Service Manual

A90

A100

A110
1
2
 General

Engine

Electrical
System

Power
Service Manual Transmision

Brake
System

Front
A90 Axle &
Steering
A100
A110
Frame &
Wheels

Cab &
Shields

Hattat Tarım Hydraulics

April, 2011
Çerkezköy
Aletler
Tools

3
4
10. General
11.Layout

12. Maintenance

5
To the reader

The Service Manual for the HATTAT A90, A100, A110 tractors is intended to be a practical reference source to be used in
workshop.

The repair instructions in the manual are based on methods which have been worked out in practice during normal
workshop conditions and which are based on the use of special tools from the manufacturer when stated in the
instructions. The manual also contains descriptions of the design and function of the components.

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

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

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

HATTAT Holding
April 2011

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 Model Page
10. General
A90-A100-A110 1

Layout of Service Manual

1. Division into groups
The manual is divided into groups (10--100) which are based on the make--up of the tractor. The groups are listed on the
firstindexf.

example. 10. General

20. Engine, fuel and cooling systems
30. Electrical system
40. Power transmission
a.s.o.
The number designation for each group is given in the top left box of the respective pages (and the first figure in the code
designation).

2. Division into components or sub—groups

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

Example. 41. Clutch

42. Gearbox
44. Low gear
45.Final drives etc.

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10. General Model Page
A90-A100-A110 2

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

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

Model Page
41. Clutch
A90-A100- A110 1

5. Additions and amendments of the service manual

New and up--dated pages will be continuously added to the service manual. The new pages should be inserted as indicated by
the code: the first digit (also the first digit on the index leaf) indicates the group:
-- the two first digits indicate the component or sub--group.
-- the third digit indicates the document group for the respective components
-- the page number indicates the definite position of the page within the service manual.
If there are two pages with the same code and page number, it is the page with the later date in the date box and the old date
in the crossed--over box which is valid or which is the current page.
When an entirely new set of repair instructions is issued, it will be accompanied by instructions on where the pages should be
inserted in the file.

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 Model Page
10. General
A90-A100-A110 3

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 Model Page
10. General
A90-A100-A110 4
Code designations in the Service Manual Direction indicator flashers and horn (3)

10. General Light switch (4)

11 General, lay out Switch for windscreen was− her (5)
12 Maintenance Switch for windscreen wiper (6)
Instrument panel (2)
20 Engine Fuel gauge (3)
Specifications Section Tachometer (4)
Engine Design Coolant thermometer (1)
Fuel Injection Lines Indicator lights for direction indicator (2)
Fuel Injection Pump Indicator light for main be−am (5)
Fuel Injectors Indicator lights on instrument panel
Fuel Transfer Pump Infoline − instrument panel operating hour meter (2.7)
Lifter Group Right Side panel of instrument panel (3)
Rocker Shaft Ignition switch (3.1)
Valve Mechanism Cover Rear window opening and locking device (2)
Cylinder Head Valves Roof console
Cylinder Head Roof fan (1)
Turbocharger Recirculation control knob (2)
Exhaust Manifold
Camshaft
40 Power transmission
Camshaft Bearings
Engine Oil Filter 41. Clutch
Engine Oil Cooler Technical data
Engine Oil Pump Setting values
Engine Oil Pressure Tightening torques
Engine Oil Bypass Valve Engine Oil Pan Clutch, description
Breather Canister Reconditioning clutch
Water Temperature Regulator and Housing 1. Changing clutch by parting tractor
Water Pump A. Parting tractor at clutch
Cylinder Block B. Removing fitting clutch
Crankshaft C. Assembling tractor at clutch
Crankshaft Seals D. Adjust clutch pedal free travel
Connecting Rod Bearing Journal E. Adjusting PTO clutch lever free travel
Main Bearing Journal 2. Changing clutch without splitting tractor
Connecting Rod A. Fitting clutch
Piston and Rings B. Reconditioning clutch release bearings
Piston Cooling Jet 3. Changing propulsion clutch disc and adjusting
Front Housing and Covers clutch
Gear Group (Front) A. Dismantling clutch
Flywheel B. Assembling and adjusting clutch
Flywheel Housing 50 Brake system
Crankshaft Pulley
Fan Drive 51 . Brake System
Engine Lifting Bracket Technical data
Alternator
Starter Motor Brake system
Glow Plugs Brake cylinder
30 Electrical system Reconditioning brakes
31 Electrical system in general 30 52. Air Brake System
General Diaghram of Air Brake System
Safety precautions for the electrical system
Twin curcuit hydraulically actuated that controlled from
Alternator
tractor air brake system
Battery checks and maintenance
When brake pedal is used that the system working
32 Electric system:
Content When hand brake is used in N position
32 Electric system When brake pedal is used in P position that the system
With Cab Models
Cabless models working
Standard trailer socket
Headlight adjustment
Electric Diagram of Tractor
Instrument panel
Instrument panel
Front panel of instrument panel (1)
Steering wheel adjustment (2)

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 Model Page
10. General
A90-A100-A110 5

60 Front axle and steering system

90 Working Hydraulics, power lift
61. Steering System
Steering System 91.Technical specialities – Valves – Mechanicisms and
Measurement of the steering system, oil pressures Working Principles
Reconditioning steering valve
Fitting steering valve Hydraulic Lift Service Guide
Main Relief Valve Operation
62. Powered Front Axle Changing of System relief valve
Adjustment of system relief valve
Changing the cylinder relief valve
General information Changing the LS (Load Sensing) relief valve
Disassembly of Hub and Planetary Gear Set
Disassembly of Joint Casing 92.Disassembling – Assembling – Adjustments
Assembly of Joint Casing
Disassembly of Steering System
Visual inspection of locking valve and replacement the
Assembly of Steering System parts
Disassembly of Drive Shaft Changing of distributor
Assembly of Drive Shaft Dismantling and re-installation of hydraulic lifts
Disassembly of Differential Unit Disassembly, control and re-assembly of hydraulic lifter
Assembly of Differential Unit arms
Disassembly of Central Housing Removal, controls and re-assamble of hydraulic cylinders
Assembly of Central Housing Setting the operation distance of outer arms of hydraulic
Conversion Table lifter
Explanation The principle of power control mechanisms
Tool numbers Setting of hydraulic lifter power control mechanism
Posıtıon Control
70 Frame and wheels Mıxed Control
Auxılıary Cylınder
Electrıcal Autolıft
71 Frame:
Electrıcal Autolıft Mechanısm Settıng
Front weight support + frame Hydraulıc Lıfter Drıve Settıngs

72 Wheels:
Technical data, technical specifications, training
material

Wheels
Tightening torques, wheel nuts
Tyre pressures and permissible loadings
Track widths

80 Cab And Shield

81 Cab
Cab
Cab Heater

82 Air conditioner
Technical data, technical specifications, training material
Safety precautions
Operating principle
Aır Condıtıoner
Technical data
CIrculation of the refrigerant
Drier
Compressor
Expansion valve

83 Instrument

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 Model Page
10. General
A90-A100-A110 6

General instructions for repairs

Outer oil seals

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

Sealing compound and glue

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

Tightening torques and setting values

Al necessary tightening torques and setting values for each repair operation are given at the beginning of each repair section
under the heading Technical Data. The most important values can also be found in the repair instructions.
Table 1 later gives the tightening torques in order of dimension, quality and surface treatment. The values given in the table
should be used if the tightening torque is not given in the repair instructions.

Safety

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

Trouble--shooting

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

a) Determine the problem

b) List possible causes
c) Differentiate the causes
d) Conduct checks in logical order to determine the exact cause
e) Consider approximate remaining service life against cost of parts and labour..
f) Make any necessary repairs.
g) Recheck the parts and functions for correct operation

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 Model Page
10. General
A90-A100-A110 7

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

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

1) 1 Nm=0,102 kpm
2) Zne=zinc electroplating
3) Znk=hot galvanized
If the bolts differs from the standard range the values in the table must not be used.

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 Model Page
10. General
A90-A100-A110 8

Conversion table for common units

Quantities and units……………………………………………………………………………… Conversion factors

Overall and detail dimensions millimetres (mm) ……………………………………………….. 100 mm=3,94 inches
1 inch=25,4 mm

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

1 ft=0,305 m

Travel distances kilometres ………………………………………………………………………1 km=0,62 mile

1 mile=1,61 km

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

1 lb=0,454 kg

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

1 mph=1,61 km/h

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

1 lb=4,448 N

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

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

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

1 ft lb=1,356 Nm

Fuel consumption by weight (kilograms per hr, kg/h) …………………………………………………1 kg/h=2,2 lb/hr
(by volume) litres per hr (l/h) …………………………………………………………………….. 1 lb=0,454 kg
1 l/h=0,22 gal/hr
1 gal=4,54 l

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

grams per kilowatt hr (g/kWh)

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

100 cu in=1,639

Hydraulic pump …………………………………………………………………………………… 1 MPa=145 psi

pressure-mecapascal (MPa) ……………………………………………………………………. 1000 psi=6,9 MPa
delivery-millimetres per sec (ml/s) ……………………………………………………………… 100 ml/s=1,32 gpm
Tyrepressure-kilopascal (kPa) ………………………………………………………………….. 1 gpm=75,77 ml/s
100 kPa=14,5 psi
1 psi=6,9 kPa

Area acres-hectare ………………………………………………………………………………. To convert multiply by

0,404686

Volume bushel-litre ………………………………………………………………………............ To convert multiply by

39,3687

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

Volume ……………………………………………………………………………………………. Multiply by

superficial foot-cubic metre ……………………………………………………………..............0,002360

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10. General
Maintenance
Note! Detailed maintenance procedures are given in the
Operator’s Manual.
When servicing:
-- Always stop the engine before doing any servicing work.
-- Apply the parking brake to ensure the tractor cannot
move.
If the ground is uneven the wheels should be scotched
-- Always observe the utmost cleanliness in al maintenance
work.
--Thoroughly wipe off filter caps and plugs as well as sur-
rounding parts of the tractor before filling up with fuel or oil.
-- Inspect the oil and filters when changing. Large amounts
of dirt (e.g. heavily clogged filters) can point to a fault which
could cause extensive and costly repairs if not corrected in
time.
-- When carrying out checks the tractor should stand on
level ground.
-- Levels should be checked in the morning when the oil is
cold and has had time to run down to the bottom of the unit
concerned.
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Model Page
A90-A100-A110 9
Lubrication of points provided with grease
nipples
-- Always clean the grease nipples before applying the
grease gun.
-- Pump in grease to the nipples until clean grease is
squeezed out (unless otherwise instructed).
-- Wipe off all surplus grease which has been squeezed
out at the lubricating points.
-- Preferably carry out lubrication with bearing points and
joints unloaded and with the bearings in different position
(e.g. lubricate the steering knuckle bearing on the steering
axle with the wheels at both full left and right lock and with
the front axle lifted up).
Lubrication and maintenance schedule
Al intervals are counted from zero on the hour recorder.
For example, 1000--hour service is carried out every 1000
and 2000 hours according to the hour recorder (yearly or
every other year) even if the operates have been carried
out at the guarantee service.
Example:
The 1000--hour service includes al operates listed under
Daily / every 10 hours, weekly / every 50 hours,250, 500
and 1000 hours.
 Model Page
10. General
A90-A100-A110 10

Maintenance daily/weekly
Weekly/every 50 hours
Daily/every 10 hours
4. Lubricate front axle and steering nipples
1. Check engine oil level 4--wheel drive
2. Check coolant level -- universal joints
3. Clean draining hose -- front axle mountings
-- steering knuckles
5. Check propeler shaft, grease nipples for propeller shaft.
(with nipple)
6. Lubricate brake and clutch pedals
7. Lubricate top link and lifting links
8. Lubricate extra lifting cylinder nipples (if fitted)
9. Check fluid level in windscreen washer
10. Check fan and alternator belt
11. Check electrolyte level in battery
12. Drain water from fuel filter, tractors also have a
separate water trap.

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 Model Page
10. General
A90-A100-A110 11

Every 250 hours Every 1000 hours/yearly

13. Clean heating system air filter. Clean air filter of roof
fan.
14. Clean air filter (change if necessary) (filter)
15. Change engine oil and oil filter
16. Change hydraulic system pressure filter. First change
at 100 hours Service inspection. The second change at
250 running hours and the third at 500 hours. After that at
intervals of 250 running hours.
17.Lubricate gear lever joints
18.Check tyre pressures and wheel nuts
Every 500 hours
19. Clean separate water trap
20. Check brake pedal free travel
21.Check propulsion clutch pedal free travel
22. Check PTO lever free travel
23. Check oil level in power transmission
24. Check oil level in differential, 4--wheel drive
25.Check oil level in hub reduction gears, 4--wheel drive
26. Check oil level in hydraulic system
27.Change pressure filter in hydraulic system
28. Change oil filter in transmission
29. Change oil in hydraulic system
30. Change oil in power transmission
31. Change oil in differential, 4--wheel drive
32. Change oil in hub reduction gears, 4--wheel drive
33. Clean hydraulic pump suction strainer
34. Drain fuel tank
35. Change fuel filter, also change the water trap filter.
36. Change safety filter in air cleaner
37. Check, adjust and lubricate front wheel bearings,
2--wheel drive (only 2wd)
38. Check and adjust front wheel toe--in
39. Lubricate drive axle bearings (2 nipples)
40. Adjust valves
40a. Change air filter of roof fan.
40b. Change breather filter (in filling cap)
Every 2000 hours/every other year
41. Clean cooling system
42. Check alternator
43. Check starter motor
44. Check and clean injectors
Every 4000 hours
45. Turbo unit checked at authorized workshop

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10. General
A90-A100-A110 12

Recommended fuel and lubricants

(All volumes are incl. of filters)

Volume when
Part of machine SAE / Viscocity API grade
changing l

Engine 10W- 40 API CF- 4

A90, A100, A110 15W- 40 11

Hydraulic system Tellus 46 ISO HM 30

Valtra HT 200
Power Transmission API GL-4 29
10W- 30

Power front axle (4WD)

6
- differential 80W-90 API GL-5 (LS)
- Hubs 2x0,8
Fuel Tank The fuel (diesel) must conform to the EN 590 70
-with extra tank standardstandard 115

Cooling system (ASTM D4985) 15,5

Air Conditioning R134 a 1200 gr

Air Conditioning Compressor oil ZXL 100 PG 207 ml.
Brake fluid Brake fluid SAEJ1703 0,5
Front window washer reserv Washer fluid 1,5

Oil recommendations according to outdoor temperature

When starting the tractor in a warm garage, oil meant for warmer areas may be used.

Note : Please see PERKINS ENGINE catalog for fuel and engine oil quality and maintance. This is the only suggestion.

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10. General
A90-A100-A110 13

Grease
Always use the following greases in Hattat tractors. Each point requires it own type of grease.

Universal grease

Lithium − based universal grease. Is suitable for greasing all heavy machines.
− 30° ... +130°C

Universal grease of high quality, lithium based grease for vehicle use. It is recommended for greasing wheel bearings,
chassis water pumps, caterpillar rollers etc. The grease is adhesive, protects against corrosion and resists water and
varying temperatures. Temperature range is
− 30° ... +130°C.

Calsium Grease LF

Is suitable for greasing all heavy machines. Long fibre grease. Colour red.
− 20° ... +60°C

Calsium LF is of long fibre, high quality and calsium based universal grease for vehicle use. It is recommended for
greasing chassis, water pumps, pins etc.The grease is adhesive, protects against corrosion and resists water and varying
temperatures. Temperature range is − 20° ....60°C.

Moly Grease

Is suitable for greasing all heavy machines. Lithium − based universal grease.
− 30° ... +130°C

Universal grease of high quality, lithium based grease for vehicle use. It is recommended for greasing wheel bearings,
chassis water pumps, catepillar rollers etc. The grease is adhesive, protects against corrosion and resists
water and varying temperatures. Temperature range is
− 30° ... +130°C.

Avoid repeating skin contact.

Protect nature and take care of empty packages

Quality requirements of engine fuel

Property Requirement Test standard

Specific weight +15ºC. ISO 12185 0,82…0,86 kg/litre ASTM D 4052. EN

2
Viscosity+40º. ISO 31041 1,2…4,5 mm /s ASTM D

Sulphur content Max. 0,2 p-% ASTM D 4294, ISO 8754

Cetan e number 4737 Min 51 ASTM D

Water content Max. 200 mg/kg ASTM D 1744

The fuel must conform to the EN 590 standard

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20. Engine 20. Engine

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 Model Page
20. Engine
A90-A100-A110 1

Table of Contents

Specifications Section
Engine Design .................................................................................................... 4
Fuel Injection Lines ............................................................................................ 4
Fuel Injection Pump ........................................................................................... 4
Fuel Injectors ...................................................................................................... 5
Fuel Transfer Pump .............................................………………………………… 5
Lifter Group ........................................................................................................ 6
Rocker Shaft ....................................................................................................... 6
Valve Mechanism Cover .................................................................................... 6
Cylinder Head Valves ......................................................................................... 6
Cylinder Head ...................................................... ………………………………… 8
Turbocharger ...................................................................................................... 9
Exhaust Manifold ................................................. ………………………………… 10
Camshaft ............................................................................................................ 10
Camshaft Bearings .............................................. ……………………………….. 12
Engine Oil Filter ................................................... ………………………………… 12
Engine Oil Cooler ............................................................................................... 13
Engine Oil Pump ................................................................................................ 14
Engine Oil Pressure ........................................................................................... 16
Engine Oil Bypass Valve .................................................................................... 16
Engine Oil Pan ................................................................................................... 17
Breather Canister ............................................................................................... 18
Water Temperature Regulator and Housing ...................................................... 19
Water Pump ....................................................................................................... 19
Cylinder Block .................................................................................................... 19
Crankshaft .......................................................................................................... 20
Crankshaft Seals ................................................................................................ 22
Connecting Rod Bearing Journal ....................................................................... 22
Main Bearing Journal ......................................................................................... 23
Connecting Rod ................................................................................................. 23
Piston and Rings ................................................................................................ 24
Piston Cooling Jet .............................................................................................. 25
Front Housing and Covers ................................................................................. 26
Gear Group (Front) ............................................................................................. 27
Flywheel ............................................................................................................. 28
Flywheel Housing ............................................................................................... 28
Crankshaft Pulley ............................................................................................... 28
Fan Drive ........................................................................................................... 30
Engine Lifting Bracket ......................................................................................... 31
Alternator ............................................................................................................ 31
Starter Motor ...................................................................................................... 32
Glow Plugs ......................................................................................................... 33

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20. Engine Model Page
A90-A100-A110 2

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
he hazards are identified by the ‘Safety Alert Symbol’ and followed by a ‘’Signal Word’’such as
‘DANGER’, ‘WARNING’or ‘CAUTION’. The Safety Alert ‘’WARNING’’ label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by ‘NOTICE’ labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins replacement parts.
Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.

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20. Engine
A90-A100-A110 3

A90 - 1104D-44T A100 - A110 1104D-44TA

A90 A100 A110

Power rating 60.5 KW / 2200 rpm 68 KW / 2200 rpm 74.9 KW / 2200 rpm
Maximum Torgue
345 Nm / 1400 rpm 393 Nm / 1400 rpm 416 Nm / 1400 rpm
ISO 143186
Turbocharged and
Yes Yes Yes
intercooler
Cylinders
4.4 4.4 4.4
displacement(lt)
Number of Cylinders 4 4 4

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20. Engine
A90-A100-A110 4

Specifications Section Fuel Injection Lines

Engine Design

Illustration 1
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve Illustration 2
Typical example
Bore ......................................... 105 mm (4.133 inch) (1) Tighten the union nuts for the fuel injector nozzles
to the following torque. ............. 30 N·m (22 lb ft)
Stroke ...................................... 127 mm (5.000 inch)
Tighten the union nuts for the fuel injection pump (not
Displacement ...................................... 4.4 L (269 in3) shown) to the following torque. ....... 30 N·m (22 lb ft)

Cylinder arrangement ..................................... In-line Fuel Injection Pump

Type of combustion ............................ Direct injection
Compression ratio
Naturally aspirated engines ...................... 19.3:1
Turbocharged engines .............................. 18.2:1
Number of cylinders ................................................ 4
Valves per cylinder .................................................. 2
Note: Before the fuel injection pump is removed from
the engine the fuel injection pump shaft must be
locked. Position the engine to TC compression stroke
of number one cylinder before tightening the locking
screw. The locking screw will prevent the shaft from
rotating. If the fuel injection pump was removed
prior to correctly timing the engine and locking the
shaft, the fuel injection pump will need to be timed by
trained personnel.

Valve lash

Inlet valve ......................... 0.20 mm (0.008 inch)

Exhaust valve ................... 0.45 mm (0.018 inch)

Firing order ................................................. 1, 3, 4, 2

When the crankshaft is viewed from the front of

the engine, the crankshaft rotates in the following
direction: ................................................... Clockwise

When the camshaft is viewed from the front of

the engine, the camshaft rotates in the following
direction: ................................................... Clockwise
Illustration 3
The front of the engine is opposite the fywheel end. Typical example
Note: The solenoid on the fuel injection pump is
The left side and the right side of the engine are
viewed from the flywheel end. The No. 1 cylinder is a serviceable item. The fuel injection pump is a
the front cylinder. nonserviceable item.

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 Model Page
20. Engine
A90-A100-A110 5
to the following torque. ............. 35 N·m (26 lb ft)
(1) O-ring
(2) Locking screw The fuel injector should be tested at the pressure in
(3) Washer table 1.
Locking the shaft
Loosen locking screw (2) and move the washer Leakage in 10 seconds ................................. 0 drops
(3) to the locked position. Tighten the bolt to the
following torque. ...................... 17 N·m (12 lb ft) Table 1
Unlocking the shaft
Loosen locking screw (2) and install the washer Service setting for the Fuel Injector
(3) to the unlocked position. Tighten the bolt to
the following torque. ................... 12 N·m (9 lb ft) Injection Pressure

29.4 + 0.8 MPa (4264 + 116 psi)

Fuel Transfer Pump

Illustration 4
Typical example of a support bracket

(4) Tighten the mounting bolt to the following

torque. ...................................... 44 N·m (32 lb ft)

(5) Tighten the mounting bolt and the nut to the

following torque. ....................... 22 N·m (16 lb ft)

Note: The support bracket must be installed after

the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the bolt
(4) and then tighten the nut and bolt (5). Tighten the Illustration 6
bolt (4). (1) Retaining bolts
Tighten the bolts that hold the fuel pump to the front (2) Clip
housing to the following torque. ...... 25 N·m (18 lb ft)
(3) Spacer
Fuel Injectors
(4) Fuel transfer pump

Type .......................... 12 or 24 volt electric motor

(5) Fuel filter element

(6) O ring

(7) Fuel filter bowl

Note: Tighten the fuel filter bowl by hand. Rotate the

Illustration 5 bowl 1/8 of a turn more by hand.
Fuel injector clamp
(1) Tighten the bolt in the clamp for the fuel injector

26
20. Engine Model Page
A90-A100-A110 6
and work toward the outside. Tighten the screws
Lifter Group to the following torque. ............. 35 N·m (26 lb ft)
(7) Rocker shaft
Diameter of the rocker
shaft .................................. 24.962 to 24.987 mm
(0.9828 to 0.9837 inch)
(8) In order to install the rocker shaft assembly,
ensure that the machined square is to the top of
the rocker shaft.

(9) Locknut
Torque for the locknut ............... 27 N·m (20 lb ft)

Valve Mechanism Cover

Illustration 7
(1) Diameter of the lifter body .. 18.987 to 19.012 mm
(0.7475 to 0.7485 inch)

Clearance of the lifter in the cylinder block

bore ....... 0.038 to 0.095 mm (0.0015 to 0.0037 inch)

Rocker Shaft

Illustration 9
Tighten the bolts for the valve mechanism cover
in the sequence that is shown to the following
torque.................................................. 9 N·m (7 lb ft)

Cylinder Head Valves

Illustration 8
The rocker shaft

Note: In order to install the rocker shaft assembly,

Tooling (A) is required.

