location: under cab upright, right-hand side - wires: VF
- for: Full Powershift tractors all countries - location: behind front left work light on footstep
- for: North American tractors only
C78 - Front left rail work light harness junction

- channels: 1 C81 - Front right work light on footstep harness
- colour: Black junction
- wires: RO - channels: 2
- location: behind front left rail work light - colour: Black
- for: tractors all countries except North America - wires: N - O
- location: behind front right work light on footstep
- for: tractors all countries except North America
C78 - Front left rail work light harness junction
- channels: 1
- colour: Black C81 - Front right work light on footstep harness
- wires: VF junction
- location: behind front left rail work light - channels: 2
- for: North American tractors only - colour: Black
- wires: N - VF
- location: behind front right work light on footstep
C79 - Front right rail work light harness junction - for: North American tractors only
- channels: 1
- colour: Black
- wires: RO C82 - Work light on left wing harness junction
- location: behind front right rail work light - channels: 1
- for: tractors all countries except North America - colour: Black
- wires: RO
- location: behind work light on left wing
C79 - Front right rail work light harness junction - for: tractors all countries except North America
- channels: 1
- colour: Black
- wires: VF
- location: behind front right rail work light
Issue 1 May 2002

Electricity 10A02.11
C82 - Work light on left wing harness junction

- channels: 1
- colour: Black
- wires: G
- location: behind work light on left wing
C83 - Work light on right wing harness junction

- channels: 1
- colour: Black
- wires: RO
- location: behind work light on right wing
- for: tractors all countries except North America
C83 - Work light on right wing harness junction

- channels: 1
- colour: Black
- wires: G
- location: behind work light on right wing
C84 - Front lights harness junction

- channels: 3
- colour: Black
- wires: B - B - N
- location: to front lights
Issue 1 May 2002

Colour codes Designation of connectors (for more details see
B . Engine and cab equipment - A : Silver § A)
Autotronic 3 (Fig. 2 to 10) B : White CD1 M/C - Engine harness / dashboard harness
BL : Blue junction
Parts list BE : Beige CD2 - Lighting harness / dashboard harness
1. Starter switch G : Grey junction
4. Water temperature indicator I : Ivory CD3 - Autotronic 3 harness / dashboard harness
7. Air filter vacuum sensor J : Yellow junction
10. Water temperature sensor M : Brown
11. Engine oil pressure switch N : Black C3 - Dashboard / console harness junction
12. Alternator O : Orange C8 - Windscreen washer junction
14. Injection pump control solenoid R : Red C10 - Dashboard to roof harness junction
16. To electronic linkage RO : Pink C12 - Rear wiper harness junction
18. Clock S : Salmon C14 - Electronic linkage harness junction
19. Radio V : Green C16 - Dashboard to roof harness junction
20. Cab relay VI : Violet C17 - Ventilation unit harness junction
22. Air conditioning pressure switch C18 - Windscreen wiper harness junction
27. Windscreen wiper switch C : Light C24 - Dashboard to roof harness junction
28. Rear wiper motor F : Dark C25 - Junction
31. Cigarette lighter C28 - Rear wiper harness junction
36. Rear wiper switch Emb.: end C47 - Cigarette lighter junction
40. Interior power socket
43. Windscreen wiper motor
49. Roof light
50. Door switch
53. Lighting switch
87. Water level sensor
88. To ground if no water level sensor
89. Thermostart
91. Cold start solenoid valve
92. Ventilation harness junction
93. Wiper time delay relay
94. Front of the cab (+) terminal
95. Front axle connector
96. Front axle switch
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
100. Trailer socket reversing light
101. Reversing light junction
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1 May 2002

CD1 M/C
B P8 P8 Ro Tb-C01 T8
7
N
Temperature probe
4
10 B P1 P1 G Tb-B05
CD1 M/C
Tb-B03
87 B P7 P7 BL.F 88
CD1 M/C
Engine oil pressure
B P5 P5 B Tb-A05 T10
11
Fig. 2
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

1
Thermostart CD1 M/C M 94
+P
1 2
P2 P2 4 3
89 B G 5
P3 P3
F5
30
Injection control
CD1 M/C
B P9 P9 1
R M 94
+P
14 P10 P10 2
1
3
4
+AC
5
N
R
B
90
91
Fig. 3
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

F18
Battery charging
7.5
Vi
Vi
CD1 M/C
12 B 6-D+ ALT P6 Vi Vi Tb-C03 T5
C14-04 Vi C3-03 C3-03
16
F9
F12
30
10
R
6 3
M
94
10
+P
2 +ACC 53
1
20 Ro 3
5 7
M.F 4
5 1 M.F F25
N Ro
M.F
O R
B P4 P4 Vi
22 B
Ventilation
CD1 M/C
C17-03 C17-02 Vi C24-01 C24-01 Vi

C24-04
92 C17-01 O R C24-02 C24-02
C24-04
O
R
Fig. 4
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

10
15
10
Suspended front axle
F27 F25
96 97
R
6 3
53
P3 P1 P8 P1A P2A
5 7
N M P2 P7 P1B P2B
M N
R
93
M +P
2
1
3
4 +AC
5
1
R
N
P1 P2
CD1 M/C
P3 M P24 P24 M
P4 R 25 P25 R
95 P5 B 26 P26 V
P7 B 27 P27 G
P6 B 28 P28 O
P8 B 29 P29 B
Fig. 5
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

Electricity 10A02.21 F9
F12
10
30
F17
30
10
Accessories
F25
94
1 R
M 6 3
+P
2
Ro
1
+AC 53
3
4 5 7
20 5
M.F M.F
N Ro M.F
M.F
O R Ro
Ro C25 C25 Ro
C24-03
Ro C24-03
R C24-04 C24-04 R
O C24-02 C24-02 O
19 18 49
ONR R R N Ro N Ro N
50
N
Fig. 6
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

F1
30
40
10
M P-04 P-04 O
Power socket inside cab
O
R F20
N
M
C03-04 C03-04
1
M 94
+P
2
1
3
4
5 +AC
Cigarette lighter
F17
30
10
R
6 3
+P
M 94
2
1 53 F24
3
1 4 5 7
5
M.F
M.F
M C03-02 C03-02
C47-01
31 C47-03
C47-02 R C03-06 C03-06
N
Fig. 7
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

F3
10
Fuel heater and pneumatic seat
CD1 M/C
B P12 P12 R
99
94
M +P
+AC
1
P-01 P-01 O
98
F4
5
CD2
Reversing light
BL PIN A PIN A
BL
94
M +P
+AC
R BL
N
100
CD3
P40
101
N Fig. 8
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

Electricity 10A02.27 F10 F9
25
10
Windscreen wiper
1
M 94
2
+P
1
Ro 3 +AC
4
20 5
M.F
N Ro
M.F
O
G
BL
B
M M
Vi
3 4 1
93
CD1 M/C 5 2
38 C8 22 P22 BL
27
C18-01 B
C18-02 BL
43 C18-03 O
C18-04 G
C18-06
Fig. 9
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
Indicator lights
Issue 1 May 2002

F11 F9
15
10
Rear wiper
10
F25
R
M 94 6 3
2
+P
1
Ro 3
+AC 53
4 5 7
20 5
1
M.F M.F
N Ro
M.F
C10-02 C10-02 R
M EMB R
R
C16-02 C16-02
C16-03 C16-03 R
C12
C12
N
36
R M V
C12
C12
N P4
C28-03 C28-03 V P3 28
C28-02 C28-02 R P2
C28-01 C28-01 M J P1
Fig. 10
Issue 1 May 2002

C . Engine and cab equipment - A : Silver § A)
Powershift (Fig. 11 to 20) B : White CD1 M/C - Engine harness / dashboard harness
BL : Blue junction
1. Starter switch G : Grey C3 - Dashboard / console harness junction
2. Safety switch I : Ivory C4 - Dashboard harness junction
4. Water temperature indicator J : Yellow C8 - Windscreen washer pump junction
7. Air filter vacuum sensor M : Brown C10 - Dashboard to roof harness junction
10. Water temperature sensor N : Black C12 - Rear wiper harness junction
11. Engine oil pressure switch O : Orange C14 - Electronic linkage harness junction
12. Alternator R : Red C16 - Dashboard to roof harness junction
13. Starter RO : Pink C17 - Ventilation unit harness junction
14. Injection pump control solenoid S : Salmon C18 - Windscreen wiper harness junction
18. Clock V : Green C24 - Dashboard to roof harness junction
19. Radio VI : Violet C25 - Junction
20. Cab relay C28 - Rear wiper harness junction
22. Air conditioning pressure switch C : Light C47 - Cigarette lighter junction
27. Windscreen wiper switch F : Dark
31. Cigarette lighter Emb.: end
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

B 8 P8 Ro Tb-F.f T8
7
CD1 M/C
Temperature probe
B 1 P1 G Tb-C.f
10 4
N
Tb-B03
CD1 M/C 88
87 B 7 P1 BL.F
Engine oil pressure
11 B 5 P5 B Tb-B.g T10
CD1 M/C
Fig. 11
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

Thermostart
M
+P
2
1 94
2 P2 4 3
89 B G 5
3 P3
1
CD1 M/C
F5
30
Injection control
B 9 P9 1
14 M
R
+P
N 10 P10 2
1
3
94
4
+ AC
5
CD1 M/C
B
90
91
Fig. 12
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

F18
7,5
Battery charging
R R
12 B 6-D+ ALT P6 Vi
CD1 M/C
1
+P + ACC
2
1
4 3
5
F9
Ventilation F12
M 6 3
+P + ACC
2 94
1
R0
4 3 53
5 5 7
1 N
M.F F25
20
M.F
Ro
N
M.F O R
B 4 P4 Vi
22 B CD1 M/C
C17-03 Vi C24-01 C24-01 Vi

92 C17-03
C17-02
O
R
C24-02
C24-04
C24-02
C24-04
O
R
Fig. 13
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

F14
Suspended front axle

15
15
10
F27 F25
96 97
6 3
53 P3 P1 P8 P1A P2A
P2 P7
5 7
N P1B P2B
M
N
R
M R
M +P
2
1
94 4 3
+ AC
5
1
R
N
P1 - P2
P3 M P24 P24 M
P4 R 25 P25 R
95 P5 B 26 P26 V
P7 B 27 P27 G
P6 B 28 P28 O
P8 B 29 P29 B
CD1 M/C
Fig. 14
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

Fuel heater and pneumatic seat
F3
10
B 12 P12 R
99
CD1 M/C
+P
2
94 1
3
4 + AC
5
1
R
P-01 P-01 O
98
Fig. 15
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

F9
F12
30
10
Accessories
F17
30
10
F25
94 53
6 3
+P + AC
2
1
R0 3
4
M.F 5 5 7
20 1 M.F
N
M.F
N R0
M.F
D R R0
R0 C25 C25 R0
C24-03
R0 C24-03
R C24-04 C24-04 R
D C24-02 C24-02 D
19 18 49
O NR R R N R0 N R0 N
50
N
Fig. 16
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

F1
Power socket inside cab
30
10
M P-04 P-04 O
R 40 F20
M
N
C03-04 C03-04
M
+P
2 94
1
4 3
+ AC
5
1
R
Cigarette lighter
F17
30
10
6 3
+P
M 94
2
1 F24
4 3 53
5 5 7
1 N
M.F
M.F
M C03-02 C03-02
C47-01
31 C47-03
C47-02 R C03-06 C03-06
N
Fig. 17
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

F10 F9
25
10
Windscreen wiper
M
+P
2 + ACC 94
1
Ro 3
4
5
1
M.F 20
Ro
N M.F
O
G
BL
B
M M
VI
3 4
CD1 M/C 93
5 2
C8 22 P22 V
38 27
C18-01 B
C18-02 BL
C18-03 O
C18-04 G
C18-06
43
N
Fig. 18
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

F11 F9
15
10
10
Rear wiper
F25
M 53 6 3
+P
2 + ACC 94
1
Ro 3
4 1
M.F 5 5 7
N
M.F
20
N Ro
M.F
C10-02 C10-02 R
M EMB R
C16-02 C16-02
C16-03 C16-03 R
C12
C12
N
36
R M V
C12
C28-03 C12 N P4
C28-02
C28-03
C28-02
V
R P2
P3 28
C28-01 C28-01 J P1 Fig. 19
Issue 1 May 2002

BL : Blue junction
49. Roof light
50. Door switch
53. Lighting switch
89. Thermostart
97. Front axle LED
98. Pneumatic seat
99. Fuel heater
122. Start relay
Indicator lights
Issue 1 May 2002

F7
5
Start
O C4-03 C4-03 O
O C4-04 C4-04 O
C4
13
O
122
94 M
+P + ACC
2 O
1
4 3
5
1
Conn 14 Conn 14 O
CD1 M/C
Fig. 20
Issue 1 May 2002

115. Left rear direction indicator Designation of connectors (for more details see
D . Lighting equipment - Europe 116. Footstep worklight switch § A)
(Fig. 21 to 23) 117. Wing mounted and rail work lights switch CD1 M/C - Engine harness / dashboard harness
118. Rear roof mounted work lights switch junction
119. Front roof mounted work lights switch
Parts list CD2 - Lighting harness / dashboard harness
120. Rear right travelling light junction
1. Starter switch
121. Rear left travelling light
17. To TCU
27. Windscreen wiper switch C10 - Dashboard to roof harness junction
32. Flashing beacon switch C16 - Dashboard to roof harness junction
39. Console lighting Indicator lights C63 - Dashboard / roof lighting harness junction
42. Roof console lighting T16 : Parking lights indicator light C64 - Front left travelling light harness junction
53. Lighting switch T17 : Headlight beam indicator light C65 - Front right travelling light harness junction
63. Rear right work light on roof T19 : 1st trailer parking light indicator light C66 - Rear left travelling light harness junction
64. Lower rear right work light C67 - Rear right travelling light harness junction
65. Trailer power socket C68 - Front left work light harness junction
66. Lower rear left work light Colour codes C69 - Front right work light junction
67. Rear left work light on roof A : Silver C70 - Rear left work light harness junction
70. Horn B : White C71 - Rear right work light harness junction
71. Front left direction indicator BL : Blue C72 - Registration plate light
72. Front left work light on footstep BE : Beige C73 - Registration plate light
73. Front left work light on rail G : Grey C74 - Flashing beacon junction
74. Front left work light on roof I : Ivory C75 - Dashboard to roof harness junction
75. Front right work light on roof J : Yellow C79 - Front right rail work light harness junction
76. Front right work light on rail M : Brown C80 - Front left work light on footstep harness junction
77. Front right work light on footstep N : Black C81 - Front right work light on footstep harness junction
78. Front left headlight O : Orange C82 - Work light on left wing harness junction
79. Front right headlight R : Red C83 - Work light on right wing harness junction
80. Front right direction indicator RO : Pink
81. Flashing beacon S : Salmon
82. Central direction indicator V : Green
83. Hazard warning switch VI : Violet
84. Front work lights on rail and footstep switch
85. Front and rear work lights on roof switch C : Light
94. Front of the cab (+) terminal F : Dark
103. Right travelling / stop light Emb.: end
104. Left travelling / stop light
105. Front left parking light
106. Front right parking light
107. Left stop light switch
108. Right stop light switch
109. Front left roof mounted headlight
110. Front right roof mounted headlight
111. Roof headlights switch
112. Roof mounted headlights option
113. Option without roof mounted headlights
114. Rear right direction indicator
Issue 1 May 2002

112
Stop light / front - rear lighting (Europe)
Roof mounted headlight (option) F25

F19
20
7.5
7.5
10
111 F26
Horn 110 10 15 15
Ro R
N
F32 F31 F22 F30
R N
N O Vi Vi
O
R-C75-P6 R-C75-P6
N-C75-P5 Ro-C75-P4 Ro-C75-P4 N-C75-P5
R-C75-P3 Vi-C75-P2 Vi-C75-P2 R-C75-P3
O-C75-P1 O-C75-P1 R-C72
R-C73
109 94 N
102
N
G
M
94 39 T17
R +P
2
O 1
3
1
4
53 5
+AC
N
A12
A1
M.F
R-C63-P6 R-C63-P6
R
O-C7
27 1 2
J-A1
R-A12
V R-C10-P2 R-C10-P2
J
G J Ro Ro-C75-P4
107 108 N N
R J V
B emb N
V.C-C7 V
B emb N
J-C7 B emb N
V V V
D47 V
D47 V TCU J J
B 17
R R
113 N-C67-P4
B-C67-P3 103
Vi R-C67-P2
R-C75
106 O
J
N
J
V
79
B
L
54g
B EMB N P-M P-M 54
58L
CD1 M/C B EMB N P-N P-N R EMB N 31 58R 65
P-J P-J
R
N J V P-H P-H
P18 P18 V N R
P19 P19 J
P20 P20 G CD2
78 R-C64 R
N
R
N-C66-P4
R-C66-P2 104
B-C66-P3
105
G
70
Fig. 21
Issue 1 May 2002

1. Starter switch
17. To TCU
Issue 1 May 2002

Direction indicator / hazard warning function

(Europe)
F21
30
T16 T16 T19 T18
82 83
M
BL Ro
L R
B
C C1 C3
A14
A6
A8
A2
G M N 94
+P
1 2
31 49 49L 3
R
4
BL-A2
N +AC
B-A14
N-A6
Ro-A8
5
V.F
1
27 B
R V.F V.F B
Ro
M
Ro
BL
B
B
M
P-L P-L
P-K P-K
CD2 N-C67-P4
114
M-C67-P1
80 M-C65
N Ro
54g 54
31
58L
58R
65
R
N
M
N-C66-P4
115
Ro-C64
71 Ro-C66-P1
Fig. 22
Issue 1 May 2002

1. Starter switch
17. To TCU
Issue 1 May 2002

Vi
Work light function (Europe) M.F
F16 25 25 F13
F25
Flashing beacon 94
25
7.5
15
F28
R Vi 25
I
53 F27
M.F F26 F29
M.F
R
P3 R Vi
77 O-C81
B
N
P2
116 117 118 119
R
76 Ro-C79
P1
BL-C69 N N N N
N-C69 J N.C V.C BL.C
75 P1
6 7 P5
BL-C69
N-C69 B Vi Vi Vi R Ro-C83
64
N
N
P4
P1 R
G V.F-C71
BL-C68
N-C68
G G G I V.F-C71 63
N
O Ro
74 P1 P-G P-G
BL-C68 P-E P-E
P-D P-D V.F-C70
N-C68
N P-B P-B V.F-C70 67
N
P2 C2
P5
73 Ro-C79
Ro Ro-C82
N 66
V.F-C63-P1 V.F-C63-P1 V.F-C10-P1 V.F-C10-P1 N
P3 G-C63-P2 G-C63-P2 R-C10-P2 R-C10-P2
BL.F-C63-P3 BL.F-C63-P3 BL.F-C10-P3 BL.F-C10-P3
O-C80 BL.F-C63P4 BL.F-C63P4 BL.F-C10-P4 BL.F-C10-P4
72 V.F-C63-P5 V.F-C63-P5 V.F-C10-P5
Be-C10-P6
V.F-C10-P5
Be-C10-P6
N
V.F
V.F
81 81 Be-C16-P1
N-C16-P2
Be-C16-P1
N-C16-P2 N
R-C16-P3 R-C16-P3
G-C16-P4 G-C16-P4 42
R
N
32
Be N
G-C74 G-C74
Fig. 23
Issue 1 May 2002

115. Rear left direction indicator Designation of connectors (for more details see
E . Lighting equipment - North 116. Footstep worklight switch § A)
America (Fig. 24 to 26) 117. Wing mounted and rail work lights switch CD1 M/C - Engine harness / dashboard harness
118. Rear roof light switch junction
1. Starter switch
17. To TCU
64. Lower Rear right work light C67 - Rear right travelling light harness junction
66. Lower Rear left work light Colour codes C69 - Front right work light harness junction
79. Front right headlight R : Red C83 - Work light on right wing junction
103. Front right travelling / stop light Emb.: end
Issue 1 May 2002

Front - rear lighting function (North America Only)
Horn
94
F25
F19
53 G 94
7.5
7.5
10
3
M F26
R
+P 2
10 15
O 1
3
1
4 +AC F32 F31 F22
5
M.F R
O-C7 39 T17
J N
A12
G
A1
27
V.C-C7
R-A12
J-A1
J-C7
R R
107 108
B emb N
B emb N
B emb N
D47 V
TCU
D47 V
B
R
17 65
J M
79
N-C67-P3
120
P-J P-J
P-H P-H R-C67-P1
N J V P18 P18 V
P19 P19 J
P20 P20 G
CD2 N
CD1 M/C N-C66-P3

121
R-C66-P1
78
N
70
Fig. 24
Issue 1 May 2002

1. Starter switch
17. To TCU
Issue 1 May 2002

Direction indicator / hazard warning function
(SAE standard)
25
10
F28
T16 T16 T19 T18
82 83
BL 27 L R
B F21
C C2 C3 Ro +P
M 94
A14
A2
A6
A8
2
1
M 3
4 +AC
M 5
31 49 49a
R
1
B-A14
Ro-A8
N
BL-A2
N-A6
V.F
B
R V.F Ro R B
M
Ro
BL
B M
B
2 3 4 5
Ro N
M
Ro
R
V.F
B
1
6 2
5
7 65
3
4
V
M
CD2
N-C67-P3
114
80 M-C65 M-C67-P2
N
N
N-C66-P3 115
71 Ro-C64 Ro-C66-P2
N
Fig. 25
Issue 1 May 2002

1. Starter switch
17. To TCU
Issue 1 May 2002

BL
Work light function (North America only) Vi
94
F13
Flashing beacon 94 F16 25 15
R F21
53 M.F N N M
10
10
25
15
F28
15 30
F27
M.F F25 F30 F29
M.F
R
+P
2
1
Vi 1
3
4 +AC
5
V-C81
77
V Vi V V BI B L R
N
49d
R 30 30b 83
V-C79
76 V-C79
15 49
N
84 117
R R
BL-C69
N-C69
R
75
P5
BL-C69 N N.C N N N
N-C69 G-C83 64
N
N
85
P4
V.F-C71
R I
BL-C68
N-C68
G V.F-C71 63
N
P-G P-G
74 P-E P-E
P-D
P-D
P-B P-B P4
BL-C68 V.F-C70
N-C68
N CD2 V.F-C70 67
N
V-C79
73 V-C79
N G-C82 66
V.F-C63-P1 V.F-C63-P1 V.F-C10-P1 BL-C10-P1
G-C63-P2 G-C63-P2 R-C10-P2 R-C10-P2
BL.F-C63-P3 BL.F-C63-P3 BL.F-C10-P3 BL.F-C10-P3
V-C80
BL.F-C63P4 BL.F-C63P4 BL.F-C10-P4 BL.F-C10-P4
72 V.F-C63-P5 V.F-C63-P5 V.F-C10-P5
Be-C10-P6
V.F-C10-P5
Be-C10-P6
N
Be-C16-P1 Be-C16-P1
81 81 N-C16-P2
R-C16-P3
N-C16-P2
R-C16-P3
N
G-C16-P4 G-C16-P4
N R
32
Be N
G-C74 G-C74
Fig. 26
Issue 1 May 2002

F . Location of fuses - Dynashift (Europe) (Fig. 27)
F 28 F 12
F 32
F 16
F 27 F 11
Note: Always replace fuses by fuses of the same amperage
F 26 F 10
Fuse Amperage Functions protected F 25 F 9
F 31
F 15
reference F 24 F 8
F 23 F 7
F1 30 (+P) Accessories power socket F 22 F 6
F2 7,5 (+AC) Linkage, diagnostic connector, electro-hydraulic spool valve
F 21 F 5
F 30
F 14
F3 10 (+AC) Pneumatic seat, fuel heater
F 20 F 4
F4 5 (+AC) Reversing light
F5 30 (+AC) Injection pump solenoid valve F 19 F 3
F6 10 (+AC) Dashboard, Autotronic 3, Hare / Tortoise switch, gearbox neutral
F 29
F 13
F 18 F 2
safety F 17 F 1
F7 5 (+AC) Dynashift steering wheel lever, starter switch, BOC, TOC, power take
off stop, rear power take off, economical power take off, cab power
socket, creeper gearbox
F8 7,5 (+AC) Starter relay
F9 10 (+AC) Cab relay, 4 WD switch, differential lock, Dynashift armrest, accelerator F1 - 30A F2 - 7,5A F3 - 10A F4 - 15A
5A F5 - 30A
pedal
F10 25 (+AC) Cab relay windscreen wiper motor, switch, time delay
F11 15 (+AC) Cab relay rear wiper motor, switch
F12 30 (+AC) Cab relay radio, ventilation
F13 25 (+AC) Front work light F6 - 10A F7 - 5A F8 - 7,5A F9 - 10A F10 - 25A
F14 15 (+AC) Front power take off, suspended front axle
F15 0 (+AC) Not used
F16 25 (+AC) Rear work light
F17 30 (+P) Clock, roof light, cigarette lighter, radio
F18 7,5 (+AC) Linkage, alternator charge F11 - 15A F12 - 30A 25A
F13 - 15A F14 - 15A F15 -
F19 7,5 (+AC) Horn
F20 10 (+AC) Accessories power socket
F21 10 (+AC) Hazard warning switch
F22 20 (+AC) Brake switch
25A
F16 - 30A F17 - 30A F18 - 7,5A F19 - 7,5A F20 - 10A
F23 7,5 (+P) Linkage control
F24 15 (+P) Autotronic 3
F25 10 (+P) Backlighting switch, dashboard, headlight relay
F26 7,5 (+AC) Travelling lights front - rear, dashboard, work light relay
F27 15 (+P) Flashing beacon, suspended front axle
F21 - 10A F22 - 20A F23 - 7,5A F24 - 15A F25 - 10A
F28 25 (+P) Hazard warning switch, footstep work light
F29 25 (+P) Wing and rail work light
F30 15 (+AC) Stop light AUTO III
F31 15 (+AC) Headlight beam
F32 10 (+AC) Dim light F26 - 7,5A F27 - 15A F28 - 25A F29 - 30A F30 - 15A
25A
HAND
+P = Permanent STOP

F31 - 15A F32 - 10A REF: 3785765M1
A 5 A fuse located on the battery cut out (if fitted) protects the clock.
Fig.27
Issue 1 May 2002

G . Location of fuses - Dynashift (North America) (Fig. 28)

F 28 F 12
F 32
F 16
Note: Always replace fuses by fuses of the same amperage F 27 F 11
F 26 F 10
F 25 F 9
F 31
F 15
reference
F 24 F 8
F2 7,5 (+AC) Linkage, diagnostic connector, electro-hydraulic spool valve F 22 F 6
F3 10 (+AC) Pneumatic seat, fuel heater F 21 F 5
F 30
F 14
F4 0 (+AC) Not used
F 20 F 4
F5 30 (+AC) Injection pump solenoid valve
F 19 F 3
F6 10 (+AC) Dashboard, Autotronic 3, Hare / Tortoise switch, gearbox neutral
F 29
F 13
safety F 18 F 2
F7 5 (+AC) Dynashift steering wheel lever, starter switch, BOC, TOC, power F 17 F 1
take off stop, rear power take off, economical power take off, cab
power socket, creeper gearbox
F9 10 (+AC) Cab relay, 4 WD switch, differential lock, Dynashift armrest F1 - 30A F2 - 7,5A F3 - 10A F4 - 15A F5 - 30A
F13 15 (+AC) Front work light
F14 15 (+AC) Front power take off, suspended front axle F6 - 10A F7 - 5A F8 - 7,5A F9 - 10A F10 - 25A
F18 7,5 (+AC) Linkage, alternator charge
F19 7,5 (+AC) Horn F11 - 15A F12 - 30A F13 - 15A F14 - 15A F15 -
F23 7,5 (+P) Linkage
F24 15 (+P) Autotronic 3 25A
F16 - 30A F17 - 30A F18 - 7,5A F19 - 7,5A F20 - 10A
F25 10 (+P) Backlighting switch, dashboard, headlight relay
F28 25 (+P) Hazard warning switch, wing work light
F29 30 (+P) Rail work light F21 - 15A F22 - 20A
3A F23 - 7,5A F24 - 15A F25 - 10A
F30 15 (+AC) Footstep work light
F31 15 (+AC) Headlight beam AUTO III
F32 10 (+AC) Dim light
F26 - 7,5A F27 - 15A F28 - 25A F29 - 30A F30 - 15A
+P = Permanent
+AC = + after contact HAND
A 5 A fuse located on the battery cut out (if fitted) protects the clock. REF: 3785917M1
F31 - 15A F32 - 10A
Fig.28
Issue 1 May 2002

H . Location of fuses - Powershift (Europe) (Fig. 29) F 28 F 12
F 32
F 16
F 27 F 11
Note: Always replace fuses by fuses of the same amperage
F 26 F 10
F 25 F 9
F 31
F 15
reference F 24 F 8
F 23 F 7
F 30
F 14
F 20 F 4
F4 15 (+AC) Park Lock switch
F 29
F 13
F6 10 (+AC) Dashboard F 18 F 2
F7 5 (+AC) Steering wheel lever, starter switch, BOC, TOC, power take off stop, F 17 F 1
rear power take off, economical power take off, cab power socket,
creeper gearbox, hand brake
F9 10 (+AC) Cab relay, 4 WD switch, differential lock buzzer F1 - 30A F2 - 7,5A F3 - 10A F4 - 15A F5 - 30A
F12 30 (+AC) Cab relay radio, ventilation APC TEMPO PARK
F13 25 (+AC) Front work light

F14 15 (+AC) Front power take off, suspended front axle F6 - 10A F7 - 5A F8 - 7,5A F9 - 10A F10 - 25A
F19 7,5 (+AC) Horn F11 - 15A F12 - 30A 25A
F13 - 15A F14 - 15A F15 -
F24 15 (+P) Park Lock DCC time delay relay
F25 10 (+P) Backlighting switch, dashboard, headlight relay F16 - 25A
30A F17 - 30A F18 - 7,5A F19 - 7,5A F20 - 10A
F28 25 (+P) Hazard warning switch, footstep work light
F29 25 (+P) Wing and rail work light
F30 15 (+AC) Rear stop light F21 - 10A F22 - 20A F23 - 7,5A F24 - 15A F25 - 10A
+P = Permanent +VBAT TEMPO PARK

F26 - 7,5A F27 - 15A F28 - 25A F29 - 30A
25A F30 - 15A
HAND
A 5 A fuse located on the battery cut out (if fitted) protects the clock. STOP
F31 - 15A F32 - 10A REF: 3785919M1

3785918M1
Fig.29
Issue 1 May 2002

I . Location of fuses - Powershift (North America) (Fig. 30)

F 28 F 12
F 32
F 16
Note: Always replace fuses by fuses of the same amperage F 27 F 11
F 26 F 10
reference F 25 F 9
F 31
F 15
F 24 F 8
F 21 F 5
F 30
F 14
F4 15 (+AC) Park Lock switch
F6 10 (+AC) Dashboard F 19 F 3
F7 5 (+AC) Steering wheel lever, starter switch, BOC, TOC, power take off stop,
F 29
F 13
F 18 F 2
rear power take off, economical power take off, cab power socket, F 17 F 1
creeper gearbox, hand brake
F9 10 (+AC) Cab relay, 4 WD switch, differential lock, buzzer
F10 25 (+AC) Cab relay windscreen wiper motor, switch, time delay F1 - 30A F2 - 7,5A F3 - 10A F4 - 15A F5 - 30A
F13 15 (+AC) Front work light APC TEMPO PARK
F14 15 (+AC) Front power take off, suspended front axle

F15 0 (+AC) Not used F6 - 10A F7 - 5A F8 - 7,5A F9 - 10A F10 - 25A
F19 7,5 (+AC) Horn
F20 10 (+AC) Accessories power socket F11 - 15A F12 - 30A F13 - 15A F14 - 15A F15 -
F24 15 (+P) Park Lock DCC time delay relay
F25 10 (+P) Backlighting switch, dashboard, headlight relay F16 - 30A F17 - 30A F18 - 7,5A F19 - 7,5A F20 - 10A
F28 25 (+P) Hazard warning switch, wing work light
F29 30 (+P) Rail work light
F30 15 (+AC) Footstep work light
F21 - 15A F22 - 20A F23 - 7,5A F24 - 15A F25 - 10A
+P = Permanent +VBAT TEMPO PARK

F26 - 7,5A F27 - 15A F28 - 25A F29 - 30A F30 - 15A
HAND
A 5 A fuse located on the battery cut out (if fitted) protects the clock.
F31 - 15A F32 - 10A REF: 3785919M1
Fig.30
Issue 1 May 2002

11 . ELECTRONICS
Contents
11 A01 AUTOTRONIC 2 - DESCRIPTION

11 A02 AUTOTRONIC 2 - CHECKING WITHOUT TESTER
11 A03 11 A03 AUTOTRONIC 3 - DESCRIPTION
11 B01 DCC / TC - DESCRIPTION
11 B02 DCC / TC - CALIBRATION
11 B03 DCC / TC - ERROR CODES
11 C01 ELECTRONIC LINKAGE - DESCRIPTION - TRACTOR WITH CAB
11 C02 ELECTRONIC LINKAGE - AUTODIAGNOSTICS - TRACTOR WITH CAB
11 C03 PREVISIONAL
11 C04 PREVISIONAL
11 D01 DATATRONIC 2 - DESCRIPTION
11 D02 DATATRONIC 2 - FRONT DUAL CONTROL
11 D03 DATATRONIC 2 - DUAL CONTROL FOR SEMIMOUNTED IMPLEMENT
11 D04 DATATRONIC 2 - TIC FOR SEMIMOUNTED IMPLEMENT
11 E01 PREVISIONAL
11 E02 PREVISIONAL
11 E03 PREVISIONAL
11 F01 WINTEST - GENERAL
11 F02 AUTOTRONIC 2 WITH WINTEST
11 F03 AUTOTRONIC 3 WITH WINTEST
11 F04 TC / DCC WITH WINTEST
11 F05 ELECTRONIC LINKAGE WITH WINTEST
11 F06 DATATRONIC WITH WINTEST
11 F07 JOYSTICK WITH WINTEST
11 F08 AUTOTRONIC 3 TO KIT AUTOTRONIC
11 F09 KIT AUTOTRONIC TO AUTOTRONIC 3
11 G01 CARRARO FRONT AXLE
11 H01 SMS SYSTEM - DESCRIPTION
Issue 2 May 2002

Autotronic 2 - Description 11A01.1
11 A01 Description
CONTENTS
A. General _____________________________________ 3
B. Flowchart of Autotronic 2 modes _____________ 4
C. Flowcharts of functions ______________________ 5
D. Diagrams ___________________________________ 10
Issue 1 May 2001

11A01.2 Autotronic 2 - Description
Issue 1 May 2001

The Autotronic 2 controls the automatic functions of the

A . General transmission according to the driver’s actions and infor-
mation from the various sensors.
The Autotronic 2 also known as the TCU (Transmission
Control Unit) is fitted to all 8200 series tractors with a
It controls:
Mechanical Reverse Shuttle.
- the shifting of the Hare / Tortoise range
- the power take-off
On 8200 series tractors fitted with a Power Shuttle, the
- the differential lock
Autotronic 2 has been replaced by a new calculator
- the front axle 4 WD
known as the Autotronic 3.
- the Dynashift
The Autotronic 2 is fitted outside beneath the right-hand
The Autotronic 2 unit can be:
flooring on tractors with cab, and inside on the right wing
- programmed: updating of the logic controllers
on tractors without a cab.
- parameterised: identification of the unit, type and
features of the tractor
Only Autotronic units with reference numbers equal to
- tested: verified using Wintest or a tester to check the
or greater than 3792092H92 can be fitted to 8200 series
correct operation of the logic controllers.
tractors.
The Autotronic 2 can be easily identified by its external

label (Fig. 1).
Phoenix PN : 3792094 M1
PHOENIX
OP Software PN : 1-91-127671 Issue D INTERNATIONAL
BOOTROM Software PN : 1-91-123234 Issue E
PN : 3792093 H94
Serial Number : 99 00 000
TRANSMISSION CONTROL Unit Assembled in USA

Tested : ______________________________ IIIIIIIIIIIIIIIII
CASE MUST BE EARTHED
Fig. 1
Issue 1 May 2001

B . Flowchart of Autotronic 2 modes

To operate correctly, the Autotronic 2 must receive a
certain amount of safety information and be in the
“Working Mode”.
> ALARM MODE
All functions locked

TCU 2
>
>
Clutch switch
signal
Low pressure Low pressure
< 9 bar = 17 bar
Engine speed Engine speed
< 200 rpm > 200 rpm
STANDBY MODE
Engine stopped
No hydraulic pressure Low pressure
> TCU OFF < 9 bar
Engine speed
< 200 rpm
>
WORKING MODE
All functions OK
TCU 4
PTO ALARM MODE Low pressure

= 17 bar
All functions locked Engine speed
TCU 7 < 200 rpm
>
Issue 1 May 2001

C . Flowchart of functions
AUTOTRONIC 2
(T . C. U .)
Automatically acts on
1 2 3 4 5
Dynashift
Hare / Tortoise Power take-off Differential Front axle or
shifting (PTO) lock 4WD Speedshift
Hydraulic protection of functions 1 - 2 - 3 - 4 - 5

If the pressure (17 bar nominal) drops too much, the red low oil pressure indicator lights on the dashboard and the
system transits to Alarm Mode.
1. The shifting of the Hare / Tortoise range is prohibited
2. The PTO is automatically disengaged
3. The differential lock is automatically disengaged
4. The front axle is automatically engaged
5. The Dynashift automatically shifts to the D ratio.
Issue 1 May 2001

SHIFTING OF THE HARE / TORTOISE RANGE
SHIFTING OF HARE / TORTOISE SHIFTING TO HARE / TORTOISE

RANGE IMPOSSIBLE RANGE PROHIBITED
- If the forward speed is greater than:

- If the Hare range is selected at the same
- 10 kph: Tortoise to Hare
time as the creeper unit, the Hare dash-
- 6 kph: Hare to Tortoise
board indicator flashes to warn the driver
he must shift into the Tortoise range.
- If sufficient hydraulic pressure
POWER TAKE-OFF
Progressive clutch control Disengagement if the PTO Does not re-engage during
during engagement clutch slips start-up
- By sending impulses to sole- - If a pressure drop occurs (17 bar - If the engine is stopped with the
noid valve until complete en- nominal) or if the clutch slips, PTO engaged or it is re-engaged
gagement the supply to the PTO clutch is before start-up, the Autotronic
cut (flashing indicator) prohibits the engagement of
the PTO during start-up (fla-
shing indicator)
Stop the PTO when the stop

Does not engage if the
switch located on the wings
implement is jammed
is pressed
- If the implement is jammed the

clutch engagement stops be-
fore stalling the engine (flashing
indicator)
Issue 1 May 2001

DIFFERENTIAL LOCKING
Unlocks when the Action on the differential

Unlocks when
three-point hitch is lock switch engages
brakes are applied
lifted 4 WD
- action on one or other of the - when the lifting / lowering - indicator lights
brake pedals unlocks the switch is in the lifting or
differential, it is not re- transport position, the
engaged until action on the differential unlocks. It re-
brakes has stopped, unless engages when the switch
it was temporarily uncou- is in the lowering position
pled by the ELC. (indicator goes out and
then relights).
Note: Manual control
has priority.
Unlocks if the hyraulic Unlocks if the

pressure drops too low (17 forward speed
bar nominal) exceeds 14 kph
- Does not re-engage when

speed drops below 14 kph
(indicator not lit).
Issue 1 May 2001

FRONT AXLE
4 WD status
Tractor stopped
Disengages if speed Remains engaged Remains engaged
Engine running
exceeds 14 kph whatever the speed whatever the speed
If parameter
B=3 and I =2
1. If the front axle is - The front axle being - Hold down the 4 WD - During braking invol-
engaged, the 4 WD engaged by a simple switch more than 2 ving both pedals, the
indicator lamp is lit, pressure on the seconds at a speed TCU automatically en-
pressing the 4 WD 4 WD button: it then below 14 kph. gages 4 WD.
switch disengages disengages above - Trigger 4 WD at a Note: Braking using
it. The 4WD sole- speeds of 14 kph. It speed greater than only one pedal (un-
noid valve is sup- re-engages when the 14 kph. latched pedals) does
plied. speed drops below not engage the 4 WD.
2. If the 4 WD indicator 14 kph.
lamp is not lit, the - If the tractor is
front axle is disen- travelling in excess of
gaged, pressing the 14 kph and the 4 WD
4 WD switch en- is disengaged, it can
gages 4 WD. The 4 be re-engaged by
WD solenoid valve pressing once on the
is no longer sup- 4 WD button.
plied.
Note: The front
axle is engaged
mechanically and
disengaged hy-
draulically.
Engages Engages when the

if hydraulic pressure differential lock is
drops activated
Issue 1 May 2001

DYNASHIFT
On starting the Progressiveness Drop in hydraulic Low temperature

engine pressure
- If parameter G = 1, the - Controlled timed shifting - Automatic shifting to D - Shifting prohibited when
range engaged corres- of intermediary ratios ratio, if hydraulic pres- the oil temperature is less
ponds to the lever posit- when the lever is moved sure < 9.5 ± 1 bar. than 5° C. The system is
ion. directly from A to D. restricted to ratio D, the A
- If parameter G = 2, 3 or 4, - Engine running, tractor and D indicator lamps
the range engaged cor- stopped, de-clutch to flash. When the tem-
responds to the last posi- shift directly from one perature is correct there
tion memorised before range to another without are two possibilities:
stopping the engine. passing through the If parameter G = 1
intermediary ranges. - the position of the
- If the forward speed Dynashift lever is
differs from 0, direct identical to the range
shifting is prohibited. selected. The indicator
lamp shows that the
ratio is engaged.
- the position of the
Dynashift is different
from the ratio engaged.
AB and CD indicators
flash alternately. Place
the lever in the
corresponding range to
authorise the shifting.
If parameter G = 2, 3 or 4
- the ratio engaged is the
last one memorised.
Note: Speed limitation
control operates even
at low temperature.
Maximum engine Low engine speed Speed limitation

speed
- Shifting down is impos- - Shifting to a higher ratio is - Down shift ratios in rela-
sible when the motor forbidden if the engine tion to the parameter E
speed is higher than 2400 speed drops more than selected.
rpm (engaged ratio indi- 2% (indicator lamp fla-
cator lamp flashes) shes)
Issue 1 May 2001


56 - Not connected (creeper unit)
D . Diagrams 57 - Shunt on 2 WD tractor only
58 - To fuse box then stop lights
Dynashift
59 - Buzzer, parking brake
1 - Autotronic unit
60 - Front lamp switch
2 - Differential lock solenoid valve
61 - Electronic linkage control supply
3 - Dynashift EV2 (3 x 2) solenoid valve
4 - Hare / Tortoise solenoid valve
5 - Rear PTO solenoid valve
Only on tractors fitted with 540 / 1000 rpm or 750 /
6 - 4 WD solenoid valve
1000 rpm PTO lever in the cab
7 - Dynashift EV1 (4 x 2) solenoid valve
44 - PTO 1000 rpm switch
8 - F18 + lighting fuse
45 - PTO 540 rpm switch
9 - Cab ground
10 - Battery
11 - Temperature sensor
On tractors fitted with a creeper gear
12 - Alternator
49 - Creeper unit switch
13 - PTO 540 / 1000 rpm switch
50 - Flasher relay
14 - Starter motor
51 - Relay
15 - PTO 540 rpm indicator lamp
52 - Creeper unit indicator lamp
16 - PTO 1000 rpm indicator lamp
17 - Low pressure indicator lamp
18 - Hare / Tortoise indicator lamp
19 - Differential lock indicator lamp
Abbreviations
20 - 4 WD indicator lamp
Example: TB.A4: terminal 4 of connector A on the
21 - PTO and speed digital display
dashboard
22 - To + AC cab relay
23 - + AC (start switch)
24 - Left brake switch
25 - Right brake switch
Fig. 1
26 - Clutch – safety switch
27 - Start switch
28 - Dynashift ratio indicator lamps
29 - To hydraulic filter clogging indicator lamp
30 - Economic PTO indicator lamp
31 - Low hydraulic pressure switch
32 - Engine speed sensor
33 - Forward speed sensor
34 - Rear PTO sensor
35 - 4 WD and differential lock sensor
36 - Start relay
37 - Rear PTO brake solenoid valve
38 - Rear PTO, power take-off selector
39 - PTO stop switch
40 - Economic PTO switch
41 - Rev counter - hourmeter
42 - Dynashift control lever
43 - Hare / Tortoise switch
46 - High pressure filter clogging indicator lamp
47 - Temperature switch
48 - Low pressure 3 bar pressure switch
53 - Selector cover ground
54 - To linkage control harness
55 - To Lifting / Neutral / Lowering, linkage control
switch
Issue 1 May 2001


36
61 14
44 45
2 3 4 5 6 7 13 12
11
15
c49
10
16
Fus. Fus. 17
7,5A 15A
57 53 18
19
9
54 20
C31
62
21
56
43 1 7 7 1
C30
22 C F B.emb.B
B
25
13 58 B.emb.N
53 A C31
41
D 14
1
C30
25 24
C B D
7 1 1 7
1
B
VI
A
42
59
26
40 23
56 23
27
F7
O
R 55
8 C60
C
28
B
35
50 51 A
38 37 60 34 33 32 31
C42 C4 TBA17
VI VI VI
30
29
18 46
52 49
48 Parts list Fig. 1

47
Issue 1 May 2001

Autotronic 2 - Checks without a tester 11A02.1
11 A02 Checks without a tester
CONTENTS
A. Test procedures _____________________________ 2
B. Analysis of possible faults ____________________ 6
Issue 1 May 2001

11A02.2 Autotronic 2 - Checks without a tester

b) If test 2a produces the correct results:
A . Test procedure Stop the engine.
This procedure allows to check for the proper operation After several seconds the red hydraulic pressure
of the Autotronic 2 unit as well as solving the most indicator lamp lights, the 4 WD, the Dynashift /
straightforward failures. Speedshift ratio engaged and the Hare range if it is
The tester or Wintest software shall be used for more engaged must light for 4 seconds before the other
complex cases. indicator lamps go out.
Note: 4 or 5 minutes may be necessary for the
hydraulic pressure indicator lamp to light
1 . Checking the power supply
(depends on the discharging of the hydraulic
Engine stopped, ignition switch turned off, all
accumulator).
indicator lamps out.
De-clutch: The following indicator lamps must light
This test shows that:
almost immediately:
- the hydraulic switch is correctly connected and is
- hydraulic pressure,
operating (re-opening).
then…
- indicator lamps A, B, C and D
lastly…
- 4 WD 3 . Differential lock
- hydraulic pressure Engine idling
- Hare / Tortoise With the 4 WD indicator lamp lit.
- D ratio - Press the differential lock button, the differential lock
Release the clutch: all the indicator lamps should go indicator lamp lights.
out after a few seconds. - Press the differential lock button again, the differential
lock indicator lamp goes out.
This test shows that: - Disengage the front axle.
- the TCU is present and supplied with 12 volts - Drive at 4 kph and engage the differential lock. The 4
- the microprocessor is functioning WD engages.
- the indicator lamps: 4 WD, hydraulic pressure, Hare - Place the Linkage Control switch in high position, then
/ Tortoise, ratios A, B, C and D and the sense of in lowering position (not in Neutral), the differential
direction are correctly cabled. lock indicator lamp goes out, then re-lights.
- the clutch switch is operating. - Turn the tractor in a tight circle, engage the differential
Note: To check that the supply is correct, check the lock, you can feel the jerk as it engages and disengages
battery voltage and lines resistance. and the rear tyres skid.
- Check that the differential lock disengages when the
forward speed exceeds 14 kph.
2 . Hydraulic pressure switch / engine
- The differential lock disengages but does not engage
speed sensor again when right or left braking is applied.
a) Engine stopped, ignition key off
De-clutch These tests show that:
The indicator lamps light as indicated in 1. - the supply to the switches is correct.
Start the engine - the differential lock button is working correctly.
The red hydraulic pressure indicator lamp should go - the differential lock indicator lamp is working correctly.
out after several seconds - the solenoid valve is correctly wired and operating.
This test shows that: - the differential lock is also functioning.
- the engine speed sensor is correctly wired and is - the speed sensor is functioning and the Autotronic
functioning correctly unit is correctly reacting.
- the hydraulic pressure switch is closing.
Issue 1 May 2001

4 . Brake switch 6 . The Lifting / Lowering linkage control

Engine idling switch
- Again press the differential lock button, the differential
Engine idling
lock indicator lamp lights.
- With the linkage control switch in the down position,
- Unlatch the brake pedals. Successively press lightly
press on the differential lock button. The differential
on each pedal (engage the lock each time a brake pedal
lock and 4 WD indicator lamps are lit.
has been pressed).The differential lock indicator lamp
- Move the linkage control switch to the Lifting position,
goes out as soon as the stop lights are lit.
the differential lock indicator lamp should go out.
Place the switch in the Lowering position, the
This test shows that :
differential lock indicator lamp should light again (the
- the electrical supply to the switches is correct
4 WD indicator lamp should always remain lit).
- both brake switches are working correctly and are
- The indicator lamps do not change status in neutral.
properly adjusted.
These tests show that:
5 . 4 WD - the Lifting / Lowering linkage control switch is
Engine idling functioning.
4 WD indicator lamp lit
- Press the 4 WD button: the 4 WD indicator lamp
should go out.
7 . Shifting the Hare / Tortoise range
- Press the differential lock button: the 4 WD and
Engine idling. Tractor stopped.
differential lock indicator lamps light up at the same
- Shift the Hare / Tortoise range using the gear lever.
time.
The Hare indicator lamp lights when the Hare range is
- Successively disengage the 4 WD and the differential
selected. No indicator lamp is lit when the Tortoise
lock, the two indicator lamps should go out.
range is selected.
- Drive the tractor at approximately 4 kph. Turn in a
- Drive the tractor forwards. Change the range several
circle using maximum steering lock.
times, checking that the forward speed changes
Engage and disengage the 4 WD several times. When
along with it. Check the correspondence between the
the 4 WD is engaged you should see the front wheels
indicator lamps and the range that is actually selected.
skid and feel a jerk with the engagement and
- Also check :
disengagement.
. that above 10 kph, the shifting of the Tortoise to
- With the front axle disengaged, when braking using
Hare range is impossible.
both pedals the front axle should engage.
. that above 6 kph the changing of Hare to Tortoise is
- With the front axle disengaged, when braking using
also impossible.
one or other of the pedals the front axle should not
engage.
These tests show that :
- Drive at less than 14kph. Press the 4WD button more
- the Hare / Tortoise switch is correctly wired
than 2seconds. The 4 WD remains engaged regardless
- the range indicator lamp is wired
of the speed
- the Hare / Tortoise solenoid valve is correctly wired
- Drive at less than 14 kph. Press the 4 WD button
and operating.
shortly. The front axle should be:
- the speed sensor is operating and the TCU reacting
. engaged below 14 kph
correctly.
. disengaged above 14 kph.
- Drive above 14 kph. Press the 4 WD button shortly.
The 4 WD remains engaged regardless of the speed.
These tests show that:

- the 4 WD button is operating correctly
- the front axle solenoid valve is correctly wired and
operating correctly
- the front axle clutch is operating
- the speed sensor is functioning and the Autotronic
unit is correctly reacting.
Issue 1 May 2001


8 . Power take-off than 14 kph the front axle disengages.
Engine idling These tests show that :
Using the 540/1000 rpm or 750 / 1000 rpm control in the - the forward speed sensor is functioning.
cab.
- Place the PTO lever in the 1000 rpm position. Note concerning checking sensors: The above tests
- Engage the PTO. show that the sensors are present, correctly wired
- The PTO 1000 rpm indicator lamp lights up on the and function. These tests do not show whether the
dashboard. sensors are correctly adjusted. The only way to
- The PTO shaft should begin turning. check this is to carry out a re-adjustment:
- Stop the PTO. - screw the sensor in without forcing it until it
- Place the PTO lever in the 540 rpm or 750 rpm position. touches the teeth of the pinion.
- Engage the PTO. - unscrew it - to - of a turn.
- The PTO 540 rpm or 750 rpm indicator lamp lights up - moderately tighten the locking nut - 20 Nm
on the dashboard. maximum.
- Also check that at 1900 rpm, the economic PTO is
triggered. 11 . Dynashift
- If the engine is stopped with the PTO engaged, the PTO Engine idling, tractor stopped, temperature above
indicator lamp flashes on start-up and the PTO is not 0° C
engaged. - Move the Dynashift lever from A to D.
- Engage the PTO and press the "Stop PTO" switch - Check that the four Dynashift indicator lamps light in
located on the rear wings. The PTO should stop. each corresponding position of the lever.
These tests show that : Tractor moving

- the PTO switches are correctly wired - Select each Dynashift ratio one by one and check that
- the PTO indicator lamps are correctly wired the speed increases or decreases.
- the PTO solenoid valve is correctly wired
- the engine speed sensor and the TCU are operating These tests show that :
- the "Stop PTO" switch is operating. - the lever is correctly wired and that its supply is correct
- the indicator lamps are connected correctly
9 . Checking the PTO speed sensor - the temperature sensor is connected
Engine idling – Engage the PTO - the solenoid valves are correctly connected and that
- Disconnect the PTO sensor (behind the right-hand lift the Autotronic unit is reacting correctly.
ram).
- The PTO should stop after 5 or 6 seconds and the PTO If only the D ratio can be obtained, check the supply to
indicator lamp begin flashing. the lever.
- Stop the tractor engine then restart with the sensor
disconnected, the PTO engages but without any
progressiveness.
This test demonstrates the correct functioning of the PTO

sensor.
10 . Checking the forward speed sensor

Drive the tractor
- Above 10 kph, the shifting of Tortoise to Hare is
impossible.
- Above 6 kph, the shifting of Hare to Tortoise is
impossible
- With the differential lock engaged: when the speed is
greater than 14 kph, the differential lock is disengaged.
- With the front axle engaged: when the speed is greater
Issue 1 May 2001

Temperature sensor – Test carried out above 0° C

If test 11 is correct, stop the engine.
- Wait until the TCU returns to Standby mode (all
indicator lamps out).
- Disconnect the temperature sensor fitted on the gear
selector cover.
- Start the engine.
- Indicator lamps A and D should flash.
- Reconnect the sensor.
- According to the position of the lever, the
corresponding range is engaged or indicator lamps AB
– CD flash alternatively.
This test shows that:

- There is not a short circuit on the sensor wiring.
The oil temperature is below 0° C

If the temperature is less than 0° C, the TCU automatically
puts the Dynashift into D and on starting the indicator
lamps A and D flash together.
As soon as the temperature is above 0°C, and according
to the position of the lever, the corresponding range is
engaged or the indicator lamps AB - CD flash alternately.
Issue 1 May 2001

B . Analysis of possible faults

The aim of this paragraph is analyse the cause of a failure without using a tester.
VERY IMPORTANT: The first operation to carry out is to check that the supply to the Autotronic and the
hydraulic pressure is correct. Therefore, in all cases, begin with the tests described under ‘Power Supply’
and ‘Hydraulic Pressure’.
The tests are carried out on the Autotronic wiring harness connectors.
After each operation, it is necessary to reconnect the connector that was used in order to carry out the followering
test.
Functions Igni- Engi- Operation to carry out Checks and results Remarks
tion ne
switch run-
on ning
Supply (1) No No Disconnect connector F Between F4 and F6, U = 9 VDC
(black) mini
Connect a 55W lamp Entre F5 et F6, U = 9 VDC
between: mini
If value incorrect
F4 and ground, the lamp lights check 15A fuse
F5 and ground, the lamp lights (battery)
No No Disconnect connector A A22 and ground, U = 0 VDC

(black)
Yes No A22 and ground, U = 12 VDC
Hydraulic Disconnect connector D

pressure (brown)
(2) No No D7 and ground, R = ∞
No Yes D7 and ground, R = 0 Ω
Differential
lock
(3)
• Indicator No No Disconnect connector C C2 and + battery = diff lock
lamp (green) indicator lights
• Switch Yes No Disconnect connector B B2 and ground, U = 0 V, switch If value incorrect

(grey) released check fuse F10
B2 and ground, U = 12 V, switch
pressed
• Solenoid Yes Yes Disconnect solenoid valve U = 0 V, switch released

valve Measure between two U = 12 V, switch pressed
terminals of connector
Stop Yes No Unlatch brake pedals

light switch
(4) pedals connector A A17 and ground, U = 0 V, pedal 1 If value incorrect
(black) and F (black) up check fuse F14
A17 and ground, U = 12 V, pedal 1
down
F7 and ground, U = 0 V, pedal 2
up
F7 and ground, U = 12 V, pedal 2
down
Issue 1 May 2001

tion ne
switch run-
on ning
4 WD (5)
• Indicator No No Disconnect connector A A5 and + battery = 4 WD
lamp (black) indicator lamp lights
• Switch Yes No Disconnect connector B B1 and ground, U = 12 V, switch If value incorrect,

(grey) pressed check fuse F10
B1 and ground, U = 0 V, switch
released
• Solenoid Yes Yes Disconnect solenoid , 4 RM engaged: lamp out

valve valve, connect 55 W 4 RM disengaged: lamp lit
to the connector.
Engage and disengage
the 4 WD
Lifting Yes Yes Disconnect connector B B4 and ground, U = 12 V, switch

/ Lowering (grey) in Lift position
linkage B4 and ground, U = 0 V, switch
control in Neutral or Lowering
switch (6) position
Hare/
Tortoise(7)
• Indicator No No Disconnect connector C C4 and + battery = Hare
lamp (green) range indicator lamp
• Switch Yes No Disconnect connector C C1 and ground, U =12 V, lever If value incorrect
(green) held in range shift position check fuse F12
C1 and ground, U = 0 V, lever
held in range position
• Solenoid Yes Yes Disconnect the Hare / Hare, U = 12 V, Hare indicator

valve Tortoise solenoid valve, lamp lit
measure between two contacts Tortoise, U = 0 V, Hare indicator
of connector lamp off
Power take-
off(8)
• Indicator No No Disconnect connector A A10 and + battery = PTO
lamp (black) indicator lamp lit if PTO
switch on 540 or 750
A10 and + battery = PTO
1000 rpm indicator lamp
lit if PTO switch on 1000
• Switch Yes No Disconnect connector B B6 and ground, U = 0 V, PTO If value incorrect

(grey) de-clutched check fuse F12
B6 and ground, U = 12 V, PTO
engaged
Issue 1 May 2001

tion ne
switch run-
on ning
Power
take-off (8)
• PTO Stop Yes No Disconnect connector B B3 and ground, U = 12 V
switch (grey) switch released
B3 and ground, U = 0 V,
switch pressed
• Electro- Yes Yes Disconnect solenoid valve U = 0 V, PTO de-clutched

valve Measure between the two U = 12 V, PTO engaged
terminals of the connector
Speed
sensor (9)
• Power No No Disconnect connector D
take-off (maroon) between D1 & D2, R = 450 Ω
• Forward No No Disconnect connector D

speed (maroon) between D3 & D4, R = 450 Ω
• Engine No No Disconnect connector D

(maroon) between D5 & D6, R = 450 Ω
Dynashift
(10)
• Indicator No No Disconnect connector A A1 and + battery = range A
lamp (black) indicator lamp lit
A2 and + battery = range B
indicator lamp lit
A3 and + battery = range C
indicator lamp lit
A4 and + battery = range D
indicator lamp lit
• Lever Yes No Disconnect connector A

(black) A19 A20 A21 If voltage = 0V
Place lever in range to be A 0V 12 V 0V in all lever positions,
checked and check voltage B 12 V 12 V 12 V check power supply
between A19 then A21 C 12 V 0V 12 V to lever (orange wire,
and ground D 12 V 0V 0V fuse F8)
• Solenoid Yes Yes Disconnect solenoid valves EV1 EV2 EV1 : vertical solenoid
valve Dynashift EV1 and EV2 A 12 V 0V valve (ivory wire)
Measure between terminals B 12 V 12 V EV2 : horizontal
of connector C 0V 12 V solenoid valve
D 0V 0V (green wire)
• Tempe No No Disconnect connector F between F2 & F3 :

rature (black) - R < 10 K Ω if temp > 0°C
sensor - R < 10 K Ω if temp < 0°C
Issue 1 May 2001

11 A03 Description
CONTENTS
A. General ________________________________________ 2
B. Autotronic 3 status flowcharts ___________________ 2
C. Automatic responses of the Autotronic 3 _________ 5
D. Operating principle of the Autotronic Dynashift ___ 14
E. Calibration of throttle pedal potentiometer _______ 18
F. Power Shuttle principles ________________________ 19
G. Calibration of the Power Shuttle _________________ 21
H. Power Shuttle error codes _______________________ 25
I. Disassembly, reassembly of the Power Shuttle

lever ___________________________________________ 29
J. Adjustment of the clutch pedal __________________ 31
K. Electrical diagram _______________________________ 32
Issue 1 May 2002

A . General B . Autotronic 3 status flowcharts

The Autotronic 3 is the transmission controller fitted to The Autotronic 3, to operate correctly, must receive
8200 series tractors. safety information allowing it to manage its automatic
The Autotronic 3 controls the automatic functions of the functions. The Autotronic 3 has a different status depending
transmission according to the driver’s actions and on the information it receives.
information from the various sensors.
The Autotronic 3 controls:

- Hare / Tortoise range
- 4 WD
- Differential lock
- Power take-off
- Dynashift or Speedshift
- Power Shuttle
- Creeper unit
The Autotronic 3 can be :

- programmed: updating of functions control
- parameterised: identified by a 12-digit code indicating
the model of the tractor it is fitted to.
- tested: testing the Autotronic 3 inputs, outputs and
functioning.
The Autotronic 3 unit is mounted beneath the external

flooring on tractors with a cab. Otherwise it is mounted
on the inside of the right wing.
The Autotronic 3 is easily identified by its label (Fig. 1) and

possesses only two 36-pin connectors.
Parst list
(1) Autotronic 3 item number
(2) Motherboard reference
(3) Program version
(4) Autotronic 3 serial number
1
P/N : 3791899F91
2
N/Y : 3 7M 700 FM
3 S/Y : 3 7M 701 FM
SERIAL N : 10000001
TESTER
4 B4 397
MADE IN UK
Fig. 1
Issue 1 May 2002

8200 SERIES TRACTORS Note : Whatever the mode, if the battery tension is upper than 16 V, the Autotronic 3 functions are lock,
only the power shuttle is working.
AUTOTRONIC 3 OFF
STANDBY MODE + AC = 0
< - + AC = 0 Indicator lamps
+ AC = 12 V – wrong parameters
- engine speed = 0 < AC / BD
TCU 6 - low pressure = 0 flash alternately
<
+ AC = 12 V
clutch pedal low
+AC = 12 V
switch signal
and parameters
OK
<
<
Low pressure < 9 bar ± 1 and <
ALARM MODE
engine speed < 200 rpm
Alarm delay
< Low pressure < 9 bar ± 1
No functions apart from Power Shuttle if low
of and engine speed > 200 rpm
pressure less than 9 bar ± 1 or engine speed PTO Alarm
6 seconds engine speed lower than 200 rpm
< all functions
TCU 1 Low pressure > 9 bar ± 1 locked except
TCU 0 Low pressure > 9 bar ± 1 Power Shuttle
engine speed > 200 rpm < and engine speed < 200 rpm
< TCU 5
<
Low pressure > 9 bar ± 1
and engine speed > 200 rpm
Low pressure < 9 bar ± 1
engine speed < 200 rpm
<
Low pressure > 9 bar ± 1 WORKING MODE Low pressure > 9 bar ± 1
Work delay < < PTO delay
of for
All functions active
4 seconds 0.5 seconds
< TCU 2 <
TCU 3 TCU 4
Low pressure > 9 bar ± 1 and engine speed < 200 rpm
Issue 1 May 2002

Issue 1 May 2002

C . Automatic responses of the

Autotronic 3
Note: The Autotronic 3 can only control its functions
in Working mode (see § B).
Functions Driver action Automatic response of the Autotronic 3
Hare / Tortoise (Hi / Lo) Wants to change range using gear On passing into Working mode, it selects
lever switch the range engaged when placed on standby.
Prohibits shifting Hare to Tortoise range

above 8 kph, and Tortoise to Hare above 10
kph (synchro version)
Selects a creeper speed with the Flashes the Hare indicator lamp indicating
Creeper unit Hare range engaged that it is shifting to Tortoise range
Selects a creeper speed with Locks the gearbox in Tortoise range

Tortoise range engaged (impossible to shift to Hare range).
Issue 1 May 2002

4 WD On passing into Working mode, it selects

the range engaged when placed on standby.
4 WD:
- indicator lamp lit
- solenoid valve = 0 V
2 WD:
- indicator lamp not lit
Presses 4 WD switch when speed If 2 WD, shifts to 4 WD automatically

is less than 14 kph. If 4 WD shifts to 2 WD
In 4 WD, if forward speed greater than 14
km/h, shifts to 2 WD and returns to 4 WD as
soon as the speed drops below 14 kph.
Presses the 4 WD switch for more Engages 4 WD manual definitively.

than 2 seconds and with speed less
than 14 kph.
Presses both brake pedals Engages 4 WD whatever the forward speed,

simultaneously. returns to previous state when pedals are
released.
Presses one or other of the unlatched Does not engage the 4 WD.
brake pedals
Issue 1 May 2002

Differential lock On passing into Working mode, the

differential lock is disengaged:
- indicator lamp not lit
Presses the differential lock switch Engages the 4 WD if the tractor is in 2 WD

- Lights the differential lock indicator lamp
- Differential solenoid valve = 12 V
Drives at more than 14 kph. Disengages the differential lock.

