Claas Renault Ares 546 556 566 616 626 636 696 Tractor Workshop Service Repair Manual
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Claas Renault Ares 546 556 566 616 626 636 696 Tractor Workshop Service Repair Manual
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Claas Renault Ares 546 556 566 616 626 636 696 Tractor Workshop Service Repair Manual
Front calibration The calibration starts by the front clutch, the pressure slowly rises in it. When the tractor is displaced forwards of about 20 cm, the operator informs the UCE by declutching using the pedal and then releasing it. The front calibration is then completed, the UCE starts then the calibration of the rear clutch .
Rear calibration In the same way, when the tractor is displaced backwards of about 50 cm, the operator informs the UCE by declutching using the pedal and then releasing it. It is the end of the first phase of the calibration. The indicators 1 and 2 are ON. The range should be contacted for 2 sec. (the calculator is informed that the gearbox is in neutral position).
Current calibration The second phase then starts (gearbox in neutral position). It lasts about 1 minute. Calibration end The operator is informed of the calibration end when the four speed indicators of the display are steady ON for 3 seconds. Pull back the lever to neutral and declutch. For the whole calibration phase The FRONT and REAR indicators alternately flash with the NEUTRAL indicator – Buzzer.
Calibration failure mode In this mode, the indicators 1,2,3 and 4 come on one after the other. They go out only when the reverser lever is set to neutral.
The calibration is then aborted. Restart the calibration. Entry conditions in failure mode:
1- engine speed not included between 1,400 and 1,600 rpm.
2- gearbox not in low range before entry in calibration
3- speed ratio not engaged after entry in calibration.
4- “TOC” failure (pedal up contact).
5- temperature on cover probe not included between 45 and 55 degrees.
TABLE OF CONTENTS:
Claas Renault Ares 546 556 566 616 626 636 696 Tractor Workshop Service Repair Manual
J1 – LIFT AND FRONT POWER TAKE-OFF
FRONT LIFT
CHARACTERISTICS J1 2
EXPLODED VIEW J1 3
TIGHTENING TORQUES J1 4
MEASUREMENT AND CHECKING POINTS
CHECKING THE JACK PRESSURE J1 5
“CONTROL VALUES STATEMENT” SHEET
CHECKING THE JACK PRESSURE J1 6
FRONT POWER TAKE-OFF
CHARACTERISTICS J1 7
EXPLODED VIEW OF THE UNIT J1 8
REMOVAL / REFITTING OF THE UNIT J1 9
CLUTCH DISASSEMBLY J1 10
EXPLODED VIEW OF THE HOUSING J1 11
MEASUREMENT AND CHECKING POINTS
CHECKING THE CLUTCH FEED PRESSURE J1 12
“CONTROL VALUES STATEMENT” SHEET
CHECKING THE CLUTCH FEED PRESSURE J1 13
HOW IT WORKS
MEASUREMENT AND CHECKING POINTS J2 3
WITH THE ENGINE RUNNING, AND TRAILOR CONNECTED, NO ACTION OF BRAKES J2 4
WITH THE ENGINE RUNNING AND TRAILOR CONNECTED, SERVICE BRAKES APPLIED J2 6
WITH THE ENGINE RUNNING AND TRAILOR CONNECTED, HAND BRAKE APPLIED J2 8
MAIN COMPONENTS
COMPRESSOR J2 10
PRSSURE REGULATOR J2 10
RESERVOIR J2 10
TRAILOR CONTROL VALVE J2 11
SOLENOID VALVE J2 11
PRINCIPAL CONTROL VALVE J2 12
BLEEDING THE HYDRAULIC AND PNEUMATIC TRAILOR BRAKING SYSTEM J2 12
TOOLS
LIFT, FRONT POWER TAKE-OFF AND PNEUMATIC BRAKING TOOLS J2 13
G1 – INSTRUMENT PANEL
GENERAL
DESCRIPTION OF PANEL G1 3
ALLOCATION OF LIGHT BULBS TO WARNING LIGHTS G1 4
INDICATOR OPERATION G1 5
TEMPERATURE DISPLAY AND DIESEL GAUGE G1 8
ALARM LIGHTS (RED) G1 11
METADIAG BREAKDOWN DIAGNOSIS
REMOVAL/REFITTING CONNECTORS “JX1” AND “JX2” G1 16