(1) Snap ring
(2) Washer
(3) Rocker arm
(4) Rocker arm bore
Diameter of the rocker arm
bore .................................. 25.013 to 25.051 mm
(0.9848 to 0.9863 inch)
Rocker arm
Clearance between the rocker arm and the rocker
shaft ...................................... 0.026 to 0.089 mm
(0.0010 to 0.0035 inch) Illustration 10
Maximum permissible clearance between the Cross section of cylinder head
rocker arm and the rocker shaft ............ 0.17 mm
(0.007 inch) (1) Valve spring
(5) Spring
Note: Install the longest screw at the front of the Naturally aspirated engines
rocker shaft assembly. The installed length of the valve
(6) Tighten the screws evenly. Begin in the center springs .......................... 35.17 mm (1.3846 inch)
27
20. Engine
The load for the installed valve springs ..... 335 N
(75 lb)
Turbocharged engines
The installed length of the inlet valve springs
(high ratings) ................. 35.17 mm (1.3846 inch)
The load for the installed inlet valve
springs ........................................... 335 N (75 lb)
The installed length of the inlet valve springs (low
ratings) .......................... 36.17 mm (1.4240 inch)
The load for the installed inlet valve
springs ........................................... 312 N (70 lb)
The installed length of the exhaust valve springs
(all ratings) .................... 36.17 mm (1.4240 inch)
The load for the installed exhaust valve
spring ............................................. 312 N (70 lb)
Turbocharged aftercooled engines
The installed length of the valve
springs .......................... 36.17 mm (1.4240 inch)
The load for the installed valve springs ..... 312 N
(70 lb)
(2) Valve spring recess
(3) The finished valve guides
Inside diameter of valve
Guide ..................................... 9.000 to 9.022 mm
(0.3543 to 0.3552 inch)
Outside diameter of the valve
Guide ................................. 13.034 to 13.047 mm
(0.5131 to 0.5137 inch)
Interference fit of valve guide in cylinder
Head ...................................... 0.007 to 0.047 mm
(0.0003 to 0.0019 inch)
Length of Valve guide .......... 51.00 to 51.50 mm
(2.018 to 2.027 inch)
Projection of the valve guide above the valve
spring recess (2) ................... 12.35 to 12.65 mm
(0.486 to 0.498 inch)
Note: When new valve guides are installed, new
valves and new valve seat inserts must be installed.
The valve guides and the valve seat inserts are
supplied as partially finished parts. The unfinished
valve guides and unfinished valve seat inserts are
installed in the cylinder head. The guides and inserts
are then cut and reamed in one operation with special
tooling. This procedure ensures the concentricity of
the valve seat to the valve guide in order to create a
seal that is tight. Refer to Disassembly and Assembly
for removal and installation procedures.
(4) Exhaust valve
Diameter of the exhaust valve
stem ...................................... 8.938 to 8.960 mm
(0.3519 to 0.3528 inch)
Clearance of valve in valve
guide ..... 0.040 to 0.062 mm (0.0016 to 0.0024 inch)
Overall length of the exhaust
valve ................................... 128.184 to 128.634 mm
(5.0466 to 5.0643 inch)
The face of the exhaust valve is recessed below the
cylinder head by the following amount.
28
Model Page
A90-A100-A110 7
Naturally aspirated engines ............ 0.55 to
0.81mm
(0.0217 to 0.0319 inch)
Service limit ............................ 1.06 mm (0.042 inch)
Turbocharged engines .................... 1.55 to 1.81 mm
(0.0610 to 0.0713 inch)
Service limit ...........................2.06 mm (0.0811 inch)
Turbocharged aftercooled engines .. 1.55 to 1.81 mm
(0.0610 to 0.0713 inch)
Service limit ...........................2.06 mm (0.0811 inch)
(5) Inlet valve
Diameter of the inlet valve
stem ...................................... 8.953 to 8.975 mm
(0.3525 to 0.3533 inch)
Clearance of valve in valve
guide .. 0.025 to 0.069 mm (0.001 to 0.0027 inch)
Overall length of the inlet
valve ................................... 128.838 to 129.288 mm
(5.0724 to 5.0901 inch)
The face of the inlet valve is recessed below the
cylinder head by the following amount.
Naturally aspirated engines ............ 0.60 to 0.85 mm
(0.0236 to 0.0335 inch)
Turbochargedengines(highrating) .. 0.60to0.85mm
(0.0236 to 0.0335 inch)
Service limit ............................ 1.09 mm (0.043 inch)
Turbocharged engines (low rating) .. 1.60 to 1.85 mm
(0.0630 to 0.0728 inch)
Turbocharged aftercooled engines .. 1.60 to 1.85 mm
(0.0630 to 0.0728 inch)
Service limit .......................... 2.09 mm (0.0823 inch)
(6) Exhaust valve face angle from the horizontal axis
Valve face angle ............................... 30 degrees
Valve seat angle ............................... 30 degrees
(7) Diameter of the exhaust
Valve head ............................ 41.51 to 41.75 mm
(1.634 to 1.643 inch)
(8) Diameter of the head of the inlet
Valve ..................................... 46.28 to 46.53 mm
(1.8220 to 1.8319 inch)
(9) Angle of the inlet valve face from the vertical axis
Valve face angle ............................... 45 degrees
Valve seat angle ............................... 45 degrees
The valve lash is the following value when the engine
is cold:
Inlet valves ........................ 0.20 mm (0.008 inch)
Exhaust valves ...................0.45 mm (0.018 inch)
20. Engine Model Page
A90-A100-A110 8

Illustration 11
Recess for the valve seat insert

(10) Machine the recess in the head for valve seat

inserts to the following dimensions.
Illustration 12
Recess for Inlet Valve Seat for Naturally Aspirated The tightening sequence
Engines and high rated turbocharged engines
(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch) Lubricate the threads and the underside of the head
(B) ..................................... 47.820 to 47.845 mm bolts with clean engine oil.
(1.8827 to 1.8837 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch) Tighten the bolts in the sequence that is shown in
llustrations to the following torque. ......... 50 N·m
Recess for Exhaust Valve Seat for Naturally (37 lb ft)
Aspirated Engines and high rated turbocharged Tighten the bolts again to the following
engines torque. .................................... 100 N·m (74 lb ft)
(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch)
(B) ..................................... 42.420 to 42.445 mm
(1.6701 to 1.6711 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
Recess for Inlet Valve Seat for low rated
turbocharged engines and turbocharged
aftercooled engines
(A) ....10.84 to 11.04 mm (0.4268 to 0.4346 inch)
(B) ..................................... 47.820 to 47.845 mm
(1.8827 to 1.8837 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)

Recess for Exhaust Valve Seat for turbocharged

engines and turbocharged aftercooled engines
(A) ....10.84 to 11.04 mm (0.4268 to 0.4346 inch)
(B) ..................................... 42.420 to 42.445 mm
(1.6701 to 1.6711 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
Illustration 13
The head bolts require an additional torque turn
procedure. The numbers (1, 3, 4) are three long
cylinder head bolts. All the other bolts are short bolts.
The tightening sequence is shown in the Illustrations .

Cylinder Head
The maximum distortion of the cylinder head is given
in table 4.
The cylinder head bolts are two different lengths. The
following information provides the proper torque for
the cylinder head bolts.
Place the angle gauge on the top of each bolt
head. Tighten the short bolts to the additional
amount. ........................................... 225 degrees
Place the angle gauge on the top of each bolt
head. Tighten the long bolts for the additional
amount. ........................................... 270 degrees
Thickness of thecylinderhead .. 117.95to118.05mm
(4.643 to 4.647 inch)

Minimum thickness of cylinder head ........117.20 mm

(4.614 inch)
Note: The maximum distortion of the cylinder head
is given in table 4.

29
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20. Engine
A90-A100-A110 9

IIIustration14
Table 4

Maximum Permissible
Dimesion
Distortion
Width (A) 0.03 mm (0.0012 inch)

Length (B) 0.05 mm (0.0019 inch)

Diagonal Line (C) 0.05 mm (0.0019 inch)

Turbocharger

Illustration 15
Typical turbocharger

(1) Actuator rod

(2) Actuator

(3) Turbocharger

(4) Tighten the nuts to the following torque. .. 44 N·m

(32 lb ft)

(5) Tighten the bolt to the following torque. ..... 9 N·m

(80 lb in)

(6) Tighten the bolt to the following torque. ... 22 N·m

(16 lb ft)

The maximum test pressure for the

wastegate ....................................... 205 kPa (30 psi)

The movement for the rod actuator ................. 1 mm

(0.0394 inch)

30
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20. Engine
A90-A100-A110 10

Table 5 Exhaust Manifold

The part number

The pressure for the
for the
wastegate
turbocharger
138 ± 3 kPa
2674A835
(20.0155 ± 0.4351 psi)
123 ± 3 kPa
2674A841
(17.8399 ± 0.4351 psi)
138 ± 3 kPa
2674A843
(20.0155 ± 0.4351 psi)
131 ± 3 kPa Illustration 16
2674A816 Typical example
(19.0002 ± 0.4351 psi)
100 ± 3 kPa Tighten the exhaust manifold bolts in the sequence
2674A817
(14.5040 ± 0.4351 psi) that is shown in illustration 16 to the following
torque. ............................................. 40 N·m (30 lb ft)
138 ± 3 kPa
2674A836
(20.0155 ± 0.4351 psi)
Camshaft
2674A818 123 ± 3 kPa
(17.8399 ± 0.4351 psi)
2674A844 8 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A819 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A821 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
2674A837 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A822 123 ± 3 kPa
(17.8399 ± 0.4351 psi)
2674A838 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
Illustration 17
2674A825 123 ± 3 kPa Checking the end play of the camshaft
(17.8399 ± 0.4351 psi)
2674A845 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A826 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A827 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
2674A842 138 ± 3 kPa
(20.0155 ± 0.4351 psi)

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20. Engine
A90-A100-A110 11

(1) End play of a new camshaft ..... 0.10 to 0.55 mm

(0.004 to 0.022 inch)

Maximum permissible end play of a worn

camshaft ................................. 0.60 mm (0.023 inch)

Illustration 18
Typical camshaft

(2) Bolt

Tighten the bolt to the following torque. ... 95 N·m

(70 lb ft)

(3) Camshaft thrust washer

Illustration 19
Thickness of the thrust washer .. 5.49 to 5.54 mm Typical example
(0.216 to 0.218 inch)
(5) Camshaft lobe lift
Depth of the recess in the cylinder block for the
thrust washer ............................ 5.54 to 5.64 mm Naturally aspirated
(0.218 to 0.222 inch) Inlet lobe ............................... 7.201 to 7.301 mm
(0.2835 to 0.2874 inch)
Tolerance of the thrust washer in cylinder block Exhaust lobe ......................... 7.404 to 7.504 mm
front face ........................... -0.154 to -0.003 mm (0.2914 to 0.2954 inch)
(-0.0006 to -0.0001 inch)
Turbocharged
(4) The diameters of the camshaft journals are given inlet lobe ............................... 7.527 to 7.627 mm
in the following table. (0.2963 to 0.3003 inch)
Exhaust lobe ......................... 7.363 to 7.463 mm
Table 6 (0.2899 to 0.2938 inch)
Diameters of Camshaft Journals Turbocharged aftercooled
Camshaft Inlet lobe ............................... 7.031 to 7.131 mm
Standard Diameter
Journals (0.2768 to 0.2807 inch)
Exhaust lobe ......................... 7.363 to 7.463 mm
50.711 to 50.737 mm (0.2899 to 0.2938 inch)
1
(1.9965 to 1.9975 inch)
(6)Camshaft lobe height
50.457 to 50.483 mm
2 (7) Base circle
(1.9865 to 1.9875 inch)
To determine the lobe lift, use the procedure that
49.949 to 49.975 mm follows:
3
(1.9665 to 1.9675 inch
1. Mount the camshaft between centers.
Maximum wear on the camshaft journals ... 0.05 mm 2. By using a dial indicator in contact with the surface
(0.0021 inch) of the lobe, rotate the camshaft and record the
maximum and minimum lift.
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20. Engine
A90-A100-A110 12

Note: There may be two lobes on the camshaft. Engine Oil Fitler
Refer to illustration 19. The surface between the
lobes may not return to the radius of the base circle.

Using a micrometer to measure the diameter of the

base circle may give a inaccurate result.

3. Subtract the smallest dimension from the largest

dimension. The difference is the actual camshaft
lobe lift.

Maximum permissible deviation between the

actual lobe lift and the specified lobe lift of a new
camshaft ................................. 0.05 mm (0.002 inch)

Camshaft Bearings

Illustration 21
Typical example

(1) Setscrew

Tighten the setscrews to the following

torque. ...................................... 22 N·m (16 lb ft)

(2) Engine oil filter

Tighten the engine oil filter to the following

torque. .................................... 12 N·m (106 lb in)

Illustration 20
Typical example

(1) The diameter of the installed camshaft

bearing .............................. 50.787 to 50.848 mm
(1.9995 to 2.0019 inch)

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20. Engine
A90-A100-A110 13

Illustration 22 Engine Oil Cooler

Typical example

Illustration 23
Typical example
(1) Joint
(2) Oil cooler
(3) Housing
(4) Setscrew
(5) Seal
(6) Setscrew
(7) Setscrew

(3) Setscrew

Tighten the setscrews to the following

torque. ...................................... 22 N·m (16 lb ft)

(4) Engine oil filter

Tighten the engine oil filter to the following

torque. .................................... 12 N·m (106 lb in)

(5) Plug

Tighten the plug to the following torque. .. 12 N·m

(106 lb in)

llustration 24
Setscrews
Tighten the setscrews (7) to the following
torque. ...................................... 22 N·m (16 lb ft)
Setscrews
Tighten the setscrews (4) and (6) in the
sequence that is in illustration 24 to the following
Torque. ...................................... 22 N·m (16 lb ft)

34
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20. Engine
A90-A100-A110 14

Engine Oil Pump Inner rotor

(2) Clearance of inner rotor to outer
Engines with Balancer Group rotor ...................................... 0.050 to 0.200 mm
(0.0020 to 0.0079 inch)
Type ............................. Gear-driven differential rotor

Number of lobes

Inner rotor ......................................................... 6

Outer rotor ........................................................ 7

Illustration 27

The end play for the rotor

(3) End play of rotor assembly

Inner rotor ..................................0.04 to 0.11 mm

(0.0016 to 0.0043 inch)
Illustration 25 Outer rotor .................................0.04 to 0.11 mm
The oil pump for the balancer (0.0016 to 0.0043 inch)

(1) Clearance of the outer rotor to the

body .. 0.130 to 0.24 mm (0.0050 to 0.0094 inch)

Illustration 28
The end cover

(4) Torque for cover bolts for oil pump .......... 26 N·m
(19 lb ft)
Illustration 26
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20. Engine
A90-A100-A110 15

Illustration 30
The oil pump
(1) Clearance of the outer rotor to the
body ...................................... 0.152 to 0.330 mm
(0.0059 to 0.0129 inch)

Illustration 29
Idler gear and pump gear

Note: Replace the idler gear bolt (5) and the nut for
the oil pump gear (6).

(5) Tighten the idler gear bolt to the following

torque. ...................................... 26 N·m (19 lb ft)

Note: Set the engine to the TC position. Refer to Illustration 31

Systems Operation, Testing and Adjusting Manual, Checking the clearance
‘Finding Top Center Position for No. 1 Piston’. Install
the balancer. Refer to Disassembly and Assembly, (2) Clearance of inner rotor to outer
‘Balancer – Install’. Install the gear for the oil pump rotor ...................................... 0.040 to 0.127 mm
and tighten the nut (6). (0.0015 to 0.0050 inch)
6) Tighten the nut to the following torque..... 95 N·m
(70 lb ft)

Tighten the bolts that hold the balancer to the cylinder

block to the following torque. .......... 54 N·m (40 lb ft)
Engines without Balancer Group

Type ............................. Gear-driven differential rotor

Number of lobes

Inner rotor ......................................................... 5

Outer rotor ........................................................ 6
Illustration 32
Checking the end play

(3) End play of rotor assembly

Inner rotor ............................. 0.038 to 0.089 mm

(0.0014 to 0.0035 inch)
Outer rotor ............................ 0.025 to 0.076 mm
(0.0010 to 0.0029 inch)

Tighten the bolts that hold the front cover of the oil
pump assembly to the following torque. ........ 10 N·m
(89 lb in)
36
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20. Engine
A90-A100-A110 16

Engine Oil Pressure

The minimum oil pressure at the maximum engine

speed and at normal operating temperature is the
following value. ............................... 280 kPa (41 psi)

Engine Oil Bypass Valve

Installed in the Oil Pump

Illustration 35

Plug

Illustration 33
Typical engine oil pump

Illustration 36
The relief valve for the balancer

(1) Tighten the plug for the relief valve to the

following torque. ....................... ………...35 N·m (26 lb ft)

(2) Plunger
Diameter of the plunger ........ …………..14.46 to 14.48 mm
(0.5692 to 0.5700
Illustration 34 inch)
Relief valve and spring Clearance of the plunger in the bore .... 0.04 to 0.08 mm
(0.0015 to 0.0031
(1) Tighten the plug for the relief valve to the inch)
following torque. ....................... 35 N·m (26 lb ft)
(3) Spring
(2) Plunger Length of the spring ........... …………….67 mm (2.6378 inch)
Diameter of the plunger .............19.186 to 19.211 mm
(0.7554 to 0.7563 inch)
Clearance of plunger in bore .. …0.039 to 0.114 mm
(0.0015 to 0.0045 inch)

Installed in the Balancer

37
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20. Engine
A90-A100-A110 17

Engine Oil Pan

Front sealant

Illustration 37
Applying sealant
If the gasket that is between the front housing and
the cylinder block is not renewed, apply Tooling (A) to
the cylinder block and to the front housing. If a new
gasket is installed, Tooling (A) is not required.
Note: Apply a sealant bead of 3.5 mm (0.1378 inch)
that is shown in illustration 37.
Illustration 39
Typical example
(1) Tighten the four front bolts in position (X) to the
following torque. ....................... 22 N·m (16 lb ft)
Tighten the remaining bolts to the following
torque. ............................................. 22 N·m (16 lb ft)
(2) Drain plug
Tighten the drain plug for the engine oil pan to
the following torque. ................. 34 N·m (25 lb ft)

Crankcase Breather

Rear sealant

Note: Install the rear oil seal before sealant is applied

to the bridge.

Illustration 38
Applying sealant

Apply Tooling (A) to the bridge. The sealant must

not protrude more than 5 mm (0.1969 inch) above
the bridge.
Illustration 40
Breather valve
(1) Cover
(2) Cover plate
(3) Screws
38
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20. Engine
A90-A100-A110 18

Tighten the screws for the cover plate with

a composite valve mechanism cover to the Breather Canister

following torque. ................... 1.3 N·m (11.5 lb in)

(4) Diaphragm

(5) Cap

(6) Spring

Illustration 41
Typical example Illustration 42
Typical example
(7) O-ring (1) Connection
(2) Clamp
Note: Apply Tooling (A) to the O-ring before installing (3) Hose
the breather pipe in the valve mechanism cover. (4) Filter base
(5) Bolts
(8) Tighten the bolts that secure the breather pipe to (6) Clamp
the cylinder head to the following torque. .. 9 N·m (7) Hose
(80 lb in) (8) Canister

(2) Tighten the clamps to the following

torque. ............................................................. 3 N·m (26 lb
in)

(5) Tighten the bolts to the following torque. ...….22N·m

(16 lb ft)
(6) Tighten the clamp to the following torque. .. …3N·m
(26 lb in)
(8) Tighten the canister to the following
torque. ............................. 12 N·m (106 lb in)

39
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20. Engine
A90-A100-A110 19

Water Temperature Regulator and Housing torque. ............................................. 22 N·m (16 lb ft)

Cylinder Block

Illustration 43
Typical example
Note: Apply Tooling (A) to the O-ring (4) in order to
install the water temperature regulator housing (2).
Illustration 45
(1) Tighten the bolts that fasten the housing to the Typical example
following torque. ....................... 44 N·m (32 lb ft)
(1) Cylinder block
(2) Water temperature regulator housing
(2) Cylinder bore ................ 105.000 to 105.025 mm
(3) Water temperature regulator (4.1338 to 4.1348 inch)
Opening temperature ........................ 82° to 87°C The first oversize bore
(179.6000° to 156.6000°F) diameter .................................. 105.5 to 105.525 mm
Full opening temperature .... 95 °C (203.0000 °F) (4.1535 to 4.1545 inch)
Minimum stroke at full temperature ........... 9 mm
(0.3543 inch) The second oversize bore
Water Pump diameter .............................. 106.000 to 106.025 mm
(4.1732 to 4.1742 inch)

The maximum permissible wear for the cylinder bore

................................. 0 to 0.15 mm (0 to 0.0059 inch)

(3) Camshaft bearings

Diameter of the bore in the cylinder

block for the number 1 camshaft
bearing .............................. 55.563 to 55.593 mm
(2.1875 to 2.1887 inch)
Diameter of the bore in the cylinder
block for the number 2 camshaft
journal ............................... 50.546 to 50.597 mm
(1.9900 to 1.9920 inch)
Diameter of the bore in the cylinder
block for the number 3 camshaft
journal ............................... 50.038 to 50.089 mm
(1.9700 to 1.9720 inch)
Illustration 44 (4) Main bearings
Tightening sequence Bore in the cylinder block for the main
bearings ............................ 80.416 to 80.442 mm
Tighten the setscrews in the numerical sequence (3.1660 to 3.1670 inch)
that is shown in illustration 44 to the following (5) Main bearing cap bolts

40

20. Engine
Use the following procedure in order to install the
main bearing cap bolts:
1. Apply clean engine oil to the threads of the main
bearing cap bolts.
2. Put the main bearing caps in the correct position
that is indicated by a number on the top of the
main bearing cap. Install the main bearing caps
with the locating tabs in correct alignment with the
recess in the cylinder block.
3. Evenly tighten the main bearing cap bolts.
Torque for the main bearing cap bolts. .... 245 N·m
(180 lb ft)
Illustration 46
Use the following procedure in order to install the
allen head bolts for the bridge.
Note: Install the rear seal before sealant is applied.
1. Use a straight edge in order to ensure that the
bridge is aligned with the rear face of the cylinder
block.
2. Tighten the allen head bolts (6) for the bridge.
Torque for the allen head bolts ... 16 N·m (12 lb ft)
3. When the bridge is installed on the cylinder block,
apply Tooling (A) into groove (7) at each end of
the bridge. Apply the sealant into the groove until
the sealant is forced through the bottom end of
the groove in the bridge.
Note: The oil pan must be installed within 10 minutes
of applying the sealant.
Total height of the cylinder block between the top and
the bottom faces. ................ 441.173 to 441.274 mm
(17.3689 to 17.3729 inch)
41
Model Page
A90-A100-A110 20
Crankshaft
Illustration 47
Typical example
(1) Crankshaft
The maximum end play of the crankshaft ... 0.51 mm
(0.0201 inch)
(2) Thrust washers
Standard thickness ................... 2.26 to 2.31 mm
(0.089 to 0.091 inch)
Oversize thickness ................... 2.45 to 2.50 mm
(0.097 to 0.098 inch)
(3) The crankshaft gear
Maximum permissible temperature of the gear for
installation on the crankshaft ........... 180 °C (356 °F)
Note: The timing mark is toward the outside of
the crankshaft when the gear is installed on the
crankshaft.
Note: All new turbocharged engines and
turbocharged aftercooled engines have crankshafts
that are nitrocarburised. The crankshaft can also
be nitrided for 20 hours, if the nitrocarburised
process is not available. After a crankshaft has
been machined, the crankshaft must be rehardened.
Inspect the crankshaft for cracks before machining
and after machining. Naturally aspirated engines
have induction hardened crankshafts.
20. Engine Model Page
A90-A100-A110 21

Illustration 48

Note: Refer to illustration 48 in order to use table 11.

Table 11
The undersize diameter of the Crankshaft Journals

NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)

75.905 to 75.926 mm 75.651 to 75.672 mm 75.397 to 75.418 mm

1
(2.9884 to 2.9892 inch) (2.9784 to 2.9792 inch) (2.9684 to 2.9692 inch)
63.216 to 63.236 mm 62.962 to 62.982 mm 62.708 to 62.728 mm
2
(2.4888 to 2.4896 inch) (2.4788 to 2.4796 inch) (2.4688 to 2.4696 inch)
37.44 mm (1.4740 inch)
3 N/A N/A
maximum
37.44 mm (1.4740 inch)
4 N/A N/A
maximum
44.68 mm (1.7591 inch)
5 N/A N/A
maximum
40.55 mm (1.5965 inch)
6 N/A N/A
maximum

7 Do notmachine this diameter. N/A N/A

3.68 mm (0.1449 inch) to

8 N/A N/A
3.96 mm (0.1559 inch)
4.36 to 4.60 mm
9 N/A N/A
(0.1717 to 0.1811 inch)

Refer to table 12 for the maximum run out of the

crankshaft journals.

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Table 12
Journal Excessive run out

(1) Mounting

(2) 0.08 mm (0.0031 inch)

(3) 0.15 mm (0.0059 inch)

(4) 0.08 mm (0.0031 inch)

(5) Mounting

Refer to Specifications, ‘Connecting Rod Bearing

Journal’ for more information on the connecting rod
bearing journals and connecting rod bearings.

Refer to Specifications, ‘Main Bearing Journal’ for

information on the main bearing journals and for
information on the main bearings.
Illustration 50
Crankshaft Seals
(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the
sequence that is shown in Illustration 50 to the
following torque. ....................... 22 N·m (16 lb ft)
Remove the alignment tool.

Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 50 to the following torque. ........ 22 N·m
(16 lb ft)

Connecting Rod Bearing Journal

Refer to Specifications, ‘Crankshaft’ for information

on the undersize crankshaft journals.

The original size of the connecting rod bearing

journal ... 63.47 to 63.49 mm (2.4988 to 2.4996 inch)

Maximum permissible wear of a bearing journal on a

Illustration 49 new connecting rod .............. 0.04 mm (0.0016 inch)
Typical example
Width of the connecting rod bearing
(1) Crankshaft journals ................................... 40.348 to 40.424 mm
(1.5885 to 1.5915 inch)
(2) Crankshaft seal
Radius of the fillet of the connecting rod bearing
(3) Plastic sleeve journals ......... 3.68 to 3.96 mm (0.145 to 0.156 inch)
(4) Alignment tool Surface finish of connecting rod bearing
journals ............................................. Ra 0.4 microns
Surface finish of radii ........................ Ra 1.3 microns

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Main Bearing Journal

Connecting Rod
Refer to Specifications, ‘Crankshaft’ for information
on the undersize main bearing journals, and
information on the width of main bearing journals.

The original size of the main bearing

journal ..................................... 76.159 to 76.180 mm
(2.9984 to 2.9992 inch)

Maximum permissible wear of the main bearing

journals ............................... 0.040 mm (0.0016 inch)

Radius of the fillet of the main bearing

journals ..... 3.68 to 3.69 mm (0.1448 to 0.1452 inch)

Surface finish of bearing journals, crank pins and

radii ................................... 0.4 microns (16 µ inches)

The shell for the main bearings

The shells for the main bearings are available

for remachined journals which have the following
undersize dimensions.
Undersize bearing shell .... 0.25 mm (0.010 inch)
Undersize bearing shell .... 0.51 mm (0.020 inch)
Undersize bearing shell .... 0.75 mm (0.030 inch)
Thickness at center of the shells .. 2.083 to 2.089 mm
(0.0820 to 0.0823 inch)
Width of the main bearing shells .. 31.62 to 31.88 mm
(1.244 to 1.255 inch)
Clearance between the bearing shell and the main
bearing journals ...........................0.057 to 0.117 mm
(0.0022 to 0.0046 inch)
Illustration 51
The mating surfaces of the connecting rod are
produced by hydraulically fracturing the forged
connecting rod.
(1) Tighten the torx screws for the connecting rod to
the following torque. ................. 18 N·m (13 lb ft)
Tighten the torx screws for the connecting rod again
to the following torque. .................... 70 N·m (52 lb ft)
Tighten the torx screws for the connecting rod for
an additional 120 degrees. The torx screws for
the connecting rod (1) must be replaced after this
procedure.

Note: Always tighten the connecting rod cap to the

connecting rod, when the assembly is out of the
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft).

(2) The bearing shell for the connecting rod

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A90-A100-A110 24

Illustration 52
Alignment of the bearing shell

Note: The bearing shell for the connecting rod must

be aligned equally from both ends of the connecting
rod. Refer to (A) in figure 52. Refer to Disassembly
and Assembly for information on the alignment tool.