Does not re-engage automatically when the
forward speed is less than 14 kph.
Puts the ELC into the Up or Transport Disengages the differential lock.
position. Re-engages the differential lock when the
ELC is placed in the Working position.
Note: Manual control of the differential
has priority
Presses one or other of the unlatched Definitively disengages the differential lock
brake pedals. unless temporarily disengaged by the ELC.
Issue 1 May 2002

Dynashift On passing into Working mode, it selects the

range memorised when placed on standby or
• Normale indicated by the position of the lever.
version
A B C D
Lamp 12 V 12 V 12 V 12 V
EV1 12 V 12 V 0V 0V
EV2 0V 12 V 12 V 0V
Selects a Dynashift ratio. Automatic time control of ratio shifting (every

0.6 seconds).
De-clutches and selects Dynashift If forward speed equals 0, direct shifting into
ratio. ratio requested.
If forward speed greater than 1kph the request
is memorised and carried out during de-
clutching.
Requests go slower ("-") with engine The request is not executed and is memorised.
speed above 2400 rpm. The indicator lamp of the selected ratio flashes.
The down shift is made when the engine
speed is less than 2400 rpm.
The request is not executed and is memorised.

Requests go faster ("+")and drop in The indicator lamp of the engaged ratio flashes.
engine speed exceeds 12%. The up shift is made when the engine speed
has recovered the 12% difference.
At 28 kph, the indicator lamp of the engaged

ration flashes.
Reaches authorised speed. At 30 kph or 33 kph, the A, B, C and D indicator
lamps flash.
At 32 kph or 35 kph, shifts to lower ratio, D to
C or C to B.
Note: With a Dynashift lever with position

hold, the shifting of ratios is only
authorised after synchronising the lever
position with the indicator lamps.
Flashes indicator lamps A and D, the Dynashift

remains in the D ratio unless the tractor is
Transmission temperature measured moving and reaches the authorised speed.
when passing into Working mode. If
temperature is less than 5° C.
Issue 1 May 2002

Dynashift (continued) When the temperature is above Power Shuttle type lever: selects the Dynashift
• Normale 5° C. ratio engaged and lights the corresponding
version indicator lamp.
Lever with position hold:

- if engaged ratio equals ratio selected by
lever, the ratio indicator lamp is lit.
- if engaged ration is different from that
selected by lever, AB and CD flash alternately.
Move the position of the lever to correspond
with engaged ratio.
Issue 1 May 2002

Functions Driver Automatic response Problems and

actions of Autotronic 3 possible causes
Dynashift (continued)
• Speed Matching
version
Switch in OFF The Autotronic 3 operates

position in normal Dynashift
Switch in ON Changes the mecha- The Autotronic 3 selects The Autotronic function
position nical gear or speed the Dynashift gear most does not work : using
range appropriate to the actual Wintest chek the :
speed of the vehicle - status of ON / OFF switch
when declutching - clutch speed sensor
- forward speed sensor
- BOC top and bottom
switches
- Autotronic 3 program
version and parameters
- Dynashift unit solenoid
valve supply
Select a Dynashift The Autotronic 3

speed operates in normal
Dynashift
Select a creeper speed Autotronic Dynashift

deactived (operation in
Normal mode
Issue 1 May 2002

Functions Driver Automatic response Problems and

actions of Autotronic 3 possible causes
Dynashift (continued)
• Autodrive version
Switch in OFF The Autotronic 3 operates

position in Speed Matching
Switch in ON 1 Changes the engine Speed of tractor above The automatic functions
Power Mode speed in forward or 1 Kph : Automatic does not work : using
position reverse changing of Dynashift Wintest, check the :
speeds to maintain - status of ON / OFF switch
constant engine speed or - engine speed sensor
torque - accelerator potentiometer
- Autotronic 3 program
Switch in ON 2 Speed of tractor above version and parameters
Eco Mode Changes the engine 1 Kph : Automatic - Dynashift unit solenoid
postion speed in forward or changing of Dynashift valve supply
reverse speeds if necessary
For all mode Selects a Dynashift The Autotronic 3 operates

speed in normal Dynashift
Selects a creeper Automatic Dynashift

speed deactivated (operation in
Normal mode)
Issue 1 May 2002

Power take-off (PTO) Starts tractor with the PTO engaged. On passing into Working mode:
- solenoid valve = 0 V if the cab control is
engaged or one of the emergency stop
controls is activated.
The PTO indicator lamp flashes.
Starts the PTO Handles the start-up progressiveness in

relation to the engine speed and the
acceleration of the PTO.
PTO indicator lamp flashes slowly.
PTO solenoid valve pulsed.
PTO clutch in:
- if PTO speed higher than 98% engine
speed
. indicator lamp stays lit
. solenoid valve = 12 V
- if PTO signal equals 0, maximum
progressiveness (sensor supposed to be
defective).
PTO de-clutched
- if engine speed drops more than 50%
- if clutch slips
. indicator lamp flashes rapidly
. solenoid valve = 0 V.
Starts economic PTO Cuts the PTO if engine speed above 1900
rpm
- indicator lamp flashes rapidly
Presses emergency stop button. Immediately stops the PTO.

Restart PTO using cab switch.
Issue 1 May 2002

Power Shuttle De-clutches and starts engine Unlocks and conforms to position of lever if
(activates bottom of clutch switch). Autotronic 3 receives at least a 17 bar low
pressure signal or engine speed is above 200
rpm.
Selects a Power Shuttle position: Automatically handles the progressiveness of

- Forward the Power Shuttle.
- Neutral
- Reverse
without action on the clutch pedal.
Selects a Power Shuttle position and Handles the progressiveness of the clutch in
lets out clutch using clutch pedal. relation to the pedal potentiometer value.
Supply to indicator lamps and solenoid
valves
Forward:
- forward indicator lamp = 12 V
- forward solenoid valve = 12 V
Neutral:
- forward & reverse indicator lamps = 0 V
- forward & reverse solenoid valve = 0 V
Reverse:
- reverse indicator lamp = 12 V
- reverse solenoid valve = 12 V
Power Shuttle locked:
- forward or reverse indicator lamp flashes
- solenoid valve = 0 V.
Note: The Power Shuttle continues to

operate with a low pressure or engine
speed fault, or battery voltage above 16 V.
Issue 1 May 2002

D . Operating principle of the Auto-

matic Dynashift
The Automatic Dynashift available on all tractors with
Power Shuttle provides an automatic changing of
Dynashift speeds in relation to information received by
the various sensors and the commands given by the
driver.
The two versions of Automatic Dynashift are available

solely on tractors fitted with the Autotronic 3 :
- Series: Speed Matching
- Optional: Autodrive
Block diagram
10
5
1
7
F
2 F
6 8
Parts list (6) Dyna 1 solenoid valve

(1) Switch (7) Dyna 2 solenoid valve
- two position for Speed Matching (8) Dynashift
- three position for Autodrive (9) Forward movement solenoid valve
(2) Accelerator pedal potentiometer (10) Reverse movement solenoid valve
(3) Dashboard indicator lamps
(4) Autotronic 3
(5) Speed sensors:
. progressive speed
. forward speed
Fig. 2
. effective engine speed
Issue 1 May 2002

Operation of Speed Matching

The Speed Matching version of the Autotronic 3 handles
the automatic changing of Dynashift speeds during a
mechanical gear or range shift.
3
The driver activates or deactivates the Speed Matching
function using the 2-position switch located on the right- AUTO
hand armrest (Fig. 3).
Parts list
(1) Indicator lamps
(2) OFF position: no automation, both indicator lamps
are out. The Dynashift operates in Normal mode. 1
(3) ON position: the Dynashift operates in Speed
2
Matching mode, both indicator lamps are lit.
To provide the Speed Matching function, the Autotronic

3 requires information from: Fig. 3
- the clutch speed sensor (Ve) located at the gearbox inlet
- the forward speed sensor (Vr) located on the rear axle
(speed measurement of design bevel gear forward
speed)
- the current values of the Power Shuttle solenoid valves.
The Autotronic 3 samples the Ve and Vr speed values

every 16 milliseconds. During the clutching / de-clutching
phase, signalled via the value of the forward or reverse
solenoid valves current, the two ratios are memorised by
the Autotronic 3:
- R = Ve / Vr : calculation carried out before full de-
1
clutching (detection of non-supplied solenoid valve)
- R = Ve / Vr: calculation carried out when start of
2
clutching phase is complete (detection of supplied
solenoid valve)
The comparison between R and R allows the Autotronic

1 2
to control the automatic changing of Dynashift speeds.
User action Change gear or range to a lower ratio Change gear or range to a highter ratio
R1<R2 R1>R2
Autotronic 3 control
parameter Speed Vr Speed Vr Speed Vr Speed Vr Speed Vr Speed Vr
decrease stable increase decrease stable increase
Autotronic 3 action
Or Or
on the Dynashift ratio
Issue 1 May 2002

Operation of Autodrive
The Autodrive version of the Autotronic 3 handles the
automatic changing of Dynashift speeds during engine
gear shifts. Two operating modes are available: the
Power mode and the Eco mode. In Eco mode the 5
changing of Dynashift speeds is carried out at engine AUTO
speeds lower than those of the Power mode. 2
The Autodrive version is controlled by the three-position
switch located on the right-hand armrest (Fig. 4) 4
Parts list
(1) Indicator lamp 1 (Autodrive Power mode) 1
(2) Indicator lamp 2 (Autodrive Eco mode)
(3) OFF position: Speed Matching operation, both indi- 3
cator lamps are out.
(4) ON 1 position: Autodrive Power mode, indicator
lamp 1 is lit Fig. 4
(5) ON 2 position: Autodrive Eco mode, indicator lamp
2 is lit
The Autodrive operates with information from:

- the real engine speed sensor located on the right-hand
side hydraulic cover
- the potentiometer located beneath the acceleration
pedal, its data permits a calculation of the design
engine speed.
Note. In Autodrive mode, the Speed Matching func-

tion is always active and overrides the Autodrive
function as soon as a mechanical gear change is
made.
Issue 1 May 2002

Increase in Decrease in Decrease in

Dynashift Dynashift Dynashift
ratios ratios ratios
+ - -
0,8 Vmt < Vmr Vmr < 0,8 Vmt
Vmt > 2100 Vmt < 1200 1200 < Vmt Vmt > 2100
Vmr > 2100 Vmr < 1800 < 2100 Vmr < 1680
Vmr > 2100
2400
2200
2000
1800
1600
1400
1200
1000
800 Vmr
800 1000 1200 1400 1600 1800 2000 2200 2400
Increase in Decrease in Decrease in

Dynashift Dynashift Dynashift
ratios ratios ratios
+ - -
0,8 Vmt < Vmr Vmr < 0,8 Vmt
Vmt > 1680 Vmt < 1200 1200 < Vmt Vmt > 1680
Vmr > 1680 Vmr < 1400 < 1680 Vmr < 1350
2400
2200
2000
1800
1600
1400
1200
1000
800 Vmr
800 1000 1200 1400 1600 1800 2000 2200 2400
Issue 1 May 2002


Potentiometer errors
E . Calibration of throttle pedal In the case of a potentiometer fault, short circuit or open
potentiometer circuit, the Autotronic 3 locks the operation of the Auto-
Drive and flashes the Dynashift indicator lamp.
The calibration of the throttle pedal potentiometer must
be carried out each time that one of the following
If the engine speed is less than 1200 rpm :
elements is replaced or modified :
- the Dynashift indicator lamp corresponding to the ratio
- throttle potentiometer
lower than the one engaged flashes (example: B range
- throttle cable
engaged, indicator lamp B is lit and indicator lamp A
- injection pump
flashes).
- Autotronic 3
If the engine speed is greater than 2100 rpm :
- the Dynashift indicator lamp corresponding to the ratio
Preliminary operations higher than the one engaged flashes (example: B range
1. Start the engine. Put on the handbrake. engaged, indicator lamp B is lit and indicator lamp C
2. Place the gear and reverse shuttle levers in neutral flashes).
position.
3. The power take off must be disengaged.
Calibration
The calibration is carried out in two successive steps so
as to determine the minimum and maximum engine
speeds in relation to the pedal.
4. Set the engine speed to 1200 rpm ± 100 rpm using the
hand throttle.
5. Press and hold down the differential lock switch.
The buzzer sounds (after approximately 2 seconds)
indicating the end of the first calibration phase. Re-
lease the differential lock switch.
6. Increase the engine speed to 2100 rpm ± 100 rpm
using the hand throttle.
7. Press and hold down the differential lock switch.
The buzzer sounds (after approximately 2 seconds)
indicating the end of the second calibration phase.
Release the differential lock switch.
Issue 1 May 2002

F . Power Shuttle principles

Block diagram
1 5
3 6 7
4
Fig. 5
Parts list The continual autodiagnostics carried out by the system

(1) Power Shuttle 3-position analog shift lever (see § G). in relation to the Power Shuttle permit an idea of any fault
(2) Top and bottom clutch pedal potentiometers to be indicated by the flashing of the indicator lamps on
(3) Dashboard indicator lamps (Forward and Reverse) the dashboard (see § F). The Wintest software allows
(4) Autotronic 3 the precise error code to be displayed (see section
(5) Speed sensors 11F03).
- gearbox input
- forward speed Operating modes of the Power Shuttle
(6) Forward solenoid valve Note: The user does not choose the mode of operation
(7) Reverse solenoid valve The information received by the Autotronic 3 allows it to
automatically select one of the two operating modes.
The Autotronic 3 automatically controls the Power Shuttle
in relation to information received from various sensors
and the commands given by the driver.
Several mechanical, hydraulic and electrical components

intervene for the operation of the Power Shuttle; it may
be necessary to carry out clutch calibration (see § E)
during replacement of one of them.
Issue 1 May 2002

USE
- Start-up - Manual shifting using the pedal or lever

and / or
- Power Shuttle shifting
OPERATING CONDITIONS
- Speed below 2 kph - Speed above 2 kph

and
- Previous clutch pressure was at least 10 bar.
AUTOTRONIC 3 ACTIONS
Without pedal signal Without pedal signal but with lever signal
- Automatic pressure increase in clutch limited to 3 - Automatic pressure increase in clutch limited to 7.5
bar bar
With pedal signal With pedal signal but no lever signal

- Pressure increase in the clutch determined by - Pressure increase in the clutch determined by
position of the pedal and limited to 3 bar position of the pedal and limited to 10 bar
With pedal and lever signals

- Pressure increase in the clutch determined by
position of the pedal and limited to 7.5 bar
Issue 1 May 2002

Legend
G . Calibration of the Power Shuttle
Note: The calibration of the Power Shuttle is essential A Indicator lamp out
where the following components are changed:
- a Power Shuttle solenoid valve or its terminals A Indicator lamp on
- the Power Shuttle hydraulic control unit
- the Power Shuttle unit or one of its components A Indicator lamp flashes
- the Autotronic 3 unit
Note: To authorise entry into calibration mode, the
transmission oil temperature must be:
- 35° C / 45° C: the temperature is measured by the
gearbox cover sensor and can be read using Wintest or
by a direct reading of a specific dashboard display.
The direct display of the temperature on the dashboard is

carried out by reading a code from the A, B, C and D
indicator lamps of the Dynashift or Speedshift.
To enter direct read mode:

- start the engine
- place the Power Shuttle lever in neutral
- Simultaneously move the gear lever (to activate the
Hare / Tortoise switch) and the differential lock switch
- The A, B, C, D indicator lamps show the temperature
as shown in the following table.
Exiting direct read mode is only completed after the

complete shut down of the engine accompanied by the
subsequent drop of the 17 bar low pressure, or by entry
into calibration mode.
Note: The direct read mode of the temperature

permits the tractor to be driven and the Dynashift /
Speedshift ratios to be used, however the display of
indicator lamps A, B, C, D only correspond to the
temperature reading.
- 45° / 55° C: measurement carried out in the gauge hole

on the rear axle using a thermometer.
Issue 1 May 2002

Direct reading of temperature for preparing calibration
Dynashift / Speedshift indicator lamps

Temperature displayed by
A B C D Wintest
10° C
17° C
22° C
27° C
31° C
36° C
Calibration authorised
39° C
The calibration may
Optimal calibration
be carried out
44° C
Calibration authorised
46° C
51° C
54° C
57° C
60° C
63° C
A B C D
Issue 1 May 2002

1. Bring the tractor up to temperature 17. De-clutch using the pedal to complete and validate
Tractor stationary the calibration of the Power Shuttle. The direction
- Run the engine, gear lever and Power Shuttle levers indicator lamp remains lit.
in neutral, PTO clutch in. Note: During the entire calibration phase, the
- Then, move the Power Shuttle lever 10 times in Forward and Reverse indicator lamps flash
each direction, leaving the lever 5 to 10 seconds in simultaneously and the buzzer sounds.
each position in order to bring the control unit and
solenoid valves up to the temperature of the
transmission.
- Measure and note the temperature.
Tractor moving
- Carry out Power Shuttle maneuvers every 5 to 10
seconds, in Hare range 2nd gear.
- Measure and note the temperature.
2. Place the tractor on a hard even surface, free of
obstacles for at least 3 metres.
3. The tractor must be free of any implements.
4. Stop the PTO, disengage the front axle.
5. Stop the engine.
6. Extinguish any work lights / road lights.
7. Put the gear lever and Power Shuttle lever into
neutral.
Automatic calibration
Note : A manual calibration may be carried out using
Wintest (see section 11F03).
8. Engage the handbrake.

10. Release the clutch pedal.
11. Increase the engine speed to 1500 rpm ± 100 (or to
PTO 400 / 410 rpm in the PTO 540 rpm position) using
the hand throttle.
12. Shift into the Tortoise range without de-clutching.
13. Place the Power Shuttle lever in Forward to re-arm
the system and then leave it in this position.
Note: Access to Automatic calibration mode
takes place immediately following the above
described maneuvers.
14. Simultaneously, and at least for 4 seconds, activate:
- the gear lever to activate the Hare / Tortoise range
switch (tractor shifts to Hare range),
- the differential lock switch.
15. The access to Automatic calibration mode is indicated
by the extinction of the A, B, C, D indicator lamps,
the two Power Shuttle indicator lamps flash at the
same time and the buzzer sounds. Release the
range and differential lock switches.
The tractor don't move and the calibration could take
5 minutes.
16. Automatic calibration is finish when the buzzer stop
and the selected direction (forward) indicator lamp
flashes. The selected Dynashift or Speedshift ratio
remains lit.
Issue 1 May 2002


Validation Calibration mode is quit if:
Immediate validation after calibration - The engine speed changes from 1500 rpm ± 100
18. Without stopping the engine, set the engine speed to - The gear lever is not engaged in 1st during phase 1
1500 rpm, engage 4th gear in the Tortoise range, - The Power Shuttle lever is placed in neutral.
Dynashift in range A or Speedshift in range C. Note: In the case of a calibration failure, the previously
19. Carry out 10 Power Shuttle maneuvers, forwards / memorised parameters are used by the system or
reverse. the default parameters in the case of a new Autotronic
20. Carry out 10 Power Shuttle maneuvers, neutral to 3 unit.
forward and neutral to reverse.
21. Judge the quality of the shuttling which should be Adjustment of the calibration parameters
deft and smooth. - Once the calibration has been correctly carried out, it is
possible to adjust the calibration parameters to obtain
Validation of an already calibrated tractor faster or slower Power Shuttle reactions.
Note: The transmission temperature must be above - The Autotronic authorises 5 adjustment procedures in
20° C. each direction and that can be reinitialised after a new
22. Put the gear lever in neutral, the power take-off must calibration.
be de-clutched, the front axle disengaged.
22. Start the engine. Adjustment Procedure
23. Put the Power Shuttle lever in Forward for at least 1 Note: During the procedure, if the Power Shuttle
minute, then at least 1 minute in the Reverse lever is placed in neutral or the ignition cut, the
position. modifications are not memorised.
24. Put the Power Shuttle lever back into neutral. 32. Engine stopped, turn it on and wait for the A, B, C,
25. Engage 4th Tortoise, Dynashift in A or Speedshift in D Hare / Tortoise range indicator lamps to go out.
C, with an engine speed of 1500 rpm. Note: Do not press the clutch pedal.
26. Carry out 10 Power Shuttle forward / reverse 33. Maintain the Power Shuttle lever in the manual de-
maneuvers. clutched position and press on the differential lock
27. Carry out 10 Power Shuttle neutral /forward and switch for at least 4 seconds.
neutral / reverse maneuvers. The A, B, C and D indicator lamps must light and
28. Judge the quality of the shuttling which should be remain lit to indicate access to the Adjustment
deft and smooth. mode. Release the differential lock switch.
Note: An abrupt reaction on the 1st maneuver is 34. Select the clutch whose parameters require
normal. modification by placing the Power Shuttle lever in the
Forward or Reverse position.
Calibration faults After approximately 4 seconds, the Forward and
Note: A fault due to the non-compliance of the Reverse indicator lamps light and remain lit.
conditions required to access to or to maintain the 35. Choose to increase or decrease the progressiveness
calibration mode is signalled by an alternate flashing of the selected clutch by pressing on the differential
of the A, B, C, D indicator lamps. switch. With each press, a direction indicator lamp
Access to calibration mode is not provided if: remains lit. Forward to obtain a faster reaction,
- The transmission temperature is not correct Reverse to obtain a slower reaction.
- The engine speed is other than 1500 rpm ± 100 Note: Only a single increase or decrease operation
- The Tortoise range has not been engaged before of calibration parameters is authorised on each
accessing calibration mode access to adjustment mode.
- The Power Shuttle lever has not been positioned in the A sixth access to adjustment mode is impossible;
Forward position. it is necessary to recalibrate the Power Shuttle.
29. Check that the access to calibration conditions in

operation 1 to 13 have been met.
30. Check the connections of the solenoid valves and
the tightness of the coils (tightening torque 5.4 - 8.1
Nm).
31. Check that TOC (top clutch pedal switch) is connec-
ted and correctly adjusted (see § H).
Issue 1 May 2002

36. To modify the opposite clutch, change the position of

the lever and carry out operations 45 and 46 again.
37. To validate your modifications, place the Power
Shuttle lever in the manual de-clutched position for
at least 4 seconds. The reset of the Autotronic is
shown by the extinction of all the indicator lamps,
then the Dynashift or Speedshift indicator lamps
should light.
Note: If, before the validation time of 4 seconds
has passed, the Power Shuttle lever is returned
to:
- neutral, the modifications are ignored.
- Forward or Reverse, the modifications remain
to be carried out from operation 45 on.
H . Power Shuttle error codes

The Autotronic 3 carries out constant checks on the
Power Shuttle function.
The driver is informed of a possible fault in a function by

an autodiagnostic indicator lamp located on the dashboard
and by the sounding of a buzzer.
The use of Wintest (see section 11F03) allows a much

more precise diagnosis.
The error codes are divided into 3 classes according to

their importance. Each class is characterised by the
different functioning of the indicator lamps and buzzer.
Issue 1 May 2002

Fault Error Autotronic 3 Forward / Diagnostic Buzzer Power Shuttle

class code action on the Reverse indicator reset after the
number transmission indicator lamp fault has been
lamp cancelled
Class I 1-2 Out Out Lit and Sounds Stop the engine
remains and wit for
Autotronic 3
standby mode (17
bar pressure
equals 0) (engine
speed equals 0)
Restard the
engine
Class II 7-8-9- Forward or Reverse lit Forward or Flashes Sounds De-clutch

10 - 23* depending on direction Reverse lit rapidly
selected. depending
Out if Power Shuttle is on direction
in neutral selected.
Out if Power
Shuttle is in
neutral
* Non direct
in Neutral
Class III 3 - 4 - 5 - Forward or Reverse Forward or Flashes Stops Place lever in

6 - 15 - 16 depending on direction Reverse slowly neutral
17 - 18 - depending
19 - 20 - on direction
21 - 22 selected.
Issue 1 May 2002

Errors code
Error number
Class displayed by Fault
Wintest
I 1 Short circuit to + 12 V on Forward solenoid valve
I 2 Short circuit to + 12 V on Reverse solenoid valve
II 107 Open circuit on + supply of analog lever
II 108 Open circuit on ground supply of analog lever
II 109 Open circuit on signal coming from analog lever
II 110 Short circuit to + 12 V on analog lever
II 123 Default in lever Reed switches
III 203 Short circuit to ground on Forward solenoid valve
III 204 Short circuit to ground on Reverse solenoid valve
III 205 Open circuit on Forward solenoid valve
III 206 Open circuit on Reverse solenoid valve
III 215 Open circuit or short circuit to ground on clutch pedal potentiometer
III 216 Short circuit to + 5 V on pedal potentiometer
III 217 Open circuit or short circuit to ground on bottom clutch pedal switch (BOC)
III 218 Short circuit to + 12 V on bottom clutch pedal switch (BOC)
III 219 Open circuit or short circuit to ground on top clutch pedal switch (TOC)
III 220 Short circuit to + 12 V on top clutch pedal switch (TOC) integrated in
potentiometer
III 221 Gearbox input speed sensor fault
III 222 Open + 12 V solenoid driver due to BOC and/or lever neutral switches
blocked in closed position
Issue 1 May 2002

Issue 1 May 2002

8200 SERIES TRACTORS Signal
Lever position Switch Signal
voltage (Volts)
Up (de-clutched) Aucun 2,5
Forward + S1 + S2 + S3 4
Forward S1 + S2 3,5
I . Disassembling, reassembling the
Forward - S1 + S2 + S4 3
Power Shuttle lever
Neutral S7 0,5
Parts list 1
Reverse - S5 + S6 + S4 2
(1) Cap
(2) Circlip 2 1KOhm Reverse S5 + S6 1,5
1
(3) Washer
1KOhm Reverse + S5 + S6 + S3 1
(4) Housing S1
(5) Bearing 3 24KOhm 36KOhm S2
10KOhm 2.55KOhm
(6) Upper spindle
(7) Compression spring 4 2.4KOhm
(8) Pin 4 x 28 2KOhm
(9) Magnet support S3

(10) Left torsion spring 5
15,8KOhm
(11) Right torsion spring 2
(12) Sliding part 100KOhm
S7 2KOhm
6 S4
(13) Compression spring 560Ohm
(14) Ferrule 10KOhm 2.55KOhm
(15) Neutral switch 9 S5 2.4KOhm
(16) Printed circuit 1.5KOhm
(17) Rubber shim

8 S6
(18) Bottom cover 24KOhm 34KOhm
(19) M4 x 14 bolt
(20) Washer dia. 4 7 12 1KOhm
3
(21) Water tight cap
(22) Plastic washer 4
10 11 5
(23) Screw 2 x 0.5 6
(24) Lever
(25) Screw HN 4 16 13
(26) Grower washer dia. 4
(27) Bolt CHC H4 x 18
(28) Pin 3 x 15 17 14 1
6 5 4 3 2 1
2
(29) O-ring and washer
3
(30) Knob
18 15 4
Connector functions
6
20
19
Terminal Designation
1 + 5 Volts
28
2 Signal
30 21 3 Ground
4 Normally closed Neutral
22 switch
5 + 12 V input to Neutral switch
29 23
6 Normally open Neutral
switch
25 26 27 24
Fig. 6
Issue 1 May 2002

Issue 1 May 2002

J . Operation of the manoeuvring 0,7/1,2 mm
pedal 1
Manoeuvring pedal assembly (Fig. 7)

(1) Top of clutch switch (TOC)
(2) Bottom of clutch switch (BOC)
10,9
(3) Starter safety switch
2,6/3,6 mm
(4) Pedal pressed adjustment screw 2
(5) Pedal released adjustment screw
- The manoeuvring pedal differs from the clutch pedal

fitted to mechanical gearboxes. It is only used when
manoeuvring in very tight spaces or when hitching an
implement.
- It is not necessary to use this pedal either when 3
engaging a gear from neutral, when changing gears or
when reversing the direction of travel. 4
- The position of the manoeuvring pedal is transmitted to
the DCC by the TOC (1) and by the BOC (2).
B
Adjustment of the potentiometer / TOC
- With the manoeuvring pedal fully pressed, adjust the
position of screw (4) to provide a clearance of 2.6 mm
to 3.6 mm between the head of the screw and the TOC
plunger.
- With the pedal released, act upon screw (5) to provide
a clearance of 0.7 mm to 1.2 mm between screw (4)
and the body of the TOC (Fig. 21). 5
- Tighten the lock nut of the TOC to a torque of 23 - 33 Nm.
- After these adjustments, check the pedal travel. It 0,3/1,0 mm
must be between 130 mm to 150 mm.
BOC adjustment
- Screw the switch so that the end of its threaded cylinder
is recessed 0.3 mm to 1 mm in its support (Fig. 7).
- Tighten the lock nut to a torque of 6 - 9 Nm.
150
130
Fig. 7
Issue 1 May 2002

(46) Hourmeter Designation of connectors

K . Electrical diagram 1 clock hour = 1 hour of hourmeter from reception CD1C : Engine harness / dashboard harness junction
of engine speed signal on CD1M : Engine harness / dashboard harness junction
Parts list (47) Dashboard displays CD2 : Lighting harness / dashboard harness junction
(1) Autotronic 3 (48) Speed signals to lift control harness CD3 : Autotronic 3 harness / dashboard harness junction
(2) Temperature sensor (49) Battery CD4A : Deutsch connector on Autotronic 3 harness side
(3) Engine speed sensor (50) Starter motor CD4T : Deutsch connector on transmission harness side
(4) Forward speed sensor (51) Ignition key switch
(5) Gearbox input speed sensor (52) Power take off brake switch
(6) Power take off speed sensor (53) Power take off brake solenoid valve
(7) Hare / Tortoise range switch (54) Gear lever neutral sensor Colour codes
(8) Low-pressure pressure switch (17 bar green dot) (55) Parking brake lever switch
B : Black
(9) Not used (56) Parking brake indicator lamp
BL : Blue
(10) Left stop light switch (57) Temperature switch
BE : Beige
(11) Right stop light switch (58) 15 micron filter clogging switch
G : Grey
(12) 4WD switch (connected to rep. 15) (59) 150 micron strainer clogging switch (open centre)
J : Yellow
(13) Eco power take off switch 5 bar booster pressure switch (closed centre)
M : Brown
(14) Power take off stop (60) Filter clogging or low pressure switch
N : Black
(15) Differential lock switch (connected to rep. 12) (61) 540 or 1000 rpm power take off dashboard display
O : Orange
(16) Creeper unit switch selector (fitted if (62) and (63) are absent)
R : Red
(17) Power take off switch (62) 540 or 1000 rpm power take off
RO : Pink
(18) Analog shuttle and Dynashift or SpeedShift switch and dashboard display
V : Green
(depending on options) (63) switch (fitted with selector lever in cab)
Vi : Violet
(19) Top of clutch switch (TOC) (connected to rep. 22) (64) CAN connector to lift control, 16-way plug
(20) Bottom of clutch switch (BOC) (65) Alternator
C : Light
(21) Engine start safety switch (66) Starter relay
F : Dark
(22) Clutch pedal potentiometer (connected to rep. 19) (67) Supply switch (12) and (15)
(23) Proportional PTO shunt (68) Dynashift armrest lever (North American version
Note: The Autotronic 3 has two components :
(24) Power shuttle buzzer only)
- J1 : black connector
(25) Power take off solenoid valve (69) Ignition switch
- J2 : red connector
(26) Differential lock solenoid valve (70) Lighting switch
Each connector has 36 pins.
(27) Reverse solenoid valve (71) Throttle pedal switch
(28) 4 WD solenoid valve (72) Autodrive or Speed Matching switch (according
(29) Hare/Tortoise solenoid valve to option)
(30) EV1 Dynashift solenoid valve (73) Dasboard power supply
(31) EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
(32) Forward solenoid valve
(33) Reverse indicator lamp
(34) Forward indicator lamp
(35) Ratio A indicator lamp
(36) Ratio B indicator lamp
(37) Ratio C indicator lamp
(38) Ratio D indicator lamp
(39) 4 WD indicator lamp
(40) Creeper unit indicator lamp
(41) Low pressure indicator lamp
(42) Self-diagnostics indicator lamp
(43) Differential lock indicator lamp
(44) Hare range indicator lamp
(45) 540 or 1000 rpm power take off indicator lamp
Issue 1 May 2002

52
CD4A
CD4T
23
32 31 30 29 28 27 26 25 53
Fig. 8
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Sensor / Switch on gearbox
51
1
CD4A
CD4T CD3
2 8 7 5 4 3 6
Fig. 9
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Parking brake and gearbox neutral safety
CD4T CD4A 51
54
56
55
CD3
Hydraulic circuit information

CD4T CD4A
60
CD3
57
58 59
Fig. 10
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Dashboard indicator lamp
62 63
61
45 CD3
45 1000
44
43
42
41
40
39
38
R
37
36
35
34
33
24
CD3
Fig. 11
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Dashboard information
R
46
CD3
47
48
Power supply
51
73
CD3
Fig. 12
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

CAN V P09
M P10
B P08
J1-34
J1-36
EHR-C
64
J1-35
Clutch pedal potentiometer
J1-01
J1-04
J1-03
BL.F P07 P07 BL.F Cnc-B

M P03 P03 M Cnc-C 22
R P24 P24 R Cnc-A
Reverse shuttle lever potentiometer

J1-03
J1-01
J1-02
P03 P03 M Cnc-3

P25 P25 B Cnc-2 18
P24 P24 R Cnc-1
Fig. 13
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Lever neutral information / BOC / Ignition switch
20
73
51
CD3
Starting
N CD1C
66
CD1M
50
69
51
49
65 Fig. 14
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Cab switch
12 / 15
70
51
61
13
16
CD3
17
Fig. 15
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Dynashift Automatic control
68
51
71
CD3
Brake information
51
11
10
CD3 Fig. 16
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

TOC information
51
N 19
CD3
PTO stop information

N
CD3 51
CD 2
14 Fig. 17
Issue 1 May 2002


B : Black
BL : Blue
BE : Beige
G : Grey
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
V : Green
Vi : Violet
C : Light
F : Dark
Issue 1 May 2002

Dynashift control for mechanical reverse shuttle
F7
51
74
D C5
J1
N C
B
J1-16J1-15
J1-14
N P26 P26 N
M P27 P27 M
R P28 P28 R
CD3
Fig. 18
Issue 1 May 2002

DCC / TC - Description 11B01.1
11 B01 Description and operation
CONTENTS
A. Description ___________________________________ 3
B. DCC dashboard ________________________________ 5
C. Status of DCC switches ________________________ 14
D. Characteristics of DCC sensor input signals _____ 18
E. Transmission Controller (TC) ___________________ 21
F. Operation of solenoid valves and test procedures 35
G. Input signals to TC sensors / switches __________ 36
H. Operation of the manoeuvring pedal ____________ 41
I. Operation of the armrest gear selector switch ___ 42
J. Steering wheel gear shift lever _________________ 43
K. Use of the backup harness _____________________ 45
L. Location of sensors ____________________________ 46
Issue 1 May 2001

11B01.2 DCC / TC - Description
11 12 13
10
9 14
10 15 15
8
5 20 16
7 0 25
KPH
RPM x 100
17
% RPM
MPH
1/MIN
6
18
GNO SL IP PTO ENG ENG FIELD
1
5 SPO % RPM RPM HRS AREA
19
! 2 P
4 20
1 21
22
3 23
24
2 38 39 40 25
37 26
A D
36 27
35 B E 28
34 29
C F
33 30
32 31
Fig. 1
Issue 1 May 2001

Input signals to the TC

A . Description (25) Engine speed
The transmission control circuit is made up of three main (26) Shaft speed / power take off clutch
components. A digital dashboard display (Display Cab (27) Forward speed
Controller, DCC), a transmission controller (Transmis- (28) Transmission temperature
sion Controller, TC) and a CAN network (Communica- (29) Gearbox hydraulic pressure
tions Area Network). These components are connected (30) Lubricating pressure
via harnesses, switches, potentiometers, sensors and (31) Hydraulic pressure (17 bar)
solenoid valves. (32) Hydraulic filter
(33) Calibration speed
The transmission electronic control circuit (34) Park Lock switch
35) Creeper unit switch
(Fig. 1)
(1) DCC
(2) TC
TC output signals
(3) CAN
(36) Gearbox solenoid valves
(37) 4WD solenoid valve
(38) Differential lock solenoid valve
DCC input signals (39) Power take off / PTO brake solenoid valves
(4) Manoeuvring pedal (40) Park Lock solenoid valve
(5) Gear shift lever
(6) Turbocharging sensor
(7) Membrane key switches
(8) Parking brake
(9) Front axle switch (4WD)
(10) Differential lock switch
(11) Power take off switch
(12) Fuel gauge
(13) Coolant liquid sensors
(14) Brake switches
(15) Engine oil pressure
(16) Radar
(17) Instrument status
(18) Headlights
Output signals from the DCC to the operator

(19) Liquid crystal display
(20) Signal lamps
(21) Alarm warning
Other CAN network connections

(22) Diagnostic connector
(23) Electronic linkage control (ELC)
(24) Datatronic
Issue 1 May 2001


The DCC and TC are two separate micro controllers that The CAN network provides a highly efficient means of
each contain sophisticated software designed to handle communication between a number of components con-
the functions of the tractor’s transmission and the Full trolled by the micro controller, these include the DCC, TC
Powershift gearbox. Both of them can be programmed and ELS (electronic linkage), Datatronic and diagnostics
and parameterised by qualified personnel in order to socket. These components are all linked by cable having
adapt them to different tractors, depending on the type of two lead wires and a ground and through which all
the transmission and the specific operating features communications are received or dispatched at a speed
required. of 250 kbits / second. The external diagnostics socket
located in the cab provides for connection to a PC or
The DCC and TC both contain a self-diagnostic function similar device in order to program, parameterise and / or
intended to warn the operator when the circuit of one of test the operation of the various elements in order to
the components is defective or disconnected. The diag- diagnose and resolve breakdowns.
nostic codes guide qualified personnel when trouble-
shooting the various control components. These codes
are displayed on the DCC and may, depending on the
seriousness of the breakdown, place the transmission in
neutral or allow it to continue functioning. Some codes
are stored in memory and can be later displayed by
qualified personnel to troubleshoot intermittent prob-
lems.
The DCC controls the functions of the tractor and sup-

plies information to the operator via a digital display,
instruments and analog warning lamps. It also commu-
nicates with the TC via the CAN network to provide it with
electric signals from the functions activated by the
operator, such as manoeuvring pedal or gear shift lever
positions, or the status of the parking brake, power take
off, differential lock or 4WD switch, as well as the
information such as turbocharging pressure and engine
torque.
The TC receives input signals generated by the opera-

tor’s actions and from signals coming from the DCC
sensors via the CAN network. It likewise receives direct
input signals from other sensors, for parameters such as
engine speed, transmission output speed, power take off
speed, transmission temperature, as well as information
from lubrication and transmission pressure switches.
The status of the sensors and switches is transmitted to
the DCC via the CAN network and is used by the TC to
activate the transmission solenoid valves, 4WD, power
take off, Park Lock and differential lock.
Issue 1 May 2001

6 2 6
1 3
10 15
5 20
0 25
RPM x 100
KPH
% RPM
MPH
1/MIN
5 4
1
SPO % RPM RPM HRS AREA
SELECT WIDTH SET

! 2 P
6 6
Fig. 2
The DCC receives and displays the tractor functions and

B . DCC dashboard supplies this information to the operator. It also receives
information concerning turbocharging pressure, manoeu-
Dashboard (Fig. 2)
vring pedal position, gear shift lever and parking brake
(1) Gauges
position, and status information of the 4WD, power take
(2) Liquid crystal display
off and differential lock switches. These sensor input
(3) Tachometer
signals and certain other switch signals are transmitted
(4) Membrane keys
to the TC via the CAN network.
(5) Signal lamps
(6) Fixing screws
There are six connectors at the rear of the DCC, these are
marked with the letters A, B, C, D, E and F. Each pin of
Only those functions linked to transmission control are
the different connectors are further marked with the
treated in this section. For further information concerning
letters A to K. The input / output signals of the connectors
lighting, engine and cab, etc., see section 10A01 or
are shown overleaf.
10A02, depending on the version.
The DCC is held by four screws on the steering column

assembly. Only the bulbs used by the signal lamps and
backlighting may be replaced. If the DCC or one of its
components fails, it must be completely replaced by
another unit. In the case of such replacement ,the new
unit must then be programmed and parameterised, see
section 11F04.
Issue 2 May 2002


DCC connectors (Fig. 3) and pin layout (Fig.
4)
(1) Connector "A"
G
H
H
K
K
J
J
F
F
(2) Connector "B" F
D
C
C
B
E
K
E
G
A
(3) Connector "C" C D J
D
B
H
C H
B E
J
C
(4) Connector "D"

K
B
A 3 4 D
G
F
E
(5) Connector "E" F

K
(6) Connector "F"
G
H
E
D 2 5 A
B
J
C H
C
A F
J
B G
K D
A F
E
1 6
Fig. 3
A K
B J
C H
D G
E F
Fig. 4
Issue 2 May 2002

Connector A Connector C Connector E

Pin Description Pin Description Pin Description
A Battery ground A Not used A 12 V differential lock switch input
B + 12 V after contact B Not used B 12V 4WD switch momentary input
C Signal to coolant level sensor (depending on options) C 12 V left brake switch input C 12 V parking brake switch input
D Turbocharging pressure sensor ground D 12 V right brake switch input D Buzzer output signal, 12 V
E Turbocharging pressure sensor + 5 V supply E Input signal to fuel level sensor, 0 V - 12 V E Not used
F Turbocharging pressure sensor input signal 0.8 V - 4.2 V F Input signal to coolant liquid temperature, 0 V - 12 V F Not used
G Not used G Rear power take off switch input, 12 V G Not used
H Not used H Rear power take off brake switch input, 12 V H Input to N.C. terminal of steering wheel Neutral lever switch
J Not used J Wing-mounted power take off emergency stop switch input, 12 V J Input to N.O. terminal of steering wheel Neutral lever switch
K + 12 V battery K Not used K Input to headlight selector, 12 V
Connector D Connector F
Connector B Pin Description Pin Description
Pin Description A CAN signal (Hi) A 12 V main beam switch input
A 5 V supply to clutch potentiometer B CAN network ground B 12 V left direction indicator switch input
B Input signal to clutch potentiometer, 0.8 V - 4.2 V C Input to N.O. terminal of armrest Neutral switch, 12 V C 12 V right direction indicator switch input
C 5 V supply to armrest speed Up / Down potentiometer D Input to top-of-clutch switch (TOC) 12 V D 12 V 1st trailer switch input V
D 5 V supply to steering wheel lever potentiometer E Radar input signal E 12 V 2nd trailer switch input
E Input signal to steering wheel gear shift lever potentiometer F Input to N.O. terminal of bottom-of-clutch switch (BOC) 12 V F open / grounded air filter switch input
(0.8 V - 4.2 V) G Input to N.C. terminal of bottom-of-clutch switch (BOC) 12 V G Not used
F Ground for steering wheel gear shift lever potentiometer H Not used H Not used
G Pressure switch (0 V - 12 V) J Input to N.C. terminal of armrest Neutral switch, 12 V J 12 V linkage position switch input
H Input signal to armrest speed Up / Down potentiometer (0.8 V K CAN signal (Low) K 12 V linkage position switch input
- 4.2 V)
J Ground for armrest speed Up / Down potentiometer
K Ground for top-of-clutch (TOC) potentiometer
Note :
- N.O. = Normally open
- N.C. = Normally closed
Issue 1 May 2001


DCC wiring diagram (Fig. 5) (93) Connector C5 - Dashboard connector Dashboard signal lamps Colour code
(1) Battery A : + 12 V Park Lock supply (47) Left direction indicator (green lamp) B = White
(2) Electronic linkage supply B : + 12 V BOC and neutral switch supply (48) Right direction indicator (green lamp) BE = Beige
(3) Steering wheel Neutral switch C : + 12 V after contact supply (49) Air filter clogging (yellow lamp) BL = Blue
(4) To alternator D : Ground (50) Rear power take off (yellow lamp) G = Grey
(5) Starter E : CAN (High) (53) Transmission oil pressure linked to gearbox 17-bar J = Yellow
(6) Cab relay F : CAN (Low) pressure switch (red lamp) M = Brown
(7) To cab harness G : Creeper unit control (54) Warning (red lamp) N = Black
(8) Electronic linkage - Supply H : Not used (55) Differential lock (yellow lamp) R = Red
(9) Armrest Neutral switch (94) Transmission oil temperature sensor (56) First trailer direction indicator (green lamp) Ro = Pink
(10) Park Lock switch (95) Gearbox oil 17-bar pressure switch (57) Second trailer direction indicator (green lamp) S = Salmon
(11) Not used (96) Rear axle 17 bar pressure switch (58) Battery charge lamp (red lamp) V = Green
(12) Linkage harness connector (97) Booster pressure 5-bar pressure switch (59) Engine oil pressure (red lamp) VI = Violet
(13) Power take off emergency stop switch (on rear (98) 15 micron filter clogging switch (61) Radiator water level (red lamp, 8270 - 8280 only)
wing) (99) Power take off clutch output speed sensor (62) Lubrication pressure linked to 5 bar booster pres- C = Light
(14) Creeper unit switch (100) Forward speed sensor (gearbox output) sure switch F = Dark
(15) 4WD and differential lock switch (101) Engine speed sensor (gearbox input) (63) Hydraulic pressure linked to rear axle 17 bar pres-
(16) Armrest lighting (102) Power take off clutch speed sensor sure switch (red lamp) emb. = End
(17) Speeds Up / Down armrest potentiometer (103) Intermediate gearbox speed sensor (used during (64) Hydraulic filter linked to 15-micron filter clogging
(18) To water temperature sensor calibration) pressure switch (yellow lamp)
(19) Rear power take off switch (104) Connection to be modified during calibration: (65) Gearbox oil temperature (red lamp)
(20) Engine oil pressure switch - normal position: power take off speed sensor (66) Main beam (blue lamp)
(21) Turbocharging pressure sensor (brown / brown wires) (67) Parking brake (red lamp)
(22) DCC dashboard - calibration position: intermediate speed sensor (68) 4WD (green lamp)
(23) Radiator water level sensor (8270 - 8280) (brown / red wires)
(24) Fuel gauge
(25) Lighting signal lamps
(26) Air filter vacuum sensor Solenoid valves
(27) Lighting switch
(79) Clutch solenoid valve «A»
(28) To main beam / dipped beam toggle
(80) Clutch solenoid valve “C”
(29) To connector C60
(81) Clutch solenoid valve “R”
(30) To dashboard switch
(82) Clutch solenoid valve “2”
(31) To work lights relay
(83) Clutch solenoid valve “1”
(32) To connector C2
(84) Clutch solenoid valve “M”
(33) Buzzer
(85) Clutch solenoid valve “L”
- continuous: parking brake on
(86) Clutch solenoid valve “H”
- intermittent: warning / fault
(87) 4WD clutch solenoid valve (mechanically engaged)
(34) Parking brake switch
(88) Clutch solenoid valve “B”
(35) CAN network plug
(89) “Power take off” clutch solenoid valve
(36) Top of clutch switch (TOC) and potentiometer
(90) “Differential lock” clutch solenoid valve
(37) Forward / Reverse potentiometer on steering wheel
(91) “Rear power take off” clutch solenoid valve
(38) Safety switch
(92) “Park Lock” clutch solenoid valve (mechanically
(39) Starter switch
engaged)
(40) Not used
(41) Right brake switch
(42) Left brake switch
(43) BOC clutch switch
(44) To stop lights
(45) Time delay relay (if not fitted is replaced by 15 A
fuse)
(46) Electronic transmission control unit (TC)
Issue 1 May 2001

10
DCC / TC - Description 11B01.9 16
9
14
15 17
5
2
18
4
6 11
1
7 19
3 47
12 20 48
13 49
21 50
53
54
8
23 55
36 56
44 41 57
37
58
59
45 42
61
35 24 22 62
63
43 64
34 65
66
67
25
68
33
26
38
31
30
29
40 39
28
27
32
Fig. 5
46
Issue 1 May 2001

Issue 1 May 2001

DCC signal lamps (Fig. 6)

(1) Engine oil pressure
(2) Air filter clogging
(3) Gearbox 17 bar pressure 1 2 3 4 5 6
(4) Rear axle 17 bar pressure
(5) 4WD
(6) Differential lock
(7) Battery
1
(8) Coolant liquid level
(9) 5 bar booster pressure ! 2 P
(10) Rear axle hydraulic filter clogging
(11) Hydraulic oil temperature
(12) Main warning signal lamp
(13) Power take off
(14) Parking brake / Park Lock 7 8 9 10 11 12 13 14
The DCC activates all the signal lamps and display Fig. 6
segments for three seconds after the ignition switch is
activated. Once ignition switch contact is made, before
the engine is started, the hourmeter displays total engine
hours until the engine is started. When the BOC switch
is activated, the digital display shows the forward speed
and the pre-selected speed range. The DCC must
receive a signal from the bottom-of-clutch pedal switch
(BOC) for at least 1 second before it will activate the
other tractor functions.
If the clutch pedal has not been pressed and the ignition
is turned on, the DCC displays the versions of the
program. The DCC program version is displayed in front
of the TC version. Example: diSP then 2.14 then trAN
then 2.14. In order to drive the tractor, press the clutch
pedal to remove the programmes versions display.
Issue 2 May 2002


Liquid crystal display (Fig. 7)
3
(1) Ratio selected
(2) Creeper unit signal lamp
(3) Pre-selected ratios A 4
(4) Automatic 4WD signal lamp 2
(5) Direction of movement:
F : Forward
R : Reverse 5
N : Neutral
P : Park Lock
(6) Display of DCC / TC information (program versions,
error codes) 1 6
(7) Display of:
- forward speed
- wheel slippage 7 KPH
RPM
- power take off speed % MPH
1/MIN
- engine speed Fig. 7
- total engine hours
- worked area
- diagnostics functions
The DCC digital display comprises two parts. The upper

part displays the data relating to the changing of speeds,
error data / parameters / diagnostics, 4WD and creeper
unit status.
The lower part displays the engine speed, the power take
off, the percentage of wheel slip, the forward speed, total
engine hours, the worked area and error data / diagnos-
tics / parameters. The digital display cannot be repaired
and must be replaced as an entire unit along with the
DCC.
Issue 2 May 2002

DCC dials and gauges (Fig. 8)

(1) Fuel gauge
(2) Engine oil pressure 3 1 2 4
(3) Engine temperature
(4) Tachometer
The DCC has four analog dials displaying engine oil

A
pressure, coolant liquid temperature, fuel level and en-
10 15
gine speed. These dials cannot be repaired separately 5 20
and the whole DCC unit must be replaced. See section 0 25
11B02 for the checking of dial functions. KPH
% RPM
MPH
RPM x 100
L/MIN
Warning buzzer
SELECT WIDTH SET

! 2 P
The DCC contains a warning buzzer that emits a sound

whenever certain error conditions are detected. The
buzzer operates under the following circumstances: Fig. 8
- engine temperature greater than 105°C
- engine pressure less than 1 bar (15 psi) when the engine
speed is less than 1000 rpm
- engine oil pressure less than 2.1 bar when the engine
speed is greater than 1000 rpm
- parking brake on when the transmission is in drive
- low engine coolant level
- transmission pressure lower than 9.1 bar
- hydraulic temperature greater than 105°C
The warning signal lamp lights whenever the above

described conditions are detected, or if the battery
voltage drops below 11 V or exceeds 16,5 V, or if the
clutch pedal is pressed while the handbrake is on.
Issue 2 May 2002


The bottom of clutch switch (BOC)
C . Status of DCC switches There are two bottom of clutch switches, both of the
The DCC receives the status of the following switches: normally open type (as long as the clutch pedal is not fully
pressed). They close when the clutch pedal is fully
The differential lock switch is a momentary pressed.
contact type, normally open switch. The DCC maintains
the differential locked until the operator places the switch The upper BOC switch is linked to the DCC and has two
in the closed position. The differential lock solenoid valve contacts:
is then activated by the TC via a signal emitted by the - the first is of the normally open type and closes when
DCC. When the differential lock is activated, the corre- the clutch pedal is pressed. It informs the DCC of the
sponding signal lamp on the DCC is lit. fully de-clutched position of the pedal.
- the second is of the normally closed type and opens
when the clutch pedal is pressed. It permits the
The 4WD switch is a momentary contact type,
gearbox solenoid valves to be supplied with current.
normally open switch. The DCC maintains the status of
the 4WD until the operator places the switch in the closed
The lower switch (safety switch) forms part of the starter
position. The 4WD solenoid valve is then activated by the
electrical circuit.
TC via a signal emitted by the DCC that indicates the
status of the 4WD. When 4WD is engaged, the 4WD
solenoid valve is no longer supplied with power and the
4WD signal lamp on the DCC is lit.
The left and right-hand side brake switches

are normally open type switches as long as the brake
pedals are up. Any pressure exerted on one or other of the
pedals closes the relevant set of contacts. If the differ-
ential lock is activated, any pressure on either brake
switches leads to a de-activation of the differential lock.
The top of clutch switch (TOC) is integrated into

the clutch pedal potentiometer. It is a normally open
switch as long as the clutch pedal is pressed. It closes
when the clutch pedal is fully released (clutch in).
Issue 2 May 2002

The Neutral position switches

Two switches are connected in series: Fig. 8A
1 2
- the first is located in the gear shift lever armrest
assembly NO NF NO NF
- the second is located in the steering wheel control
lever. C C
TC : B/B
DCC : D/J
Neutral switch connections (Fig. 8A) DCC : D/C
(1) Steering wheel Neutral switch
(2) Armrest Neutral lever switch DCC : E/H
DCC : D/G
The N.O. position of the switches corresponds to the DCC : E/J

Neutral position of the levers.
BOC
The N.C. position of the switches corresponds to the Non
Neutral position of the levers. + 12 V
NO NF
The supply to the Neutral switches is effected via the

upper BOC switch. The Neutral position of the steering
wheel lever has priority over the armrest lever.
With the clutch pedal released, the N.C. switch of BOC

must be closed.
The inputs to the DCC of the Neutral switches in relation

to their position are:
- armrest lever and steering wheel lever in Neutral
. 12 V input to DCC E/J
- armrest lever in Neutral and steering wheel lever in Non

Neutral:
. 12 V input to DCC E/H
DCC D/C
- armrest lever in Non Neutral and steering wheel lever in

Neutral:
. 12 V input to DCC E/J
- armrest lever in Non Neutral and steering wheel lever in

Non Neutral:
. 12 V input to DCCE/H
DCC D/J
TC B/B
Note: When the clutch pedal is fully pressed (disen-

gaged position), the power supply to the Neutral
switches is cut and the DCC D/G input is 0 V.
Issue 1 May 2001


The Park Lock switch is located at the rear of the The air filter clogging switch is located in the
Park Lock lever. This switch is activated when the lever engine air intake pipe between the air filter and the inlet
is placed in the brake engaged position. manifold. It is a normally closed type switch that opens
Important: The tractor may be in drive and move when air filter clogging creates a vacuum of 635 mm of
when the Park Lock is engaged. In such an event, the water, this lights the air filter clogging signal lamp.
Park Lock signal lamp lights and the warning buzzer
sounds. Do not operate the tractor with the Park
Lock engaged.
The power take off switch has three positions

(brake, neutral and on) and is located in the cab on the
right-hand side console:
- in the On position, the power take off solenoid valve is
supplied with current from the TC via a signal from the
DCC.
- in the Brake position, electrical current is supplied to the
power take off brake solenoid valve from the TC via a
signal from the DCC.
- in the Neutral position, the switch circuit of the power
take off to the DCC is open and the TC supplies neither
the power take off nor the power take off brake. When
the power take off is activated, the DCC lights the
corresponding signal lamp.
The power take off emergency stop switch

is located on the rear wings.
It is normally closed and supplies the C/J input to the
DCC with 12 V.
When the switch is opened, the C/J input to the DCC
drops to 0 V, the power take off solenoid valve is no
longer supplied with current and the signal lamp flashes.
To re-engage the power take off, first place the power
take off switch in the cab to the Neutral position, then to
On.
The MoveUp / MoveDown switch indicates to

the DCC whether or not the implement is in the Work
position. This signal is used to calculate the worked area.
The switch is closed when the implement is raised and
opens when the implement is in the Work position.
Issue 1 May 2001

The DCC is equipped with six membrane keys. Three of

them are used by the operator to select the different
display modes and the three others allow qualified 1 2 3
personnel to carry out calibration and diagnostics opera-
tions. GNO SL IP PTO ENG ENG FIELD

Membrane key pad (Fig. 9) SELECT WIDTH SET
The six membrane keys are used to select the following:
Key (1)
- Select forward speed or wheel slippage ratio
- Select a number in order to modify it
- Enter the radar forward speed calibration value
Key (2)
- Select the PTO speed or engine speed 4 5 6
- Save a modified constant Fig. 9
- Confirm the tool width parameter
Keys (4) and (5)
Key (3)
- Enter level 1 calibration
- Select total engine hours or worked area
. transmission calibration
- Modify a selected number
. turbocharging pressure calibration
- Delete the worked area data
Key (4) Keys (5) and (6)

- Select the different calibration values available - Enter level 2 calibration
. gear shift lever calibration
Key (5) . display DCC / TC constants
- Display the current calibration value . delete saved error codes
- Select Diagnostics mode
Keys (4) and (6)
Key (6) - Enter level 3 calibration
- Decrement one level in the current calculator value . modify DCC / TC constants.
- Exit the calibration level
Issue 1 May 2001


The engine oil pressure sensor is of the variable
D . Characteristics of DCC sensor resistance type located in the engine lubricating channel.
input signals The sensor supplies the TC with the information neces-
sary for the functioning of the pressure gauge and oil
The turbocharging pressure sensor is located pressure light. The values shown in the table below allow
behind the engine, on the left-hand side of the tractor. It the sensor to be checked for correct operation.
detects pressure via a tube connected to the engine inlet
manifold. Faults with the pressure sensor can be identi-
fied using the turbocharging pressure diagnostics func-
Oil pressure Resistance Ω
tion.
0 10 Ω ± 3
The turbocharging pressure sensor can be checked by
injecting controlled compressed air (not exceeding 1.7 1 bar (15 psi) 47 Ω ± 4
bar) into the sensor tube. 3 bar (45 psi) 116.5 Ω ± 5
5 bar (75 psi) 183 Ω ± 7
In diagnostics mode, the DCC displays the pressure
measured by the sensor.
There are 2 fuel level sensors, one in the main tank and If the engine oil pressure is less than 1 bar when the
one in the auxiliary tank. Once they have been removed engine speed is less than 1000 rpm, or less than 2 bar
from the tanks the sensors can be checked using a digital when the engine speed is greater than 1000 rpm, the
multimeter. The values shown in the table below allow engine oil pressure lamp and fault warning lamp light and
checking of the accuracy of the sensors. the buzzer sounds.
Two tanks
Upper tank Lower tank

sensor sensor
Resistance in position Resistance in position

High Low High Low
1-16 Ω 220-240 Ω 1-16 Ω 110-130 Ω
One tank only
Top resistance Bottom resistance
1-16 Ω 340-360 Ω
Also check that continuity is maintained throughout the

full travel of the sensors.
Issue 1 May 2001

The right-hand side speed lever On the largest tractors, the coolant liquid level sensor is
potentiometer is located in the armrest. It controls mounted on the expansion tank. The switch opens when
the changing up and changing down of the ratios. Its the coolant liquid temperature drops below the recom-
mended level and closes when the level is sufficient. If
resistance varies between 5.40 Ω and 3.70 Ω from
the coolant liquid level drops below the recommended
terminal E and G of the black connector, 10 wires, level, the buzzer is sounded and both the coolant liquid
located in the armrest. temperature signal lamp and the warning signal lamp
light.
The steering wheel speed lever integrates a

series of resistances that allow the DCC input voltage to
vary in order to obtain Neutral, Forward or Reverse and
changing Up or Down through the engaged ratios.
The TOC comprises a top of clutch potentiometer and

a switch integrated into the same component. A pin in
contact with the clutch pedal indicates its position to the
DCC.
The resistance of the potentiometer between terminals
1 and 3 is around 5 kΩ.
The resistance between terminals 1 and 2 of the sensor
range from 3 kΩ to 8 kΩ depending on the movement
of the pedal.
The engine temperature sensor is a variable

resistance sensor located near the temperature switch
unit or in the upper front part of the cylinder head. The
sensor provides the DCC with the necessary information
for the gauge and the engine temperature signal lamp.
The values shown in the table below enable the sensor
to be checked.
Temperature Resistance Ω
25° C 282 Ω ± 5 %
100° C 180 Ω ± 2.5 %
125° C 89 Ω ± 3 %
When the engine temperature reaches 105 °C (221 °F),

the warning signal lamp lights and the buzzer sounds.
Issue 1 May 2001


Turbocharger check
The DCC controls and handles the turbocharging pres-
sure inputs in order to calculate the degree of
turbocharging. The turbocharging pressure is detected by
the relevant sensor mounted on the engine inlet mani-
fold. The DCC uses the signal from the sensor along with
engine speed to determine the engine charging, this is
based on a three dimensional torque table stored in
memory via the DCC program.
Each type of engine has different turbo charging charac-
teristics. It is therefore essential that calibration of the
engine and turbocharger parameters are correctly carried
out in order to guarantee a continuous quality of gear
shifting. For parameterisation and calibration procedures,
see section 11B02.
Adaptation to the forward speed