CONNECTION AND FUNCTIONS OF THE WIRES OF THE DOUBLE CONNECTOR “JX2” G1 17
CONNECTION AND FUNCTIONS OF THE WIRES OF THE SINGLE CONNECTOR “JX1” G1 18
METADIAG CONNECTION FOR INSTRUMENT PANEL APPLICATION G1 19
CALIBRATION ON 100 METRES G1 22
LOW PRESSURE OIL PRESSURE SENSOR G1 23
ENGINE OIL PRESSURE SENSOR G1 23
OIL TEMPERATURE SENSOR G1 23
SPEED SENSOR G1 24
TOOLS
INSTRUMENT PANEL TOOLS G1 25
G2 – ELECTRONIC/RADAR LIFT
PRESENTATION
SIMPLIFIED VERSION: TCE 15 G2 2
SIMPLIFIED VERSION: TCE 25 G2 2
ACCESS TO THE INSTALLED SOFTWARE VERSION (TCE 15, TCE 25) G2 3
LINKAGE OPERATION CONDITIONS G2 3
VERSION TCE 15 T G2 4
LINKAGE OPERATION CONDITIONS G2 4
CHECKS AND ADJUSTMENTS
POSITION AND SPEED SENSORS G2 6
CONNECTIONS ON UNITS TCE 15/TCE 25 G2 7
CONNECTIONS ON UNITS TCE 15 T G2 8
STRESS SENSOR G2 9
POSITION SENSOR G2 9
THEORETICAL SPEED SENSOR G2 10
METADIAG BREAKDOWN DIAGNOSIS
APPLICATION TCE 15 T/TCE 15-25
METADIAG CONNECTION FOR APPLICATION TCE 15 T G2 12
INSPECTIONS G2 12
METADIAG CONNECTION FOR APPLICATION TCE 15/TCE 25 G2 13
INSPECTIONS G2 13
METADIAG USE G2 14
TOOLS
ELECTRONIC LIFT TOOL G2 20
G3 – DRIVETRONIC III
PRESENTATION
FUNCTIONING MODE G3 2
GEOGRAPHICAL SITUATION OF CONTROLS G3 3
GEOGRAPHICAL SITUATION OF SENSORS AND SOLENOIDS
OPEN CENTRE CIRCUIT G3 4
GEOGRAPHICAL SITUATION OF SENSORS, SOLENOIDS AND SWITCHES
CLOSED CENTRE CIRCUIT G3 5
BLOCK DIAGRAM OF THE UCE G3 6
FUNCTIONS OF THE BLACK SWITCH (INPUTS) G3 7
FUNCTIONS OF THE RED SWITCH (OUTPUTS) G3 8
ELECTRICAL COMPONENTS
FEATURES/SETTINGS G3 10
ADJUSTING THE PEDAL POSITION AND STROKE G3 11
CALIBRATING THE REVERSHIFT CLUTCHES G3 12
POTENTIOMETER G3 12
INVERTER LEVER G3 13
CLUTCH CONTROL CYCLE G3 14
REVERSHIFT SOLENOIDS (EVP1 AND EVP2) G3 15
TWINSHIFT AND QUADRISHIFT II CONTROL SWITCHES G3 16
QUADRISHIFT SOLENOIDS (EV1 AND EV2) G3 17
ELECTROHYDRAULIC RANGE CHANGE G3 18
QUADRISHIFT II AUTOMATIC SYSTEM CONTROL SWITCH G3 19
QUADRACTIV CONTROL SWITCH G3 19
ACCELERATOR PEDAL ANGLE DETECTOR G3 22
SENSORS G3 24
TRANSMISSION DISPLAY (TWINSHIFT / QUADRISHIFT II / QUADRACTIV) G3 25
FUNCTIONS
FRONT AXLE G3 28
FRONT AXLE ELECTRONIC MANAGEMENT MODES G3 29
REAR AXLE G3 30
REAR AXLE ELECTRONIC MANAGEMENT MODES G3 31
WET CLUTCH G3 32
TWINSHIFT / QUADRISHIFT II G3 33
QUADRISHIFT II AUTOMATIC SYSTEM CONTROLS G3 34
QUADRISHIFT II/QUADRACTIV TRANSMISSION ELECTRONIC MANAGEMENT MODES G3 35
TWINSHIFT/QUADRISHIFT II/QUADRACTIV TRANSMISSION ELECTRONIC MANAGEMENT MODES G3 36
REAR POWER TAKE-OFF G3 38
REAR POWER TAKE-OFF ELECTRONIC MANAGEMENT MODES
ELECTRONIC POWER TAKE-OFF CONTROL G3 40
STARTER SAFETY DEVICE G3 41
METADIAG DIAGNOSIS
METADIAG CONNECTION G3 44
METADIAG LAUNCH G3 45
METADIAG USE G3 46
TRANSMISSION BLOCK DIAGRAM G3 47
UCE STATES G3 48
ERROR CODES G3 48
ELECTRICAL TESTS: SUPPLY AND SAFETY G3 50
ELECTRICAL TESTS: FRONT AXLE G3 51
ELECTRICAL TESTS: REAR POWER TAKE-OFF G3 52
ELECTRICAL TESTS: REVERSHIFT G3 53
ELECTRICAL TESTS: QUADRACTIV G3 54
ELECTRICAL TESTS: RANGES G3 55
ELECTRICAL TESTS: DIFFERENTIAL LOCKING G3 56
ELECTRICAL TESTS: QUADRISHIFT G3 57
ELECTRICAL TESTS: TWINSHIFT G3 59
TOOLS
DRIVETRONIC TOOLS G3 62
G4 – INFOTRAC AND ISO SOCKET
PRESENTATION
FUNCTIONS OF THE ON-BOARD COMPUTER G4 2
DESCRIPTION OF THE FRONT PANEL G4 2
OPERATION G4 3
REMOVAL / INSTALLATION
ELECTRIC CHECKS
REMOVAL OF HOUSING – CHANGING BULBS G4 8
ISO SOCKET G4 9
ISO UNIT G4 9
OUTSIDE TEMPERATURE PROBE G4 9
SCHEMATIC DIAGRAM G4 10
FUNCTIONS OF CONNECTOR WIRES G4 11
ELECTRICAL CHECK OF THE ISO SOCKET G4 12