Table 13

Bearing Width for the 31.62 to 31.88 mm

Connecting Rod
Bearing Width for the
Connecting Rod Cap
Thickness of Connecting
Rod Bearing at the
Center
Thickness of Connecting
Rod Bearing for the Cap
at the Center
Bearing Clearance
Table 14
(1.245 to 1.255 inch)
31.62 to 31.88 mm
(1.2449 to 1.2551 inch)
1.835 to 1.842 mm
(0.0723 to 0.0725 inch)
1.835 to 1.842 mm
(0.0723 to 0.0725 inch)
0.034 to 0.081 mm
(0.0013 to 0.0032 inch)
Illustration 53
(3) Inside diameter of the small
bush .................................. 39.723 to 39.738 mm
(1.5639 to 1.5645 inch)
(4) Distance between the parent
bores ................................. 219.05 to 219.10 mm
(8.624 to 8.626 inch)
(5) Diameter for the parent bore for the connecting
rod bearing ........................... 67.21 to 67.22 mm
(2.6460 to 2.6465 inch)

Undersized Connecting Rod Bearing

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)

0.76 mm (0.030 inch)

Illustration 54

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Connecting rods are color coded. The color code
is a reference for the length (Y) of the connecting
rod. Refer to table 15 for the different lengths of
connecting rods.
Table 15
The shape of the intermediate compression
ring ........................... Keystone with a barrel face
Width of the top compression ring .................... tapered
Ring gap ................................... ……….0.30 to 0.45 mm
(0.0118 to 0.0177 inch)

Length Grades for Connecting Rods
Grade
Color Code Length (Y)
Letter
165.682 to 165.715 mm
F Red
(6.5229 to 6.5242 inch)
165.728 to 165.761 mm
G Orange
(6.5247 to 6.5260 inch)
165.637 to 165.670 mm
H White
(6.5211 to 6.5224 inch)
165.591 to 165.624 mm
J Green
(6.5193 to 6.5206 inch)
165.545 to 165.578 mm
K Purple
(6.5175 to 6.5188 inch)
165.499 to 165.532 mm
L Blue
(6.5157 to 6.4961 inch)
Note: When you install a new top compression ring,
make sure that the word ‘TOP’ is facing the top of the
piston. New top piston rings for naturally aspirated
engines have a red identifcation mark which must
be on the left of the ring end gap when the top
piston ring is installed on an upright piston. New top
piston rings for turbocharged engines have a yellow
identifcation mark which must be on the left of the
ring end gap when the top piston ring is installed on
an upright piston.
(2) Intermediate compression ring
The shape of the intermediate compression
ring ........................................... Internal chamfer in the
bottom edge with a tapered face
Width of intermediate compression ring for
naturally aspirated engines ................. 2.47 to 2.49 mm
(0.097 to 0.098 inch)

Width of intermediate compression ring for

Piston and Rings
turbocharged engines ...................... 2.470 to 2.495 mm
(0.0972 to 0.0982 inch)

Clearance between the intermediate compression

ring and the piston groove for naturally aspirated
engines ... 0.05 to 0.09 mm (0.002 to 0.003 inch)
Clearance between the intermediate compression
ring and the piston groove for turbocharged

engines ............................................0.065 to 0.110 mm

(0.0026 to 0.0043 inch)

Ring gap for naturally aspirated

engines ..................................... ……...0.70 to 0.95 mm
(0.0275 to 0.0374 inch)
Illustration 55 Ring gap for turbocharged
Typical example engines ................................................ 0.65 to 0.85 mm
(0.0256 to 0.0335 inch)
(1) Top compression ring
Note: When you install a new intermediate
Naturally Aspirated compression ring, make sure that the word ‘TOP’
The shape of the top compression is facing the top of the piston. New intermediate
ring ...................... Rectangular with a barrel face rings for naturally aspirated engines have a green
identifcation mark which must be on the left of the
Width of the top compression ring end gap when the top piston ring is installed
ring ...... 2.47 to 2.49 mm (0.0972 to 0.0980 inch) on an upright piston. New intermediate rings for
turbocharged engines have a blue identifcation mark
Clearance between the top compression ring and which must be on the left of the ring end gap when
the piston groove ...................... 0.09 to 0.13 mm the top piston ring is installed on an upright piston.
(0.0035 to 0.0051 inch)

Ring gap ................................... ……...0.30 to 0.55 mm

(0.0118 to 0.0217 inch)
Turbocharged
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A90-A100-A110 26

(3) Oil control ring Piston Cooling Jet

Shape of oil control
ring ............ a two-piece coil that is spring loaded
Width of oil control ring for naturally aspirated
engines ..................................... 3.47 to 3.49 mm
(0.1366 to 0.1374 inch)
Width of oil control ring for turbocharged
engines ..................................... 2.97 to 2.99 mm
(0.1169 to 0.1177 inch)

Clearance between the oil control ring and

the groove in the piston for naturally aspirated
engines ..................................... 0.03 to 0.07 mm
(0.0011 to 0.0027 inch)
Ring gap ................................... 0.30 to 0.55 mm
(0.0118 to 0.0216 inch)
Note: A pin is used in order to hold both ends of the
Illustration 56
spring of the oil control ring in position. The ends of
(1) Installed piston cooling jets
the spring of the oil control ring must be installed
opposite the end gap of the oil control ring.
Note: Ensure that the ring end gaps of the piston The valve must move freely. Tighten the bolt to the
following torque. .................................. 9 N·m (7 lb ft)
rings are spaced 120 degrees from each other.

Piston

Note: An arrow which is marked on the piston crown

must be toward the front of the engine.

The combustion bowl re-entrant angle for the

turbocharged engine ............................... 72 degrees

The combustion bowl re-entrant angle for the

naturally aspirated engine ....................... 70 degrees

Piston height above cylinder block .. 0.21 to 0.35 mm

(0.008 to 0.014 inch)

Width of top groove in piston for the naturally

aspirated engine ............................. 2.58 to 2.60 mm
(0.1016 to 0.1024 inch) llustration 57
(2) Piston cooling jet
Width of top groove in piston for the turbocharged (3) Rod
engine .......................................................... Tapered (4) Cylinder block

Width of second groove in piston for naturally Use the following procedure in order to check the
aspirated engines ........................... 2.54 to 2.56 mm alignment of the piston cooling jet.
(0.1000 to 0.1008 inch)

Width of second groove in piston for turbocharged

engines ..... 2.56 to 2.58 mm (0.1008 to 0.1016 inch)

Width of third groove in piston for naturally aspirated

engines ..... 3.52 to 3.54 mm (0.1386 to 0.1394 inch)

Width of third groove in piston for turbocharged

engines ...... 3.02 to 3.04 mm (0.1189 to 0.1197 inch)

Piston pin
Diameter of a new piston
pin ..................................... 39.694 to 39.700 mm
(1.5628 to 1.5630 inch)
Diameter of the bore for the piston
pin ..................................... 39.703 to 39.709 mm
(1.5631 to 1.5633 inch)
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1. Insert rod (3) into the end of the piston cooling

jet (2). Rod (3) has a diameter of 1.70 mm
(0.067 inch). Rod (3) must protrude out of the top
of the cylinder block.

2. Dimension (A) is 50.75 mm (1.9980 inch)

and dimension (B) is 9.35 mm (0.3681 inch).
Dimension (A) and dimension (B) are tangential
to the cylinder bore (4).

3. The position of the rod (3) must be within

dimension (C). Dimension (C) is 10 mm
(0.3937 inch).

Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
piston cooling jets can not be adjusted. If a piston
cooling jet is not in alignment the piston cooling jet
must be replaced.

Front Housing and Covers

Illustration 59
Front cover
The front housing must be aligned to the cylinder
block face...........................+ 0.05 to minus 0.05 mm (2) Tighten the bolts that fasten the water pump to the
(+ 0.0020 to minus 0.0020 inch) front housing to the following torque. ....... 22 N·m
(16 lb ft)

Note: Refer to Specifications, ‘Water Pump’ for the

correct bolt tightening sequence for the water pump.

Gear Group (Front)

Illustration 58
Alignment

(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
Illustration 60
Gear train

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(1) Fuel injection pump drive gear

Tighten the nut to the following torque. ... 24 N·m
(18 lb ft)
Release the lock on the fuel injection pump shaft.
Torque the nut to the following torque. .... 90 N·m
(66 lb ft)
Maximum permissible end play ............ 0.38 mm
(0.015 inch)
Number of teeth .............................................. 73

Number of teeth .............................................. 68

Note: Refer to Specifcations, Fuel Injection Pump

for the locking torque for the fuel injection pump shaft.

(2) Camshaft gear

Tighten the bolt for the camshaft gear to the

following torque. ....................... 95 N·m (70 lb ft)

Bore diameter of the camshaft

gear ...................................... 34.93 to 34.95 mm
(1.3750 to 1.3760 inch)
llustration 61
Outside diameter of the camshaft The gear train for the oil pump
hub .. 34.90 to 34.92 mm (1.3741 to 1.3747 inch) (4) Crankshaft gear
Bore diameter of crankshaft gear
Clearance between the camshaft gear and the 47.625 to 47.650 mm (1.8750 to 1.8760 inch)
camshaft hub ........................ 0.003 to 0.048 mm
(0.0001 to 0.0019 inch) Outside diameter of crankshaft
ub ......................................... 47.625 to 47.645 mm
Number of teeth .............................................. 68 (1.8750 to 1.8758 inch)
Clearance of gear on
(3) Idler gear and hub crankshaft .............................. - 0.020 to +0.020 mm
( - 0.0008 to +0.0008 inch)
Tighten the bolts for the idler gear to the following Number of teeth .............................................. 34
torque. ...................................... 44 N·m (33 lb ft)
(5) Oil pump idler gear
Bore diameter of the idler gear
........ 57.14 to 57.18 mm (2.2495 to 2.2512 inch) Inside diameter of oil pump idler gear
Bore diameter of the idler gear with roller bearing .............................. 16.012 to 16.038 mm
bearings ................................ 72.35 to 72.36 mm (0.6304 to 0.6314 inch)
(2.8484 to 2.8488 inch)
Outside diameter of oil pump idler gear
Width of idler gear and split bearing shaft .................................. 15.966 to 15.984 mm
assembly .............................. 30.14 to 30.16 mm (0.6286 to 0.6293 inch)
(1.186 to 1.187 inch) Clearance of oil pump idler gear bearing on
shaft ......................................... 0.028 to 0.072 mm
Inside diameter of idler gear bearings with (0.0011 to 0.0028 inch)
_anges .................................. 50.78 to 50.80 mm
(1.999 to 2.000 inch) End play of the oil pump idler
gear ......................................... 0.050 to 0.275 mm
Outside diameter of idler gear (0.0019 to 0.0108 inch)
hub .. 50.70 to 50.74 mm (1.9961 to 1.9976 inch)
Outside diameter of idler gear hub with roller (6) Oil pump gear
bearings ............................ 49.975 to 49.988 mm The number of teeth on the oil pump gear ..... 17
(1.9675 to 1.9680 inch)
Backlash values
Clearance of idler gear bearing on Backlash between the idler gear (5) and the oil
hub ...... 0.04 to 0.10 mm (0.0016 to 0.0039 inch) pump drive gear (6) ................ 0.046 to 0.106 mm
(0.0018 to 0.0041 inch)
Idler gear end play .................... 0.10 to 0.20 mm
(0.004 to 0.008 inch)

Idler gear end play with roller

bearings .................................... 0.10 to 0.75 mm
(0.0039 to 0.0295 inch)
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Flywheel
Backlash between the oil pump idler gear (5) and
the crankshaft gear (4) ......... 0.095 to 0.160 mm
(0.0037 to 0.0063 inch)

Backlash between the idler gear (3) and the

crankshaft gear (4) ............... 0.064 to 0.124 mm
(0.0025 to 0.0049 inch)

Backlash between the camshaft gear (2) and the

idler gear (3) ......................... 0.052 to 0.107 mm
(0.0020 to 0.0042 inch)

Backlash between the fuel injection pump gear

(1) and the idler gear (3) ....... 0.054 to 0.109 mm
(0.0021 to 0.0043 inch)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear
(1) ... 0.073 to 0.133 mm (0.0028 to 0.0052 inch)
Backlash between the power take-off
drive (if equipped) and the idler gear
(3) ....0.112 to 0.172 mm (0.0044 to 0.0068 inch)

Engines that have a Balance

Illustration 63
Typical example

(1) Flywheel ring gear

Heat the flywheel ring gear to the following

temperature. .............................. 250 °C (480 °F)

Note: Do not use an oxyacetylene torch to heat the

flywheel ring gear.

(2) Flywheel

(3) Bolt

Illustration 62 Tighten the flywheel bolts to the following

Balancer gears torque. ..................................... 115 N·m (85 lb ft)

(7) Idler gear for the oil pump that has a balancer

The number of teeth on the gear .................... 44

The bore diameter of the idler
gear .................................. 37.197 to 37.212 mm
(1.4644 to 1.4650 inch)
The hub diameter for the idler
gear .................................. 37.152 to 37.162 mm
(1.4627 to 1.4631 inch)
The end play for the idler gear .. 0.12 to 0.27 mm
(0.0047 to 0.0106 inch)

(8) Gear for the oil pump that has a balancer

The number of teeth on the gear .................... 17

Backlash between the oil pump gear (8) and the idler
gear (7) ... 0.097 to 0.17 mm (0.0038 to 0.0067 inch)

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Flywheel Housing
Crankshaft Pulley

Illustration 65
A standard pulley

(1) Tighten the three bolts for the crankshaft pulley

to the following torque. ............ 115 N·m (85 lb ft)

Note: Recheck the torque of the bolts (1) once.

(2) Thrust block

Note: The chamfers on the bolt holes must face

toward the front of the engine.

(3) Crankshaft pulley

Illustration 64
Typical example

(1) Bolt

Tighten the bolts for the cast iron flywheel

housing to the following torque:
M10 ‘8.8’ .................................. 44 N·m (33 lb ft)
M10 ‘10.9’ ................................ 63 N·m (47 lb ft)
M12 ‘8.8’ .................................. 75 N·m (55 lb ft)
M12 ‘10.9’ ............................... 115 N·m (85 lb ft)

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Crankshaft Pulley for the Poly (1) T Mark

V-Belt (2) Alignment mark
Note: The marks (1 and 2) on the pulley must be
vertical when the pulley is installed on the engine.
Number one piston of the engine must be at top dead
center.

Fan Drive

Illustration 66
Typical example
(1) Bolt
(2) Thrust block
(3) Crankshaft adapter
(4) Crankshaft pulley
(5) Bolt

(1) Tighten the three bolts for the thrust block to the
following torque. ...................... 115 N·m (85 lb ft)

Note: Recheck the torque of the bolts (1) once. Illustration 68

Note: The chamfers on the bolt holes must face
toward the front of the engine.
(5) Tighten the three bolts for the crankshaft pulley
to the following torque. ............. 78 N·m (58 lb ft)
Non - Standard Pulley
Typical example
(1) Tighten the bolts to the following torque. .. 22N·m
(16 lb ft)
Fan drive housing
Tighten the bolts (2) that secure the fan drive
housing (3) to the cylinder head to the following
torque. ............................................. 44 N·m (32 lb ft)

Maximum permissible end play of the shaft ........ 0.20mm

(0.0079 inch)

Illustration 67

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Engine Lifting Bracket

The 12 Volt and 24 Volt Iskra
All engines are equipped with two engine lifting Alternator
brackets.
12 volt output
Tighten the two bolts on each engine lifting
bracket to the following torque. .. 44 N·m (32 lb ft) Two alternators are
available. ....................... 150 Amp and 175 Amp

Alternator 24 volt output

The 24 volt alternator ............................ 100 Amp
The 12 Volt and 24 Volt Denso
Alternators

Three types of alternator are available.

Output
Two 12 volt alternators are
available. ....................... 100 Amp and 120 Amp
One 24 volt alternator ............................. 80 Amp

Illustration 70
Typical example

(1) Terminal ‘B+’

Tighten the terminal nut to the following

torque. ...................................... 11 N·m (97 lb in)

(2) Terminal ‘D+’

Illustration 69
Typical example Tighten the terminal nut to the following
torque. ........................................ 3 N·m (26 lb in)
(1) Terminal ‘W’
(3) The terminal ‘W’ is spade-type.
Tighten the terminal nut to the following
torque. ..................................... 3.7 N·m (33 lb in)
(2) Terminal ‘D+’
Tighten the terminal nut to the following
torque. ..................................... 3.7 N·m (33 lb in)

(3) Terminal ‘B+’

Tighten the terminal nut to the following

torque. ........................................ 7 N·m (62 lb in)

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Starter Motor
24 Volt Starting Motor

Illustration 71

The 24 volt starting motor which shows the electrical connections

(1) Tighten the negative terminal nut to the following torque. ...................................... 16 N·m (12 lb ft)
(2) Tighten the positive terminal nut to the following torque. ........................................ 21 N·m (15 lb ft)
(3) Tighten the solenoid terminal to the following torque. ............................................ 3.6 N·m (32 lb in)
Rated voltage .................................................................................................................. 24 volts

12 Volt Starting Motor

Illustration 72
The 12 volt starting motor which shows the electrical connections
(1) Tighten the solenoid terminal to the following torque. ....................................... ….8 N·m ( 70 lb in)
(2) Tighten the positive terminal nut to the following torque. ....................................... .6 N·m ( 53 lb in)
(3) Tighten the negative terminal nut to the following torque. ........................................8 N·m (70 lb in)
Rated voltage ................................................ ……………………………………………...12 volts

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Glow Plugs

Illustration 73
Typical example

(1) Tighten the glow plugs (3) in the cylinder head to

the following torque. .................. 15 N·m (11 lb ft)

Tighten the nuts (2) for the bus bar (1) that is
installed on top of the glow plugs to the following
torque................................................ 2 N·m (18 lb in)

Voltage ................................................. 12 or 24 volts

Note: Glow plugs are not installed on all engines.

Engines that do not have glow plugs are installed
with threaded plu

55
56
 31. General
30. Electrical system

32. Electric system

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31. General
A90-A100-A110 1

Content

31 Electrical system in general:

Technical data, technical specifications, training material

General ………………………………………………………………………………………………….. 2
Safety precautions for the electrical system …………………………………………………………. 3

Alternator ………………………………………………………………………………………………… 3
Battery checks and maintenance ……………………………………………………………………… 3

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31. General
A90-A100-A110 2

General

Tractors have 12 V electrical system (negative earthing). Battery is fitted in the engine compartment in front of the cab.

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V, negative ground

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Ah
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75A
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 kW

Bulbs:
- headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- parking/brake lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60/55 W-H4
- direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 W, 5/21 W
- working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 W
- instrument panel and warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 W-H3
- cabin light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 W-1,2 W
5W

- Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 A ( 5 pcs )
10 A ( 4 pcs )
15 A ( 6 pcs )
20 A ( 3 pcs )
25 A ( 2 pcs )

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 Model Page
31. General
A90-A100-A110 3

Safety precautions for the electrical system:

-always connect the battery with the correct polarity disconnect the negative lead of the battery first and connect it last
-disconnect the battery leads before removing the alternator remove the battery caps during charging to prevent the build

up of explosive gases in the battery

Alternator

The tractor has a negative-earthed alternator which can

easily be damaged if incorrect connections are made in the
electrical system. For example, connection of the battery
with wrong polarity can burn the alternator or rectifier.

Battery checks and maintenance

-Check the charge in the battery using a hydrometer (acid tester). The density of the electrolyte should be at least

-Make sure that the fan belt (belts) are always correctly tensioned.

-Keep the battery clean. It can be washed with lukewarm water after removal from the tractor.

-Also clean the pole studs, the cable terminals and the battery retainer thoroughly. Wash off oxidized spots with water.

Wipe the outside of the battery when it is clean, and coat the pole studs and the cable terminals with petroleum jelly.

-Refit the battery.

WARNING
It is forbidden to smoke or have a naked flame near the battery. The battery gives off explosive
hydrogen gas!
Battery electrolyte is corrosive.

CAUTION
-Always when the electric welding is done to the tractor, disconnect both battery cables (+ and -) and
alternator wires.
-Otherwise the tractor electric system can be damaged.
-Auxiliary equipment must be fitted according to the instructions. Fuse nominal current rating must be checked before

fitting.

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 Model Page
32. Electrical System
A90-A100-A110 1

Content

32 Electric system:

Content ………………………………………………………………………………………………. 1
32 Electric system…………………………………………………………………………………… 1
With Cab Models……………………………………………………………………………………. 3
Cabless models……………………………………………………………………………………… 4
Standard trailer socket ……………………………………………………………………………... 5
Headlight adjustment……………………………………………………………………………….. 5
Electric Diagram of Tractor ………………………………………………………………………… 6
Instrument panel ……………………………………………………………………………………. 7
Instrument panel ……………………………………………………………………………………. 9
Front panel of instrument panel (1) ………………………………………………………………. 9
Steering wheel adjustment (2) ……………………………………………………………………. 9
Direction indicator flashers and horn (3) …………………………………………………………. 9
Light switch (4) ………………………………………………………………………………………. 9
Switch for windscreen was− her (5) ……………………………………………………………….. 10
Switch for windscreen wiper (6) …………………………………………………………………… 10
Instrument panel (2) ………………………………………………………………………………… 10
Fuel gauge (3) ………………………………………………………………………………………. 10
Tachometer (4) ……………………………………………………………………………………… 10
Coolant thermometer (1) ……………………………………………………………………………. 10
Indicator lights for direction indicator (2) ………………………………………………………….. 10
Indicator light for main be−am (5) …………………………………………………………………. 10
Indicator lights on instrument panel ……………………………………………………………….. 11
Infoline − instrument panel operating hour meter (2.7) ………………………………………….. 12
Right Side panel of instrument panel (3) ………………………………………………………….. 12
Ignition switch (3.1) …………………………………………………………………………………. 12
Rear window opening and locking device (2) ……………………………………………………. 12
Roof console ………………………………………………………………………………………… 13
Roof fan (1) ………………………………………………………………………………………….. 13
Recirculation control knob (2) ……………………………………………………………………… 13

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 Model Page
32. Electrical System
A90-A100-A110 2

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 Model Page
32. Electrical System
A90-A100-A110 3

-With Cab Models

FA, FB, FC, FD Fuses that left side to right side

FA1 3A Air compressor , differential , dashboard

FA2 5A. Beacon lamp
FA3 10A Wiper switch, automatic wiper relay
FA4 25A Parking lamp switch
FA5 20A 4WD relay, brake relay , 4WD switch, hazard warning flasher

FB1 10A Light, direction indicators, horn handle

FB2 10A Dipped beam ,
FB3 15A Main beam , main beam indicator light
FB4 5A Lift relay
FB5 20A Starter switch

FC1 3A Lighter
FC2 5A Rear working lights relay
FC3 15A Flasher , horn, front working lights relay,
FC4 15A Dashboard, left light
FC5 25A Rear working lights

FD1 15A Air conditioning relay, roof fan motor

FD2 5A Lift relay, lift switch
FD3 15A PTO relay , cab light
FD4 10A Radio - CD, dashboard
FD5 5A Washer

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 Model Page
32. Electrical System
A90-A100-A110 4

- Cabless models

FA, FB, FC Fuses that left to right side.

FA1 10A Instrument,instrument lamps, fuel gauge.

FA2 15A Beacon lamp.
FA3 5A
FA4 15ABeam switchı,lihtning lamp.
FA5 25A Indicator lights, brake lamps, 4WD, differential lock.

FB1 15A Beam switch

FB2 15A Dipped beam
FB3 3A Main beam, - warning lamps
FB4 20A Lamp warning buzzer.
FB5 15A Starter switch, elektrik-stop,

FC1 5A Rear working lights.

FC2 10A horn. front working lamps,
FC3 25A left park lamp,instrument lamps,working lamps switch, warning flashes, lighting lamp
FC4 10A right park lamp.
FC5 5A warning lamps flashes.

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 Model Page
32. Electrical System
A90-A100-A110 5

Standard trailer socket

1. Brake light (red)

2. LH side direction indicator (yellow)
3. Earthing (white)
4. RH side direction indicator (violet)
5. RH side parking light (brown)
6. LH side parking light (black)
7. Continuous current, max. 15 A. The possibility to switch off the currentsupply is only available on the models with a
main switch or a rear fog light.

Headlight adjustment

Correct adjustment of the headlights is very important when running on the public highway.
Headlight adjustment can be carried out quickly and accurately by using an optical headlight adjusting unit. If no optical in
strument is available, adjustment can be done as follows:
- Check before adjusting the headlight that the tractor loading is normal and tyre pressures are correct.
- With dipped-beam switched on, the cutoff edge of the light pattern should come at height H when the tractor is at
distance L.
- With full-beam switched on, the distance between the light points should be B.
Any necessary adjustment is done with the headlamp adjusting screws.
Measurements:
L=5m
B = Distance between headlight centres
H = Height of headlights above ground minus 50 mm

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 Model Page
32. Electrical System
A90-A100-A110 6

Electric Diagram of Tractor

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32. Electrical System Model Page
A90-A100-A110 7

Instrument panel

Front panel of instrument panel

1. Controls for:
− direction indicator flashers
− full/dipped − beam
− horn
2. Fuel gauge
3. Tachometer
4. Coolant thermometer
5. Info line − instrument panel for operating hours
6. Switch for windscreen washer (Old and new design)
7. Switch for windscreen wiper (Old and new design)
8. Ashtray
9. Switch for differential lock
10. Lift switch
11. Front working light
12. Rear working light
13. Peak lamp switch
14. Rear window wiper switch
15. Lift Air
16. Signal button
17. 4WD için Switch
18. Lighter
19. Glasses

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 Model Page
32 .Electrical System
A90-A100-A110 8

1
7
4
5
6
3
2

1. Clutch lever, power take − off

2. Fuse box, open able lower panel for books
3. Accelerator pedal
4. Brake pedals
5. Clutch pedal
6. Steering adjustable system
7. Hand accelerator lever

Fuse box, place for books (5)

On the openable cover there is also a place (1) for

books.

A blown fuse indicates a fault condition, which should be traced and repaired. Fuses must not be replaced with ones of a
higher rating, since this may cause damage to the electrical equipment.

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 Model Page
32.Electrical System
A90-A100-A110 9

Instrument panel
. Front panel of instrument panel (1)

. Steering wheel (1.1)

Full/dipped − beam headlights,
Direction indicator flashers and horn (3)
Headlight dipper
Main beam, when pushing the lever to the outermost
position away from the driver.
Dipped beam, when pulling the lever into the middle
position towards the driver.

Direction indicators LH/RH: Lever in rear position/in front

position.
Horn: Push the button at the end of the lever.

Headlight flasher
Operates when moving the lever towards the driver when
the headlights on dipped beam are switched on.

. Light switch (4)

IMPORTANT: Do not hold the front wheels at full steering

lock for long periods as the oil temperature quickly rises
increasing the risk of damage to the pump. If the oil
supply from the hydraulic pump should fail for any reason,
the tractor can still be steered manually with the steering
wheel. Steering is heavy to use and it operates slowly.

At full − lock it is possible to force the steering wheel

further manually. This slip of the steering wheel, also
noticeable when driving across a slope, is normal and is
caused by an internal flow of oil for lubrication of the
steering valve.
WARNING: If a malfunction occurs in the
steering system the tractor should be
stopped and the malfunction corrected
before restarting.
. Steering wheel adjustment (2)
The steering wheel can be adjusted to different driving
positions by first opening the lock. After adjusting tighten
the lock.
With the lights switched on, the rocker switches are
internally illuminated for ease of operation in the dark.
Position 1: Marker lights switched on.
Position 2: Marker lights and full/dipped − beam
headlights switched on.
NOTE: If the lights are left on after turning the current off
the buzzer begins to sound.
When the current is off, the parking lights and the
headlights can be switched on without buzzer sounding.
This function is useful when leaving the tractor standing
with parking lights on.

WARNING: Do not adjust steering wheel

position while driving.

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 Model Page
32.Electrical System
A90-A100-A110 10

. Switch for windscreen was− her (5)

When pressing the spring returned side of the switch, the

windscreen washer operates.

. Switch for windscreen wiper (6)

The switch has three positions. .Fuel gauge (3)
Off position =the opposite side to the lens depressed The fuel level warning light (5) comes on, when about 14 l
of fuel is left. To prevent formation of condensation, it is
Drizzle position = middle position recommended that the tank should be kept full.

The wiper on = the lens side depressed . Tachometer (4)

The tachometer (rev. counter) shows the engine speed in
. Instrument panel (2) hundreds of revolutions per minute.

. Coolant thermometer (1)

The white zone shows the limits for the normal operating
temperature. Stop the engine if the needle moves into the
red zone.

. Indicator lights for direction indicator (2)

There is an indicator light for the right and left direction
indicators.