To limit clutch wear and avoid major gear changes during
declutching operations or during transitions to neutral or
a re-taking up of the drive, the DCC automatically
changes ratios, under certain conditions, so that the
ratios continuously correspond to the forward speed.
The highest ratio that can be selected from neutral when
the tractor is stopped is 13 F (13th forward) or 5 R (5th
reverse). In such cases where the tractor is actually
moving while in neutral, it is recommended that the ratio
most suited to the forward speed be selected.
When the 13 F (13th forward) to 18 F (18th forward) ratios
are engaged and the gear shift lever is in neutral, the DCC
checks the transmission input and output shafts via the
TC and determines the gear ratio that corresponds best
to the current output speed of the transmission. This ratio
then becomes the current ratio so that when the gear
shift lever is placed in the forward position, the forward
speed changes very little. If the forward speed of the
tractor falls until it corresponds to ratio lower than 13 F,
this lower ratio becomes the current one.
Issue 1 May 2001

E . Transmission Controller (TC)

Via the CAN network, the DCC transmits to the TC the
input signals from sensors and the operator’s com-
mands. It also directly receives the following informa-
G
H
H
K
K
J
J
F
F
tion:
D
C
C
B
E
- engine speed (gearbox input) A D
- forward speed (gearbox output)
F E A K
- power take off clutch output speed or calibration speed G D B J
- transmission oil temperature

H
J
C
B
B E C
D
H
G
K A E F
- 15 micron filter clogging pressure switch status (on rear
axle)
- booster pressure 5 bar pressure switch status C
A
C
B
E
- rear axle 17 bar oil pressure switch status
G
H
K
F
J
- gearbox 17 bar oil pressure switch status
- Park Lock switch position (on rear axle)
Fig. 10
The status of these switches and sensors it transmitted
to the DCC via the CAN network and used by the TC to
activate the gearbox, 4WD, power take off, Park Lock
and differential lock solenoid valves. The TC compen-
sates for changes in hydraulic temperature, engine load
and engine speed in order to guarantee gear shifting of
continuous quality. A K
The TC is mounted on a silent block, on the right-hand
side of the chassis below the cab. The TC can be
B J
programmed and parameterised using Wintest (see
section 11F04). If the TC has been replaced, it must be C H
calibrated according to the procedures described in
11B02. D G
E F
TC (Fig. 10) and TC connector (Fig. 11)
The TC is linked to the switches, sensors, solenoid Fig. 11
valves and DCC by 5 connectors. The five TC connectors
are marked A, B, C, D and E. The TC has a sixth
connection port F that is blocked off and not used. Each
of the pins of the connectors is marked from A through
to K. The inputs / outputs of the connectors are as
follows:
Issue 1 May 2001

Issue 1 May 2001

Description of connectors
Connector A Connector C Connector E
Pin Description Pin Description Pin Description
A Solenoid valve C (+ 12 V) supply A Solenoid valve C ( - ) ground return A Rear axle 17 bar pressure
B Solenoid valve A (+ 12 V) supply B Solenoid valve A ( - ) ground return B Gearbox 17 bar pressure
C Solenoid valve B (+ 12 V) supply C Solenoid valve B ( - ) ground return C Creeper unit switch input
D Differential lock solenoid valve (+ 12 V) supply D Solenoid valve 1 ( - ) ground return D Input to calibration or rear PTO clutch output
E Solenoid valve H (+ 12 V) supply E Solenoid valve H ( - ) ground return E Engine speed input
F Solenoid valve L (+ 12 V) supply F Solenoid valve L ( - ) ground return F Forward speed input
G Solenoid valve M (+ 12 V) supply G Solenoid valve M ( - )ground return G Not used
H Solenoid valve 1 (+ 12 V) supply H Solenoid valve 2 ( - ) ground return H Speed sensors common ground
J Solenoid valve 2 (+ 12 V) supply J Solenoid valve R ( - ) ground return J 15 micron filter clogging pressure switch on rear axle input
K Solenoid valve R (+ 12 V) supply K Differential solenoid valve ( - ) ground return K 5 bar booster pressure switch input
Connector B Connector D
Pin Description Pin Description
A Ground ( - ) A CAN signal (Hi)
B + 12 V Neutral and BOC switches return supply B Not used
C Park Lock solenoid valve (+ 12 V) supply C Not used
D Rear power take off solenoid valve ( - ) ground return D Not used
E Park Lock solenoid valve ( - ) ground return E Not used
F Power take off brake solenoid valve (+ 12 V) supply F Park Lock switch input on rear axle
G Rear power take off solenoid valve (+ 12 V) supply G Transmission temperature and CAN (ground)
H 4WD solenoid valve (+ 12 V) supply H Not used
J + after contact J Transmission temperature input signal
K Ground ( - ) K CAN signal (Low)
Issue 1 May 2001


Parts list (93) Connector C5 – Dashboard connector Dashboard signal lamps Colour code
(1) Battery A : + 12 V Park Lock supply (47) Left direction indicator (green lamp) B = White
(2) Electronic linkage supply B : + 12 V BOC and neutral switch supply (48) Right direction indicator (green lamp) BE = Beige
(3) Steering wheel Neutral switch C : + 12 V after contact supply (49) Air filter clogging (yellow lamp) BL = Blue
(4) To alternator D : Ground (50) Rear power take off (yellow lamp) G = Grey
(5) Starter E : CAN (High) (53) Transmission oil pressure linked to gearbox 17 bar J = Yellow
(6) Cab relay F : CAN (Low) pressure switch (red lamp) M = Brown
(7) To cab harness G : Creeper unit control (54) Warning (red lamp) N = Black
(8) Electronic linkage - Supply H : Not used (55) Differential lock (yellow lamp) R = Red
(9) Armrest Neutral switch (94) Transmission oil temperature sensor (56) First trailer direction indicator (green lamp) Ro = Pink
(10) Park Lock switch (95) Gearbox oil 17-bar pressure switch (57) Second trailer direction indicator (green lamp) S = Salmon
(11) Not used (96) Rear axle 17 bar pressure switch (58) Battery charge lamp (red lamp) V = Green
(12) Linkage harness connector (97) Booster pressure 5-bar pressure switch (59) Engine oil pressure (red lamp) VI = Violet
(13) Power take off emergency stop switch (on rear (98) 15 micron filter clogging switch (61) Radiator water level (red lamp, 8270 - 8280 only)
wing) (99) Power take off clutch output speed sensor (62) Lubricating pressure linked to 5 bar booster pres- C = Light
(14) Creeper unit switch (100) Forward speed sensor (gearbox output) sure switch F = Dark
(15) 4WD and differential lock switch (101) Engine speed sensor (gearbox input) (63) Hydraulic pressure linked to rear axle 17 bar pres-
(16) Armrest lighting (102) Power take off clutch speed sensor sure switch (red lamp) emb. = End
(17) Speeds Up / Down armrest potentiometer (103) Intermediate gearbox speed sensor (used during (64) Hydraulic filter linked to 15-micron filter clogging
(18) To water temperature sensor calibration) pressure switch (yellow lamp)
(19) Rear power take off switch (104) Connection to modify during calibration: (65) Gearbox oil temperature (red lamp)
(20) Engine oil pressure switch - normal position: power take off speed sensor (66) Main beam (blue lamp)
(21) Turbo charger pressure sensor (brown / brown wires) (67) Parking brake (red lamp)
(22) DCC dashboard - calibration position: intermediate speed sensor (68) 4WD (green lamp)
(23) Radiator water level sensor (8270 – 8280) (brown / red wires)
(24) Fuel gauge
(25) Lighting signal lamps
(26) Air filter vacuum sensor
(27) Lighting switch Solenoid valves
(28) To main beam / dipped beam toggle (79) Clutch solenoid valve "A"
(29) To connector C60 (80) Clutch solenoid valve "C"
(30) To dashboard switch (81) Clutch solenoid valve "R"
(31) To work lights relay (82) Clutch solenoid valve "2"
(32) To connector C2 (83) Clutch solenoid valve "1"
(33) Buzzer (84) Clutch solenoid valve "M"
- continuous: parking brake on (85) Clutch solenoid valve "L"
- intermittent: warning / fault (86) Clutch solenoid valve "H"
(34) Parking brake switch (87) 4WD clutch solenoid valve (mechanically engaged)
(35) CAN network plug (88) Clutch solenoid valve "B"
(36) Top of clutch switch (TOC) and potentiometer (89) "Power take off" clutch solenoid valve
(37) Forward / Reverse potentiometer on steering wheel (90) "Differential lock" clutch solenoid valve
(38) Safety switch (91) "Rear power take off" clutch solenoid valve
(39) Starter switch (92) "Park Lock" clutch solenoid valve (mechanically
(40) Not used engaged)
(41) Right brake switch
(42) Left brake switch
(43) BOC clutch switch
(44) To stop lights
(45) Time delay relay (if not fitted is replaced by 15 A
fuse)
(46) Electronic transmission control unit (TC)
Issue 1 May 2001

79 80 81 82 83 84 85 86 87 88 89 90 91 92
B
C
93
D
E
F
G
H
94
10
46
104
103 102 101 100 99 98 97 96 95

Fig. 12
Issue 1 May 2001

Issue 1 May 2001

Calculator Neutral
The TC places itself in calculator Neutral and displays an
error code when certain faults are detected. This action
is designed to protect the tractor and its driver from the
consequences of certain breakdown conditions. The
following conditions lead to the TC activating calculator
Neutral:
1. Open circuit or short circuit to ground of the solenoid
valves of gearbox clutches
2. Power supply short circuit of the solenoid valves of
gearbox clutches
3. Error between the presumed current and the meas-
ured current on a gearbox clutch
4. Failure of the CAN network communications be-
tween the DCC and TC
5. Attempted re-programming while the engine is run-
ning
6. Problem in an internal circuit (protection transistor
remains open)
7. Short circuit to + 12 V on the power take off solenoid
valve
8. Park Lock engagement error
9. Problem with electrical signals from steering wheel Fig. 13
or armrest shuttle lever
10. Short circuit to + 12 V in lower clutch pedal switch
(BOC) Pulse modulation diagram (Fig. 13)
11. Fault in the parameter table V = Voltage
12. Neutral lever switch fault on the analog shuttle lever T = Time
13. Neutral switch fault on the armrest lever A = Average voltage
Note:
- The details of each error code is explained in
section 11B03.
- To remove calculator Neutral, first correct the fault.
Then place the gear shift levers in neutral and fully
press the clutch pedal.
Solenoid valve control

The TC controls 14 solenoid valves operating the gear-
box, power take off, power take off brake, Park Lock,
4WD and differential lock. The 9 solenoid valves of the
gearbox and the control solenoid valve of the power take
off clutch are of the proportional type, activated by pulse
width modulation (PWM). The solenoid valves that
control the differential lock, 4WD, power take off brake
and Park Lock are of the On / Off type and operate without
modulation.
Issue 1 May 2001


Pulse modulation allows the current supplying all the
solenoid valves of the gearbox to be controlled. The value
of the current supplied by the TC is obtained by the
successive opening and closing of the solenoid valve
supply circuit. The ratio of the duration of this closing over
the duration of the opening of the circuit determines the
average value of the current supplied to the solenoid
valve. The usage factor (duration: on / off) varies propor-
tionally in relation to the desired and required average
current to produce a desired hydraulic pressure in the
clutch. The TC monitors the current when the control
relay is activated and periodically adjusts the usage
factor in function of the measured current quantity in
relation to the required quantity.
The TC is capable of determining if the pulse modulation

circuit is open, short circuited to battery or short circuited
to ground. It can also determine whether there is an open
circuit, short circuit to battery or a grounding of the ON /
OFF type solenoid valves. If this is the case, the TC
transmits an error code to the DC that then displays it.
The TC used two types of current to control the solenoid

valves:
- the first type supplies current to the solenoid valves L,
M, H via a control circuit activated by BOC and the lever
Neutral switches. When the circuit is open, the supply
to the L, M, and H solenoid valves is interrupted.
- the second type supplies current to the other solenoid
valves via a separate line.
The following table indicates the solenoid valves that are

activated and the clutches engaged for any given se-
lected ratio.
Issue 1 May 2001

Table showing the clutches engaged and solenoid valves activated
1 2 R A B C L M H
F1 X X X
F2 X X X
F3 X X X
F4 X X X
F5 X X X
F6 X X X
F7 X X X
F8 X X X
F9 X X X
F10 X X X
F11 X X X
F12 X X X
F13 X X X
F14 X X X
F15 X X X
F16 X X X
F17 X X X
F18 X X X
R1 X X X
R2 X X X
R3 X X X
R4 X X X
R5 X X X
R6 X X X
* R7 X X X
* R8 X X X
* Indicates ratios that are only available in certain countries.
Issue 1 May 2001

Right-hand side of transmission (Fig. 14)

AG 150 Fig. 14
(1) Clutch solenoid valve "A"
(2) Clutch solenoid valve "2" 1
(3) Clutch solenoid valve "M" 2
(4) Clutch solenoid valve "H"
AG 250
(1) Clutch solenoid valve "A" 3
(2) Clutch solenoid valve "2"
(3) Clutch solenoid valve "M"
(4) Clutch solenoid valve "H"
Left-hand side of transmission (Fig. 15)

(1) Clutch solenoid valve "R"
(2) Clutch solenoid valve "B" 1 2
(3) Clutch solenoid valve "1"
(4) Clutch solenoid valve "C" 4
(5) Clutch solenoid valve "L"
Tightening torque
- Nut holding solenoid on the spool valves: 1.7 - 2.8 Nm
- Spool valve on housing: 15 - 20 Nm 5
Fig. 15
Issue 1 May 2001

Power take off control 4. Power take off emergency stop button on wings
On request from the operator the TC engages and When an operator presses one of the emergency stop
disengages the power take off via the DCC and the CAN buttons mounted on the rear wings, the TC cuts off the
network. It also controls the engagement of the power solenoid valve power supply and the power take off
take off and transmits this information to the DCC which signal lamp flashes. To re-engage the power take off,
then displays the speed and lights the power take off first place the main switch in the Stop position and
signal lamp. then move it to On.
The TC handles the progressive engagement of the If the TC detects the following faults, the operation of the
power take off, regardless of engine speed and the load power take off will be affected in the following manner:
on the output shaft. It controls a proportional solenoid 1. Engagement while the power take off clutch speed
valve via pulse width modulation (PWM) in order to sensor is defective. In such cases, the TC controls the
obtain a linear speeding-up and down ramp right up until solenoid valve and increases the pressure in the
full engagement. clutch in a linear manner so that it reaches 17 bar at
the end of 10 seconds, it transmits an error code 90 via
The TC detects two power take off speed inputs, one the CAN network, this leads to the power take off
represents the input speed of the power take off clutch signal lamp flashing at 5 second intervals on the DCC.
(engine speed) and the other corresponds to the power
take off clutch output speed. These speeds are used to 2. Engagement when the transmission input speed sen-
determine faults in the power take off circuit. sor is defective.
In such cases, the TC controls the solenoid valve so
The safety functions aimed at protecting the tractor and as to obtain a linear increase in pressure and to obtain
the implement are as follows: a clutch output speed of 1500 rpm at the end of 5
1. If the main power take off switch is active when the seconds. It transmits an error code 91 via the CAN
engine starts, the power take off is not engaged and network, this leads to the flashing of the power take
the power take off signal lamp on the DCC flashes. No off signal lamp on the DCC at 5 second intervals.
error code is transmitted or displayed. To start up the
power take off, the power take off switch must first be 3. Power take off brake fault detected. If, after the brake
turned to the Off position, then placed in the On has been operated, the speed of the power take off
position. shaft does not equal 0 after 3 minutes, the TC cuts the
power supply to the power take off brake and trans-
2. Protection against excessive power take off clutch mits an error code 94 via the CAN network to the DCC.
slip.
If excessive clutch slip takes place, the TC cuts the
power supply to the power take off solenoid valve and
transmits an error code 93 via the CAN network. This
leads to a flashing of the power take off signal lamp
on the DCC. Maximum permitted clutch slip is 2% for
a period of 5 minutes.
3. Protection against jammed power implements

Protection against engine stalling if the engagement of
the power take off leads to a drop of more than 50%
of speed below initial engine speed. In such cases the
TC cuts off the power supply to the power take off
solenoid valve and transmits an error code 92 via the
CAN network, this leads to a flashing of the power
take off signal lamp on the DCC.
Issue 2 May 2002


Front axle control (4WD)
On request from the DCC, via the CAN network, the TC
can engage or disengage 4WD. The TC indicates the A 1
status of the 4WD and transmits the information to the
DCC via the CAN network so that the 4WD signal lamp
can be lit or extinguished. To activate 4WD, the TC
activates a solenoid valve of the ON / OFF type. 4WD is
engaged when the solenoid valve is de-activated and
disengaged when the solenoid valve is activated.
The status of the 4WD system is stored during the time

the engine is stopped and restored when the engine is
started again. If the engine is cut when the 4WD is
KPH
engaged it will be engaged when the tractor is started RPM
% MPH
again. If the 4WD is not engaged when the engine is cut L/MIN
it will not be engaged when the tractor is started again.
If the tractor is stopped and the front axle disengaged, the Fig. 16
solenoid valve is supplied with 12 V.
The 4WD can be activated either automatically or manu- 4WD Auto signal lamp (Fig. 16)
ally. These modes are as follows: (1) Automatic 4WD signal lamp
Automatic mode The normal operating conditions of the 4WD are as

- On starting up the tractor, the 4WD is in automatic follows:
mode. "A" is displayed in the upper right-hand corner of 1. If both brake pedals are pressed, the 4WD is engaged
the display. If the speed exceeds 14 kph when 4WD is to ensure braking of all four wheels regardless of the
engaged then the TC disengages it. It re-engages it forward speed.
when the speed drops below 13.5 kph. 2. The 4WD is engaged as soon as the differential lock
is activated but it may be disengaged if desired.
Manual mode 3. The 4WD remains disengaged and its signal lamp
- To leave automatic mode and enter manual mode extinguished even if the tractor is stationary.
when the speed is less than the above described limit,
press the 4WD switch and maintain it pressed for a
period of at least 2 seconds. If the forward speed is
greater than the 4WD speed limit, pressing the 4WD
switch temporarily places the circuit in manual mode.
- When the 4WD is in manual mode it is then perma-
nently engaged regardless of the forward speed. Sim-
ply pressing on the 4WD switch disengages the 4WD
and re-pressing it engages the 4WD again.
US mode (depending on the country)

- When the 4WD switch is pressed for a long time (15
seconds), the front axle switches to US mode. In this
case, the front axle symbol (1) on the DCC flashes.
- In this mode, the front axle only disengages when a
brake pedal is pressed. It reengages when the pedal is
released.
Issue 2 May 2002

Differential lock control

The TC can engage or disengage the differential lock on
request from the DCC via the CAN network. It indicates
the status of the differential lock and transmits this
information to the DCC via the CAN network so that it
lights the corresponding signal lamp. The TC activates an
ON / OFF type solenoid valve to engage or disengage the
differential lock.
On starting the engine, the differential lock is disen-

gaged. Pressing the differential lock switch engages the
rear differential lock, the front differential lock (depending
on options) and the 4WD, if the latter is not engaged.
Pressing the switch again disengages the differential
lock while leaving the 4WD engaged.
The differential lock also operates as follows:

1. The differential lock definitively disengages when the
forward speed is greater than 14 kph.
2. The differential lock disengages when the linkage
MoveUp / MoveDown switch is in the MoveUp
position. It re-engages when the switch is placed in
the Neutral or Lower position.
3. The differential lock disengages when either of the
brake pedals is pressed, and is only re-engaged when
the brakes are released.
Park Lock control

The TC can engage or disengage the Park Lock on
request from the operator via the Park Lock switch on the
armrest mounted gear shift lever. It indicates the Park
Lock position via a position sensor on the control shaft
located on the left-hand side of the intermediate housing.
This data is transmitted via the CAN network to the DCC
so that it lights the corresponding signal lamp and places
the gearbox in Neutral. The TC activates an ON / OFF type
solenoid valve to engage or disengage the Park Lock. The
Park Lock is engaged when the solenoid valve is de-
activated.
Warning: The tractor cannot be towed un-

less the Park Lock solenoid valve is acti-
vated and supplied with hydraulic pressure or towed
without the Park Lock being manually removed.
Issue 1 May 2001


To manually remove the Park Lock when the engine is
not running, screw in the special bolt located on the Park
Lock solenoid valve block (see section 6F01).
The TC prevents the operator from engaging the Park

Lock if the forward speed is greater than 1 kph and
prevents engaging any gear on start up if the Park Lock
is activated. When the tractor is started, if the operator
attempts to engage a gear while the Park Lock is fully or
partially engaged, the TC holds the tractor in neutral and
transmits error code 99 via the CAN network. If the gear
shift lever is not in the neutral position, the DCC displays
"P" and the buzzer sounds.
If the tractor is moving at more than 1 kph, the TC

activates the Park Lock solenoid valve in order to
maintain the Park Lock disengaged, regardless of the
position of the Park Lock switch on the armrest. If the
forward speed drops below this limit and the operator
requests the Park Lock, the TC places the gearbox in
neutral and cuts the power supply to the Park Lock
solenoid valve in order to engage the Park Lock.
If during movement, the TC detects that the Park Lock is

not fully disengaged, it transmits error code 98 to the
DCC and maintains the Park Lock disengaged for as long
as the forward speed is greater than the limit. In this
case, the operator may change gear but, when the
forward speed drops below the limit, the TC places the
gearbox in neutral and cuts the power supply to the Park
Lock solenoid valve to engage the Park Lock.
Issue 1 May 2001

Park Lock solenoid valve

F . Operation of solenoid valves and The Park Lock solenoid valve is of the ON / OFF type but
test procedures differs from the previously described ones.
The Park Lock is engaged when the solenoid valve is de-
Gearbox clutch and power take off clutch activated.
solenoid valves
The solenoids of the nine solenoid valves on the Full
Powershift gearbox and that on the power take off clutch Characteristics of the Park Lock solenoid valve
are identical. Voltage ....................................... 12 V DC
Resistance ................................. 8.3W ±2 % at 20°C
These solenoids operate the proportional valves that Diode ......................................... No
supply hydraulic pressure to the gearbox and the power
take off clutch in response to the supply current. Note: Tightening torque
- Nut holding coils on spool valves: 1.7 to 2.8 Nm
The proportional valves of the gearbox and power take off - Spool valve on the housing: 15 – 20 Nm.
are different.
Characteristics of the gearbox / power take off

solenoids
Voltage ............................................. 12 V DC
Consumption .................................... 9 watt maximum
Resistance ....................................... 10.1Ω at 20 °C
Diode ............................................... No
If a problem is suspected with a gearbox / power take off

solenoid valve, check the resistance of the solenoid. It
must be 10.1 Ω ± 3%. Equally check the resistance
between the solenoid valve body and each pin. The
resistance must be greater than 50 kΩ. Note that the
solenoid valves mounted on the gearbox / power take off
are not connected to diodes.
ON / OFF solenoid valves

The 4WD, differential lock and power take off solenoid
valves are identical and are of the ON / OFF type.
Characteristics of the 4WD, differential lock and

power take off solenoid valves
Voltage ....................................... 12 V DC
Consumption .............................. 14.8 watt maximum
Resistance ................................. 9.7 Ω ±10 % at 20°C
Diode ......................................... No
If a problem is suspected in a 4WD, differential lock or

power take off solenoid valve, check the resistance of
the solenoid. It must be 9.7 Ω ± 10%.
Issue 1 May 2001

G . Input signals of TC sensors / swit-

ches
Speed sensors
The TC controls speed inputs through five different
sensors: engine speed, forward speed, gearbox calibra-
tion speed, power take off clutch speed and power take
off shaft output sensors.
The engine speed, gearbox, calibration and power take

off sensors are all of the magnetic type having two leads
(signal and ground). A magnetic sensor consists of a
permanent magnet surrounded by a coil that creates a
magnetic field. An alternating frequency is generated
when the rotation of nearby pinion teeth disturbs the 1
magnetic field created by the magnet. A sinusoidal wave Fig. 17
results (frequency). This is received by the TC which then
uses the information to control the various elements and
transmits information to the DCC via the CAN network.
2
Right-hand side of the gearbox (Fig. 17)
(1) Forward speed sensor
The gearbox forward speed sensor is fitted on the right-

hand rear side of the gearbox housing. The output speed
is detected using the 7th stage transmission pinion that
is permanently engaged with the output shaft pinion.
Left-hand side of the gearbox (Fig. 18)

(2) Calibration speed sensor
The engine speed sensor is fitted on the rear left gearbox 1 Fig. 18
housing. The engine speed is detected via the 4th stage
transmission pinion that is permanently engaged with
These sensors can be checked using a digital multimeter.
the input shaft pinion.
The resistance between the terminals must be 500 Ω ±
10%.
The gearbox calibration speed sensor is located on the
front housing, on the upper left of the gearbox. The
calibration speed is detected via the hub of the clutch on
the 5th stage shaft.
The engine speed, forward speed and calibration speed

sensors are identical. They are of the inductive type and
require no adjustment. Screw in the sensor and tighten
to a maximum torque of 14 Nm.
Issue 1 May 2001

Power take off speed sensors (Fig. 19)

(1) Clutch output speed sensor
(2) Output shaft speed sensor
1
The clutch output speed sensor (1) is located on the

right-hand side of the power take off housing, near the
linkage ram. It must be adjusted when installed. Screw
in the sensor until it touches the power take off pinion,
then unscrew it by 1/2 to 3/4 turn. Tighten the lock nut to
14 Nm. Its correct adjustment for proper functioning is
essential.
The speed sensor can be checked using a digital

multimeter. The resistance across the terminals of the 2
sensor must be 450 Ω ± 10%. The sensor can also be
checked by checking the voltage across the terminals Fig. 19
with the power take off engaged and the engine at idle
speed. Check using a voltmeter that the sensor emits
pulses, the display must change rapidly. The voltage This sensor cannot be adjusted. It is held by a single bolt
should be around 6 V when the power take off is engaged and oil tightness is provided by an O’ring.
at idle speed. This sensor can be checked using a digital multimeter.
The resistance values across the terminals of the sensor
must correspond to the values indicated in the table
The output shaft speed sensor (2) is a Hall effect type below:
sensor. It is located in an indent on the right-hand side of
the power take off housing, near the linkage ram. This Digital Ω Digital Ω
sensor generates an alternating digital frequency when multimeter multimeter
the teeth of the pinion cross through its magnetic field. It connection connection
has three leads: + - value - + value
- supply + 12 V Sensor Sensor
- signal terminal terminal
- ground
1 2 0.L 1 2 0.L
2 3 0.L 2 3 4.1MΩ
1 3 14.3MΩ 1 3 0.L
Note: O.L = infinite resistance
Issue 1 May 2001


The Park Lock switch
This is located in the armrest gear shift lever and
indicates the position of the lever to the TC.
This switch has two positions:

- normally closed; this supplies the Park Lock solenoid
valve with 12 V when the armrest lever is in the Neutral
or On position
- normally open; this supplies the DCC E/C input with

12 V. The DCC informs the TC via the CAN network that
the solenoid valve is no longer supplied with power and
that the Park Lock must be engaged.
If the forward speed exceeds 1 km/h, the TC controls the
Park Lock solenoid valve until the speed decreases
below that value.
The Park Lock position sensor

This is located on the left-hand side of the intermediate
housing. It is normally open when the Park Lock is
engaged.
It closes and sends a ground signal to the TC D/F input
when the Park Lock is disengaged.
The TC uses this sensor to validate the position of the
Park Lock. It transmits this information to the DCC via
the CAN network in order to compare it with the informa-
tion from the armrest lever switch and then displays the
corresponding signal lamps.
The creeper unit switch (optional)

This is located on the creeper unit selection lever.
It signals to the TC that the creeper unit is engaged. The
TC calculates the forward speed in relation to
demultiplication data stored in memory and sends this
information to the DCC in order to display the speed. The
DCC then lights the creeper unit signal lamp and displays
the forward speed as received from the TC. The creeper
unit switch is a normally open switch that closes when
the creeper unit is engaged. It supplies a ground signal to
the TC E/C input.
Issue 1 May 2001

The transmission temperature sensor

This is located on the left-hand side of the gearbox on the
front housing. This sensor supplies information used by
the TC to control the gear shifting and for calibration
procedures. This information is also transmitted to the
DCC in order that it lights the corresponding signal lamp.
The sensor can be checked using the values below
(Fig. 20):
Temperature Resistance
25° C (77°F) 2820 Ω ± 5 %
100° C (212°F) 180 Ω ± 2.5 %
125° C (257°F) 89 Ω ± 3 %
1
When the hydraulic oil temperature exceeds 105 °C Fig. 20
(221 °F), the hydraulic oil temperature signal lamp and
the warning signal lamp are lit and the buzzer sounds.
The booster pressure switch
This pressure switch is located below the right-hand side
Gearbox 17 bar pressure switch hydraulic cover, behind the 15 micron hydraulic filter.
This pressure switch is placed beneath the cab floor on It is the normally closed type.
top of the front gearbox housing. It is of the normally open If the pressure is lower than 1.5 bar ± 0.2, the pressure
type. is closed and sends a ground signal to the TC E/K input.
If the pressure drops below 9 bar ± 1 bar, the pressure The status of the pressure switch is transmitted to the
switch is open. If the pressure exceeds 9 bar ± 1 bar the DCC via the CAN network.
pressure switch closes and sends a ground signal to the The DCC activates the corresponding signal lamps and
TC E/B input. the buzzer.
The status of the pressure switch is transmitted to the If the pressure is greater than 1.5 bar ± 0.2, the pressure
DCC via the CAN network. switch is open.
If the pressure is lower than 9 bar ± 1 bar, the DCC This pressure switch is identified by a green mark.
activates the corresponding signal lamp and the buzzer.
This pressure switch is identical to the rear axle 17 bar
pressure switch.
The 15 micron hydraulic filter clogging pres-
sure switch
This pressure switch is placed on top of the 15 micron
The main circuit 17 bar pressure switch hydraulic filter located on the right-hand side hydraulic
This pressure switch is located beneath the right-hand
cover. It is of the normally open type.
side hydraulic cover. It is of the normally open type.
If the difference between the input and output pressure
If the pressure is less than 9 bar ± 1 bar, the pressure
of the filter exceeds 2.4 bar ± 0.3, the pressure switch is
switch is open. If the pressure is greater than 9 bar ± 1
closed and transmits a ground signal to the TC E/J input.
bar, the pressure switch closes and sends a ground
The status of the pressure switch is transmitted to the
signal to the TC E/A input.
DCC via the CAN network.
The status of the pressure switch is transmitted to the
The DCC activates the hydraulic filter clogging signal
DCC via the CAN network.
lamp.
If the pressure is less than 9 bar ± 1 bar, the DCC
To deactivate the signal lamp, the pressure difference
activates the corresponding signal lamps and the buzzer.
must be lower than 1.8 bar ± 0.3.
This pressure switch is identical to the 17 bar gearbox
pressure switch.
Issue 1 May 2001

0,7/1,2 mm
10,9
2,6/3,6 mm
2
0,3/1,0 mm
150
130
Fig. 21
Issue 1 May 2001

H . Operation of the manoeuvring

pedal
Manoeuvring pedal assembly (Fig. 21)
(1) Top of clutch switch (TOC)
(2) Bottom of clutch switch (BOC)
(3) Starter safety switch
(4) Pedal pressed adjustment screw
(5) Pedal released adjustment screw
- The manoeuvring pedal differs from the clutch pedal

fitted to mechanical gearboxes. It is only used when
manoeuvring in very tight spaces or when hitching an
implement.
- It is not necessary to use this pedal either when
engaging a gear from neutral, when changing gears or
when reversing the direction of travel.
- The position of the manoeuvring pedal is transmitted to
the DCC by the TOC (1) and by the BOC (2).
Adjustment of the potentiometer / TOC

- With the manoeuvring pedal fully pressed, adjust the
position of screw (4) to provide a clearance of 2.6 mm
to 3.6 mm between the head of the screw and the TOC
plunger.
- With the pedal released, act upon screw (5) to provide
a clearance of 0.7 mm to 1.2 mm between screw (4)
and the body of the TOC (Fig. 21).
- Tighten the lock nut of the TOC to a torque of 23 - 33 Nm.
- After these adjustments, check the pedal travel. It
must be between 130 mm to 150 mm.
BOC adjustment
- Screw the switch so that the end of its threaded cylinder
is recessed 0.3 mm to 1 mm in its support (Fig. 21).
- Tighten the lock nut to a torque of 6 - 9 Nm.
Issue 1 May 2001


- The selector switch assembly is fitted with a mechani-
I . Operation of the armrest gear cal locking device beneath the control button. This must
selector switch assembly (Fig. 22) be held in position in order to move the switch from the
Park Lock position into Neutral or from Neutral into On.
Gear selector switch assembly - The gear shift selector switch assembly comprises:
(1) Location of the electronic linkage MoveUp / . a selection mechanism that operates the Park Lock
MoveDown switch . a Neutral switch
(2) Depth / lift height potentiometer . a selection potentiometer
(3) Neutral switch - It also incorporates the differential lock / 4WD switch
and the electronic linkage controls.
(4) Park Lock switch
- If the gear shift selector switch assembly must be
(5) Park Lock ratchet disassembled, it is necessary to carry out a new
(6) Selection potentiometer calibration of the selection potentiometer after
(7) Neutral / Change up / Change down ratio ratchet reassembly.
(8) Mechanical lock
- The right-hand gear selector switch assembly allows

for selection of the Park Lock, the Neutral position, the
On position and the changing up and down of gear
ratios.
- The changing of gears is carried out either:
. by pulses, by momentarily pushing the switch to the
Up (+) or Down (-) position
. or in a continuous manner, by maintaining the switch
in the Up (+) or Down (-) position
1 8 5 4 2
3 6
Fig. 22
Issue 1 May 2001

Signal
Lever position Switch Signal
DCC / TC - Description 11B01.43 voltage
(Volts)
High (declutched) Non 2,5
Forward + S1 + S2 + S3 4
Forward S1 + S2 3,5
J . Steering wheel gear shift lever
Forward - S1 + S2 + S4 + S7 3
It is located on the steering column to the right and 1

1KOhm Neutral S7 0,5
permits: 1KOhm Reverse - S5 + S6 +S4 2
S1
- selecting of the gearbox Neutral position S2
- forward or reverse operation 2.55KOhm
24KOhm 36KOhm Reverse S5 + S6 1,5
10KOhm
- changing up or changing down through the gears Reverse + S5 + S6 + S3 1

2KOhm 2.4KOhm
This lever comprises a series of resistors and flexible

S3
contact switches that depends on the position of the
lever, send different analog signals to the DCC. 2
15,8KOhm
100KOhm
S7 2KOhm
Parts list S4
560Ohm
(1) Cap 10KOhm 2.55KOhm
(2) Circlips S5 2.4KOhm

(3) Washer 1.5KOhm
(4) Top cover
(5) Bearing 24KOhm 34KOhm S6
(6) Upper pin
(7) Compression spring
1KOhm
(8) 4 x 28 pin 3
(9) Magnet support 4
(10) Left torsion spring 5
6
(11) Right torsion spring
(12) Moulding
(13) Compression spring
(14) Cups
(15) Neutral switch 1
6 5 4 3 2 1
(16) Printed circuit 2
(17) Rubber wedge 3
(18) Bottom cover 4
5
(19) M4 x 14 bolt
6
(20) Washer dia. 4
(21) Water tight cap
(22) Plastic washer
(23) Bolt No. 2 x 0.5 Connector functions
(24) Lever
(25) Nut HN 4 Terminal Designation
(26) Grower washer dia. 4
(27) Bolt CHC H 4 x 18 1 + 5 Volts
(29) O’ring and washer
(30) Pommel 2 Signal
3 Ground
4 Normally closed Neutral switch output
Closed
5 Switch Neutre entrée + 12 V
6 Normally open Neutral switch output
Fig. 22A Open
Issue 1 May 2001

Issue 1 May 2001

K . Use of the Backup Harness

- In the unlikely event of a DCC / TC failure that immobi-
lises the tractor, it is still possible to move the tractor
by using a backup harness.
- The breakdown backup mode allows the operator to
manually select the F3 ratios (3rd forward) and R2 (2nd
reverse).
Important: The Breakdown Backup mode is not
designed for normal working conditions.
- In Breakdown Backup mode, there is no clutch modu-
lation. The tractor starts to move as soon as the
manoeuvring pedal frees the BOC switch.
- To install the breakdown backup harness, the operator
must first take the protection cover off the transmission
controller (TC) in order to gain access to the harness
connectors. Fig. 23
Connection of the Backup Harness (Fig. 23

- 24)
1. Remove connectors A, B and C from the TC harness.
2. Connect connectors A, B and C of the backup harness
in to their corresponding connectors of the TC har-
ness.
3. The end of the harness with the individual connectors
remains in the cab.
The connection of the female connector with the male
connector having a salmon lead provides the F3
forward gear.
The connection of the female connector with the male
connector having a violet lead provides the R2 reverse
gear.
To modify the direction of movement, the operator
must change this connection.
Fig. 24
- The solenoids are supplied from the Neutral switches of
the gear shift selector switches and the BOC. To be
able to move the tractor, the gear shift selector switches
must be placed elsewhere than the Neutral position.
- The direction of advance depends upon the connection
of the connectors in the cab and not the position of the
gear shift selector switches.
Issue 1 May 2001

L . Location of sensors (Fig. 25 - 26)

Parts list
(1) Linkage position sensor
(2) Forward speed sensor on the crownwheel (fitted
with Datatronic option only)
(3) Rear axle 17 bar pressure switch (red sticker, black
/ beige lead)
(4) PTO solenoid valve (black / green)
(5) PTO brake solenoid valve (black / white)
(6) Differential lock solenoid valve (black / blue)
(7) TC transmission calculator
(8) Gearbox 17 bar pressure switch (red sticker, black /
red leads)
(9) Clutch A solenoid valve (black / beige)
(10) Clutch 2 solenoid valve (black / green)
(11) Clutch M solenoid valve - AG 150 gearbox (black /
brown)
Clutch solenoid valve H - AG 250 gearbox
(12) Clutch H solenoid valve - AG 250 gearbox (black /
red)
Clutch M solenoid valve - AG 250 gearbox
(13) Forward speed sensor (black / grey)
(14) Temperature switch (black)
(15) Booster 5 bar pressure switch (white / black)
(16) Park Lock solenoid valve (black / grey)
(17) Front axle solenoid valve (black / yellow)
(18) 15 micron clogging pressure switch (black / blue)
(19) Linkage draft sensor
(20) PTO output shaft speed sensor (black / red / green)
(21) PTO clutch output speed (black / brown)
(22) Clutch solenoid 1 (black / salmon)
(23) Clutch solenoid C (black / blue)
(24) Clutch solenoid R (black / violet)
(25) Clutch solenoid B (black / white)
(26) Intermediate speed sensor (black / red)
(27) Engine speed sensor (black / yellow)
(28) Park Lock switch (black / pink)
Issue 1 May 2001

21 1 2 3 4 5 6 7 8 9 10
11
20 19 18 17 16 15 14 13 12
Fig. 25
Issue 1 May 2001

8200 SERIES TRACTORS8200 SERIES TRACTORS

Parts list
(1) Linkage position sensor
(2) Forward speed sensor on crownwheel (fitted with
Datatronic option only)
(3) Rear axle 17 bar pressure switch (red sticker,
black / beige leads)
(4) PTO solenoid valve (black / green)
(5) PTO brake solenoid valve (black / white)
(6) Differential lock solenoid valve (black / blue)
(7) TC transmission calculator
(8) Gearbox 17 bar pressure switch (red sticker, black
/ pink leads)
(9) Clutch A solenoid valve (black / beige)
(10) Clutch 2 solenoid valve (black / green)
(11) Clutch M solenoid valve - AG 150 gearbox (black
/ brown)
Clutch H solenoid valve - AG 250 gearbox
(12) Clutch H solenoid valve - AG 150 gearbox (black
/ red)
Clutch M solenoid valve - AG 250 gearbox
(13) Forward speed sensor (black / grey)
(14) Temperature switch (black)
(15) 5-bar booster pressure switch (white / black)
(16) Park Lock solenoid valve (black / grey)
(17) Front axle solenoid valve (black / yellow)
(18) 15 micron filter clogging pressure switch (black /
blue)
(19) Linkage draft sensor
(20) PTO output shaft speed sensor (black / green / red)
(21) PTO clutch output speed sensor (black / brown)
(22) Clutch 1 solenoid valve (black / salmon)
(23) Clutch C solenoid valve (black / blue)
(24) Clutch R solenoid valve (black / violet)
(25) Clutch B solenoid valve (black / white)
(26) Intermediate speed sensor (black / red)
(27) Engine speed sensor (black / yellow)
(28) Park Lock switch (black / pink)
(29) Clutch L solenoid valve (black / pink)
(30) Transmission oil temperature sensor
Issue 1 May 2001

24
é 25 26 27
23
22
30 29 28 19
Fig. 26
Issue 1 May 2001

DCC / TC - Calibration 11B02.1
11B02 Calibration
CONTENTS
A. General ________________________________________________ 2
B. Level 0 _________________________________________________ 3
C. Level 1 _________________________________________________ 5
D. Level 2 _________________________________________________ 8
E. Level 3 _________________________________________________ 17
F. Adjust the shifting ______________________________________ 18
G. Diagnostic modes _______________________________________ 19
Issue 1 May 2001

11B02.2 DCC / TC - Calibration
A. General 1 2 3
Each time an electrical component is removed or re-
placed, this component must be recalibrated. If this
calibration is not carried out the DCC may display an error
message indicating a condition that falls outside the
tolerances or indicating that the component has not been
calibrated. The elements that particularly require calibra-
tion are the DCC and the TC, the turbo boost pressure, the
gearbox, the gear shift potentiometers, the forward
speed sensor and the implement width.
The procedures for calibrating the DCC and TC are

divided into 4 maintenance levels numbered from 0 to 3.
6
Level 0
These calibration functions are designed for use by the 4 5 Fig. 1
operator during normal functioning of the vehicle. They
use the membrane keys 1, 2 and 3. The 0 level calibra-
tions include the following: forward speed, wheel slip
ratio, engine speed, PTO speed, area worked, total
engine hours, calibration of the forward speed, adjust-
ment of the implement width and deleting of the worked
area.
Level 1
These calculation functions are designed to be used by
the operator during normal maintenance operations.
Level 1 includes calibration of the gearbox and turbo
boost pressure.
Level 2
These calibration functions are used by qualified person-
nel during maintenance and repairs. The level 2 calibra-
tions include the display of DCC and TC constants, and
calibration of the armrest gear shift lever.
Level 3
These calibration functions concern factory calibration.
They are used by qualified personnel when replacing the
DCC or TC. These calibration functions include the type
of engine, gear locking, the choice of the measurement
units system, the selection of the type of gear shift lever
and modification of constants of the DCC and TC.
Issue 1 May 2001

B . Level 0 1 2 3
Direct selections (Fig. 1)

GNO SL IP
- Press SPO %
to select ground speed or percent slip.
PTO ENG
- Press to select Engine rpm or PTO rpm.

RPM RPM
ENG FIELD
- Press to select Field area or engine hours.

HRS AREA
Ground speed calibration (tractors fitted with

a radar) 6
This calibration is to set with the maximun accuracy for
the radar input. 4 5 Fig. 1
1. Mark out a 100 meter (400 ft) course according to units
selected, on a firm surface.
GNO SL IP
2. Press and hold SPO %

for 4 seconds.
3. "CAL"will be dispayed on the display (Fig. 2).
4. Drive the tractor at normal operating speed along the
100 m (400 ft) course.
PTO ENG
5. Press when passing over the course start point

RPM RPM
ENG FIELD
6. Press when crossing the end point of the couse

HRS AREA
The DCC will calculate a new ground speed constant and

a radar constant.
Fig. 2
Issue 1 May 2001


Implement width setting
The width of the implement must be entered into the DCC
to obtain an accurate measurement of the fiel area.
PTO ENG
7. Press and hold for 4 seconds.

RPM RPM
8. The implement width which has just been stored

must be displayed on the screen (Fig. 3) with the
selected digit flashing.The upper display will read
"FEEt" or "SI" according to unit selected.
ENG FIELD
9. Press to increment the flashing digit.

HRS AREA
GNO SL IP
10. Press SPO %

to select a different digit.
PTO ENG
11. press to memorise and leave the mode.

RPM RPM
Fig. 3
Clear the area covered
ENG FIELD
12. Press and hold for 4 seconds.

HRS AREA
13. The area is cleared when "0000" appears on the

lower display for three seconds (Fig. 4).
Fig. 4
Issue 1 May 2001

C . Level 1
Condition to enter calibration level 1 1 2 3
- Engine temperature > 80 °C for Turbo boost calibration
- Gearbox temperature between 50 °C and 60 °C for
gearbox calibration (select all the solenoid valves to
ensure they are at correct temperature) GNO SL IP PTO ENG ENG FIELD
- Tractor must be placed on a flat area without obstacle

- Put the handbrake on SPO % RPM RPM HRS AREA
- Put the two shift levers in neutral position SELECT WIDTH SET
- Stop all the lights
- Stop the engine
4 5 6
14. Press slowly the clutch pedal, wait the complete
illumination of the DCC. Start the engine and before
20 seconds
Fig. 5
15. Press and hold 4 5 for 5 seconds (Fig.5)
16. "CAL1" will be appear on the lower display (Fig. 6)
17. Select by press 4 the turbo boost calibration

"tb14" and "tb20" or the transmission calibration
"trnc"
Note : Automatic exit of calibration occurs if :

- gearbox temperature is too cold, it displayed on the
lower sceen "trAn COld" or error code 21.
- engine speed is out of range, it displayed on the
lower screen "Spd FAIL" or error code 22, 23, 24.
Transmission calibration "trnc" (Fig. 5)

Note : Before starting the transmission calibration,
connect the calibration speed sensor (red single
wire) to PTO wire (brown single wire, near the TC Fig. 6
connector E). This operation is done by removing the
TC shield.
18. Select "trnc" (see operations 14 to 17)

19. Set the engine speed at 1300 rpm.
20. Press 5 then "St0" is displayed (Fig. 7) in the

lower screen and in middle screen"trAn" and "CAL"
are flashing alternately
21. First put the armrest lever in forward position and
after words the steering column lever in forward
position.
Note : For tractor fitted with shift lever NAO type
(single lever NAO type 8170/8180), put it in
forward position.
Fig. 7
Issue 1 May 2001

Clutches
activated
St0 Calibration of solenoid valve current (arround 15 s)
St1 Check the correct speed of the gearbox shaft R-C
St2 Check the correct speed of the gearbox shaft 2-C
St3 Check the correct speed of the gearbox t shaft 2-B
St4 Calibration of low pressure for clutch 1 1-R-C
St5 Calibration of low pressure for clutch 2 2-R-C
St6 Calibration of low pressure for clutch R 2-R-C
St7 Calibration of low pressure for clutch A 2-A-C
St8 Calibration of low pressure for clutch B B-2-C
St9 Calibration of low pressure for clutch C B-2-C
St10 Calibration of low pressure for clutch L L-2-C
St11 Calibration of low pressure for clutch M M-2-C
St12 Calibration of low pressure for clutch H H-2-C
St13 Calibration of clutch 1 filling time H-1-C
St14 Calibration of clutch 2 filling time H-2-C
St15 Calibration of clutch R filling time H-R-C
St16 Calibration of clutch A filling time H-2-A
St17 Calibration of clutch B filling time H-B-2
St18 Calibration of clutch C filling time H-2-C
St19 Calibration of clutch L filling time L-B-2
St20 Calibration of clutch M filling time M-B-2
St21 Calibration of clutch H filling time)˜ H-B-2
Issue 1 May 2001

22. The calibration is starting.

The lower screen displays the stages of the calibra-
tion (see after table).
23. When the calibration is finish "donE" is display on the
lower screen (Fig. 8)
24. Put the two shift levers in neutral (or one lever for
NAO type 8170 / 8180)
25. Stop the engine (this is mandatory, otherwise the
calibration process restarts.)
26. Reconnect the PTO speed sensor (brown to brown)
Note :
- Wait 30 seconds, due to the park lock relay, before
starting the engine again. If not waiting, error code
could appear.
- If an error code 101 to 109 and 111 to 119 appear Fig. 8
during the calibration, you should restart it.
Issue 1 May 2001


Turbo boost calibration
27. Repeat operation 14 to 17 and select "tb14" (Fig. 9)
28. Set engine speed at 1400 rpm.
29. Press 5 to start the calibration :

- 'tb14" disappears on the lower screen.
- the old value is display during 3 seconds.
- then the new value is display during 3 seconds.
- automatic exit of the calibration and return to
normal screen
- stop the engine
30. Repeat operation 14 to 17 and select "tb20" (Fig. 10)
31. Set engine speed at 2000 rpm.
32. Press 5 , to start the calibration :

- "tb20" disappears on the lower screen.
Fig. 9
- the old value is display during 3 seconds.
- then the new value is display during 3 seconds.
- automatic exit of the calibration and return to
normal screen
- stop the engine
Fig. 10
Issue 1 May 2001

D . Level 2
33. Put the ignition on. Do not start the engine.
34. Before 20 seconds, press and hold 5 6 for 5

seconds
35. "CAL2" will be apprear on the lower display (Fig. 11)
36. Press 4 to select the fonction to control
Available fonction functions
SnA Analogic lever calibration (NAO, type 8170/

8180)
ErS Analogic levers calibration type 8200 (lever Fig. 11

on armrest and lever on the steering lever)
dcon Display DCC constants
tcon Display TC constants
CLEd Clear DCC stored error codes
CLEt Clear TC stored error codes
Note : In anytime, press 6 to exit menu or cali-

bration
8200 levers calibration

37. Select "ErS" to do the 8200 levers calibration.
38. Put the steering column lever in forward position Fig. 12
39. The armrest lever should be put in neutral position
before 5 seconds
40. Press 5 to start calibration.
41. "nEU" will appear in the middle screen (Fig. 12)

Note : If the armrest lever is not in neutral
position, the buzzer is activate and the DCC
cleared the calibration mode after 10 seconds.
GNO SL IP
42. After the buzzer activation press SPO %

before 10
seconds
Issue 1 May 2001


43. "FOr" will be appear in the middle screen (Fig. 13) put
the armrest lever in forward position before 10
seconds
GNO SL IP

before 10
seconds.
The calibration is finish, the normal display appear.
Note : If an error appear during the calibration,
"CAL" will be appear and the error code is
display on the lower screen.
NAO8170/8180 lever calibration

45. Repeat operation 33 to 36
46. Select "SnA" to do the NAO 8170/8180 lever calibra-
tion.
47. Put the lever in neutral position
Fig. 13
48. Press 5 to start calibration
49. "nEU" will appear in the middle screen (Fig. 12) and
the lever should be put in neutral position before 5
seconds
Note : If the lever is not in neutral position, the
buzzer is activate and the DCC cleared the cali-
bration mode after 10 seconds.
GNO SL IP

before 10
seconds
51. "FOr" will be appear in the middle screen (Fig. 15) put
the lever in forward position before 10 seconds
GNO SL IP

before 10
seconds
53. "rEu" will be appear in the middle screen (Fig. 14) put
the lever in reverse position before 10 seconds
GNO SL IP
Fig. 14
before 10
seconds.
The calibration is finish, the normal display appear.
Note : If an error appear during the calibration,
"CAL" will be appear and the error code is
display on the lower screen.
Issue 1 May 2001

Display DCC constants 57. Press 5 to select the parameter

56. Select "dcon" to see DCC constants. 58. Press one time 6 to return to the menu and two
time to return to the working screen.
Display Parameter Default Parameter Options

Code Value
50 = White 8810 / DT225

51 = Allis 9785
52 = MF 8180 / 8280
53 = White 8710 / DT200
54 = Allis 9775
55 = MF 8170 / 8270
56 = White 8610 / DT 180
57 = Allis 9765
trAc Tractor code (model) 55 58 = MF 8260 up to K066009
59 = White 8510 / DT 160
60 = Allis 9755
61 = MF 8250
62 = White 8410 /RT145
63 = Allis 9745
64 = MF 8220
65 = White 8310
66 = Allis 9735
67 = MF 8210
68 = MF 8240
70 = MF 8245
71 = MF 8260 from K066010
77 = RT130
tESt Tester code 0 01001 to 99999 tester serial number
trAn Transmission Type 1 1 = AG 150

2 = AG 250
cntr Control type 1 1 = NAO lever (8170 / 8180 type)

2 = European Levers (8200type)
ShUt Shuttle type 4 4 = Powershuttle
0 = None
PLOt Park lock type 3 2 = Electrohydraulic
3 = Electrohydraulc and park brake
0 = None
3Pth 3 point hitch type 1 1 = EHRC
2 = EHRB
bStS Boost sensor type 1 0 = None

1 = Lucas 92VB
EtSt Engine Temp sensor 1 0 = None

1 = Funk temperature sensor
PPSt Pedal position sensor 3 0 = None

3 = Bourns 1
rAdr Radar Horn 273 0 = without

base = 273 Hertz per 10 kph
0 = USA
unit Units 2 1 = English
2 = Metric

May 2002

Code Value
Engine overspeed 0 0 = Disabled

EOSP protection 1 = Enabled
Engine overspeed 2600 Maximun engine speed value

En9S parameter
Preset forward gear 8 Preset forward speed

PF9S
Preset reverse gear 3 Preset reverse speed

Pr9S
Gear preselection 0 0 = Disabled

9rPr memorization 1 = Enable
Forward speed 13 Gear engaged when start again

HSGF selection
StLL Not used
StrL Not used
Shift forward calibration 719

ASFC parameter Lever forward calibration value
Shift neutral calibration 496

ASnC parameter Lever neutral calibration value
Shift reverse calibration 282

ASrC parameter Lever reverse calibration value
Clutch pedal upper 980

PPUC calibration parameter Value in high position
Clutch pedal lower 30

PPLC calibration parameter Value in low position
Ground speed 6100

9SPd constant According to calibration level 0
Euro shift neutral 0

ESnC calibration parameter Neutral position
Euro shift move 0

ES9C calibration parameter Forward position
Maximum forward 18
FSPd speed allowed. Maximum forward speed
18 = 40 Kph
17 = 30 Kph
Front PTO installed 0
FPt0 16 = 25 Kph
0 = without
1 = with
Issue 2
1 May 2002
December

Code Value
Eur9 Maxi reverse speed 0 0 = R6 USA

selection 1 = R8 Europe
PtLt Engine load to start

correction with PTO 0 Used only with PTO if hard shifting
PtLd Value to take away

from the load when 0 Used only with PTO if hard shifting
using PTO
LOAd Always 0 0
tb14 Turbo calibration at

1400 rpm 0 Calibration value level 1
tb20 Turbo calibration at

2000 rpm 0 Calibration value level 1
Issue21
Issue December 2000
May 2002
Display TC constants 62. Press one time 6 to return to the menu and two
60. Select "tcon" to see DCC constants. time to return to the working screen.
61. Press 5 to select the parameter

Code Value
50 = White 8810 / DT225

51 = Allis 9785
52 = MF 8180 / 8280
53 = White 8710 / DT200
54 = Allis 9775
55 = MF 8170 / 8270
56 = White 8610 / DT 180
57 = Allis 9765
trAc Tractor code (model) 55 58 = MF 8260 up to K066009
59 = White 8510 / DT 160
60 = Allis 9755
61 = MF 8250
62 = White 8410 /RT145
63 = Allis 9745
64 = MF 8220
65 = White 8310
66 = Allis 9735
67 = MF 8210
68 = MF 8240
70 = MF 8245
71 = MF 8260 from K066010
77 = RT130
tESt Tester code 0 01001 to 99999 tester serial number
trAn Transmission Type 1 1 = AG 150

2 = AG 250
cntr Control type 1 1 = NAO lever (8170 / 8180 type)

2 = European Levers (8200 type)
ShUt Shuttle type 4 4 = Powershuttle
ttSt Transmission 1 1 = Funk temperature sensor

temperature sensor
PFA Front axle 1 0 = 2 WD

1 = 4 WD
dloc Differential lock 1 0 = None

1 = installed
rPto Rear PTOr 1 0 = None

1 = 8170, White and Allis type
2 = 8200 Type
PLCt Park lock type 0 0 = None

2 = Electrical command
rPPr Number of pulses for 44 Number of pulses per revolution of rear PTO cluth
rear PTO clutch output output
Issue 21
Issue December 2002
May 2002
Display Default
Parameter Parameter Options
Code Value
Number of pulses for Number of pulses per revolution of rear PTO output
FPPr 18
rear PTO output shaft shaft
LPtO Low speed PTO ratio 0 Low speed PTO ratio
Number of pulses per 32 = AG 150

EPPr 32
engine revolution 38 = AG 250
Number of pulses per 72 = AG 150

TPPr 72
transmission revolution 81 = AG 250
CrPr Creeper ratio 0 Creeper ratio
Pto1 PTO parameter 1 5 PTO parameter 1
FP1 Clutch 1 base 128 Clutch 1 base calibration value
FP2 Clutch 2 base 128 Clutch 2 base calibration value
FP3 Clutch R base 128 Clutch R base calibration value
FP4 Clutch A base 128 Clutch A base calibration value
FP5 Clutch B base 128 ClutchB base calibration value
FP6 Clutch C base 128 Clutch C base calibration value
FP7 Clutch L base 128 Clutch L base calibration value
FP8 Clutch M base 128 Clutch M base calibration value
FP9 Clutch H base 128 Clutch H base calibration value
FP10 Clutch 1 fill 19 Clutch 1fill time calibration
FP11 Clutch 2 fill 19 Clutch 2fill time calibration
FP12 Clutch R fill 19 Clutch R fill time calibration
FP13 Clutch A fill 19 Clutch A fill time calibration
FP14 Clutch B fill 19 ClutchB fill time calibration
FP15 Clutch C fill 19 Clutch C fill time calibration
FP16 Clutch L fill 19 Clutch Lfill time calibration
FP17 Clutch M fill 19 Clutch Mfill time calibration
FP18 Clutch H fill 19 Clutch Hfill time calibration
Issue 1 May 2001


Clear DCC stored code
64. Select "CLEd"
65. Press 5 to enter. "9999" will be appear in the

ENG FIELD
66. Press to clear the error code. "0000" will appear

HRS AREA
during 10 seconds.
67. Press one time 6 to return to the menu and two

Clear TC stored code

68. Repeat operation 33 to 36 Fig. 15
69. Select "CLEt"
70. Press 5 to enter. "9999" will be appear in the

ENG FIELD
71. Press to clear the error code. "0000" will appear

HRS AREA
during 10 seconds.
72. Press one time 6 to return to the menu and two

Fig. 16
Issue 1 May 2001

E . Level 3
With level 3 calibration, the qualified personnel can
modify the DCC and TC parameters.
73. Put the ignition on.

Note : You must not press the clutch pedal
74. Before 20 seconds, press and hold 4 6 for 5

seconds
75. "CAL3" will be apprear on the lower display (Fig. 17)
76. Press 5 to select the fonction to control
Available fonctions functions :

Fig. 17
Display Readout Calibration function
dCnt Edit DCC constants
tCnt Edit TC constants
Check the DCC and TC constant in calibration level 2

(pages before).
77. After selected the constants to edit, select the
parameter by press 5
78. When the parameter to change is selected, press
GNO SL IP
SPO %
to select the digit. The digit selected is flashing
(Fig. 17).
ENG FIELD
79. Press to increment the digit selected.

HRS AREA
PTO ENG
80. Press to stock the parameter.

RPM RPM
81. Press 6 to exit calibration mode.
Issue 1 May 2001


Examples
F . Adjust the shifting - If the torque on the PTO shaft is high and the wheel
If you have a bad shifting only when using PTO imple- torque is low (stone crusher, rotary cultivator), enter a
ments, it is possible to adjust the shifting of the gearbox. high PtLd value. Example: during use of a Rotary
cultivator to prepare potatoes or rice, the values read
82. Work normally with the tractor with the power take and entered to obtain the correct gear shifting for the
off engaged. Check and note the ‘LoAd’ value in customer are:
diagnostic mode ‘A’. . LoAd ......... 358
83. If the implement can be used without engaging the . PtLt ........... 178
power take off, carry out a pass with the power take . PtLd ........... 248
off disengaged. Note the new value of ‘LoAd’ ‘B’.
84. Stop the engine and go to Level 3 calibration (see § E).
85. Select ‘PtLt’. - If the torque on the PTO shaft is low and the wheel torque
86. Enter value ‘B’ noted during operation 83 and store it. is high, enter a low PtLd value. Example: during use of
Note: The higher the value, the higher the correc- a combined implement, seeder plus rotary harrow, the
tion with a high engine load. values read and entered to obtain the correct gear
87. Select ‘PtLd’. shifting for the customer are:
88. Input a constant value equal to A – B and store this . LoAd .......... 500
constant. . PtLt ............ 250
Note: The higher the value the more flexible the . PtLd ........... 138
gear shifting up until a downgrade limit value.
89. If the implement cannot be used without engaging
the power take off, input an estimated ‘B’ value for
‘PtLt’, for example half the value of ‘A’, then input
the value of A – B for ‘PtLd’.
90. Return to the normal screen
91. Carry out field test with PTO implement and ajust the
value to obtain good shifting.
Note : This system is working only if the PTO is
ON and the "LoAd" value above the "PtLt" value.
Issue 1 May 2001

G . Diagnostic modes
The diagnostic functions are used by service personnel
to test and monitor the functions of the tractor electron-
ics. The diagnostics system uses the same type of
menu system as calibration levels 1 through 3.
The diagnostic menu may be entered at any time using
the following process.
92. Press and hold switch 5 for 5 seconds.