OUTSIDE AIR TEMPERATURE SENSOR G4 13
CALIBRATING THE FORWARD SPEED G4 14
G5 – ELECTROPILOT
PRESENTATION
CONTROL DESCRIPTION G5 2
CONNECTIONS TO THE JOYSTICK G5 3
SWITCH CONNECTIONS G5 3
CONNECTIONS ON UNIT G5 3
ELECTROHYDRAULIC DISTRIBUTOR G5 4
CONTROL HANDLE FITTING (JOYSTICK) G5 5
ELECTRIC CHECKS G5 6
METADIAG BREAKDOWN DIAGNOSIS
METADIAG CONNECTION G5 8
METADIAG USE G5 9
TOOLS
ELECTROPILOT TOOLS G5 16
LOCATION OF COMPONENTS AND SENSORS
CLOSED CENTRE CIRCUIT 100 LITRES G6 2
SCHEMATIC DIAGRAM
ELECTROHYDRAULIC RANGE CHANGE G6 4
DRIVETRONIC G6 4
ADJUSTMENTS
TOC, BOC SWITCHES AND ANGLE DETECTOR G6 8
ACCELERATOR PEDAL ANGLE DETECTOR G6 10
STATIC CALIBRATION OF CLUTCHES G6 10
METADIAG APPLICATION
ARÈS DRIVETRONIC 3 APPLICATION G6 11
TRANSMISSION BLOCK DIAGRAM G6 12
ELECTRICAL TESTS G6 13
CONDITIONS FOR PLACING THE TRACTOR IN GRADUATED MODE
DEFECT ON THE TRACTOR’S FORWARD SPEED SENSOR G6 16
DEFECT ON AT LEAST ONE QUADRISHIFT CONTROL SOLENOID G6 16
CAN DEFECT G6 16
G7 – ENGINE MANAGEMENT TIER II
ENGINE MANAGEMENT
LOCATION OF COMPONENTS AND SENSORS G7 2
FEATURES OF COMPONENTS AND CONNECTIONS G7 4
ADJUSTING THE ACCELERATOR DETECTOR G7 11
METADIAG APPLICATION G7 12
SPN AND FMI CODES G7 13
TOOLS
ENGINE MANAGEMENT TOOLS G7 51
GENERAL CONTENTS
ITEM LIST F 2
WIRING AND GENERAL LISTS F 3
SCHEMATIC DIAGRAMS ACCORDING TO FUNCTIONS F 5
CONNECTOR AND HARNESS TRACKING F 85
TOOLS
ELECTRICITY TOOLS F 160
E1 – OPEN CENTRE HYDRAULICS
PRESENTATION
CHARACTERISTICS E1 2
HYDRAULIC CIRCUIT E1 3
HYDRAULIC CIRCUIT – LAYOUT OF ITEMS E1 4
TIGHTNESS TORQUES OF HYDRAULIC COMPONENTS AND CONNECTIONS E1 5
REMOVAL/REFITTING OF ELEMENTS
RH COVER E1 9
HIGH PRESSURE VALVE E1 13
HYDRAULIC PUMP E1 14
BRAKING VALVE E1 19
SUPPLY PLATE AND DISTRIBUTORS E1 23
SUPPLY PLATE E1 24
LIFTING DISTRIBUTOR E1 25
AUXILIARY DISTRIBUTOR 3 POSITIONS E1 26
CONTROL ADJUSTMENTS E1 30
LIFTING JACKS E1 32
STEERING UNIT E1 33
ACCESS TO STEERING UNIT E1 35
LIFT COVER E1 38
MEASUREMENT AND CHECKING POINTS
“CONTROL VALUES STATEMENT” SHEET E1 45
LIFTING E1 45
STEERING ACTUATOR E1 46
STEERING UNIT E1 46
STEERING DIAGNOSIS
DIFFICULT STEERING WHEEL MANOEUVRES E1 48
ABNORMAL STEERING WHEEL VIBRATIONS – “SHIMMY” (OSCILLATIONS) IN STEERING –
INACCURATE STEERING – SHIM CLEARANCE TAKE-UP E1 50
HYDRAULIC TOOLS E1 52
E2 – CLOSED CENTRE HYDRAULICS (110 L/MIN)
PRESENTATION
CHARACTERISTICS E2 2
HYDRAULIC CIRCUIT E2 3
HYDRAULIC CIRCUIT – LAYOUT OF ITEMS E2 4
TIGHTNESS TORQUES OF HYDRAULIC COMPONENTS AND CONNECTIONS E2 5
REMOVAL/REFITTING OF ELEMENTS
RH COVER E2 8
VARIABLE CAPACITY PUMP E2 14
PRIORITY UNITS (NO TRAILOR BRAKE) E2 15
PRIORITY UNITS (WITH TRAILOR BRAKE) E2 16
LH COVER E2 17
BOOSTER PUMP E2 21
REPLACEMENT OF PUMP SEALS E2 22
SUPPLY PLATE AND DISTRIBUTORS E2 23
SUPPLY PLATE E2 24
AUXILIARY DISTRIBUTOR 3 POSITIONS “ZF” OPTION “KO” E2 26
AUXILIARY DISTRIBUTOR 4 POSITIONS “KO – ZF” E2 27
AUXILIARY DISTRIBUTOR WITH ELECTROHYDRAULIC CONTROLS E2 28
CLOSING PLATE E2 29
CONTROL ADJUSTMENTS E2 31
MEASUREMENT AND CHECKING POINTS
POWER TAKE-OFFS E2 36
VARIABLE CAPACITY PUMP SUPERCHARGE PRESSURE E2 37
IDLING PRESSURE AND XLS PRESSURE E2 37
FLOW AND MAXIMUM PRESSURE E2 38
CHECKING THE AUXILIARY DISTRIBUTORS FLOW REGULATOR E2 39
AUXILIARY DISTRIBUTOR WITH AUTOMATIC RETURN TO NEUTRAL E2 39
LIFTING E2 39
STEERING E2 39
“CONTROL VALUES STATEMENT” SHEET E2 40
HYDRAULIC TOOLS E2 42
E3 – CLOSED CENTRE HYDRAULICS (100 L/MIN)
PRESENTATION
CHARACTERISTICS E3 2
TIGHTNESS TORQUES OF HYDRAULIC CONNECTIONS E3 3