. Indicator light for main be−am (5)

The tractor is available an İnstrument pane.
Infoline − instrument panel: This indicator light comes on, when the main beam is on.
− Infoline − instrument panel is equipped with a
mechanical hour meter

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 Model Page
32.Electrical System
A90-A100-A110 11

-Indicator lights on instrument panel

1. Direction indicator warning light for second trailer

(green, if one of the bulbs on the combination has
failed, this light will not come on)
2. Direction indicator warning light for first trailer (green, if one of the bulbs on the combination has failed, this light will not
come on)
3. Not in use
4. Engine air cleaner warning light for blocked filter (yellow), filter must be serviced
5. Engine oil pressure (red) is too low
6. Not in use
7. Engine STOP (red) is flashing. The tractor and the engine must be stopped immediately. Must only be
continued in an emergency, e.g. the tractor can be
moved to the roadside.
8. Not in use
9. Not in use
10. Not in use
11. Four − wheel drive (yellow) is engaged, 4WD models 2
12. Not in use
13. Cold start glow (yellow) is on when the starter switch is in
the position 1 and automatic glowing is in operation.
14. Rear power take − off (yellow) is disengaged with PTO
Clutch lever, max 5 min
15. Parking brake (red) is applied
16. Low fuel level (yellow), comes on when about 14 l fuel is left
without extra tank.The indicator light comes on if the fuel feed
pressure is too low.
17. Battery charging (red) is on when charging does not operate
18. Not in use
19. Not in use
20. Not in use
21. Differential lock (yellow) is engaged
22. Not in use The stop indicator light is operated at the same as
the engine oil pressure indicator light.

If only the central warning light (STOP) starts to flash, the

engine temperature is too high (can be seen also on the 1
temperature gauge).

If the central warning light (stop) starts to flash when the tractor has been driven the engine must be stopped immediately
and the fault must be repaired before continuing again.
When the starter switch is turned on to position 1, the following indicator lights must come on:
− engine oil pressure (5.)
− stop light is flashing (7.)
− parking brake (15.), when the parking brake is applied
− battery charging (17.)

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 Model Page
32.Electrical System
A90-A100-A110 12

Infoline − instrument panel operating hour meter (2.7)

The hourmeter always shows the total number of hours worked.

. Right Side panel of instrument panel (3)

. Ignition switch (3.1)
Starter switch positions
Stop, motor

1 Power on
When the ignition switch is turned from the stop posi tion to position 1, in cold conditions, while the engine is cold, the
automatic glowing is turned on and the glow indicator light in the instrument panel comes on. (normal position for running the
engine, which also allows for the electrical equipment to be used when the engine is not running).

Starting position

If the automatic glowing is on, the engine can be started when the glowing light in the instrument panel is gone out.
If automatic glowing is not used, the switch can be turned directly to the starting position

Controls on rear side

Rear window opening and locking device (2)

By pulling the handle (2) the window can be opened.
By pulling the handle (1) the window can be shut.

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 Model Page
32.Electrical System
A90-A100-A110 13

. Roof console

5 5
6

4 4

7
1 2 3

8
4 4

. Roof fan (1)

This fan blows air through the ventilation nozzles.

. Recirculation control knob (2)

On the front part of the roof console there is an adjustable control knob for air recirculation. Turning this knob clocwise
progressively closes the air inlet from outside.
With the knob in this position:
− The cab will heat up faster
− The heating capacity will be higher
− Higher cooling capacity with air conditioning.

With the knob in this position

− The windows will demist faster (reduces humidity/ice forming)
− The pressure in the cab will be higher (reduces dust quantity)

73
74
40. Power Transmission 41. Clutch

42. Gearbox

43. Lowgear

Overdrive Shuttle

44. Final gears

45. Power take--off

75
40. Clutch Model Page
A90 - A100 - A110 1

Contents

41. Clutch

Technical data ………………………………………………………………………………………………….. 2

Setting values ………………………………………………………………………………………………….. 2

Tightening torques …………………………………………………………………………………………….. 2
Clutch, description …………………………………………………………………………………………….. 4
Reconditioning clutch ………………………………………………………………………………………….. 7
1. Changing clutch with splitting tractor ………………………………………………………………… 7

A. Parting tractor at clutch ………………………………………………………………………………… 7

B. Removing fitting clutch ………………………………………………………………………………….. 8
C. Assembling tractor at clutch …………………………………………………………………………….. 9

D. Adjust clutch pedal free travel ………………………………………………………………………….. 10

E. Adjusting PTO clutch lever free travel ………………………………………………………………… 11

2. Changing clutch without splitting tractor …………………………………………………………….. 12

A. Fitting clutch ……………………………………………………………………………………………….. 12

B. Reconditioning clutch release bearings ………………………………………………………………… 14
3. Changing propulsion clutch disc and adjusting clutch …………………………………………….. 15

A. Dismantling clutch …………………………………………………………………………………………. 15

B. Assembling and adjusting clutch ………………………………………………………………………… 16

76
41. Clutch Model Page
A90 – A100 – A110 2

Technical data

The clutch is a mechanically controlled double, dry disc clutch, which is bolted to the flywheel. The
clutch disc closest to the flywheel is for the PTO and the disc inside the clutch is for the propulsion clutch.

Type:
- A80, A90, A100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LuK 295/280
Clutch disc:
- propulsion clutch/PTO clutch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 295/280 mm, organic linings
Thrust spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . disc spring
Thrust of disc spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6200--7000 N
- release force, propulsion clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1320 N
- release force, PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 N
Thrust of disc spring (LuK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400--7600 N
- release force, propulsion clutch (LuK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 1740 N
- release force, PTO clutch (LuK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 2260 N
Required pedal force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 kp

Setting values
Clutch pedal free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--25 mm
PTO clutch lever free travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30--40 mm
Thickness of spacer blocks (4 pcs) when adjusting clutc
- LuK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,6 mm
Distance between flywheel--propulsion clutch levers:
- LuK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 ± 0,5
Distance between flywheel--PTO clutch levers
- LuK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 ±0,5 mm

Tightening torques
Engine--fuel tank:
- hexagonal socket head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
- hexagonal head bolts 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
- hexagonal head bolts 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Clutch--flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Flywheel--engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Pressure oil pipe for hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Pressure oil pipe. steering system--pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Hose unions, steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Connection sleeve, clutch shaft -- gearbox input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . …. 55 Nm
Clutch shaft--low gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Release bearing brackets--tractor frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Clutch housing--tractor frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Top link bracket nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
PTO--gearbox:
- 10 pcs (19 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
- 2 pcs (M16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm
- 2 pcs (M20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm

77
41. Clutch Model Page
A90 – A100 – A110 3

Special tools

Clutch A
Part no Description
ETV 891 211* Centring drift for PTO clutch disc
ETV 892 570 Kit for adjusting clutch containing the following parts:
1. ETV 892 571 Adjusting fixture
2. ETV 892 592 Centring sleeve for propulsion clutch disc
3. ETV 892 575 Press drift D = 150 mm, L = 50 mm
ETV 892 578 Press drift D = 90 mm, L = 40 mm
4. ETV 892 570 Pressure and turning lever, complete
7. ETV 893 710* Spacer block 6,5 mm (4 pcs) (Spacer block 7,6 mm for LuK--clutch)
8. Std. Bolt M8X60, at least 4 pcs
10. ETV 892 582 Guide pin
12. ETV 893 711* Spacer sleeve 72 mm, propulsion clutch (Spacer sleeve 68 mm for LuK--clutch)
ETV 893 712* Spacer sleeve 96 mm, PTO clutch (Spacer sleeve 93 mm for LuK--clutch)
13. ETV 892 584 Indicator sleeve, L = 30 mm
14. ETV 892 585 Long indicator, PTO clutch
ETV 892 586 Short indicator, propulsion clutch

15. ETV 892 58 Indicator nut

(ETV 893 650) Drift for fitting needle bearing and seal inside clutch shaft (see Gearbox)

Clutch A

78
41. Clutch Model Page
A90 – A100 – A110 4

Clutch, description
At the lower end of the PTO clutch lever there is
The clutch is double, dry disc clutch. The disc nearest the
a switch for a control lamp on the instrument panel which
flywheel is for the PTO and the disc inside the clutch is for
the propulsion of the tractor. The hub of the disc for the lights when the clutch lever is in the disengaged position
propulsion clutch is provided with springs which dampen ( which should not be used more than necessary and at the
vibrations. The nominal diameter of the discs is 295 mm. most for 5 minutes).
The discs have organic compound linings.
The power for the PTO clutch is transmitted via a long shaft
which runs inside the main input shaft to the gearbox right
through to the back of the tractor. The propulsion clutch
transfers the power from the flywheel via the tubular clutch
shaft to the main input shaft of the gearbox.

Both clutch discs are operated separately. The propulsion

clutch is operated with a pedal and the PTO clutch with a
lever. The free--travel of both the pedal and the clutch
lever can be adjusted with screws on the respect-
ive controls.
The clutch pedal mechanism includes a starter interlock
Switch, which means that the starter motor can only be en-
gaged when the clutch pedal is depressed fully.

Fig. 1. Sectional drawing of clutch mechanism (not 205)

1. EP--grease on splines
2. Universal grease on sliding surfaces
3. The bearings are to be filled with grease
NOTE: With effect from ser. no. 606690 bearing bands are
fitted on the sliding surfaces between the release bearing
sleeves and their supports (points 2 in figure). These
bearing bands must be greased with multi--purpose grease
when re-pairs are carried out. The clutch cover no longer
contains oil holes and screws.

79
 Model Page
41. Clutch
A90 – A100 – A110 5

Figure 2. Clutch controls.

1. Universal Grease
2. Adjusting distance for PTO clutch control lamp switch
3. Adjusting distance for starter interlock switch pedal fully depressed
A. Screw for adjusting PTO clutch pedal free travel
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 Model Page
41. Clutch
A90 – A100 – A110 6

Figure 3. Connecting sleeve

1. Universal grease
2. Extra pressure grease on splines
N.B. Bolts to be secured with tab washer at arrows
3. Connecting sleve
4. Safety plate
5. Gearbox input shaft. At the front end of the shaft there is a lubricating hole.
5a. Plug.
6. Clutch shaft. The connecting sleeve 3 fixing bolts have been made longer, at which time the splines on the sleeve have
been shortened.
7. Bearing cover.
8. Long PTO clutch shaft. A thinning for lubricating oil has been made on the shaft 8

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41. Clutch
A90 – A100 – A110 7

Reconditioning clutch

1. Changing clutch by parting tractor

A. Parting tractor at clutch

(see N.B. under point 11 in the following text)
1. Remove the engine hood plates. Remove the battery
and the battery shelf (17 and 19 mm).
2. On the left--hand side of the engine disconnect

5. Disconnect the heater hoses and disconnect the roller

blind chain.

-- governor and stop controls at the rear ends.

NOTE: (Tractors with a separate stop control knob on the
instrument panel:) the stop control wire must be
disconnected from the injection pump. Later tractors has a
throttle control wire and not a linkage as above.

6. Loosen the clamp for the steering system pressure oil

pipe (lower hose) and disconnect the oil lines to the
steering cylinder (22 mm).
7. Disconnect the steering system pressure oil pipe and the
suction pipe at the pump.

-- fuel lines

3. Disconnect the cable harnesses from the front wall of the

cab.
4. Drain the oil from the hydraulic system (approx. 30
litres).
8. Disconnect the hydraulic lift pressure oil pipe (27 and 26
mm). Free the engine breather hose under the front edge
of the cab.

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41. Clutch
A90 – A100 – A110 8

N.B.On tractors with powered front axle: disconnect the B. Removing fitting clutch
guard for the propeller shaft (17 and 19 mm) and unscrew
the threaded sleeve on the propeller shaft. N.B. Later
tractors have not the threaded sleeve.
9. Position trestles on castors under the tractor from both
sides of the frame joints.
N.B. Fit support plates ET 893 760 on both sides under the
front end of the tractor to prevent the front axle from
oscillat-
ing.

1. Unscrew the clutch attaching bolts evenly and gradually

around the circumference of the clutch.
2. Remove the clutch and the PTO clutch disc from the
flywheel.
3. Check the contact surface on the flywheel. Also check
the tightness of the flywheel attaching bolts (120 Nm).
4. Remove the circlip for the ball bearing in the flywheel

10. Unscrew the bolts between the engine and the fuel tank
(17 mm at the top and 10 mm underneath, socket head).
N.B.Before splitting the tractor, engage the PTO, i.e. the
clutch
engaging sleeve in the PTO housing should be in the
engaged position.

5. If necessary, change the bearing in the flywheel and

grease the new bearing with universal grease. Fit the
circlip.

11. Push the engine part of the tractor forwards by rolling

the front wheels. Check that the long PTO shaft does not
come out forwards with the clutch (the splines at the end of
the shaft should always be level with the front end of the
propulsion clutch shaft.)

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41. Clutch
6. Press in the centring drift ETV 891 211 in the flywheel
and fit the clutch disc on the drift (the longer part of the hub
turned towards.
7. Fit the clutch and tighten to a torque of 23 Nm.
8. Remove the centring drift ETV 891 211 with a bolt
M12x100.
9. Check the clutch shaft splines and lubricate them with
EPgrease.
10. Change the release bearing if necessary.
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A90 – A100 – A110 9
C. Assembling tractor at clutch
Assembling the tractor is made easier by using two bolts
(M12, l=100) as guide pins.
1. Push the frame parts together, while at the same time
guiding the propeller shaft for the front axle onto its splines
(the universal joints should lie in the same relative
position).
2. Guide the hydraulic system suction pipe into place.
N.B. The clutch shafts are easier to insert in the clutch if
the engine is cranked slightly when fitting.
3. Tighten the bolts in the lower part of the joint to 80 Nm
(hexagonal socket head 10 mm) and the bolts in the upper
part of the joint to 45 Nm (8.8) or 60 Nm (10.9) apart from
the battery shelf attaching bolts.
4. On four--wheel drive models tighten the threaded sleeve
on the propeller shaft. Fit the protecting plate for the
propeller shaft. (N.B. On later models there is no threaded
sleeve on the propeller shaft).
5. Fit the battery shelf. Remove the support plates and
trestles.
 Model Page
41. Clutch
A90 – A100 – A110 10

D. Adjust clutch pedal free travel

6. Connect the fuel lines (note position of breather and

return hoses) and the rear ends of the accelerator and stop
control (or on the latest models connect the stop control
wire to the
injection pump). Later models have a throttle control wire Adjust the pedal free travel with the adjusting bolt which is
which should be connected. located in the clutch pedal mechanism with clutch cable on
the left side of the frame. The free travel should be 20--25
mm.

7. Connect the hydraulic system suction pipe, pressure oil

pipe (60 Nm) and hoses to the steering valve (45 Nm).
8. Connect the steering hydraulic pipe to the pump (45 Nm)
and fit the clamp on the pipe.
9. Connect the engine breather pipe. Connect the electrical
leads at the front wall of the cab.

10. Connect the heater hoses. Fit the roller blind. Fit the
battery.
11. Fil with hydraulic oil (approx. 35 litres). Bleed the fuel
system.
12. Adjust the PTO lever free travel and the clutch
pedal free travel (see Op. D and E). Test drive the tractor.

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41. Clutch
A90 – A100 – A110 11

E. Adjusting PTO clutch lever free travel

The free travel at the top of the lever should be 30--40 mm.

1. Slacken the locking nut B.

2. Turn the adjusting bolt A until the correct free travel is
achieved.
3. Tighten down the locking nut.
N.B. Check the function of the control lamp. When necessary the switch can be adjusted according to item 2 in fig.

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41. Clutch
A90 – A100 – A110 12

2. Changing clutch without splitting tractor

A. Fitting clutch
If the clutch shaft and release bearings have been
removed, on machines with low gear these should be fitted
before fitting the clutch.

Before fitting clutch,

5. Fit the clutch bolts and tighten them evenly to a torque of

23 Nm.

1. Fit the centring drift ETV 891 211 on the flywheel

ensuring that the pin on the drift faces upwards. Fit the
PTO clutch disc on the drift and fit the clutch.

2. Machines without low gear: check the connecting sleeve

O--rings, change them if necessary. Note that flatareas for
the locking bolts on the splines. Lubricate the splines with
EP grease.

3 a) Machines without low gear: push the front end of the

clutch shaft onto the propulsion clutch disc splines and fit
the release bearings on the frame.
6 a) Machines without low gear: fit the connecting sleeve
between the clutch shaft and the gearbox input shaft.
3 b) Machines with low gear: push the clutch shaft into the Tighten the bolts to a torque of 55 Nm and lock with locking
clutch once the clutch is attached to the flywheel.
washers.
N.B. Lubricate the clutch shaft splines with EP grease.

4. Fit the clutch loosely by its upper part with some bolts,
and mark with chalk the position for the centring drift pin in
the upper part of the clutch.

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41. Clutch
A90 – A100 – A110 13

tighten it down into the drift threads. Carefully withdraw the

drift with out rotating the handle.

10. Push in the long PTO shaft. The shaft is fully home
when the distance between its rear end and the contact
surface for the PTO is at least 45 mm.

N.B. If the long PTO shaft does not go fully home against
the flywheel, the fitting may be made easier by disengaging
the PTO clutch slightly.

N.B. Check that the ball and needle bearing are in position
at the rear end of the shaft. Apply locking fluid to the outer
bearing race.

6 b) Machines with low gear: push in the clutch shaft onto

the clutch splines and fit the rear end of the clutch shaft in
the low
gear and tighten to a torque of 55 Nm.

7. Turn the clutch so that the pin on the centring drift points
upwards (see the marking).

11. Lubricate the release forks with universal grease and fit
them.

8. Fit the release bearings to the tractor frame according to

the
guide pins and markings which were made when removing
them. Tighten the nuts to a torque of 45 Nm.

N.B. Assembling must be carefully carried out as any

inaccur-
acies may cause the mechanism to bind

12. Fit the clutch cover and tighten down to a torque of 45

Nm. One of the bolts is used for securing the switch for the
PTO clutch control lamp. Two of the bolts attach the battery
shelf. Fit the cover for the clutch shaft tunnel.

9. Carefully push the handle ET 891 200 from behind the

tractor through the tubular shaft to the centring drift and
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41. Clutch
13. Fit the lower part of the PTO clutch lever on its shaft.
Connect the accelerator linkage and the fuel hoses. Fit the
battery shelf and battery.
14. Fit the service hatch to the front wall of the cab and fit
the floor plate.
15. Fit the floor mat and strips. Fit the knob on the
hydraulic lift lowering speed control and the plate for the
low gear lever grommet (models without low gear).
16. Fit the grommets for the pedals, the pedals and
accelerator pedal. Fit the PTO lever adjusting bolt and the
lever support rail to the front wall of the cab. Fit the switch
for the clutch lever control lamp.
17. Fit the PTO. Fill the gearbox with oil.
18. Adjust the clutch pedal and the PTO lever free travel.
Check that the control lamp for the PTO lever functions.
19. Bleed the fuel system and fit the engine hood plates.
Test drive the tractor.
B. Reconditioning clutch release bearings
1 a) Machines without low gear: remove the release
bearings according to
1 b) Machines with low gear: remove the release bearings
according
2. Fit a counter hold to the end of the release bearing guide
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Model Page
A90 – A100 – A110 14
sleeve and pull out the propulsion clutch bearing from the
guide sleeve. Release the springs and free the support
sleeve.
3. Knock the PTO bearing out of the support sleeve and fit
a new bearing.
4. Check the condition of the guide sleeve for wear. Apply
multi--purpose grease to the sliding surfaces of the
sleeves.
With effect from ser. no. 606690 the sliding surfaces are
fitted with bearing bands, which should be changed when
necessary. Lubricate the bearing bands with grease.
5. Fit the PTO bearing with bearing support on the guide
sleeve. Tap the propulsion clutch bearing into the guide
sleeve end.
6. Fit the release bearings in position.
N.B. Changing the propulsion clutch release bearing is
poss-
ible even when the tractor frame is parted at the propulsion
clutch. The bearing is then pulled out with a puller. The
puller
is supported on the sleeve (ETV 893 780) which is
positioned against the end of the guide sleeve. The puller
should notunder any circumstances be supported against
the end of theclutch shaft.
 Model Page
41. Clutch
A90 – A100 – A110 15

3. Changing propulsion clutch disc and

adjusting clutch

A. Dismantling clutch

3. Slacken the locking nuts (14 mm) for the PTO clutch
levers.
Check the condition of the levers for any damage resulting
from wear.

1. Position spacers ETV 892 571 (4 pcs), with a thickness

of 7,6 mm on the clutch fixture ETV 892 571.

4. Slacken the clutch attaching bolts and carefully lift away

the clutch casing. remove the plastic sleeves and springs
which sit on the attaching bolts. Remove the release pins.

5. Remove the clutch disc, pressure plate and disc spring.

Clean the parts and check their condition.

N.B. Checking the disc spring force is only possible by

using a special method (see Technical Data). Permissible
final machining for the pressure plate is 0,5 mm per friction
2. Place the clutch on the fixture and bolt it down with the
surface. The clutch surface should be machined by the
clutch attaching bolts M8X60.
same amount so that the disc spring position is constant.
N.B. Mark the pieces while in place in order to make
assem- bling easier. If the pressure plates need to be
changed, the
clutch should be balanced afterwards.

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41. Clutch
A90 – A100 – A110 16

B. Assembling and adjusting clutch

1. Screw the guide pin ETV 892 582 into the clutch fixture
and fit the centring sleeve ETV 892 592 on the pin.

2. Position the spacers on the fixture.

3. Place the PTO clutch pressure plate with attaching bolts

on
the fixture.

4. Fit the disc spring with the concave side facing upwards.
Lubricate the spring and pressure plate contact surfaces
with
grease.

9. Release the guide stud from the fixture (centring sleeve

to remain in place). Fit pressure drift ETV 892 575 (diam.
150 mm) on the pressure lever ETV 892 570 and bolt down
the lever on the fixture. Press down the PTO clutch levers
a couple of times.

10. Replace the pressure drift with pressure drift ETV 892
578 (diam. 90 mm) and depress the propulsion clutch
levers a couple a time.

Note! The levers are depressed in order that the parts

should become seated.

5. Fit the propulsion clutch pressure plate and disc (with
the longer part of the hub facing upwards). Fit springs and
plastic
sleeves on the attaching bolts.
6. Fit the clutch casing. Guide the plastic sleeves and fit the
release pins through the openings in the side of the clutch
casing.
11. Remove the pressure lever from the fixture and remove
the propulsion clutch disc centring sleeve.
12. Fit the guide stud to the fixture. Fit the spacer sleeve
ETV 893 712 (l=96 mm) on the stud (the larger diameter
hole turned downwards (for LuK--clutch the spacer sleeve
length must be 93 mm).

N.B. The ends of the release pins should be by the studs

which are there for the pins. Grease the ends of the pins.

7. Bolt down the clutch to the fixture.

8. Use new nuts on the PTO clutch levers.

N.B. The nuts should always be changed.

13. Bolt the indicator sleeve, indicator and indicator nut

onto the guide studs. Adjust the height of the PTO clutch
lever swith the help of the indicator by turning the adjusting
bolts.

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41. Clutch
A90 – A100 – A110 17

14. Lock the adjusting nuts on the adjusting bolts.

15. Fit a 72 mm spacer sleeve (for LuK--clutch 68 mm)

and shorter indicator on the guide stud in order to adjust
the propulsion clutch lever. Adjust the height of the
propulsion clutch levers.

16. Lock the adjusting bolt with locking nuts after

adjustment.
Apply locking fluid to the threads, for example Loctite 270.

N.B. Check the height of the levers once more after

applying the locking fluid.

17. After adjustment, the clutch is released from the

fixture.

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A90 – A100 – A110

Contents
42 Gearbox:
Technical data, technical specifications, training material

Technical data………………………………………………………………………………………………………. 1
Transmission 274…………………………………………………………………………………………………… 2
Power train (gearbox type 274) ………………………………………………………………………………….. 3
Gearbox 12+12R ………………………………………………………………………………………………….. 4
Assembling the transmission 274 in short ……………………………………………………………………… 5
Main shaft ………………………………………………………………………………………………………….. 6
Output sahaft (4wd models) ……………………………………………………………………………………... 8
Pinion shaft …………………………………………………………………………………………………………. 10
Countershaft ……………………………………………………………………………………………………….. 12
Gear in neutra ………………………………………………………………………………………………………. 14
Hydraulic differential lock ………………………………………………………………………………………….. 16
Differential …………………………………………………………………………………………………………… 18
Selector forks ………………………………………………………………………………………………………. 20
Lubricating oil pump ………………………………………………………………………………………………. 24
Gearbox lubrication pump ………………………………………………………………………………………… 26
Valve block …………………………………………………………………………………………………………. 28
Special tools
Special tools ……………………………………………………………………………………………………….. 1
Reconditioning pinion shaft ………………………………………………………………………………………. 2
Reconditioning main shaft ……………………………………………………………………………………….. 3
Reconditioning 4WD shaft ……………………………………………………………………………………….. 4

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42. Gearbox
A90 – A100 – A110 1
Technical data
Gears ……………………………………………………………………………….4-step, fully synchronized, operated by lever
Speed ranges ……………………………………………………………………...3 ranges, operated by lever:
H = high range, synchronized
M = medium range, synchronized
LL = creeper range, not synchronized
Forward/reverse gear unit…………………………………………………………synchronized, operated by lever
No. of speeds ………………………………………………………………………12+12
Lubrication of gearbox with gear wheel pump:
- pump volume ………………………………………………………………………………………………… 5,8 cm3/r
- pressure limiting valve opens at…………………………………………………………………………… 0,7 MPa
- filter, by-pass valve opens at ………………………………………………………………………………. 0,2 MPa
- filtration capacity…………………………………………………………………………………………….. 0,15 mm

Tightening torques
Gearbox-fuel tank:
- M14…………………………………………………………………………………………………………… 200 Nm
- M16 …………………………………………………………………………………………………………... 300 Nm
Gearbox-rear axle housing…………………………………………………………………………………... 230 Nm
Gearbox-PTO:
- 10 pcs………………………………………………………………………………………………………… 100 Nm
- 2 pcs M20……………………………………………………………………………………………………. 380 Nm
Gearbox-hydraulic lift………………………………………………………………………………………… 195 Nm
Draw bar-gearbox…………………………………………………………………………………………….. 380 Nm
Side cover …………………………………………………………………………………………………….. 46 Nm
Pinion shaft, round nut……………………………………………………………………………………….. 270
Pinion shaft, front end cover ………………………………………………………………………………… 23 Nm
Main shaft, front end cover ………………………………………………………………………………….. 23 Nm
Countershaft, front end cover ………………………………………………………………………………. 23 Nm
4WD shaft to powered front axle, round nut ………………………………………………………………. 127 Nm
Selector shaft locking nuts …………………………………………………………………………………... 23 Nm
Selector shaft nut, outgoing shaft to powered front axle …………………………………………………. 120 Nm
Lubricating oil pump:
- 2 pcs ………………………………………………………………………………………………………….. 23 Nm
- 3 pcs ………………………………………………………………………………………………………….. 6 Nm
Propeller shaft drive flanges:
- 8.8 bolts ………………………………………………………………………………………………………. 23 Nm
- 10.9 bolts …………………………………………………………………………………………………….. 35 Nm
Main shaft - clutch shaft, connecting sleeve ………………………………………………………………. 55 Nm
Crown wheel, attaching bolts ……………………………………………………………………………….. 46 Nm
Differential bearing …………………………………………………………………………………………… 46 Nm
Cab - rear axle housing ……………………………………………………………………………………… 220 Nm
Rim disc - hub ………………………………………………………………………………………………… 330 Nm
Steering system return oil pipe (rear end) …………………………………………………………………. 50 Nm
Hydraulic system pressure pipe to pressure filter …………………………………………………………. 120 Nm
Pressure filter …………………………………………………………………………………………………. 200 Nm
Lower links - rear axle housing ……………………………………………………………………………… 380 Nm

Settings

Pinion shaft, rolling resistance:

- measured with torsion meter at end of shaft ……………………………………………………………... 1,7-2,3 Nm
Differential, rolling resistance:
30 km-transmission
- measured with torsion meter at end of pinion shaft, where the resistance is the rolling
resistance of the pinion shaft bearings plus ......................................................................................... 0,6-2,0 Nm
40 km-transmission
- measured with torsion meter at end of pinion shaft, where the resistance is the rolling
resistance of the pinion shaft bearings plus …………………………………………………………………0,8-2,6 Nm
Countershaft, end float ………………………………………………………………………………………...0,025-0,075 mm
Main shaft, end float…………………………………………………………………………………………... 025-0,075 mm
Tooth backlash, pinion/crown wheel ………………………………………………………………………………………………… 0,18-0,33 mm

Required sealing compounds and locking fluids:

Side cover - gearbox ………………………………………………………………………………………….. Silastic 738 RTV
Selector rail locking bolts ……………………………………………………………………………………. Loctite 242
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A90 – A100 – A110 2

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42. Gearbox
A90 – A100 – A110 3

Power train (gearbox type 274)

- Electro-hydraulic coupling of the 4WD (NB! four wheel braking); 4WD multi-disc clutch, new 4WD gearbox shaft + gear
- Electro-hydraulic coupling of the differential lock

- The valve block for 4WD and diff. lock on the part of the power lift housing

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A90 – A100 – A110 4

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42. Gearbox
A90 – A100 – A110 5

Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-step, fully synchronized, operated by lever

Speed ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3 ranges, operated by lever:
H = high range, synchronized
M = medium range, synchronized
LL = creeper range, not synchronized
Forward/reverse gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …synchronized, operated by lever
No. of speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . … 12+12

1) Main shaft
2) Countershaft
3) Bevel pinion shaft
4) 4WD multi-disc clutch
5) Shuttle unit

Assembling the transmission 274 in short:

1. Install lubrication pipes into the housing.

2. Assemble the main shat on the table. Note! Bearing of a front-end side must be installed afterwards when the shaft is on
its plave in the housing.
3. The races of the countershaft bearings must be assembled before installing the countershaft to the gearbox.
4. Install the main and the countershaft into the housing at same time. Fix the bearing covers and check tolerance.
5. Install the bearings, bush and spacer ring to the pinion shaft's gear Z58. Glue the bush and the plate with instant adhesive.
Note! Glue must not be dropped on the needle bearing. Install complete gear Z58 into the housing.
6. Install 4WD shaft to the housing. Thread gear wheels, bearings, spacer rings, circlip and bushing. Then install the bearing
of the both side and a circlip of the rear end side.
7. Install M-LL synchro and selector forck into the housing together. Note! Spring and ball must be installed in the fork
beforehand.
8. Install all parts of the pinion shaft into the housind and then push the shaft on its place. Check clearance and rolling
resistance.
9. Install lubrication oil pump.
10. Install the fork of the differential lock.
11. Install the differential and check preload of the bearings.
12. Check a tooth backlash.