93. Once the diagnostics mode has been entered, "dIA9"
will be displayed on the lower section of the LCD
(Fig. 18).
94. After entering the diagnostic mode the operator
should press switch 4 to cycle through the list

Fig. 18
of diagnostic functions.
95. To start the diagnostic function currently displayed
press switch 5 .
96. To back out of the diagnostic menus press switch
6 .
When monitoring switch states, A/D (analog/digital)
inputs and stored error codes press switch 5 to

toggle between the different parameters, and switch
6 to leave the diagnostics function.
Upper display Lower display Diagnostic function
dAtA trAc System data DCC
dbin dcc DCC switch states
dAdc dcc DCC A/D inputs
dErr dcc DCC stored error codes
dLPS dcc DCC lamp check
9AU9 dcc DCC gauge check
tbin tad TC switch states
tAdc tad TC A/D frequency inputs
tErr tad TC stored error codes
Issue 1 May 2001


System data diagnostics "dAtA"
97. Repeat operation 92 to 94 to display "dAtA" (Fig. 19).
98. To cycle through this diagnostic function press
switch 5 . To leave it press switch 6 .

99. Readings values should be within the following units
to have good operations.
Fig. 19
Display code Parameters Units
E9tP Engine temperature 50 - 120 ° C

122 - 248 ° F
LoAd Engine torque Ft / lbs
trtP Transmission temperature 0 - 120 ° C

32 - 248 ° F
CPPS Clutch pedal percent 0 - 100 %
bStP Turbo boost pressure 0 - 1,72 bar

0 - 25 psi
bAtF Filtered battery voltage 0 - 16 volts
OILP Engine oil pressure 0 - 6,2 bar

0 - 92 psi
FUEL Percent fuel left 0 - 100 %
ACCL Accelerator potentiometer pedal value Not used

Navistar engine
rAdr Radar frequency Hz
Issue 1 May 2001

DCC Switch State Diagnostics “dbin”

100. Repeat operation 92 to 94 to display "dbin" function
(Fig. 22).
101. To cycle through this diagnostic function, press
5 . To leave it press 6 .
102. The "dbin" function is used to check the DCC
switch inputs.Switch states are displayed as "0" or
"1" according to position.
Fig. 20
Display code Parameters

PFA 4 WD switch
LbrA Left brake switch
rbrA Right brake switch
rPtO Rear PTO switch
FPtO PTO brake switch
SPtO PTO stop switch on the fender
dIFF Differential lock switch
IPS High position for trailed implement if switch enter
L9ht Headlights
AUtS Not used
Prbr Park brake and Park lock
LinS Not used
bclt Bottom of clutch (BOC)
tclt Top of clutch (TOC)
RlnO Armrest neutral switch normally open (NO)
RInC Armrest neutral switch normally closed (NC)
StOp Not used
NErr Not used
LLnC Neutral normally closed on steering column
LLnO Neutral normally open on steering column
Brlu Not used
Airl Not used
Issue 1 May 2001


DCC A / D input diagnostics "dAdC"
103. Repeat operation 92 to 94 to display "dAdC" function
(Fig. 21).
104. To cycle through this diagnostic function, press
5 . To leave it, press 6 .

105. The "dAdC" function is used to check analogic
inputs (value in point at ± 20).
Fig. 21
Display code Parameters A / D value
ShrL Armrest shifter Forward + = 802

Forward = 731
Forward - = 666
Neutral = 525
Reverse - = 370 As a reminder
Reverse = 295 NAO type lever
Reverse + = 208 8170 / 8180
SFnr Steering column shifter Forward + = 800

Forward = 693
Forward - = 604
Neutral = 100
Reverse - = 415
Reverse = 312
Reverse + = 221
Declutch = 486
StEr Not used
bAtr Rax battery voltage 11 V = 314

15,5 V = 442
FUEL Fuel level sensors Empty = 890

Full = 25
OILP Engine oil pressure 37 to 610
bAtF Filtered battery volts 12 V = 350
Issue 1 May 2001

DCC stored error codes "dErr"

106. Repeat operation 92 to 94 to display "dErr" function
(Fig. 22).
107. To cycle through the error code, press 5 . To
leave it, press 6 .

108. The "dErr" function is used to check the error code
in DCC memory. The DCC could stock 16 error
codes. The first value is the error code number. The
second value is the number of time of the error code
occured.
Fig. 22
Err1 Number of the 1st error code
tEr1 Number of time of the 1st error code occured
......
Err16 Number of the 16th error code
tEr16 Number of time of the 16th error code occured
Issue 1 May 2001


DCC lamp check "dLPS"
109. Repeat operation 92 to 94 to display "dLPS" function
(Fig. 23).
110. Press 5 to display each lamp during 5 seconds.

When the indicator light is "ON", the lower display
will read "ON".
When the indicator light is "OFF", the lower display
will read "OFF"
111. To leave this diagnostic function, press 6 .
Fig. 23
DCC analog gauge check "9AU9"

112. Repeat operation 92 to 94 to display "9AU9" function
(Fig. 24).
113. Press 5 to display the gauge at middle position.
114. Press 5 to display the gauge at maximum

position.
115. Press 5 to display the gauge at minimum

position
116. To leave this diagnostic function, press 6 .
Fig. 24
CEnt Middle position
HI9H Maximum position
LO Minimum position
Issue 1 May 2001

TC switch state diagnostics "tbin"

117. Repeat operation 92 to 94 to display "tbin" function
(Fig. 25).
leave it, press 6 .

119. The "tbin" function is used to check the TC switch
inputs. The switch states are displayed as "0" or "1"
according to position
Fig. 25
hPrS Rear axle hydraulic pressure (17 bar)
hFLt Clogging switch hydraulic filter (15 µ)
tPrS Gearbox transmission pressure (17 bar)
LUbE Rear axle lubrication switch (5 bar)
CrEP Not used
PrLc Park lock switch on the rear axle
Issue 1 May 2001


TC A / D input diagnostics "tAdc"
120. Repeat operation 92 to 94 to display "tAdc" function
(Fig. 26).
leave it, press 6 .

122. The "tAdc" function is used to check analogic
inputs and frequencies on the TC.
Fig. 26
Code affiché Parameters
En9S Engine speed sensor
trnS Transmission output speed sensor
FPtO PTO clutch output speed sensor
rPtO Rear PTO shaft sensor
Issue 1 May 2001

TC stored error codes "tErr"

123. Repeat operation 92 to 94 to display "tErr" function
(Fig. 27).
leave it, press 6 .

125. The "tErr" function is used to check the error codes
in TC memory. The TC could stock 20 error codes.
The first value is the error code number. The second
value is the number of time of the error code
occured.
Fig. 27
Err1 Number of the 1st error code
tEr1 Number of time of the 1st error code occured
......
Err20 Number of the 20th error code
tEr20 Number of time of the 20th error code occured
Issue 1 May 2001

DCC / TC - Error codes 11B03.1
11B03 Error codes
CONTENTS
A. General ___________________________________________ 2
B. List of TC and DCC error codes _____________________ 2
- TC error codes ____________________________________ 3
- DCC error codes __________________________________ 6
C. TC and DCC error codes analysis ____________________ 7
Issue 1 May 2001

11B03.2 DCC / TC - Error codes

A . General B . List of TC and DCC error codes
The TC (Transmission Controller) and the DCC (Display All error codes of the TC and DCC are displayed on the
Cab Controller) form the transmission control system for LCD screen of the DCC.
tractors fitted with the Full Powershift gearbox.
If an intermittent Error Code is encountered, it can be
These 2 electronic units control all the automatic func- displayed by using the diagnostics function providing it is
tions of the transmission according to the driver's ac- set to store such errors.
tions and the information received from various sensors.
According to the severity of the Error Code, one of the
The TC and DCC control : following may occur:
- the Full Powershift gearbox - the tractor is placed in computer Neutral (C.N.)
- the front axle - the buzzer sounds on certain DCC errors (123 / 124 / 125
- the front and rear differential locks / 126 / 156)
- the power take-off - the Error Code may be stored according to a pre-set
option that is programmed in the factory.
The TC and DCC can be :
- programmed : to improve the control of functions Error codes 2 to 119 correspond to TC failures.
- parameterised : identified by a 12-digit code indicating
the model and options of the tractor both units are Error codes 121 to 162 correspond to DCC failures.
mounted on
- tests : Check the operation of the functions
The TC and DCC are located :

- the TC is mounted on the right-hand side of the gearbox
- the DCC is mounted in the cab and replaces the
dashboard
The TC and DCC has self-diagnostic modes :

- the reading of Error codes can be carried out in 2 ways:
. by the direct reading of the Error Code on the DCC
. by direct reading of the error code using Wintest
Certain TC and DCC error codes are stored in the DCC

and can be displayed at any time providing a reset has
not been carried out.
Issue 1 May 2001

TC error codes
0 Not used
1 Not used
2 Clutch L electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
3 Clutch L electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
4 Clutch M electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
5 Clutch M electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
6 Clutch H electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
7 Clutch H electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
8 Clutch 1 electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
9 Clutch 1 electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
10 Clutch 2 electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
11 Clutch 2 electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
12 Clutch R electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
13 Clutch R electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
14 Clutch A electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
15 Clutch A electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
16 Clutch B electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
17 Clutch B electrical fault (short circuit on + 12 AC) Error Not StoredC.N.
18 Clutch C electrical fault (open circuit or short circuit to earth) Error Not Stored C.N.
19 Clutch C electrical fault (short circuit on + 12 AC) Error Not Stored C.N.
20 Incorrect gear requested by DCC Error Not Stored C.N.
21 Temperature of transmission oil for calibration less than 50°C Error Not Stored
22 Engine speed above the calibration limit (1800 rpm) Error Not Stored
23 Engine speed below the calibration limit (1250 rpm) Error Not Stored
24 Gearbox output speed above calibration limit Error Not Stored
25 Default calibration values used Error Not Stored
26 Wrong parameter for number of pulses per PTO rev Error Not Stored
27 No speed sensor signal at calibration Error Not Stored
28 Incorrect Forward speed sensor signal at calibration Error Not Stored
29 Incorrect Reverse speed sensor signal at calibration Error Not Stored
30 Speed sensor signal at calibration does not drop Error Not Stored
31 Engaging pressure higher than 5.1 bar Error Not Stored
32 Clutch 1 filling fault (above 300ms) Error Not Stored
33 Clutch 2 filling fault (above 300ms) Error Not Stored
34 Clutch R filling fault (above 300ms) Error Not Stored
35 Clutch A filling fault (above 300ms) Error Not Stored
36 Clutch B filling fault (above 300ms) Error Not Stored
37 Clutch C filling fault (above 300ms) Error Not Stored
38 Clutch L filling fault (above 300ms) Error Not Stored
39 Clutch M filling fault (above 300ms) Error Not Stored
40 Clutch H filling fault (above 300ms) Error Not Stored
41 Detection of transmission slip Error Stored
42 Not used
Issue
Issue 2
1 May 2002
December 2000

43 Not used
44 Not used
45 High alternator regulator voltage (filtered battery signal) Error Stored
46 Low alternator regulator voltage (filtered battery signal) Error Stored
47 Not used
48 Not used
49 High transmission temperature sensor signal Error Stored
50 Low transmission temperature sensor signal Error Stored
51 Not used
52 Not used
53 High PTO solenoid valve current Error Stored
54 Low PTO solenoid valve current Error Stored
55 High PTO brake solenoid valve current Error Stored
56 Low PTO brake solenoid valve current Error Stored
57 High clutch C solenoid valve current Error Stored
58 Low clutch C solenoid valve current Error Stored
59 High clutch R solenoid valve current Error Stored
60 Low clutch R solenoid valve current Error Stored
61 High clutch A solenoid valve current Error Stored
62 Low clutch A solenoid valve current Error Stored
63 High clutch 2 solenoid valve current Error Stored
64 Low clutch 2 solenoid valve current Error Stored
65 High clutch B solenoid valve current Error Stored
66 Low clutch B solenoid valve current Error Stored
67 High clutch 1 solenoid valve current Error Stored
68 Low clutch 1 solenoid valve current Error Stored
69 High differential lock solenoid valve current Error Stored
70 Low differential lock solenoid valve current Error Stored
71 High clutch M solenoid valve current Error Stored
72 Low clutch M solenoid valve current Error Stored
73 High clutch H solenoid valve current Error Stored
74 Low clutch H solenoid valve current Error Stored
75 High clutch L solenoid valve current Error Stored
76 Low clutch L solenoid valve current Error Stored
77 CAN message lost Error Not Stored
78 CAN network deactivated Error Stored
79 No CAN message from the DCC Error Stored C.N. Special
80 Minor Checksum Error in serial EEPROM (Table Of Contents) Error Stored
81 Fatal Checksum Error in serial EEPROM (resets default values) Error Stored
82 Minor fault in transmission service hours counter (internal to TC) Error Stored
83 Major fault in transmission service hours counter (internal to TC) Error Stored
84 Minor fault in transmission tenths of service hours counter (internal to TC) Error Stored
85 Major fault in transmission tenths of service hours counter (internal to TC) Error Stored
86 Gearbox 17 bar pressure switch fault Error Stored
Issue
Issue 12 December
May 2000
2002
87 Lubrication 3 bar pressure switch fault Error Stored

88 Attempt to reprogram with engine running Error Not Stored C.N.
89 TC internal circuit (protection transistor stuck open) Error Stored C.N.
90 No electrical signal from PTO speed sensor Error Stored
91 No electrical signal from engine speed sensor Error Stored
92 Engine speed drop with engine stalling Error Stored
93 PTO clutch slip Error Stored
94 PTO brake failure Error Stored
95 No hydraulic pressure Error Stored
96 Short circuit on +12V AC of PTO clutch solenoid valve Error Stored C.N.
97 Over voltage detected on PTO clutch solenoid valve Error Stored
98 Park lock engagement error Error Stored C.N.
99 Park lock move error Error Stored
100 Front axle solenoid valve failure Error Stored
101 Clutch 1 engaging pressure calibration fault Error Stored
102 Clutch 2 engaging pressure calibration fault Error Stored
103 Clutch R engaging pressure calibration fault Error Stored
104 Clutch A engaging pressure calibration fault Error Stored
105 Clutch B engaging pressure calibration fault Error Stored
106 Clutch C engaging pressure calibration fault Error Stored
107 Clutch L engaging pressure calibration fault Error Stored
108 Clutch M engaging pressure calibration fault Error Stored
109 Clutch H engaging pressure calibration fault Error Stored
110 TC internal circuit (protection transistor stuck closed) Error Stored
111 Fault between specified and measured current on clutch 1 Error Stored C.N.
112 Fault between specified and measured current on clutch 2 Error Stored C.N.
113 Fault between specified and measured current on clutch R Error Stored C.N.
114 Fault between specified and measured current on clutch A Error Stored C.N.
115 Fault between specified and measured current on clutch B Error Stored C.N.
116 Fault between specified and measured current on clutch C Error Stored C.N.
117 Fault between specified and measured current on clutch L Error Stored C.N.
118 Fault between specified and measured current on clutch M Error Stored C.N.
119 Fault between specified and measured current on clutch H Error Stored C.N.
Issue 12 May 2000

December 2002

DCC error codes
121 High alternator regulator voltage (filtered battery signal) Error Stored
122 Low alternator regulator voltage (filtered battery signal) Error Stored
123 High engine oil pressure sensor electrical signal Error Stored
124 Low engine oil pressure sensor electrical signal Error Stored
125 High engine temperature sensor signal Error Stored
126 Low engine temperature sensor signal Error Stored
127 High fuel gauge electrical signal Error Not Stored
128 Low fuel gauge electrical signal Error Not Stored
129 High battery voltage (non filtered battery signal) Error Not Stored
130 Low battery voltage (non filtered battery signal) Error Not Stored
131 Boost sensor too high Error Stored
132 Boost sensor too low Error Stored
133 Not used
134 Not used
135 Analogue reverse/forward lever sensor too high Error Stored C.N.
136 Analog reverse/forward lever sensor too low Error Stored C.N.
137 Armrest lever sensor too high Error Stored C.N.
138 Armrest lever sensor too low Error Stored C.N.
139 Clutch pedal potentiometer too high Error Stored
140 Clutch pedal potentiometer too low Error Stored
141 Engine speed out of range Error Stored
142 Top of clutch (TOC) short circuited to + 12 V AC Error Stored
143 Bottom of clutch (BOC) short-circuited to +12 V AC Error Stored C.N.
144 NAO shuttle lever neutral switch normally open failed - high Error Stored
145 NAO shuttle lever neutral switch normally open failed - low Error Stored
146 NAO shuttle lever neutral switch normally closed failed - high Error Stored
147 NAO shuttle lever neutral switch normally closed failed - low Error Stored
148 Attempt to reprogram with engine running Error Not Stored C.N.
149 CAN bus off Error Stored
150 CAN bus off error Error Stored
151 Gearbox output speed out of range Error Not Stored
152 Major fault on engine service hours counter Error Stored
153 Parameter table fault Error Not Stored C.N.
154 Normal CAN communication with TC has failed Error Stored C.N. Special
155 Incorrect tractor code selected Error Not Stored
156 Clutch pedal top switch (TOC) stuck open Error Stored
157 Engine sensor off Error Stored
158 Armrest lever calibration error Error Not Stored
159 Analog reverse/forward lever neutral switch failure in neutral Error Stored C.N.
160 Analog reverse/forward lever neutral switch failure outside neutral Error Stored C.N.
161 Armrest lever neutral switch failure in neutral position Error Stored C.N.
162 Armrest lever neutral switch failure in non neutral position Error Stored C.N.
Issue
Issue 12 December
May 2000
2002
Error Code 22
C . TC and DCC error codes analysis Engine speed above the calibration limit (1800-rpm).
- Possible causes: The calibration of the transmission
Error Codes 2, 4, 6, 8, 10, 12, 14, 16 and 18 has been undertaken with the engine speed above 1800
Clutch electrical fault (open circuit or short circuit to rpm. Calibration must be carried out at 1300-rpm +/-50.
earth) Speed sensor or wiring defective.
- Possible causes : The maximum supply current to the - Tests : Reduce the engine speed and carry out calibra-
solenoid valve has been reached by the TC due to an tion again. Check the speed sensor and test the wiring
open circuit, or short circuit to earth on the positive or for any open circuit or short circuit.
negative leads in the solenoid valve harness, or the
resistance of the solenoid in the solenoid valve is Error Code 23
excessive. Engine speed below the calibration limit (1250 rpm).
- Tests : Check continuity in the harness between the TC - Possible causes: The calibration of the transmission
and the solenoid valve to detect any open circuit, or was undertaken with an engine speed of less than 1150
short circuit to the frame / earth. Check the resistance rpm. Speed sensor or wiring defective.
of the solenoid in the solenoid valve. - Tests: Increase engine speed and recalibrate. Check
the speed sensor and test wiring for any open circuit.
Error Codes 3, 5, 7, 9, 11, 13, 15, 17 and 19
Clutch electrical fault (short circuit on + 12 AC) Error Code 24
- Possible causes: The minimum supply current for the Gearbox output speed above the calibration limit.
clutch solenoid valve has been reached by the TC due - Possible causes: The calibration of the transmission
to a short circuit on the supply on the positive, or was undertaken at an output speed greater than 100
negative leads in the solenoid valve harness. rpm. The tractor has moved because the parking brake
- Tests: Check the supply to the leads of the solenoid was not on. Output speed sensor or wiring defective.
valve harness with the ignition key turned, engine not - Tests : Check that the parking brake is on. Check the
running. Test the harness to detect any 12-volt short output speed sensor and test the circuit for any open
circuit in the harness. circuit or a short circuit in the wiring.
Error Code 20 Error Code 25
Incorrect gear requested by DCC Default calibration values used.
- Possible cause: The TC has received a request for a - Possible causes: The TC is using the default values for
gear change from the DCC which is not defined in the the calibration. The transmission has not been cali-
programming of the TC. brated. The TC memory is damaged or the TC is
- Test: Check DCC/TC constants and calibration of the defective.
gear lever. - Tests: Calibrate the transmission. Replace the TC.
Temperature of transmission oil for calibration less than Wrong parameter for number of pulses per PTO rev.
50°C. - Possible causes: Incorrect parameter input, enter new
- Possible cause: The calibration of the transmission has parameters for the tractor.
been undertaken with the transmission oil below the
specified calibration temperature of 50°C (120°F).
- Tests: Heat the transmission oil. Then check the
correct operation of the temperature sensors and the
wiring.
Issue 1 May 2001


No speed sensor signal at calibration Engaging pressure greater than 5.1 bar.
- Possible causes: The speed of the shaft (gearbox 5th - Possible causes: A pressure in the clutch engaging
stage) was zero during calibration phases 1, 2 or 3 due was greater than 5.1 bar (75 psi) during one of the cali-
to an incorrect conversion parameter in the TC; wiring bration steps (4 to 12) due to high pressure in the circuit;
defect on the calibration speed sensor; partial failure of failure of a solenoid valve; failure in the transmission or
the TC; low clutch pressure; defective solenoid valve or failure of the TC.
mechanical failure in the transmission. - Tests: Check the pressure in the clutch circuit, check
- Tests: Check that the calibration speed sensor is whether a solenoid valve corresponding to the stage
connected and test the wiring to detect any open circuit being calibrated is stuck or defective. Check whether
or short circuit. Check the pressure in the clutch circuit there is a mechanical failure in the transmission or in
and the correct operation of the solenoid valves the TC.
(clutches R, C, 2 and B). Replace the TC.
Error Code 28 Error Codes 32, 33, 34, 35, 36, 37, 38, 39, 40
Incorrect Forward speed sensor signal at calibration Clutch filling fault (above 300 ms)
- Possible causes: The speed of the shaft (gearbox 5th - Possible causes: Clutch filling time too slow (greater
stage) was not within admissible limits during phases than 300 milliseconds) due to low circuit pressure;
2 or 3 of the calibration due to an incorrect conversion failure of a solenoid valve; partial failure of the TC or a
parameter in the TC; calibration speed sensor wiring mechanical failure in the gearbox.
fault; partial failure of the TC; low clutch pressure; - Tests: Check clutch circuit pressure. Check whether a
defective solenoid valve or mechanical failure in the stuck or defective solenoid valve is linked to the error
transmission. code. Check for mechanical failure in the gearbox or a
- Tests: Check that the calibration speed sensor is failure in the TC.
connected and test the wiring for any open circuit or
short circuit. Check the pressure in the clutch circuit Error Code 41
and the correct operation of the solenoid valves Detection of transmission slip
(clutches 2, C and B). Replace the TC. - Possible causes: The engaging of the gearbox clutches
remained 10% below total engagement for a period of
Error Code 29 10 seconds with the clutch pedal positioned at more
Incorrect Reverse speed sensor calibration signal than 40% of its total travel; or during 30 seconds with
- Possible causes: The speed of the shaft (gearbox 5th the pedal at less than 40% of its travel. This may be due
stage) was not within admissible limits during phase 1 to prolonged overuse of the clutch pedal; starting in too
of the calibration due to an incorrect conversion param- high a gear for the load; low pressure in the circuit;
eter in the TC; a wiring fault on the calibration speed failure of a solenoid valve or a mechanical failure in the
sensor; partial failure of the TC; low clutch pressure; transmission.
defective solenoid valve or mechanical failure in the - Tests: Start in a lower gear. Check pressure in the
transmission. clutch circuit. Check if one of the solenoid valves linked
- Tests: Check that the calibration speed sensor is to the gear indicating the fault is stuck or defective; or
connected and test the wiring for any open circuit or whether there is a mechanical failure in the transmis-
short circuit. Check the pressure in the clutch circuit sion. Avoid slipping the clutch with the clutch pedal.
and the correct operation of the solenoid valves
(clutches R and C). Replace the TC. Error Code 45
High alternator regulator voltage (filtered battery signal).
Error Code 30 - Possible causes: The filtered battery voltage, terminal
Speed sensor signal at calibration doesn’t drop. B - J, at the TC is higher than 16.5 V. The alternator is
- Possible causes: The speed of the shaft (gearbox 5th providing too high a charge.
stage) did not drop during one of the pressure mainte- - Tests: Check voltage at terminal B - J and the alternator
nance calibration phases (4 to 12) due to a solenoid output current.
valve failure; partial failure of the TC or mechanical
failure in the transmission.
- Tests: Check whether the solenoid valve correspond-
ing to the stage being calibrated is stuck or defective;
or whether there is a failure in the transmission or the
TC.
Issue 1 May 2001


Low alternator regulator voltage (filtered battery signal). High PTO brake solenoid valve current.
- Possible causes: The filtered battery voltage, terminal - Possible causes: The fine control circuit of the PTO
B - J, at the TC is less than 11 V. The alternator is not brake solenoid valve is defective following a short
charging enough. circuit to 12 V in the return circuit, or due to a TC failure.
- Tests: Check the voltage at terminal B - J of the TC. If - Tests: Check the circuit between terminal B - E of the
the voltage is low, check whether the alternator output TC and the PTO brake solenoid valve to detect any short
is low or whether there is an open circuit or short circuit circuit to 12 V. Replace the TC.
in the wiring harness.
Error Code 56
Error Code 49 Low PTO brake solenoid valve current.
High transmission temperature sensor signal. - Possible causes: The fine control circuit of the PTO
- Possible causes: The earth circuit of the temperature brake solenoid valve is defective following a short
sensor between terminal D - G of the TC and the sensor circuit to earth in the return circuit, or due to a TC failure
is open; or the signalling circuit between terminal D - J - Tests: Check the circuit between terminal B - E of the
of the TC and the sensor is open or short circuited to TC and the PTO brake solenoid valve to detect any short
12 V. circuit to earth. Replace the TC.
- Tests: Check the circuit between terminal D-G of the
TC and the sensor to detect any open circuit. Check the Error Code 57
circuit between terminal D-J of the TC and the sensor High clutch "C" solenoid valve current.
to detect any open circuit or short circuit to system - Possible causes: The fine control circuit of the solenoid
voltage. valve of clutch "C" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
Error Code 50 - Tests: Check the circuit between terminal C - A of the
Low transmission temperature sensor signal. TC and the solenoid valve of clutch 'C' to detect any
- Possible cause: The temperature sensor signalling short circuit to 12 V. Replace the TC.
circuit between terminal D - J of the TC and the sensor
is short-circuited to earth. Error Code 58
- Tests: Check the circuit between terminal D - J of the Low clutch "C" solenoid valve current.
TC and the sensor for any short-circuiting to earth. - Possible causes: The fine control circuit of the solenoid
valve of clutch "C" is defective due to a short circuit to
Error Code 53 earth in the return circuit, or due to a TC failure.
High PTO solenoid valve current . - Tests: Check the circuit between terminal C-A of the TC
- Possible causes: The fine control circuit of the rear PTO and the solenoid valve of clutch "C" to detect any short
solenoid valve is defective following a short circuit to circuit to earth. Replace the TC.
12 V in the return circuit, or a TC failure.
- Tests: Check the circuit between terminal B - D of the Error Code 59
TC and the rear PTO solenoid valve to detect any short High clutch "R" solenoid valve current.
circuit to 12 V. Replace the TC. - Possible causes: The fine control circuit of the solenoid
valve of clutch "R" is defective due to a short circuit to
Error Code 54 12 V in the return circuit, or due to a TC failure.
Low PTO solenoid valve current. - Tests: Check the circuit between terminal C - J of the
- Possible causes: The fine control circuit of the rear PTO TC and the solenoid valve of clutch "R" to detect any
solenoid valve is defective following a short circuit to short circuit to 12 V. Replace the TC.
earth in the return circuit, or due to a TC failure
- Tests: Check the circuit between terminal B - D of the
TC and the rear PTO solenoid valve to detect any short
circuit to earth. Replace the TC.
Issue 1 May 2001


Low clutch "R" solenoid valve current. Low clutch "B" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid - Possible causes: The fine control circuit of the solenoid
valve of clutch "R" is defective due to a short circuit to valve of clutch "B" is defective due to a short circuit to
earth in the return circuit, or due to a TC failure. earth in the return circuit or due to a TC failure.
- Tests: Check the circuit between terminal C - J of the - Tests: Check the circuit between terminal C - C of the
TC and the solenoid valve of clutch "R" to detect any TC and the solenoid valve of clutch "B" to detect any
short circuit to earth. Replace the TC. short circuit to earth. Replace the TC.

High clutch "A" solenoid valve current. High clutch "1" solenoid valve current.
valve of clutch "A" is defective due to a short circuit to valve of clutch "1" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure. 12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - B of the - Tests: Check the circuit between terminal C-D of the TC
TC and the solenoid valve of clutch "A" to detect any and the solenoid valve of clutch "1" to detect any short
short circuit to 12 V. Replace the TC. circuit to 12 V. Replace the TC.

Low clutch "A" solenoid valve current. Low clutch "1" solenoid valve current.
valve of clutch "A" is defective due to a short circuit to valve of clutch "1" is defective due to a short circuit to
earth in the return circuit, or due to a TC failure. earth in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - B of the - Tests: Check the circuit between terminal C - D of the
TC and the solenoid valve of clutch "A" to detect any TC and the solenoid valve of clutch "1" to detect any
short circuit to earth. Replace the TC. short circuit to earth. Replace the TC.

High clutch "2" solenoid valve current. High differential lock solenoid valve current.
- Possible causes: The fine control circuit of the solenoid - Possible causes: The fine control circuit of the differen-
valve of clutch ²2² is defective due to a short circuit to tial lock solenoid valve is defective due to a short circuit
12 V in the return circuit, or due to a TC failure. to 12 V in the return circuit, or due to a TC failure.
Tests: Check the circuit between terminal C-H of the TC - Tests: Check the circuit between terminal C - K of the
and the solenoid valve of clutch „2“ to detect any short TC and the differential lock solenoid valve to detect any
circuit to 12 V. Replace the TC. short circuit to 12 V. Replace the TC.

Low clutch „2“ solenoid valve current. Low differential lock solenoid valve current.
- Possible causes: The fine control circuit of the solenoid - Possible causes: The fine control circuit of the differen-
valve of clutch "2" is defective due to a short circuit to tial lock solenoid valve is defective due to a short circuit
earth in the return circuit or due to a TC failure. to earth in the return circuit, or due to a TC failure..
- Tests: Check the circuit between terminal C-H of the TC - Tests: Check the circuit between terminal C - K of the
and the solenoid valve of clutch "2" to detect any short TC and the differential lock solenoid valve to detect any
circuit to earth. Replace the TC. short circuit to earth. Replace the TC.

High clutch "B" solenoid valve current. High clutch "M" solenoid valve current
valve of clutch "B" is defective due to a short circuit to valve of clutch "M" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure. 12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - C of the - Tests: Check the circuit between terminal C - G of the
TC and the solenoid valve of clutch "B" to detect any TC and the solenoid valve of clutch "M" to detect any
short circuit to 12 V. Replace the TC. short circuit to 12 V. Replace the TC.
Issue 1 May 2001


Low clutch "M" solenoid valve current CAN network deactivated
- Possible causes: The fine control circuit of the solenoid - Possible causes: Hardware failure either in the DCC or
valve of clutch "M" is defective due to a short circuit to in the 3 CAN network cables linking the systems.
earth in the return circuit, or due to a TC failure. - Tests: Check the continuity of the 3 CAN cables
- Tests: Check the circuit between terminal C - G of the between terminals D - A, D - B and D - K of the DCC and
TC and the solenoid valve of clutch "M" to detect any terminals D - A, D - G and D - K of the TC. Replace the
short circuit to earth. Replace the TC. DCC.

High clutch "H" solenoid valve current No CAN message from the DCC
- Possible causes: The fine control circuit of the solenoid - Possible causes: Open circuit or short circuit in the 3
valve of clutch "H" is defective due to a short circuit to CAN network cables linking the DCC and TC.
12 V in the return circuit or due to a TC failure. - Tests: Check the continuity of the 3 CAN cables
- Tests: Check the circuit between terminal C - E of the between terminals D - A, D - B and D - K of the DCC and
TC and the solenoid valve of clutch "H" to detect any terminals D - A, D - G and D - K of the TC.
short circuit to 12 V. Replace the TC. Note: Computer Neutral Special = gearbox will not
go any more to neutral but PTO will be shut off,
Error Code 74 4WD will be engaged and Diff.lock will be disen-
Low clutch "H" solenoid valve current. gaged. The error code 79 will be displayed on the
- Possible causes: The fine control circuit of the solenoid DCC but the tractor can still move in the selected
valve of clutch "H" is defective due to a short circuit to gear until the clutch pedal is depressed (BOC
earth in the return circuit or due to a TC failure. switch activated) or one of the gear lever is moved
- Tests: Check the circuit between terminal C - E of the to neutral position (neutral switch activated).
TC and the solenoid valve of clutch "H" to detect any
short circuit to earth. Replace the TC. Error Code 80
Minor Checksum Error in serial EEPROM (Table Of
Error Code 75 Contents)
High L clutch solenoid valve current - Possible cause: An error was generated while saving
- Possible causes: The fine control circuit of the solenoid the parameter in the TC. The system will delete the error
valve of clutch "L" is defective due to a short circuit to after one or two ignition cycles, but the parameter may
12 V in the return circuit or due to a TC failure. not have been saved and the default parameters will be
- Tests: Check the circuit between terminal C - F of the used.
TC and the solenoid valve of clutch "L" to detect any - Tests: Check the "dcon" and "tcon" parameters.
short circuit to 12 V. Replace the TC.
Error Code 81
Error Code 76 Fatal Checksum Error in serial EEPROM (resets default
Low L clutch solenoid valve current. values)
- Possible causes: The fine control circuit of the solenoid - Possible cause: The operating parameters have been
valve of clutch "L" is defective due to a short circuit to lost.
earth in the return circuit or due to a TC failure. - Tests: Check and re-enter the correct parameters for
- Tests: Check the circuit between terminal C - F of the the tractor.
TC and the solenoid valve of clutch "L" to detect any
short circuit to earth. Replace the TC.
Error Code 77
Loss of CAN message
- Possible causes: Hardware failure either in the DCC or
in the 3 CAN network cables linking the systems.
- Tests: Check the continuity of the 3 CAN cables
between terminals D - A, D - B and D - K of the DCC and
terminals D - A, D - G and D - K of the TC. Replace the
DCC.
Issue 1 May 2001


Minor fault in transmission service hours counter (inter- Lubrication 3 bar pressure switch fault
nal to TC) - Possible causes: The circuit between the oil pressure
- Possible cause: The transmission service hours are switch and terminal E - A of the TC is short-circuited to
stored in 3 different places. If one of the values differs earth. The contacts of the oil pressure switch are
from the other two, these two values will be copied to shorting together. The hydraulic pressure has not
replace the wrong value. If the three values are differ- reached the minimum required.
ent, there is no majority and the real number of trans- - Tests: Check that the hydraulic oil pressure is above the
mission service hours are lost. To delete this error, turn specified minimum. Test the circuit between the oil
the key to OFF position, then to ON again. pressure switch and terminal E - A of the TC to detect
any short circuit to earth. Check that the oil pressure
Error Code 83 switch itself is not short-circuiting.
Major fault in transmission service hours counter (inter-
nal to TC) Error Code 88
- Possible cause: The transmission service hours are Attempt to reprogram with engine running
stored in 3 different places. If the three places contain - Possible cause: An attempt has been made to
different values, the real number of transmission serv- download new software while the engine was running.
ice hours are lost. Certain figures will be stored as hours - Tests: To download new software, the ignition key
but they will not be correct. To delete this error, turn the switch must be on but the engine must be stopped.
key to OFF position, then to ON again. Note: This is an additional safety as Wintest
system normally does not allow reprogramming
Error Code 84 with engine running.
Minor fault in transmission tenths of service hours
counter (internal to TC) Error Code 89
- Possible cause: The tenths of transmission service TC internal circuit (protection transistor stuck open)
hours are stored in 3 different places. If one of the - Possible cause: TC failure
values differs from the other two, these two values will - Tests: Replace the TC
be copied to replace the wrong value. If the three values
are different, there is no majority and the real number of Error Code 90
tenths of transmission service hours are lost. To delete No electrical signal from PTO speed sensor
this error, turn the key to OFF position, then to ON again. - Possible causes: The PTO operates but the TC is
receiving no input from the sensor. The sensor is
Error Code 85 defective or one of the two sensor wires is short
Major fault in transmission tenths of service hours circuited or broken.
counter (internal to TC) - Tests: Check for breaks in the two wires running from
- Possible cause: The tenths of transmission service the sensor to the TC. Test the wiring from terminal E -
hours are stored in 3 different places. If the three places H of the TC to detect any short circuit to 12 V. Test the
contain different values, the real number of tenths of wiring from terminal E - D of the TC to detect any short
transmission service hours are lost. Certain figures will circuit to 12 V or earth. Replace the sensor.
be stored as tenths of hours but they will not be correct. Note: After a gearbox calibration, if the PTO speed
To delete this error, turn the key to OFF position, then sensor has not been reconnected (brown wire on
to ON again. brown wire near the TC) this error code can occur
when using PTO.
Error Code 86
Gearbox 17 bar pressure switch fault
- Possible causes: The circuit between the oil pressure
switch and terminal E - B of the TC is short-circuited to
earth. The oil pressure switch contacts are shorted
together. The transmission oil pressure is not reaching
the minimum required pressure.
- Tests: Check that the transmission oil pressure is
above the specified minimum. Test the circuit between
the oil pressure switch and terminal E - B of the TC to
detect any short circuit to earth. Check that the oil
pressure switch itself is not short-circuited.
Issue 1 May 2001


No electrical signal from engine speed sensor PTO brake failure
- Possible causes: The engine is running but the TC is - Possible causes: The TC has deactivated the PTO and
receiving no input from the engine speed sensor. The activated the PTO brake but detects that the PTO shaft
sensor is defective or the circuit to the sensor is open is still turning. Mechanical failure of the PTO brake.
or short-circuited. Mechanical failure of the input gear - Tests: Check pressure in the PTO clutch and PTO
train. brake. If the pressure is correct, there is a mechanical
- Tests: Check wiring between the engine speed sensor failure in the brake itself. If the pressure is not within
and terminals E - E and E - H of the TC to detect any open specified limits, check whether the PTO brake or clutch
circuit. Test the wiring from terminal E - H of the TC to solenoid valves are jammed.
detect any short circuit to 12 V. Test the wiring between
the engine speed sensor and terminal E - E of the TC to Error Code 95
detect any short circuit to earth or 12 V. Remove the No hydraulic pressure
sensor and check that the pinions are turning. Replace - Possible cause: Hydraulic pressure was lower than 12
the sensor. bar (176 psi) for more than 2 seconds. This puts all
transmission and rear axle solenoid valves out of
Error Code 92 service.
Engine speed with engine stalling - Tests: Connect a pressure-gauge and check the low-
- Possible causes: The engine speed dropped more than pressure hydraulic circuit. Check the correct operation
50% of its initial speed when the PTO was engaged. of the low-pressure switch. Check the wiring between
Attempt at starting with too high a load on the PTO. PTO the pressure switch and terminal E - A of the TC.
speed sensor incorrectly adjusted. Low clutch pressure
or mechanical failure. Error Code 96
- Tests: Reduce the load on the PTO before engaging it; Short circuit on +12V AC of PTO clutch solenoid valve
check that the tool driven by the PTO has not seized up - Possible cause: The current still reaches the PTO
or jammed. Check the adjustment of the PTO speed solenoid valve when the TC has deactivated the PTO.
sensor; the clutch pressure and whether there is a Due to a short circuit to +12 V AC in the wiring harness
mechanical failure. Check continuity in the harness or a TC failure.
between the speed sensors and the corresponding TC - Tests: Disconnect connector B of the TC and check for
terminals. the presence of voltage on terminal C towards the earth
and on terminal G towards the earth. With the ignition
Error Code 93 key switch on, if a voltage is present, the harness is
PTO clutch slip faulty. Repair the harness. If no voltage is measured,
- Possible causes: The TC monitors the input and output replace the TC.
speeds of the PTO clutch and detects any clutch slip.
This may be caused by too high a load; poor adjustment Error Code 97
of the PTO speed sensor or a lack of clutch pressure due Over voltage detected on PTO clutch solenoid valve
to a mechanical failure. - Possible causes: The filtered battery voltage is above
- Tests: Reduce the load on the PTO. Check the adjust- 16.5 V. This may be due to an alternator failure.
ment of the PTO speed sensor. Check the clutch pres- - Tests: Check that the output of the alternator is correct.
sure. Check continuity in the wiring harness between
the speed sensors and corresponding terminals of the
TC.
Note: After a gearbox calibration, if the PTO speed
sensor has not been reconnected (brown wire on
brown wire near the TC) this error code can occur
when using PTO.
Issue 1 May 2001


Park lock engagement error. TC internal circuit (protection transistor stuck closed)
- Possible cause: The Park lock switch on the left-hand - Possible cause: Short circuit to earth on one of the
side of the transmission / axle unit is signalling that the solenoid outputs of the TC or TC failure.
Park lock is engaged although the TC has disengaged - Tests: Check all solenoid circuits to detect any wiring
the Park lock. harness damage. Replace the TC.
- Tests: Check the correct operation of the Park lock
switch on the left-hand side of the transmission / axle Error Code 111
unit. Test the wiring from the Park lock switch to the TC Fault between specified and measured current on clutch
to detect any open circuit or short circuit (terminals D - 1.
F of the TC). Check the solenoid valve wiring. Check the - Possible cause: If this error code occurs when starting
solenoid valve itself. a gearbox calibration check that the software program
numbers are not displayed any more on the DCC, if they
Error Code 99 are still displayed depress the clutch pedal fully with
Park-lock movement error one of the gear levers in neutral position.
- Possible cause: The status of the Park-lock switch on Clutch 1 solenoid coil resistance not adequate. TC
the left-hand side of the transmission / axle unit does battery voltage too low or too high. Bad earth on TC.
not change during the disengagement of the Park-lock Internal TC problem.
or the handbrake is still engaged. - Tests: Check coil resistance and harness (change if
- Tests: Check the correct operation of the Park-lock necessary). Do complete wiring and connectors check-
switch on the left-hand side of the transmission / axle list. Change TC.
unit. Test the wiring from the Park-lock switch to the
TC to detect any open circuit or short circuit (terminals Error Code 112
D - F of the TC). Disengage the handbrake. Fault between specified and measured current on clutch
2.
Error Code 100 - Possible cause: If this error code occurs when starting
Front axle solenoid valve failure a gearbox calibration check that the software program
- Possible causes: The 4WD actuator has detected an numbers are not displayed any more on the DCC, if they
error. Perhaps a short circuit or a break in the 4WD are still displayed depress the clutch pedal fully with
solenoid valve circuit. one of the gear levers in neutral position.
- Tests: Check the 4WD solenoid valve circuit to detect Clutch 2 solenoid coil resistance not adequate. TC
any open circuit or short circuit. Check the wiring battery voltage too low or too high. Bad earth on TC.
harness between the solenoid valve connector and Internal TC problem.
terminals B - H and C - K of the TC to detect any short - Tests: Check coil resistance and harness (change if
circuit, short to earth or 12 V. necessary). Do complete wiring and connectors
checklist.Change TC.
Error Codes 101, 102, 103, 104, 105, 106, 107, 108, and
109 Error Code 113
Clutch engaging pressure calibration fa ult Fault between specified and measured current on clutch
- Possible causes: The calibration has failed due to low R.
pressure in the circuit; a solenoid valve failure; partial - Possible cause: If this error code occurs when starting
failure of the TC or a mechanical failure in the transmis- a gearbox calibration check that the software program
sion. numbers are not displayed any more on the DCC, if they
- Tests: Check the circuit pressure. Check whether the are still displayed depress the clutch pedal fully with
solenoid valve corresponding to the Error Code is one of the gear levers in neutral position.
jammed, has failed or has defective O-rings. Check for Clutch R solenoid coil resistance not adequate. TC
a mechanical failure in the transmission. battery voltage too low or too high. Bad earth on TC.
Internal TC problem.
- Tests: Check coil resistance and harness (change if
necessary). Do complete wiring and connectors check-
list. Change TC.
Issue 1 May 2001


Fault between specified and measured current on clutch Fault between specified and measured current on clutch
A. L.
- Possible cause: If this error code occurs when starting - Possible cause: If this error code occurs when starting
a gearbox calibration check that the software program a gearbox calibration check that the software program
numbers are not displayed any more on the DCC, if they numbers are not displayed any more on the DCC, if they
are still displayed depress the clutch pedal fully with are still displayed depress the clutch pedal fully with
one of the gear levers in neutral position. one of the gear levers in neutral position.
Clutch A solenoid coil resistance not adequate. TC Clutch L solenoid coil resistance not adequate. TC
battery voltage too low or too high. Bad earth on TC. battery voltage too low or too high. Bad earth on TC.
Internal TC problem. Internal TC problem.
- Tests: Check coil resistance and harness (change if - Tests: Check coil resistance and harness (change if
necessary). Do complete wiring and connectors check- necessary). Do complete wiring and connectors check-
list. Change TC. list. Check the correct operation of the BOC switch.
Change TC.
Error Code 115
Fault between specified and measured current on clutch Error Code 118
B. Fault between specified and measured current on clutch
- Possible cause: If this error code occurs when starting M.
a gearbox calibration check that the software program - Possible cause: If this error code occurs when starting
numbers are not displayed any more on the DCC, if they a gearbox calibration check that the software program
are still displayed depress the clutch pedal fully with numbers are not displayed any more on the DCC, if they
one of the gear levers in neutral position. are still displayed depress the clutch pedal fully with
Clutch B solenoid coil resistance not adequate. TC one of the gear levers in neutral position.
battery voltage too low or too high. Bad earth on TC. Clutch M solenoid coil resistance not adequate. TC
Internal TC problem. battery voltage too low or too high. Bad earth on TC.
- Tests: Check coil resistance and harness (change if Internal TC problem.
necessary). Do complete wiring and connectors check- - Tests: Check coil resistance and harness (change if
list. Change TC. necessary). Do complete wiring and connectors check-
list. Check the correct operation of the BOC switch.
Error Code 116 Change TC.
Fault between specified and measured current on clutch
C. Error Code 119
- Possible cause: If this error code occurs when starting Fault between specified and measured current on clutch
a gearbox calibration check that the software program H.
numbers are not displayed any more on the DCC, if they - Possible cause: If this error code occurs when starting
are still displayed depress the clutch pedal fully with a gearbox calibration check that the software program
one of the gear levers in neutral position. numbers are not displayed any more on the DCC, if they
Clutch C solenoid coil resistance not adequate. TC are still displayed depress the clutch pedal fully with
battery voltage too low or too high. Bad earth on TC. one of the gear levers in neutral position.
Internal TC problem. Clutch H solenoid coil resistance not adequate. TC
- Tests: Check coil resistance and harness (change if battery voltage too low or too high. Bad earth on TC.
necessary). Do complete wiring and connectors check- Internal TC problem.
list. Change TC. - Tests: Check coil resistance and harness (change if
necessary). Do complete wiring and connectors check-
list. Check the correct operation of the BOC switch.
Change TC.


Error Code 121 A of DCC; the reference voltage must be 5 V.
High alternator regulator voltage (filtered battery signal) Error Code 127
- Possible causes: The filtered battery supply voltage, High fuel gauge signal
terminal A - K, going to the DCC is above 15.5 V. The - Possible causes: The circuit between terminal C - E of
alternator is over charging. the DCC and the fuel gauge is open or the return circuit
- Tests: Check the voltage at terminal A - K and the power to earth is open.
output of the alternator. - Tests: Check the circuit between terminal C - E of the
DCC and the fuel gauge to detect any open circuit and
Error Code 122 check the wiring between the fuel gauge and the earth
Low alternator regulator voltage (filtered battery signal) to detect any open circuit. Check whether the fuel level
- Possible cause: The voltage from the regulator, termi- sensor is defective.
nal A - K, reaching the DCC is below 11 V.
- Tests: Measure the voltage at terminal A - K of the DCC. Error Code 128
If the voltage is low, check whether the power output Low fuel gauge signal
of the alternator is low or whether there is an open - Possible cause: The circuit from terminal C - E of the
circuit or short circuit in the harness. DCC is short-circuited to earth.
- Tests: Check the wiring from terminal C - E of the DCC
Error Code 123 to detect any short circuit to earth. Check whether the
High engine oil pressure sensor signal fuel level sensor is defective.
- Possible causes: The circuit between terminal B - G of
the DCC and the sensor is open, or the sensor is not Error Code 129
sufficiently earthed. High battery voltage (non filtered battery signal)
- Tests: Check wiring between terminal B - G and the - Possible causes: The supply voltage of the battery,
sensor to detect any open circuit and to check that the terminal A - K, to the DCC is above 15.5 V or the
sensor housing is properly earthed. alternator is over charging.
- Tests: Check the voltage at terminal A - K and the power
Error Code 124 output of the alternator.
Low engine oil pressure sensor signal.Only recorded 8
seconds after start-up. Error Code 130
- Possible cause: The circuit between terminal B - G of Low battery voltage (non filtered battery signal)
the DCC and the sensor is short-circuited to earth. - Possible cause: The supply voltage of the battery,
- Tests: Check wiring between terminal B - G and the terminal A - K, to the DCC is less than 11 V.
earth to detect any short circuit. - Tests: Check the voltage at terminal A - K. If the voltage
is low, check whether the power output of the alternator
Error Code 125 is low or whether there is an open circuit or short circuit.
High engine temperature sensor signal
- Possible causes: The circuit between terminal C - F of Error Code 131
the DCC and the sensor is open or short-circuited to >5 Boost sensor too high
V or the earth return circuit is open. - Possible causes: The supply between terminal A - F of
- Tests: Check the wire between terminal C - F and the the DCC and terminal B of the sensor is >5 V or the
sensor to detect any open or short circuit to >5 V and reference earth circuit between terminal A - D of the
check the sensor is correctly earthed. DCC and terminal A of the sensor is open.
- Tests: Check the supply line between terminal A - F of
Error Code 126 the DCC and terminal B of the sensor to detect any short
Low engine temperature sensor signal circuit to 12 V. Test the earth between terminal A of the
- Possible causes: The circuit between terminal C - F of sensor and terminal A - D of the DCC to detect any open
the DCC and the sensor is short circuited to earth or the circuit.
circuit from terminal C - A of the DCC has a reference
voltage lower than 5 V.
- Tests: Check the wire from terminal C - F to detect any
short circuit to earth. Check the voltage at terminal C -
Issue
Issue 12 December
May 2000
2002

Boost sensor too low Clutch pedal potentiometer too high
- Possible causes: The reference voltage between A - E - Possible causes: The potentiometer supply line be-
of the DCC and terminal C of the sensor is open circuit; tween terminal B - B of the DCC and the sensor is >5
the supply circuit between terminal A - F of the DCC and V or the reference earth circuit between terminal B - K
terminal B of the sensor is open circuit; or the supply of the DCC and the sensor is in open circuit.
line of the potentiometer from terminal A - F of the DCC - Tests: Check the line between terminal B - B of the DCC
is short circuited to earth. and the sensor to detect any short circuit to 12 V. Test
- Tests: Check the line between terminal A - E of the DCC the line between terminal B - K of the DCC and the
and terminal C of the sensor to detect any open circuit. sensor to detect any open circuit.
Check whether the circuit between terminal A - F of the
DCC and terminal B of the sensor is open. Test the line Error Code 140
from terminal C - B of the DCC to detect any short circuit Clutch pedal potentiometer too low
to earth. - Possible causes: The reference voltage between termi-
nal B - A of the DCC and the sensor is in open circuit;
Error Code 135 or the supply line of the potentiometer between terminal
Analog reverse/forward lever sensor too high B - B of the DCC and the sensor is in open circuit; or the
- Possible causes: One internal reed switches damaged supply line of the potentiometer between terminal B - B
or DCC internal problem. of the DCC and the sensor is short circuited to earth.
- Tests: Check power supply lines positive and negative - Tests: Check the line between terminal B - A of the DCC
to lever and check output voltage in each lever position. and the sensor to detect any open circuit. Test the line
If problem change DCC or lever. between terminal B - B of the DCC and the sensor to
detect any open circuit or short circuit to earth.
Error Code 136
Analog reverse/forward lever sensor too low. Error Code 141
- Possible causes: One internal reed switches damaged Engine speed out of range
or DCC internal problem. - Possible cause: The DCC is detecting that the TC is
- Tests: Check power supply lines positive and negative transmitting an unrealistic engine speed.
to lever and check output voltage in each lever position. - Tests: Check that the engine speed sensor is correctly
If problem change DCC or lever. connected and is not defective. Partial TC failure.

Armrest lever sensor too high Top of clutch (TOC) short circuited to + 12 V AC
- Possible causes: The potentiometer supply between - Possible causes: Input line at terminal D - D of the DCC
terminal B - H of the DCC and the sensor is >5 V or the is short circuited to 12 V or TOC switch is defective or
reference earth circuit between terminal B - J of the wrongly adjusted.
DCC and the sensor is open. - Tests: Check the input line at terminal D - D to detect
- Tests: Check the line between terminal B - H of the DCC any short circuit to 12 V. Check whether the TOC switch
and the sensor to detect any short circuit to 12 V. Check is incorrectly adjusted or defective.
the line between terminal B - J of the DCC and the sen-
sor to detect any open circuit. Error Code 143
Bottom of clutch (BOC) short-circuited to +12 V AC.
Error Code 138 - Possible causes: The input line to terminal D - F of the
Armrest lever sensor too low DCC is short circuited to 12 V or the BOC switch is
- Possible causes: The reference voltage between termi- defective or incorrectly adjusted.
nal B - C of the DCC and the sensor is in open circuit; - Tests: Check the input line to terminal D - F of the DCC
or the supply line to the potentiometer between terminal to detect any short circuit to 12 V. Check whether the
B - H of the DCC and the sensor is in open circuit; or the BOC switch is incorrectly adjusted or defective.
supply between terminal G - H of the DCC and the
sensor is short circuited to earth.
- Tests: Check the line between terminal B - C of the DCC
and the sensor to detect any open circuit. Check the
line between terminal B - E of the DCC and the sensor
to detect any open circuit or short circuit to earth.
Issue 1 May 2001


NAO shuttle lever neutral switch normally open failed - Attempt to reprogram with engine running.
high - Possible cause: An attempt to download new software
- Possible causes: The input line to terminal D - C of the while the engine was running.
DCC is short circuited to 12 V or the neutral safety - Tests: To download new software, the ignition key
switch is defective or incorrectly adjusted. switch must be on but the engine must be stopped.
- Tests: Check the input line to terminal D - C of the DCC Note: This is an additional safety as Wintest sys-
to detect any short circuit. Check if the neutral safety tem normally does not allow reprogramming with
switch is defective or incorrectly adjusted. engine running.
Note: This error code is no more used since version
2.02 of software program. Error Code 149
CAN bus off.
Error Code 145 - Possible causes: Hardware error either in the TC or DCC
NAO shuttle lever neutral switch normally open failed - or in CAN network (3) wire linking the systems.
low - Tests: Check the continuity of the CAN wires (3)
- Possible causes: The input line to terminal D - C of the between terminals D - A, D - B and D - K of the DCC and
DCC is short-circuited to earth or the neutral safety the terminals D - A, D - G and D - K of the TC. Replace
switch is defective or incorrectly adjusted. the TC and/or DCC.
- Tests: Check the input line to terminal D - C of the DCC
to detect any short circuit to earth. Check whether the Error Code 150
neutral safety switch is defective or incorrectly ad- CAN bus off error
justed. - Possible causes: Hardware error either in the TC or DCC
Note: This error code is no more used since version or in CAN network (3) wire linking the systems.
2.02 of software program. - Tests: Check the continuity of the CAN wires (3)
between terminals D - A, D - B and D - K of the DCC and
Error Code 146 the terminals D - A, D - G and D - K of the TC. Replace
NAO shuttle lever neutral switch normally closed failed the TC and/or DCC.
high
- Possible causes: The input line to terminal D-J of the Error Code 151
DCC is short circuited to 12 V or the neutral safety Gearbox output speed out of range
switch is defective or incorrectly adjusted. - Possible causes: Incorrect gearbox type selected
- Tests: Check the input line to terminal D-J of the DCC AG150/AG250 or incorrect constants loaded in TC.
to detect any short circuit to 12 V. Check whether the - Tests: Check that gearbox type and selection is correct
neutral safety switch is defective or incorrectly ad- using the "dcon" and "tcon" calibration procedure, check
justed. the following parameters: "trAn" and "tPPr".
2.02 of software program. Error Code 152
Major fault on engine service hours counter
Error Code 147 - Possible causes: Engine hours are saved in 3 different
NAO shuttle lever neutral switch normally closed failed places and if ever 1 value is different from the other 2
low then the value saved in the 2 places will be copied over
- Possible causes: : The input line to terminal D-J of the the bad value. If ever all 3 locations have different
DCC is short-circuited to earth or the neutral safety values then there is no majority and the true engine
switch is defective or incorrectly adjusted. hours are lost. Turning key OFF then ON will clear this
- Tests: Check the input line to terminal D-J of the DCC error.
to detect any short circuit to earth. Check whether the
neutral safety switch is defective or incorrectly ad-
justed.
2.02 of software program.
Issue 1 May 2001


Parameter table fault Engine sensor off
- Possible causes: An error occurred in saving a param- - Possible causes: Engine oil pressure detected with no
eter to the DCC due to incorrect power down sequence, engine speed due to failed speed sensor or failed wiring
or connector A removed prior to parameter being to TC or TC is off (E154 should be displayed too).
updated. The system will eventual clear the error after - Tests: Check the resistance of the speed sensor and
a couple of ignition cycles but the parameter being continuity to TC input. Check TC power supply lines to
saved may or may not have been saved and default terminal B - J of the TC including Park Lock temporisa-
parameters will be used. tion relay, 30 Amps fuse located near the starter motor,
- Tests: Check "dcon" and "tcon" parameters. 15 Amps fuse located near the relay below the cab right
hand side console panel and fuse F12. Check TC itself.
Error Code 154
Normal CAN communication with TC has failed Error Code 158
- Possible causes: CAN connection problem between Armrest lever calibration error
TC and DCC. TC is off. - Possible causes: The calibration of the lever is incorrect
- Tests: Check the 3 CAN lines between TC terminals D- since it is out of the range of specified parameters.
A, D - G, D - K and DCC terminals D - A, D - B, D - K. - Tests: Enter DCC diagnostic mode (dAdc) and check
Check TC power supply lines to terminal B-J of the TC that the "ShrL" parameters are within the limits
and fuse including Park Lock temporisation relay, 30 . Neutral position : from 350 to 600
Amps fuse located near the starter motor, 15 Amps . Forward position : from 600 to 900
fuse located near the relay below the cab right hand side . Reverse position : from 100 to 400 (NAO lever type
console panel and fuse F12. Check TC itself. only. ex: 8170)
Note: Computer Neutral Special = gearbox will not If the calibration values are not within these limits,
go any more to neutral but PTO will be shut off, check the lever potentiometer and its harness and
4WD will be engaged and Diff.lock will be disen- recalibrate the lever.
gaged. The error code 154 will be displayed on the
DCC but the tractor can still move in the selected
gear until the clutch pedal is depressed (BOC
switch activated) or one of the gear lever is moved
to neutral position (neutral switch activated).
Error Code 155

Incorrect tractor code selected
- Tests: Download new parameter.
Error Code 156

Top of clutch stuck open (TOC)
- Possible causes: Circuit providing 12V to switch is
open or TOC switch is out of mechanical adjustment or
switch has failed.
- Tests: Check for 12V at red wire to TOC switch. If no
voltage check for open in the supply line to TOC switch.
Check TOC switch for out of adjustment condition or
failed switch.
Issue 1 May 2001


Analog reverse/forward lever neutral switch failure in Armrest lever neutral switch failure in neutral position
neutral (EUROPE model) - Possible causes: Neutral switch failure in armrest
- Possible causes: Neutral switch failure in left-hand lever. The error comes from the two contacts of the
lever. The error comes from the two contacts of the Neutral switch which are both open or closed when in
Neutral switch which are both open or closed when in fact one should be open and the other closed when the
fact one should be open and the other closed when the lever is in the Neutral position.
lever is in the Neutral position. - Tests with Wintest: Compare the status of the armrest
- Tests with Wintest: Compare the status of the shuttle lever switches in Wintest when changing the lever
lever switches in Wintest when changing the lever position
position. If the Wintest result does not correspond to the position
If the Wintest result does not correspond to the position of the lever, check that contacts are not stuck; check
of the lever, check that contacts are not stuck; check the switch harness Neutral to the DCC for an open
the switch harness Neutral to the DCC for an open circuit or short circuit. Replace the switch.
circuit or short circuit. Replace the switch. - Tests without Wintest: Enter the diagnostic mode of the
- Tests without Wintest: Enter the diagnostic mode of the DCC (dbin) and check the status of the Neutral switch
DCC (dbin) and check the status of the Neutral switch with "rLnC" and "rLnO" :
with "LLnC" and "LLnO" : Lever in the Neutral position: rLnC = 1 and rLnO = 0
Lever in the Neutral position: LLnC = 1 and LLnO = 0 Lever in the Forward position: rLnC = 0 and rLnO = 1
Lever in the Forward or Reverse position: LLnC = 0 and Lever in the Reverse position: rLnC = 0 and rLnO = 1
LLnO = 1 (NAO lever type only. ex: 8170)
If the values do not correspond, check that contacts are If the values do not correspond, check that contacts are
not stuck; check the Neutral switch harness to the DCC not stuck; check the Neutral switch harness to the DCC
for an open circuit or short circuit. Replace the switch. for an open circuit or short circuit. Replace the switch.
Error Code 160

Analog reverse/forward lever neutral switch failure out-
side neutral (EUROPE model)
- Possible causes: Neutral switch failure in left-hand
lever. The error comes from the two contacts of the
Neutral switch which are both open or closed when in
fact one should be open and the other closed when the
lever is in the Forward or Reverse position.
- Tests with Wintest: Compare the status of the shuttle
lever switches in Wintest when changing the lever
position
If the Wintest result does not correspond to the position
of the lever, check that contacts are not stuck; check
the switch harness Neutral to the DCC for an open
circuit or short circuit. Replace the switch.
- Tests without Wintest: Enter the diagnostic mode of the
DCC (dbin) and check the status of the Neutral switch
with "LLnC" and "LLnO" :
Lever in the Neutral position: LLnC = 1 and LLnO = 0
Lever in the Forward or Reverse position: LLnC = 0 and
LLnO = 1
If the values do not correspond, check that contacts are
not stuck; check the Neutral switch harness to the DCC
for an open circuit or short circuit. Replace the switch.
Issue 1 May 2001