GENERAL HYDRAULIC CIRCUIT CLOSED CENTRE LS 100 L/MIN E3 4
LH HYDRAULIC COVER E3 7
RH HYDRAULIC COVER (WITH BRAKING VALVE) E3 8
GEOGRAPHICAL SITUATION OF THE HYDRAULIC COMPONENTS ON THE PRIORITY UNIT E3 9
REMOVAL/REFITTING OF ELEMENTS
REMOVAL/REFITTING THE RH COVER E3 10
REMOVAL/REFITTING THE MAIN PUMP E3 10
REPLACING THE RH COVER E3 11
ADJUSTING THE SENSOR E3 11
REMOVAL/REFITTING THE LH COVER E3 12
REMOVAL/REFITTING THE STEERING PUMP E3 12
TABLE OF THE OTHER ELEMENTS, COMMON TO THE HYDRAULIC CIRCUITS CLOSED CENTRE 110 L/MIN AND
OPEN CENTRE E3 13
STEERING MEASUREMENT AND CHECKING POINTS
CHECKING THE STEERING PUMP E3 14
CHECKING THE STEERING GEAR BOX AND ACTUATOR E3 14
STEERING “CONTROL VALUES STATEMENT” SHEET
STEERING “CONTROL VALUES STATEMENT” SHEET E3 15
HYDRAULIC MEASUREMENT AND CHECKING POINTS
CHECKING THE IDLING PRESSURE OF THE 14 CM3 PUMP E3 16
CHECKING PRESSURES FOR A FLOW LESS THAN 40 L/MIN AND A FLOW OF 60 L/MIN E3 17
CHECKING THE MINIMUM/MAXIMUM FLOW OF THE AUXILIARY DISTRIBUTORS E3 19
CHECKING THE BRAKING VALVE E3 19
HYDRAULIC “CONTROL VALUES STATEMENT” SHEET
HYDRAULIC “CONTROL VALUES STATEMENT” SHEET E3 20
TOOLS
HIGH PRESSURE AND STEERING HYDRAULIC CIRCUIT TOOLS E3 21
D1-1 – STANDARD FRONT AXLE
PRESENTATION
GENERAL SPECIFICATIONS D1-1 2
DIFFERENTIAL AND BEVEL GEAR D1-1 4
EPICYCLOID REDUCER AND UNIVERSAL DRIVE SHAFT D1-1 4
TORQUE LOADINGS AND SETTINGS D1-1 5
USE OF SPECIAL TOOLING D1-1 6
GEOGRAPHICAL SITUATION OF CONTROL ELEMENTS D1-1 6
OPERATING DIAGRAM D1-1 7
MAINTENANCE D1-1 8
REMOVAL / INSTALLATION
PRELIMINARY OPERATIONS D1-1 10
ADJUSTING THE WHEEL ALIGNMENT D1-1 10
STEERING LINKS AND ACTUATOR D1-1 11
EPICYCLOID REDUCERS AND WHEEL HUBS D1-1 12
WHEEL PINS – UNIVERSAL DRIVE SHAFTS D1-1 14
AXLE BODY D1-1 15
CROWN WHEEL-BEVEL GEAR AND DIFFERENTIAL – AXLE A 86-1 D1-1 16
CROWN WHEEL-BEVEL GEAR AND DIFFERENTIAL – AXLE A 87-2 D1-1 17
CROWN WHEEL-BEVEL GEAR AND DIFFERENTIAL – AXLE A 88-3 D1-1 18
SETTING THE FINAL DRIVE D1-1 19
ADJUSTMENT OF THE PINION PROTRUSION D1-1 19
SETTING THE FINAL DRIVE PRE-LOAD D1-1 20
ADJUSTMENT OF THE MESHING BACKLASH D1-1 20
DIFFERENTIAL BEARING BLOCK PRE-LOAD D1-1 20
FINAL REASSEMBLY D1-1 20
HYDRAULIC CHECKS
“CONTROL VALUES STATEMENT” SHEET
PRESSURE INTAKE ON THE A 88-3 AXLE DIFFERENTIAL LOCKING CIRCUIT D1-1 22
ELECTRIC CHECKS
WIRING ON DRIVETRONIC III D1-1 24
STANDARD FRONT AXLE TOOLS D1-1 26
D1-2 – PROACTIV FRONT AXLE
PRESENTATION
GENERAL SPECIFICATIONS D1-2 2
TORQUE LOADINGS AND SETTINGS D1-2 4
LAYOUT OF ITEMS D1-2 5
OPERATION D1-2 6
DIFFERENTIAL LOCKING D1-2 6
FRONT AXLE ENGAGEMENT D1-2 6
SUSPENSION D1-2 6
OPERATING DIAGRAM D1-2 7
MAINTENANCE D1-2 8
REMOVAL / INSTALLATION
PRELIMINARY OPERATIONS D1-2 10
ADJUSTING THE WHEEL ALIGNMENT D1-2 10
STEERING LINKS AND ACTUATOR D1-2 11
EPICYCLOID REDUCERS AND WHEEL HUBS D1-2 12
EPICYCLOID REDUCER D1-2 13
WHEEL HUB D1-2 13
WHEEL SWIVEL PINS AND UPPER ARM D1-2 14
WHEEL SWIVEL PIN D1-2 15
UPPER ARM D1-2 15
SUSPENSION CYLINDER AND LOWER ARM D1-2 16
WHEEL PIVOTS D1-2 16
LOWER ARM AND TORSION BAR D1-2 17
SETTING THE TORSION BAR PRE-LOADS D1-2 18
UNIVERSAL JOINT SHAFTS D1-2 19
BEVEL GEAR AND DIFFERENTIAL D1-2 20
ADJUSTMENT OF THE PINION PROTRUSION D1-2 20
SETTING THE FINAL DRIVE PRE-LOAD D1-2 20
ADJUSTMENT OF THE MESHING BACKLASH D1-2 23
DIFFERENTIAL BEARING BLOCK PRE-LOAD D1-2 23
INSTALLATION D1-2 23
SUSPENSION POSITION SENSOR D1-2 24
HYDRAULIC CHECKS
CHECK GROUP D1-2 26
ACCUMULATOR INFLATION D1-2 28
“CONTROL VALUES STATEMENT” SHEET D1-2 29