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42. Gearbox
A90 – A100 – A110 7

- The main shaft is fitted with two synchromesh units. The front unit is used for selecting gears 1...4.
The synchromesh units are equal and interchangeable (with exception of hubs). The mounting direction is free.
After fitting new bearings the bearing clearance must to be adjusted.

Adjust the bearing end float :

- Fit the spacer ring and shims to the front of the front bearing and fit the bearing cover so that the bearings have a definite
clearance.

- Turn the shaft 20-30 revolutions, in order to set the bearings.

- Put a dial gauge against the front end of the shaft and push the shaft forwards and backwards and read the value of end
float on the gauge. The correct value is 0,025-0,075 mm

- Increase or decrease the shim thickness if necessary

1) Shims s= 0,10; 0,15; 0,20; 0,50 mm.

2) In connection with repairs, use sliding compound e.g. Molykote 321 R Spray (UC3957) on sliding surfaces or oil them.
Clean parts well before treatment!

3) Needle bearing is pushed into the shaft until front side ot the bearing front side is level with shaft end. Bearing number side
forwards.

4) The bushing pins can be fitted with Loctite 641. Do not allow locking fluid to leak on to the bearing!

5) Lubricating oil pump.

6) The shaft has an indication shoulder for identification.

Notice when installing:

- Install the main shaft and countershaft at the same time into the housing. Install the bearing covers and check tolerance.

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A90 – A100 – A110 8

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42. Gearbox
A90 – A100 – A110 9

- On tractors with a powered front axle, there is a shaft in the lower part of the gearbox which transfers the engine power to
the front axle.

The output shaft has ball bearings. The gear (Z42) on this shaft is in mesh with a gear on the pinion shaft.

- Gearbox type 274 :

The gear Z42 is fixed to the shaft with splines. The 4WD clutch drum is fitted to the shaft's front end. There is no an o-ring
between the bearing cover and the gearbox housing.

1) Not shaft seal (oil can flow to the 4WD multi-disc clutch)

Notice when installing:

- Assemble 4WD axle to the housing. Thread first the gear wheels, bearings, spacer rings, circlip and bush. Then assemble
the bearing of the front end side and the bearing of the rear end side and the circlip.

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A90 – A100 – A110 10

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42. Gearbox
A90 – A100 – A110 11

- The pinion shaft has conical roller bearings. The gears have pressure lubrication.

- The pinion shaft is fitted with two synchromesh units. The front unit is used for selecting the M-group or LL group without
syncro. The rear synchromesh unit engages high group.

- The other movement direction of the rear synchromesh unit has been eliminated with a blocking plate (note the mounting
direction). Note! the blocking plate must be mounted forward.

- Note the mounting direction of the bearing busshings under the gears Z61 and Z58.

- Gearbox type 274:

- The M-LL -range, with the twin gear Z58/34 + needle bearings.

- Selection of the range M-group has been improved by enlarging the synchro of the M-group (82mm -> 90mm).

NB! The LL group has no synchronizing ring!

1) Shims.
2) Spacer rings.
3) Sliding lac, e.g. Molykote 321 R spray
4) Glue the bush and the plate with instant adhesive. Note! Glue should not be dropped on the needle bearing.
5) Note! Direction of installation.

Notice when installating:

- After Installation of the main shaft and countershaft, assemble the bearings, bush and spacer ring to the Z58 gear wheel of
the pinion shaft. Glue the bush and the plate with instant adhesive.
Note! Glue should not be dropped on the needle bearing. Install the complete Z58 gear into the housing.

- Install the 4WD axle.

- Install all parts of the pinion shaft into the housing and theb push the shaft on its place. Check clearance and rolling
resistance

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A90 – A100 – A110 12

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42. Gearbox
A90 – A100 – A110 13

1) Adjusting bearing clearance:

- place a sufficient number of shims under the end cover to give the bearings a definite clearance and tighten down the
cover

- Measure the bearing clearance with a dial gauge.

Reduce the shim thickness until the bearing clearance is 0,025-0,075mm.

- turn the shaft at least 20-30 revolutions and check the clearance again.

2) Bearing cover, see main shaft

Notice before the installation:

- The inner races of the countershaft bearings must be assembled before installing the countershaft into the gearbox.
Notice when installing:

- Install the main and counter axles into the housing together and fix the bearing covers and check tolerance.

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A90 – A100 – A110 14

Synchronization
All gears (except LL) are synchronized. The synchromesh
units on the main shaft and pinion shaft are of different Synchromesh unit function (pinion shaft)
design. On the main shaft the synchronizing cones have
locking lugs and wire springs, whilst locking lugs, ball studs
and coil springs are used on the pinion shaft.

The synchromesh unit for high gears (H) is single

actingand is therefore blocked in the opposite direction

A. Gear in neutra
B. During the initial stage of the engagement, the sliding
coupling presses the locking lugs (ball stud and angle
piece) against the synchronizing cone. The cone is pressed
against the cup (taper) on the gear wheel under friction.
The difference in speed between the synchromesh unit and
the gear wheel begins to even out. The teeth on the synch
ronizing cone still prevent the gear from engaging
C. When the synchromesh unit and gear wheel have the
1. Main shaft
- gears 1, 2, 3 and 4 (diam. 68 mm, steel) same speed, the cone is turned out of the locked position
2. Pinion shaft exactly opposite the teeth on the sliding coupling so that it
- reverse/low gear (diam. 82 mm, steel) can engage the teeth on the gear wheel.
- high gear (diam. 82 mm, steel) 1. Synchromesh unit engagement lock:

The shape of the teeth inside the sliding coupling and on

the gear, lock the coupling sleeve and prevent it from slip
ping out of engagement when accelerating or engine bra

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king.
Model Page
42. Gearbox
A90 – A100 – A110 15

Synchromesh unit function (main shaft)

The function is the same as for the pinion shaft synchromesh unit. The sliding coupling presses the syncromesh cone locking
lug against the synchronizing cone. This is due to the goove on the inside of the sliding coupling. When the speed of the
synchromesh unit and gear wheel is nearly the same the sliding coupling engages with the gear wheel.

1. When assembling it should be noted that the bent ends

of the springs are not to be fitted in the same locking lug.
2. Sliding coupling

3. Hub

4. Synchronizing cone locking lug

5. Synchronizing cone

6. Gear wheel

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42. Gearbox
A90 – A100 – A110 16

Hydraulic differential lock

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 Model Page
42. Gearbox
A90 – A100 – A110 17

1) Frame parts

2) Piston

3) Cup springs (4pcs)

- secures quick coupling when the pins are moving to
wards the holes in the differential gear

4) Locking screw

5) Spring nut
- adjusting measure 83 mm

6) Return spring

7) Selector fork
7a) Retaining ring has to be mounted with the sharp edge
outwards from the selector

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42. Gearbox
A90 – A100 – A110 18

Differential

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42. Gearbox
A90 – A100 – A110 19

- Adjustment of the differential bearing preload by nuts in the bearing housing.

- Lock the adjusting nut with locking plate. The plate is placed under two suitable screws.

- Note! The sharp edge of the circlip must be outwards.

Removing differential:

When no parts are changed (with no affect on bearing clearance).

- Remove PTO.

- Remove rear wheels, final drives. Remove the differential.

In other case the gearbox must be removed from the fuel tank.

1. Crown wheel

2. Differential pinion

3. Differential side gear

4. Engaging sleeve for differential lock

5. Selector fork. The sharp edge of the retainer ring for the fork must be outwards.

6. Adjusting nuts

7. Switch for differential lock control lamp (S22 in the wiring diagram).

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42. Gearbox
A90 – A100 – A110 20

Selector forks

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42. Gearbox
A90 – A100 – A110 21

- The selector forks are fitted in pairs on the selector rails. Two blocking pins (point A) on the selector rail prevents two
speeds from becoming engaged at the same time on the input shaft. On the pinion shaft, a blocking plate 6 for the same pur
pose is fitted on the selector rail (point B).

The position of the selector forks relative to the synchronization rings and synchronization unit can be adjusted with nuts at
the front end of the selector shaft.

1) Shift arm tension pins. Fit first the bigger pin the split side upwards and then inside the bigger pin a smaller pin with the
split side turned downwards.

2) Gearbox main shaft

3) Bevel pinion shaft

5) Adjusting nuts for adjusting position of rails.

A) Blocking pins to prevent two speeds from becoming engaged at the same time on main shaft.

B) Blocking plate to prevent two speeds from becoming engaged at the same time on pinion shaft.

6) Blocking plate

The blocking plate has a longer nose, so that the plate do not fasten to the edges of the selector fork. In this way the selector
lever cannot even in extraordinary circumstances go over the blocking plate.

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42. Gearbox
A90 – A100 – A110 22

115
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42. Gearbox
A90 – A100 – A110 23

- The forks are adjusted with aid of the adjusting flanges at the rail front ends so that when the forks are in the middle posi
tion, the sliding coupler is in the middle position, i.e. a=a and the synchronizing cones on both sides of the coupler move
freely.

NB! The mounting of the pins.

- Pinion shaft and main shaft have slide pieces in the selector forks ( 4pcs /fork ) in order to improve the wear durability.
When assembled, the slide piece is fitted with grease.

1) Locking screw. Loctite 242 on threads.

2) The selector levers are lubricated with universal grease.

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42. Gearbox
A90 – A100 – A110 24
Lubricating oil pump

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42. Gearbox
A90 – A100 – A110 25

The pump rotates in one direction. Revolution capacity is

9,1 cm3 .
The middle gear of the shuttle unit drives the pump. The
pump rotates, although the forward-reverse shuttle is in
neutral.
- In connection with repairing, do not block up the tube
which comes to the front part of the pinion shaft with silicon.
- If the lubrication pump has been opened, secure the
screws with locking fluid Loctite 242 (UK0126).
1) Lubrication oil pump

1a) Drive lug

2) Suction from the tank (gearbox housing)

3) Pressure oil for filter

4) Distribution piece

5) Lubricating oil for main shaft

6) Driving shaft for pump

7) Seal of the PTO drive shaft

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42. Gearbox
A90 – A100 – A110 26
Gearbox lubrication pump

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 Model Page
42. Gearbox
A90 – A100 – A110 27

- The filter seat (13) has also a by-pass valve (0,4 MPa), which protects the system when e.g. oil is stiff in the oil cooler.

- Shuttle unit lubrication:

The lubrication oil is led through the groove on the joint surface and with help of the tube Z to the bearings of the shuttle unit
clutch shaft. In the shuttle unit housing there is a throttle (1,0 mm, by which the lubrication oil flow to the shuttle unit is ad
justed).

1) Intake/suction pipe
2) Pump

3) Pressure oil pipe to filter

4) Filter

5) Distribution piece

6) For lubrication of the main shaft

7) Oil to final drives and brakes

8) Lubrication for bevel pinion shaft

10) Return oil from low gear

11) Lubricating pipe for PTO

12) Oil cooler

13) Filter seat

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42. Gearbox
A90 – A100 – A110 28

Valve block

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42. Gearbox
A90 – A100 – A110 29

1 ) Valve block

1a) Non-return valve (opening pressure 0,2 MPa)

- prevents the falling of the operating pressure in the valveblock when the pressure decreases in the pump (e.g. during idle
running).

1b) Pressure measuring connector (operating pressure12-22 bar)

1c) Pressure reducing valve

- The pressure relief valve reduces the pump pressure(15-180 bar) to 19 bar (1,9 MPa)

2 ) 4WD multi-disc clutch

- NB! when the clutch is under pressure - 4WD is off- When repairing the tractor, observe that the front axle
starts to drive when the pressure decreases. When the transmission have to be tested, all wheels must be free (lifted up).

3 ) Actuating cylinder of the differential lock

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42. Gearbox
A90 – A100 – A110 1
Special tools
Reconditioning pinion shaft
1. ETV 892 230……………………….. Key for pinion shaft round nut
2. ETV 892 490 ………………............ Plate for fitting pinion shaft rear bearing bearing race
3. ETV 892 210……………………….. Sleeve for fitting bearing race for pinion shaft front bearing
4. ETV 890 830……………………….. Sleeve for fitting front bearing on pinion shaft

Reconditioning countershaft
5. ETV 891 220………………………… Sleeve for fitting bearing on countershaft
Sleeve for fitting rear bearing on 4WD shaft, front wheel drive
Reconditioning main shaft
6. ETV 893 614 .................................
Drift for removing/fitting shaft
7. ETV 893 611 .................................
Spindle
8. ETV 893 612 .................................
Sleeve for removing shaft
9. ETV 892 350 ................................
Sleeve for fitting front bearing on 4WD shaft, front wheel drive
Sleeve for fitting rear bearing on main shaft
10. ETV 893 613………………........... Sleeve for fitting shaft
11. ETV 891 900 ……………….......... Sleeve for fitting outer bearing race for main shaft front bearing
12. ETV 893 630……………………… Plate for fitting seal in bearing cover, main shaft

Reconditioning 4WD shaft

13. ETV 893 260 …………………….. Key for round nut, 4WD shaft front wheel drive
14. ETV 892 350 …………………….. Sleeve for fitting front bearing on 4WD shaft, front wheel drive
Sleeve for fitting rear bearing on main shaft
15. ETV 893 640 …………………….. Plate for fitting seal in bearing cover, 4WD shaft front wheel drive
16. ETV 891 220 …………………….. Sleeve for fitting bearing on countershaft

Changing / reconditioning differential

17. ETV 891 870 …………................. Plate for fitting thrust bearings for differential side gears
18. ETV 893 660…………................. Key for adjusting differential bearings
Sleeve for fitting rear bearing on 4WD shaft, front wheel drive

Differential adjustments
19. ETV 892 490……………………… Plate for fitting pinion shaft rear bearing bearing race
20. ETV 892 210……………………… Sleeve for fitting bearing race for pinion shaft front bearing
21. ETV 890 830………….………….. Sleeve for fitting front bearing on pinion shaft
22. ETV 892 230……………………… Key for pinion shaft round nut
23. ETV 893 660……………………… Key for adjusting differential bearings

Locally prepared tools

Reconditioning selector forks

24. ET 893 570………………………… Drift for removing/fitting selector shaft

Reconditining pinion shaft

25. ET 893 620………………………… Sleeve for fitting rear bearing on pinion shaft
Sleeve for fitting counter shaft bearing races
Sleeve for fitting rear bearing on main shaft

Reconditining countershaft
26. ET 893 620………………………… Sleeve for fitting rear bearing on pinion shaft
Sleeve for fitting counter shaft bearing races
Sleeve for fitting rear bearing on main shaft

Reconditining main shaft

27. ET 893 620……………….............. Sleeve for fitting rear bearing on pinion shaft
Sleeve for fitting counter shaft bearing races
Sleeve for fitting rear bearing on main shaft

Differential adjustments
28. ET 893 620……………….. ……… Sleeve for fitting rear bearing on pinion shaft
Sleeve for fitting counter shaft bearing races
Sleeve for fitting rear bearing on main shaft

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42. Gearbox
A90 – A100 – A110 2

Reconditioning pinion shaft

Reconditioning countershaft

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42. Gearbox
A90 – A100 – A110 3

Reconditioning main shaft

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42. Gearbox
A90 – A100 – A110 4

Reconditioning 4WD shaft

Changing / reconditioning differential

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42. Gearbox
A90 – A100 – A110 5

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 Model Page
42. Gearbox
A90 – A100 – A110 6

Locally prepared tools

Reconditioning selector forks

Reconditining pinion shaft, Reconditining countershaft, Reconditining main shaft, Differential adjustments

128
 Model Page
42. Gearbox
A90 – A100 – A110 1

Reconditioning selector forks

N.B. In these instructions the gearbox has been removed

from the tractor. The selector forks for the speed gears can
also be removed through the side cover of the gearbox, i.e.
without parting the tractor. In which case the selector shaft
is drawn out forwards after the floor plate in the cab has
been removed

4. Withdraw the selector shaft carefully while at the same

time ensuring that the ball and spring, located inside the
selector forks, do not fall down into the gearbox.
5. Lift the speed gear selector forks out of the gearbox.
Assembling:

1. Put the gears in neutral and remove the gearbox side

cover (17 mm).

1. Fit the spring and ball on the front selector fork using ET
2. Remove the selector shaft locking bolt (13 mm) from the
893 570. Position the selector fork in the gearbox and push
front end of the shaft.
in the selector shaft through the selector fork.

2. Fit the other selector fork by the same method.

N.B. The Drift for removing/fitting selector shaft (ET 893

570) tool is pushed out of the selector fork and can be
removed from the space between the selector fork and the
rear wall of the gearbox.

3. Push the selector shaft into position and turn it so that

the
grooves in the shaft face the balls.
4. Move the selector forks on the shaft when necessary
and
tap in the locking pins on upper shaft with circlips.
N.B. The tubular pins should not be tapped in further than
the same level as the shaft.

3. Move the selector forks on the shaft. Turn the shaft and
tap out the locking pins on upper shaft with circlips.

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42. Gearbox
5. Adjust the position of the selector forks. Push the shaft
axially and check the play on the selector forks. Centre the
shaft with the nut. Check that the sliding coupling and the
synchromesh cones move freely, when the selector forks
are in the middle position (neutral). Adjust when necessary
the position of the selector shaft.
130
Model Page
A90 – A100 – A110 2
6. Tighten the locking bolt on the selector shaft to a torque
of 23 Nm (16 lbf ft). Use locking fluis Loctite 242 on the
threads.
7. Put the gears in neutral. Clean the side cover sealing
surfaces and apply sealing compound (e.g. Silastic 738
RTV black) on the sealing surfaces. Position the gear shift
levers in the selector fork grooves. Tighten the side cover
bolts (17 mm) to 46 Nm (33 lbf ft).
Changing selector forks for range gears
A visual inspection of the selector forks for the range gears
can be carried out through the access hole. When chan
ging the selector forks the tractor must be split between the
gearbox and fuel tank in order that the selector shaft can
be withdrawn forwards.
N.B. Changing of selector forks for range gears can be
carried out only after removal of pinion shaft.
1. Before tapping out the tubular pin push the selector haft
towards the rear, until the front end of the shaft is level
withthe front face of the gearbox. Put the rear ynchromesh
unit slide coupling in the rear position and the front in
neutral
2. The tubular pin can now be tapped out of the shaft bet
ween the selector forks. Turn the shaft slightly if necessary.
3. Fitting occurs in the same way. The tubular pin istapped
through the locking lug and shaft at the same time.
N.B. On the selector forks there are plastic sliding pieces.
Fasten the sliding pieces on the forks with a little grease
when you fit the forks onto the pinion shaft.
 Model Page
42. Gearbox
A90 – A100 – A110 3

Reconditioning pinion shaft 5. Remove the selector forks.

Before removing the pinion shaft, remove: Note! Take care of the plastic sliding pieces on the selector
- gearbox from tractor forks.
- differential from the gearbox
Removing pinion shaft
N.B. In the following figures the gearbox is held in a fixture,
which simplifies the reconditioning work.

6. Remove the bearing cover at the front end of the pinion

shaft (13 mm).
1. Free the circlip from the differential lock selector shaft.

2. Pull out the selector shaft past the lubricating oil pump at 7. Undo the shaft nut locking and the nuts using ETV 892
the rear of the input shaft. 230. Stop the shaft from rotating by engaging two gears at
the same time with the synchromesh units.

4. Put the gears in neutral. Remove the side cover (17 mm)
together with the selector levers.

3. Remove the two bolts (13 mm) from the oil pump and
disconnect the oil pipe from the pump (18 mm). Remove
the pump.

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42. Gearbox
8. Tap the pinion shaft free from the bearings. Pull the shaft
out backwards from the gearbox. At the same time remove
the bearing and the two spacer rings from the front end of
the shaft.
9. Lift out the synchromesh units and gears from the gear
box through the access hole. Remove the rear gear and
synchromesh unit first. Pull out the flanged sleeve from the
middle gears. Remove the middle gears and finally the
front
synchromesh unit and gear.
10. Remove the intermediate plate from the gearbox and
tap out the plate behind the front bearing with a drift.
132
Model Page
A90 – A100 – A110 4
Reconditioning synchromesh unit and changing
bearings
1. Check the wear on the synchromesh unit and change
any worn part. When assembling the synchromesh unit, the
synchronizing cone locking lug is pushed into the hub.
Push the sliding coupling onto the hub so that the teeth in
the sliding coupling are opposite the cut-out in the hub.
2. Check the wear of the synchronizing cones. Their inner
surfaces should be clearly fluted. Change worn cones.
3. Remove the rear bearing from the shaft with a drift and
fit
a new one with ET 893 620.
4. Tap out the outer bearing races from the gearbox hou
sing with an impact puller.
N.B. The outer bearing race of the front bearing is fitted
once the shaft is in place in the housing. Under the outer
bearing race of the rear bearing there are shims. The outer
bearing race is fitted after adjusting the position of the
shaft.
 Model Page
42. Gearbox
A90 – A100 – A110 5

Adjusting pinion shaft position

N.B. The position of the pinion shaft must be adjusted if the

shaft, the gearbox housing or the taper roller bearings have
been changed. The purpose of the adjustment is to deter
mine the number of shims under the rear bearing.

D = the measurement stamped into the end surface of the

pinion shaft, gives the distance between the top face of the
bearing and the centre line of the differential bearing loca
tion.

1. Measure the thickness of the rear taper roller bearing

(dimension C) by placing it on two blocks of known thick
ness and measure the distance from the upper surface of
the bearing to the surface of the table with a depth micro
meter. Subtract the thickness of the blocks from this
measurement.

N.B. The bearing should be rotated at least 20 times under

load, before measuring. Carry out a check measurement,
rotate the bearing between measurements.
2. Fit the bearing on the pinion shaft using ET 893 620
after
measuring.
3. The required thickness (X) of the shims is obtained as
follows: (note the shim (thickness 0,3 mm) that is fitted as
standard at the bottom of the bearing location).
E = the measurement between the differential center line
and the pinion bearing surface. The nominal measurement
is 181 mm. Any differences are marked in decimals on the
gearbox housing. In the case shown the measurement E =
181,13 mm, of which "13" is marked. If the tolerance is
under 181 mm the whole measurement is marked in the
housing

X = E-(C+D)
C = the thickness of the bearing

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42. Gearbox
A90 – A100 – A110 6

Fitting pinion shaft and adjusting bearing pre

Load

1. Place the pinion shaft gears and synchromesh units in

the correct order and the right way round in the gearbox.
The sleeve located inside the first gear wheel and the end
plate is pushed onto the shaft from the front.
2. Push in the shaft through gear wheels and synchromesh
units.

4. Fix the required number of shims according to the pre

vious calculation with a little grease at the bottom of the
bearing location (first fit the shim with the three lugs). Avai
lable shim thicknesses are: 0,10 mm, 0,15 mm, 0,30 mm
and 0,50 mm.

3. Push in the bearing sleeve inside the first gearwheel on

the shaft. Fit the end plate and spacer rings (2 pcs) on the
shaft. Select the spacer rings in order to achieve a com
bined thickness of for example 11,50 mm.

5. Drive in the outer bearing race for the rear bearing

against the shims using ETV 892 490.

4. Tap in the disc in the bearing housing drilling using a

drift.