Error Code 162

Armrest lever neutral switch failure in non neutral posi-
tion
- Possible causes: Neutral switch failure in armrest
lever. The error comes from the 2 contacts of the
Neutral switch which are both open or closed when in
fact one should be open and the other closed when the
lever is in the Forward or Reverse position.
- Tests with Wintest: Compare the status of the armrest
lever switches in Wintest when changing the lever
position
If the Wintest result does not correspond to the position
of the lever, check that contacts are not stuck; check
the switch harness Neutral to the DCC for an open
circuit or short circuit. Replace the switch.
- Tests without Wintest: Enter the diagnostic mode of the
DCC (dbin) and check the status of the Neutral switch
with "rLnC" and "rLnO" :
Lever in the Neutral position: rLnC = 1 and rLnO = 0
Lever in the Forward position: rLnC = 0 and rLnO = 1
Lever in the Reverse position: rLnC = 0 and rLnO = 1
(NAO lever type only. ex: 8170)
If the values do not correspond, check that contacts are
not stuck; check the Neutral switch harness to the DCC
for an open circuit or short circuit. Replace the switch.
Issue 1 May 2001

Electronic linkage - Description 11C01.1

Tractor with cab
11 C01 Description of electronic linkage
CONTENTS
A. Description _________________________________ 2
B. Console _____________________________________ 6
C. Diagram ____________________________________ 9
Issue 1 May 2001

11C01.2 Electronic linkage - Description

Tractor with cab
A . Description
The electronic linkage system (Fig. 1) is composed of
the following components:
- A control console (1)
- A digital or electronic calculator (2)
- A position sensor (3)
- A depth button (4)
- A Lifting / Working selector with neutral position (5)
- Two draft sensors (6)
- A wiring harness (7)
- An electro-hydraulic proportional control solenoid
valve (8)
- Four or six external control switches depending on
option (9)
- A 3 A fuse (10) fitted beneath the right-hand side of the
linkage control console
- A button for quick soil engagement (11) fitted on the
right-hand side of the control armrest.
Issue 1
2 May 2002
2001

Tractor with cab
1 9 7 9
10
2 6
3
11 5
B 8
D E
A C
Fig. 1
Issue 1 May 2001


Tractor with cab
(1) Control console (5) Selector
On the right-hand side inside the cab, it comprises: This is located at the front of the control armrest. It
- three potentiometers permits the selection of the Lifting, Lowering, Neutral
- a push button and Working functions.
- five indicator lamps
(6) Draft sensors

(2) Digital ot electronic calculator These two sensors are fitted to the shaft of the lower
It is fitted on the right-hand side in the cab beneath the arms of the hitch linkage. They transform the forces
linkage control console. applied to the hitch linkage during tillage into signals.
The calculator records the signals sent from the different These are then transmitted to the ELC calculator.
console controls and compares them with the signals
transmitted by the sensors. If the two signals have
different values, the calculator sends its own signals to (7) Electrical harness linking the various
the coils of the lift control valve. This permits the raising components
or lowering of the lifting arms until the values displayed
on the console equal those of the sensors.
When the tractor is working, corrections are constantly
carried out, permitting an optimal work quality.
(8) Electro-hydraulic solenoid valve
Safety The electrohydraulic spool valve is fixed with the auxiliary
In order to avoid the electronic system remaining active spool valves.
when the engine is stopped, a safety system is installed. Its function is to regulate the oil flow to lift or lower the
When the ignition switch is turned on, the calculator lifting arms according to the signals sent by the ELC to
receives 12 volts from the switch. This lights the three the two solenoid valves. The spool valve is fitted to the
indicator lamps "I", "J" and "K". high pressure (high flow rate) hydraulic circuit.
"K" and "J" light up for 0.5 seconds.
"I" remains lit until an "engine running" signal is received
from the engine speed sensor and the Lifting / Lowering (9) External control switches
selector is placed in the position 1 then Lowering 2. These are fixed on the wings or in the cab depending on
Caution, turn knob "B" to 1 to control the position. the specifications. Their aim is to simplify the hitching of
certain equipment by allowing the operator to control
the height of the implement.
(3) Position sensor These switches can be used if the control console is
The position sensor is fitted at the rear of the tractor, in activated and the Lifting / Neutral / Lowering selector is
front of the right bearing of the linkage shaft. It is in the ‘neutral’ or ‘lowering’ position. For safety reasons,
connected to a cam fixed onto the shaft. the linkage controls in the cab are automatically isolated
The sensor records the angular position of the linkage when the external buttons are being used.
arm and sends the information to the electronic linkage To regain control of the linkage on the control console,
calculator. it is necessary to turn the selector "E" to the "Lifting"
position.
(4) Tillage height and depth adjustment

button
This is located at the rear of the control armrest.
Issue 1
2 May 2002
2001

Tractor with cab
(10) Fuses
7.5 Amp fuse for battery + 12 V
- it is located above the batteries and protects battery
+ 12 V to the ELC
25 Amp fuse for battery + 12 V AC
- it is located in the fuse box and protects all tractor +
12 V AC supplies
3 Amp fuse for battery + 12 V AC (10)
- it is located under the linkage control console and
protects the + 12 V AC supply to the ELC.
(11) Quick soil engagement

It is located on the right-hand side of the armrest and
during its use it cancels the command of the depth
button.
The quick soil engagement only functions when the
selector (5) is in the Working position.
Issue 1 May 2001


Tractor with cab
B D C
I
5
4
2
K F JA G H
A L E
Fig. 2
(G) Lifting arms lifting indicator lamp

B . Console (H) Lifting arms lowering indicator lamp
(I) Console locking and error diagnostic indicator lamp
List of controls (J) Transport Damper indicator lamp
(A) Height / depth adjustment (K) Lifting arms lifting / lowering automatic control
(B) Function selector (Draft, Intermix, Position) indicator lamp
(C) Maximum lift limiter (high position adjustment) (L) Quick soil engagement button
(D) Adjustment of manual and automatic lowering
speed and locked position (padlock symbol) or
automatic control
(E) Lifting / Working selector with Neutral position
(F) Button for the Transport Damper
Issue 1 May 2001


Tractor with cab
Description of controls - Automatic speed position (yellow sector): when the
A. Height / depth adjustment potentiometer potentiometer is in the maximum position, the speed
The potentiometer "A" must be used to adjust the depth is automatically adjusted according to the weight of
(or height) of the implement after a selection has been the implement (measured by the draft sensors in the
made on function selector "B". high position) and the forward speed of the tractor
In position control, the potentiometer travel is maximum. (measured by the forward speed sensor connected to
The maximum high position is slightly higher when the Autotronic or to the TC units, depending on the
using the external controls instead of potentiometer "A". version).
A floating position can be obtained by positioning When the automatic speed mode is selected, the "K"
potentiometer "A" on position 9. In this case, the Lowering indicator lamp is lit.
indicator lamp remains lit. - Manual speed position (red sector): when the
potentiometer is in the red sector, the operator adjusts
the lowering speed in relation to the weight of the
B. Function selector potentiometer (Draft / implement.
Intermix / Position)
This potentiometer must be adjusted in relation to the E. Lifting / Working / Neutral selector
work being carried out: This switch allows work to be carried out in the following
- Position control: used with transported implements modes:
- Draft control: used with soil penetrating implements - Lifting position: the implement raises until it attains
(rarely 100% control). the maximum position as selected by potentiometer
- Intermix: used with soil penetrating implements, in "C".
order to control the maximum force while keeping a - Neutral position: the implement is locked in its position.
regular depth (most commonly used position for This position must not be used for the work phase.
ploughing, subsoiling, etc.). - Working position: the implement lowers until it reaches
the position selected by the depth potentiometer "A"
and the function selector potentiometer "B".
C. High position potentiometer - Note: On starting or after having used the external
This potentiometer is used to adjust the maximum controls, the switch "E" must be toggled to the
height of the lifting arm. Lifting position in order to activate the system.
When the switch "E" is toggled to the Lifting position, the
lifting arm raises until it reaches the adjustment value F. Selector button for the Transport Damper
selected on the high position potentiometer "C". This button must be pressed once when switch "E" is in
the Lifting position in order to be activated. In this case,
each time that switch "E" is placed in the Lifting position,
D. Lowering speed potentiometer the ELC sends current to the coils of the lift control valve
This potentiometer is used to adjust the Lowering in order to keep the implement stable, whatever the
speed of the implement according to its weight and speed of the tractor.
when switch "E" is in the Working position. The system is automatically disengaged when switch
The potentiometer functions in the following three "E" is in the Neutral or Working position.
modes: The indicator lamp "J" is lit whenever the system is in the
- Locked position: when the potentiometer is in the active Transport position.
maximum anti-clockwise position, the lowering of the To deactivate this function, place the lifting arms in the
linkage is impossible (transport safety function). Lifting position and press the button "F" once.
Issue 1 May 2001


Tractor with cab
G - H. Lifting arms lifting and lowering indicator
lamps
The indicator lamps are lit at the same time as the
solenoid valves receive the current and indicate the
correct functioning of the system.
Their status changes continually when the linkage is
used in Draft and Slippage control.
I - J - K. Indicator lamps for corresponding

functions
L. Quick soil engagement button

Place selector "E" in the Working position. Press and
maintain the switch "L" to activate quick soil engagement.
The commands given by potentiometers "A" and "B" are
cancelled and the implement penetrates the soil more
rapidly. Release switch "L" and the linkage assumes its
working position as given by the potentiometers "A" and
"B".
Issue 1 May 2001


Tractor with cab
C . Diagram
Description
The electrical circuit is made up of the following elements:
1. Ignition switch
2. Linkage control console lighting
3. Battery
4. Radar (if fitted)
5. Onboard computer (if fitted)
6. Engine speed sensor (Autotronic or TC speed
output)
7. Forward speed sensor (Autotronic or TC speed
output)
8. Lift control valve
9. Left draft sensor
10. Right draft sensor
11. Position sensor
12. External control buttons
13. External control buttons
14. 3rd set of external controls for automatic coupling
15. Linkage control console
16. Lifting / Working selector with Neutral position
17. Quick soil engagement button
18. Electronic linkage calculator
19. Depth / height potentiometer
Issue 1 May 2001


Tractor with cab
Identification of terminals and connectors
Item Connector colour Wires Description Pins Wire colour
A White 5 General supply to 1. + battery Red

connector C14 2. – battery Black
3. + 12 V lighting Orange
4. not used Violet
5. + 12 V AC Red
B Black 3 CAN network 1. CAN lo Brown

2. CAN hi Green
3. CAN ground Red
C Black 7 Signals to 16-pin 1. CAN lo Brown

diagnostics connector 2. CAN hi Green
3. CAN ground White
4. drawn implement Violet
signal
5. + 12 V AC Black
6. battery ground Black
7. not used Not used
D Black 7 Speed signals for 1. Wheel speed signal Violet

Datatronic 2. Slippage control signal Orange
3. Engine speed signal Brown
4. Radar speed signal White
5. Radar supply (+ 12 V Grey
AC)
6. not used Not used
7. PTO speed signal Pink
E Black 5 Speed signals 1. Wheel speed signal Violet

2. Engine speed signal Brown
3. Radar speed signal White
4. Radar presence (+ 12 Grey
V AC)
5. PTO speed signal Pink
F Brown 2 Lower solenoid valve 1. + 6 V for control Red

supply 2. Ground Red / White
G Black 2 Lift solenoid valve supply 1. + 6 V for control Light green

2. Ground Red / White
H Grey 3 Left draft sensor 1. Ground Black / White

2. Sensor signal Yellow
3. + 9.5 V from calculator Brown /
Yellow
I Grey 3 Right draft sensor 1. Ground Black / White

2. Sensor signal Yellow
3. + 9.5 V from calculator Brown /
Yellow
Issue 1 May 2001


Tractor with cab
J Black 3 Position sensor 1. Ground Black / White

2. Sensor signal Dark green
3. + 9 V from calculator Brown / Yellow
K Black 3 External controls 1. Lift control supply Yellow

2. Lift or Lower control Dark blue
signal
3. Lower control supply Orange
K1 Black 3 External controls 1. Lift control supply Yellow

signal
Yellow
K2 Black 3 External controls 1. Lift control supply
signal

signal

signal

signal
L Round black 16 Linkage control console 1. Intermix signal Yellow

2. + 9.5 V from calculator Grey / Red
3. Ground from calculator Black / Grey
4. Lowering speed signal Grey
Issue 1 May 2001


Tractor with cab
L Round black 16 Linkage control console 5. High position signal Dark green
6. Diagnostic LED supply Pink
7. Automatic lowering Dark green
LED supply
8. Transport damper LED Brown
supply
9. Transport damper ON / Dark green
OFF signal
10. Lift solenoid valve Light green
supply
11. Lower solenoid valve Red
supply
12. Battery ground Black
13. D+ alternator Violet
14. External linkage control Yellow
supply
15. External control signal Dark blue
16. External lower control Orange
supply
M Black 10 Right armrest A. not involved with -

linkage
B. not involved with -
linkage
C. not involved with -
linkage
D. not involved with -
linkage
E. Depth control Green
F. Ground Blue
G. + 9.5 V from calculator Orange
H. Lifting / Working toggle Pink
switch
N Black 7 Right armrest 1. Radar signal White

2. Drawn implement Violet
signal
3. Lifting / Neutral / Green
Working toggle switch
4. Ground Blue
5. + 9.5 V from calculator Orange
6. Depth control White
7. Not used Not used
Issue 1 May 2001


Tractor with cab
P Black 55 ELC connector 1. Sensors ground -

2. Sensors supply 9.5 V -
3. Engine speed signal -
4. Slippage control signal -
5. Not used -
6. + 12 V AC -
7. Position sensor signal -
8. Depth potentiometer -
signal
9. Battery ground -
10. Battery + 12 V -
11. Not used -
12. Lighting + 12 V -
13. Automatic lowering -
indicator lamp
14. CAN H (linked to 15) -
15. CAN H -
16. Engine running signal -
17. Not used -
18. Not used -
19. Lower coil supply -
20. Linkage console -
ground
21. Signal for mounting -
Load Sensing
22. Ground -
23. Radar speed signal -
24. Theoretical forward -
speed signal
25. Right force signal -
26. Intermix -
27. Lowering speed -
28. External Lift / Lower -
controls
29. Not used -
30. Not used -
31. Not used -
32. Transport damper -
indicator lamp
33. CAN L (linked to 34) -
34. CAN L -
35. CAN network ground -
36. Not used -
37. Not used -
38. Not used -
39. Console 9.5 V supply -
Issue 1 May 2001


Tractor with cab
P Black 55 ELC connector 40. Not used -

41. Ground -
42. Ground -
43. Left draft signal -
44. High position signal -
45. Battery ground -
46. Lifting / Neutral / -
Lowering selector
47. Battery + 12 V -
48. Not used -
49. Diagnostics indicator -
lamp
50. Not used -
51. Transport damper -
switch
52. Not used -
53. Coils ground -
54. Not used -
55. Lift coil supply -
Q Black 2 Closed centre lift control 1. Ground Orange

valve 2. Signal or lack of signal Grey / Black
of the presence of the
closed centre lift
control valve
Issue 1 May 2001

Electronics – Linkage 11C01.15

Tractor with cab
14
16 K4 13
K2 K3 55
17 12
15
K K1
19
L J
M 11
I
N
10
8
F
P
E
18
7
6
D
5
B
B
Q
A
3
Fig. 3
2
1
Issue 1 May 2001

Electronic linkage - Auto-diagnostics 11C02.1

Tractor with cab
11 C02 Linkage auto-diagnostics
CONTENTS
A. Operation ___________________________________ 2
Issue 1 May 2001

11C02.2 Electronic linkage - Auto-diagnostics

Tractor with cab
When a fault is identified, the driver is informed by an
A . Operation error code on display I on the linkage console.
The first figure of the code indicates the severity level of
The electronic linkage calculator is capable of detecting
the fault ( 1 = major, 2 = medium, 3 = minor ).
certain faults in the wiring harness or lifting components.
Code Fault Reaction of the system Action required
1-1 Lift or Lower solenoid valvel Stops supplying the lift Cut supply. Repair fault.
disconnected control valve. Re-supply and reactivate
No lift authorised the system.
1-2 Short circuit on Lift solenoid valve Idem Idem
1-3 Short circuit on Lower solenoid valve Idem Idem
1-5 Problem on external controls Idem Idem
1-6 Supply exceeds 18 V Idem Idem
1-7 Short circuit on 9.5 V line Idem Idem
1-8 Problem on Lifting / Neutral / Idem Idem

Lowering selector
2-2 Problem on position sensor Linkage console locked Repair the fault. Reset
the console by toggling
Lifting / Neutral /
Lowering selector to Lift
2-3 Problem on depth / height adjustment Idem Idem

potentiometer
2-4 Problem on high position Idem Idem

potentiometer
Issue 1 May 2001

Electronic linkage - Auto-diagnostics 11C02.3

Tractor with cab
Code Fault Reaction of the system Action required
2-7 Supply less than 10 V Idem Idem
3-1 Problem on right draft sensor The system operates but Idem
the diagnostics indicator
lamp flashes.
3-2 Problem on left draft sensor Idem Idem
3-3 Problem on drawn implement draft Idem Idem

sensor (if option fitted)
3-4 Problem on lowering speed The system operates but Idem

potentiometer the diagnostics indicator
lamp flashes.
The automatic lowering
speed is selected.
3-6 Problem on function selector The system operates but Idem

potentiometer (Draft, Intermix, the diagnostics indicator
Position) lamp flashes.
3-8 Tractor parameters are lost Selection of defaut AA Set calculator parameter
parameters pertaining to If the problem persist,
the transmission calcu- replace the calculator
lator.
The electronic linkage
control operates with the
wrong parameters. The
diagnostic lamp flashes.
Issue 21 2001
May 2002
Datatronic 2 - Description 11D01.1
11 D01 Datatronic
CONTENTS
A. General ________________________________________________ 2
B. Activating the basic data ________________________________ 7
C. The "Working" key ______________________________________ 9
D. The "Implement Width" key ______________________________ 10
E. The "Screen Contrast" key _______________________________ 10
F. The "Wheel Slip Control" key ____________________________ 11
G. "Memory" keys _________________________________________ 12
H. Comparative mode ______________________________________ 16
I. Flowmeter fitting _______________________________________ 18
J. Diagram ________________________________________________ 24
Issue 1 May 2001

11D01.2 Datatronic 2 - Description

(10) Key selection of four memories
A . General (11) Key to activate working position
The Datatronic is a measurement instrument that per- (12) Key to activate wheel slip control
mits the optimisation of tractor functions. It is located on (13) Active wheel slip control signal lamp
the right-hand side upright in the cab. (14) Rotating knob for:
- selecting functions within the menus
Description of the Datatronic - modifying contrast after pressing key (9)
Reading of data (Fig. 1) - modifying tool width, cumulated values, time,
(1) Liquid crystal display split in two parts date … after pressing key (6)
(2) Selection key for upper screen - modifying the title of the displayed memory
(3) Selection key for lower screen
(4) Lower screen selection lamp
(5) Upper screen selection lamp
Function keys (Fig. 1)

(6) Keys to modify data to be stored
(7) Key to adjust implement width
(8) Reset cumulated and stored data
(9) Screen contrast key for both screens (1)
4 . PLOUGH
1
4 1000
2
A
9 8 0
n/min
RP/M 3
5
1 8 5 0 6
10
7
11
8
B
12
9
13 14
Fig. 1
Issue 1 May 2001

Description of menu functions and sym- AREA: total area worked since last
bols reset or adjustment
ENGINE SPEED: instantaneous en-

n/min gine speed in rpm
DISTANCE : indicates work distance

covered
PTO : power take off speed in rpm
HOURS WORKED : total time with

engine speed above 1000 rpm
SPEED: actual forward speed of the
tractor
- if the speed is less than 1 kph, the Datatronic displays

0 kph, COUNTER : totals and stores the
- if the speed is between 1 kph and 20 kph, the radar number of work units for an implement
provides the information, (e.g. counting of bales)
- if the speed is greater than 20 kph the forward speed
sensor provides the information.
The zero wheel slip function is automatically calibrated
each time that the tractor exceeds 20 kph. COMPARE : displays and stores an instantaneous value
used as a reference.
After modification of tractor adjustments, compares
stored value with displayed value
WHEEL SLIP: actual wheel slip
TEMPERATURE : displays outside

MAX SLIP: maximum limit of wheel temperature (sensor mounted be-
slip accepted by the operator neath cab roof)
AREA/HR: instantaneous area

worked per hour
TIME : clock (H.M.S)
FUEL/HR: instantaneous hourly con-

sumption
DATE : date of the day (D.M.Y)
FUEL/HECT: instantaneous hourly

consumption per unit of worked area
SERVICE : indicates number of hours

before next servicing. When the
COUT/HECT: instantaneous cost per number of hours have been reached or
unit of worked area exceeded, the maintenance function automatically dis-
plays every time the Datatronic is turned on.
FUEL: total consumption since last

reset or adjustment
Issue 1 May 2001

COST/L: local cost of one litre of fuel; TOWED IMPL: option to improve per-
stored in memory formance of towed implements
COST/HR: local hourly cost of opera-

tion; stored in memory ADJUST TOW: adjusts parameters of
Towed Implement option
UNITS: Choice of measurement units

- metric = litre, hectare, metre, kilometre, currency
symbol: Franc
- USA = US gallon, acre, yard, mile, currency symbol:
Dollar
- UK = imperial gallon, acre, yard, mile, currency sym-
bol: Pound Sterling
Depending on the country it is necessary to select the
appropriate units of measurement. The currency is only
provided as an indication, the Datatronic does not con-
vert between currencies.
DUAL CTRL: option to automatically

handle plough furrows in and out mo-
tions on a semi-mounted plough.
REGL. DUAL : adjusts plough furrows

in and out motions for the Dual Control
option.
Issue 1 May 2001

UNITS RESET WORKING DISPLAY MINIMUM COMPARE

MENU FUNCTION Metric OR POSITION INCREMENT VALUE MODE
USA ADJUST REQUIRED DISPLAYED
English
Engine speed Engine speed rpm no no 10 rpm 100 rpm yes
PTO PTO speed rpm no no 5 rpm 50 rpm yes
SPEED Forward speed kph or mph no no 0.1 kph 1 km/h yes
WHEEL SLIP Actual wheel slip % no no 1% 0% yes
MAX. WHEEL SLIP Wheel slip limit % yes - 1% 0% no
AREA/HR Instantaneous area hect/h or acre/h no yes 1.0 hect/h or 0.1 acre/h 0 yes
worked per hour
FUEL/HR Instantaneous hourly l/hr or gal/hr no no 0.5 litre/hr or 0.5 gal/hr 0 yes
consumption
FUEL/HECT Instantaneous hourly l/hr or gal/hr no yes 0.5 litre/hr or 0.5 gal/hr 0 yes
consumption per unit
of worked area
COST/HECT Instantaneous cost per currency unit no yes 0.01 0 yes

unit of worked area
FUEL Fuel consumed litre yes or adjust no 1 litre 0 no
AREA Area worked hect or acre yes yes 0.1 hectare or 0.1 acre 0 no
DISTANCE Distance covered metre or mile yes yes 1 metre or 1 mile 0 no
HOURS WORKED Hours worked hour yes yes 0.1 hour 0 no
COUNTER Counter none yes yes 1 0 no
COMPARE Comparative mode
TEMPERATURE Temperature ° C ou ° F no no 1 ºC or 1 ºF -35° C or -31° F no
Issue 1 May 2001

UNITS RESET WORKING DISPLAY MINIMUM COMPARE

MENU FUNCTION Metric OR POSITION INCREMENT VALUE MODE
USA ADJUST REQUIRED DISPLAYED
English
HOUR Hour H.min.sec yes no 1 second 00.00.00 no
DATE Date J,M,A yes no 1 day 00.00.00 no
SERVICE Service Hour yes; 250 hr or adjust no 1 hour 0 no
COST/L Cost of fuel currency unit adjust no 0.01 0 no
COST/HR Hourly cost currency unit adjust no 0.01 0 no
UNITS Choice of units Metric, USA or UK
DUAL CTRL Work screen
ADJUST DUAL Adjustment of

semi-mounted implements
TOWED IMPLEMENT Work screen
ADJUST TOWED IMPLEMENT Adjustment of towed

implements
ICON Implement width Metre or yard adjust no 0.1 metre or 0.1 yard 0 no
Issue 1 May 2001

B . Activating the basic data

Adjusting the clock (Fig. 2) FUEL USED
- Press key (2) or (3) to display the list of functions. AREAWORKED
DISTANCE
- Select TIME and press again key (2) or (3), the display HRS WORKED
2
COUNTER
appears in the selected window with signal lamp (4) or COMP.MODE
(5) lit. EXT.TEMP.
TIME
- Press one of the keys (6) that correspond to the digit you DATE
SERVICE
wish to modify, then turn knob (14) to change the digit. FUEL/COST
COST/HOUR
METRIC/IMP 3
Adjusting the date (Fig. 2)

- Using the function DATE, proceed in the same way in
order to adjust the clock date.
4 . PLOUGH
D M Y
4 2
2 1 0 2 9 5
H M S
5
3
1 6 1 3 2 5
14
Fig. 2
Issue 1 May 2001


Entering the costs (Fig. 3)
Hourly cost
- Press key (2) or (3) to bring up the functions menu.
FUEL USED
- Select COST/HR, then using button (14) again press AREAWORKED
key (2) or (3), the display appears in the selected DISTANCE 2
HRS WORKED
window with indicator lamp (4) or (5) lit. COUNTER
COMP.MODE
- Press one of the keys (6) corresponding to the digit you EXT.TEMP.
wish to modify, then turn knob (14) to increase or TIME
DATE
decrease the value of the selected digit. Carry out this SERVICE
FUEL/COST
operation for each of the digits to be modified, taking the COST/HOUR
3
decimal place into account. METRIC/IMP
Note: The hourly cost value must correspond to the

actual operating costs of the tractor.
4 . PLOUGH
/HR
Cost of fuel per litre $ 2
4
- Proceed in the same way as when adjusting the hourly
cost, but this time select the COST/L function.
Note: COST/L is entered in relation to the cost of
200.00
H M S
fuel in each country.
5
3
1 6 1 3 2 5
Servicing (Fig. 2)
Adjustment of service to a period other than 250
hours:
6
. Proceed in the same way as with the hourly cost but by
first selecting the SERVICE function.
-The default servicing period is 250 hours:
. Press key (2) or (3) to display the list of functions 14
. Select SERVICE and press key (2) or (3) so that it
appears in the selected window with indicator lamp
(4) or (5) lit.
.Press and hold down the "Reset" key
. 250 hours is automatically displayed on screen. Fig. 3
Issue 1 May 2001

C . The "Working" key (Fig. 4)

4 . PLOUGH
Once the "Working" function has been selected it must
be validated by one of three entries available so that the 1000
Datatronic can calculate or indicate the selected values,
either the: 9 8 0
- MoveUp / MoveDown switch
- PTO speed signal M
- or, signal from the 16-way connector (for example, for
towed implements).
2.5
The "Working" function is active when diode (15) is lit 11
(Fig. 4).
15
The "Working" position acts upon the following functions
even when they are not displayed on the screen:
- AREA/HR Fig. 4
- FUEL/HECT
- COST/HECT
- AREA
- DISTANCE
- HOURS WORKED
- COUNTER
Important: To calculate all the functions in relation

to area worked, remember to correctly adjust the
implement width.
Issue 1 May 2001

D . The "Implement Width" key (7)

4 . PLOUGH
(Fig. 5)
1000
To calculate all functions in relation to the area worked,
it is necessary to adjust the implement width:
- Press IMPLEMENT WIDTH, the implement width is 9 8 0
displayed in the lower part of the screen.
- Press one of the keys (6) corresponding to the digit to M 14
modify, then turn knob (14) to increase or decrease the
value. Carry this out for each digit to be modified, taking 2.5
into account the decimal place.
- Press on IMPLEMENT WIDTH again to return to the 6
original screen.
7
Fig. 5
E . The "Screen Contrast" key (9)

(Fig. 6) 4 . PLOUGH
n/min
The screen contrast can be modified at any time: 4 RP/M
- Press key (9), both indicator lamps (4) and (5) then light.
- Adjust the contrast by turning the knob (14). 1 8 5 0
- Press key (9) again to return to the original screen.
Note: Screen contrast may vary in relation to the n/min
RP/M
ambient temperature and lighting. 5
1 5 0 0
Fig. 6
Issue 1 May 2001

- Press any of the keys (6) to modify the digits and turn
F . The "Wheel Slip Control" key knob (14) to increase or decrease the selected digit.
(Fig. 7) Carry out the same operation with the other digits to be
modified.
The wheel slip value must be greater than 5% of the
Principle actual wheel slip in order to obtain efficient control.
- This mode of operation allows optimisation of the
- Press key (2) or (3) again to return to the original screen.
tractor’s performance by avoiding excessive wheel
slip.
- In relation to the actual wheel slip, calculated by the
Activating "wheel slip control" function
difference between the design speed provided by the - Press key (12) to activate wheel slip control, the
forward speed sensor and the actual speed provided by corresponding LED lights.
the radar, the operator determines and displays the
limit of wheel slip that should not be exceeded during
the working session.
- As soon as actual wheel slip exceeds the wheel slip
limit determined by the operator, the Datatronic acts
upon the linkage and raises the implement as long as
the wheel slip exceeds this limit.
Adjustment of the wheel slip limit

- Select the two functions: WHEEL SLIP and MAX. SLIP
from the menu in order to display them on screen.
- Note the actual wheel slip displayed in the WHEEL
SLIP half screen in order to determine the actual wheel
slip value.
- Press key (2) or (3) corresponding to the MAX. SLIP
function.
4 . PLOUGH
ENGINE RPM n/min
PTO RP/M
FWD SPEED
WHEEL SLIP 2
SLIP LIMIT
AREA/HOUR
1 8 5 0
FUEL/HOUR
FUEL/AREA
COST/AREA
FUEL USED 3
AREAWORKED
DISTANCE
2 5
5
6
12
14
13
Fig. 7
Issue 1 May 2001


Fonctionnement
- When the actual percentage of slippage exceeds the
limit of slip fixed by the operator, LED (13) correspond- 1 . SEED DRILL
ing to the ACTIVE SLIP CONTROL button, lights. 2 . SEMOIR.
3 . SEMOIR. 41.8 HA
- At the same time, the linkage rises and the LED lights. 4 . SEMOIR. 41.8 HA
132.3 L
HA
41.8132.3
- As the traction load reduces, the slip value drops until L H
it reaches the limit set by the operator. 132.3 6.0L 6.0
H KM
123.7
6.0123.5
H
- As soon as the actual wheel slip is less than the slip KM
123.5 2.5KM2.5 M M
limit, LED (13) and the MoveUp LED go off, the 5 >999<
2.5 5 M
MoveDown LED lights and the linkage lowers until the 5 >999<
>999<
implement reaches its initial position.

- The wheel slippage control acts in exactly the same
ON ON1ON21 321432 43 4
manner as an operator who is constantly modifying the ON 1 2 3 4
adjustment of the height / depth control on the linkage
console.
Fig. 8
G . "Memory" keys
The Datatronic allows working with four independent
memories (Fig. 8)
The functions taken into account are:

. the total worked area
. the quantity of fuel consumed
. the total work time
. the total distance run
. the implement width
. the counter
These four memories can be used at any time.
Issue 1 May 2001

Creating a memory entry (Fig. 9)

- Turn on the ignition switch.
- Press the MEMORY key (10)
- The presently active memory is displayed on screen.
- Select the desired memory by pressing the keys (6) that
correspond to memories 1, 2, 3 or 4. The selected
number is highlighted.
- Press key (2) to display the memory contents in the
upper screen with its number highlighted.
- Press key (2) again to move the highlight to the first
letter of the memory name.
- Turn knob (14) to modify the highlighted letter.
- With the first letter now correctly displayed, press key
(2) again to place the highlight on the second letter.
- Repeat this operation in order to enter all the letters in
the name (8 characters maximum).
- Once the correct name has been entered, press key
(10) to store the new memory name.
- Adjust the implement width (see § D) in the selected
memory.
- Once the operation is completed, the memory is
correctly configured.
1 . SEED DRILL 4 . PLOUGH
41.8 HA 41.8 HA 2
132.3 L 132.3 L
6.0 H 6.0 H
123.7 KM 123.7 KM
2.5 M 2.5 M 3
5 >999< 5 >999< 14
ON 1 2 3 4 ON 1 2 3 4
10
6
Fig. 9
Issue 1 May 2001


To activate data recording in a memory (Fig.
10)
MEMORY OFF
- Only one memory can record data during a working
session. 41.8 HA
- Press the MEMORY (10) key in order to select the 132.3 L
desired memory number and press one of keys (6) 6.0 H
corresponding to memory 1, 2, 3 or 4. The number of the 123.7 KM
selected memory is highlighted. 2.5 M
- Press the MEMORY (10) key again. The memory name 5 >999<
and its number are displayed at the top of the screen

and the MEMORY (10) key is lit. OFF 1 2 3 4
- Do not forget to enter the correct implement width.
- Press the WORKING POSITION (11) key to begin 16
10
recording working data (Fig. 4).
Note: By default, one of the four memories is
always active.
Fig. 11
To deactivate working data recording (Fig.

11)
- Press the MEMORY (10) key, then press key (16).
- OFF appears at the lower left corner of the screen.
- Press the MEMORY (10) key again to return to the initial
screen.
- MEMORY OFF appears at the top of the screen.
- All four memories are now deactivated.
1 . SEED DRILL 4 . PLOUGH 4 . PLOUGH
1000
41.8 HA 1000
132.3 L
6.0 H
9 8 0 123.7 KM 9 8 0
2.5 M
n/min n/min
RP/M 5 >999< RP/M
1 8 5 0 ON 1 2 3 4 1 8 5 0
10 6 10
Fig. 10
Issue 1 May 2001

To reset the data in one or more memories

(Fig. 12)
- Press the MEMORY (10) key, then select the number 4 . PLOUGH
of the memory you desire by pressing on one of keys
41.8 HA
(6) that correspond to memory 1, 2, 3 or 4. The number
132.3 L
of the selected memory is highlighted. 6.0 H
- Press twice the RESET (8) key to reset the data. 123.7 KM
- Press the MEMORY (10) key again to return to the initial 2.5 M
screen. 5 >999<
ON 1 2 3 4
8
Fig. 12
Issue 1 May 2001

H . Comparative mode
This mode of operation allows the tractor’s performance
FUEL USED
to be optimised by comparing reference working values AREAWORKED
DISTANCE
to the new values that the operator varies and acts upon HRS WORKED
COUNTER 2
while driving the tractor. COMP.MODE
EXT.TEMP.
TIME
DATE
In relation to the new values obtained, the operator can SERVICE
FUEL/COST
judge whether or not they improve the economic per- COST/HOUR
3
METRIC/IMP
formance of the tractor.
If the new adjustments correspond to the operator’s

economic performance criteria, they can be retained. ENGINE RPM
PTO
FWD SPEED
The variables in this mode of operation are:

WHEEL SLIP
SLIP LIMIT
2
AREA/HOUR
- engine speed FUEL/HOUR
FUEL/AREA
- PTO speed COST/AREA
FUEL USED 3
- forward speed AREAWORKED
DISTANCE
- wheel slip
- cost / hectare
- fuel / hour
- fuel / hectare 14
4 . PLOUGH
Starting comparative mode (Fig. 13)

n/min
RP/M
- Press twice key (2) or (3) to display the function menu. 1 8 5 0

- Select COMPARE using knob (14).
n/min
- Press key (2) or (3) to display the comparative mode RP/M
menu.
- Select the function to be compared using knob (14) 1 5 0 0
- Press key (2) or (3) to confirm it and display the screen
showing the compared function. 10
Use (Fig. 13)

- The upper part of the screen displays the reference Fig. 13
value of the function when the operator selects it.
The lower part of the screen displays the value of the
function presently in use.
- Modify one or more of the conditions in order to
appreciate the gain obtained.
- If the gain obtained is satisfactory, the operator can
continue to use the new adjustment parameters for this
type of work.
- If the gain is not satisfactory, the operator modifies
again one or more of the parameters to obtain a
satisfactory gain.
Issue 1 May 2001

To modify the REFERENCE VALUE

- Press the MEMORY (10) key if you wish to record a
different reference value during the working session. ENGINE RPM
PTO
FWD SPEED
WHEEL SLIP 2
SLIP LIMIT
AREA/HOUR
FUEL/HOUR
To exit COMPARATIVE MODE (Fig. 14) FUEL/AREA
COST/AREA
- Press key (2) or (3) to display the comparative mode. FIN 3
- Select END.
- Press key (2) to return to the initial screen.
5
To load a reference function

- Proceed in the same way as when leaving comparative 14
mode but instead of exiting, select the function to be
used. Fig. 14
Issue 1 May 2001


(4) Injectors
I . Flowmeter fitting (Figs. 15 - 20) (5) Filters
Parts list (6) Injection pump
(7) Tank return
(1) Flowmeter
- inlets: . EA: decanting device inlet (8) Tank inlet
. EA: leak return (9) Cooler
- outlets: . A: to feed pump
. R: to tank
(2) Decanting device
(3) Feed pump
8210 - 8220 Dynashift
8
2
5 7
Fig. 15
Issue 1 May 2001

Parts list (4) Injectors

(1) Flowmeter (5) Filters
- inlets: . EA: decanting device inlet (6) Injection pump
. EA: leak return (7) Tank return
- outlets: . A: to feed pump (8) Tank inlet
. R: to tank (9) Cooler
(3) Feed pump
8210 - 8220 Full Powershift
9
1
5
7
Fig. 16
Issue 1 May 2001


(3) Feed pump
8240 Dynashift
6
Fig. 17
Issue 1 May 2001


(3) Feed pump
8240 Full Powershift
9
1
8
2
5 4
Fig. 18
Issue 1 May 2001


(3) Feed pump
8250 Dynashift
8
2
Fig. 19
Issue 1 May 2001


(3) Feed pump
8250 - 8260 - 8270 - 8280 Full Powershift
9
1
8
2
4
6
Fig. 20
Issue 1 May 2001


(8) Cab 16-way connector
J . Diagram 1. + 12 V AC
(1) Datatronic 2 2. Ground
(2) Connectors on Datatronic 2 3. Not used
1. Engine / radar programmable frequency output 4. Not used
2. PTO / design forward speed programmable 5. Analog signal input
frequency output 6. Ground
3. Max. wheel slip frequency output 7. Counter input
4. CAN network ground 8. Towed implement working position input
5. CAN network ground 9. Engine / radar programmable frequency output
6. PTO input speed 10. PTO / theoretical forward speed programmable
7. Fuel output flowrate frequency input frequency output
8. Fuel return flowrate frequency input 11. + 9.5 V analog sensor supply
9. Ground 12. Not used
10. + 9.5 V sensor supply 13. Not used
11. CAN network (low) 14. CAN network (high)
12. Not used 15. CAN network (ground)
13. Not used 16. CAN network (low)
14. Design forward speed input
15. Ground (9) Linkage connection
16. Towed implement working position information 1. Forward speed signal
input 2. Wheel slip instruction signal
17. Counter information input 3. Engine speed signal
18. Analog signal input 4. Radar speed signal
19. Not used 5. Radar supply (+ 12 V AC)
20. CAN network (high) 6. Not used
21. Not used 7. PTO speed signal
22. Not used
23. Ground
24. Radar signal input
25. Not used
26. Linkage position signal input
27. + 12 V after contact Colour code
28. Not used B = White
29. Air temperature sensor BE = Beige
BL = Blue
(3) Air temperature sensor G = Grey
(4) Radar J = Yellow
(5) Flowmeter M = Brown
(6) Datatronic 2 supply (connector C14) N = Black
1. + 12 V battery R = Red
2. Chassis ground Ro = Pink
3. + 12 V lighting S = Salmon
4. + engine running V = Green
5. + 12 V AC Vi = Violet
(7) Linkage CAN network connection C = Light

1. CAN network (low) F = Dark
2. CAN network (high)
3. CAN network (ground)
4. Towed implement working position input
Fig. 21
5. Not used
6. Not used
7. Not used
Issue 1 May 2001

2 1 10
11 19
20 29
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
1
2
3
4
5
6
7 4
1
2
3
9 4
5
6
7
1
2
3
4
5
6
7
8 8
9
10
11
12
13
14
15
16
1 2
3 6
7 10
11 14
15 16
7
1 1
2 2
1 2 3 4 5 6 7
3 3
4 3 2 1
3 4
1 2
5 5 5 4
4 5
Parts list Fig. 21
Issue 1 May 2001

Datatronic 2 - Dual Control 11D02.1
11 D02 Front Dual Control
CONTENTS
A. General ________________________________________________ 2
B. Block diagram __________________________________________ 3
C. Description of the Adjustment screen _____________________ 6
D. Adjustments ____________________________________________ 7
E. Use ____________________________________________________ 8
F. Error codes _____________________________________________ 9
G. Assembly of the additional lever _________________________ 9
Issue 1 May 2002

11D02.2 Datatronic 2 - Dual Control
A . General
In addition to the basic electronic linkage functions, the
ELC calculator is allocated new functions such as Dual
Control.
With this system, when the front plough is to be used, it

is possible to lower the front plough in relation to the rear
and vice versa, depending on the selected mode (Furrow
start or Furrow end).
Since mid January 2001, this system is available on the

6200 and 8200 series with at least two electro-hydraulic
spool valves and the Joystick. It is however possible to
have a third electro-hydraulic spool valve controlled by an
additional lever.
The Dual Control can be used either manually via the

Joystick or additional lever, or automatically after having
entered data into the Datatronic.
The ELC calculator serves as an interface between the

control switches, the potentiometers, sensors,
Datatronic, solenoid valves, etc.
All this information transits via the BUS CAN, which cuts
out the need for a great deal of wiring.
Note:
- The calculator is the same model on all tractors
and can operate Rear Dual Control, Front Dual
Control and the TIC, but only one of these func-
tions may be used at any one time. It is however
possible to have all three functions on the same
tractor.
Dual Control is available with the Joystick and therefore

two electro-hydraulic spool valves. In this case, one of
the two spool valves is used for the Dual function. The
manual control is carried out through action on the
Joystick along the red coloured Y axis.
If there is Front Dual Control then there is also Rear Dual

Control.
Issue 1 May 2002

B . Block diagram
With the front Dual Control, the rear implement enters the
earth at the precise spot where the forward implement
entered the ground.
To do this, the system needs to take into account all the
functions and parameters shown below, in order to
provide optimum operation.
+ 9,5 V Lever
or Joystick
+ 9,5 V Position sensor on

E front lift control
system
BATTERY L
Solenoid valve
C + 12 V control system FRONT
DUAL
CONTROL
Spool valve
C + 12 V control valve
A
LED diagnostic on
L Ground solenoid valve
C
Lift control external
U 12 V +AC
button
ACTIVATION L
BUTTON
A Engine speed
and forward speed,
CAN BUS Auto 3 to Dynashift
T
or TC to PowerShift
R + 9,5 V Potentiometers
and lift control switch
CAN BUS
Datatronic
Issue 1 May 2002

Composition of the Front Dual Control sys- Parts list (Fig. 1)

tem See section 11D01 - General
ELC calculator
- the calculator is the same on all models, only one
reference is available.
- this calculator allows parameterisation, see section
11C01 - Operation of the calculator.
Components of the Front Dual Control

- 12 V supply to the calculator.
Note:
- If the front external control button is pushed, the
Spool valve Management System (SMS) and the
rear lift are secured. To unlock them, press on the
Joystick activation switch and the lift control
switch (in lift raise position).
- If the rear external control button is pushed, only
the rear lift will be secured.
4 1
5
3
10
7
11
8
12
9 14
13
Fig. 1
Issue 1 May 2002

Datatronic Parts list (Fig. 2)

The Datatronic is the interface between the driver and the (1) Datatronic
calculator: (2) Radar
- on one hand, it allows initial adjustments to be made to (3) Engine and forward speed sensors
the Front Dual Control (4) Front lift position sensor
- on the other hand, it controls the operation of the Front (5) Position sensor on control lever or Joystick control-
Dual Control. ling the Dual Control electro-hydraulic spool valve
(6) Draft sensor
Communication between the calculator and the Datatronic (7) Dual Control electro-hydraulic spool valve
is carried out via the CAN BUS. (8) Lift control electro-hydraulic spool valve
(9) ELC calculator
2
9
CAN
8
4
5
7
Fig. 2
Issue 1 May 2002

C . Description of the Adjustment EXT.TEMP.

screen TIME 2
DATE
SERVICE
To find the Front Dual Control menu in the Datatronic, FUEL/COST
COST/HOUR
enter the main menu (press key (2) or (3), select FRONT METRIC/IMP
JOYSTICK
ADJ. by turning knob (14), press key (2) or (3) to display MAX FLOW
the menu (Fig. 3). KICK OUT
TRAILED 3
TRAIL. ADJ
Adjustment of Front Dual Control (Fig. 4) DUAL CTRL

REAR ADJ 14
-1 :Maximum height of front linkage REAR CTRL
FRONT ADJ
-2 :Maximum height of rear linkage FRONT CTRL
-3 :Maximum depth of front linkage

-4 :Maximum depth of rear linkage
-5 :Distance between the last front plough share and
the first rear share at the Furrow start phase
- 6 : Distance between the last front plough share and
Fig. 3
the first rear share at the Furrow end phase
Use of Front Dual Control (Fig. 5)

In the main menu: DUAL FRONT ADJ.
(1) High position of front implement, between 0 and 99
(2) High position of rear implement, between 0 and 99 A C
(3) Rear implement raise or lower indicator lamp B D
(4) Console status
(5) Front Dual Control function status (in this case E G
active)
(6) Front implement raise or lower indicator lamp F H
Note: Each time the tractor is started, the system is I
de-activated. OFF appears instead of ON and the
padlock symbol appears. To unlock the system, J
place the lift control switch in the Raise position.
M
N
5
2 1
6
1 2
50 50
3
ON 3
10
2 1
5 4 6
Fig. 5 Fig. 4
Issue 1 May 2002

J : Length between the front and rear programmable in

D . Adjustments the “Furrow start” phase (value between 0 and 100).
K : Length between the front and rear stored in the
“Furrow start” phase (value between 0 and 100).
Front lift control position sensor adjustment
L : Length between the front and rear programmable in
- The Dual Control is OFF and the front lift must be raised
the “Furrow end” phase (value between 0 and 100).
to the maximum
- To adjust the potentiometer (Hall effect type sensor), it
Note: Values I, J, K and L between 0 and 100 are
is necessary to separate the link from the sensor, to
points and each point equals 25 cm, therefore the
turn the sensor until the maximum value of between
distance may be between 0 cm and 250 m.
200 and 210 can be read on the Datatronic.
- Then retighten the link / sensor fixing.
Datatronic adjustment of Front Dual Con-

trol parameters (Fig. 6)
- To access this menu, see § C.
- To adjust the Front Dual Control parameters, it must be
de-activated and in the OFF position.
- To move from one symbol to the other, use the arrows
(6.1) and (6.2).
- To store, press the STORE key (10).
A : Height of the front implement stored (value between
0 and 255) A C
B : Actual height of the front implement (value between
0 and 255) B D
C : Height of the rear implement stored (value between
0 and 255) E G
D : Actual height of the rear implement (value between
0 and 255)
F H
E : Depth of the front implement stored (value between
0 and 255) I
F : Actual depth of the front implement (value between
0 and 255) J
G : Depth of the rear implement stored (value between
0 and 255)
M
H : Actual depth of the rear implement (value between N
0 and 255) 5
I : Length between the front and rear and stored in the
“Furrow start” phase (value between 0 and 100).
2 1
6
10
Fig. 6
Issue 1 May 2002

Furrow start
E . Use - When the system detects a Transport / Work transition
- The screen shown in Fig. 7 is displayed to the driver via movement of the lift control switch, the sequence
when he uses the Front Dual Control. is:
- To activate the Front Dual Control, press key 6 - 5 (OFF/ . Lowering of the front lift to the pre-adjusted depth
ON transition on Datatronic). . Lowering of the rear lift when the distance travelled by
- To remove the padlock symbol on the Datatronic the tractor equals the programmed distance (front
screen, move the lift control switch to the Raise implement and rear implement).
position.
Working mode Safety delay

- When Front Dual Control is in Working mode, the front - When one of the Furrow start or Furrow end phases has
lift reproduces the movements of the rear lift. begun, a countdown of 8 seconds begins; if the Work-
- In this mode, the position of the front lift can be ing mode or Headland furrow mode has not been
corrected by manual action on the Joystick or the reached after this time, the system is forced into the
additional lever. position that it should be in, i.e., Working mode with
- This correction is stored in this mode as long as the Dual and ELC adjustments.
function is ON and the mode has not been changed.
Example: Value
. Furrow start mode 25
. Working mode (action on lever) 35
. Headland furrow mode 235
. then Furrow start mode again 25
In this case, the Datatronic will not have stored the
Working mode height, only the height pre-programmed
in the Datatronic (the above values are the values given
by the Datatronic to the driver).
Furrow end
- In Working mode, if the system detects a Work /
Transport transition, the system goes into Furrow end
mode.
- The sequence that is then carried out is:
. The front lift raises to the pre-adjusted height
. When the distance travelled by the tractor is identical to
the programmed distance between front implement
and rear implement, the rear lift raises to the pre-
adjusted height set in the Datatronic.
Note: When the front implement is raised, the rear
implement can continue to work normally with the
pre-defined settings.
1 2
Headland furrow mode 50 50
- The front lift and the rear lift are raised to the maximum 3
of the pre-adjusted height. The height can be adjusted
using the lever. ON 3
- But this setting will not be stored and the next time that
Headland furrow mode is used the tool will raise to the
pre-adjusted height.
2 1
5 4 6
Fig. 7
Issue 1 May 2002

F . Error codes
Front Dual Control errors that may appear
on the Datatronic screen
E-60 : Position sensor disconnected
E-61 : Position sensor height limit exceeded
E-62 : Position sensor depth limit exceeded
E-63 : Manual lever sensor disconnected
E-65 : Depth limit by the manual lever sensor exceeded
E-66 : Raise solenoid valve disconnected
E-67 : Lower solenoid valve disconnected
E-68 : Raise solenoid valve short-circuited
E-69 : Lower solenoid valve short-circuited
For errors relating to solenoid valves, see section 11H01

- Description of the SMS system.
G . Assembly of the additional lever

See section 11D04§G
Issue 1 May 2002

11 D03 Dual Control for Semi-mounted implement
CONTENTS
A. General ________________________________________________ 2
B. Block diagram __________________________________________ 3
C. Description of the Adjustment screen _____________________ 6
D. Adjustments ____________________________________________ 7
E. Use ____________________________________________________ 9
F. Error codes _____________________________________________ 11
G. Assembly of the additional lever _________________________ 11
Issue 1 May 2002

A . General
In addition to the basic electronic linkage functions, the
ELC calculator is allocated new functions such as
handling Rear Dual Control.
With this system, when the driver uses a semi-mounted
plough, he only has to operate the lift.
For example, during the Furrow start phase, press on the

lift control switch:
· the lift lowers and the wheel partially lowers
· then the wheel support completely lowers when it
reaches the level of the furrow start of the first plough
share (automatically).
Since mid January 2001, this system is available on the

6200 and 8200 series with at least two electro-hydraulic
spool valves and the Joystick. It is however possible to
additional lever.
Before January 2001, the Rear Dual Control was offered

with:
- an additional electric lever
- an electro-hydraulic spool valve controlled by 17 bar
pressure. Nowadays, the spool valves use 22 bar
pressure.
The Dual Control can be used either manually via the

Joystick or additional lever, or automatically after having
entered data into the Datatronic.
The calculator serves as an interface between the control

switches, potentiometers, sensors, Datatronic, spool
valves, etc.
All this information is transmitted via a CAN BUS which

cuts off the need for a great deal of wiring.
Note: The calculator is the same on all tractors and

can control the Rear Dual Control, Front Dual Con-
trol and TIC. But only one of the three functions can
be used at any one time. Nevertheless, it is possible
to have all three systems on the same tractor.
If there is Front Dual Control then there is also Rear
Dual Control.
Issue 1 May 2002

For optimum operation of the system, it is necessary to

B . Block diagram take into account all these functions and parameters.
The Rear Dual Control is generally used on Semi-mounted
ploughs in order to enter both parts of the plough on the
same line, to produce headland furrows that are as short
as possible.
+ 9,5 V Lever
or Joystick
+ 9,5 V
Position sensor on
E semi-mounted plough
BATTERY L
Solenoid valve
C + 12 V control system REAR
DUAL
CONTROL
Spool valve
C + 12 V control valve
A
LED diagnostic on
L Ground solenoid valve
C
Lift control external
U 12 V +AC button
ACTIVATION L
BUTTON
A Engine speed
and forward speed,
CAN BUS Auto 3 to Dynashift
T
or TC to PowerShift
O
Potentiometers
R + 9,5 V and lift control
switch
CAN BUS
Datatronic
Issue 1 May 2002

Composition of the Rear Dual Control sys-

tem
ELC calculator
- The calculator is the same on all models, only one
reference is available.
- This calculator allows parameterisation, see section
11C01- Operation of the calculator.
Components of the Rear Dual Control

- 12 V supply to the calculator.
Note:
- If the front external control button is pushed, the
Spool valve Management System (SMS) and the
rear lift are secured. To unlock them, press on the
activation switch on the Joystick and the lift con-
trol switch (in lift raise position).
- If the rear external control button is pushed, only
the rear lift will be secured
4 1
5
3
10
7
11
8
12
9 14
13
Fig. 1
Issue 1 May 2002


The Datatronic is the interface between the driver and the (1) Datatronic
calculator: (2) Radar
- on one hand, it permits initial adjustments to be made (3) Engine and forward speed sensors
to the Rear Dual Control (4) Rear implement position sensor
- on the other, it controls the operation of the Rear Dual (5) Position sensor on control lever or Joystick control-
Control. ling the Dual Control electro-hydraulic spool valve
(6) Draft sensor
Communication between the calculator and the Datatronic (7) Dual Control electro-hydraulic spool valve
is carried out via the CAN BUS. (8) Lift control electro-hydraulic spool valve
(9) ELC calculator
2
9
BUS CAN
8
4
5
7
Fig. 2
Issue 1 May 2002

C . Description of the Adjustment

EXT.TEMP.
screen TIME 2
DATE
SERVICE
To find the Rear Dual Control menu in the Datatronic, FUEL/COST
COST/HOUR
enter the main menu (press key (2) or (3), select REAR METRIC/IMP
ADJ. by turning knob (14), press key (2) or (3) to display JOYSTICK
MAX FLOW
the menu (Fig. 3). KICK OUT
TRAILED 3
TRAIL. ADJ
DUAL CTRL
REAR ADJJ 14
Adjustment of Rear Dual Control (Fig. 4) REAR CTRL
FRONT ADJ
A : High lift stored position FRONT CTRL
B : High wheel support stored position
C : Actual lift height
D : Actual height of wheel support
E : Stored lift depth
F : Actual lift depth Fig. 3
G : Stored depth of wheel support
H : Actual depth of wheel support
I : Stored distance between lift and wheel support in
furrow start phase
J : Actual distance between lift and wheel support A C
K : Partial height stored in furrow start phase B D
L : Actual partial height E G
M : Distance stored between lift and wheel support in
F H
Furrow end phase
N : Actual distance between lift and wheel support I K
O : Partial height stored Furrow end phase J L
P : Actual height of wheel support
M O
N P
5
Rear Dual Control use screen (Fig. 5)
In the main DUAL menu, select REAR CTRL. 2 1
(1) Position of wheel support
(2) to (6) 6
Correction of plough length in relation to type of Fig. 4
headland furrow (point headland furrow, straight
headland furrow)
(3) Automatic phase control indicator
4 . CHARRUE
(4) Plough length time delay
D MY 1
(5) Dual Control Stop / Start function. Each time the
tractor is started 5 is de-activated for safety reasons.
2 1 0 2 9 5 2
Note: Each time the tractor is started, the system is
25
de-activated. OFF appears instead of ON and the 3
padlock symbol appears. To unlock the system, -10 -10
6
place the lift control switch in the Raise position. ON
4
5 2 1
14
Fig. 5
Issue 1 May 2002

D . Adjustments
A
Adjustment of the position sensor on the
rear implement (Fig. 6)
B
- With the Rear Dual Control OFF, vary the height of the
implement for manual adjustment:
· ram completely retracted with a clearance of 4 mm,
the Datatronic indicates 23 points on the scale from 0
to 255 and the sensor must provide 0.94 V for a supply
of 9.59 V.
· ram completely extended with a clearance of 11 mm, A = 11 mm
the Datatronic indicates 215 points on the scale from B = 04 mm
0 to 255 and the sensor must provide 3.25 V for a
supply of 9.59 V. The clearance is the space between
the sensor, here on the rear implement, and the
chassis of the same implement.
Fig. 6
Adjustment of Dual Control parameters in

the Datatronic (Fig. 7)
A to D: Horizontality when the tractor lift and the plough
wheel support are in high position:
- set the plough horizontal in the high position by using the
following controls: A C
B D
· set selector "Q" to lower position and height/depth
E G
adjustment knob to high position F H
· select manual control of the spool valve for the wheel I K
support part J L
- store the values using key (10) for each of the windows M O
concerned (see Description of Screen for correspond- N P
ence with the following):

A : 0 to 255
B : 0 to 255
C : 0 to 255
D : 0 to 255
E to H: Horizontality when the tractor lift and of the plough

wheel support are in low position:
- set the lift and the wheel support horizontally in the low
position and if possible at the mechanical stop position,
using the following controls:
· set selector "Q" to lower position and height / depth
adjustment knob "R" Q R
· select manual control of the spool valve for the wheel
support part
- store the values by pressing key (10) for each of the 1234
windows concerned (see Description of Screen for
correspondence with the following):
E : 0 to 255
F : 0 to 255
G : 0 to 255
H : 0 to 255.
Fig. 7
Issue 1 May 2002

-15
I to L: Adjusting the plough length and the partial lowering
of the wheel support at the furrow start: -15
- to obtain the correct adjustment, proceed in consecu-
-0
tive steps until the optimum adjustment is obtained by
selecting functions one after the other using keys 6.1,
6.2 and knob (14). Then store the values using key (10)
(see Description of Screen for correspondence with the
following):
I : 0 to 100 -0 16 17 +15
J : 0 to 100
K : 0 to 100 ON
L : 0 to 100
M to P: Adjusting the plough length and partial lifting for

the furrow end: 2
- to obtain the correct adjustment, proceed in the same
way as I to L
M : 0 to 255 6
N : 0 to 255
O : 0 to 255
P : 0 to 255
Note:
- The adjustment phases I to P are extremely impor- 14
tant and affect the performance of the system.
- The values I, J, K and L between 0 and 100 are points
and each point equals 25 cm, therefore the distance Fig. 8
may be between 0 cm and 250 m.
Furrow start and furrow end adjustments

(Fig. 8)
- The reference numbers (16) (17) indicate the correction
of the plough length applicable to the next furrow start
and furrow end.
- To modify the values, select the window using keys 6.1
or 6.2 and turn knob (14).
Examples:
· correction (- 0) at the start of the field (straight
headland furrow)
· correction (+ 15) at the end of the field (point headland
furrow).
The values (+) are placed at each end of field after lifting
the plough (on the headland).
In the Working position, the reference numbers (16) (17)
are automatically activated at the end of the field.
Note: If the field is rectangular, the correction
values for reference numbers (16) (17) must be set
to zero.
Issue 1 May 2002

E . Use
4 - PLOUGH
- Each time the tractor is started, for safety reasons, OFF D MY

appears at the bottom left of the screen.
- Each time it is necessary, re-activate it using key 6.5 2 1 0 2 9 5
in the REAR CTRL. menu so that ON appears (Fig. 9)
25
Working mode -10 -10
- When Rear Dual Control is in this mode, the plough ON
wheel support reproduces the movements of the lift
while respecting amplitude and the phase of the lift
movements.
- It is possible to correct the position of the wheel support
by activating the manual spool valve control.
Furrow end (Fig. 10) Fig. 9

- As soon as a Work / Transport transition is carried out,
the system changes to furrow end mode.
- The following steps then succeed each other:
· (24): the lift raises and the wheel support raises partially
to reach the adjusted and stored value.
· (25) and (26): the lift keeps on raising, the plough wheel
support does not move as long as the equivalent
distance travelled by the tractor is less than the ad-
justed and stored value called “furrow start plough
length.”
20 21
X
22 23
25 26
24
Fig. 10
Issue 1 May 2002

Headland Furrow Mode

- The lift is in the maximum high position (value set by the
high position potentiometer), the plough wheel support
is at the stored high position.
Furrow start (Fig. 10)

- When the system detects a Work / Transport transition
through action on the lift control switch, the sequence
is:
· (21): the lift lowers and the wheel support lowers
partially to pre-adjusted height.
· (22) and (23): when the distance travelled by the
tractor is equal to the programmed distance (first
ploughshare to wheel support), the wheel support
lowers completely and the plough operates fully.
Plough length
- This data represents a value from the distance of the
tractor rear wheel axis to the plough wheel support axis.
- This adjustment affects the time delay for the partial
lowering or raising of the plough wheel support.
Optimum adjustment
- Adjustment obtained by search for best plough length
values providing entry into the earth of the first and last
share on a same furrow start line.
Safety time delay

- When one of the Furrow start or Furrow end phases has
begun, a countdown of 8 seconds begins; if the Work-
ing mode or Headland furrow mode has not been
reached after this time, the system is forced into the
position that it should be in, i.e., Working mode with
Dual and ELC adjustments.
Issue 1 May 2002

F . Error codes
Dual Control error codes that may appear
on the Datatronic screen
E-61 : Position sensor height limit exceeded
E-62 : Position sensor depth limit exceeded
E-63 : Manual lever sensor disconnected
E-65 : Depth limit by the manual lever sensor exceeded
For errors relating to solenoid valves, see section 11H01

- Description of the SMS system.
G . Assembly of the additional lever

See section 11D04 § G.
Issue 1 May 2002

Datatronic 2 - TIC 11D04.1
11 D04 TIC for semi-mounted implements
CONTENTS
A. General ________________________________________________ 3
B. Block diagram __________________________________________ 4
C. Description of the adjustment screen _____________________ 8
D. Adjustments ____________________________________________ 9
E. Using __________________________________________________ 12
F. Error codes _____________________________________________ 12
G. Lever and electro-hydraulic spool valve assembly __________ 13
Issue 1 May 2002

11D04.2 Datatronic 2 - TIC
Issue 1 May 2002

A . General
The TIC (Trailed Implement Control) is a digital control
system ensuring the automatic steering of trailed imple-
ments through the ELC console. The information required
for system operation is gathered by the sensors. This
information is processed by Datatronic. The ELC calcu-
lator ensures the control of the trailed implement through
an electro-hydraulic spool valve.
Since January 2001, this system is available for 6200

and 8200 tractors with at least two electro-hydraulic
spool valves and a joystick. However, it is possible to
extra lever. The wheel slip control comes with the basic
equipment, the drawbar draft control is an option avail-
able on 8200 tractors but not on 6200.
Before January 2001, the TIC was already proposed

(only on 8200) with:
- an extra electronic lever
- an electro-hydraulic spool valve controlled with 17 bar
pressure whereas today the spool valve is controlled
under 22 bar pressure.
Electronic information circulates through a CAN bus

system, which helps reduce the number of wires.
Note: The calculator is the same for all tractors; it

can manage the rear and front Dual Controls and the
TIC, but only one of these three functions can be
used at a time.
However, it is perfectly possible to have all three
functions on the same tractor.
Issue 1 May 2002

B . Block Diagram
To allow the control of the trailed implement according to
the effort provided by the tractor, different protection
components and sensors should be taken into account,
so that an optimal operation of the system is achieved.
Lever or
+ 9,5 V
Joystick
+ 9,5 V Position sensor on

Semi-mounted
implement
E
Solenoid valve
BATTERY + 12 V management system
L
C Control valve of
+ 12 V spool valve
TIC
C + 9, 5 V Draft sensor on
the drawbar
A
L Diagnostic LED on the

Masse solenoid valve
C
ACTIVATION
BUTTON
U External linkage
12 V +AC
button
L
A Engine speed and

BUS CAN Auto 3
T Forward speed
O
Potentiometers and
R + 9,5 V
ELC switch
BUS CAN
Datatronic
Issue 1 May 2002

Description of the TIC System (2) Upper screen selection key

ELC calculator (3) Lower screen selection key
- The calculator is the same for all, only one reference is (4) Lower screen selector light
available. (5) Upper screen selector light
- This calculator allows parameter setting. See section Function keys
11F05 for calculator operation. (6) Keys for modifying data to be stored
(7) Work width adjusting key
TIC components (8) Reset cumulated values and stored data key
- The extra lever fed with +9.5V supply (9) Screen Contrast key for the two half screens (1)
- The position sensor fitted on the implement (10) Four memories recall key
(11) Lower screen selector light
Note: (12) Wheel slip control selector light
- If the Front linkage external control button is (13) Active wheel slip control indicator lamp
pressed, the SMS and the rear linkage are blocked. (14) Rotary knob for:
To release it, press the activation switch of the - selecting functions from the menu
Joystick and the ELC switch (in raise position). - modifying contrast after pressing key (9)
- If the rear linkage controls are pressed, only the - modifying implement width, cumulated values,
rear linkage will be blocked. date, hour etc. after pressing keys (6)
- modifying displayed memory title
Parts list (Fig.1)
Reading of data
(1) A two-part liquid crystal display screen
Issue 1 May 2002

4 1
5
3
10
7
11
8
12
9 14
13
Parts list
Fig. 1
Issue 1 May 2002


The ELC calculator is connected with Datatronic through (1) Datatronic
the CAN bus. (2) Radar
Datatronic receives information from the TIC system (3) Engine speed and forward speed sensors
(error codes, position sensor on the extra implement lever) (4) TIC draft sensor
and sends radar speed, wheel slip required value. Datatronic (5) Inductive position sensor
allows to adjust the implement height to its maximum and (6) Position sensor on the control lever
minimum, and to activate the TIC function. (7) ELC draft sensor
(8) TIC electro-hydraulic spool valve
(9) ELC calculator
2
9
CAN
8
7
Fig. 2
Issue 1 May 2002

C . Description of the screen

To access the TIC menu (Fig. 3) press on (2) or (3). In the
main menu select TRAIL ADJ after scrolling down with COST / HOUR
the wheel (14). Click again on (2) or (3) and another UNITS
TRAILED
window appears (Fig. 4). TRAIL. ADJ
A : Height of the memorised implement .... DUAL ....
B : Present height of the implement FRONT CTRL
C : Depth of the memorised implement REAR CTRL
FRONT ADJ
D : Present depth of the implement REAR ADJ
.. JOYSTICK ..
Once the parameters have been set (see §D), press (2) 5
or (3) and another window appears; it will be used for
work (Fig.5) settings.
(1) indicates (Transport or Work) function Fig. 3
(2) indicates position of the implement in %:
- Low position = 0 %
- High position = 99 %
(3) indicates whether the implement is raised or lo-
A
wered
(4) the padlock indicates whether the ELC console is 0
locked or open 0 B
(5) indicates whether the TIC function is ON or OFF
0 C
Note : Every time the tractor starts, the system is 0
deactivated, OFF appears instead of ON, and the D
padlock is displayed. To unlock, press the ELC
switch to raise.
Fig. 4
Fig. 5
1
2
50
3
5
ON 5
Issue 1 May 2002

D . Settings A
Setting the position sensor on the rear im-
plement (Fig. 6)
B
The position sensor mounted on the implement should
have a gap of 11 mm in the high position and 4 mm in the
low position.
The calculator feeds the sensor with a electric supply of

9.5 V DC
- 4 mm should correspond to 23 on the Datatronic A = 11 mm
adjustment screen, 0.94 V on the sensor output B = 04 mm
- 11 mm corresponds to 215 on the Datatronic adjust-
ment screen (0 to 255), 3.25 V on the sensor output
- if the sensor is disconnected, the display shows 0.
Fig. 6
Sensor Sensor Sensor Sensor Sensor

disconnected adjustment in low in raise adjustment
limit position position limit
0 5 23 215 250 255
Setting the TIC parameters in Datatronic

(Fig. 7)
Important: The TIC should be turned OFF.
- To access this menu, see § C.