PRESSURE INTAKE ON THE DIFFERENTIAL LOCKING CIRCUIT D1-2 29
PRESSURE INTAKE AT THE LEVEL OF THE SUSPENSION CYLINDERS D1-2 30
PRESSURE INTAKE OF THE “LS” SIGNAL D1-2 31
ELECTRIC CHECKS
CONTROL SWITCHES D1-2 34
SUSPENSION CONTROL SOLENOIDS D1-2 35
SUSPENSION SENSORS D1-2 36
CALIBRATING THE SUSPENSION D1-2 37
WIRING ON DRIVETRONIC III D1-2 38
BREAKDOWN DIAGNOSIS
VALUES TO BE CHECKED D1-2 40
INTERPRETING ERROR CODES D1-2 41
TOOLS
PROACTIV FRONT AXLE TOOLS D1-2 44
C1 – REAR AXLE
PRESENTATION
TECHNICAL SPECIFICATIONS C1 7
REAR TRANSMISSION UNIT (CROSS SECTION) C1 7
CENTRAL HOUSING UNIT (LENGTHWIDE SECTION) C1 8
SHD HEAVY DUTY AXLE TUBES
OVERALL AND EXPLODED VIEW C1 12
AXLE TUBE ASSEMBLY C1 13
PLANET CARRIER C1 15
BEARINGS AND SEALS C1 16
PRELOAD OF THE AXLE SHAFT BEARINGS (P1) C1 17
REPLACING THE WHEEL STUD C1 17
SHD HEAVY DUTY AXLE TUBES
OVERALL AND EXPLODED VIEW C1 20
AXLE TUBE ASSEMBLY C1 21
PLANET CARRIER C1 23
BEARINGS AND SEALS C1 24
PRELOAD OF THE AXLE SHAFT BEARINGS (P1) C1 25
REPLACING THE WHEEL STUD C1 25
DIFFERENTIAL
OVERALL AND EXPLODED VIEW C1 28
DISASSEMBLY AND REASSEMBLY OF THE DIFFERENTIAL LOCK C1 29
DIFFERENTIAL REMOVAL C1 30
DISASSEMBLING THE DIFFERENTIAL AND THE CROWN WHEEL C1 31
REMOVAL AND DISASSEMBLY OF THE DRIVE PINION C1 31
ADJUSTMENT OF THE PINION PROTUSION DISTANCE (P3) C1 32
PRELOAD ADJUSTMENT OF THE DRIVE PINION BEARINGS (P1) C1 33
PRELOAD ADJUSTMENT OF THE BEARINGS OF THE DIFFERENTIAL BEARING BLOCKS (P2) C1 34
BACKLASH ADJUSTMENT (J2) C1 35
REASSEMBLY OF THE CROWN WHEEL AND DIFFERENTIAL C1 36
REASSEMBLY AND INSTALLATION OF THE DRIVE PINION C1 36
REAR POWER TAKE-OFF
TECHNICAL SPECIFICATIONS C1 38
OVERALL VIEW C1 39
REAR POWER TAKE OFF CLUTCH
OVERALL AND EXPLODED VIEW C1 42
REMOVAL/REFITTING THE POWER TAKE-OFF CLUTCH C1 43
CLUTCH DISSASSEMBLY AND REASSEMBLY C1 44
UPPER SHAFT REAR POWER TAKE-OFF
EXPLODED VIEW C1 48
2 SPEED POWER TAKE-OFF UPPER SHAFT (WITHOUT ADJUSTMENT) C1 49
2 SPEED POWER TAKE-OFF UPPER SHAFT (WITH ADJUSTMENT) C1 50
4 ECONOMICAL SPEED POWER TAKE-OFF UPPER SHAFT (WITHOUT ADJUSTMENT) C1 52
4 ECONOMICAL SPEED POWER TAKE-OFF (WITH ADJUSTMENT) C1 54
ECONOMY POWER TAKE-OFF CONTROLS C1 55
LOWER SHAFT REAR POWER TAKE-OFF
OVERALL AND EXPLODED VIEW C1 58
REMOVAL-INSTALLATION OF THE STUB SHAFT C1 59
REMOVAL-INSTALLATION OF THE REAR BEARING C1 59
DISASSEMBLY AND REASSEMBLY OF THE 540 AND 1000 RPM PINIONS AND OF THE FRONT BEARING C1 60
PROPORTIONAL POWER TAKE-OFF
OVERALL AND EXPLODED VIEW C1 62
POWER TAKE-OFF DISASSEMBLY C1 63
POWER TAKE-OFF REASSEMBLY C1 65
ASSEMBLY AND ADJUSTMENT OF THE CONTROL CABLE C1 67
DETAIL OF THE PROPORTIONAL PTO CONTROL C1 68
TOOLS
REAR AXLE TOOLS AND REAR POWER TAKE-OFF C1 70
C2 – SERVICE BRAKES – HAND BRAKE
PRESENTATION
CHARACTERISTICS C2 2
BRAKE PISTONS AND SEALS
DRAINING THE OPERATING BRAKE CIRCUIT C2 3
SERVICE BRAKE C2 4
TRACTORS NOT EQUIPPED WITH BOOSTERS
PRESENTATION C2 7
ASSEMBLING THE MASTER CYLINDERS C2 7
TRACTORS EQUIPPED WITH BOOSTERS AND BRAKING VALVE
OPEN CENTRE HYDRAULIC CIRCUIT C2 8
CLOSED CENTRE HYDRAULIC CIRCUIT (LS 110 L/MIN) C2 8
CLOSED CENTRE HYDRAULIC CIRCUIT (LS 100 L/MIN) C2 9
TRACTORS FITTED WITH BOOSTERS LUCAS
MASTER CYLINDER/BOOSTER EXCHANGE AND ADJUSTMENT C2 10
TRACTORS FITTED WITH BOOSTERS IRUNA
DESCRIPTION OF MASTER CYLINDERS/BOOSTERS IRUNA C2 15
ADJUSTMENT OF THE BRAKE PEDALS
ADJUSTMENT PROCEDURE C2 16
BLEEDING THE BRAKING CIRCUIT
INITIAL CHECKS C2 17
MANUAL BLEEDING OF THE SERVICE BRAKE CIRCUIT C2 18