5. Fit the outer bearing race of the front bearing using ETV
892 210.

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42. Gearbox
6. Adjust the pinion shaft bearing preload as follows:
- fit the front bearing on the shaft using ETV 890 830
- Tighten the round nut to 270 Nm using ETV 892 230.
- Measure the end float of the bearings using a dial gauge.
135
Model Page
A90 – A100 – A110 7
- add approx. 0,050 mm to the reading on the dial gauge
and reduce the thickness of the spacer rings by the calcu
lated amount. The spacer rings are found in the following
thicknesses: 5,05-6,18, 15 pcs.
- fit new spacer rings on the shaft. Tap the front bearing
onto the shaft and tighten the shaft nut to 270 Nm.
- Turn the shaft at least 20 revolutions and measure the
rolling resistance of the shaft with a torsion meter at the
end of the shaft. The rolling resistance should be between
1,7-2,3 Nm. If the rolling resistance deviates from the
given values, increase or decrease the spacer ring
thickness.
N.B. Check that the shaft can rotate freely when measuring
with the torsion meter, i.e. that the synchromesh units are
in neutral.
7. Tighten the round nut to 270 Nm using ETV 892 230. Fit
the locking washer on the shaft and tighten the other round
nut. Lock the nuts with the locking washer.
8. Change the o-ring in the front end cover. Fit the cover
and tighten the bolts to 23 Nm.
9. Fit the lubricating oil pump at the rear of the input shaft
and tighten the bolts to 23 Nm. Connect the oil pipe to the
pump (18 mm). N.B. the oil pipe support plate should be
placed under one of the attaching bolts for the pump.
 Model Page
42. Gearbox
A90 – A100 – A110 8

10. Fit the differential lock selector fork and selector shaft.
Lock the selector fork with the circlip. N.B. The longer half
of the selector fork should face the gearbox wall.

11. Fit the selector forks for the speed and range gears.
Fasten the plastic sliding pieces onto the pinion shaft selec
tor forks with a little grease.

12. Clean the access (inspection) cover sealing surfaces.

Apply sealing compound (e.g. Silastic 738 RTV) to the seal
ing surfaces. Fit the cover and tighten to 46 Nm (the gears
should be in neutral).

13. Fit the differential.

14. Fit the gearbox to tractor.

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 Model Page
42. Gearbox
A90 – A100 – A110 9

Reconditioning countershaft
Removing countershaft and changing bearings

Before removing the countershaft the following parts hould

be removed:
- gearbox from tractor
- selector forks
- differential and pinion shaft

1. Remove the main shaft bearing cover (13 mm). Push the
shaft forward slightly until it is free of the rear bearing.

2. Undo the bearing cover from the front end of the coun
tershaft (13 mm) and remove the spacer ring and shims
that are located under the cover.

3. Lift the main shaft slightly. Raise the countershaft with 6. Fit new bearings on the shaft using ETV 891 220
one hand and tap it forward so that the outer bearing race
7. Remove the outer bearing race of the rear bearing from
of the front bearing comes free from the housing. Remove
the drilling in the housing using a drift or impact puller. Fit
the shaft.
the new bearing race ET 893 620.

Fitting countershaft and checking bearing

clearance

4. Remove the countershaft from the gearbox through the

access hole.

1. Lift the rear end of the main shaft and position the coun
tershaft in the gearbox front end first. Tap in the outer bea
ring race for the front bearing using ET 893 620.

2. Adjusting bearing clearance:

- place a sufficient number of shims under the end cover
to give the bearings a definite clearance and tighten down
the cover

5.Pull the bearings from the shaft with puller.

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 Model Page
42. Gearbox
A90 – A100 – A110 10
- Measure the bearing clearance with a dial gauge. Place
the stylus against the rear end of the shaft.
- Reduce the shim thickness until the bearing clearance is
0,025-0,075 mm.
- turn the shaft at least 20-30 revolutions and check the

clearance again.
- Increase or decrease the shim thickness as necessary
- Fit a new oil seal under the bearing cover. Fit the cover
and tighten the bolts to 23 Nm.
N.B. The following shims are available; 0,10, 0,15, 0,20,
0,50.
3. Fit the spacer ring and shims under the input shaft bear
ing cover and tighten the cover to 23 Nm.
After fitting the countershaft the following parts should be
fitted:
- Pinion shaft
- Differential
- Selector forks

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 Model Page
42. Gearbox
A90 – A100 – A110 11
Reconditioning main shaft Changing bearings/synchronizing cones and

Removing main shaft

fitting main shaft”+8,
Before removing main shaft, the following parts should be
removed:
- gearbox from tractor
- selector forks
- pinion shaft

1. Remove the bearing cover at the front end of the shaft

(13 mm) and remove the shims and spacer ring located
under the cover.

1. Remove the outer bearing race for the main shaft rear
bearing through the rear wall of the gearbox using an
impact puller.

2. Fit the pulling piece ETV 893 614 to the end of the
pulling rod ETV 893 611 and insert the rod from behind
through the main shaft. Fit the sleeve ETV 893 612 to the
front of the pulling rod and pull the shaft forwards with the
nut until it is free from the bearings.

2. Fit a new outer bearing race (using ET 893 620 when

necessary).

3. Withdraw the main shaft from the front of the gearbox

and remove the gear wheels and synchromesh units thro
ugh the access hole. N.B. Check that the locking pins in
the middle sleeve remain in place.

3.*Remove the main shaft front bearing from the shaft

using a puller.

139

42. Gearbox
oun
4. Fit the parts to the main shaft and tap the rear bearing
onto the shaft using ETV 892 350.
N.B. The locking pins should be inside the sliding sleeves
of the middle gear wheels.
5. Before fitting the main shaft, remove the counter shaft
bearing cover and lower the counter shaft to the bottom of
the gearbox.
6. In the same way, the bearing cover for the four Wheel
drive output shaft is removed on four wheel drive models
and the shaft is lifted forwards out of the gearbox, as fas as
the gearwheel on the shaft permits.
7. Insert the complete main shaft in the gearbox. The shaft
is inserted with the rear end first after which the front end is
angled up in its bearing location and then the shaft is
straightened up.
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Model Page
A90 – A100 – A110 12
8. Fit the pulling piece ETV 893 614 to the pulling rod ETV
894 611 and push in the rod from behind through the main
shaft. Fit the bearing for the front end of the main shaft and
push the bearing into the housing using sleeve ETV 893
613.
9. Fit the outer bearing race of the front bearing for the
main shaft in the housing using ETV 891 900.
N.B. Before the main shaft is fitted in place the counter
shaft should be lifted up onto its bearings.
Adjust the bearing end float as follows:
- Fit the spacer ring and selected shims so that the bea
rings have a definite clearance in front of the front bearing
and fit the bearing cover.
- Turn the shaft 20-30 revolutions, in order to bed in the
bearings.
- Position a dial gauge against the front end of the shaft
and push the shaft forwards and backwards and note the
value of the end float on the gauge. The correct value is
0,025 -0,075 mm
- Increase or decrease the shim thickness as necessary.
42. Gearbox Model Page
A90 – A100 – A110 13

10. When the correct end float is achieved a new shaft seal
and O-ring is fitted in the bearing cover using ETV 893 630.
Apply universal grease to the seal. Wrap some thin plastic
foil round the splines in order to protect the seal and push
the bearing cover onto the shaft. Tighten the bearing cover
bolts to 23 Nm.
11. Tighten down the countershaft bearing cover (13 mm)
to 23 Nm. Fit the 4WD shaft and tighten the bearing cover
to 23 Nm on four wheel drive models.
After fitting the main shaft the following parts should be
fitted:
- pinion shaft
- selector forks
- fit the gearbox to the tractor
Changing main shaft front oil seal The main shaft seal can
be changed without parting the tractor on machines which
are not equipped with the addi tional low gear.
1. Remove the PTO and the long PTO shaft.Remove the
cab floor plate and the cover for the clutch shaft tunnel.
2. Unscrew the lock bolts for the connecting sleeve
between the clutch shaft and main shaft, and push the
sleeve onto the clutch shaft. Push the clutch shaft forward,
which creates enough space between the clutch shaft and
main shaft to be able to remove the seal cover.
3. Remove the seal cover at the front of the main shaft. Fit
the new seal using V893 630. Wrap e.g. a thin plastic bag
around the splines on the main shaft when the seal cover is
fitted. Remove the protective plastic bag after fitting the
seal cover.
4. Tighten the seal cover to 23 Nm (17 lbf ft). Fit the con
necting sleeve and tighten the bolts to 55 Nm (40 lbf ft). Fit
the floor plate in the cab. Fit the long PTO shaft and the
PTO.

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 Model Page
42. Gearbox
A90 – A100 – A110 14
Reconditioning 4WD shaft for powered 4. Remove the gear wheel circlip and spacer ring and
front axle remove the gear wheel from the shaft.
Removing shaft
Before removing the shaft the following parts should be
removed:
- gearbox from tractor
- differential
- pinion shaft

5. Lift the shaft forwards out of the gearbox.,

1. Remove the bearing cover from the front of the output

shaft (13 mm).

6. Secure the shaft in a vice and unscrew the shaft nut

using ETV 893 260. Remove the washer, drive flange and
2. Lever the shaft forwards until the bearings come free bearing cover from the shaft.
from the housing. Remove the circlip and spacer ring from
the rear bearing via the access hole.

7. Remove the O-ring from the shaft and pull the front
bearing off the shaft using a puller.

3. Remove the rear bearing using a puller through the

access hole.

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42. Gearbox Model Page
A90 – A100 – A110 15

Fitting shaft
Changing 4WD shaft front oil seal
The shaft can be changed from below without
parting the tractor as follows:

1. Drain the oil from the gearbox. Remove the propeller

shaft protecting plate under the tractor (17 and 19 mm).
2. Disconnect the rear drive flange of the propeller shaft
(13 mm).

3. Engage the front wheel drive and apply the parking

brake. Unscrew the shaft nut on the output shaft using
V893 260. Remove the washer and the drive flange from
the shaft.

4. Remove the seal cover and change the seal using V893
640.

5. Tighten the bolts of the seal cover to a torque of 23 Nm.

1. Fit the front bearing on the shaft using V892 350. Fit a
new O-ring on the shaft. Change the bearing cover shaft
seal using ETV 893 640 and fill the space between the lips
of the seal with grease.
N.B. When necessary, the shaft seal and O-ring can be
changed without further dismantling the gearbox.
Fit the drive flange and washer.
6. Tighten the shaft nut to 127 Nm. Tighten the bolts of the
flange to 23 Nm. (8.8) or 35 Nm (10.9).
7. Fit the propeller shaft protecting plate and fill the
gearbox with oil.

2. Fit the bearing cover, drive flange and washer on the

shaft and tighten the shaft nut to 127 Nm using V893 260.

3. Insert the shaft from the front of the gearbox and fit the
gear wheel, spacer ring and circlip on the shaft. Push the
shaft into position and tap it into the front bearing.

4. Secure the bearing cover to the front wall of the gearbox

to a torque of 23 Nm.

5. Fit the rear bearing using ETV 891 220 and fit the spacer
ring and circlip on the shaft.

After fitting the shaft the following parts are fitted:

- pinion shaft
- differential
- gearbox to the tractor

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42. Gearbox
A90 – A100 – A110 16

Changing / reconditioning differential

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42. Gearbox
A90 – A100 – A110 17

Removing differential
First remove the following parts:
- PTO
- Final drives
- Gearbox
N.B. The rolling resistance of the differential bearings (in
common with the pinion shaft bearings) is measured at the
front end of the pinion shaft using a torsion meter. Because
of this the tractor should be parted between the gearbox
and fuel tank when adjusting the differential bearing
preload.

When only reconditioning the differential or the differential

lock there is no need to split the tractor between the gear
box and fuel tank, if the positions of the bearing nuts are
marked before the nuts are removed.
3. Remove the differential from the gearbox.

1. Position a wooden wedge under the crown wheel.

4. Remove the differential bearings by using a puller and a
Unscrew the bolts for the differential bearing housing suitable counterhold.
(17 mm) on both sides of the gearbox.

2. Pull out the bearing housings using two pinchbars.

N.B. Mark up the positions of the bearing nuts in 5. Also change the outer bearing races of the differential
relation to the housing in order to simplify the bearings. The bearing races are removed from the housing
assembly. Also indicatem from which side they were by turning the bearing adjusting nuts.
removed.

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A90 – A100 – A110 18

Changing differential side gears

5. Remove the tubular pin for the differential pinion shaft

and tap out the shaft from the drilling. Remove the differen
1. Unscrew the crown wheel attaching bolts (17 mm). tial pinions.

Remove the differential casing half.

6. Remove the slide bearing for the other differential side
2. Remove the slide bearing for the differential side gear gear using a suitable cranked lever.
which is located in the casing half. 7. Fit a new slide bearing using ETV 891 870.

8. Lubricate the slide bearing and fit one of the differential

3. Fit a new bearing using ETV 891 870. side gears in the casing half. There are drillings in the gear
4. Remove the differential side gear. for the differential lock.

9. Lubricate the sliding surfaces of the differential

pinionsand fit them in the housing. Tap in the shaft so that
the holes for the tubular pin in the shaft and casing align.

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42. Gearbox
A90 – A100 – A110 19

10. Fit the tubular pin. 1. Lift the differential into place in the gearbox housing and
11. Position the other differential side gear on the position the differential lock coupling sleeve in the selector
Differential pinions. Fit the crown wheel on the casing so fork. Block up the differential with a wooden wedge under
that the attaching bolt holes marry up. the crown wheel.

2. Fit the bearing housing and tighten the nuts.

12. Fit the differential casing half and tighten the bolts
(10.9) evenly to a torque of 60 Nm (43 lbf ft). Check that
bolts are M10x60 (10.9).

3. Tighten the differential bearings using ETV 893 660 until

there is no clearance. Rotate the differential in order to
"bed-in" the bearings.

13. Fit the differential lock coupling sleeve.

Fitting differential

4. Arrange a dial gauge with the stylus at right angles to the

side of a tooth on the crown wheel, and measure the tooth
backlash between the pinion and the crown wheel. The
correct backlash is 0,18-0,33 mm.

5. If the recorded backlash deviates from the given value,

adjust the backlash by turning both nuts.

N.B. Ensure that there is no play in the bearings during the

adjustment by turning both nuts equally in the same
direction.
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42. Gearbox
A90 – A100 – A110 20

6. After adjusting the tooth backlash, measure using a tor

sion meter the common rolling resistance of the differential
and the pinion shaft at the front end of the pinion shaft. The
value on the torsion meter should be the rolling resistance
of the pinion shaft bearings + rolling resistance of the dif
ferential bearings (see picture above) as follows:
On transmission 30 km/h (number of teeth on pinion/differ
ential Z7/43):
2,3-4,3 Nm (1.6-3.1 lbf ft).
On transmission 40 km/h (Z9/42):
2,5-4,9 Nm (1.8-3.6 lbf ft).
Adjust the rolling resistance by turning the differential bear
ing adjusting nuts.

7. When the bearing preload is correctly adjusted, fit the

locking plates for the adjusting nuts and tighten the bearing
housings to a torque of 46 Nm (33 lbf ft).

8. Check the bearing rolling resistance and the tooth back

lash between pinion and crown wheel.

Reconditioning differential lock

Changing selector fork and selector shaft
1. The selector fork can be removed by first removing the
final drives, the differential and the circlip for the selector
fork on the selector shaft.

2. Withdraw the selector shaft. Remove the selector fork

from the differential housing.

3. Fit a new selector fork and push in the selector shaft

through the fork. Lock the fork on the selector shaft using
the circlip.

4.Fit the differential and the final drives.

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7. 42. Gearbox
A90 – A100 – A110 21
Differential adjustments
Adjusting pinion shaft position:

The position of the pinion shaft must be adjusted if the

shaft, the gearbox housing or the taper roller bearings have been
changed. The purpose of the adjustment is to determine the number of shims under the rear bearing race.
1. Measure the thickness of the rear taper roller bearing, dimension C, (see code 425.2, adjusting pinion shaft position").
Note! The bearing should be rotated at least 20 times under load, before measuring. Carry out a check measurement, rotate
the bearing between measurements.
2. Fit the bearing on the pinion shaft after measuring. Use ET 893 620.

3. The required thickness (X) of the shims is obtained as follows: (note the shim (thickness 0,3 mm) that is fitted as standard
at the bottom of the bearing location).
X=E-(C+D)

C=the thickness of the bearing

D=the distance between the top face of the bearing and the centre line of the differential bearing location (stamped)
E=181 mm+decimals stamped on the gearbox housing (e.g. 37)=the measurement between the differential centre line and
the pinion shaft bearing location bottom. If the tolerance is under 181 mm, the whole measure is marked in the housing e.g.
180,97 mm).

4. Fix the required number of shims according to the previous calculation with a little grease at the bottom of the bearing
location (first fit the shims with the three lugs, s= 0,30 mm).

5. Drive in the outer bearing race for the rear bearing against the shims (V892 490 if needed).

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7. 42. Gearbox
A90 – A100 – A110 22

Adjust the pinion shaft bearing preload:

- Fit the end plate and spacer rings ( 2pcs) on the shaft. Select the spacer rings in order to achieve a combined thickness of
for example 11,50 mm.
- Tap in the disc in the bearing housing drilling using a drift. Fit the outer bearing race of the front bearing (use ETV 892 210 if
needed). Fit fit the front bearing on the shaft (ETV 890 830 if needed).
- tighten the round nut to 270 Nm (ETV 892 230).
- measure the end float of the bearings using a dial gauge.
- add approx. 0,050 mm to the reading on the dial gauge and reduce the thickness of the spacer rings by the calculated
amount.
- fit new spacer rings on the shaft front end. Tap the front bearing onto the shaft and tighten the shaft nut to 270 Nm.
- turn the shaft at least 20 revolutions and measure the rolling resistance of the shaft (should be between 1,7-2,3 Nm). If not,
increase or decrease the spacer ring thickness.
Note! Check that the pinion shaft can rotate freely when measuring with the torsion meter, i.e. that the synchromesh units are
in neutral and on 4WD models, that the dog clutch for the front wheel drive is in neutral.
- Tighten the round nut to 270 Nm using key ETV 892 230. Fit the locking washer on the shaft and tighten the other nut. Lock
the nuts with the locking washers.

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42. Gearbox
A90 – A100 – A110 23

Adjusting of differential bearings:

- Fit the bearing housings and tighten the nuts.

- Tighten the differential bearings (ETV 893 660) until there is no clearance. Rotate the differential in order to "bed-in" the
bearings.
- Arrange a dial gauge with the stylus at right angles to the side of a tooth on the crown wheel, and measure the tooth
backlash between the pinion and the crown wheel. The correct backlash is 0,18-0,33 mm.
- If the recorded backlash deviates from the given value, adjust the backlash by turning both nuts.
Note! Ensure that there is no play in the bearings during the adjustment by turning both nuts equally in the same direction.
- When the tooth backlash is correct, measure using a torsion meter the total rolling resistance for the differential and the
gearbox pinion shaft at the front end of the pinion shaft, The torsion meter reading must be

the pinion shaft rolling resistance (Z9/42, 40km/h) +0,8--2,6 Nm (i.e. 2,5-4,9 Nm)

(Z7/43, 30km/h) +0,6--2,0 Nm (i.e. 2,3-4,3 Nm)

- Adjust the differential bearing preload by turning the adjusting nut.

- When the bearing preload is correctly adjusted, fit the locking plates for the adjusting nuts and tighten the bearing
housings to a torque of 46 Nm.
- Check the bearing rolling resistance and the tooth backlash between pinion and crown wheel

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110

Contents

43 Power shuttle and 4WD clutch:

Technical data, technical specifications, training material

Power shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …… 1
4WD clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ……… 3

Special tools
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …….. 7

Work instructions
Power shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ……. 7
Disassembling / Assembling Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …….. 8

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 1

Power shuttle

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 2

The reverse speeds are 1 % faster.

The lubrication pump rotates in one direction. The middle
gear of the shuttle unit drives the pump. The pump rotates,
although the forward-reverse shuttle is in neutral.

1) Multi-purpose Grease

2) High pressure grease (2g Olista long-time 3EP

(UC3907) or equivalent will be smoothly laid to grooving.

3) Lubrication oil to the gear shaft bearings

4) PTO drive shaft

5) Clutch shaft

6) Gear shaft

7) Selector rail

8) Gear shaft (Z22/20)

9) Gear shaft (Z24)

10) Slide pieces (4 pcs)

11) When fitting the shuttle unit onto the main shaft be
careful not to pre load the thrust bearing (point A). Before
fitting check clearance A.

12) Grease filling (multipurpose grease)

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 3
4WD clutch

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 Model Page
43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 4

The lubrication way (gearbox-pinion shaft end)

- The oil flows through a hole in the housing and via a pressed sleeve 9a to the end of the pinion shaft. The pinion shaft end
has also a guide sleeve made of teflon.

1) Driving shaft

2) Output shaft for powered front axle (gearbox)

3) Piston

3a) Groove for collecting impurities

4) Flange

5) Clutch housing

6) Pressure spring (5 pcs)

- the springs keep a suitable pre-tightening for the bearings when the 4WD is on.

7) Shaft nut (2pcs)

Adjusting: Tighten the shaft nut 7 first completely home (7a = 85,5 - 86,5 mm, max torque 80 Nm) and the open it up by
1,25 rounds.
The shaft nuts (2 pcs) are to be tightened toward each other with torque 270 Nm; the nut 7 must be held in its place.

8) Seal

- Take care of not damaging the seals when repairing, because it is important that the seals do not leak (hydraulic oil is used
for the opening of the clutch, and it must not be mixed with the transmission oil).

When repairing the clutch:

- glide surfaces of the seals must be checked
- clean the piston pressure space from impurities
- renew always the seals

9) Lubricating oil from the gearbox (pump) to the end of the bevel pinion shaft

9a) Sleeve (pressed to the housing)

Do not press the sleeve too deep by hand. Let shuttle unit press it to the suitable depth when installing.

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 5

4WD control (+ differential lock control)

157

43. Power Shuttle And 4wd Clutch
4WD switch (S30).
(The switch has two positions)
-The opposite side of the symbol lens is pressed
down: 2 WD on.
The 4WD solenoid valve Y3 is energized and keeps the
4WD function off.
- The symbol lens side is pressed down: 4WD (light is
on in instrument panel).
The coil of the relay K27 is now energized. At the same
time the other end of the coil is earthed by the switch S30
(the switch pin no 2). The relay K27 cuts the current
supply off to the solenoid valve Y3, and the 4WD engages.
The earthing of the brake light relay (K11) coil has been
prevented with diodes.
The 4WD engages always when braking with both brake
pedals or when engaging the hand brake. In both cases the
relays K7 and K27 will be earthed at the same time and
the current supply to the solenoid valve Y3 cuts off.
When depressing only another brake pedal (e.g. left) the
relay K7 functions and connects the current to the coil of
the relay K27 , but the coil will not be earthed (the brake
pedal switch S10 is open) and the relay K27 don't func
tion.
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Model Page
A90 – A100 – A110 6
The differential lock switch (S22).
(The switch has two positions)
- The opposite side of the symbol lens is pressed
down: the differential lock is off.
- The symbol lens side is pressed down: differential
lock is on
The lock is only on when the indicator light lights up in the
instrument panel. Due to the construction of the lock (pins)
there will be a delay while coupling.
Warning! The differential lock is allowed to be engaged
only while running straight ahead without wheel slip.
When the differential lock in engaged, it is forbidden to
use the brakes as steering brakes.
Also when disengaging the lock there can occur a delay.
When the indicator light is off, the differential lock is disen
gaged.
 Model Page
43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 7

Special tools

Shuttle

ETV 892 350 . . . . . . . . . . . . . . . . . . . . . . . . . Sleeve for fitting front bearing on 4WD shaft, front wheel drive
Sleeve for fitting rear oil seal

Locally prepared tools

Shuttle
ET 893 380 . . . . . . . . . . . . . . . . . . . . . . . . . . Drift for fitting selector fork rail
Shuttle

Locally prepared tools

Shuttle

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 8

Disassembling/assembling Shuttle

To avoid loosing the syncronizer, put the shuttle to neutral

position, place a extra ball to the selector and do not lift
from shuttle lever when disassembling or assembling the
shuttle.

Disassembling shuttle

2. Oil pump drive gear and shuttle rear gear remain with in
gearbox. They can be disconnected by pulling.

1. Unscrew two uppermost attaching bolts of the shut

tle(13mm) and use for align M8 bolts.
Unscrew the rest attaching bolts of the shuttle(13mm) and
pull off the shuttle from gearbox.

3. Knock off the forks for gear tension pins and remove the
selector shaft. Remove the shift lever. Open screw with
forks for gear and remove sliding coupling, forks and coun
tershaft. Take care of the selector fork plastic sliding pieces
(4 off)

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 9

7. Check the condition of synchronizing ring and the sliding

coupling. Change the parts thet are wore out if needed
Shuttle assembly
4. Remove the overdrive input shaft front end: circlip,
shims, wear ring and the o-ring under the wear ring. Tap
the input shaft rearwards out of the housing.

5. Remove the selector shaft and take care of locking ball.

Open the plug on side and remove circlip.

1. Check, and if needed, change the bearings of input

shaft. Then advance change also new oil seal with in hou
sing.

2. Thread the input shaft in, and turn the housing upside
support, the input shaft and press the shaft in the housing,
for example with hydraulic press.

3. If you change the rearside seal of the input shaft, you

can
install the new one by a socket ETV 892 350. Spread some
grease into the lip seal.

6. Check the oiltube for bearings. There is a throttle under

the oiltube. Check thet the throttle is clear, because the
bea rings of input shaft will get their lubrication through this
throttle.

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 10

4. Put in the spring and ball into the housing of the shuttle.
Press the ball with drift (ø 16 mm, e.g. ET 893 380) and
7. Put in the circlip. Notice that the heads of the circlip must
push in the selector shaft. Turn in the plug.
be placed on the both sides of the tension pin, that is instal
led into the wear ring. By doing this you will make sure that
the wear ring doesn't left turning on the input shaft.

5. Install the o-ring under the wear ring.

8. Check, and if needed, change the bearings of both

countershaft.
Note! Axles second head bearings are in the gearbox he
ad. The lower countershaft also lubrication pump by axle.

6. Install the new oil seal into the housing and push in the
wear ring.

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43. Power Shuttle And 4wd Clutch
A90 – A100 – A110 11

11. If you have disconnected rear gear and lower counters

9. Install in the selector shaft and lever to the housing. The
plastic sliding pieces can be fastened on the fork with a
little
grease.
Install in the housing, syncronizer, fork and upper
countershaft at the same time
haft of the shuttle, install them to the front side of the gear
box
Note! If you have changed the axle of the oil pump make
sure thet the axle has enoungh axial slip. The axial slip can
be checked by taking off the service hatch of the gearbox.
12. Apply sealing compoud to the contact surface between
the housing and the gearbox. Clean coontact surfaces if
needed.Note! Put sealing compound only to the outer ed
ge of housing of the shuttle.
13. Install the second syncronizing ring for example using
grease and lift the shuttle in its place. By align you can use
M8 bolts

14. Tighten the housing srews to a torque of 23Nm and

10.Put in the tension pins of the lever of forks. Notice of the check shuttle float
assembly direction, slotted holes must be cross direction of 15. Assemble the tractor frame alike as low gear and overd
the selector shaft. Rive.