- Start the tractor, press Datatronic key (2) or (3) to come
to the main menu.
- Select TRAIL ADJ in the main menu using the scrolling
wheel (14) then validate with (2) or (3).
- With the 6.1 key you can switch from B to D and with
the 6.2 key from D to B.
- Once on B, adjust the desired maximum height with the
manual control lever. Press key (10) to store the value 217 A
of B appearing in the window A.
- Then, pass on to C and adjust the desired maximum 217 B
work depth.
A : Programmed height
37 C
B : Present height
C : Programmed depth
37 D
D : Present depth
Fig. 7
Issue 1 May 2002

The draft sensor

This sensor is different from the one used for the lift
function. This 150 KN sensor is fed with 9.5 V. It supplies
a signal equal to 50% of the supply voltage at rest, 25%
of this voltage when it is subjected to a traction of 150 KN
and 75% of this voltage when subject to a compression
of 150 KN (Fig. 8).
Parts list (Fig. 8)

(1) Bar
(2) Pin
(3) Screw
(4) Pin
(5) Ring
(6) Bearing
(7) Screw
(8) Plate
(9) Retainer
(10) Shackle
(11) Washer
(12) Pin
(13) Lever
(14) Cotter pin
(15) Clevis
(16) Bar
(17) Screw
(18) Ring
(19) Lock plate
(20) Screw
(21) Washer
(22) Draft sensor
(23) Connector
(24) Screw
(25) Plate
(26) Guard
(27) Screw
(28) Guard
(29) Clevis
(30) Washer
Issue 1 May 2002

6 25
2
23
24
21 22
18
3
27
28 12
29 30
26
5 13
7
19 8
4 9
1
21 14
15 1
20
16
10
11
17
Parts list
Fig. 8
Issue 1 May 2002

E . Using
The user interface consists of a Datatronic half-screen.
Each time the tractor is stopped, the TIC function is

disabled for safety reasons, and OFF is displayed on the
screen.
50
To activate the function, press the ELC switch to raise
position, then on TIC user screen press the 6-5 key (Fig.
9). ON
Working mode
- when the TIC is in this mode, the height of the
implement can be adjusted with the lift height adjust-
ment potentiometer situated beside the armrest. Fig. 9
- To change the implement from the working mode to
headland furrow mode, press the lift button.
E-70 : Implement sensor disconnected
With the draft sensor E-71 : Upper limit of implement position sensor ex-
- The system adjusts the implement position as any ceeded
traditional lift system i.e. draft sensor, lowering speed E-72 : Lower limit of implement position sensor ex-
and wheel slip control. ceeded
E-73 : Spool valve control sensor disconnected
E-74 : Upper limit of spool valve control sensor ex-
Headland furrow mode ceeded
- In this mode the implement is raised to the maximum. E-75 : Lower limit of spool valve control sensor ex-
ceeded
E-76 : Draft sensor disconnected
E-77 : Upper or lower limit of the draft sensor exceeded
Faults due to solenoid valves are dealt with in chapter

F . Error codes 11H01 - Description of the SMS.
TIC errors that may be displayed on the

Datatronic screen
E-61 : Upper limit of implement position sensor ex-
ceeded
E-62 : Lower limit of implement position sensor ex-
ceeded
E-63 : Spool valve control sensor disconnected
E-64 : Upper limit of spool valve control sensor ex-
ceeded
E-65 : Lower limit of spool valve control sensor ex-
ceeded
Issue 1 May 2002

G . Lever and electro-hydraulic spool

valve assembly 3
23 2
1 . Lever assembly 19 9
- It is possible to control the front / rear Dual Control and DUAL 31
the TIC through an extra lever even though you have a 11
13
joystick or compulsorily if you have bought your tractor 1 30
before February 2001. 7
- In principle the lever controls a potentiometer that
12
informs the ELC calculator of its position. 6 33
- The voltage signal from the potentiometer allows the 35 1
47 10
ELC calculator to control the electro-hydraulic spool 51
valve. Therefore, it is necessary to set the potentiometer 14 50
correctly to obtain optimal performance of the spool 16 34
valve. 42
- The neutral point is adjusted with Wintest (see section 46 27
11F05) : 11 28
. neutral point: 144 points (voltage between signal and
ground is = 5.16 V)
. lower limit reached: 20 points (voltage between
signal and ground is = 0.84 V)
. upper limit reached: 240 points (voltage between 3
signal and ground is = 9.15 V)
. sensor disconnected: 252 points (voltage between 46 45
12 4
signal and ground is = 9.59 V) 8
- The digital values corresponding to sensor data and to 9 44
the information controlling the spool valve are available 10 48 52
49 38
through the CAN network. 5
43
Note: The electro-hydraulic spool valves are differ- 24
ent for the periods before and after February 2001 21 32
(see below) 53
22 25 2
- Rexroth MP18 type before January 2001, current
adjustments to be carried out with Wintest (see
section11F05) 41
- Bosch SB23 type after January 2001, valve param-
eter settings to be carried out with Wintest (see
25
section 11F07)
For assembly and disassembly of this lever with: 17

37
- two mechanical spool valves plus an electro-hydraulic 26
18
spool valve (Fig. 10). 36
17
15
27
39 29
40
Fig. 10
Issue 1 May 2002

For assembly and disassembly of this lever with: - Overall assembled view (Fig. 12)
- two mechanical spool valves plus an electro-hydrau-
lic spool valve (Fig. 11). 3
23 2
19 9
31
11
DUAL 13
35 30
1 7
14 12
33
6 8 1
47 10
51
46 50
16 34
4
42
12 27
11 28
3
12 45
13 4
31 44
9 48
10 49 52
46 38
5
24 32
21
28 53
22 25 2
43
27
41
25
17
37
26
18
36
17
15
27
39 29
40 Fig. 11
Fig. 12
Issue 1 May 2002

2. Assembly of the Dual Control electro- Fig. 13

hydraulic spool valves before January 2001
- Rexroth MP18 2
- Electro-hydraulic spool valves
. uncouple the spool valves by removing the three nuts
on part 2 (Fig. 14).
. depending on the number of spool valves stacked, the
threaded rods are modified.
. put the electro-hydraulic spool valve at the bottom of
the stack and lift the whole. Make sure to put the set-
washers.
. tightening torque 27 Nm (see section 9D01).
- The control circuit for this spool valve is electro-

hydraulic, therefore it is necessary to have :
. electric current supplied by two terminals: black 1 3
connector for lifting (output 18 (+) and 54 (-) of the ELC,
and a brown connector for lowering (output 36 (+) and
17 (-) of the ELC)
. hydraulic pressure, in this case a 17 bar pressure
taken from the priority block outlet (see 9B01 or Fig.
15 and 17) and by connecting the priority block to the
hose with a “T” union (Fig. 13).
Parts list
(1) Priority block
(2) Electro-hydraulic spool valve
(3) “T” union
Issue 1 May 2002

Spool valves disassembly
9 1
2 3
x3
6
7
11
4
12
14
15
16
13
17
5
10
Fig. 14
Issue 1 May 2002

17 bar pressure connector for

18 17 19 20 2 14 15 16 11
Dual Control - Before
January 2001
3
18
1
2 23
3 22 21 4
5
5 12
9
4 6 12
13
10
8
7
7
12
21 22 23 2 15 10 12 10 9 8
16
3
20
17
21
19 18
26
13
11
25
5 4
24
7
10 12
9 10 9
13
13
10
6
8 9 13 8 8 14 13 8 Fig. 15
Issue 1 May 2002

Issue 1 May 2002

3. Assembly of the spool valves since Janu- U - Position sensor and ELC connector intermediary
ary 2001 - Bosch SB23 cable
- The differences compared to Rexroth are the following: - channels : 3
. a different electrical diagram (Fig. 16 and 17), different - colour : Black
connections, use of the CAN bus - pins :
. spool valve control hydraulic supply is now 22 bar 1 : ground (blue wire)
instead of 17 bar. To obtain this pressure it was 2 : implement position signal (black wire)
necessary to install an end plate containing a pressure 3 : + 9.5 V (brown wire)
reducing valve, which by dividing the main hydraulic
flow allows to obtain a 22 bar pressure to control V - Draft sensor connections
electro-hydraulic spool valves. This end plate also - channels : 3
contains a solenoid valve that blocks oil flow in case - colour : Black
a problem is detected by the ELC and the internal - pins :
management system of the spool valves. 1 : ground (black/white wire)
2 : draft sensor signal (blue wire)
Parts list of the electrical diagram SB 23 (Fig. 16) 3 : + 9.5 V (brown/yellow wire)
(20) SB23 Dual Control spool valve
(21) Manual control lever W - Front position sensor and ELC connector inter
(22) Position sensor fitted on the implement mediary cable
(23) TIC draft sensor - channels : 3
(24) Position sensor - colour : Black
(25) Front linkage external controls - pins :
1 : ground (blue wire)
2 : output voltage (black wire)
Parts list of the different connections 3 : electric supply (brown wire)
R - Control connections of the external linkage
- channels : 5 X - Dual Control spool valve connector
- colour : Black with red mark - channels : 4
- pins : - colour : Black
1 : raise signal (violet wire) - pins :
2 : not used (pink wire) 1 : 12 V after contact (red wire)
3 : lower signal (yellow wire) 2 : CAN low (brown wire)
4 : ground (orange wire) 3 : CAN high (green wire)
5 : electric supply + 12 V after contact (red wire) 4 : ground (black wire)
S - Control lever connections

- channels : 3
- colour : Black
- pins :
1 : + 9.5 V (brown/yellow wire)
2 : lever sensor signal (pink wire)
3 : ground (black/white wire)
T - Position sensor cable connection

- channels : 3
- colour : Black
- pins :
2 : implement position signal (dark green wire)
Issue 1 May 2002

Parts list of the Rexroth spool valves before January

2001 (Fig. 17)
(1) Dual Control manual control lever
(2) Position sensor fitted on the implement
(3) TIC draft sensor
(4) Dual Control spool valve
Parts list of the different connections

R - Dual Lowering solenoid valve
- channels : 2
- colour : Brown
- pins :
1 : lower solenoid valve(red wire)
2 : lower solenoid valve code (black wire)
R (bis) - Dual Raise solenoid valve

- channels : 2
- colour : Black
- pins :
1 : raise solenoid valve(red wire)
2 : lower solenoid valve code (black wire)
S - Dual manual lever sensor

- channels : 3
- colour : Black
- pins :
2 : lever sensor signal (pink wire)
T - Position sensor cable connections

- channels : 3
- colour : Black
- pins :
2 : implement position signal (dark green wire)
U - Position sensor and ELC connector intermediary

cable
- channels : 3
- colour : Black
- pins :
1 : ground (blue wire)
2 : implement position signal (black wire)
3 : + 9.5 V (brown wire)
V - Draft sensor connector

- channels : 3
- colour : Black
- pins :
2 : draft sensor signal (blue wire)
Issue 1 May 2002


14
N
16 N N N
13
O
BF
J
15 K3 K5
N N 12
19 K1
17 J
L
N
M/J
M VF
N/B 11
I
N G
Ro
10
H
G
J
9
G
VC N
F 8
J
R
R/B
Vi
7
M
B
G
Ro
6
D
5
Vi
O
M
B
B
Q
B
23 N/G
V
O A
N
3
R
Vi
O
21 N
R
R
S N
M
R
N R bis 2
R 1
20
T U 22
Fig. 16
Issue 1 May 2002

SERIES 6200 / 8200 TRACTORS
Electronics - Wintest 11F01.1
11 F01 Wintest – General
CONTENTS
A. General – Description ______________________________ 3
B. Installing Wintest on the PC's hard drive _____________ 4
C. Updating Wintest software _________________________ 5
D. Connections _______________________________________ 6
E. Access to the Wintest main menu ___________________ 9
F. Wintest version ____________________________________ 13
Issue 2 May 2002

11F01.2 Electronics - Wintest
Issue 2 May 2002

Tested PCs
A . General - Description - Toshiba Satellite 2520 CDT
. AMD K6 microprocessor
Wintest software allows to: . 300 MHz
- program Autotronic 2, Autotronic 3, TC, DCC and . 64 MB SDRAM
Datatronic during part replacement, or following the . 4.1 GB hard drive
issue of a new and improved program . CD-ROM and floppy drive
- change the parameters of Autotronic 2, Autotronic 3, . 12.1 inch colour monitor
TC, DCC, ELC, SMS system and Datatronic according . Windows 98 OS
to the options fitted to the tractor and its features . Optional: 12V cigar lighter power supply
- display the operation of Autotronic 2, Autotronic 3, TC,
DCC and Datatronic and linkage and to detect any - Dell Latitude Cpi
malfunction. . Pentium II microprocessor
. 233 MHz
Its use with each device is described in the following . 32 MB SDRAM, extendable to 128 MB
sections: . 4.1 GB hard drive
- Autotronic 2 ................................................. 11 F02 . 12.1 inch colour monitor
- Autotronic 3 ................................................. 11 F03 . Windows 95 or Windows 98 OS
- TC / DCC ..................................................... 11 F04 . Optional: 12V cigar lighter power supply
- Electronic linkage ........................................ 11 F05
- Datatronic .................................................... 11 F06 Both these PCs have been tested with the Wintest
- SMS ............................................................ 11 F07 software. It is recommended that you check the guaran-
- Autotronic 3 towards Autotronic Kit ............. 11 F08 tee and breakdown service conditions with your local
- Autotronic kit towards Autotronic 3 .............. 11 F09 dealer.
To use Wintest, it is necessary to have:

- A locally supplied PC with the following minimum
configuration:
. A 386 microprocessor
. 25 MHz
. 4 MB SDRAM minimum
. 10 MB hard drive minimum
. preferably a colour screen
. Windows 3.11, Windows 95 or Windows 98 OS
. 12V cigar lighter power supply (for portables).
The PC must be fitted with the following service tools

(supplied by Beauvais):
- a CAN BOX interface, ref. 3378243 M1
- a type A harness, ref. 3378244 M1, with round 4-pin
connector for tractors not having the 16-pin connector
at the rear right hand side of the cab. To be connected
on harness, ref. 3378245 M1.
- a type B harness, ref. 3378245 M1, with round 16-pin
connector for tractors having the 16-pin connector at
the rear right hand side of the cab
- the latest version of Wintest comprising a CD.
- an extension wire (10 cm) between the PC and the
CAN BOX, ref. 3378246M1.
Note: The CAN BOX interface and Wintest software

cannot be supplied separately.
Issue 2 May 2002

B . Installing Wintest on the PC’s

hard drive
To use Wintest it is first necessary to install it on the hard
drive from the diskettes provided.
Wintest runs only under Windows 3.11, Windows 95 or
Windows 98. Depending on the version of the OS, the
installation operations differ slightly (details follow).
Installation procedure
- Boot the PC so that the desktop is displayed.
Windows 3.11 Windows 95 or 98

. Click on the "File" menu . Click on the "Start" menu
. Click on "Run" . Click on "Run"
Insert the CD in your CD-Rom reader

- click on "Start" then on "Run"
- Type: d:\DISK1\Setup (d = your CD-Rom reader ad-
dress)
- Click on "OK"
- Select your language
- Click on "OK"
- Follow the Wintest installation instructions
- Type your name and your company name in capitals,
then type the Wintest serial number (serial number
given on CD box)
- Follow the Wintest installation instructions
Wintest is automatically installed on your PC in:

- c:\programf\wintest
If you wish to rapidly access Wintest, create a shortcut

and place it on the desktop.
Issue 2 May 2002

C . Updating Wintest software

Updating is necessary:
- when a new version of the program is available for one
or more electronic devices
- when improvements to one or more functions have
been made via their parameters
- when improvements have been made to the Wintest
software.
- After having started the Wintest software, click on

"Options", then "Update"
Wintest
Test Options Help
Update
GO! Help
WGE-1
The following screen is displayed:
Update
Insert update disk in drive A
OK
Yes Cancel
WGE-2
- Insert the update diskette in the drive

- Click on "OK"
- Wait approximately 1 minute
- Check the Wintest version number (see § F).
Issue 2 May 2002

D. Connections
- Connect the CAN BOX interface to the laptop.
- According to version, connect the 16 pins or 4 pins
connector to the tractor.
Important :
- Never directly connect the PC to the 16-pin connec-

tor without the CAN BOX interface
- Battery voltage must be 12.5V minimum.
Opérations could be done according to the

connection
Connection Auto 2 Auto 3 TC/DCC Connectors used
Fig. 1 •Programing - -
• Setting - - E on Auto 2 and C33
• Test - -
Fig. 2 - • Programming • Program

•Setting parameters • Setting parameters • Setting parameter Cab 16 pin
•Test • Test • Test connector
• Power Shuttle
manal calibration
Fig. 3 - - -
• Setting parameters - - E and C33 and C35
• Test - -
Connection Linkage Data 2 SMS Connectors used
Fig. 1 - - -
- - - -
- - -
Fig. 2 - • Programming • Joystick

calibration
• Setting parameters • Setting parameters • Setting valve Cab 16 pin
• Test • Test parameters connector
• Test
Fig. 3 - - -
- - - E and C33 and C35
• Test - -
Issue 2 May 2002

Connection with type A harness, ref. 33780244 M1

3378246M1
3378243M1
3378245M1
CAN BOX
AGCO
Ref : 3 378 243 M1
E
3378244M1
3714779M1
C33
Fig. 1
Connection with type B harness, ref. 3378245 M1

3378245M1
3378246M1
3378243M1
CAN BOX
AGCO
Ref : 3 378 243 M1
Fig. 2
Issue 2 May 2002

Linkage test on tractor without 16 pin connector in the cab
3378246M1
3378243M1
CAN BOX
AGCO
Ref : 3 378 243 M1
3378245M1
C35
3715767M1
C33
3714779M1
3378244M1
Fig. 3
Issue 2 May 2002

E . Accessing the Wintest main

menu
Wintest
File Edit Display ?
With the Wintest window visible on the Windows desk-
top:
WIN
- Turn the ignition key on.
TEST
- Double click on the Wintest icon. Wintest
1 objects 652 octets

bytes
WGE-3
The following screen is displayed :
Wintest
Test Options Help
GO! Help
WinTest V1.10.06
B00AA03001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
D CC : 2.14
TCU 0 92 : R
TCU 0 93 : C
D ATA 2 : D 001208
AUTO3 : B11
KIT AUT OTRO NIC : X32
WGE-4
- Wintest software version ........ V1.10.06

- Serial number and name of Wintest owner
- Calculators software include in Wintest
- Click on "GO" to access the Wintest main menu
- Click on to return to the Windows desk-

top and exit Wintest
- Click on "Help" to access the Wintest Help files.
Issue 2 May 2002


Setup
Auto
Auto 32Kit Autotronic
Auto 3
OK
Autotronic 2
TC-DCC Cancel
Autotronic 3
Help
Datatronic 2
Linkage
Joystick
WGE-5
Depending on the type of tractor, select the type of

transmission controller :
- Kit Autotronic 3 towards Autotronic
- Autotronic 2
- TC / DCC
- Autotronic 3
Then according to the other functions available, select:

- Datatronic 2
- Linkage
- Joystick
When the transmission controller and the various options

are selected, click on "OK".
Note: The description of Wintest operation with the

different calculators is explained in the following
sections.
Issue 2 May 2002

One or more error messages may be displayed:
Programming TC
Check the connections
Turn the ignition key
Retry Cancel
- Turn the ignition key on and check the connections

between the PC and the 16-pin connector, then click on
"Retry"
CAN error
Initialization of CAN BOX not

possible
OK
WGE-7
- Check the connections between the PC and the 16-pin

connector, then click on "OK".
Issue 2 May 2002

- If there are no error messages, the main menu is

displayed.
Wintest
Test Options Help
GO! Help
Wintest
Tester
OK
Help
DATA : D960500 TCU : R 9:25 NUM
WGE-8
Note: A status bar at the bottom of the screen

displays the versions of the electronic devices fitted
to the tractor.
Example: Datatronic .............. DATA: D960500

Autotronic 2 ........... TCU: R
Issue 2 May 2002

F . Wintest version
- Click on "Help", then "About Wintest" to display the
Wintest
software version and the programmes in the various
Test Options Help
electronic devices. Index
How to use Help
GO! About Wintest... Help
WGE-9
Wintest
Tester Option Aide
GO! H elp
Abou t teste
r
WinTest
WinTest Version 18016
C opyright ' 1995. A llR ights R eserved
TC : 2.08
D CC : 2.13
D A TA 2 : D 001208
TC U 092 : R
TC U 093 : C
A U TO 3 : B 09
M . R O C H EFO U C A U LT.
A G C O FR A N C E B eauvais
B 00AA 03001456
OK
WGE-10
- Wintest software version ................. V1.10.06 - Software serial number and name of Wintest CD
- TC version ....................................... 2.14 owner.
- DCC version .................................... 2.14
- Datatronic 2 version ......................... D001208
- Autotronic 2 version ......................... R or C
- Autotronic 3 version ......................... B11
Issue 2 May 2002

11 F02 Autotronic 2 with Wintest
CONTENTS
A. Using Autotronic 2 with Wintest ____________________ 2
B. Programming and Setting parameters _______________ 3
C. Setting parameters _________________________________ 19
D. Tests and diagnostics

- "Safety" function _________________________________ 31
- "Gearbox" function _______________________________ 33
- "Front axle" function ______________________________ 37
- "Differential lock" function _________________________ 40

- "Power take-off" function __________________________ 43
Issue 2 May 2002

A. Using Autotronic 2 with Wintest Autotronic 2 status

The Autotronic 2 operates via 12 main states. The
status of the Autotronic 2 is displayed at the bottom of
Description each test screen.
The Wintest software allows to program and set the
parameters of Autotronic 2 as well as to display and List of statuses
detect faults within its various functions. - TCU 0: Autotronic in standby mode
To carry out testing with Wintest, the status of a - TCU 1: No program
function on the tractor is modified and compared with - TCU 2: 17 bar pressure lower than 9.5 bar and
status displayed on the screen of the PC. engine speed lower than 200 rpm
- If the icon corresponding to the function is displayed - TCU 3: 17 bar pressure lower than 9.5 bar and
in reverse video, this indicates that 12V is present. engine speed lower than 200 rpm for at
- If the icon corresponding to the function is displayed least 6 seconds
in normal video, this indicates that 12V is absent. - TCU 4: 17 bar pressure correct and engine speed
- If no there is no change whatsoever, check the above 200 rpm
connectors, the ignition switch and test the wiring - TCU 5: 17 bar pressure drop for less than
corresponding to the relevant function. 4 seconds
- TCU 6: engine speed down for less than
Where the function being tested seems defective, click 0.5 seconds
on the icon that represents it: - TCU 7: engine speed down for greater than
- a window is displayed showing the identity of the 0.5 seconds
connector terminals and the colour of the - TCU 8: not used
corresponding wires. - TCU 9 -10: incorrect parameters
Example: The icon corresponding to the Hare / - TCU 11: battery voltage above 16 V
Tortoise range switch has been selected. Information
concerning it is displayed in a window:
J1 – 32 = Switch J1 of Autotronic 3, terminal No. 32,
wire colour white.
Wintest
Test
Testing the gearbox
GO! Help Autotronic
1064 0.0 Amps Off

4.1 100 %
0.0 Amps Off
280
280
Range switch
Err : 0
Connector: J1-32
Colour: White
Off
Switch black --> Range switched
OK
EV1 On
OK
EV2 Off
TCU 2 Help
WA2-1
Issue 2 May 2002

B. Programming and Setting

parameters
Programming
- Turn the ignition key on and start the engine to carry
out this operation. The voltage must be at least 12.5 V.
- The programming of the Autotronic 2 is necessary:

. when the former Autotronic 2 has been replaced by
a new one
. when a new program becomes available to improve
the product
Note: It is necessary to set the Autotronic
2 parameters again after programming.
Wintest recognises two versions of the Autotronic 2
program:
- TCU R: for tractors without a proportional PTO
solenoid valve
- TCU C: for tractors with a proportional PTO solenoid
valve
The choice of program is made according to the AA
parameter code. If Wintest cannot read the AA code,
the following screen is displayed.
Enter the AA code according the tractor type (see
parameter table).
Wintest
Test Options Help
GO! Help
Version of Auto2 unknown

Enter the tractor code (AA)
Tractor code 19
OK
WA2-2
Issue 2 May 2002


Programming / Reprogramming
The software of Autotronic 2 will be incorrect for

tractor where it should be fitted.
To modify the Autotronic 2 software:

1. Connect the PC with Wintest to the tractor fitted
with the Autotronic 2 (Fig. 1).
2. Disconnect the "E" CAN harness between the
Autotronic 2 and the testing equipment (Fig. 1).
3378246M1
3378243M1
3378245M1
CAN BOX
AGCO
Ref : 3 378 243 M1
E
3378244M1
3714779M1
C33
Fig. 1
Issue 2 May 2002

3. Start Wintest.
4. Click on "GO" to access the main menu.
Wintest
Test Options Help
GO! Help
WA2-3
5. Select "Autotronic 2".

Click on "OK" to valid.
Setup
Auto 2 Auto 3
OK
Autotronic 2
TC-DCC Cancel
Autotronic 3
Help
Datatronic 2
Linkage
Joystick
WA2-4
Issue 2 May 2002


6. The following screen is display.
Click on "Cancel".
Depress the clutch pedal

fully
Retry Cancel
WA2-5
7. The following screen is display.

Note : The screen is display when Wintest cannot
read the code AA (ex : Autotronic 2 without
software)
Wintest
Test Options Help
GO! Help
Version of Auto2 unknown

Enter the tractor code (AA)
Tractor code 19
OK
WA2-6
Issue 2 May 2002

8. Reconnect the CAN "E" connector if disconnect

(Fig. 1).
9. Enter the "AA" code for your tractor using the digital
keys of your PC keyboard.
10. Click on "OK" to valid.
11. The following screen is displayed.
Click on "Tool" icon and "programming Autotronic 2".
Winest
Test Options Help
GO! H elp
Wintest
Parameters ......
Autotronic 2 parameters
Programming Autotronic 2
OK
Help
TCU : O FF 9:25 NUM
WA2-7
Nota :
- The software version "R" or "C" is automatically
selected by Wintest according to the "AA" code
entered at the operation 9 or read when you start
Wintest.
- To program, put the ignition on and start the
engine. The voltage must be at least 12,5 V.
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Are you sure?
Yes No OK
Help
WA2-4
- Click on: “YES” to carry out programming

“NO” to cancel programming
Issue 2 May 2002

During programming, several error messages Correction method

may be displayed: Message 1: Stop the engine
1. Stop the engine Message 2: Check battery voltage
2. Battery voltage too low Messages 3 - 4 - 5: Check connection of the CAN BOX
3. Unable to enter Programming mode interface and turn the ignition key off
4. Unable to begin Boot programming Messages 6 - 7 - 8 - 9 - 10: The Autotronic 2 is defective
5. Unable to leave Programming mode Message 11: Hard drive problem. Re-install the
6. Unable to delete program WINTEST software on your PC.
7. Unable to change page
8. Unable to program line
9. Cannot program a byte
10. Programming impossible
11. Unable to open source file
Wintest
Test Options Help
GO! Help
Wintest
Error message
Battery voltage too low

OK
Help
Retry Cancel
WA2-5
Issue 2 May 2002


After correction, or if no error messages are displayed,
the following screen appears:
Wintest
Test Options Help
GO! Help
Wintest
Start the engine

OK
Help
OK
WA2-6
- Start the engine.

- Click on “OK”
Issue 2 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Remove connector F
OK
OK
Help
WA2-7
- Remove connector F
- Click on “OK”
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Connect connector F
OK
OK
Help
WA2-8
- Connect connector F
- Click on “OK”
Issue 2 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Depress the clutch pedal fully
OK
OK
Help
WA2-9
- Fully depress the clutch pedal, then release it

- Click on “OK”
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
100 %
OK
Help
WA2-10
- A gauge indicates the progression of the

programming.
Note: The indicator gauge may take 1 or 2 minutes
to be displayed.
Issue 2 May 2002

- When the programming is completed, the following

screen is displayed:
Wintest
Test Options Help
GO! Help
Wintest
Programming completed
Programming Autotronic
Programmation 2 2
Autotronic
100 %
OK
Yes No
Help
WA2-11
- Click on “OK”
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Remove connector F
OK
OK
Help
WA2-12
- Disconnect connector F
- Click on "OK"
Issue 2 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Connect connector F
OK
OK
Help
WA2-13
- Connect connector F
- Click on “OK”
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Depress the clutch pedal fully
OK
OK
Help
WA2-14
- Fully depress the clutch pedal, then release it

- Click on “OK”
Note: It is necessary to set the Autotronic2 param-

eters again after programming (see § C)
Issue 2 May 2002

Setting parameters
- Turn the ignition key on to carry out this operation. The
voltage must be 12.5 V minimum.
- It is necessary to change the parameters:
. if the Autotronic 2 has been replaced by a new device
. if improvements have been made to one or more
functions by changing the parameters
. if programming has been carried out
The parameter code is found on a label on the left hand

side dashboard support near the fuse box. This code
has 12 figures and corresponds to the 11 parameters
whose meaning is shown below.
Important: Discard all letters and numbers before

the serial number H099011.
Parameter code AA B C D E F G H I J K
Example of setting 72 3 1 1 2 0 1 0 2 0 0
Code AA = 72 = 6280 open centre

Code B = 3 = 4 WD memory
Code C = 1 = with Hare / Tortoise synchro
Code D = 1 = with 4 x 2 gearbox
Code E = 2 = speed limited to 40 Kph
Code F = 0 = without Speedshift
Code G = 1 = Dynashift with steering wheel lever
Code H = 0 = mechanical shuttle
Code I = 2 = for 6200 / 8200
Code J = 0 = no creeper unit
Code K = 0 = Autotronic 2 for 6200 PTO
Note: The Autotronic 2 does not control the creeper unit
Issue 2 May 2002

Autotronic 2 parameter codes: 6100 - 8100 - 3000 - 3100 - 3600
CODE AA
MODEL Open centre hydraulics Closed centre hydraulics

with
AUTOTRONIC 2 Non modified Increased flow rate hydraulic Speedshift Speedshift
flow rate pump from No.D125027 tractors with tractors with
VERSION R hydraulic pump onwards 30 Kph 30 Kph
up to mechanical electronic speed
References No.D125026 Speedshift Speedshift limitation or limitation from
3715631M1 tractors with tractors with Dynashift No.G083035
3792092M92 30 Kph 30 Kph onwards
mechanical electronic speed
limitation or limitation from
Dynashift No.G083035
onwards
6110 - 6120 00 19 30 25 32
6130 - 6140
3050 - 3055
3060 - 3065
3065S
3070 01
6150 - 6160 02 20 31 26 33
6170
3075 - 3080
3085 - 3090
3095
6180 03 21 - 27 -
3115 - 3120
6190 04 22 - 28 -
3125 - 3140
Issue 2 May 2002

MODEL PTO 540 / 1000 rpm PTO 750 / 1000 rpm

with AUTOTRONIC 2
Version R
References
3715631M1 / 3792092M92
8110 - 8120 Normal Duty 05 12

3635 - 3645 Normal Duty
8110 - 8120 Heavy Duty 06 13

3635 - 3645 Heavy Duty
8130 Normal Duty 07 14

8130 Heavy Duty 08 15

8140 - 8150 Heavy Duty 09 16

3680 Heavy Duty
8150 Double drive unit 10 17

3680 Double drive unit
8160 Double drive unit 11 18

3690 Double drive unit

Reinforced Transmission
Issue 2 May 2002

Code B Code C Code D Code E

Front axle Hare / Tortoise Gearbox type Maximum speed
1 = 2WD 0 = Non synchronised 0= 4x2 1 = 30 kph

2 = 4WD (a) 1 = Synchronised (without AB range) 2 = 40 kph except 8160
3 = 4WD memory (b) 2= 4x4 Heavy Duty
(with AB range) Reinforced
3 = 33 kph (Japan)
4 = 40 kph for 8160 with
Heavy Duty
reinforced gearbox
Code F: Speedshift Code G: Dynashift Code H: Reverse shuttle
0 = No Speedshift 0 = No Dynashift 0 = Mechanical

1 = Speedshift with button 1 = Dynashift with steering wheel 1 = Pre-selection
control lever • with button
2 = Speedshift with steering 2 = Dynashift with gear lever • with MCB sensor (old
wheel lever button model)
3 = for AGCO Allis or White 2 = Pre-selection
• with lever
• with MCB sensor (old
model)
3 = Pre-selection
• with lever
• with Bosch sensor (new
model)
4 = Pre-selection
• with button
model)
(a) Each time the engine is started, the 4WD indicator lamp is lit and the front axle engaged.
To disengage 4WD:
- press the brake pedal,
- press the 4WD switch.
The indicator lamp goes out.
The front axle is actually disengaged when the Autotronic receives a speed signal greater than 1 kph.
(b) Each time the engine is started, the 4WD is in the position stored when the engine was stopped. The 4WD
function may different according to the code (see (d)).
Issue 2 May 2002

Code I: Factory Code I: Creeper unit
0 = AGCO MF with Autotronic 371563M1 (c)

1 = Not used
2 = AGCO MF with Autotronic 3792092M92 (d) 0 = None
Code K: PTO
0 = with PTO
(c) Code I = 0
- changing from 4WD to 2WD is actually carried out when the speed sensor sends a signal
- the 4WD engages if there is action on one of the two brake pedals above 5 kph
(d) Code I = 2
- changing from 4WD to 2WD when stopped is actually carried out without any received speed sensor signal
- 4WD engages if there is action on one of the two brake pedals above 5 kph
Issue 2 May 2002


Autotronic 2 code parameters : 6200
CODE AA
MODEL
with Open centre Closed centre
AUTOTRONIC 2 hydraulic circuit hydraulic circuit
Version C
3792093M93
6235 - 6245 70 74
6255 - 6260 - 6265 - 6270 71 75
6280 72 76
6290 73 77
Autotronic 2 code parameters : 8200

CODE AA
MODEL
with
AUTOTRONIC 2 PTO 540 - 1000 rpm PTO 750 - 1000 rpm
Version C
3792093M93
8210 - 8220 34 79
Heavy Duty
8210 - 8220 35 80
Heavy Duty sealed
8240 82 83
Heavy Duty sealed
8240 - 8250 36 81
Double drive unit
Issue 2 May 2002


Front axle Hare / Tortoise Gearbox type Max. speed
1 = 2WD 0 = Non synchronised 1=4x2 1 = 30 kph

2 = 4WD (a) 1 = Synchronised (without AB range) 2 = 40 kph except 8160
3 = 4WD with memory 2=4x4 Heavy Duty
(b) (with AB range) Reinforced
3 = 33 kph (Japan)
4 = 40 kph for 8160 with
Heavy Duty
reinforced gearbox
To disengage 4WD:
- press the brake pedal,
- press the 4WD switch.
(b) Each time the engine is started, the 4WD is in the position memorised when the engine was stopped. The 4WD
function may differ according to the code I (see (d)).
Issue 2 May 2002


1 = Speedshift with button 1 = Dynashift with steering 1 = Pre-selection
control wheel lever • with button
2 = Speedshift with steering 2 = Dynashift with gear lever • with MCB sensor (old
wheel lever button model)
3 = for AGCO Allis or White 2 = Pre-selection
• with lever
• with MCB sensor (old
model)
3 = Pre-selection
• with lever
model)
4 = Pre-selection
• with button
model)
Code I: Factory Code J: Creeper unit
0 = AGCO MF old range 0 = None

1 = Not used 1 = With
2 = AGCO MF 6200 / 8200 (c)
Code K: PTO
0 = with PTO
(c) New ranges 6200 / 8200

Code I = 2
- changing from 4WD to 2WD when halted is actually carried out without any received speed sensor signal
- 4WD is engaged only if there is action on both brake pedals at whatever speed
- differential lock is definitively disengaged if there is action on a brake pedal
- PTO emergency stop switch located on fenders (if fitted)
Issue 2 May 2002

- Click on the “Tools” icon and then on “Parameters”
Wintest
Test Options Help
GO! H elp
Wintest
Parameter
Autotronic2 parameter...
Programming Autotronic2...
OK
Help
WA2-19
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
AA B C D E F G H I J K
7272 3 1 1 2 0 1 0 2 0 0
OK Cancel
OK
Help
WA2-16
- Using the Tab key, select the code to modify, then

type in the new parameter.
- Confirm the code by clicking on “OK”
Note: If an Autotronic parameter is incorrect in

relation to the possible parameters, the parameter
is highlighted.
Enter the correct code and confirm it by clicking on
“OK”.
Issue 2 May 2002

- Another screen allows to display the values entered

during parameter setting.
- Click on the “Tools” icon and then on "Autotronic 2
parameter..."
Wintest
Test Options Help
GO! H elp
Wintest
Parameter
Paramétrer
Autotronic 2 parameter ....
Programming Autotronic2...
OK
Help
WA2-20A
Issue 2 May 2002


The following screen is displayed
Tractor code Parameter Parameter value
Synchro type Synchro

Front axle With front axle stored
Tester code !0
Extended display ..... Pulse/10 kph 115
RPTO pulse/rev 28
PTO ECO ratio 12917
Engine pulse/rev 77
Eng. Nominal speed 2200
Display all
Max. PFA & Diff speed 14
Hi -> Lo max speed ! 10
Lo -> Hi max speed 8
Trans type 4*2 Transmission
Dynashift Telma
Speedshift None
Shuttle type Preselect Reverse Shuttle lever
Speed limit 0
C ratio (eng./Fwd *8) 112
D ratio (eng./Fwd *8) 128
OK Cancel Help
WA2-20B
- Select "Display all" to display all the parameters.

- The "Parameter" column defines the parameter.
- The "Parameter value" column gives the characteristics
of the parameter.
Issue 2 May 2002

D . Tests and diagnostics
“Safety” function
- Start the engine.
- Click on the “Safety” icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA2-21
Issue 2 May 2002


Wintest
Test
Testing the Safety Function
GO! Help Autotronic
1064
14,3
OK
TCU 4 Help
WA2-22
Engine speed sensor value in rpm Bottom clutch pedal switch
1064
17 bar hydraulic circuit Low Pressure indica-

Battery voltage in volts.
tor lamp
Value between 11V and 15V
143 - if pressure is correct, it is displayed in normal video,
- if pressure is below 9 bar ± 1, it is displayed in reverse
video or red if the indicator lamp on the dashboard is
lit.
17 bar low pressure hydraulic circuit

pressure switch.
TCU 4 Autotronic 2 status.
- if pressure is correct, it is displayed in reverse video.

- if pressure below 9 bar ± 1, it is displayed in normal
video.
Issue 2 May 2002

"Gearbox" function
- Start the engine.
- Click on the "Gearbox" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA2-19
Issue 2 May 2002


Wintest
Test
Testing the gearbox
GO! Help Autotronic
1064 Off
Off
155
On
180 EV1 On
OK
EV2 Off
TCU 4 Help
WA2-20
Transmission oil temperature sensor value in

Engine speed sensor value in rpm points
1064 180
- error at 255
Design forward speed indicated by forward

ground speed sensor in tenths of kph 17 bar low pressure hydraulic circuit pressure
switch.
0

Pre-selection shuttle fork value in - if pressure is below 9 bar ± 1, it is displayed in normal
potentiometer points video
155
- forward maximum: 160 points

- reverse maximum: 40 points Bottom clutch pedal switch
- difference between forward and reverse to be
between 70 and 110 points
Issue 2 May 2002

Pre-selection shuttle selector switches 17 bar low pressure hydraulic circuit pressure
switch.
- Forward - if pressure is correct, it is displayed in normal video

- if pressure below 9 bar ± 1, it is displayed in reverse
- Reverse video or red if the dashboard indicator lamp is lit
Hare / Tortoise range switch Forward indicator lamp
- contact = reverse video

Reverse indicator lamp
- no contact = normal video
Dynashift selector switch Tortoise range indicator (no lamp on dash-

board)
Dynashift range A B C D
OFF ON ON ON
Hare range indicator lamp
OFF OFF ON ON
OFF OFF OFF ON
- ON = reverse video Dynashift or Speedshift indicator lamps

- OFF = normal video
-A-B-C-D
Speedshift range switch TCU 4 Autotronic 2 status
- C range = normal video Forward ON / OFF solenoid valve status

- D range = reverse video
Off
OFF = solenoid valve deactivated

ON = solenoid valve activated
Issue 2 May 2002

Reverse ON / OFF solenoid valve status
Off

Warning buzzer
Hare / Tortoise range solenoid valve status
- Tortoise = OFF = solenoid valve deactivated

- Hare = ON = solenoid valve activated
EV1 Dynashift EV1 solenoid valve status

EV2 Dynashift or Speedshift EV2 solenoid valve

status

Solenoid valve EV 1 ON ON OFF OFF
Solenoid valve EV 2 OFF ON ON OFF
Speedshift range C D
Solenoid valve EV2 ON OFF
Issue 2 May 2002

“Front Axle” function

- Start the engine.
- Click on the “Front Axle” icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA2-25
Issue 2 May 2002


Wintest
Test
Testing the Front Axle
GO! Help Autotronic
1064
PFA Off
OK
TCU 4 Help
WA2-22
Engine speed sensor value in rpm Front axle pulse switch
1064

Left and right brake pedal switches
ground speed sensor in kph
0
17 bar low pressure hydraulic circuit pressure Front axle indicator lamp
switch.

video
Issue 2 May 2002

17 bar low pressure hydraulic circuit pressure

switch.
- if pressure is correct, it is displayed in normal video.

- if pressure below 9 bar ± 1, displayed in reverse video
or red if the dashboard indicator lamp is lit.
Front axle overspeed
PFA
Front axle ON / OFF solenoid valve
Off
- ON = 2WD
- OFF = 4WD
TCU 4 Autotronic 2 status
Issue 2 May 2002


“Differential Lock” function
- Start the engine.
- Click on the “Differential Lock” icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA2-23
Issue 2 May 2002

Wintest
Test
Testing the differential lock
GO! Help Autotronic
1064
Diff Off
OK
TCU 4 Help
WA2-24
Engine speed sensor value in rpm Differential lock pulse switch
1064
Right and left brake pedal switches

0
17 bar low pressure hydraulic circuit pres- Differential lock indicator lamp
sure switch.
- if pressure is correct displayed in reverse video

- if pressure below 9 bar ± 1, displayed in normal video
Issue 2 May 2002

17 bar low pressure hydraulic circuit indicator

lamp
- if pressure correct, it is displayed in normal video.

lit.
Linkage 3-position switch
- only the up position and the work position are repre-

sented
Differential lock overspeed
Diff Differential lock ON / OFF solenoid valve
Off
ON = Differential lock engaged

OFF = 4WD differential lock disengaged
TCU 4 Status of the Autotronic 2
Issue 2 May 2002

Power Take-Off function

- Start the engine.
- Click on the “Power Take-Off” icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA2-29
Issue 2 May 2002


Wintest
Test
Testing the Power Take-Off
GO! Help Autotronic
1064
PTO Off
OK
TCU 4 Help
WA2-30
Engine speed sensor value in rpm 17 bar low pressure hydraulic circuit pressure
switch.
1064

video
Power take-off clutch speed sensor in rpm
0
PTO clutch switch
- PTO sensor speed = engine speed

The comparison of these two speeds allows the detec-
tion of PTO clutch slip
1550 rpm economic PTO switch
Issue 2 May 2002

PTO emergency stop switch (fitted on rear

wing according to options)
- if switch not fitted = reverse video
PTO indicator lamp

tor lamp
- if pressure correct, it is displayed in normal video.

lit.
PTO PTO solenoid valve
Off
ON = engaged
OFF = disengaged
Issue 2 May 2002

11 F03 Autotronic 3 with Wintest
CONTENTS
A. General ___________________________________________ 2
B. Using Autotronic 3 with Wintest ____________________ 3
C. Programming ______________________________________ 4
D. Setting parameters _________________________________ 7
E. Tests and diagnostics
- "Safety" function _________________________________ 15
- "PTO" function ___________________________________ 29
F. Manual calibration of the power shuttle _____________ 32
G. List of error codes __________________________________ 37
Issue 2 May 2002

A . General
Note: There are now several configurations for in-
stalling the Autotronic 3:
- Tractor with basic Autotronic 3 (CAN network
speed: 250 Kbits)
- Tractor with basic Autotronic 2 and now equipped
with an Autotronic Kit (CAN speed: 100 Kbits) (see
section 11F08)
- Tractor with basic Autotronic 1 and now equipped
with an Autotronic Kit (no CAN network) (see
section 11F08).
It is imperative to program an Autotronic 3 used as an

Autotronic Kit (CAN network speed 100 Kbits) to obtain
a 250 Kbit CAN network speed, when the Autotronic 3 is
to be installed on a tractor equipped with a basic
Autotronic 3.
For the above, refer to section 11F09 (Kit Autotronic

towards Autotronic 3).
Issue 2 May 2002

B . Using Autotronic 3 with Autotronic 3 status

The Autotronic 3 operates using 9 main states. The
Wintest status of the Autotronic 3 is displayed at the bottom of
each test screen.
Description
parameters of Autotronic 2 as well as to display and List of statuses
detect faults within its various functions. - TCU 0: ignition key turned on and parameters correct
To carry out testing with Wintest, the status of a or 17 bar pressure drop for more than
function on the tractor is modified and compared with 4 seconds
status displayed on the screen of the PC. - TCU 1: 17 bar pressure lower than 9.5 bar and engine
- If the icon corresponding to the function is displayed speed lower than 200 rpm
in reverse video, this indicates that 12V is present. - TCU 2: 17 bar pressure correct and engine speed
- If the icon corresponding to the function is displayed higher than 200 rpm
in normal video, this indicates that 12V is absent. - TCU 3: 17 bar pressure drop for less than 4 seconds
- If no there is no change whatsoever, check the con- - TCU 4: engine speed down for less than 0.5 seconds
nectors, the ignition switch and test the wiring corre- - TCU 5: engine speed down for greater than
sponding to the relevant function. 0.5 seconds
- TCU 6: 17 bar pressure lower than 9.5 bar and engine
Where the function being tested seems defective, click speed lower than 200 rpm for at least
on the icon that represents it: 6 seconds
- a window is displayed showing the identity of the - TCU 7: ignition key turned on and incorrect para-
connector terminals and the colour of the correspond- meters
ing wires. - TCU 8: not used
Example: The icon corresponding to the Hare / Tor- - TCU 9: battery voltage above 16 V
toise range switch has been selected. Information
J1 - 32 = Switch J1 of Autotronic 3, terminal No. 32,
wire colour white.
Wintest
Test
Testing the gearboc
GO! Help Autotronic
1064 0.0 Amps Off

4.1 100 %
0.0 Amps Off
280
280
Range switch
Err : 0
Connector: J1-32
Colour: White
Off
OK
EV1 On
OK
EV2 Off
TCU 2 Help
WA3-1
Issue 2 May 2002

C . Programming
voltage must be at least 12.5 V.
- The programming of the Autotronic 3 is necessary:

. when the former Autotronic 3 has been replaced by
a new one
the product
Note: It is necessary to set the Autotronic 3 param-
eters after programming.
- Click on the "Tools" icon and then on "Programming

Autotronic 3".
Wintest
Test Options Help
GO! H elp
Wintest
Parameter ......
Auto 3 parameter
List of error codes
OK
Help
WA3-2
Issue 2 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Are you sure?
Yes No OK
Help
WA3-3
- Click YES to carry out programming

NO to cancel programming.
- A gauge indicates the progress of the programming.
Issue 2 May 2002


During programming, several error messages Correction method
may be displayed: Message 1: Stop the engine
2. Battery voltage too low Messages 3 - 4 - 5: Check connection of the CAN BOX
3. Unable to enter Programming mode interface and turn the ignition key off
4. Unable to begin Boot programming Messages 6 - 7 - 8 - 9 - 10: The Autotronic 3 is defective
5. Unable to leave Programming mode Message 11: Hard drive problem. Re-install the
6. Unable to delete the program WINTEST software on your PC.
8. Unable to program the line
9. Unable to program a byte
11. Unable to open the source file
Wintest
Test Options Help
GO! Help
Wintest
Error message
Stop the engine

OK
Help
Retry Cancel
WA3-4
Issue 2 May 2002

D . Setting parameters
Setting parameters
- It is necessary to change the parameters:
. if the Autotronic 3 has been replaced by a new device
functions by changing the parameters
. if programming has been carried out.

side of the dashboard near the fuse box. This code has
12 figures and corresponds to the 11 parameters
whose meaning is shown below.

setting 39 3 1 1 2 0 4 5 2 1 2
Code AA = 39 = 6280
Code E = 2 = forward speed not limited
Code G = 4 = Dynashift with power shuttle type lever control
Code H = 5 = Power shuttle
Code I = 2 = for 6200 / 8200
Code J = 1 = with creeper unit
Code K = 2 = 6200 PTO
Issue 2 May 2002

Models with AGCO MF Type of Control panel AA Code

Autotronic 3 model model final drive unit switch N0 (*)
1 - 2 - 3 - 4 -5 - 6 - 7
Hydraulic 6235 -6245 1-1-1-0-1-0-0 37

pump
Open centre 6255 - 6260 0-1-1-0-1-0-0 38
6265 - 6270
6280 0-0-0-1-1-0-0 39
6290 1-1-1-0-1-0-0 40
Hydraulic 6235 -6245 1-1-1-0-1-0-0 41

pump
Load sensing RT 95 6255 - 6260 0-1-1-0-1-0-0 42
6265 - 6270
6280 0-0-0-1-1-0-0 43
RT 115 6290 1-1-1-0-1-0-0 44
540 rpm 8210 - 8220 Heavy Duty 1-0-1-1-1-1-1 45

PTO
8210 - 8220 Heavy Duty sealed 0-0-1-1-1-1-1 46
RT 130 8240 - 8250 Heavy Duty sealed 0-0-1-1-1-1-1 47

RT 145
8240 - 8250 Composite 1-0-1-1-1-1-1 48
750 rpm 8210 - 8220 Heavy Duty 1-0-1-1-1-1-1 84

PTO
RT 130 8210 - 8220 Heavy Duty sealed 0-0-1-1-1-1-1 85
RT 145
8240 - 8250 Heavy Duty sealed 0-0-1-1-1-1-1 86
8240 - 8250 Composite 1-0-1-1-1-1-1 87
(*) Switch No. 8: 0 for miles

1 for km
Issue 2 May 2002


Front axle Hare / Tortoise Gearbox type Max. speed
1 = 2WD 0 = Non synchronised 1=4x2 1 = 30 Kph

2 = 4WD (a) 1 = Synchronised (without AB range) 2 = 40 Kph except 8160
3 = 4WD with memory operated by Heavy Duty rein-
(b) gear shift lever forced
5 = 4WD US mode (c) 2 = Synchronised 3 = 33 Kph (Japan)
controlled by button 4 = 40 kph for 8160
with Heavy Duty rein
forced gearbox

1 = Speedshift with button control 1 = Dynashift with steering wheel 5 = Power shuttle
2 = Speedshift with steering lever
wheel lever 2 = Dynashift with gear lever
3 = Not used button
4 = Speedshift with power shuttle 3 = for AGCO Allis or White
type lever 4 = Dynashift with power shuttle
type lever
5 = Dynashift with Power Shuttle
and DynashiftAuto2 (Auto-
drive)
6 = Dynashift with Power Shuttle
and DynashiftAuto1 (Speed
matching)
Code I: Factory Code J: Creeper unit
0 = AGCO MF old range (d) 0 = None (f)

1 = Not used 1 = With (f)
2 = MF 6200 / 8200 (e)
Code K : PTO
0 = without PTO
1 = PTO with ON / OFF solenoid valve
2 = PTO with proportional solenoid valve on MF 6200 and AGCO RT 95 - RT 115
3 = PTO with proportional solenoid valve on MF 8200 and AGCO RT 130 - RT 145
Issue 2 May 2002


To disengage 4WD:
- press the brake pedal
- press the 4WD switch
(b) Each time the engine is started, the 4WD is in the position stored when the engine was stopped. The 4WD function
may different according to the code I (see (e)).
(c) Operation identical as for code 3.

US Mode is activated by pressing for at least 5 seconds on the 4WD switch. In this mode, the front axle
disengages when a brake pedal is pressed. When the brake pedal is released it re-engages.
(d) Code I = 0
- 4WD is engaged if there is action on one of the two brake pedals above 5 kph
- changing from 4WD to 2WD is actually carried out when the forward ground speed sensor sends a signal
- the differential lock is disengaged and re-engaged by action on a brake pedal.
(e) New 6200 / 8200 ranges

Code I = 2
- the 4WD only engages if there is action on both pedals at whatever speed
- the changing from 4WD to 2WD when halted is actually carried out without a signal from the forward ground
speed sensor.
- the differential lock definitively disengages if there is action on a brake pedal
- the PTO emergency stop switch is located on the wings (if fitted)
(f) The creeper unit from now on is controlled by the Autotronic 3.
Issue 2 May 2002

- Click on the "Tools" icon and then on "Parameters"
Wintest
Test Options Help
GO! H elp
Wintest
Parameters ......
Auto 3 parameters
List of error codes
OK
Help
WA3-5
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Autotronic 3 Parameters
39 3 1 1 2 0 4 5 2 1 2
OK Cancel
OK
Help
WA3-6
- Using the tab key, select the code to modify and then
- Confirm your modifications by clicking on "OK".
Issue 2 May 2002

- Another screen allows to display the values entered

during parameter setting.
- Click on "Tools" icon and then on "Programming
Autotronic 3".
Wintest
Tester Option Help
GO! H elp
Wintest
Parameters....
Auto 3 parameters
List of error codes
OK
Help
WA3-6A
Issue 2 May 2002

Tractor code
Parameter Parameter value
Synchro With synchro

Front axle With Front axle stored
Tester code 0
Extended display ..... Wheel pulse ratio/10 kph 146
PTOPPR 44
LSPTO ratio 10000
Pulse/engine rev 82
PPR Intermediate speed 36
Display all
Engine nominal speed/100 22
Max PFA and Diff speed 14
Hi -> Lo limit speed 6
Lo -> Hi limit speed 10
Trans type 4*2 transmission
Dynashift lever Analog with Power shuttle
Speedshift None
Shuttle type Power shuttle analog lever
Speed limit 0
Creeper type No creeper
OK Cancel Help
WA3-6B
- Select "Display all" to display all parameters.

- The "Parameter" column defines the parameter.
- The "Parameter value" column gives the parameter
characteristics or the value entered during calibration.
Issue 2 May 2002

E . Tests and diagnostics

Note: The Autotronic 3 has a diagnostics mode for
the power shuttle and the error codes are displayed
on the Wintest diagnostic screens. The meaning of
the codes is given in section 11B01.
Safety functions
- Start the engine.
- Click on the "Safety" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA3-7
Issue 2 May 2002


Wintest
Test
GO! Help Autotronic
1064
14.3
Err : 0
OK
TCU 2 Help
WA3-8
Engine speed sensor value in rpm Bottom of clutch pedal switch
1064
- pedal up: normal video

- pedal down: reverse video
Battery voltage in volts. Value between 11V

and 15V.
14,3
Power shuttle neutral switch

switch. - if bottom of clutch pedal switch not closed: reverse
video
- if bottom of clutch pedal switch closed: normal video
- if pressure is correct displayed in reverse video.

- if pressure below 9 bar ± 1, displayed in normal video.
Issue 2 May 2002


tor lamp
- if pressure correct, displayed in normal video.

or red if the indicator lamp on the dashboard is lit.
Power present for Autotronic 3 internal elec-

tronic relays controlling shuttle solenoid
valves.
- If the shuttle lever is in de-clutched position and

bottom clutch pedal switch open: reverse video (re-
lays powered).
- If the shuttle lever is in forward or reverse and the
bottom clutch pedal switch is open: reverse video
(relays powered).
- If the shuttle lever is in neutral and whatever the
position of the clutch pedal: normal video (relays not
powered).
- If the bottom clutch pedal switch is closed and what-
ever the position of the shuttle lever: normal video
(relays not powered).
Error warning buzzer
Flashing dashboard diagnostics error indica-

tor lamp
Err : 0 Error code indicator
Issue 2 May 2002


"Gearbox" function
- Start the engine.
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA3-9
Issue 2 May 2002

Testing the gearbox
Autotronic Calib
AUTO
0.0 Amps Off

0
0.0 0%
0.0 Amps Off
0.0
0
Err : 109
0.0 Off
-25.6 EV1 On
OK
EV2 Off
TCU 6 Help
WA3-10
Dynashift or Speedshift shuttle lever output

Engine speed sensor value in rpm analog signal in volts:
1064 0.5
- high lever position (de-clutched) ....... 2,5 V

- FWD + .............................................. 4V
- FWD ................................................. 3,5 V
Gearbox input speed sensor value in rpm - FWD - ............................................... 3V
- N ....................................................... 0,5 V
280 - REV- .................................................. 2V
- REV ................................................... 1,5 V
- REV+ ................................................. 1V
- Dynashift = from 0 to 1 times the engine speed in D
range
- Speedshift = from 0 to 1.26 times the engine speed in
D range
Transmission oil temperature sensor value in
°C
Design forward speed indicated by forward 21.4

ground speed sensor in tenths of kph
Issue 2 May 2002

17 bar low pressure hydraulic circuit pressure Clutch pedal travel potentiometer value (in
switch volts)
4.1
- if pressure is correct displayed in reverse video - clutch engaged = 100% = 4.5V

- if pressure below 9 bar ± 1, displayed in normal video - mid way = 50% = 2.3V
- de-clutched = 0% = 0.5V
AUTO
Automatic Dynashift option selected
Bottom of clutch pedal switch
"Speed Matching" or "Auto Drive" Power

mode switch
- switch open (normal video): Dynashift normal or Auto Power shuttle shifting switches
Drive Economic mode according to selected option and
switch position
- switch closed (reverse video): "Speed Matching" or . Forward
"Auto Drive" Power mode selected according to option.
. Neutral
. Reverse
Auto Drive Economic mode switch
- switch open (normal video): Dynashift normal or Auto Hare / Tortoise range switch
Drive Power mode according to selected option and
switch position
- switch closed (reverse video): "Auto Drive" Economic
mode
- switch closed = reverse video
- switch open = normal video
"Auto Drive" throttle pedal potentiometer
Creeper unit switch

0.0
- the value in volts must vary between 0 and 5 V.