BLEEDING THE BRAKING CIRCUIT (WITH DRAIN COCK) C2 21
CHECKING THE EFFECTIVENESS OF THE AIR BLEED C2 23
HAND BRAKE
PRESENTATION C2 24
REMOVAL / INSTALLATION C2 26
HAND BRAKE ADJUSTMENT C2 28
TOOLS
SERVICE BRAKE AND HAND BRAKE TOOLS C2 30
C3 – 4 WD POWER TAKE-OFF HOUSING
PRESENTATION
TECHNICAL SPECIFICATIONS C3 7
REMOVAL / INSTALLATION
OVERALL AND EXPLODED VIEW C3 10
CLUTCH ASSEMBLY REMOVAL C3 11
CLUTCH DISASSEMBLY C3 12
CLUTCH REASSEMBLY C3 12
CLUTCH ASSEMBLY INSTALLATION C3 13
TOOLS
4 WD POWER TAKE-OFF HOUSING TOOLS C3 17
C4 – REAR AXLE ADDITIVE TIER II
GENERAL SPECIFICATIONS
REAR AXLE C4 2
HD+ GPA 22+ HEAVY DUTY AXLE TUBES C4 3
PROPORTIONAL POWER TAKE-OFF
PRESENTATION C4 4
REMOVAL / REFITTING THE HOUSING C4 7
SETTING THE CONTROLS C4 8
SWITCH OPERATION C4 8
B1 – GBA 20 GEARBOX
GENERAL SPECIFICATIONS
PRESENTATION B1 3
GEARBOX B1 4
REVERSHIFT CLUTCH B1 4
QUADRISHIFT B1 4
TWINSHIFT B1 4
OPERATING DIAGRAM B1 5
GTA 2022 – QUADRISHIFT B1 5
GTA 2022 – TWINSHIFT B1 5
GTA 2023 – QUADRISHIFT B1 5
GTA 2023 – TWINSHIFT B1 5
DISMANTLING/ASSEMBLY RANGE SUMMARY B1 6
TIGHTENING TORQUES AND PRINCIPAL ADJUSTMENTS
MAIN CLUTCH – FORWARD B1 8-1 9
MAIN CLUTCH – REVERSE B1 9
INPUT UNIT B1 10
GEARBOX – ADJUSTMENT VALUES B1 12
COUPLING SPACER RING / GEARBOX B1 13
COUPLING GEARBOX / REAR AXLE B1 13
REVERSHIFT CLUTCH POWERCLUTCH FRONT AND REAR
“POWERCLUTCH” WET CLUTCHES B1 16
REVERSER UNDER TORQUE(ISC)CLUTCH OPERATING DIAGRAM B1 17
FORWARD B1 17
REVERSE B1 17
NEUTRAL B1 17
DISMANTLING RANGE – ACCESS TO FRONT CLUTCH B1 17
FRONT CLUTCH B1 18
FRONT CLUTCH REMOVAL, REPLACEMENT AND TIMING B1 19
FRONT CLUTCH DISMANTLING AND REASSEMBLY B1 20
INSTALLATION B1 21
DISMANTLING RANGE – ACCESS TO REAR CLUTCH B1 21
REAR CLUTCH B1 22
REAR CLUTCH REMOVAL AND REPLACEMENT B1 23
QUADRISHIFT UNIT
GENERAL B1 28
OPERATING DIAGRAM B1 28
QUADRISHIFT INLET UNIT REMOVAL RANGE B1 29
CLUTCH AND REAR BRAKE B1 30
PRELIMINARY OPERATIONS B1 31
REMOVAL OF HOUSING B1 31
REMOVAL AND SEPARATION OF THE PLANET CARRIER UNIT B1 32
ASSEMBLING THE PLANET CARRIERS B1 32
DISMANTLING THE REAR CLUTCH AND THE BRAKE B1 32
REMOVAL/ASSEMBLY OF THE BEARINGS AND THE UNIT OUTLET SHAFT B1 33
CLUTCH AND FRONT BRAKE B1 36
REMOVAL AND REFITTING THE CLUTCH HOUSING COVER AND THE BRAKE B1 37
TWINSHIFT UNIT
GENERAL B1 40
OPERATING DIAGRAM B1 40
TWINSHIFT INLET UNIT REMOVAL RANGE B1 41
REMOVAL OF INLET UNIT B1 42
ADJUSTING THE PRELOAD P4 B1 43
REMOVAL/REFITTING THE SHAFT AND OUTLET PINION B1 44
REMOVAL OF THE PLANET CARRIER UNIT B1 44
REMOVAL OF HYDRAULIC COVER B1 44
REFITTING THE PLANET CARRIER B1 45
REFITTING THE HYDRAULIC COVER B1 46
ASSEMBLING THE PLANET CARRIER B1 47
REFITTING THE FRONT COVER B1 47
PRIMARY SHAFT
GENERAL B1 50
PRIMARY SHAFT REMOVAL/REFITTING RANGE B1 50
PRELIMINARY OPERATIONS B1 50
REMOVAL B1 52
INSTALLATION B1 52
REFITTING THE INLET UNIT AND PRIMARY SHAFT TIMING B1 53
REAR INTERMEDIARY SHAFT
GENERAL B1 56
REAR INTERMEDIARY SHAFT REMOVAL/REFITTING RANGE B1 56
REMOVAL OF OUTLET SHAFT B1 58
REAR INTERMEDIARY SHAFT REFITTING AND TIMING B1 59
FRONT INTERMEDIARY SHAFT
GENERAL B1 62
FRONT INTERMEDIARY SHAFT REMOVAL/REFITTING RANGE B1 62
PRELIMINARY OPERATIONS B1 62
REMOVAL/ REFITTING AND ASSEMBLY OF THE FRONT INTERMEDIARY SHAFT B1 64
RIGHT COVER AND FORKS
OPERATING PRINCIPLES B1 68
TIGHTNESS TORQUES OF SCREWS ON COVER B1 70
TIGHTNESS TORQUES GUIDE RODS AND FORKS B1 71
GEAR FORK LOCKING ADJUSTMENT B1 72
REMOVAL OF RIGHT COVER B1 73
DISMANTLING THE COVER B1 73
INSTALLATION B1 73
ADJUSTING THE RANGE FORK AND CAM FOLLOWER B1 74