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44. Final Drive
A90 – A100 – A110

CONTENT

44.FİNAL DRIVES:

Technical data, technical specifications, training material

Technicaldata…………………………………………....................................................................................1
Final drives ..………………………………………………………………………………………………………..2

Special tools
Special tools ………………………………………………………………………………………………………...1

Adjusting drive shaft bearing clearance…………………………………………………………………………..6

Fitting final drive …………………………………………………………………………………………………….6

Work instructions
Reconditioning final drive ..…………………………………………………………………………………………1

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44. Final Drive
A90 – A100 – A110 1

Technical Data

Gear ratio, planetary gears …………………………………………………………….i=5,6

Rear axle flange distance ……………………………………………………………...750 mm
Tightening torques
Drive axle housing-gearbox ……………………………………………………………230 Nm (24 mm)
Wheel nuts, rear wheels ………………………………………………………………..550 Nm (M20)

Oil draining plug …………………………………………………………………………65 Nm (36 mm)

Centre bolt, outer drive shaft …………………………………………………………..3-5 Nm (24 mm)

Cab-rear axle housing ………………………………………………………………….220 Nm (24 mm)

Check links-rear axle housing …………………………………………………………80 Nm (19 mm)

Lower links-rear axle housing …………………………………………………………380 Nm (30 mm)

Brake mechanism-rear axle housing ………………………………………………….80 Nm (19 mm)

Setting values
End float, outer drive shaft …………………………………………………………….0,010-0,075 mm
Distance between drive shaft end-rear axle housing contact surface…………….max 128,7 mm
Brake pedal free travel, approx ……………………………………………………….n. 50 mm

Oil
(Final drives have oil space in common with gearbox)
Total oil volume …………………………………………………………………………27 l

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44. Final Drive
A90 – A100 – A110 2

Final drives, description

The final drives are of the planetary gear type with mechanically operated multi-disc brakes which run in oil. The rear axle
housing is bolted to the gearbox by eight screw studs. The brakes are fitted between the gearbox and the planetary gear in
the final drive and the brake control mechanism is fitted on top of the rear axle housing.
The power is transmitted from the differential via the inner drive shaft to the planetary gear and on to the outer drive shaft. The
gear ratio in the planetary gear is 5,6:1.
The planetary ring gear is fitted in the rear axle housing with a press fit. The planetary sun gear is machined integrally with the
inner drive shaft. When the inner drive shaft rotates it drives the planetary pinions and the planetary retainer. The power is
then transferred via the splined joint between the planetary retainer and the outer drive shaft and further on to the driving
wheels.
The outer drive shaft is carried in taper roller bearings in the rear axle housing. The planetary pinions are carried in needle
bearings on the shaft studs which are fixed to the planetary retainer.
The final drives are fully encased and run in the same oil as the gearbox and differential.

There is a grease nipple on top of the axle housing for greasing the outer bearing of the drive shaft. The inner bearing is lubri
cated by the gearbox oil.

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44. Final Drive
A90 – A100 – A110 3

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44. Final Drive
A90 – A100 – A110 4

1) Paper gasket
2) Wear ring
3) Return spring
4) Cassette type seal
5) Drive shaft (the sun gear machined in the end of
the sun gear).
6) Planetary gears (3 pcs).
7) Planetary ring gear
8) Hub axle
9) Drive shaft housing
10) The fastening screw for the planet wheel carrier
and the hub axle.
- Preload of the tapered roller bearings: 3-5 Nm
- Loctite Loctite 242 (UK0126) on threads
11) Brake discs, 4 pcs/side (organic).
12) Application ring

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44. Final Drive
A90 – A100 – A110 1

Special tools

Final drive

1. ETV 893 690 ………………………………… Plate for fitting bearing race for outer drive shaft

2. ETV 893 320 ………………………………… Plate to fit drive shaft bearing outer races

3. ETV 892 210 ………………………………… Sleeve for fitting oil seal for outer drive shaft

4. ETV 891 710 ………………………………….Sleeve for fitting bearing race for outer drive shaft

5. ETV 894 210 ………………………………….Centring tool foor outer brake application ring when fitting final
drives

Locally prepared tools

Final drive

6. ET 893 410 ……………………………………Support to remove drive shaft bearing outer races

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44. Final Drive
A90 – A100 – A110 2

Final drive

Locally prepared tools

Final drive

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44. Final Drive
A90 – A100 – A110 3

Reconditioning final drive

N.B. Removing the rear axle housing from the gearbox is
Removing final drive made easier by removing the brake mechanism from the
rear axle housing.
1. Drain the oil (3 drain plugs, max 23 litres). Free the
check link bracket from the rear axle housing. Note! When the rear axle housing is pulled apart from the
gearbox housing side, brake balls (6 off) release and fall
2. Free the lower link (and extra lifting cylinder if fitted) from
down. It is possible that the inner brake ring remains on the
underneath the rear axle housing. side of the gearbox housing.
3. Slacken the wheel nuts. Block up the tractor under the
Changing roller bearings in planetary pinions
gearbox. Remove the wheel.
1. Remove the final drive
4. Remove the cab rear attaching bolts. Lift the rear of the
cab slightly and block it up with suitable supports or a lifting
device.
5. Position an axle stand on castors under the rear axle
housing.

2. Before reconditioning, remove the rear axle housing,

brake application ring, inner drive shaft and brake discs
and the brake support behind the discs.
3. Unscrew the centre bolt and remove the planetary gear.

6. Unscrew the rear axle housing nuts (24 mm).

4. Cut the locking wire which is located under the locking

spring for the planetary pinion shaft studs. Remove the
locking wire.

7. Pull the rear axle housing straight outwards so that it

clears the gearbox.

5. Compress the locking spring with a pair of pliers and pull

the shaft studs out of the planetary retainer.

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44. Final Drive
A90 – A100 – A110 4
10. Adjust the drive shaft bearing clearance and fit the final
drive on the tractor.

Note! In assembly the outer drive shaft bearing clearance

is adjusted by tightening the centre bolt to a certain torque,
see the instruction Adjusting drive shaft bearing clear
ance".
Note! There are four friction discs and three intermediate
discs in the brake disc pack. Fit first the friction disc against
the brake support and then by turns intermediate disc and
friction disc.

Changing bearings and seals on drive shaft

1. Remove the rear axle housing from the chassis. Remove
the planetary gear.
6. Remove the planetary pinions from the planetary
retainer.
Change the bearing rollers. The easiest way of fixing the
rollers in position is by pacing them in a little grease.
Note the spacer ring between the two rows of rollers.
7. Press the bearing wear washers against the sides of the
planetary pinions and press them into the retainer. Com
press the locking spring and push the shaft studs into posi
tion and make sure the locking spring engages the groove
in the studs.
2. Tap the end of the drive shaft so that it slides out of the
Note! Fit the attaching plate for the planetary retainer
bearings. Pull the shaft out of the axle housing.
before fitting the third planetary pinion.
8. Push in a wire diam. 2,0 mm under the locking spring.
Wind the wire ends together one and a half turns and bend
them down.
Note! The ring gear is fitted in the rear axle housing by a
press fit. If the ring gear is damaged the whole rear axle
housing must be changed as well as the ring gear.

3. Remove the drive shaft outer bearing using a puller.

Heat the new bearing and fit it on the shaft.

N.B. When necessary the wear ring on the shaft should be

changed. Removing and fitting is carried out by heating the
metal ring.

9. Lower the planetary retainer onto the splines on the

drive shaft and so that the planetary pinions engage the
ring gear. Secure the planetary retainer to the end of the
drive shaft by tightening the centre bolt.

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44. Final Drive
A90 – A100 – A110 5

4. Remove the shaft outer seal using a puller.

8. Remove the inner seal. Fit a new seal using ETV 892
210.

5. Position support bar ET 893 410 against the rear axle

housing. Pull out the outer bearing race. Fit a new bearing
race using plate ETV 893 690.

6. Fit a new seal using ETV 893 320. Lubricate the felt
seal. 9. Fit a new bearing race using ETV 891 710.
10. Grease the bearings thoroughly before fitting. Carefully
insert the drive shaft in the axle housing. Ensure that the
seals are not damaged.

11. Fit the drive shaft inner bearing on the shaft. Fit the
planetary retainer on the splines on the drive shaft and
press the planetary retainer home. Secure the planetary
retainer to the end of the drive shaft with the attaching plate
and the centre bolt.

12. Adjust the drive shaft bearing clearance. Fit the final
drive.

7. Remove the inner bearing race using a puller and

support bar ET 893 410.

173

44. Final Drive
Adjusting drive shaft bearing clearance
1. Place the drive shaft with the wheel flange on the floor.
Bed in the bearings by rotating the axle housing approx. 20
turns.
2. Tighten the bolt fixing the planetary retainer to the shaft
to a torque of 3-5 Nm. Again rotate the axle housing and
check the torque. After some time of operation the correct
shaft bearing clearance, i.e. 0,010-0,075 mm will be es
tablished.
3. Lock the planetary retainer attaching bolt (shaft centre
bolt) with the locking washer. The correct position is found
by moving the washer round to different positions.
Fitting final drive
1. Fit the inner drive shaft, brake discs and pressure plate.
174
Model Page
A90 – A100 – A110 6
2. Position the brake discs in place on the inner drive shaft.
Push the inner drive shaft fully home. Compress the outer
brake application ring against the springs (2 pcs) and fit the
centring tool ETV 894 210 into place so that it supports and
centres the application ring.
Note! The plug of the centring tool ETV 894 210 is
screwed into the oil draining hole of the rear axle housing
and the upper end of the bolt, which goes through the plug,
sup ports the brake application plate.
3. Fasten the brake balls (6 pcs) onto the grooves on the
inner brake ring by using thick grease (e.g. Renax). Posi
tion the inner brake ring onto the side of the gearbox in
correct position.
N.B. Check that the distance between the end of the inner
drive shaft and the contact surface of the rear axle housing
is max. 129 mm.
4. Clean the contact surfaces between the gearbox
housing and the rear axle housing and fit a new gasket.
Also can be used sealing compound (e.g. Hylosil).
5. Position an axle stand with castors under the final drive
and move it inwards at right angles so that the inner drive
shaft engages in the differential.
N.B. Fit the brake mechanism on the rear axle housing if it
has been removed.
 Model Page
44. Final Drive
A90 – A100 – A110 7

6. Remove the support tool. Tighten the nuts for the rear
axle housing to a torque of 230 Nm.

7. Press in approx. 20 g of grease through the lubricating

nipple by the drive shaft outer bearing. Rotate the shaft
while doing this.

8. Secure the check link bracket to the rear axle housing up

to a torque of 80 Nm.

9. Secure the lower link (and extra lifting cylinder) to the

underside of the rear axle housing, tightening torque is 380
Nm.

10. Lower the cab and tighten the attaching bolts to 220
Nm.

11. Fit the rear wheel and tighten the wheel nuts to 330
Nm. Fill with oil and adjust the brakes. Test-drive the
tractor.

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 Model Page
45. Power Take Off
A90 – A100 – A110 1

Content

45 Power take-off:

Technical data, technical specifications, training material

Technical data ……………………………………………………………………………………. 2
2-speed PTO ……………………………………………………………………………………… 3
PTO brake …………………………………………………………………………………………. 5
Lubrication of PTO …………………………………………………………………………………6
Reconditioning PTO ………………………………………………………………………………. 7
Removing PTO ……………………………………………………………………………………. 7
Dismantling PTO …………………………………………………………………………………...8
Assembling PTO …………………………………………………………………………………..10
PTO brake ………………………………………………………………………………………….11

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45. Power Take Off
A90 – A100 – A110 2

Technical Data

PTO shaft end (ISO 500-1979 Z6):

- Nominal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 mm
- Number of splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Nominal speed, engine/PTO shaft end 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1890 rpm /540 rpm
Nominal speed, engine/PTO shaft end 540E (=750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1594 rpm/540 rpm
Nominal speed, engine/PTO shaft end 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2074 rpm/1000 rpm

Tightening torques
PTO housing-gearbox:
- 10 pcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Nm
- 2 pcs, M20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Nm
PTO shaft end guard plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195 Nm
Bolt for top link bracket spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Nm
Top link bracket lower attaching point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Nm

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45. Power Take Off
A90 – A100 – A110 3

2-Speed PTO

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45. Power Take Off
A90 – A100 – A110 4

1) Clutch shaft
2) Selector fork
3) PTO- shaft
4) Paper gasket
5) Lubrication oil from distribution piece
6) Selector lever
- spread multipurpose grease on the lever shaft
7) PTO selector lever
8) Mechanical controlled power lift housings: the
diameter of the top link support hole is ø 25 E8
9) PTO brake
10) Spacer ring (s=3,0) + shims (s=0,1 or 0,3).
11) Identification number for PTO type
12) Scharmüller -Coupling for 2 axle trailers

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45. Power Take Off
A90 – A100 – A110 5

PTO brake
The 2-speed PTO unit has a brake which ensures, that the PTO shaft stops rotating, when the control lever is moved to the
neutral position.

5. Pivot pin of the brake shoe upper end

In the neutral position, spring (4) presses the brake shoe 6. Ball for releasing the brake
(1) against the big gearwheel (7) on the PTO shaft and pre 7. Gearwheel Z63
vents the PTO shaft from rotating.
When the PTO is engaged, the selector fork moves and
ball
(6) presses the brake shoe away from the gearwheel.
1. Brake shoe
2. Selector fork
3. Selector fork rail
4. Brake spring

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45. Power Take Off
A90 – A100 – A110 6
Lubrication of PTO

The PTO shaft has a lip-type oil seal. Both shafts are sup
1. Lubricating oil inlet
ported with ball bearings. A paper gasket or a suitable sea
2. Oil space at the rear end of the upper shaft
ling compound is used between the gearbox and the PTO
3. Selector arm
housing.
Lubricating oil is directed from the gearbox lubricating sys
Important! If the selector fork of the 2-speed PTO unit has
tem distribution piece via pipe 1 to the front end of the
been changed due to the excess wear, it is necessary to
selector rail.
make a modification also to the PTO control lever linkage.
On the earlier PTO units the selector fork wear may be cau
Oil flows through the rail to the oil space 2 at the rear end
sed by a wrong control lever mounting. This control lever
of the upper shaft and inside the upper shaft via the oil dril
modification has already been carried out in the tractor
lings to the sliding surfaces of the gear wheels.
works for all new tractors.
The lower shaft has a splash lubrication.

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45. Power Take Off
A90 – A100 – A110 7

Reconditioning PTO
Removing PTO
1. Drain the oil from the gearbox. Remove the top link.
2. Disconnect the upper ends of the pick-up hitch lifting
links and lower the hitch.
3. Disconnect the lower end of the pick-up hitch release
control. Disconnect the control rod from the selector lever
on the right side of the PTO housing.

7. Pull out the PTO housing straight backwards so that it

becomes free from the guide pins.

4. Slacken and remove the nut for the top link bracket
(spring). Remove the tubular pin from the shaft at the top of
the bracket (impulse transmitter lock) and remove the shaft
and its cup spring.
N.B. There are shims under the top link bracket spring
which become free when the bracket is removed. When
fitting the bracket the same number of shims must be pla
ced under the spring.
5. Remove the top link bracket lower shaft in order to free
the top link bracket.

6. Remove the PTO shaft end guard plate. Attach a

suitable lifting device to the PTO housing and unscrew the
attaching bolts.

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45. Power Take Off
A90 – A100 – A110 8

Dismantling PTO
1. Remove the PTO unit.

4. Take the large gear (Z63) out of the housing.

5. Remove the smaller gear wheel from the housing.

2. Remove spring (4). Unscrew the three fixing bolts for the
Note! The PTO selector fork and its lever can be removed
bearings. The upper bolt fixes the pivot pin (5) of the brake
without removing the PTO shaft as described above.
shoe (1). Remove the pin (5).
6. Unscrew the selector fork rail locking screw on the RH
side of the housing.

7. Push the selector fork rail rearwards and take it out of its
location at which time also the selector fork locking ball and
spring release.

3. Tap at the PTO shaft rear end until the shaft releases
from its bearings and remove the PTO shaft forwards. The
front bearing remains on the shaft and the rear bearing
remains in its location on the housing.
Note! Take care of the possible spacer ring and shims
behind the PTO shaft front ball bearing.

8. Turn the selector fork so that the shifter lever ball-

shaped end releases from the fork hole. Remove the fork.
9. Pull the shifter lever outwards and remove it.
Note! Take care of the steel balls.
10. Remove the upper shaft and the brake shoe.

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45. Power Take Off
A90 – A100 – A110 9

Changing oil seal at PTO shaft end

1. Drain the oil (23 litres). Remove the PTO shaft end cup
guard and guard plate.
2. Remove the protecting ring in front of the seal. Tap a
small hole in the seal using a centre punch.
3. Carefully screw in a self-tapping screw or similar in the
hole. Take care not to damage the shaft.

11. Remove the circlip inside the upper shaft front end.

4. Break the seal out of the housing.

5. Fit a new seal using sleeve ETV 893 700.

6. Fit the protecting ring in front of the seal. Fit the guard
plate and tighten to a torque of 195 Nm. Fit the PTO cup
guard.
7. Fill the gearbox with oil (23 litres).

12. Insert an impact puller inside the upper shaft and tap
the shaft forwards until it releases.
Note! The front bearing of the shaft remains on the shaft
and also the front gear wheel (Z18).
13. Take the coupling sleeve and the bigger gear wheel
out of the housing.
14. If the shaft rear bearings have to be changed, remove
them with an impact puller and fit new bearings by using
sleeve ETV 893 700 or use a suitable drift.
Note! The upper shaft rear ball bearing is fitted so that the
bearing protective plate is turned forwards (towards the
PTO).
15. If you change the shaft front bearings, pull them out
with an extractor and fit new bearings.
Note! Before fitting the upper shaft front bearing, ensure
that the front gear (Z 18) is placed on the shaft.
Important! If the upper shaft must be replaced, always fit a
latest spare shaft, which have three axially machined flat
surfaces for lubrication.

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45. Power Take Off
A90 – A100 – A110 10

Assembling PTO Note! The selector fork rail forces the tool ETV 894 080 out
1. Place the foremost gearwheel (Z18) onto the upper shaft and the locking ball remains under the selector fork rail.
and fit the ball bearing in front of the gear fully home (if
removed).

2. Push the upper shaft into place and place (inside the
housing) the brake shoe, sliding coupler and the rear
gearwheel onto the shaft.

3. Push the upper shaft into place and tap at its front end
until the shaft rear end is pushed through the rear bearing
and the foremost bearing is pushed into its location.

8. Take the tool ETV 894 080 out of the housing.

9. Apply locking fluid Loctite 572 to the threads of the rail
locking screw. Ensure that the rail hole is at the locking
screw hole and screw in the screw.
10. Turn the brake shoe into a correct position.

4. When the upper shaft is in place, place the selector fork
onto the coupling sleeve. Pass the shifter lever into place
and fit its round-shaped end into the hole on the selector
fork.
11. Put the PTO shaft gears into the housing. The brake
shoe notch must engage with the big gearwheel.
12. Fit the ball bearing onto the front end of the PTO shaft
using sleeve ETV 893 700 (if removed).
Note! Make sure that the PTO shaft rear bearing is in its
location fully home. Tap, if necessary, using sleeve ETV
893 700.

Note! Check/change, if necessary, the shifter lever o-ring

and grease it before fitting the lever.

5. Position the spring into the drilling in the fork.

6. Place the ball onto the spring and push tool ETV 894
080 from the rear into the fork so that the tool chamfered
side presses the ball into place and the tool remains on the
ball.

13. Fit the PTO shaft smaller gear into the housing with the
hub longer side turned forwards and then, in front of the
smaller gear, the larger gear (Z63) with the longer hub side
turned rearwards.
14. Push the PTO shaft from the front through the gears
and tap the shaft into place (ETV 893 700), until it is
pushed into the rear bearing and the front bearing into its
location.
7. Push in the selector fork rail from the rear so that the rail
Note! Observe the possible spacer ring and shims behind
hole more chamfered side is turned towards the rail locking
screw hole. the front bearing,
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45. Power Take Off
A90 – A100 – A110 11

PTO brake
258
Adjust the position of the brake shoe so that the gearwheel
rotates without dragging

15. Fit the pin (5) so that it engages with the brake shoe
hole. Fit the bearing fixing bolts (3 off) together with was
hers. The washer of the upper bolt must engage with a
groove on the pin (5).

16. Fit the steel ball (3) into the selector fork drilling and fit
the brake shoe in place so that the shoe notch is engaged
with the big gearwheel and the ball (3) remains under the
shoe. Fit the spring (4) (lower end first). Fit the PTO unit.

186
50. Brake System
51. Service Brake

52. Air Brake System

187
 Model Page
50. Brake System
A90 – A100 – A110

51 . Brake System
Technical data ……………………………………………………………………………………………………….. 1
Brake System ………………………………………………………………………………………………………... 2
Brake cylinder ……………………………………………………………………………………………………….. 4
Reconditioning brakes ………………………………………………………………………………………………. 6

52. Air Brake System

Diaghram of Air Brake System
Twin curcuit hydraulically actuated that controlled from tractor air brake system …………………………….. 1
When brake pedal is used that the system working ……………………………………………………………… 2
When hand brake is used in N position …………………………………………………………………………… 3
When brake pedal is used in P position that the system working ………………………………………………. 4

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51. Brake System
A90 – A100 – A110 1

Technical data
Brake type ………………………………………………………………………………. Mechanical control disc brake
running in oil
Number of friction discs per brake …………………………………………………….4 pcs
Number of intermediate steel discs per brake………………………………………..3 pcs
Friction area, total: ………………………………………………………………………2950 cm2
Brake disc, diameter …………………………………………………………………….224 mm
Depth of oil grooves in new friction discs……………………………………………...0,3 mm
Number of balls per brake ………………………………………………………………6 pcs
Brake pedal free travel, approx…………………………………………………………50 mm
Parking brake …………………………………………………………………………….Actuates the foot brake
mechanically
Tightening torques
Gearbox-rear axle housing ……………………………………………………………..230 Nm (24 mm)
Cab-rear axle housing …………………………………………………………………..220 Nm (24 mm)
Rear wheel nuts ………………………………………………………………………….550 Nm
Check link-rear axle housing…………………………………………………………….80 Nm (19 mm)
Lower link bracket-rear axle housing ………………………………………………….380 Nm (30 mm)
Brake mounting-rear axle housing ……………………………………………………..80 Nm (19 mm)

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 Model Page
51. Brake System
A90 – A100 – A110 2

Brake System
Description

The brakes are multi-disc brakes running in oil and are fitted in the final drive housing between the planetary gear and the
differential. The brakes are mechanically controlled by the brake pedals. The brake pedals can be used latched together for
when transport driving, or individually as steering brakes. The parking brake actuates the service brakes mechanically.
The brakes can be adjusted by means of adjusting nuts which are fitted on the brake rods. Trailer brake valve and trailer air
braking system can be delivered as option.

1) Oil for the final drive and wet type brakes 10) Pedal (2 pcs)
2) Ball (2 x 6 pcs) 11) Container
3) Brake ring 12) Brake cylinder (2 pcs)
4) Organic friction plate (2 x 4 pcs) 13) Parking brake lever
5) Intermediate disk (2 x 3 pcs) 14) Pin + return spring
6) Brake retainer 15) Parking brake release knob
7) Brake rod 16) Locking plate
8) Ball ring 17) Parking brake cable
9) Final drive housing 18) Master cylinder (2 pcs)

190
 Model Page
51. Brake System
A90 – A100 – A110 3

A) Brake pedal is not depressed

Reservoir 1 is connected with the cylinder space 4. The cylinder space is pressureless. Balancing valve 5 is closed.

B) Brake pedal is depressed

The brake fluid flows from the reservoir through pipe into the master cylinder. When the pedals are depressed, the non-
return valve 3 at the front end of the master cylinder closes preventing oil from returning to the reservoir. The fluid, now under
pressure in the cylinder, flows through pipe to the brake cylinder.

The valves 5 and the intermediate pipe 7 in the master cylinders serve as an equalising mechanism, if the mechanical setting
of the two brakes differs. When the pedals are depressed, the pistons actuate the valves so that they open and any pressure
differences in the brake circuits are equalised through the intermediate pipe.

If only one of the brakes is applied, the valve is opened by the piston, thus pressurising the intermediate pipe 7. This causes
the valve in the other (not actuated) master cylinder to close. Oil under pressure now flows from the master cylinder which is
being applied to the corresponding brake cylinder.

The brake system bleeder nipples are placed on top of the respective brake cylinders.

Adjusting the clearance of the push rod and piston:

- Slacken the locking screw 8 and turn the push rod so that it touches the bottom of the cup in piston, and then turn back
about 1/3 turn (that results a clearance of 0,5 mm).
When the pedal is not actuated, the push rod should be freely in it's recess (not push the piston).

1) Brake fluid reservoir

2) Main cylinder

3) Valve

4) Cylinder space

5) Balancing valve

6) Brake cylinder

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 Model Page
51. Brake System
A90 – A100 – A110 4

Brake cylinder

192
51. Brake System Model Page
A90 – A100 – A110 5
1) Brake cylinder

2) Brake rod

3) Brake ring

4) Adjusting nut for hand brake

5) Lever adjusting nut

6) The basic setting for the nut 6 is about 11mm from the end of the brake rod (with new brake discs)

- If brake parts have been changed , check the position of the levers see picture at bottom. Adjusting measure 37-40 mm
(see that the parking brake cable do not tight the levers under checking). Possible adjusting with the nuts 5.

Adjusting travel of brake pedals:

The travel should be 60 mm with pedals connected together.

- Fit blocks in front of the front wheels to prevent the tractor from moving.

- Raise the rear end of the tractor off the ground and adjust both brakes separately by turning the brake rods (2) on the drive
gear (NOTE: with the box socket wrench of 9 mm, the fork spanner may slip) until the brakes are on.

- Slacken the brake rods 1 turn and check that the wheels can rotate freely.

- Check by driving with the pedals connected together that the brakes do not pull to one side.

Adjusting parking brake:

- The parking brake is controlled mechanically and it is connected to the foot brake mechanism by a cable.
The parking brake is adjusted in the factory and re-adjustment is not necessary unless parts of brake mechanism have been
changed (the parking brake is affected when the foot brakes are adjusted).

- When necessary, adjust parking brake lever free travel to about 50 mm (at lever end) by turning the adjusting nut (4) at the
rear end of the cable.

NOTE: Always adjust the driving brakes before adjusting the parking brake.

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51. Brake System
A90 – A100 – A110 6

Reconditioning brakes
There are grooves on the ceramic friction surfaces of the
brake discs. The depth of these grooves is 0,3 mm (0.012
in) when the ceramic discs are new. When these grooves
become shallow, the oil cannot pass through the friction
discs and this results in impaired brake action. If the brake
discs are worn they should be changed.

Changing brakes
1. Remove the final drive

2. Remove the circlips and washers from the application
plate attaching lugs and pull out the application plate.
Remove the springs from the lugs.
7. Push the application plate against the discs and fit the
washers and circlips on the lugs.
8. Fit the final drive.
N.B. The brake application balls, (6 pcs) which are posi
tioned in both sides of the differential housing, can be
removed from their drillings with the aid of compressed air.
Seats are fitted behind the application balls.

3. Pull the friction and intermediate discs off the shaft.

4. Check the surfaces of the support plate and the applica

tion plate and remove dirt and uneven spots using an
emery cloth.

5. Fit new friction and intermediate discs alternately (friction

discs first and last).