Note: For calibrating the potentiometer, see section
11B01.
- engaged = reverse video
- disengaged = normal video
Top of clutch pedal switch
Issue 2 May 2002

Dynashift or Speedshift selector switch Reverse indicator lamp
- with each gear change up = reverse video

- with each gear change down = reverse video Creeper unit indicator lamp
- if no action on the shuttle lever = normal video
100 % Clutch pedal travel potentiometer value in

percent. Tortoise range indicator (no indicator lamp
Value ranges from 0% = de-clutched to 100% fully on dashboard)
clutched.
Hare range indicator lamp

0.0 Amps Forward proportional solenoid valve
current
- lever in Neutral ............................ 0.0A
- lever in Forward ........................... 0.2 to 1.2A
- lever in de-clutched position ........ 0A
Speedshift or Dynashift indicators
- lever in Reverse .......................... 0.1A if reverse
gear engaged
-A-B-C-D
0.0 Amps Reverse proportional solenoid valve

current Autotronic 3 status
TCU 2
- lever in Neutral ............................ 0.0A
- lever in Reverse .......................... 0.2 to 1.2A
- lever in de-clutched position ........ 0A This function allows a manual calibration of
- lever in Forward ........................... 0.1A if Forward CALIB
the power shuttle.
gear engaged
For calibration procedure, see § E.

tor lamp Forward proportional solenoid valve status
. if pressure correct, displayed in normal video.

. if pressure below 9 bar ± 1, displayed in reverse video, Off
or red if the indicator lamp on the dashboard is lit
OFF = solenoid valve at rest
ON = solenoid valve open or fully open
Forward indicator lamp
Reverse proportional solenoid valve status
Off
Shuttle neutral indicator
ON = solenoid valve open or fully open
Issue 2 May 2002

Dashboard diagnostic lamp indicating error

codes
ERR : 0 Error code indicator when fault develops
Status of Hare / Tortoise solenoid valve
- Tortoise = OFF = solenoid valve at rest

- Hare = ON = solenoid valve activated
EV1 Dynashift or Speedshift EV1 solenoid valve

status

Dynashift or Speedshift EV2 solenoid valve

EV2
status

Solenoid valve EV 1 ON ON OFF OFF
Solenoid valve EV 2 OFF ON ON OFF
Speedshift range C D
Solenoid valve EV2 ON OFF
Issue 2 May 2002

"Front Axle" function

- Start the engine.
- Click on the "Front Axle" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA3-11
Issue 2 May 2002


Wintest
Test
GO! Help Autotronic
1064
PFA On
0
Err : 0
OK
TCU 2 Help
WA3-12
Engine speed sensor value in rpm Front axle pulse switch
1064

Left and right brake pedal switches
0
17 bar low pressure hydraulic circuit pressure Front axle indicator lamp
switch

Issue 2 May 2002


switch.
- if pressure is correct displayed in normal video.

or red if the dashboard indicator lamp is lit.
Front axle overspeed
PFA
Front axle ON / OFF solenoid valve
On
- ON = 2WD
- OFF = 4WD

codes
Issue 2 May 2002


"Differential Lock" function
- Start the engine.
- Click on the "Differential Lock" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA3-13
Issue 2 May 2002

Wintest
Test Testing the Differential Lock
GO! Help Autotronic
1064
Diff Off
0
Err : 0
OK
TCU 2 Help
WA3-14
Engine speed sensor value in rpm Differential lock pulse switch
1064
Right and left brake pedal switches

0
17 bar low pressure hydraulic circuit pres- Differential lock indicator lamp
sure switch

Issue 2 May 2002


tor lamp
- if pressure correct, displayed in normal video.

or red if the indicator lamp on the dashboard is lit.
3-position Linkage switch

sented
3-position Linkage switch

sented
Diff Differential lock overspeed

Differential lock ON / OFF solenoid valve
Off
ON = Differential lock engaged

OFF = Differential lock disengaged

codes
Issue 2 May 2002

"Power Take-Off" function

- Start the engine.
- Click on the "Power Take-Off" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WA3-15
Issue 2 May 2002


Wintest
Test Testing the Power Take-Off
GO! Help Autotronic
1064
PTO Off
Err : 0
OK
TCU 2 Help
WA3-16
Engine speed sensor value in rpm

17 bar low pressure hydraulic circuit pres-
sure switch.
1064
- if pressure is correct displayed in reverse video.

Power take-off clutch speed sensor in rpm
0
PTO clutch switch
- PTO sensor speed = engine speed

The comparison of these two speeds allows the detec-
tion of PTO clutch slip
1550 rpm economic PTO switch
Issue 2 May 2002


wing according to options)

- if switch not fitted = reverse video
PTO indicator lamp
17 bar Low Pressure hydraulic circuit indica-

tor lamp
- if pressure correct, displayed in normal video

or red if the indicator lamp on the dashboard is lit
PTO PTO solenoid valve
Off
ON = engaged
OFF = disengaged

codes
Issue 2 May 2002


Legend
F . Manual calibration of the power
shuttle A Light off
Note: Calibration of the power shuttle is imperative
A Light on, not flashing
if any of the following are changed:
- a shuttle solenoid valve or its coil
- shuttle hydraulic control unit,
A Flashing light
- shuttle housing or any of its components
- Autotronic 3 housing.
Note: For the automatic calibration procedure, see

section 11B01.
Note: To authorize entering into calibration mode,
the transmission oil temperature must be:
- 35/45°C: temperature measured by the gearbox cover
probe and that can be read using Wintest or by
following the procedure for direct display of temperature
on the instrument panel.
Direct display of the temperature on the instrument panel

is through a light code provided by the Dynashift or
Speedshift A, B, C, D indicator lights.
Input in reading mode:

- start the engine
- place shuttle lever in neutral
- simultaneously activate the gear shift lever for at least
4 seconds in order to activate the Hare/Tortoise switch
and the differential lock switch.
- the A, B, C, D indicator lights show the temperature
according to the table below.
Exit from reading mode only takes place after the engine
has been stopped and the pressure in the 17 bar low
pressure circuit has dropped or if there is a shift to
calibration mode.
Note: Temperature reading mode makes it possible

to drive and use the Dynashift/Speedshift ratios, but
the display of A, B, C, D indicator lights corresponds
to the temperature.
- 45° / 55° C: measured with a thermometer at the rear

axle gauge hole.
Issue 2 May 2002

Temperature display in readiness for calibration
Dynashift / Speedshift indicator light

Temperature displayed by
A B C D Wintest
10° C
17° C
22° C
27° C
31° C
36° C
Calibration authorized
39° C
Calibration can be
Optimal calibration
launched
44° C
Calibration authorized
46° C
51° C
54° C
57° C
60° C
63° C
A B C D
Issue 2 May 2002


Manual calibration
- Start the engine.
- Start Wintest and select Autotronic 3.
- Click on
- Increase engine speed to 1500 rpm + (or 400/410 rpm

PTO speed on PTO 540 rpm position) using the lever.
- Shift into the Hare range (high position) without de-
clutching
- Place the shuttle lever in forward position and leave it
there.
Issue 2 May 2002

- Click on the CALIB icon
- Click on icon OK
- Engage the 1st gear.
- Manual calibration begins.

- After a few moments, when the tractor has moved 50
cm forward by itself, de-clutch pushing the pedal as far
as it will go and then release the pedal. Front clutch
calibration is complete.
- Do not touch the reversing or gear levers; after a few
seconds, the tractor will move in reverse by itself.
- Once the tractor has run 50 cm backwards, de-clutch
pushing the pedal as far as it will go and then release
the pedal. Rear clutch calibration is complete.
- A and B indicator lights get on without flashing, this
confirms the clutches have been calibrated.
- Place the gear shift lever back in neutral, the shuttle
lever must remain in forward position.
Important: the 50 cm automatic movement of the
tractor forward and in reverse is compulsory; it
allows the Autotronic 3 system to store the correct
clutch engaging pressure.
Issue 2 May 2002

Validation Calibration mode is not maintained if:

Immediate validation after calibration - engine speed varies from 1500 rpm + 100
1. Without stopping the engine, set the engine speed at - the gear shift lever is not switched to 1st position during
1500 rpm, engage Tortoise range 4th gear, Dynashift phase 1
in range A or Speedshift in C. - Shuttle lever is placed in neutral.
2. Carry out ten forward/reverse shuttle maneuvers Note: If calibration fails, the system either takes into
3. Carry out ten neutral to forward and neutral to reverse account the previously stored parameters or, in the
shuttle maneuvers case of a new Autotronic 3 unit, the default
4. Assess shuttle quality, it should be a smooth reaction parameters.
without any jerks.
Adjusting the calibration parameters
Validation of a tractor that has already been calibrated - If calibration has proceeded correctly, it is possible to
Note: Transmission temperature must be higher correct the calibration parameters in order to obtain a
than 20°C faster or slower shuttle reaction.
5. Put the gear shift lever in neutral, the power take-off - The Autotronic allows five adjustment procedures to be
must be de-clutched, the front axle disengaged. applied in each direction, which can be reinitialised after
6. Start the engine. a new calibration (see section 11B01).
7. Put the Power Shuttle lever in Forward for at least 1
minute, then at least 1 minute in the Reverse
position.
8. Put the Power Shuttle lever back into neutral.
9. Engage 4th Tortoise, Dynashift in A or Speedshift in
C, with an engine speed of 1500 rpm.
10. Carry out 10 Power Shuttle forward / reverse
maneuvers.
11. Carry out 10 Power Shuttle neutral / forward and
neutral / reverse maneuvers.
12. Assess shuttle quality, it should be a smooth reaction
without any jerks.
Note: An abrupt reaction on the 1st maneuver is
normal.
Calibration anomalies
Note: a defect due to the non-compliance of the
calibration input mode conditions or to failure to
maintain the calibration mode is indicated by
alternate flashing of the A, B, C and D indicator
lights.
Switching to calibration input mode does not occur if:
- transmission temperature is not correct,
- engine speed is other than 1500 rpm + 100
- the Tortoise range was not engaged before switching to
calibration input mode
- shuttle lever was not placed in forward mode
13. Check that operations 1 to 7 for calibration input

mode have been correctly carried out.
14. Check solenoid valve coil tightness and connections
(torque values 5.4 to 8.1 Nm).
15. Check that the TOC (Top Of Clutch pedal switch) is
correctly adjusted and connected.
Issue 2 May 2002

G . List of error codes

- Wintest allows to display and erase error codes stored
by Autotronic 3.
- Click on the "Tools" icon and on "List of error codes."
Wintest
Test Options Help
GO! H elp
Wintest
Parameters ......
Auto 3 parameters
List of error codes
OK
Help
WA3-17
Issue 2 May 2002


Errors stored
215
109 OK
Help
Erase
WA3-18
- It enables display of all the error codes stored in the

memory.
- If you click on "Erase", all error codes will be deleted

from Autotronic 3 memory.
Issue 2 May 2002

There are three classes faults depending on degree of

importance. Each class is characterized by a different
indicator light or buzzer behavior.
Fault Error Autotronic 3 Forward / Diagnostic Buzzer Shuttle reset

class code action on the Reverse indicator after the fault
number transmission indicator light has been
light cancelled.
Class I 1-2 Forced de-clutching, Off Lit and Sounds Stop the engine
power shuttle locked remains on and wait
Autotronic 3
standby mode (17
bar pressure
equals 0) (engine
speed equals 0).
Restard the
engine
Class II 7-8-9- None, but shuttle locked Forward or Light Sounds De-clutch
10 - 23* if engine stops Reverse lit flashes
depending rapidly
on direction
selected.
Out if Power
Shuttle is in
neutral
* Non direct
in Neutral
Class III 3 - 4 - 5 - None, normal Forward or Light Stops Place lever in

6 - 15 - 16 operation Reverse flashes neutral
17 - 18 - depending slowly
19 - 20 - on direction
21 - 22 selected.
Issue 2 May 2002

Errors code
Error No.
Class displayed on Fault
Wintest
I 1 Short circuit on + 12 V of forward solenoid valve
I 2 Short circuit on + 12 V of reverse solenoid valve
II 107 Open circuit on + of analog lever power supply
II 108 Open circuit on ground of analog lever power supply
II 109 Open circuit on analog lever signal
II 110 Short circuit on + 12V of analog lever
II 123 Fault on lever Reed switches (ILS)
III 203 Short circuit on forward solenoid valve ground
III 204 Short circuit on reverse solenoid valve ground
III 205 Open circuit on forward solenoid valve
III 206 Open circuit on reverse solenoid valve
III 215 Open circuit or short circuit on clutch pedal potentiometer ground
III 216 Short circuit on + 5V of pedal potentiometer
III 217 Open circuit or short circuit (BOC) switch ground
III 218 Short circuit on + 12 V of (BOC) switch
III 219 Open circuit or short circuit on ground of (TOC) switch integrated with
potentiometer
III 220 Short circuit to + 12 V on top of clutch pedal switch (TOC) integrated in
potentiometer
III 221 Gearbox input speed sensor fault
III 222 12 V open circuit on solenoids due to BOC and/or Neutral lever switches being
jammed in closed position.
Issue 2 May 2002

11 F04 TC and DCC with Wintest
CONTENTS
A. General ___________________________________________ 2
B. Programming ______________________________________ 3
C. Setting parameters _________________________________ 8
D. Adjusting the restarting speeds _____________________ 16
D. Tests and diagnostics

- "Safety" function _________________________________ 17
- "Power take-off" function __________________________ 32
E. List of error codes __________________________________ 36
Issue 2 May 2002


Example: The icon corresponding to the gearbox input
A . General speed has been selected. Information concerning it is
displayed in a window:
To carry out testing with Wintest, the status of a Ee – TC = Connector E, terminal e of the TC, wire
function on the tractor is modified and compared with colour: yellow.
status displayed on the screen of the PC. Eh – TC = Connector E, terminal h of the TC, wire
- If the icon corresponding to the function is displayed colour: black.
in reverse video, this indicates that the switch is
activated.
- If the icon corresponding to the function is displayed
in normal video, this indicates that the switch is not
activated.
- If no there is no change whatsoever, check the con-
nectors, the ignition switch and test the wiring corre-
sponding to the relevant function.
Where the function being tested seems defective, click

on the icon that represents it:
- a window is displayed showing the identity of the
connector terminals and the colour of the correspond-
ing wires.
Wintest
Test
GO! Help
DCC TC
892
Engine Speed Sensor
Connector: Ee-TC Eh-TC

Colour: Yellow – Black P-Lck OFF
OK
Error : 0 Error : 0
CAN
Request: No request OK Help Response: No response
WTD-1
Issue 2 May 2002

B . Programming
Programming the TC unit
- Programming of the TC is necessary:
. when the former TC unit has been replaced by a new
one
the product
Note: The version of the TC program is shown
alternately with the DCC program on the dashboard.
- Click on the "Tools" icon and then on "Programming TC".
Wintest
Test Options Help
GO! H elp
Wintest
Parameter...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-2
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Programming TC
Are you sure?
YES No OK
Help
WTD-3
- Click on "YES".
- A gauge indicates the progress of the programming.
Issue 2 May 2002

Several error messages may be displayed:
Wintest
Test Options Help
GO! Help
Wintest
Programming TC
Stop the engine

OK
Help
Retry Cancel
WTD-4
Messages: Correction method

1. Stop the engine Message 1: Stop the engine
2. Battery voltage too low Message 2: Check battery voltage
3. Unable to enter Programming mode Messages 3 – 4 – 5: Check connection of the CAN BOX
4. Unable to begin Boot programming interface and turn the ignition key off.
5. Unable to leave Programming mode Messages 6 – 7 – 8 – 9 – 10: The TC unit is defective
6. Unable to delete the program Message 11: Hard drive problem. Re-install the
7. Unable to change page WINTEST software on your PC.
Issue 2 May 2002


Programming the DCC
- Programming of the DCC is necessary:
. when the former DCC unit has been replaced by a
new one
the product
Note: The version of the DCC program is shown
with the TC program on the dashboard.
- Click on the "Tools" icon and then on Programming

DCC.
Wintest
Test Options Help
GO! H elp
Wintest
Parameter...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-5
Issue 2 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Programming DCC
Are you sure?
YES No OK
Help
WTD-6
- Click on "YES"
- A gauge indicates the progression of the program- Correction method
ming. Message 1: Stop the engine
Message 2: Check battery voltage
Several error messages may be displayed: Messages 3 – 4 – 5: Check connection of the CAN BOX
1. Stop the engine interface and turn the ignition key off.
2. Battery voltage too low Messages 6 – 7 – 8 – 9 – 10: The DCC unit is defective
3. Unable to access Programming mode Message 11: Hard drive problem. Re-install the
4. Unable to begin Boot programming WINTEST software on your PC.
5. Unable to leave Programming mode
6. Unable to delete the program
Issue 2 May 2002

C . Setting parameters
- Parameterisation is necessary:
. if the TC or DCC has been replaced by a new device
functions via the parameterisation
. if programming has been carried out.

side dashboard support near the fuse box. This code has
12 figures and corresponds to the 11 parameters whose
meaning is shown below.
Example of setting 68 3 1 3 2 2 2 1 2 1 2
Code AA = 68 = 8240
Code C = 1 = with creeper unit
Code D = 3 = with Full Powershift gearbox
Code F = 2 = with Park Lock
Code G = 2 = metric units
Code H = 1 = with radar
Code I = 2 = PTO stop on the fender
Code J = 1 = with pre-selection memory
Code K = 2 = with Europe type analog lever
Issue 2 May 2002

Code parameters
Models Code AA
Perkins Cummins engine Navistar Valmet
MF 8210 67 - - -
MF 8220 64 - - -
MF 8240 - - - 68
MF 8250 - - - 61
MF 8260 - - - 58
MF 8170 / 8270 - - - 55
MF 8180 / 8280 - - - 52
DT225 / White 8810 - 50 - -
Allis 9785 - - 51 -
DT200 / White 8710 - 53 - -
Allis 9775 - - 54 -
DT180 / White 8610 - 56 - -
Allis 9765 - - 57 -
DT160 / White 8510 - 59 - -
Allis 9755 - - 60 -
RT145 / White 8410 - 62 - -
Allis 9745 - - - 63
White 8310 - 65 - -
Allis 9735 - - - 66
RT130 - 77 - -
MF 8245 - - - 70
Issue 2 May 2002

Code B Code C Code D

Front axle Creeper unit Gearbox
1 = 2WD 0 = None 3 = Full Powershift

3 = 4WD memory (a) 1 = With
5 = 4RM mode US (b)
Code E Code F Code G Code H

Max. speed Park Lock Type of units Radar
1 = 30 kph 0 = None 0 = U.S. 0 = None

2 = 40 kph 2 = With Park Lock 2 = Metric 1 = With
Code I Code J Code K

Gear pre-selection Type of lever
memory
0 = Without PTO stop 0 = None 1 = N.A. analog (c)

2 = With PTO stop on the fender 1 = With 2 = Euro analog (d)
Issue 2 May 2002

(a) 4WD with memory

- the changing from 4WD to 2WD when halted is actually carried out without a signal from the forward ground
speed sensor.
- the 4WD only engages if the two brake pedals are simultaneously pressed whatever the speed.
- on starting the engine, the 4WD remains in the same configuration as when the engine was stopped.
(b) Operation identical as for code 3 for automatic Mode and manual Mode (see figure).
US Mode is activated by pressing for at least 5 seconds on the 4WD switch, in which case the front axle symbol
on the DCC flashes. In this mode, the front axle disengages when a brake pedal is pressed. When the brake pedal
is released it re-engages.
(c) the power shuttle shift lever is located on the right on the armrest
(d) the power shuttle shift lever is located on the left under the steering wheel
Issue 2 May 2002


- Click on the "OK" icon and on "Parameters".
Wintest
Test Options Help
GO! H elp
Wintest
Parameters...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-7
Issue 2 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Autotronic 3 Parameters
68 3 1 3 2 2 2 1 1 2
OK Cancel
OK
Help
WTD-8
- Using the Tab key, select the code to modify, then

- Confirm the code by clicking on "OK".
Issue 2 May 2002


- The following screen is displayed :
Wintest
Test Options Help
GO! H elp
Wintest
Parameters...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-8A
- Two other screens display TC and DCC constants (see

8200 Workshop Service Manual, section 11B01).
- Click on the “Tools” icon and on “TC parameters” or

“DCC parameters”.
Issue 2 May 2002

- The following screen is displayed :
TC parameters
Tester ! - 17493
Transmission type AG150
Lever type EUR dual type lever
Extended display ..... Shuttle type Power Shuttle
Temperature sensor Current sensor
Front axle 4RM with Memo
Differential lock Type1
Rear PTO Type2
Display all
Park Lock type Electrohydraulic
Hi Lo limit speed range 2
Hi Hi limit speed range 2
RPTO inter Pulse/rev 44
RPTO output Pulse/rev 18
Eco PTO ratio (*10000) 0
Engine Pulse/rev 32
Pulse/rev at unit output 72
Creeper speed ratio 0
PTO para 1 5
OK Cancel Help
WTD-8B
- Select “Display all” to display all parameters.

- The “Parameter” column defines the parameter.
- The “Parameter value” column gives the parameter
characteristics or the value entered during calibration.
Issue 2 May 2002

D . Adjusting the restarting speed

With the 2.14 version of the TC/DCC programme, you
can adjust the forward restarting speed using the shuttle
lever.
By default, the maximum gear allowed is the 13th.
1st case: Changing to a restarting speed

lower than the present speed
1. Engine running
2. Armrest lever in forward position (engaged)
3. Place the lever in forward position
4. Press on the clutch pedal
5. Select the restarting speed with the shuttle lever
6. Raise the lever for 10 seconds and wait for the buzzer
(see figure)
7. The restarting speed is stored
2nd case: Resetting the restarting speed

1. Engine running
2. Armrest lever in forward position (engaged)
3. Place the lever in reverse position
4. Press on the clutch pedal
5. Raise the lever for 10 seconds and wait for the buzzer
(see figure)
6. The restarting speed is stored in 13th ratio
7. It is possible to repeat the 1st case operation
Issue 2 May 2002

E . Tests and diagnostics

Note: The test screen is divided in two halves:
- left hand side for DCC functions
- right hand side for TC functions
"Safety" function
- Start the engine
- Click on the "Safety" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WTD-9
Issue 2 May 2002


Wintest
Test
GO! Help
DCC TC
892
P-Lck OFF
N
Error: 0 Error: 0
CAN
Request: No request OK Help Response: No response

WTD-10
Parking brake switch and/or Park Lock lever

switch N
Faulty switch
Steering wheel lever Neutral switch (the

position of the steering wheel lever overrides Armrest lever Neutral switch
N N
the action of the armrest lever)
N
N
Steering wheel lever Neutral position Armrest lever in Neutral or Park Lock posi-
N
N tion
Steering wheel lever non-Neutral position N

Armrest lever switch in Working mode
Issue 2 May 2002

N Low pressure hydraulic circuit pressure

Faulty switch switch (pressure in bar)
Gearbox 15µ filter clogging switch
DCC touch sensitive switches Booster pump pressure switch (3 bar)

- change to reverse video when pressed
Fault
Transmission mechanism Park Lock switch

- if this icon is in reverse video with the N flashing on the
dashboard a fault has occurred. Click on the icon to
learn the nature of the fault.
Displays the error code number if a fault

Error: O occurs in the DCC Park Lock solenoid valve status
P-Lck
OFF
Request: No request
- ON: solenoid valve activated. Park Lock disengaged
Not used in the safety tests - OFF: solenoid valve deactivated. Park Lock engaged
Gearbox input speed in rpm (equals engine Fault

speed)
892 - if this icon is in reverse video with the N flashing on the

Gearbox output speed in rpm
Issue 2 May 2002

Error: 0 Displays the error code number if a fault

occurs in the TC
Response: No response
Not used in the safety tests
Indicates the CAN link between the DCC

CAN and the TC but no test is carried out, solely
used as information.
Issue 2 May 2002

"Gearbox" function
- Start the engine.
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WTD-11
Issue 2 May 2002

Wintest
Test
Testing the Gearbox
GO! Help
DCC TC 1 OFF
897
0.5 2 OFF
0 1: 0.00 Amps
R OFF
2: 0.00 Amps
1.41 R: 0.00 Amps
4 -2 A OFF
24 A: 0.00 Amps
B: 0.00 Amps B OFF
16 C: 0.00 Amps
L: 0.00 Amps C OFF
100 %
M: 0.00 Amps
L OFF
0.49 H: 0.00 Amps
0.74
M OFF
Error: 0 2.41 Error: 0 H OFF
CAN
Request: Neutral OK Help Response: Neutral Gear engaged

WTD-12
+ Power shuttle type lever, gear change up

switch or armrest lever
Power shuttle type lever or armrest lever
neutral switch
- changes to reverse video when a higher gear is - not active

selected
- Power shuttle type lever, gear change down

switch or armrest lever
Power shuttle type lever or armrest lever
Reverse switch
- changes to reverse video when a lower gear is se- - changes to reverse video if Reverse is selected
lected
Power shuttle type, Forward switch Top clutch pedal switch
- changes to reverse video when Forward speed is - pedal up: reverse video
selected - pedal down: normal video
Issue 2 May 2002

Front axle and differential overspeed (14

Clutch pedal travel potentiometer value (in
kph)
volts)
0.74
- clutch engaged = 0.67V ± 0.20

Displays the number of the error code if
- de-clutched = 3.82V ± 0.20 Error : 0 a fault occurs in the DCC
Bottom clutch pedal switch

- pedal up: normal video
- pedal down: reverse video
Requested: Neutral
Displays the requests made to the DCC or T
Display of speed requested by the DCC

0
Design ground speed relationship to real
speed (if radar is fitted)
0.5
Forward gear pre-selected
4
Turbocharger pressure value converted to
volts
1.41
Reverse gear pre-selected
-2
Engine load in points (engine speed / turbo-
charger pressure ratio)
16
Clutch pedal travel potentiometer in per-
centage - value between 0 and 255.
100 %
- value between 0% = de-clutched
- 100% = clutch engaged
Fault

Issue 2 May 2002

Analog lever value in volts Signal from gearbox oil pressure switch
(17 bar)
- left side
0.49
- 17 bar = switch in reverse video

- 0 bar = switch in normal video
- high lever position (de-clutched) ................. 2.5 V
- FWD+ ......................................................... 4V
- FWD ........................................................... 3,5 V
- FWD- .......................................................... 3V
- N ................................................................. 0,5 V Display of gear selected by the TC
- REV- ........................................................... 2V
0
- REV ............................................................ 1,5 V
- REV+ .......................................................... 1V
Armrest lever potentiometer value in volts:
1 : 0.00 Amps
2.41 Current value in Amps of the 9
- Neutral ...... 2,2 to 2,8 V solenoid valves corresponding to
- Forward ...................... 3,8 to 4,4 V the clutches:
- Reverse ...................... 0,6 to 1,6 V
H : 0.00 Amps
Gearbox input speed in rpm - 0.0A = solenoid valve closed

- 0.0A to 0.7A = solenoid valve opening
- 0.7A = solenoid valve full ope
897
Fault
Gearbox output speed in 100th of kph

0 dashboard a fault has occurred. Click on the icon to
Transmission temperature sensor in °C
Displays the number of the error code if

24 Error: 0 a fault occurs in the TC
Issue 2 May 2002

Response: Neutral Gear engaged
Displays the responses of the TC to the requests made

by the DCC.
Shows the CAN link between the DCC and

CAN the TC. No test is carried out, for information
only.
1 H
OFF OFF
Status of the 9 proportional solenoid valves correspond-

ing to the clutches:
- OFF = solenoid valve closed
- ON = solenoid valve opening or fully open.
Issue 2 May 2002


"Front Axle" function
- Start the engine.
- Click on the "Front Axle" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WTD-13
Issue 2 May 2002

Følgende skærmbillede fremkommer:

Wintest
Test
GO! Help
DCC TC
1.2
PFA ON
Error: 0 Error: 0
CAN
Request: No request OK Help Response: Front Axle Off

WTD-14
Left and right brake switches Fault

learn the nature of the DCC fault.
4WD switch
Icon changes to reverse video during front
axle overspeed.
4WD indicator lamp (in automatic mode an A

is displayed, in manual mode the A disap- Displays the number of the error code if
Error: 0 a fault occurs in the DCC.
pears)
Issue 2 May 2002


Actual ground speed given by radar Error: 0 occurs in the TC
0.0

Value of the gearbox output speed sensor
corresponding to forward speed in 100th of
kph
0
Request: No request
Low pressure hydraulic circuit pressure Indicates request for engaging or disengaging of 4WD
switch pressure in bar by the DCC (only if the 4WD toggle is held down)
- if pressure correct = reverse video Response: Front Axle Off

- if pressure less than 9 bar ± 1 = normal video
Indicates the engaging or disengaging of 4WD by the
TC.
PFA 4WD solenoid valve status
ON
- ON = solenoid valve activated 4WD disengaged

- OFF = solenoid valve deactivated 4WD engaged
Fault

learn the nature of the TC fault.
Issue 2 May 2002

Differential Lock function

- Start the engine.
- Click on the "Differential Lock" icon.
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WTD-15
Issue 2 May 2002


Wintest
Test
Testing the Differential lock
GO! Help
DCC TC
0.0
Diff: 0.0 Amps Diff OFF
Error: 0 Error: 0
CAN
Request: No request OK Help Response: Differential Off
WTD-16
Left and right brake pedal switches Fault

Differential lock switches

Icon changes to reverse video during differ-
ential lock overspeed
Displays error code number if a fault

Differential lock indicator lamp Error: 0 occurs in the DCC
Issue 2 May 2002


Actual ground speed given by radar Error: 0 occurs in the TC
0.0
Diff Differential lock ON / OFF switch

Value of the gearbox output speed sensor
corresponding to forward speed in 100th of
kph OFF
0
- ON = Differential lock engaged

- OFF = Differential lock disengaged
Low pressure hydraulic circuit pressure
switch pressure in bar
- if pressure correct = reverse video
Request: No request
Indicates the requests of the DCC toTC
Response: Differential Off
Diff : 0.00 Amps Value of supply current to differ-

Indicates the response of the TC to the DCC request.
ential lock solenoid valve
- 0.0A = solenoid valve deactivated

- 0.5A to 1.2A = solenoid valve activated
or
Lift control 3-position switch. Shows Work or Up posi-

tion
Fault

Issue 2 May 2002

"Power Take-Off" function

- Start the engine.
- Click on the "Power Take-Off" icon.
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WTD-17
Issue 2 May 2002

Wintest
Test
Testing the Power Take-Off
GO! Help
DCC
1102
TC
0
PTO: 0.00 A PTO OFF
Stop: 0.00 A
Stop OFF
Error: 0 Error: 0
CAN
Request: No request OK Help Response: PTO Off
WTD-18

PTO switch wing)
- PTO disengaged: normal video - emergency stop deactivated: circuit closed, icon in
- PTO engaged: reverse video reverse video
- emergency stop pressed: circuit open, icon in normal
video
- switch not fitted: reverse video
PTO brake switch
- brake off: normal video PTO indicator lamp

- brake on: reverse video
Issue 2 May 2002

Fault
Gearbox 15 µ filter clogging switch

PTO: 0.00 A Value of supply current to PTO

Displays the error code number if a fault solenoid valve
Fejl: 0 occurs in the DCC
Engine speed sensor value in rpm

STOP : 0.00 A Value of supply current to PTO
brake solenoid valve
1102
PTO clutch output sensor value. The PTO

speed = engine speed
Fault
0
- Comparison of the two speeds permits detection of - if this icon is in reverse video with the N flashing on the
PTO clutch slip. dashboard a fault has occurred. Click on the icon to
PTO output shaft sensor value. Displays Displays the error code number if a fault
Error: 0 occurs in the TC
PTO speed in rpm
- This value must correspond to that displayed by the

DCC
PTO
PTO solenoid valve
Low pressure hydraulic circuit pressure OFF

switch pressure, in bar
- ON = solenoid valve activated, PTO engaged
- OFF = solenoid valve deactivated, PTO disengaged.
- if pressure correct = reverse video

Issue 2 May 2002

STOP PTO brake solenoid valve
OFF
- ON = solenoid valve activated, brake on

- OFF = solenoid valve deactivated, brake off.

Request: No request
Indicates the requests of the DCC to TC
Response: PTO Off
Indicates the response of the TC to the DCC request.
Issue 2 May 2002

E . List of error codes

- Wintest allows you to display and erase the error codes
stored by the TC/DCC.
- Click on the "Tool" icon and on "List of Error codes"
Wintest
Test Options Help
GO! H elp
Wintest
Parameters...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-19
Issue 2 May 2002

Stored errors
81 x 00001
80 x 00001
OK
136 x 00052
138 x 00052
140 x 00052
156 x 00032
Help
Erase
WA3-20
- It enables you to see all the error codes that have been
stored and the number of times they have appeared.
- If you click on "Erase", all the error codes will be deleted

from the TC and DCC memory.
Note: For the list of error codes, see section 11B01 of

this manual.
Issue 2 May 2002

11 F05 Electronic linkage with Wintest
CONTENTS
A. Using the Electronic linkage control with Wintest ____ 2
B. Tests and diagnostics ______________________________ 3
C. Error codes ________________________________________ 7
D. Adjusting the position sensor _______________________ 10
E. Setting the parameters _____________________________ 12
F. Dual control/TIC ___________________________________ 19
Issue 2 May 2002

A. Using the Electronic linkage

control with Wintest
Description
The Wintest software allows to display the functioning
of the electronic control linkage and to detect any
malfunction.
To carry out testing with Wintest, the status of a
function on the tractor is modified and compared with
status displayed on the screen of the portable PC.
in reverse video, this indicates that 12V is present.
in normal video, this indicates that 12V is absent.
- If no there is no change whatsoever, check the
connectors, the ignition switch and test the wiring
corresponding to the relevant function.

connector terminals and the colour of the corresponding
wires.
Example: The icon corresponding to the Hare / Tor-
toise range switch has been selected. Information
J1 – 32 = Switch J1 of Autotronic 3, terminal No. 32,
wire colour white.
Wintest
Test
Wintest
GO! Help Autotronic
1064 0.0 Amps Off

4.1 100 %
0.0 Amps Off
280
280
Range switch
Err : 0
Connector: J1-32
Colour: White
Off
Switch black--> Range switched
OK
EV1 On
OK
EV2 Off
TCU 2 Help
WRE-1
Issue 2 May 2002

B. Tests and diagnostics

"Electronic control linkage" function
- Start the engine
- Toggle the 3-position selector at least once to the

Raise position to activate linkage control
- Click on the "Electronic Linkage Control" icon
ELECTRONIC LINKAGE CONTROL TEST
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WRE-2
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Testing the Electronic Linkage Control
215 240 0 18 159 159 41 140
--
1098 0.0 0 99
OK
Help
OK Help
WRE-3
Lowering speed potentiometer value in 3-position selector position indicator - Low-

points: ered Position
215
- lock position = 0
- red sector (manual control = from 0 to approximately Lift arm height limit potentiometer, value in
200) points:
- yellow sector (automatic control) = from approxi- 240
mately 200 to 250
- error at 255 - maximum limit = 61
- minimum limit = 240
- error at 255
3-position selector position indicator - Neu-
tral Position
Solenoid valves activated indicator - No

solenoid valve activated
3-position selector position indicator -

Raised Position
Issue 2 May 2002

Solenoid valves activated indicator - Raise - - Display of error code in case of fault
Solenoid valves activated indicator - Lower Left draft sensor value in points
159
- no load approximately 165

- error at 255
Intermix potentiometer value in points
0 Right draft sensor value in points
- pure draft = 0
- pure position = 250 159
- error at 255
- no load approximately 165
- error at 255
Transport damper indicator lamp
Position sensor value in points

- if transport damper is activated and 3-position switch
is in high position = reverse video 41
- high position = 235

- low position = 50
Transport damper pulse switch
- correct adjustment = 235 ± 1 point
Battery voltage value in points. A value

between 120 and 160
Depth potentiometer value in points
140
18
- position 10 (low) = about 11

- position 5 = about 125 Power supply to lift control computer safety
- position 0 (high) = about 236 approximately relay
- error at about 255
- relay powered = reverse video
Error indicator
- this icon flashes according to the linkage error code
Issue 2 May 2002

Engine speed sensor value in rpm External Lower control push button
1098
Sidelights and headlights switch

Ground speed provided by radar in tenths of
kph
0.0
Autotronic 2 only
Design ground speed provided by forward + power supply engine running
speed sensor in tenths of kph
- + present with engine running: reverse video
0 - + absent with engine running: normal video
"Tools" icon for adjustment of the position

sensor (see further on).
Wheel slip control value in Hertz
99
Required value Frequency

on Datatronic to be read
display on ELC
0% slip 100 Hz
5% slip 150 Hz
10% slip 200 Hz

15% slip 250 Hz
20% slip 300 Hz
etc.
Note: To display the frequency in Wintest, activate

wheel slip control on the Datatronic.
External Raise control push button
Issue 2 May 2002

C. Error codes
- The electronic linkage control computer is able to detect certain faults in the wiring harness or lift control components.
- When a fault is identified:
. the auto-diagnostic lamp on the lift control console flashes according to the error
. in Wintest, the error code is displayed
- The first figure of the error code denotes the gravity of the failure:
. 1 = serious
. 2 = medium
. 3 = minor
- The second figure of the error code indicates the fault.
Code Fault Effect Action
1-1 Raise or Lower solenoid valve Supply cut to solenoids of lift valve. Stop the
disconnected No lift arm movements authorised. engine. Correct
the fault.
Restart the
engine. Reset
the console
1-2 Short circuit on Raise solenoid Cuts power to lift control valve Stop the
valve solenoids. engine. Correct
No lift arm movements authorised. the fault.
Restart the
engine. Reset
the console
1-3 Short circuit on Lower solenoid Cuts power to lift control valve Stop the
valve solenoids. engine. Correct
Restart the
engine. Reset
the console
1-5 External controls fault Cuts power to lift control valve Stop the
solenoids. engine. Correct
Restart the
engine. Reset
the console
1-6 Supply greater than 18V Cuts power to lift control valve Stop the
Restart the
engine. Reset
the console
Issue 2 May 2002

1-7 Short circuit in internal 9.5V relay line Cuts power to lift control valve Stop the
solenoids. engine.
No lift arm movements authorised. Correct the
fault. Restart
the engine.
Reset the
console
1-8 Fault in 3-position switch Cuts power to lift control valve Stop the
Restart the
engine. Reset
the console
2-2 Fault in position sensor ELC console locked Repair fault.

Reset ELC
2-3 Fault in depth potentiometer ELC console locked Repair fault.

Reset ELC
2-4 Fault in height limit potentiometer ELC console locked Repair fault.
Reset ELC
2-7 Power supply below 10V ELC console locked Repair fault.
Reset ELC
3-1 Fault on right draft sensor The ELC operates but the diagnostics Repair fault.
lamp flashes Reset ELC
3-2 Fault on left draft sensor The ELC operates but the diagnostics Repair fault.
Issue 2 May 2002

3-4 Fault in lowering speed The ELC operates but the diagnostics Repair fault.
potentiometer lamp flashes. The automatic lowering Reset ELC
speed is selected
3-6 Fault in intermix potentiometer The ELC operates but the diagnostics Repair fault.
3-8 Tractor parameters are lost Selection of default AA parameters Reset calculator
in relation to the transmission calculator. parameters. If
The electronic linkage control operates problem per-
with the wrong parameters. The diagnostic sists, replace
lamp flashes. the calculator.
Issue 2 May 2002

D . Adjusting the position sensor

Selecting "Position sensor" selection
Wintest
Linkage Diagnostics
204 249 174 158 191 184 170 130
- - 0 118 255
0 00 0 0
OK
Help
OK Help
Position sensor Linkage .....
Linkage diagnostics Dual Control parameters
Linkage parameters Trailed implements parameters
WRE-4
Issue 2 May 2002

Selecting "Position sensor" selection

- The following screen is displayed:
Wintest
Tester Option Aide
GO! Help
Wintest
Linkage Diagnostics
252 240 0 16 162 163 46 140
Linkage Parameters
46
853 Visser Capteur Position
OK
OK Help
Help
OK Help
WRE-5
- Using the external controls, place the lift arms in the

maximum raised position.
- Screw the sensor in completely on the cam.
First method
- Mark the linkage cover and the upper lift arm.
- Lower the linkage 3 to 5 mm in relation to the mark.
Second method
- Measure the distance between the ground and the ball
joint of the lower arm.
- Lower the linkage about 35 to 45 mm in relation to the
1st measured value.
- Screw or unscrew the position sensor according to the
request displayed on screen in order to obtain a value
of 235 ± 1 point.
- When the correct adjustment value is reached the
gauge colour changes to green.
Issue 2 May 2002

Testing the Electronic Linkage Control
E . Setting the parameters

Setting the linkage parameters
- When you select "Linkage parameters" the following
screen is displayed:
- Enter the AA and BB codes depending on the type of

tractor and options.
- Click on "OK" if you have modified a parameter to

validate the code.
- Click on "Cancel" if you have merely checked the

parameter code or if you want to quit this mode.
Note: The parameter code is printed on an adhesive

label beneath the fuse box.
Issue 2 May 2002

Parameter codes
AA CODE FOR MF TRACTORS LINKAGE CALCULATOR
Models Hydraulic circuit lift ram Ø AA Code
6235 to 6270 Open centre Ø 66 mm 01
6270 / 6280 / 6290 Open centre Ø 75 mm 02
6235 / 6245 CCLS 90 l Ø 66 mm 05
6245 CCLS 90 l Ø 75 mm 19
6255 à 6270 CCLS 105 l Ø 66 mm 09
6270 / 6280 / 6290 CCLS 105 l Ø 75 mm 10
8210 to 8250 Dynashift CCLS 110 l Ø 95 mm 11
8210 to 8250 Dynashift CCLS 150 l Ø 95 mm 13
8210 to 8250 CCLS 110 l Ø 95 mm 15

Full Powershift
8260 to 8280 CCLS 110 l Ø 105 mm 16

Full Powershift
8210 to 8250 CCLS 150 l Ø 95 mm 17

Full Powershift
8260 to 8280 CCLS 150 l Ø 105 mm 18

Full Powershift
Issue 2 May 2002


Parameter codes
AA CODE FOR AGCO TRACTORS LINKAGE CALCULATOR
Models Hydraulic circuit lift ram Ø AA Code
RT 95 CCLS 105 l Ø 66 mm 09
RT 115 CCLS 105 l Ø 75 mm 10
AGCO RT 130 / RT 145 CCLS 110 l Ø 95 mm 11
AGCO RT 130 / RT 145 CCLS 150 l Ø 95 mm 13
AGCO DT CCLS 110 l Ø 95 mm 15
Issue 2 May 2002

BB CODE - LINKAGE CALCULATOR OPTIONS
No. of Front Rear Front Trailed BB

electro Joystick Dual Dual linkage implement code
-hydraulic control control capacity control (TIC)
spool valves
0 0 0 0 * 0 01
2 1 0 0 * 0 02
2 1 0 1 * 0 04
3 1 0 1 * 0 05
2 1 0 1 * With 08
Drawbar sensor
2 1 0 1 * With and without 09

Drawbar sensor
3 1 0 1 * With 10
Drawbar sensor

Drawbar sensor
2 1 1 1 * 0 13
3 1 1 1 * 0 14
2 1 1 1 * With 17
Drawbar sensor

Drawbar sensor
Nota : 0 = Without option

1 = With option
* = Whatever the capacity
Issue 2 May 2002

BB CODE - LINKAGE CALCULATOR OPTIONS
No. of Front Rear Front Trailed BB

electro Joystick Dual Dual linkage implement code
-hydraulic control control capacity control (TIC)
spool valves
3 1 1 1 3,5 t With 25
Drawbar sensor
3 1 1 1 5t With 26
Drawbar sensor
3 1 1 1 2,2 t With and without 27

Drawbar sensor
3 1 1 1 3,5 t With and without 28

Drawbar sensor
3 1 1 1 5t With and without 29

Drawbar sensor
Nota : 0 = Without option

1 = With option
* = Whatever the capacity
Issue 2 May 2002

- Select "Linkage Diagnostics".
- The following screen is displayed:
Linkage Diagnostics
P1 100
P2 100
P3 100
P4 100
Extended display .....
P5 0
P6 0
P7 0
Display all P8 0
P9 16683
P10 7
P11 4
P12 6
P13 5
P14 200
P15 51
P16 8
P17 8
P18 7
OK Cancel Help
Linkage Diagnostics
P 55 9
P 56 10
P 57 5
P 58 74
Extended display ..... P 59 34
P 60 64
P 61 20
Display all P 62 14
P 63 7
P 64 2
P 65 4
P 66 5
P 67 6
P 68 2
P 69 1
DeadBandJoystick 10
Seuilthreshold
K.O. K.O. 80
Pin sensing 60kN
OK Cancel Help
Issue 2 May 2002


Linkage Diagnostics
Pin sensing 60kN

Drawbar 150kN
Trans. controller type TC
Extended display…. Position sensor type BOSCH
Panel type 6200/8200
EH Dual valve None
Dual pos. sensor With
Front linkage pos. sensor With
Display all
Ram type Diameter 95
Joystick Without
Front linkage Without Front linkage
TIC With TIC
Dual With dual Ctrl
Lift control valve LS 110L
Hydraulic pump EHR23 LS100L
P 90 0
P 91 0
Programme version 18
OK Cancel Help
- The values or option are displayed according to the

parameter code of the ELC calculator
Issue 2 May 2002

F . Dual Control/TIC
1. Test
The Dual Control icons and parameters can be
accessed to via the "Testing the Electronic Linkage
Control" screen.
Wintest
Linkage Diagnostics
Test du Relevage
204 249 174 158 191 184 170 130
- - 0 118 255
0 00 0 0
OK
Help
OK Help
WRE-6
Spool valve control lever potentiometer,

value in points Truck sensor value in points
144 188
- lower limit: 20 - 4 mm truck fully down: 23

- neutral adjustment: 144 - 1 mm truck fully up: 215
- upper limit: 250 Note: Unlock the ELC console to adjust the sensors
- error at 255
(TIC) drawbar draft sensor
255
- at no load: about 165

- default value : 255
Issue 2 May 2002


2. Dual Control Parameters
- Click on the "Tools" icon and then "Dual Control
Parameters".
Wintest
Linkage Diagnostics
Test du Relevage
204 249 174 158 191 184 170 130
- - 0 118 255
0 00 0 0
OK
Help
OK Help
Position sensor Linkage .....
Linkage diagnostics Dual Control parameters
Linkage parameters Trailed implements parameters
WRE-7
Note: The "Trailed implements parameters" function

is not available.
Issue 2 May 2002

Wintest
Test Options Help
GO! Help
ParaDual
Move Up
63
No Move
59
Move Down
OK Cancel
WRE-8
Move Up current, value in points 59 More Down current, value in point.

63
t t
- The aim of the parameter setting is to adjust the - Disconnect the pressure gauge.
beginning of the opening of the solenoid valves of the
electro hydraulic spool valves. The adjustment is correct if the tool reacts at the same
- Connect a 0 - 300 bar pressure gauge to the hydraulic time as the ELC. If the reactions are too abrupt, reduce
pump output connector. the value of the current. On the other hand, if they are too
- Bring the oil temperature up to between 50°C and 60°C. slow, increase the current value.
- Nothing must be connected to the auxiliary spool Note:
valves. - A value of 40 points corresponds to a slight open-
- On the ParaDual screen click on "Move Up". Increase ing and therefore a slight flow rate.
or reduce the value of the current by clicking on s or t - A value of 100 points corresponds to full opening
to obtain a pressure of 200 bar. Stop the control by and therefore the full flow rate.
clicking on "No move".
- Click on "Move Down". Increase or reduce the value of
the current by clicking on s or t to obtain a pressure of
200 bar. Stop the control by clicking on "No Move".
Issue 2 May 2002

11 F06 Datatronic 2 with Wintest
CONTENTS
A. Using the Datatronic 2 with Wintest ________________ 2

1. Testing the Datatronic ___________________________ 3
2. Programming, setting parameters
and Selecting the language ______________________ 6
Issue 2 May 2002

A . Using the Datatronic 2 with

Wintest
Description
Autotronic 2 parameters as well as to display and detect
any malfunction.
To carry out testing with Wintest, the status of a
function on the tractor is modified and compared with
status displayed on the screen of the portable PC.
in reverse video, this indicates that 12V is present.
in normal video, this indicates that 12V is absent.
- If no there is no change whatsoever, check the con-
nectors, the ignition switch and test the wiring corre-
sponding to the relevant function.

connector terminals and the colour of the correspond-
ing wires.
Example: The icon corresponding to the Hare / Tortoise
range switch has been selected. Information concern-
ing it is displayed in a window:
J1 - 32 - Switch J1 of Autotronic 3, terminal No. 32, wire
colour: white.
Wintest
Test
Testing the gearbox
GO! Help Autotronic
1064 0.0 Amps Off

4.1 100 %
0.0 Amps Off
280
280
Range switch
Err : 0
Connector: J1-32
Colour: White
Off
OK
EV1 On
OK
EV2 Off
TCU 2 Help
WDA-1
Issue 2 May 2002

B . Tests and diagnostics

Datatronic function
1. Testing the Datatronic
- Start the engine.
- Click on the "Datatronic" icon
Wintest
Test Options Help
GO! Help
Wintest
OK
Help
WDA-2
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
Testing the Datatronic
273 113
0 0
1 1
21
188 166 OK
OK Help Help
WDA-3
273 Display of radar signal = 273 Hz for 10 kph Design forward speed indicated by forward
(fixed value). ground speed sensor in tenths of kph
Real ground speed (radar) in tenths of kph 0 Design or actual forward speed displayed by
the Datatronic in tenths of kph
0
- if the tractor travels at a speed less than 1 kph = design
- less than 1 kph = value is not reliable speed displayed
- if the tractor travels at a speed greater than 1 kph = real
ground speed displayed
- if design and real ground speeds are greater than 20
Design forward speed value in Hertz (value kph and there is a 10% difference between them =
113 varies according to calibration): design speed displayed.
- default value = 108 Hz for 10 kph

- calibration is automatically carried out each time the
tractor exceeds 20 kph
- depending upon tractor models, the calibration value
is between 100 Hz and 150 Hz.
Issue 2 May 2002

1 Value of one cubic centimetre per flow me-

ter turbine revolution (fixed value)
- value 1 = Perkins engine

- value 5 = Valmet engine
Fuel flow rate value at flow meter input in

tenths of litres/hour
188
Fuel flow rate value at flow meter output in

tenths of litres/hour
166
Fuel consumption value displayed on

21
Datatronic in tenths of litres/hour
- value displayed equals difference between flow me-

ter input and output
"Tools" icon for programming, setting pa-

rameters and selecting the language.
Issue 2 May 2002


2. Programming, setting parameters and selecting
the language
- It is necessary to turn the ignition off after each
manipulation of the different menus.
Programming
- Turn off the ignition key
- Start the engine
- Click on "Tools" and then "Programming Datatronic 2"
Wintest
Test Options Help
GO! Help
Wintest
273 115
0 0
1 1
17
192 176 OK
OK Help Help
Parameters
Programming Datatronic 2
WDA-4
Issue 2 May 2002

Wintest
Test Option Help
GO! Help
Wintest
273 115Datatronic
Testing the
0 0 Are you sure?
1 1
17
192 176 Yes No OK
OK Help Help
WDA-5
- Click on: YES to carry out the programming After each programming operation, it is
NO to cancel the programming. necessary to set the parameters and select
- Two successive gauges indicate the progression of the desired language.
programming.
- After programming, check the CAN speed of the
Datatronic which must be:
. 100 for tractors fitted with Autotronic 2
. 250 for tractors fitted with Autotronic 3 or TC / DCC
- The CAN speed is displayed on the Datatronic screen
for 3 seconds after turning on the ignition.
- To modify the CAN network speed, carry out the
following:
- turn off the ignition key
- turn on the ignition key, you have 3 seconds to press
the Datatronic memory key (100 is in reverse video)
and to turn clockwise the Datatronic button to display
250 instead of 100.
- turn the ignition key off and then turn it on again to
check that SPEED 100 has changed to SPEED 250.
- turn off the ignition key.
Issue 2 May 2002


PARAMETERS
- Turn the ignition key on and restart the engine.
- Click on the "Tools" icon and on "Parameters", then on
"Programming Datatronic 2".
Wintest
Test Options Help
GO! Help
Wintest
273 113
0 0
1 1
20
188 168 OK
OK Help Help
Parameters Datatronic 2 Parameters
Programming Datatronic 2 Translate Datatronic 2
WDA-6
Issue 2 May 2002

Wintest
Test Option Help
GO! Help
Wintest
Datatronic 2 Parameters
273 115
39 Dual Control
0 Imp.
Trailed
0 0
10
1 1
9
17
100
192 176 OK
40
OK Help Help
OK Cancel Help
Trailed Imp.
Option not available
WDA-7
Setting the Datatronic parameters

The Datatronic parameter code is composed of 2 fig-
ures corresponding to the tractor code or AA code.
Dual Control
s AA code (tractor model) found on
Dual Control option
39 the tractor’s code label
- if the tractor has Dual Control, tick the box
t - if the tractor does not have Dual Control, remove the
tick from the box
- using the up or down arrow select the correct code
Issue 2 May 2002


Setting the frequency output parameters
Front Dual Control
- 2 frequency outputs are possible at the 16-pin connec-
tor:
- if the tractor has Front Dual Control, tick the box.
- terminal 9: design forward speed (speed sensor) or
- if the tractor has no Front Dual Control, click on box to
PTO speed frequency.
remove tick.
- terminal 10: real ground speed (radar) or engine speed
frequency.
Trailed Imp.
- Calculation of real and design speeds:
X = (f x 10) / V
- if the tractor is fitted with the TIC function, tick the box.
where:
- if the tractor is not fitted with the TIC function, click on
X is in Hz / 10 kph = Coefficient to be set on the
box to remove tick.
Datatronic 2
f is in Hz = Desired output frequency on
the 16-pin connector
Joystick
V is in kph = Forward speed for the desired
frequency
- if the tractor is fitted with the Joystick function, tick
the box.
- Calculation of engine speed and PTO frequencies:
- if the tractor is not fitted with the Joystick function, click
Y = (f x 60) / M
on box to remove tick.
where:
Y is in Hz / rev/sec = Coefficient to be set on the
Datatronic 2
f is in Hz = Desired output frequency on
Click on the icon to show the frequency the 16-pin connector
selected for pin 10 M is in rev/min = Rotational speed for the de-
sired frequency
Example:
Click on the icon to show the frequency An implement manufacturer needs a 130 Hz m/s output
selected for pin 9 frequency in order to operate his electronic device from
the tractor’s radar.
1 m/s = 3.6 kph therefore 130 Hz / m/s =
130 Hz / 3.6 kph
t 100
Using the formula: X = (f x 10) / V
Gauge for adjusting the frequency of the real or design X = (130 x 10) / 3.6
ground speed X = 361 Hz / 10 kph
- click on the pointer and drag it to the desired X value
(figure displayed to right of gauge) - Adjust the output frequency using the gauge pointer
- possible adjustment of X is between 100 and 400 Hz and set it to 361.
/kph
t 40
Gauge for adjusting the frequency of the PTO or engine

speed
- click on the pointer and drag it to the desired Y value
(figure displayed to right of gauge)
- possible adjustment of Y is between 40 and
60 Hz/rev/sec.
Issue 2 May 2002

SELECTING THE LANGUAGE

- Turn off the ignition key.
- Start the engine.
- Click on "Tools", "Parameters" then "Translate
Datatronic 2".
Wintest
Test Options Help
GO! Help
Wintest
273 113
0 0
1 1
20
188 168 OK
OK Help Help
Programming Datatronic 2 Translate Datatronic 2....
WDA-8
Issue 2 May 2002


Wintest
Test Options Help
GO! Help
Wintest
273 115
FRANCAIS
0
ENGLISH UK
0 0 ENGLISH US
FUOMI
PORTUGUES
1 1
ITALIANO
SVENSKA
17
DEUTSCH
192 174 ESPAGNOL
OK
DANSK
NORGE
HOLLANDS
OK Help Help
Programming Datatronic 2 Translate Datatronic 2....
WDA-9
- Click on the desired language

- Turn off the ignition key
- Turn on the ignition key
- Check that the Datatronic is in the selected language.
Issue 2 May 2002

SERIES 6200/8200 TRACTORS
11 F07 Joystick with Wintest
SOMMAIRE
A. Using the Joystick _________________________________ 2
C. Joystick calibration ________________________________ 6
D. Valve parameters __________________________________ 8
Issue 2 May 2002

A . Using the Joystick Spool valve screen

- When starting Wintest, select tractor options to have
The Joystick called SMS (Spool valve Management the Joystick screen.
System) controls two electro hydraulic proportional
spool valves.
The electric deplacement of the Joystick is check by the

ELC who controls the movement of the spool valve
according the informations received from the various
switchs or the Datatronic.
As an option, a button can be installed on the Joystick

pommel to control two additional spool valves.
Since this information is not transmitted through the CAN

network, it cannot be displayed by Wintest.
Description
The Joystick and SMS (Spool valve Management Sys-
tem) could be tested and the default functions could be
detected with Wintest software.
A self-diagnostics system generates error codes that are

displayed on the Wintest Test screen of the Datatronic (if
installed) and lights the indicator lamp located on the ON/
OFF switch (see GUF71).
To carry out testing with Wintest, the status of a function

on the tractor is modified and compared with status
displayed on the screen of the portable PC.
- If the icon corresponding to the function is displayed in
reverse video, this indicates that 12V is present.
- If the icon corresponding to the function is displayed in
normal video, this indicates that 12V is absent.
- If no there is no change whatsoever, check the connec-
tors, the ignition switch and test the wiring correspond-
ing to the relevant function.
Issue 2 May 2002

B . Tests and diagnostics

The "Joystick" function
- Start the engine.
- Click on the "Joystick" icon
Wintest
OK
Help
WJO-1
Issue 2 May 2002


Joystick
Joystick EHRC Valve SB23
On Up
Neutral
Down 47 %
M Float
X+:100%
X-:100%
Err : 0
Y+:100%
Y-:100%
CAN CAN Up
1: -47 %
Neutral
2: 0 %
Down 0 %
Float
Err : 0
Ver : 2. 1
OK Help
WJO-2
X+:100%
On X-:100%
Y+:100% Stored flowrate values according to different
SMS ON / OFF switch Y-:100% axes
- switch ON = reverse video
Joystick positioning
Indicator lamp situated in the middle of the
ON / OFF switch
- indicator lamp ON = reverse video

- The blue point shows the current position of the Joystick.
It remains at the centre when no manoeuvre is engaged.
- The 1st inner square corresponds to 80% of the flowrate.
M - The 2nd square corresponds to 100% of the flowrate.
Beyond this range the position becomes floating.
Flowrate memory switch
- switch ON = reverse video
Issue 2 May 2002

1:0% % value of the Joystick movement along the

X+ / X- axis
% value of the Joystick movement along the

2:0%
Y+ / Y- axis
Up
Neutra Each tick in box shows the lever position
Down (Up, Neutral, Down, Floating position)
Float
Err : 0 Shows SMS related error codes
- if an error code is displayed, see section 11H01
47 %
Displays the instantaneous valve flowrate in
%
Shows the CAN link between the

CAN Joystick, the ELC calculator and
the valves
“Tools” icon for calibrating the Joystick and

setting valve parameters
Issue 2 May 2002

C . Joystick calibration
- Click on the "Tools" icon, then on "Joystick calibration"
Joystick
Joystick EHRC
On Up
Neutral
D own 0 %
M Float
X+:100%
X-:100%
Err : 0
Y+:100%
Y-:100%
CAN CAN Up
1: 0 %
Neutral
2: 0 %
D own 0 %
Float
Err : 0
Ver : 2. 1
OK Help Joystick calibration

Valve parameters
WJO-3
Issue 2 May 2002

Joystick calibration
Joystick EHRC
C AN C AN
1: 0 %
2: 0 %
Move the Joystick
Stop
Ver : 2. 1
OK Help
WJO-4
- The system will record the lever movement in each

direction. Therefore the lever should be moved to the
maximum in the four directions (X+ / X- / Y+ / Y-) till
the first hard spot (without going, in the floating position,
beyond the second dotted square).
Note : The blue point moves on the screen according

to the last calibration values. If the last values are
very small, it is possible not to see the point moving.
So don't care of the movement of the point.
- When you have moved the lever in the four directions,

click on "STOP" to stop the Joystick calibration.
- The calibration is then accepted. During the Joystick

movement the hard spot of the floating position should
be situated around the second square.
Issue 2 May 2002

D . Valve parameters
- Click on the "Valve parameters"
Valve parameters
Valve Type
DUAL
CONTROL
Longitudinal Joystick
OK Retry Cancel Help
Valve
WJO-5
Note: If no valve is detected, no icons are displayed

in the left-side windows. Tick the box for setting X valve
parameters
Green valve
Tick the box for setting Y valve

- valve configured along the X axis of the Joystick
parameters
Red valve
DUAL Tick the box for setting Dual
CONTROL Control valve / TIC valve para-
- valve configured along the Y axis of the Joystick
meters
Black valve
- valve configured for Dual Control / TIC
Issue 2 May 2002

The setting is done in three steps

- detection of the present spool valve.
- selection of the type of spool valve and its position .
- start the parametering .
Detection of the present spool valve

- The software programme should detect only one valve
at a time. Disconnect valves that do not need parameter
settings. Only the valve requiring parameter settings
should be connected.
- If all the valves are connected, when you parameter, all
the valves are going to work in the same way.
Exemple : The two valves are parameter in X position,
the system doesn't detect the Y valve and error 10 will
be flashing on the ON/OFF switch or diplayed on
theDataronic.
- At the opening of the parameter screen, the software
detects the type of valve connected on the CAN.
There are four possibilities:
. Joystick crosswise movement related spool valve
(Red).
. or Joystick fore and aft movement related spool valve
(Green).
. or DUAL spool valve (Black).
. or service exchange valves (White).
- When the software doesn’t detect any spool valve the
message “No detection, valve 100Khz or 29 bits”
appears.
Check the connection of the concerned spool valve :
. if connected check out the harness, the ELC
parameter, The ELC calculator references.
. if not reconnect it and click on "RETRY".
Issue 2 May 2002


Select the type of valve and its position
- Before starting parametering, the type of valve and its
position needs to be selected on the right of the screen.
- Click the selected valve. Only one choice is possible.
If it is not done, the message ‘’ No selection’’ will
appear.
- There are three choices:

. Joystick crosswise movement related spool valve
(Green).
. or Joystick fore and aft movement related spool valve
(Red).
. or DUAL spool valve (Black).
- Click on OK to parameter the connected valve

Note : Parametering will be done correctly only if
the selected valve is different from the detected
valve.
Valve parameter
Valve Type
DUAL
CONTROL
Longitudinal Joystick
OK Retry Cancel Help
Valve
WJO-6
- The types of valves are always (like the detection)

relative to a colour (see Detection of type of valve ).
Issue 2 May 2002

Starting parameter
- Once the spool valve has been detected and selected,
press "OK" to start the parametering.
- The software is sending instructions to the spool valve.