REFITTING THE COVER B1 75
ADJUSTING THE GEAR CONTROL CABLES B1 76
CRAWLER SPEEDS
GENERAL B1 78
OPERATION B1 78
OVERALL VIEW B1 79
REMOVAL OF HOUSING AND CROWN WHEEL B1 80
EXPLODED VIEW B1 80
DISMANTLING THE PLANET CARRIER B1 81
REFITTING THE PLANET CARRIER AND REPLACNG THE HOUSING B1 81
FINAL STEPS B1 81
SETTING THE CONTROLS B1 82
TOOLS
GEARBOX TOOLS B1 84
B2 – LOW PRESSURE HYDRAULIC CIRCUIT
PRESENTATION
OPEN CENTRE CIRCUIT B2 3
CLOSED CENTRER CIRCUIT B2 4
LOW PRESSURE OPEN CENTRE HYDRAULIC CIRCUIT
(FED BY THE ORBITROL STEERING UNIT RETURN) B2 5
LOW PRESSURE CLOSED CENTRE HYDRAULIC CIRCUITLOW PRESSURE OPEN CENTRE HYDRAULIC CIRCUIT
(FED BY THE SAFETY UNIT) B2 6
GEARBOX CONTROL AND LUBRICATION
DISTRIBUTION VALVE B2 9
ARES 500 B2 9
ARES 600 B2 9
CONTROL B2 10
LUBRICATION B2 14
MEASUREMENT AND CHECKING POINTS
REVERSHIFT HYDRAULIC UNIT B2 19
“CONTROL VALUES STATEMENT” SHEET B2 19
QUADRISHIFT HYDRAULIC UNIT B2 20
“CONTROL VALUES STATEMENT” SHEET B2 20
TWINSHIFT HYDRAULIC UNIT B2 21
“CONTROL VALUES STATEMENT” SHEET B2 21
OPEN CENTRE HYDRAULIC CIRCUIT ARÈS 500-600
(CHECK VALID FOR CLOSED CENTRE CIRCUIT, UNLESS OTHERWISE INDICATED) B2 22
“CONTROL VALUES STATEMENT” SHEET B2 22
REAR AXLE CONTROL AND LUBRICATION
OPEN CENTRE CIRCUIT B2 25
CLOSED CENTRE CIRCUIT B2 26
MEASUREMENT AND CHECKING POINTS
LUBRICATION CIRCUIT B2 27
CONTROL AND LUBRICATION CIRCUIT B2 28-2 29
OPEN CENTRE: ARÈS 500-600 TRACTORS B2 33
“CONTROL VALUES STATEMENT” SHEET B2 33
OPEN CENTRE: TRACTORS ARÈS 600 WITH BRAKING BOOSTER B2 34
“CONTROL VALUES STATEMENT” SHEET B2 34
CLOSED CENTRE: ARÈS 500 TRACTORS B2 35
“CONTROL VALUES STATEMENT” SHEET B2 35
“CONTROL VALUES STATEMENT” SHEET B2 36
TOOLS
LOW PRESSURE HYDRAULIC CIRCUIT TOOLS B2 38
B3 – GEARBOX ADDITIVE TIER II
GENERAL SPECIFICATIONS
PRESENTATION B3 2
QUADRISHIFT OVERDRIVE OPERATING DIAGRAM B3 2
REAR INTERMEDIARY SHAFT
REAR INTERMEDIARY SHAFT TIMING B3 3
FINAL FITTING OF THE REAR INTERMEDIARY SHAFT B3 6
B4 – LOW PRESSURE HYDRAULIC CIRCUIT ADDITIVE TIER II
PRESENTATION
CLOSED CENTRE CIRCUIT DEPTH OF ENTRY LS 100 L/MIN B4 2
LOW PRESSURE CLOSED CENTRE HYDRAULIC CIRCUIT LS 100 L/MIN B4 3
DISTRIBUTION VALVE B4 4
LUBRICATION LS 100 L/MIN CIRCUIT
GEARBOX AND POWER TAKE-OFF B4 5
BRAKES B4 6
MEASUREMENT AND CHECKING POINTS
CHECKING THE FLOW COMING FROM THE STEERING BOX B4 7
CHECKING THE CONTROL PRESSURE B4 7
CHECKING THE COOLER BYPASS B4 8
CHECKING THE LUBRICATION PRESSURE B4 8
“CONTROL VALUES STATEMENT” SHEET
“CONTROL VALUES STATEMENT” SHEET B4 9
TOOLS
LOW PRESSURE HYDRAULIC CIRCUIT TOOLS B4 11
A0 – INJECTION DATA SHEETS
A1 – INJECTION FEED TIER I
IDENTIFICATION
INJECTION PUMPS IDENTIFICATION A1 2
CHARACTERISTICS
MAIN CHARACTERISTICS A1 4
ENGINES 4 CYLINDERS A1 4
ENGINES 6 CYLINDERS A1 5
TIGHTENING TORQUES
TIGHTENING TORQUES A1 8
OPERATING PRINCIPLES
POWER SUPPLY A1 10
PRE-FILTER A1 11
FUEL FILTER A1 11
INJECTION PUMP A1 12
INJECTORS A1 13
CHECKS/ADJUSTMENTS
ENGINE SPEED A1 16
CHECKING THE MAXIMUM NO LOAD SPEED A1 16
CHECKING AND ADJUSTING THE TICK-OVER A1 16
STATIC ADJUSTMENT OF THE INJECTION PUMP A1 17
DYNAMIC ADJUSTMENT OF THE INJECTION PUMP A1 17
INJECTOR ADJUSTMENT A1 21
CRACKING PRESSURE ADJUSTMENT A1 21
NEEDLE STROKE ADJUSTMENT A1 22
SHUT-OFF SOLENOID VALVE FUNCTIONAL CHECK A1 23
COLD-START SWITCH FUNCTIONAL CHECK A1 23
SUPPLY PRESSURE CHECK A1 24
REMOVAL / INSTALLATION
FUEL FILTER REPLACEMENT A1 26
INJECTION SYSTEM BLEEDING A1 26
INJECTION PUMP REMOVAL A1 27
INJECTION PUMP INSTALLATION A1 28