A few seconds is needed to send the parameters.
During this time, the message "Parametering" is written
in the bottom left corner of the screen.
- When done, another message appears, that can be

different depending of the results:
When the parametering is done right

- the message "Parameters OK" appears a few seconds.
When the parametering is not done right

. the valve keeps the original parameters (same state as
before the operation).
- In both cases, the software stops automatically the

function ‘’Parametering’’.
- Some error messages could be displayed:
. Selection = Detection: the selected spool valve is
the same as the detected spool valve.
. No Detection, valve 100Khz or 29 bits: no spool
valve detected (see Detection of the type of valve ).
. No Selection: No valve type selected (see Selection of
type of spool valve).
. Parameter error: The valve doesn’t accepted the
parameters and kept the original ones.
Note : reset the Joystick menu to main menu to be

able to use it. Otherwise Joystick menu remains
locked.
Issue 2 May 2002

11 F08 Autotronic 3 to Kit Autotronic
CONTENTS
A. Programming Autotronic 3 __________________________ 2
B. Accessing the Wintest main menu __________________ 6
C. Parameters ________________________________________ 7
Issue 1 May 2002


Important
A . Programming Autotronic 3 - When programming Autotronic 3 as a replacement
to Autotronic 2, only the CAN network between the
- Programming Autotronic 3 in Autotronic Kit is required
PC and Autotronic 3 should be left connected
to :
(disconnect the ELC calculator and Datatronic 2, if
. change the CAN network from 250 Kbits (Autotronic
installed).
3) over to 100 Kbits (Autotronic 2 type)
- Use the harness ref. 3378244 M1.
. integrate the X32 program in Autotronic 3
- Switch on the ignition key to carry out this operation. The

minimum voltage should be 12.5 Volts.
Note: It is necessary to set Autotronic 3 parameters

after programming.
- After accessing Wintest, click on “Options” then on

“Auto 3 ---> Autotronic Kit”.
Wintest
Test Options Help
GO! Autotronic kit ----> Auto3Help

Auto3 ----> Autotronic kit
Update
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
DCC : 2.14
TCU 092 : R
TCU 093 : C
DATA2 : D001208
AUTO3 : B11
KIT AUTOTRONIC : X32
Issue 1 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Are you sure?
Yes No OK
Help

Issue 1 May 2002


Wintest
Tester Option Aide
GO! Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
DCC : 2.14
TCU 092 : R
TCU 093 : C
DATA2 : D001208
AUTO3 : B11
KIT AUTOTRONIC : X32 AUTO3_100K
- A gauge indicates the progression of the programming.
Note: The indicator gauge may take 1 or 2 minutes to

be displayed.
Issue 1 May 2002

During programming, several error messages may Correction method

be displayed: Message 1: Stop the engine
2. Battery voltage too low Message 3 : Autotronic 3 is already programmed in
3. Unable to enter Programming mode Autotronic Kit
4. Unable to begin Boot programming Messages 4 - 5: Check connection of the CAN BOX
5. Unable to leave Programming mode interface and turn the ignition key off
6. Unable to delete the program Messages 6 - 7 - 8 - 9 - 10: The Autotronic 3 is defective
7. Unable to change page Message 11: Hard drive problem. Re-install the
8. Unable to program the line WINTEST software on your PC.
9. Unable to program data
Wintest
Test Options Help
GO! Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
DCC : 2.14
TCU 092 : R
TCU 093 : C
DATA2 : D001208
AUTO3 : B11
KIT AUTOTRONIC : X32 AUTO3_100K
Impossible to enter in
programming mode
Retry Cancel
Issue 1 May 2002

B . Accessing the Wintest main menu

- To access the Wintest main menu in Autotronic kit
mode, click on “GO”.
Wintest
Test Options Help
GO! Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
DCC : 2.14 Setup
TCU 092 : R
TCU 093 : C
DATA2 : D001208 Kit Autotronic
AUTO3 : B11 OK
KIT AUTOTRONIC : X32 Autotronic 2
TC-DCC Cancel
Autotronic 3
Help
Datatronic 2
Linkage
Joystick
- Select “Autotronic Kit”
- Select, according to functions available:

. Datatronic 2
. Linkage
- Click on “OK”.
Issue 1 May 2002

C . Parameters

side of the dashboard near the fuse box. This code has
12 figures and corresponds to the 11 parameters whose
meaning is shown below.

Setting 27 3 1 1 2 0 1 4 0 0 1
Code AA = 27 = 6180 Dynashift hydraulic closed center

Code G = 1 = Dynashift with steering wheel lever
Code H = 4 = Preselect reverse shuttle
Code I = 0 = 3000 - 3100 - 3600
Code J = 0 = without creeper unit
Code K = 1 = PTO with ON / OFF solenoid valve
Issue 1 May 2002


Parameter codes for Autotronic 1 and basic Autotronic 2 : 6100 - 3000 - 3100
CODE AA
MODEL Open centre hydraulics Closed centre hydraulics
WITH Non modified Increased flow rate hydraulic Speedshift Speedshift

flow rate pump from No.D125027 tractors with tractors with
AUTOTRONIC 1 hydraulic pump onwards 30 Kph 30 Kph
up to mechanical electronic speed
OR No.D125026 Speedshift Speedshift limitation or limitation from
tractors with tractors with Dynashift No.G083035
BASIC 30 Kph 30 Kph onwards
mechanical electronic speed
AUTOTRONIC 2 limitation or limitation from
Dynashift No.G083035
onwards
6110 - 6120 00 19 30 25 32
6130 - 6140
3050 - 3055
3060 - 3065
3065S
3070 01
6150 - 6160 02 20 31 26 33
6170
3075 - 3080
3085 - 3090
3095
6180 03 21 - 27 -
3115 - 3120
6190 04 22 - 28 -
3125 - 3140
Issue 1 May 2002

Parameter codes for Autotronic 1 and basic Autotronic 2 : 8100 - 3600
MODEL PTO 540 / 1000 rpm PTO 750 / 1000 rpm

WITH AUTOTRONIC 1 OR
BASIC
AUTOTRONIC 2
8110 - 8120 Normal Duty 05 12

8110 - 8120 Heavy Duty 06 13

8130 Normal Duty 07 14


8140 - 8150 Heavy Duty 09 16

3680 Heavy Duty
8150 Double Reduction 10 17

3680 Double Reduction
8160 Double Reduction 11 18

3690 Double Reduction

Reinforced Transmission
Parameter codes for basic Autotronic 2 : 6200

CODE AA
MODEL
WITH
BASIC Open centre hydraulics Closed centre hydraulics
AUTOTRONIC 2
6235 - 6245 70 74
6255 - 6260 - 6265 - 6270 71 75
6280 72 76
6290 73 77
Issue 1 May 2002


Parameter code for basic Autotronic 2 : 8200
CODE AA
MODEL
WITH
BASIC PTO 540 - 1000 rpm PTO 750 - 1000 rpm
AUTOTRONIC 2
8210 - 8220 34 79
Heavy Duty
8210 - 8220 35 80
Heavy Duty with sealed
8240 82 83
Heavy Duty with seales
8240 - 8250 36 81
Double reduction
Parameter codes for basic Autotronic 2 : Allis - White

CODE AA
MODEL
WITH PTO ON / OFF PTO proportional
BASIC solenoid valve solenoid valve
AUTOTRONIC 2
Allis 9735 - 975 - 29

White 8310 - 8410
Allis 8775 26 75
White 6710
Allis 8785 28 77
White 6810
Issue 1 May 2002


Pont avant Lièvre / Tortue Type boîte de vitesses Vitesse maxi
1 = 2 RM 0 = Non synchronisé 1=4x2 1 = 30 Km/h

2 = 4 RM (a) 1 = Synchronisé (sans gammeAB) 2 = 40 Km/h sauf 8160
3 = 4 RM "à mémoire" (b) 2=4x4 Heavy Duty
(avec gamme AB) renforcée
3 = 33 Km/h (Japon)
4 = 40 Km/h pour
8160 avec boîte de
vitesses Heavy Duty
renforcée
Code F : Speedshift (e) Code G : Dynashift (e) Code H : Inverseur de marche
0 = Sans Speedshift 0 = Sans Dynashift 0 = Mécanique

1 = Commande Speedshift par 1 = Commande Dynashift par 1 = Pré-sélection
bouton levier au volant • avec bouton
2 = Commande Speedshift par 2 = Commande Dynashift par • avec capteur MCB (ancien
levier au volant bouton sur levier de modèle
vitesses 2 = Pré-sélection
3 = pour AGCO Allis ou White • avec levier
• avec capteur MCB (ancien
modèle
3 = Pré-sélection
• avec levier
• avec capteur Bosch
(nouveau modèle)
4 = Pré-sélection
• avec bouton
• avec capteur Bosch
(nouveau modèle)
Code I : Usine Code J : Vitesse rampantes
0 = MF 3000 / 3100 / 3600 / 6100 / 8100 (c) 0 = Non utilisé sur tracteur Autotronic 1 et
1 = Non utilisé Autotronic 2 de base
2 = MF 6200 / 8200 / AGCO Allis / White (d)
Code K : PDF
0 = sans PDF
1 = PDF avec électrovalve ON / OFF
2 = PDF avec électrovalve proportionnelle sur MF 6200 / AGCO White - Allis (6810/6710/8775/8785)
3 = PDF avec électrovalve proportionnelle sur MF 8200 / AGCO White - Allis (8310/8410/9735/9745)
Issue 1 May 2002


(a) A chaque démarrage du moteur, le témoin de 4 RM est allumé et le pont avant engagé.
Pour désengager le 4 RM :
- appuyer sur les freins,
- appuyer sur le contacteur de 4 RM.
Le témoin s'éteint.
Le pont avant est réellement désengagé lorsque le boîtier Autotronic reçoit un signal de vitesse d'avancement
supérieur à 1 km/h.
(b) A chaque démarrage du moteur, le 4 RM se trouve dans la position mémorisée lors de l'arrêt du moteur.
La fonction 4 RM peut être différente en fonction du code I (voir (d))
(c) Code I = 0
- le 4 RM s’engage si action sur une des deux pédales de freins au dessus de 5 Km/h
- le passage de 4 RM en 2 RM s’effectue réellement quand le capteur vitesse d’avancement envoie un signal
- le blocage différentiel se désengage et se réengage après action sur une pédale de frein.
(d) 6200 / 8200 / White / Allis

Code I = 2
- le 4 RM s’engage uniquement si action des deux pédales de freins quelque soit la vitesse
- le passage de 4 RM en 2 RM à l’arrêt s’effectue réellement sans avoir le signal du capteur vitesse d’avan-
cement
- le blocage différentiel se désengage définitivement si action sur une pédale de frein
- contacteur d'arrêt d’urgence PDF situé sur les ailes (si monté).
(e) Pour les tracteurs avec Autotronic 1 d'origine, mettre les codes F et G à zéro quelque soit le type de trans-
mission.
Issue 1 May 2002

11 F09 Kit Autotronic to Autotronic 3
CONTENTS
A. General ___________________________________________ 2
B. Reprogramming Autotronic 3 _______________________ 3
Issue 1 May 2002

A . General
It is necessary to reprogramm an Autotronic 3 to fit on a
tractor with Autotronic 3 in base (250 Kbits), when the
Autotronic was fitted on a tractor with a kit Autotronic
(software X32 and CAN 100 Kbits).
Note: When programming is carried out on a tractor

equipped with a basic Autotronic 3, it is imperative
to disconnect the ELC calculator and the Datatronic
2 (if installed). The connection is to be re-established
after the programming is completed.
Issue 1 May 2002

B . Reprogramming Autotronic 3
- Switch on the ignition key to carry out this operation. The
minimum voltage should be 12.5 Volts.
Note: It is necessary to set Autotronic 3 parameters

after programming.
- After accessing Wintest, click on “Options” then on

“Autotronic Kit ---> Auto 3”.
Wintest
Test Options Help
GO! Kit Autotronic ----> Auto3Help

Auto3 ----> Kit Autotronic
Update
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
DCC : 2.14
TCU 092 : R
TCU 093 : C
DATA2 : D001208
AUTO3 : B11
KIT AUTOTRONIC : X32
Issue 1 May 2002

Wintest
Test Options Help
GO! Help
Wintest
Are you sure?
Yes No OK
Help

Issue 1 May 2002

Wintest
Test Options Help
GO! Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
DCC : 2.14
TCU 092 : R
TCU 093 : C
DATA2 : D001208
AUTO3 : B11
KIT AUTOTRONIC : X32 AUTO3
- A gauge indicates the progression of the programming.
Note: The indicator gauge may take 1 or 2 minutes to

be displayed.
Issue 1 May 2002

During programming, several error messages may Correction method

be displayed: Message 1: Stop the engine
2. Battery voltage too low Message 3 : Autotronic 3 is already programmed in
3. Unable to enter Programming mode Autotronic 3
4. Unable to begin Boot programming Messages 4 - 5: Check connection of the CAN BOX
5. Unable to leave Programming mode interface and turn the ignition key off
6. Unable to delete the program Messages 6 - 7 - 8 - 9 - 10: The Autotronic 3 is defective
7. Unable to change page Message 11: Hard drive problem. Re-install the
8. Unable to program the line WINTEST software on your PC.
9. Unable to program data
Wintest
Test Options Help
GO! Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC : 2.14
DCC : 2.14
TCU 092 : R
TCU 093 : C
DATA2 : D001208
AUTO3 : B11
KIT AUTOTRONIC : X32 AUTO3
Impossible to enter in
programming mode
Retry Cancel
Issue 1 May 2002

Front axle - Carraro suspension 11G01.1
11G01 Carraro suspension
CONTENTS
- General ____________________________________________________ 2
A. Suspension control system __________________________________ 2
B. Disassembling and assembling of the sensor __________________ 3
C. Electronic control unit _______________________________________ 7
D. Service tools _______________________________________________ 10
Issue 1 May 2002

General
your axle, but the process is the same.
A. Suspension control system

(1) Position sensor
(2) Suspension ram
(3) Electro-hydraulic control unit
(4) Electronics connecting plug
(5) Hydraulic connection unit
2
A P 5
B LS
Fig. 1
Issue 1 May 2002

B . Disassembling and assembling

of the sensor
A
Disassembling of the sensor
1. Unscrew the cover B fastening screws A of the sen-
sor wiring-in kit.
Disconnect the wiring-in kit connecting plug C from
the sensor (Fig.2)
Warning : Don’t damage the electrical wires.
2. Unscrew and remove both fastening screws D of the B
sensor E.
Only if needed, remove the connector cable and
collect the lower washer F (Fig.3).
3. Remove the rubber guide G of the sensor control pin C
assembled on the position ring H.
Take a note of the relative sensor plate position of the
Fig. 2
rubber position ring, then remove the position ring
from the plate housing (Fig.4)
Note : This is a destructive operation for the
position ring.
E
F
Fig. 3
H
Fig. 4
Issue 1 May 2002

Assembling of the sensor

4. Insert the position ring A in the sensor plate using the
special tool CA715362 (see § D) (Fig.5).
Note : Respect the annotated position marked
during the disassembly phase. 90˚
A
5. Assemble the sensor rubber B in the positioning ring
with the text “OUTSIDE” on the outer side (Fig.6).
Note : The rubber outer boss must be inserted in
the hole on the positioning ring.
6. Insert the washer C on the sensor control pin.
Assemble the sensor D to the plate inserting the
control pin in their housing in the rubber.
Note : Respect the position given by the pin flat A
surface.
Assemble, without tightening, the two sensor fasten-
ing screws E.
Connect the sensor to the wiring-in kit (Fig.7). Fig. 5
Note : Before assembling the sensor cover adjust
the sensor position.
B
A
Fig. 6
D
C
Fig. 7
Issue 1 May 2002

7. In order to adjust the sensor position let down com-

pletely the axle arms, in a way that the pads leaned
on the axle body (Closed Axle) (Fig.8).
Note : If the axle is already assembled to the
vehicle, this position is reached putting down the
vehicle till the end of stroke is reached.
8. If the axle has been installed on the vehicle with all
accessories including the battery, disconnect the
connector between the sensor and the suspension
control unit, and use service tool ref. 3378322M1 to
connect up a milliammeter in order to measure the
intensity of the current absorbed (Fig. 9).
9. If the axle is on a workbench with equipment consist-
ing of 12 V battery and a milliammeter connected to
the angle sensor measure the absorbed electric cur-
rent intensity (Fig.10).
Fig. 8
+ -
Amp.
BATTERY 12V
Fig. 9
Amp.
-VB
+VB
+ -
BATTERY 12V
Fig. 10
Issue 1 May 2002

10. To adjust the sensor position loosen the screws and

rotate the sensor slowly until the electric current
intensity prescribed value IAC is shown on the meas-
ure instruments.
Lock the sensor tightening the fastening screws
with a dynamometric wrench to the requested torque
(see section 08A01 § A) (Fig.11) :
- for 20.19 S and 20.22 S
IAC = 6.10 ± 0.5 mA
- for 20.29 S
IAC = 7.0 ± 0.5 mA
11. Lift completely the axle arms (Opened Axle) and
check that electric current intensity value is within
the prescribed range IAA, using the equipment previ-
ously described (Fig.12) :
- for 20.19 S et 20.22 S
IAA = 16,9 ± 0.5 mA
- for 20.29 S Fig. 11
IAA = 17.5 ± 0.5 mA
Note : if the axle is already assembled to the
vehicle, this position is reached putting up the
vehicle till the end of stroke is reached.
12. Assemble the sensor wiring-in kit cover F and
tighten the fastening screws G with a dynamometric
wrench to the requested torque (see section 08A01
§A) (Fig.13).
Fig. 12
Fig. 13
Issue 1 May 2002

Operational modes
C. Electronic control unit (Fig.14) When the system is started a sensor scans the axle
position. Depending upon the scanned actual value, the
Description electronics will assign an operation mode, which will
The axle active suspension system is electronically then be displayed with the help of the respective signal
controlled by means of special control unit that perform lamp.
some advanced functions.
It’s strongly advisable to follow with attention all the The possible operational modes are the following:
instructions about the electronic control unit, considering 1. Axle is within the tolerance band of active suspension
the importance of this part for the function of all the level : Automatic Operation
suspension system. 2. Axle is within the tolerance band of the lower stop :
Blocked position
Definitions 3. Axle is not in previous states : (L1) and (L2) (Fig.14)
Two different operation modes and one calibration mode flash, that is operational mode has to be selected by
can be chosen. mean of toggle key (valves are not activated)
- Blocked position : the suspension cylinder space is
emptied (Closed Axle) and the axle operates without - Blocked position
suspension. As soon as the toggle key for the operational mode
- Automatic operation : the axle is automatically con- Blocked Position T1 is activated, the vehicle lowers,
trolled in accordance with a set value (middle position) the lamp L2 (Fig.14) shines.
independent of the load. By pressing the key Blocked Position T1 the valve WV2
- Calibration : the end stops are calibrated in the control (Fig.14) is activated for 15 seconds in order to release
unit. pressure from the cylinder and from the accumulators.
- Automatic Operation
Control system components As soon as the toggle key is pressed in Automatic
- Automatic Operation/Blocked Pos. Toggle key Operation, signal lamp L1 (Fig.14) starts to shine and
. Automatic levelling into middle position T2 the the axle to middle position.
. Blocked position at cylinder stop T1 (Fig.14) In after 30 seconds the desired value has not been
- Signal lamps reached, the control is deactivated for 30 seconds.
. L1 shines = Automatic Operations mode After 30 seconds the procedure is repeated for 30
. L2 shines = Blocked Position mode seconds.
. L1 flashes = Calibration mode If three attempts fail, the control switches to the
. L1 and L2 flash = operation mode is to be selected operation mode “Overload” that is L1 and L2 (Fig.14)
(Fig.14) flash and an operation mode has to be selected by
- Sensor (inputs) mean of the toggle key.
. angular sensor, analogue input WS1 for axle position The operation mode Automatic Operation can be quit by
(Fig.14) activating the operation mode Blocked Position.
- Valves (outputs)
. in order to lower the vehicle WV2 is activated
. in order to lift the vehicle WV1 and WV2 are activated
(Fig.14)
Issue 1 May 2002

- Calibration
Calibration consists in determining the values of the
upper and lower cylinder stops.
If no calibration value has been recorded, the control
system automatically selects the Calibration mode
when the system is activated.
To manually select the Calibration mode, press on T2
Automatic Operation mode toggle key for 10 seconds.
Wait till the system changes to Calibration mode to
release the toggle key. This makes the suspension
manual control functions available.
Press on T1 key to manually lower the cylinders or on
T2 key to raise them.
When the cylinder stops have been adjusted, activate
the toggle key to leave the Calibration mode. The sys-
tem immediately changes to Automatic Operation
mode.
If required, the cylinder stop adjustment can be modi-
fied. When a change is made the new values replace
the old ones.
If the stop values exceed the allowed limit values or
the cylinder travel is lower than the minimum fixed
value, the system remains in Calibration mode.
Calibration tolerances
- lower stop (axle closed) : 5 mA
- upper stop (axle open) : 19 mA
- minimum travel : 9.35 mA
- Error modes
The system recognizes the following error modes:
- position sensor error (position lower than 4 mA or
higher than 20 mA)
- overload or cable breaking at the level of the solenoid
valve.
When one of these error modes occurs, the L1 indica-
tor light gets on with the relevant error code and the
solenoid valve is disabled. To validate the error mode,
switch off the system.
Error codes
21 WS1 angle sensor
31 VW1 and/or VW2 solenoid valve raised
32 VW2 solenoid valve lowered
33 No movement of the axle: overload or circuit brea-
king
41 T1 and T2 short-circuited
Issue 1 May 2002

UZ UB
T1 T2
L1 L2
6 7 4 3 5 8
1 GND
2 LGND
WV1
Green
S
WS1
J
WV2
Black
Carraro electronic box
Fig. 14
Issue 1 May 2002

D. Service tools
- CA 715362 - Sensor rubber positioning ring driver
(Fig.15).
- 3378322 M1 - front axle position sensor adjust-
ment harness (Fig. 16)
Fig. 15
1
2
3
1
2
3
Fig. 16
Issue 1 May 2002

SMS System - Description 11H01.1
11H01 Description
CONTENTS
A. General ___________________________________________________ 3
B. Description of SMS components ____________________________ 4
C. Operation and troubleshooting without a tester ______________ 10
D. SMS error codes ___________________________________________ 12
E. Disassembling, reassembling of the Joystick ________________ 17
F. Replacing of ON / OFF or Memory switches __________________ 17
G. Electrical diagram __________________________________________ 18
Issue 1 May 2002

11H01.2 SMS System - Description
Issue 1 May 2002

The ELC calculator transmits information received from

A . General the user via the SMS or Datatronic 2 to the auxiliary spool
The SMS (Spool valves Management System) controls valves concerned. The communication takes place
two proportional electro-hydraulically controlled spool across the CAN bus.
valves. It is available as an option on all 6200 series
tractors fitted with a closed centre hydraulics circuit. Parts list
(1) Joystick, ON / OFF switch and Memory switch
Its functions are : (2) Datatronic 2
- the control of electro-hydraulically controlled propor- (3) ELC calculator
tional spool valve flowrates (4) Auxiliary spool valve X
- the memorising of selected flowrates (5) Auxiliary spool valve Y
- the reinitialising of memorised flowrates (6) Outlet valves X- and X+
- the transition to Floating mode (7) Outlet valves Y- and Y+
- the Time Delay function (with the Datatronic option) (8) Safety solenoid valve
which allows for adjusting the valve supply time delay.
Block diagram (Fig. 1)

The control of the SMS is carried out via the Joystick and
connectors located at the end of the right-hand armrest.
The Datatronic displays the functions of the SMS with
accuracy.
6 7
X- X+ Y- Y+
5
4
-
+ -
+
3 Fig. 1
Issue 1 May 2002

B . Description of SMS components

(Fig. 2)
The SMS comprises the following elements:
- the Joystick (1)
- the ELC calculator (2)
- a switch (3) (additional function)
- an ON / OFF switch (4)
- an indicator lamp (5)
- a Memory switch (6)
- a harness (7)
- two electro-hydraulically controlled proportional spool
valves (8)
- a safety solenoid valve (9)
- the Datatronic (option) (10)
- possible connection for an additional function (11)
Issue 1 May 2002

5
3
1
4
6 ON
M
AUT
UTO
11
10
2 C52
C5
Fig. 2
Issue 1 May 2002

(1) Joystick
- The Joystick is the lever mounted on the right-hand A 3
armrest that is used to control the auxiliary spool
valves. It comprises a knob A, having a switch 3, a dust B
cover B, a plastic washer C, a control unit D, a support
E, and a cable F (Fig. 3).
C
- The travel of the lever determines the opening of the
F
main spool of the auxiliary spool valves. The flowrate D
Q is proportional to the travel Dp of the lever (Fig. 4)
(example: if the lever is in the mid-position, Q equals
50% of the maximum available or memorised flowrate.
- The supply current for the various valves is determined
E
by the direction of movement of the lever (Fig. 5). The
directions X+, X-, Y+ or Y- allows the flowrate of each
valve to be controlled separately. The direction X- Y-, Y-
X+, X+ Y+ or Y+ X- allows the simultaneous control of Fig. 3
the flowrates of the two mentioned valves.
- The "100%" circle corresponds to 100% of the available
flowrate (lever resistance on a hard spot) Q
- The "127%" circle corresponds to the Floating position
(overcoming of the hard spot). 100%
- During movement of the lever, the electronic unit of the
joystick sends an electrical signal to the ELC calculator,
which then sends this information to the spool valve
concerned via the CAN bus.
50%
Note:
- Any replacement or disassembly of the Joystick
requires calibration using Wintest
- This operation allows the 100% travel of the lever 0
across the X and Y-axes to be defined. 50% 100%
Dp
- + --
+ - +-
+ + + -
Fig. 4
X-
Y+/X- X-/Y-
%
127
%
100
-
Y+
+ - Y-
+
X+/Y+ Y-/X+
X+ Fig. 5
Issue 1 May 2002

(2) ELC calculator

- The calculator receives signals from the various com-
ponents of the SMS and the Datatronic controls and
then transmits this information to the auxiliary spool
valves via the CAN bus.
Note: For the SMS to operate, the ELC calculator

parameters must be correctly set (see section
11F05).
(3) SMS 3rd function switch

- This switch is used with an additional harness (Kit
reference 3788679 M11) to be mounted. This assembly
allows the functions of each electro-hydraulic spool
valve to be doubled by controlling another solenoid
valve located on the implement itself.
- For example, in the case of a front loader: the displace-
ment along X allows the loader to be lifted or lowered,
whereas the displacement along Y controls the dis-
placement of the bucket, or a third function such as a
claw or a bale clamp can be controlled by pressing the
switch.
(4) ON / OFF switch

- It is fitted above the Joystick on the right-hand armrest.
The ON / OFF switch activates and deactivates the
SMS.
(5) Indicator lamp

- An indicator lamp is located in the centre of the ON /
OFF switch. If:
- The indicator lamp is lit continuously: the system is not
active
- The indicator lamp is off: the system is active
- The indicator lamp flashes once to indicate the
reinitialising of the oil flowrates (see § C).
- The indicator lamp flashes in a specific manner to
indicate various error codes (see § D).
(6) Memory switch

- This switch is fitted between the Joystick and the ON
/ OFF switch. It memorises the flowrates selected with
the Joystick and reset them (example: a flowrate of 30
l/min is desired on X+. Move the lever to obtain the
desired flowrate. Press the Memory switch down for 1
second. The maximum flowrate for 100% travel is now
set to 30 l/min).
(7) Electrical harness linking various com-

ponents
Issue 1 May 2002

(8) Electro-hydraulically operated propor-

tional spool valves
- The spool valves are of the BOSCH SB23 type and are
electrically controlled. After contact they are supplied
with 12 V.
- They have an internal electronic circuit that decodes the 1
CAN signals sent by the ELC calculator to control the 2
main spool. The circuit also analyses the operation of
100
the spool valve and is able to generate error codes (see 10
§ D). 75 % 50
Note: To operate in the desired direction (X+, X-, 11
4 0
Y+, Y- or Dual), the spool valves parameters must
be set using Wintest whenever they have been
replaced or moved (see section 11F07 – Joystick 15 ∞ 3
with Wintest).
5 ON ~ 7
(9) Safety solenoid valve 6 5 4 3 2 1 8

- This solenoid valve is located in the end plate of the
distribution block. It is of the ‘On-Off’ type and is
controlled during activation of the SMS. The safety
valve cuts the pilot pressure to the distribution block for
all error codes above 40 and for error code 26 (see § D).
Note: The safety valve remains supplied when the
SMS is placed in the OFF position. It cuts out when
the engine is stopped. 9
(10) Datatronic
- If fitted, the Datatronic displays the precise flowrates
Fig. 6
memorised for each valve and allows the adjustment
of the spool valve opening time (Time Delay function).
It also displays the possible error codes (see § D). The SMS is active when the padlock symbol (4) is absent
Note: To display the SMS windows, the Datatronic from the MAX FLOWRATE and TIME windows.
parameters must be correctly set (see section
11F06)
Parts list (Fig. 6)

(1) Adjustment of oil flowrates
(2) Upper screen selection key
(3) Bottom screen selection key
(4) SMS activation indicator lamp
(5) ON / OFF time delay
(6) Floating mode
(7) Activation of Time Delay mode
(8) Selection keys
(9) Selection knob
(10) Y- and Y+ valves
(11) X- and X+ valves
Issue 1 May 2002

The maximum flowrate of each valve

1. In the Datatronic menu, select JOYSTICK then MAX
FLOWRATE. Window (1) is displayed.
2. Press keys (8.1) and (8.2) to select the maximum
flowrate to be modified. The value to be modified is
displayed in reverse video.
3. Turn knob (9) to change the selected flowrate (100 in
Fig. 6). The flowrate can be adjusted from 0 to 100%
in steps of 1%.
Example shown in Fig. 6
- X- : 100% of available flowrate
- X+ : 0% of available flowrate
- Y- : 75% of available flowrate
- Y+ : 50% of available flowrate
Note: Adjusting a valve to 100% is equivalent to
reinitialising the maximum flowrate.
‘Time delay’ mode

1. In the Datatronic menu, select JOYSTICK then TIME.
2. Press the key (8.5) to activate the Time Delay func-
tion. ON appears at (5) and the time delay memorised
during the last use of the tractor is displayed.
3. The horizontal and vertical double headed arrows (10)
and (11) (the Y axis, X axis respectively) refer to the
spool valves; press keys (8.1) and (8.2) to select
them.
4. Turn knob (9) to adjust the time from 0 to 60 seconds,
in steps of 1 second, or set to continuous (infinity
symbol ∞).
5. To launch the time delay, push the joystick above the
80% position, then release the lever.
During the Time Delay phase, the Datatronic displays
the clock symbol (7). It is possible to stop the time
delay by moving the lever 10% in the opposite control
direction.
Note: As long as the position of the lever is less
than 80%, the flowrate of the solenoid valve
concerned is proportional to its position. Above
80%, the flowrate is equal to 100% of the memo-
rised flowrate.
Transition to ‘Floating’ mode

- When the operator moves to ‘Floating’ mode using the
Joystick, symbol (6) is displayed in the TIME screen of
the Datatronic.
Issue 1 May 2002

C . Operation and troubleshooting

without a tester
Functions User actions Reaction of SMS Problem Possible causes
SMS activation Press ON / OFF switch ⇒ SMS is No activation Using Wintest
with the joystick in activated check:
neutral ⇒ Indicator lamp − ON / OFF switch
Conditions : of ON / OFF − engine speed
- Engine has run switch gets out sensor
for more than ⇒ Padlocks on − ELC calculator
2 seconds. Datatronic TIME − safety valve
- Joystick is in and MAX
neutral FLOWRATE − reference of ELC
disappear calculator
⇒ Safety valve − parameters of
opens the ELC calculator
hydraulic circuit
Changing of 1. Operate the joystick ⇒ Memorises the Maximum Using Wintest,
maximum to reach desired new maximum flowrate check:
flowrate flowrate flowrate doesn’t vary − Memory switch
2. Press Memory − ELC calculator
switch for 1 second − Joystick
3. Return Joystick to calibration
neutral position − Set spool valves
With Datatronic: : parameters
Vary desired percentage
up to the flowrate
desired
Reinitialisation 1. Operate joystick in ⇒ Reinitialises Reinitialisation Using Wintest,
of a valve desired direction maximum not carried out check:
flowrate 2. Press for at least 3 flowrate of all − Memory switch
seconds on the valves − ELC calculator
Memory switch ⇒ ON / OFF
switch indicator
lamp flashes
once
With Datatronic:
vary desired flowrate up
to 100%
Reinitialisation 1. Joystick in neutral ⇒ - Reinitialises Reinitialisation Using Wintest,
of flowrate of all 2. Press for at least 3 maximum not carried out check:
valves seconds on the flowrate of all − Memory switch
Memory switch valves − ELC calculator
⇒ - ON / OFF
switch indicator
lamp flashes
once
With Datatronic:
vary all flowrates up to
100%
Issue 1 May 2002

Functions User actions Reaction of SMS Problem Possible causes

Floating Push the Joystick ⇒ Transition to No transition Using Wintest
beyond 100% position in Floating mode: 2 to Floating − check ELC
X- or Y- spool valves (X or Y mode calculator
depending on − check operation of
choice) are linked spool valves
with return to − check valves
housing parameters
⇒ ~ displayed on − Recalibrate the
Datatronic TIME Joystick
screen
−Check that TIME
mode is OFF or at 0
Time delay Only with Datatronic: ⇒ Activation of Time No Time Using Wintest:
1. Activate TIME mode delay mode delay mode − Check Datatronic
(ON displayed on ⇒ Clock symbol parameters
screen) displayed during
2. Select spool valve time delay
3. Select time (0 to 60
seconds or infinity ∞)
4. Push Joystick
beyond 80% position
Time delay stop 1. Operate the Joystick ⇒ Time delay stops
at least 10% in
opposite control
direction
Issue 1 May 2002

2. The LED of the auxiliary spool valve concerned

D . SMS error codes flashes once every second:
- 1st series: 1st number of error code
Display of error codes - 2nd series: 2nd number of error code
Different messages indicate errors occurring in the SMS:
1. ON / OFF indicator lamp 3. The Datatronic indicates the error code in the TIME
- If it is a Joystick error (error code 0 - 1 to 0 - 8) the window : letter E followed by error code (Fig. 7)
ON / OFF indicator lamp flashes in the following In the case of a three figure number, the first figure
sequence: represents the valve, and the second and third the
. A series of flashes every 14 seconds, the number error code itself.
of flashes indicates the error code. Note: In the case of error code 1 - 0, the Datatronic
Example: error code 0 - 3 displays E10 (no indication of the valve number
concerned) and in the case of error code 0 - 9 the
Datatronic displays E9.
1s
4. Wintest indicates and identifies the error codes.
5s 2s 2s 5s
Note: The number associated with a valve is defined
by its parameters
Number 1 : Green valve X
Number 2 : Red valve Y
Number 3 : Black valve DUAL CONTROL/TIC
- If it is a valve error, the ON / OFF indicator lamp

flashes as follows:
. 1st flash: valve number
. 2nd flash: 1st number of error code
. 3rd flash: 2nd number of error code
Example: valve number 2, error code 3 - 1
1s
5s 2s 2s 5s
- The ELC calculator can diagnose error codes 0 – 9 or 100

1 - 0 on the electro-hydraulic spool valve system.
The ON / OFF indicator lamp flashes in the following 75 % 50
manner:
0
. Error code 0 - 9 : 3 series of 8 flashes
∞
. Error code 1 - 0 :
1st series: valve number 15
2nd series: 3 flashes
OFF E231
3rd series: 3 flashes
Note: If two valves are concerned by error code
1 - 0, the ON / OFF indicator lamp indicates error
code 1 - 3 - 3. Fig. 7
Issue 1 May 2002

Error code Flash on ON / OFF Flash on spool valve Datatronic display

0-1 0-1 E1
0-2 0-2 E2
0-3 0-3 E3
0-4 0-4 E4
0-5 0-5 E5
0-6 0-6 E6
0-7 0-7 E7
0-8 0-8 E8
0-9 8-8-8 E9
1-0 1-3-3 E 10
2-3-3
3-3-3
1-1 1-1-1 1-1 E 111
2-1-1 E 211
3-1-1
1-2 1-1-2 1-2 E 112
2-1-2 E 212
3-1-2
1-3 1-1-3 1-3 E 113
2-1-3 E 213
3-1-3
1-4 1-1-4 1-4 E 114
2-1-4 E 214
3-1-4
1-5 1-1-5 1-5 E 115
2-1-5 E 215
3-1-5
1-6 1-1-6 1-6 E 116
2-1-6 E 216
3-1-6
1-7 1-1-7 1-7 E 117
2-1-7 E 217
3-1-7
2-1 1-2-1 2-1 E 121
2-2-1 E 221
3-2-1
2-2 1-2-2 2-2 E 122
2-2-2 E 222
3-2-2
2-3 1-2-3 2-3 E 123
2-2-3 E 223
3-2-3
2-4 1-2-4 2-4 E 124
2-2-4 E 224
3-2-4
2-5 1-2-5 2-5 E 125
2-2-5 E 225
3-2-5
Issue 1 May 2002

Error code Flash on ON / OFF Flash on spool valve Datatronic display

2-6 1-2-6 2-6 E 126
2-2-6 E 226
3-2-6
3-1 1-3-1 3-1 E 131
2-3-1 E 231
3-3-1
3-2 1-3-2 3-2 E 132
2-3-2 E 232
3-3-2
4-1 1-4-1 4-1 E 141
2-4-1 E 241
3-4-1
4-2 1-4-2 4-2 E 142
2-4-2 E 242
3-4-2
4-3 1-4-3 4-3 E 143
2-4-3 E 243
3-4-3
8-1 1-8-1 8-1 E 181
2-8-1 E 281
3-8-1
8-2 1-8-2 8-2 E 182
2-8-2 E 282
3-8-2
Issue 1 May 2002

Table of error codes
Error code Fault Reaction of the Action required

System
0-1 Analog input error 1 Function jammed, spool Test with Wintest and
(X+ position sensor) valves in neutral replace joystick
0-2 Analog input error 2 (X- Function jammed, spool Test with Wintest and
position sensor) valves in neutral replace joystick
0-3 Analog input error 3 (Y+ Function jammed, spool Test with Wintest and
Detected by Joystick electronic unit

0-4 Analog input error 4 (Y- Function jammed, spool Test with Wintest and
0-5 Joystick internal Function jammed, spool Test with Wintest and
calculator error valves in neutral replace joystick
0-6 EPROM error. Function jammed, spool Recalibrate or replace
Too little difference valves in neutral joystick
between each position
X+ / centre / X- or Y+ /
centre / Y- of joystick
during calibration
0-7 Safety message on Function jammed, spool Test with Wintest ,

CAN valves in neutral check harness and
replace joystick
0-8 9.5 V voltage error Function jammed, spool Test with Wintest,
valves in neutral check harness and
replace joystick
0-9 No joystick detected Function jammed, spool Test with Wintest,
Detected by

calculator
replace joystick
ELC
1-0 No valve detected Function jammed, spool Test with Wintest,

replace joystick
Issue 1 May 2002

Error code Fault Reaction of the System Action required

CAN 1-1 CAN message missing Valve returns to neutral. Repair fault and / or
errors 1-2 CAN message missing Correct voltage received move control to neutral
1-3 Wrong CAN message within 4 seconds = valve to reinitialise.
1-4 Wrong CAN message returns to previous position.
1-5 Spool valve internal Error present after 4 Repair fault
signal error (PWM) seconds = valve remains in
neutral.
1-6 Valve EPROM problem Valve returns to neutral Repair fault
1-7 No error but return to Displayed when return to Move control to neutral
neutral necessary neutral not carried out after to reinitialise.
1-1, 1-2, 1-3, 1-4, 2-3, 2-4, 3-
1 and 3 - 2 errors.
Minor 2-1 Undervoltage: < 8.2 V Error displayed but system Repair fault
Detected by electro-hydraulic spool valves
errors and > 8 V continues to operate.

2-2 Overvoltage: > 18 V and
< 36 V
2-3 Spool movement too
low
2-4 Spool movement too Return of spool to neutral Move control to neutral
great to reinitialise.
2-5 Floating position not
reached
2-6 Manual control Valve answers manual Stop and restart tractor
control, electronic control engine.
locked out.
Major 3-1 Voltage low: < 8 V Return of spool to neutral. Stop and restart tractor
errors 3-2 Voltage high: > 36 V Correct voltage received engine.
within 4 seconds = valve
returns to previous position.
Error present after 4
seconds = valve remains in
neutral.
4-1 Large over voltage: > 45 Valve returns to neutral. Stop and restart tractor
V Pressure relief valve cut engine.
4-2 Valve power error (OFF)
4-3 Position sensor error
8-1 Valve can’t return to Pressure relief valve cut
neutral (OFF)
8-2 Valve spool not in Valve remains in neutral.
neutral at power up
Issue 1 May 2002

E . Disassembly, reassembly of the

Joystick
Any Joystick breakdown requires its entire replacement.
Disassembly of Joystick
1. Disassemble the armrest by unscrewing the 6 bolts
linking the upper and lower parts.
2. Loosen the 3 bolts holding the Joystick support and
the internal armrest support.
3. Remove the plastic washer linking the Joystick dust
cover to the upper part of the armrest.
4. Remove the Joystick (Fig. 8).
Reassembly of the Joystick Fig. 8

5. Put the joystick in place (Fig. 8)
6. Replace the plastic washer linking the dust cover to
the upper part of the armrest.
7. Replace the 3 bolts holding the Joystick support to the M
armrest internal support.
8. Fit the armrest by replacing the 6 bolts holding the
upper and lower parts.
F . Replacement of ON / OFF or
Memory switches
If it is necessary to replace the ON / OFF or Memory
switches, separate the pin connector. During reassembly, 2
1
take care to respect the following connections:
Fig. 9
Memory switch (Fig. 9)
Way Wire colour
1 Blue
2 Brown
ON
ON / OFF switch (Fig. 10)

Way Wire colour
1 Brown
2 White
3 Green 1 4
4 Yellow
2 Fig. 10
3
Issue 1 May 2002

Parts list
G . Electrical diagram (Fig. 11) (26) Joystick
(27) Joystick function multiplier switch
(28) ON / OFF switch
(29) Memory switch
Item Colour Ways Description Pins Wires

AA Grey 7 Joystick / AE connector 1 12 V after contact Orange
2 Signal to solenoid Grey
valve
3 CAN high Green
4 CAN low Brown
5 +9.5V Red
6 Ground Black
7 Not used
AB Black 2 Switch connected to 1 12 V after contact Blue
Joystick terminals 2 Signal to solenoid White
valve
AC 4 Activation switch and 1 12 V after contact Orange
status diode 2 Joystick activation Blue
signal
3 LED ON/OFF Green
4 Ground Black
AD 2 Zero reset and Memory 1 12 V after contact Orange
switches 2 Signal for calculator Yellow
AE 10 Calculator armrest K Towed implement Violet
connection signal
J Radar speed signal White
B Multiplier solenoid Grey
valve control
F Joystick LED Green
E Joystick activation Blue
signal
D Memory Yellow
Zero reset signal.
A +9.5V Red
H Depth control Green
C Ground Black
G Raise / lower toggle Pink
AF 10 Dashboard armrest A Not used
connection B Not used
C Not used
D Radar speed White
E Not used
F 12 V after contact Orange
G CAN low Brown
H CAN high Green
J CAN low Brown
K CAN high Green
Issue 1 May 2002

28 29
N
27 26 AC AD N O N N
BF
J
AB
J N N
B
V
AA
G
M/J N
R VF
N N/B
AF G
AE RO
B
O
M
V
G
G
J
N
VC
J
R
R/B
V
M
B
G
Ro
V
O
M
B
30 31 25
R X
M
V
R B
Vi V
J
20 N
R
23
N
V
24 M
B
V
N/B
R
M/J
A
21 N N w
M N
N R
B 22 O
R
T U
N
Fig. 11
Issue 1 May 2002

CHAPTER
UNDER
CONSTRUCTION
CHAPTER
UNDER
CONSTRUCTION
14 . SERVICE TOOLS
Contents
14 A01 SERVICE TOOLS
Issue 1 May 2001

Service tools 14A01.1
Reference Designation
14 A01 Service tools
CONTENTS
Splitting the tractor ____________________________________________ 2
Perkins engines _______________________________________________ 3
Valmet engines ________________________________________________ 8
Clutch ________________________________________________________ 19
Gearbox ______________________________________________________ 20
Rear axle ______________________________________________________ 23
Power take off _________________________________________________ 25
Front axle _____________________________________________________ 26
Hydraulics ____________________________________________________ 32
Electricity - Electronics _________________________________________ 34
Cab and equipment ____________________________________________ 41
Issue 1 May 2001

14A01.2 Service tools
3376935 M1 • Air conditioning plugs kit
3378152 M11 • Uncoupling tools comprising

- 2 trolleys with adjustable axle stands
- 1 fixed axle stand
E
BL
- 4 m rail
LA
AI
AV
T
O
N
Issue 1 May 2001

MS.76 - 73B • Set of adjustable mills for valve seats
PD.1D • Valve guide removal / fitting tool (main tool)
PD.1D-1A • Adaptor for use with PD.1D
PD.1C-6 • Adaptor for inlet valve for use with PD.1D and PD.1D-1A
PD.41D • Indicator gauge for measuring piston height, valve depth cylinder liner
collar: for use with PD.208
Issue 1 May 2001

PD.145D • Crankshaft rear seal fitting tool
PD.150B • Cylinder liner removal / fitting tool (main tool)
PD.150B-17 A • Adaptors for use with PD.150B
PD.155C • Universal extractor
PD.155C-5 • Adaptors for use with PD.155C
Issue 1 May 2001

PD.170 • Fitting tool for timing gear housing cover lip seal (main tool)
PD.170-1 • Pressure plate for use with PD.170
PD.170-2 • Sleeve for use with PD.170
PD.170-3 • Attachment plate for use with PD.170
PD.170-4 • Lip seal adaptor for use with PD.170
Issue 1 May 2001

PD.206 • Piston fitting tool
PD.208 • Dial gauge for use with PD.41D
PD.221A • Piston position adjusting rod
PD.248 • Adaptor for exhaust valve, for use with PD.1D and PD.1D-1A
PD.6118-7 • Stud adaptor for use with 6118B
Issue 1 May 2001

PD.6118-8 • Locking adaptor bolt for use with 6118B
6118B • Valve spring compressor
3378242 M1 • Perkins green engine timing tool for Lucas and Stanadyne pump
Issue 1 May 2001

9020 01100 • Piston fitting cone for 612 / 620 DS engines
9024 55800 • Socket for crankshaft nut for 612 / 620 DS and 645 engines
9025 79200 • Sleeve height gauge for 612 / 620 DS and 645 engines
9025 87400 • Camshaft plug tool for 620 / 634 and 645 enginess
9025 98700 • Locating pin insertion mandrel for 612 / 620 DS engines
Issue 1 May 2001

9025 98800 • Locating pin insertion mandrel for 612 / 620 DS engines
9025 98900 • Crankshaft dust cover fitting mandrel for 612 / 620 DS engines
9025 99000 • Injection timing socket for 612 / 620 DS engines
9030 15200 • Crankshaft front seal fitting mandrel for 612 / 620 DS engines
9051 71300 • Injector extractor for 612 / 620 DS engines
Issue 1 May 2001

9051 73100 • Cylinder liner extractor for 612 / 620 DS engines
9051 79300 • Water pump seal fitting tool for 612 / 620 DS engines
9052 46300 • Crankshaft rear seal fitting mandrel for 612 / 620 DS engines
9052 46400 • Centering ring for flywheel housing for 612 / 620 DS engines
9052 46620 • Bearing cup plug mandrel (Æ 40 mm) for 620 DS and 645 engine
Issue 1 May 2001

9052 46650 • Bearing cup plug mandrel (Æ 16 mm) for 612 / 620 DS and 645 engines
9052 46660 • Bearing cup plug mandrel (Æ 36 mm) for 612 / 620 DS and 645 engines
9052 46900 • Piston ring pliers for 612 / 620 DS and 645 engines
9052 47200 • Nut for valve spring compression lever for 612 / 620 DS and 645 engines
9052 47600 • Injection timing pipe for 612 / 620 DS engines
Issue 1 May 2001

9052 47800 • Test pressure gauge for injection pump valve for 612 / 620 DS engines
9052 48800 • Crankshaft pinion extractor for 612 / 620 DS engines
9052 48900 • Water pump hub and injection pump pinion extractor for 612 / 620 DS
and 645 engines
9101 65502 • Exhaust valve seat mill for 620 DS and 645 engines
9101 65503 • Exhaust valve seat mill for 620 DS and 645 engines
Issue 1 May 2001

9101 65505 • Inlet valve seat mill for 620 DS and 645 engines
9101 65506 • Inlet valve seat mill for 620 DS and 645 engines
9101 65600 • Reamer for sleeve housing for 620 / 634 engines
9101 65700 • Crankshaft nut wrench for 620 / 634 engines
9101 65800 • Valve guide removal mandrel for 620 DS and 645 engines
Issue 1 May 2001

9101 65900 • Valve guide fitting mandrel for 620 DS and 645 engines
9101 66000 • Mill for injector seat for 620 DS and 645 engines
9101 66100 • Grip for 620 DS and 645 engines
9101 66200 • Valve spring compression lever for 620 DS and 645 engines
9101 66300 • Liner holding flange (2 parts) for 620 DS and 645 engines
Issue 1 May 2001

9101 71100 • Mill for exhaust valve seat for 620 DS and 645 engines
9101 75800 • Mill for inlet valve seat for 620 DS and 645 engines
9101 93200 • Water pump turbine extractor for 612 / 620 DS engines
9103 41000 • Water pump shaft seal insertion tool for 645 engine
9103 41100 • Water pump seal insertion tool for 645 engin
Issue 1 May 2001

9103 41300 • Water pump bearings insertion tool for 645 engine
9103 94600 • Crankshaft front seal insertion tool for 645 engine
9103 94700 • Crankshaft pinion insertion tool for 645 engine
9103 94800 • 45 mm plug insertion tool for 645 engine
9103 94900 • Crankshaft front oil deflector insertion tool for 645 engines
Issue 1 May 2001

9104 05800 • Conical piston fitting sleeve for 645 engine
9104 34600 • Intermediate pinion centering tool for narrow timing gear housing on
645 engine
9104 51500 •Sleeve extractor for 645 engine
9104 52000 • Sleeve seat mill for 645 engine
9104 52600 • Crankshaft rear seal insertion tool for 645 engine
Issue 1 May 2001

9104 52700 • Engine flywheel housing centering tool for 645 engine
9104 52800 • Injection advance check tool for 645 engine
9104 53300 • Crankshaft hub extractor for 645 engine
9104 53700 • Injector extractor for 645 engine
Issue 1 May 2001

3378004 M1 • Wet clutch special sleeve
3378012M2 • Wet clutch seal protector
3378262 M1 • Clutch shock absorber centering tool
Issue 1 May 2001

MF 391 • Layshaft nut socket
MF 459 • Front PTO shaft snap ring fitting tool
MF 460 • Front PTO shaft snap ring removal tool
MF 462 A • Hare / Tortoise selector adjusting gauge
3376883 M1 • Front unit removal and fitting sling
Issue 1 May 2001

, ,,
Reference
, ,
Designation
, ,
,,,,,,,,,
3376887 M1 • Dynashift centering tool
,, ,,
3376888 M1 • Dynashift secondary crownwheel holding tool
3376920 M2 • Dynashift compression tool
3378013 M1 • Adaptation plate (for wet clutch)
3378059M1 • Hydraulic accumulator test and load equipment
Issue 1 May 2001

3378263 M1 • Layshaft bearings adjusting tool
ATP.3002 • Clutch spring compression tool for Full Powershift gearbox (AG 150 /
AG 250)
ATP.3015 • Full Powershift gearbox tool kit (AG 150 / AG 250)
ATP.3030 • Full Powershift gearbox pinion extractor set (AG 150 / AG 250)
Issue 1 May 2001

MS 550 • Universal sleeve
3376885 M1 • Seal protector (sealed compartment trumpet housing and double drive
unit)
3378116 M1 • Rear differential sling
3378117 M1 • Differential blocking tool
3378118 M1 • Drive pinion holding wrench
Issue 1 May 2001

3378119 M1 • Splined socket for drive pinion
3378123 M1 • Lift control shaft protector
3378124 M1 • Insertion tool for lift control shaft support seal, used with MS550
3378151 M1 • Insertion tool for trumpet housing shaft cassette seal (∅ 110)
Issue 1 May 2001

3378115 M1 • Fitting tool for PTO cassette seal, used with MS550
3378135 M1 • Compression tool for PTO clutch Belleville washer
Issue 1 May 2001

MF 195 C • Bearing cup removal / fitting tool (basic tool)
MF 451 B • Removal tool for 4WD swivel pins, used with MF 195 C
MF 451 B.2 (M14) • Replacement adaptor, used with MF 451 B
MF 451 B.3 (M18) • Replacement adaptor only

• Replacement adaptor, used with MF 451 B
MF 471.A • 4WD - differential lock spring compression tool
Issue 1 May 2001

3378028 M1 • Front axle special socket - AG 125 - 155 - 200
3378038M1 • Hub extractor - AG front axles
AG 155H
AG 200H
3378039 M1 • Fitting tool for Cassette seal and crownwheel (AG 125 - 155 - 200 axles)
3378051M1 • Differential nut wrench (AG 155 - 200 axles)
3378056M1 • Cassette seal fitting ring (AG 125 - 155 axles)
Issue 1 May 2001

3378057M1 • Cassette seal fitting ring (AG 200 axles)
3378122 M1 • Sleeve for extractor (AG 155H front axle)
3378275 M1 • Nut wrench for AG 200CDH flanged front axle drive pinion
3378276 M1 • Locking wrench for AG 200CDH flanged front axle drive pinion
5870 055 006 • Insertion tool for ZF APL 5052 front axle final drive unit seal, used with
5870 260 00024
Issue 1 May 2001

5870 055 019 • Ring for lip seal insertion tool - ZF APL 5052 front axle
5870 055 073 • Insertion tool used with 5870 905 004 and 5870 260 002 - ZF APL 5052
front axle
5870 058 026 • Insertion tool for final drive unit ring, used with 5870 260 002 - ZF APL
5052 front axle
5870 204 016 • Planetary gear carrier extracting bolt - ZF APL 5052 front axle
5870 240 002 • Drive pinion plate holder - ZF APL 5052 front axle
Issue 1 May 2001

5870 260 002 • Lip seal insertion tool grip - ZF APL 5052 front axle
5870 340 010 • Drive pinion adjusting gauge - ZF APL 5052 front axle
5870 401 082 • Crownwheel carrier nut socket - ZF APL 5052 front axle
5870 500 001 • Conical distance adjustment tool, used with 5870 500 101 - ZF APL
5052 front axle
5870 500 010 • ZF APL 5052 front axle - rings for conical distance adjustment tool used
with 5870 500 101
Issue 1 May 2001

5870 905 004 • ZF APL 5052 front axle - centering ring used with 5870 055 073 and
5870 260 002
Issue 1 May 2001

MF 3001 • Hydraulic pressure test kit

1 = 0 - 10 bar
2 = 0 - 35 bar
1 = 0 - 420 bar
MF 3016 • Hydraulic flowmeter

Q = 4 - 160 l/min
MF 3017 • Hydraulic flowrate test equipment used with MF 3016
3376882 M91 • Depollution kit
3378174 M1 • Hose kit for testing Full Powershift gearbox
Issue 1 May 2001

3378272 M1 • Clutch 17 bar pressure connector - Full Powershift gearbox
3378273 M1 • 17 bar pump outlet pressure connector - Full Powershift gearbox
3378274 M1 • Lubricating pressure connector - Full Powershift gearbox
3582045 M1 • Female hydraulic coupler
3583550 M91 • Hose piping for coupler
Issue 1 May 2001

MF 3005 • Multimeter for use with electronic test equipment
3378077 M1 • Adaptor
3378207 M91 • Datatronic programming harness

M91
207
3378
3378234 M1 • 16-way extension cable (10 m)

33
78
23
4M
1
3378243 M1 • CANBOX and WINTEST software (chip 527) with user guide
Supersedes 3790726 H1
WINTEST
CAN BOX
AGCO
Ref : 3378243 M1
Issue 1 May 2001

3378244 M1 • Wintest type A harness with CAN 4-way connector for Autotronic 2
used with 337845M1
3378245 M1 • Wintest type B harness with CAN 16-way connector for cab upright
379
socket
072
8H
1
3378246 M1 • CANBOX / PC extension (L = 10 cm)
3378281 M1 • 2-way AMP junior timer female connector

1
2
3378282 M1 • 2-way AMP junior timer male connector
Issue 1 May 2001


1
2 3

1
2
3

1 2 3 4
5

5
4
3
2
1

1 2 3 4 5 6 7
Issue 1 May 2001

3378288 M1 • AMP 7-way AMP junior timer male connector

7
6
5
4
3
2
1
3378289 M1 • Packar 2-way connector
3378290 M1 • Packar grey 10-way AMP junior timer female connector

A
B
C
D
E
3378291 M1 • Packar black 10-way AMP junior timer female connector

A
B
C
D
E
3378292 M1 • Packar black 10-way AMP junior timer male connector

E
D
C
B
A
Issue 1 May 2001

3378293 M1 • Packar black 10-way AMP junior timer male connector

E
D
C
B
A
3378296 M1 • Proportional solenoid valve socket (Facom S29LA)
3378302 M12 • Complete electrical / electronic service suitcase
3378304 M11 • Empty electrical / electronic service suitcase
3580817M1 • male connector extractor
Issue 1 May 2001

3580818 M1 • Clip extractor
3580820 M1 • Circular connector contact extractor
3712723 M1 • 4 LED harness (Autotronic 2)
3714779M1 • Adaptation harness for tester / programmer, included in tester kit
3715767 M1 • Tester connection harness / Programmer on electronic linkage

connector
Issue 1 May 2001

114 010 • Deutsch extractor 2 mm2 (yellow)
0411-204-1605 • Deutsch extractor 1.5 mm2 (blue)
0411-204-2005 • Deutsch extractor 0.5 mm2 (red)
Issue 1 May 2001

3376935 M1 • Air conditioning plugs kit
Issue 1 May 2001

Massey Ferguson 8200 - Workshop Manual PDF

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Massey Ferguson 8200 - Workshop Manual PDF

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Workshop service manual N° 3378177 M1

Issue 1 May 2001

E. Instructions for putting the tractor in service 23

G. Locking compounds and sealants 32

Issue 2 May 2002

Page numbering Repair Times Schedule

At the bottom of the page is shown the issue number and

Using the manual

Repairs and replacement of parts

Issue 2 May 2002

PERKINS ENGINE 1006 1006

Injection and air filter

8210 8220 / 8240 / 8250 /

Fuel filter Yes Yes Yes Yes

Issue 2 May 2002

VALMET ENGINE 634 645 645

Injection and air filter

8260 / 8260 Xtra 8270 / 8270 Xtra 8280 / 8280 Xtra

Issue 2 May 2002

RANGE FORWARD REVERSE

1 A 2.36 0.6 2.30 0.6

Issue 2 May 2002

RANGE FORWARD REVERSE

Issue 2 May 2002

RANGE FRONT REAR

Issue 2 May 2002

RANGE FRONT REAR

Issue 2 May 2002

RANGE FRONT REAR

Issue 2 May 2002

• Filtering - 1 x 60 micron suction strainer

Dynashift gearbox with power shuttle - 32 forward speeds

• 8210 - 8220 power shuttle - clutch controlled

• 8240 power shuttle - clutch controlled

• 8250 power shuttle - clutch controlled

• ¼ Creeper gearbox : - 48 forward speeds

• Filtering - 1 x 60 micron suction strainer

Issue 2 May 2002

Full Powershift gearbox : - 17 or 18 forward speeds (depending on 30 km/h or 40 km/h version)

Final reduction drive units

Front axle with 2-wheel drive

Front axle with 4-wheel drive

8270 / 8280 ................ APL5052 20.475/1 Up to L074008

Issue 2 May 2002

Low-pressure circuit (17 bar) supplies the following functions :

Low pressure circuit for Full Powershift gearbox

Position of lift Length Horizontal Drawbar in

547.5 824 7149 9365

918 7373 8627

600.0 824 7769 9865

918 7927 9109

Issue 2 May 2002

Position of lift Length Horizontal Drawbar in

Mini 530.4 838 8741 11387

915 8994 10656

Maxi 580.9 838 9475 12001

915 9667 11252

Rear differential lock

Control: Electrically controlled hydraulics.

Issue 2 May 2002

Cooling system ................................................................................................. 8210/8220 : 28,5 l

Engine sump ..................................................................................................... 8210/8220 : 15,6 l