INJECTOR REMOVAL A1 29
INJECTOR SEATING CLEANING (IF REQUIRED) A1 29
INJECTOR INSTALLATION A1 29
CARRYING OVER OF THE ADJUSTMENT MARK ONTO THE FRONT PLATE A1 30
CONTROL ADJUSTMENTS
ADJUSTING THE ACCELERATOR CABLE A1 32
DIAGNOSTIC SHEETS
“ENGINE START UP DEFECT” SHEET A1 34
“IRREGULAR ENGINE OPERATION” SHEET A1 35
“GREY OR BLACK SMOKE EMISSION” SHEET A1 36
“WHITE SMOKE EMISSION” SHEET A1 37
“CHECK THE FUEL FEED CIRCUIT” SHEET A1 38
TOOLS
INJECTION TOOLS A1 40
A2 – ENGINE TIER I
GENERAL SPECIFICATIONS
IDENTIFICATION OF THE ENGINES A2 2
ENGINES 4 CYLINDERS A2 3
ENGINES 6 CYLINDERS A2 4
DIMENSIONAL SPECIFICATIONS
CYLINDER HEAD AND VALVES A2 6
CYLINDER BLOCK A2 8
LINERS AND PISTONS A2 9
CONNECTING RODS A2 10
CRANKSHAFT, BEARINGS AND FLYWHEEL A2 11
CAMSHAFT A2 12
DISTRIBUTION A2 13
LUBRICATION A2 14
OIL PUMP A2 14
COOLING A2 15
THERMOSTAT A2 15
WATER PUMP AND FAN DRIVE SUPPORT A2 15
TURBOCHARGER A2 16
TIGHTENING TORQUES
ENGINE/TRANSMISSION LINK A2 18
FRONT CHASSIS / ENGINE LINK A2 18
OTHER ITEMS A2 19
OPERATING PRINCIPLES
DISTRIBUTOR DIAGRAM A2 22
LUBRICATION SYSTEM A2 23
COOLING CIRCUIT A2 24
CHECKS/ADJUSTMENTS
CHECK OF ENGINE OIL PRESSURE A2 26
CHECK OF COMPRESSION A2 26
CHECK OF VALVE LIFT (ENGINE COLD) A2 27
VALVE CLEARANCE (ENGINE COLD) A2 27
VALVE ADJUSTMENT SEQUENCE A2 28
CHECK OF SUPERCHARGING PRESSURE A2 28
CHECK OF THE BELT AND THE TENSIONER SPRING A2 29
REMOVAL / INSTALLATION
PRELIMINARY OPERATIONS A2 32
SEPARATE ENGINE/FRONT AXLE A2 32
SEPARATE ENGINE/GEARBOX A2 34
ENGINE INSTALLATION SPECIFICATIONS A2 36
CYLINDER HEAD A2 37
CAMSHAFT A2 41
CYLINDER BLOCK A2 42
LINERS A2 43
PISTONS AND CONNECTING RODS A2 46
CRANKSHAFT, BEARINGS, AND FLYWHEEL A2 52
CAMSHAFT, BALANCER SHAFTS AND DISTRIBUTOR A2 61
LUBRICATION A2 67
COOLING A2 72
TURBOCHARGER A2 78
DIAGNOSTIC SHEETS
“EXCESSIVE OIL CONSUMPTION” SHEET A2 80
INSPECTION PROCEDURE OF THE CYLINDER HEAD GASKET A2 81
“ENGINE OIL PRESSURE TOO HIGH” SHEET A2 82
CHECKING PROCEDURE OF THE HIGH OIL PRESSURE IN THE CRANKCASE A2 83
“ENGINE OIL PRESSURE TOO LOW” SHEET A2 84
“COOLING FLUID TEMPERATURE TOO HIGH” SHEET A2 85
“COOLING FLUID TEMPERATURE TOO LOW” SHEET A2 86
FAILURE SEARCHING PROCEDURE OF CYLINDER HEAD SEAL A2 87
TOOLS
ENGINE TOOLS A2 90
A3 – INJECTION ADDITIVE TIER II
TIGHTENING TORQUE
TIGHTENING TORQUE A3 2
OPERATING PRINCIPLES
INJECTION PUMP A3 3
INJECTORS A3 5
SITUATION OF THE DIFFERENT SENSORS A3 5
CHECKS/ADJUSTMENTS
ACCELERATOR CONTROL ADJUSTMENT A3 6
ADJUSTING THE ENGINE INJECTOR A3 7
SUPPLY PRESSURE CHECK A3 8
FUEL FILTER REPLACEMENT A3 9
REMOVAL / INSTALLATION
INJECTION SYSTEM BLEEDING A3 9
INJECTION PUMP REMOVAL A3 11
INJECTION PUMP INSTALLATION A3 11
DIAGNOSTIC SHEETS
DIAGNOSTIC SHEETS A1 34
SPN AND FMI CODES G7
TOOLS
INJECTION FEED TOOLS TIER II A3 13
A4 – ENGINE ADDITIVE TIER II
GENERAL SPECIFICATIONS
IDENTIFICATION OF THE ENGINES A4 2
ENGINES 4 CYLINDERS A4 3
ENGINES 6 CYLINDERS A4 4
DIMENSIONAL SPECIFICATIONS
CONNECTING RODS A4 5
TIGHTENING TORQUES
FRONT CHASSIS / ENGINE LINK A4 6
ENGINE/TRANSMISSION LINK A4 6
CRANKSHAFT WITH STRAIGHT FRONT END A4 7
CRANKSHAFT WITH TAPERING FRONT END A4 7
CHECKS/ADJUSTMENTS
CHECK OF SUPERCHARGING PRESSURE A4 8
PROCEDURE FOR CHECKING THE VISCOUS FAN COUPLING A4 9
REMOVAL / INSTALLATION
ENGINE INSTALLATION SPECIFICATIONS A4 10
REFITTING THE FRONT BEARING SEAL ON THE ENGINES 6068 TRT 70, 6068 TRT 71 AND 6068 TRT 72 A4 11
TOOLS
ENGINE TOOL DPS TIER II A4 13
PLEASE NOTE:
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