6. Fit the springs onto the application plate attaching lugs

and fit the plate onto the springs.

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 Model Page
52. Air Brake System
A90 – A100 – A110

195
Diaghram of Air Brake System

196
These are the components of air brake system.
1- ø 75 Air compressor
2- Air exit valve with dryer
3- Air tank 1 lt.
4- Air pressure switch – 4 bar
5- Air tank – 15 lt.
6- Automatic air drainer valve
7- Air gauge
8- Brake pedal with hydraulic actuated
9- Load adjustment ventil
10- Two way valve
11- Hand brake control valve
12- Automatic air coupling – yellow
13- Automatic air coupling – black
14- Automatic air coupling – red

Air brake system should be tested according to table below.

When The Brake Pedal Pressed When The Brake Pedal Not Pressed Hand Brake is in service and park position Hand brake is in service position

-Red exit line: Air tank pressure(max. 8 bar) -Red exit line: Air tank pressure(max. 8
bar)
- -Black exit line:Exit pressure 0 bar
- -Black exit line:Exit pressure 4,8 - 6 bar
-Yellow exit line:Exit pressure 6,2 – 8 bar
-Yellow exit line:Exit pressure 0 bar
-Red exit line: Air tank pressure(max. 8 -Red exit line: Air tank pressure(max. 8
bar) bar)
- -Black exit line:Exit pressure 0 bar - -Black exit line:Exit pressure 4,8 - 6 bar
-Yellow exit line:Exit pressure 6,2 – 8 bar -Yellow exit line:Exit pressure 0 bar

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 Model Page
52. Air Brake System
A90 – A100 – A110 1

Twin curcuit hydraulically actuated that controlled from tractor air brake system

Twin curcuit hydraulically actuated that controlled from tractor air brake system

When brake system is used

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 Model Page
52. Air Brake System
A90 – A100 – A110 2
Scheme - Operating principle in driving conditions
Twin curcuit hydraulically actuated that controlled from tractor air brake

When brake system is not used

When brake pedal is used that the system working

When brake system is not used

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 Model Page
52. Air Brake System
A90 – A100 – A110 3

When hand brake is used in N position

Twin curcuit hydraulically actuated that controlled from tractor air brake

Hand brake is in P position

200
 Model Page
52. Air Brake System
A90 – A100 – A110 4

When brake pedal is used in P position that the system working

FAILURE
Failure REPAIRING AND MAINTINANCE
DESCRIPTI REASON FOR FAILURE
code PROCEDURES
ON
Snap ring chins for compressor piston’s Cylinder sleeve remove from side to sump and
keep together in the same axle. then snap rings reassembly again 120°
Compressor pressure line is blokcaged Cylinder head remove and pressure line is to
with outside effects. be cleaned and repair kit is to be changed.

Compressor Compressor suction line blockage with Cylinder head remove and pressure line is to
does not outside pollutant. be cleaned and repair kit is to be changed.
FK F 10 produce
enough Compressor cylinder sleeve,piston and
pressurized air Cylinder sleeve,piston and snap ring threefold
snapring threefold have wearing or
have to be changed.
scoring.
Compressor crank pulley belt has not
enough tightness.Compressor does not Check compressor crank pulley belt tension.
rotate proper revolution.
Returning circuit should check out.If that needs
Returning oil does not enough.
system is to be cleaned properly.
Engine oil level is too high. Check the oil level.
Compressor pressure line cross sectional
Compressor
FK F 20 area has restriction.Pumping air to Check the pressure line,If it needs it clean the
gives out oil to
pressure line is less than normal system
system.
condition.
Change compressor snap rings.If wearing is
Compressor snap rings completed its
tto high.Change cylinder sleeve,piston and
working life and have wearing.
piston rings threehold.

Compressor Crank bearing has high spacing that the Check the tightness of belt and change
crank bearing reason excessive of belt tightness. compressor bearing cover repair kit.
FK F 30
gives out
noise.
Wearing caused by poor lubricating. Check lubricating system.

Crank oil seal is damaged caused by Change compressor bearing cover reparing
Compressor excessive of oil pressure. kit.
has oil leakage
FK F 40
from behind İncreasing pressure in returning pipe
pulley. caused by restriction of cross sectional
area of pipe and damaged crank oil seal.

FAILURE
Failure REPAIRING AND MAINTINANCE
DESCRIPTI REASON FOR FAILURE
code PROCEDURES
ON
Air pressure
Cartridge did not change on time. Change cartridge.
FK 0601 system
contains vapor. 12 V heater has a failure. Change heater.
Valve’s set pressure was changed. Set valve unit in test unit.

Relief valves have a pollution with

Change valve repair kit and to set again.
external effected.
Air is not Meausure leakage values and provide the
stored in set System have external leakages.
FK 0602 components sealing.
pressure. ( 8.1
Bar ± 0.2) Changing cartridge does not use orginal
Use orginal filter.
filter.
System equipments have failure caused
by compressor does not maintain properly Maintain the compressor properly.Solve the
on time and compressor loose its failure and change repair kit.
functions.

201
 Model Page
52. Air Brake System
A90 – A100 – A110 5

FAILURE
Failure REPAIRING AND MAINTINANCE
DESCRIPTI REASON FOR FAILURE
code PROCEDURES
ON
Tank does not Compressor valves have external dusts
Maintain compressor and also maintain valves
FK 3301 drain its water caused by maintaing the system properly
before compressor with changing repair kits.
in system. on time.
Valve has
FK 3302 continously air Valve components are damaged. Change valve repair kit.
leakage.

FAILURE
Failure REPAIRING AND MAINTINANCE
DESCRIPTI REASON FOR FAILURE
code PROCEDURES
ON
Hydraulic system contains air. Bleeding the system air on bleeding valves.
Valve’s outlet
pressure Braking and after braking composing air Valf drainers can be blockage.Change new
FK 0961 measure less does not even drain from valve. ones.
than inlet
pressure. Valve components have wearings.
Change valve repair kit.

Hydraulic pressure on hydraulic port does

Hydraulic oil can not arrive its reserve.Check
not arising on time or composing anti
Valve egzosts the hydraulic system.
pressure.
FK 0962 have a
leakage.
Check components before valve.If it needs to
External polluter composes in valve.
maintain its maintinance.

FAILURE
Failure REPAIRING AND MAINTINANCE
DESCRIPTI REASON FOR FAILURE
code PROCEDURES
ON
Valve outlet External polluter composes in valve.. Change valve repair kit.
pressure
FK 1411
exceed set Valve components wear. Change valve repair kit.
pressure.
Valve egzost Check components before valve.If it needs to
FK 1412 External polluter composes in valve.
bleeds off air. maintain its maintinance.Change repairing kits.

FAILURE
Failure REPAIRING AND MAINTINANCE
DESCRIPTI REASON FOR FAILURE
code PROCEDURES
ON
Valve outlet External polluter composes in valve.. Change valve repair kit.
pressure
FK 1211
exceeds set Valve components wear. Change valve repair kit.
pressure.
Valve egzost Check components before valve.If it needs to
FK 1212 External polluter composes in valve..
bleeds off air. maintain its maintinance.Change repairing kits.

Failure FAILURE REPAIRING AND MAINTINANCE

REASON FOR FAILURE
code DESCRIPTION PROCEDURES
Warning lamp
FK 1461 Warning led is damaged. Change warning let.
does work.
Check components before valve.If it needs to
Valve egzost
FK 1462 External polluter composes in valve.. maintain its maintinance.Change repairing
bleeds off air.
kits.
Valve does not
Locking mechanism is deformed
FK 1463 position in Change valve upper cover.
physically.
locking position.
202
 Model Page
52. Air Brake System
A90 – A100 – A110 6

Ord. Hattat Code Product inform. Accesories Product

Air compressor
1 9HT! 3500 A1A All accesories on system
Ø75 – 100 cc

Compressor
2 9HT! 3501 A1A connection All accesories on system
bracket

Drier with air

3 9HT! 3502 A1A relief valve 12V

Automatic
4 9HT! 3503 A1A Water drainer
valve
(2quantity)

Two way Check

5 9HT! 3504 A1A
valve
(3 quantity)

Load adjusting
6 9HT! 3505 A1A
ventil

Hydraulically
7 9HT! 3506 A1A actuated brake All accesories on system
pedal valve

Twin Circuit
8 9HT! 3507 A1A
brake valve

(2quantity)

Air Tank
9 9HT! 3508 A1A
15 l

(1quantity)

Air Tank
10 9HT! 3509 A1A
1l
(2quantity)

Automatic
11 9HT! 3510 A1A coupling
Yellow
(1quantity)

203
204
60. Front Axle and Steering System 61. Steering System

62. Powered Front Axle

205
 Model Page
61. Steering System
A90 – A100 – A110

61. Steering System

Steering System ………………………………………………………………………………………………. 1

Measurement of the steering system, oil pressures………………………………………………………. 4
Reconditioning steering valve ………………………………………………………………………………. 5
Fitting steering valve …………………………………………………………………………………………. 6

62. Powered Front Axle

Content

General information…………………………………………………………………………………………... 1
Disassembly of Hub and Planetary Gear Set……………………………………………………………… 3
Disassembly of Joint Casing ………………………………………………………………………………… 11
Assembly of Joint Casing …………………………………………………………………………………… 15
Disassembly of Steering System …………………………………………………………………………… 20
Assembly of Steering System ……………………………………………………………………………… 22
Disassembly of Drive Shaft ………………………………………………………………………………….. 24
Assembly of Drive Shaft ……………………………………………………………………………………… 25
Disassembly of Differential Unit …………………………………………………………………………….. 26
Assembly of Differential Unit ………………………………………………………………………………… 28
Disassembly of Central Housing ……………………………………………………………………………. 30
Assembly of Central Housing ……………………………………………………………………………….. 34
Conversion Table …………………………………………………………………………………………….. 40
Explanation ……………………………………………………………………………………………………. 42
Tool numbers …………………………………………………………………………………………………. 42

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 Model Page
61. Steering System
A90 – A100 – A110 1

Steering System

The tractor is fitted with a hydrostatic steering system which means that the steering wheel movements are transmitted to the
front wheels by oil under pressure. This provides a steering system which is easy to handle.Should the oil pressure fail for some
reason, e.g. when the engine stops, the tractor can still be steered. The steering valve then acts as a pump, but a considerably
greater effort is required for turning the steering wheel.

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 Model Page
61. Steering System
A90 – A100 – A110 2

The gear-type pump on the right-hand side of the engine (front pump for working hydraulics, rear pump for steering hydraulics)
draws oil from the hydraulic housing via the suction strainer (6) through the suction pipes (2). The gear-type pump (1) for the
steering hydraulics supplies the oil to the steering valve (3).

The steering valve directs the oil flow to either end of the steering cylinder (4) depending on the direction in which the steering
wheel is turned. If the steering wheel is not turned, the steering valve allows the oil to circulate back to the hydraulic housing.
The return oil from the steering cylinder is conducted through the steering valve (3) and through the return pipe back to the
hydraulic housing.

Steering cylinders, description

The steering cylinder is a double-acting special cylinder. The piston rod acts as a piston and there are only seals round the
piston rod. The steering arm is secured to the centre of the piston rod. The track rods, in their turn, are secured to the steering
arm. This design provides for an ample steering force even close to the full steering lock positions.

The steering cylinder is secured to the front axle member with a tapered nut and two bolts. The front bolts are provided with lock
washers.

208
 Model Page
61. Steering System
A90 – A100 – A110 3

Steering cylinder for non-powered front axle

1. Screw studs secured with Loctite 222

2. The bearing sleeve is provided with a groove which should be facing upwards.
3. Check that there is a clearance between the bearing sleeve and the seal
4. Cylinder frame
5. Cylinder ends
6. Piston (=piston rod)
7. Steering arm

209
 Model Page
61. Steering System
A90 – A100 – A110 4

Measurement of the steering system, oil pressures

Measurement of the pressure-limiting valve opening pressure (9-10 MPa)

Pressure test procedure should test tehese parts.

1. Remove the engine hood upper side plate on the right-

hand side.

2. Unscrew the hose union (22 mm) on the oil hose to the
steering cylinder.

3. Fit the gauge using the necessary union and adapters.
4. Start the engine and set the hand throttle to approx.
1500 rpm. Turn the steering wheel to full lock and read off
the opening pressure. The pressure valve should be 9 + 1
MPa.. If the opening pressure deviates from the mentioned
value, the pressure-limiting valve must be cleaned or
changed.

5. Remove the gauge and connect the steering hose (22

mm, 45 Nm (33 lbf ft)). Fit the engine hood plate.
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 Model Page
61. Steering System
A90 – A100 – A110 5

Reconditioning steering valve

Removing steering valve

1. Remove the knob from the stop/hand throttle control (13

mm) and the rubber grommet for the control (later type
models have a stop control in the instrumrnt panel).

2. Remove the guard plate under the instrument panel (at

the same time disconnect the heater hoses from the
nozzles).

3. Disconnect the oil hoses from the steering valve (delivery and return hoses (22 mm) and the hoses to the steeringcylinder (24
mm)).

N.B. If the flasher relay is removed it will be easier to remove the steering valve.

4. Undo the lock washers and remove the steering valve attaching bolts (13 mm). Take care not to damage the electrical leads.

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 Model Page
61. Steering System A90 – A100 – A110 5

5. Remove the steering valve.

Fitting steering valve

1. Fit the steering valve attaching bolts, rubber damber and

washers (fix the lowermost washers with a quick-acting
glue).

2. Fit the valve and tighten the bolts (13 mm, 20 Nm (15 lbf
ft)) and secure with the tab washer.

3. Connect the oil hoses to the steering valve (22 and 24

mm, 45 Nm (33 lbf ft)). secure the flasher relay if it was
removed earlier.

4. Fit the guard plate under the instrument panel and con
nect the heater hoses to their respective nozzles.

5. Fit the stop control rubber grommet and the knob (13
mm).

6. Check the oil level in the hydraulic housing and top up

with hydraulic oil if necessary. Start the engine and check
that the system works.

212
62. Powered Front Axle Model Page
A90-A100-A110 1

General Information also bearings must be greased, too. The prescribed pre-
loading, backlash and torque of parts must be maintained
General: while mounting
The efficiency and continued operation of front axle unit
depends on regular, correct maintenance and also on Lubrication:
efficient repair work. In describing the following operations, Where applicable, fill the compartments of repaired or
it is presumed that the unit has already been removed from renewed components quantity, type and grade of clean
the tractor. lubricant recommended in the routine maintenance
This manual provides a quick and sure guide which, mentioned sections of this sevice manuel.
with the use of photographs and diagrams illustrating the
various phases, allows accurate work. All the information Shims:
needed for correct disassembly, checks and assembly When shims are removed, tie them together and identify
of each component is given in this service book. Data their location. Keep shims clean and take care not to bend
subject to change without notice. We decline all them before refitting them.
responsibility for the use of non-orijinal components, or
accessories which have not been tested and submitted for Lip type rubber seals: Lubricate the lips of lip-type rubber
approval. seals with oil before fitment. Do not use grease on seals,
except for grease seals.
Handling of heavy components:
Unless otherwise specified, all removals should be
accomplished using adjustable lifting eguipment. All The main parts of lip-
supporting slings must be parallel to each other and as type seal:
near vertical as possible in relation to the object being
lifted. However, where slings are of a far greater capacity 1. Case
than the weight of the load to be fitted, a triangular 2. Sealing element
lifting arrangement may be used. 3. Ring spring

Cleanless: Clean and inspect all parts. Make sure that all
passages and holes are clear. Cover all parts to keep them
clean. Make sure parts are clean when they are
reassembled. Leave new parts in their

Disassembling:
All the disassembled mechanical units should be
thoroughly cleaned with appropriate products replaced if
damage, wear, cracking or seizing have occurred. In
particular, thoroughly check the condition of all moving
parts (bearings, gears, shafts) and sealing parts such as
o-rings which are subject to major stress and wear. In any
case, it is advisable to replace the seals every time a
component is overhauled and repaired. The figure above shows the construction of a simple lip-
type seal. The cross section shows the heel (4) and the toe
Assembling: (5), used to identify the sides of a single element seal. With
When reassembling the front axle, complete each step in a few exceptions, the toe of a single-lip is located on the
sequence. Make all recommended adjustments. Always lubricant side. Some seals have a second auxiliary lip
check the job on completion to ensure that nothing has which has no spring.
been overlooked. Recheck the various adjustments before
putting the axle back into service. During assembly, the
sealing rings must be lubricated on the sealing edge and

213

62. Powered Front Axle
Locking devices:
Slackening of nuts and bolts is prevented by
mechanical means such as lockwashers, tab
washers and cotter pins, or by Loctite-type locking
agents.
Flat retainers must be installed properly to be effective.
Bend one end of the retainer against the edge of the part.
Bend the other end againist one of the nut or bolt head.
Always fit new retainers in conpartments which house
moving parts.
Bushes and press fits:
Do not fit bushes with a hammer alone. Use a suitable
fitting tool and a hammer or, better still, a press if
possible.
When using a press, ensure that pressure is applied
directly in line with the bore. When press fitting a part into
another part, lubricate the mating surfaces. Tapered parts
sould be assembled dry. Before assembly, check that the
tapers are dry and free from burrs.
Fitting bolts in blind holes:
Use bolts of the correct length. A bolt which is too long may
"bottom" before the head comes into contact with the part it
is to hold: this will cause damage to the threads. If a bolt is
too short, there may not be enough threads engaged to
hold the part securely.
Outer oil seals:
This service manual contains instructions for changing all
outer oil seals (eg. Oil seals on the pinion shaft, and so on).
Sealing compound and glue:
If sealing compounds or glue are required for the repair
work, the instructions will specify a sealing compound or
glue which is readily available through specialist dealers.
Some seals should be greased before fitting and the space
between the lips of the seal should be filled with universal
grease. If the seal is to be pushed over splines or sharp
edges the seal should be protected with for example a thin
plastic foil.
214
Model Page
A90-A100-A110 2
Tightening torques and setting values:
All necessary tightening torques and setting values for
each repair operation are given at the each section under
the "assembly" and "disassembly" headings.
Table in section 80-02 gives the tightening torques in order
of dimension, quality and surface treatment. The values
given in the table should be used if the tightening torque is
not given in related sections.
Specific Equipments:
The HEMA numbers of all specific tools required for
maintenance and repair work can be found at the end of
this manual in a list.
Spare Parts:
Spare parts and also specific equipments can be ordered
from the vehicle manufacturer or Hattat Otomotiv A.Ş.
Safety:
Always bear safety in mind when repairing or servicing the
front axle. Use tools and lifting devices in the correct way.
When you are removing the front axle components or
splitting the front axle, every front axle part must be
supported in such a way, that no risk of accident exists.
Avoid working under the supported front axle part if it is not
absolutely necessary. When supporting the front axle the
center of gravity of the frame part must always be checked.
Always wear gloves and non-slip rubber shoes when
performing repair work. Use only clean, quality tools;
discard all worn, damaged, low quality or improvised
wrenches have been checked and calibrated.
 Model Page
62. Powered Front Axle
A90-A100-A110 3

Disassembly of Hub and Planetary Gear Set

CAUTION: Perform all operations on both arms.

1- Remove the oil plug with washer and drain the oil. 4- Remove the o-ring from the flange
Note: Before draining the oil, position the hub so that the
oil plug is on the upper position.

2- Remove the (two) bolts from the flange.

5- Remove the snap rings over the planet gears.

3- Pull out the hub from the flange using a lever.

6- Remove the plates, planet gears, needles and the other
Note: There are two opposite gaps over the flange to plates under them respectively.
separate the hub from the flange.
Note: Some of the needles may come with the planet gear

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 Model Page
62. Powered Front Axle
A90-A100-A110 4

7- CAUTION: Do not try to remove the locked plate from
the hub.
Note: If hub, shaft(s) or plate is damaged, use a new hub
fitted with new shafts and with a new plate.
10- Pull out the ring gear assembly.
Note: Pay attention to keep the ring assembly together
while disassembling.

8- Remove the snap ring, plate and spacer ring on the 11- Remove the snap ring and disjoin the ring gear from
shaft gear respectively. the ring gear assembly.
Note: If the pins on the ring gear support are in poor
condition, replace the ring gear support with fitted pins.

9- Remove the (six) screws on the ring gear support.

Screw two (M8x1.25) bolts in the threaded holes to remove 12- Remove the shim.
the ring gear assembly from the knuckle housing.
Note: This shim may be damaged while disassembling and
do not try to use it again.

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 Model Page
62. Powered Front Axle
A90-A100-A110 5

13- Remove the flange assembly using a plastic hammer 16- Remove the bearing cones from the flange using a
and a lever on several opposing points. suitable extractor or lever.
Note: Pay attention to collect the bearing while removing
the flange.

14- If the (8) screws on the flange are in poor condition, 17- Remove the bearing using a puller with a suitable
replace the flange with fitted screws. counterhold.

Note: This bearing may also be removed using two levers

oppositely.

18- Check the wear conditions of all components.

15- Remove the seal from the flange using suitable

extractor(s).
Note: The seal can not be used after this operation.

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 Model Page
62. Powered Front Axle
A90-A100-A110 6

CAUTION: Perform all operations on both arms. measure the thickness (D) between outside faces of the
1- Before the assembly of the hub and planetary gear set, bearings using tool (HFA100/T002).
please look at the section "Assembly of Joint Casing".

2- Use pre-assembled flange with fitted bolts. If flange or *5- If necassary, measure the depth of the mounting
one of the bolt is dameged, supply new pre-assembled distance of the flange (C) on the steering knuckle.
flange with fitted bolts.

3- Fit the bearing cones to the flange using tool

(HFA100/T001).

*6- If necassary calculate the shim thickness(S) using

formula, S= (C+0.5)-D, values in mm.

*4- If necassary, locate the bearings on the flange and

218
 Model Page
62. Powered Front Axle
A90-A100-A110 7

7- Fit the bearing to the steering knuckle using tool 10- Fit the bearing on the flange assembly using tool
(HFA100/T003). (HFA100/T003).

8- Fit the new seal to the flange using tool
(HFA100/T004). Apply Loctite 290 on the outer surface of
the sealing.
Note: Pay attention to control the direction of assembly of
the seal ring.
11- Locate the new appropriate shim with grease on the
steering knuckle.
*Note: Items 4, 5 and 6 should be considered when a new
bearing, steering knuckle or flange is used.

12- Use pre-assembled ring gear support with fitted

pins or supply new one.
9- Install the flange assembly on the steering knuckle. If If necessary, fit the (six) pins to the heated ring gear
necessary, use a plastic hammer. support up to 150 ºC using tool (HFA100/T005) under the
press.

219

62. Powered Front Axle
13- Place the ring gear support to the ring gear and then
insert the snap ring to fix the ring gear support.
Note: Pay attention to check that snap ring is properly
inserted in the slot of the ring gear.
14- Locate the ring gear assembly on the steering
knuckle.
Note: Pay attention to check the shim to exist on the
steering knuckle before assembling the ring gear
assembly.
15- Tighten the (six) bolts to 90 Nm torque. Apply
loctite 243 on threads.
Note: Tighten the bolts applying crisscross method and
one flat sides of the bolt heads must be tangent to the
center.
220
Model Page
A90-A100-A110 8
16- Install the spacer ring, plate and snap ring
respectively on the shaft gear.
Note: Be sure that the snap ring should be rotate with shaft
easily without touching the bolts when the shaft is turning.
17- Use pre-assembled hub with fitted pins.
If hub or one of the pin is dameged, supply new pre-
assembled flange with fitted pins.
*18- If necessary, measure the length "X5" from flange
face to the face of the shaft gear using tool
(HFA100/T006).

62. Powered Front Axle
*19- If necessary, measure the dimension "X6" is
from the outer face of the hub to the sitting face of
plate in the hub using tool (HFA100/T007).
*20- If necessary, calculate the plate thickness
(S) using formula, S= X6 - (X5+0.5), values in mm.
21- Apply grease oil to the inside surfaces of the planet
gears. Locate the needles onto this surfaces.
221
Model Page
A90-A100-A110 9
22- Locate the plates with grease on both faces of the
planet gears and then insert them to the shafts.
Note: Pay attention that the needle(s) may come out
while locating the planet gears to the shafts.
23- Install the snap rings to the grooves on the shafts.
Grease the planet gears and shaft gear.
Note: Pay attention to control that each planet gear rotates
freely.
24- If disassemblied hub with caulked plate is not used,
locate the new appropriate plate which is calculated at item
20 and lock it with calk using tool (HFA100/T008). *Note:
Items 18, 19 and 20 should be considered when a new
hub, shaft gear or flange is used.
 Model Page
62. Powered Front Axle
A90-A100-A110 10

25- Grease and locate the new o-ring on the flange 28- Tighten the (two) bolts to 45-50Nm torque. Apply loctite
assembly. 542 on threads.
Note: Pay attention not to damage the o-ring.

26- Apply Loctite 518 on the hub. 29- Fill in the each hub with 0.7 lt. oil
(80W90-GL-5 EP) from the oil hole.
Note: Before filling the oil, be sure that position of the oil
hole is the upside.

27- Install the sub-assembled hub to the flange. 30- Tighten the oil plug with a new washer on the hub.

Note: Turn the input flange of the axle slowly to align the Note: Use new washer for optimum sealing.
gears in the hub assembly so that hub sits on flange
easier.

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 Model Page
62. Powered Front Axle
A90-A100-A110 11

Disassembly of Joint Casing

3- Remove the nut of the articulation pin of the steering
CAUTION: Perform all operations on both arms. rod.
1-Before the disassembly of the joint casing, please look
at the section "Disassembly of Hub and Planetary Gear
Set".

4- Disjoin the tapered articulation pin from the steering

knuckle.

2- Remove the oil plug with washer under the central

housing and wait untill the all oil to be emptied from the
housing.

Note: Pay attention to put a big box under the oil plug
before remove it.

5- Remove the (four) bolts of the kingpin.

6- Remove the kingpins from the steering knuckle

using levers.
Note: Pay attention not to damage the surfaces.
Note: Secure the steering knuckle before
removing the kingpins.

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 Model Page
62. Powered Front Axle
A90 - A100 - A110 12

7- Remove the steering knuckle from the axle 10- Remove the bearings from the kingpin houses
housing.
Note: Pay attention not to damage the bushing and
the seal on the steering knuckle during this
operation.

8- Remove the shim(s) over the kingpin house that is 11- Remove the bearing cones from the kingpin houses on
upperside steering knucle. the axle housing by using a puller with a suitable
Note: Shim(s) may come out with the kingpin while counterhold or lever.
removing the kingpins.

9- Remove the seals from the kingpin houses on axle
housing using a suitable extractor or lever.
Note: Seal(s) may come out while removing the kingpins
and they can not be used after this operation.
12- Pull out the complete drive shaft assembly from the
axle housing.
Note: Pay attention not to damage the bushing and the
seal on the axle housing during this operation

224
 Model Page
62. Powered Front Axle
A90 - A100 - A110 13

13- If you need, diassemble the drive shaft assembly.

Note: Please look at the section "Disassembly of Drive 16- Remove the (eleven) bolts after securing the axle
Shaft". housing.

14- Remove the seal on the steering knuckle by using a

17- Pull out the axle housing from the center housing.
suitable exctractor.
Note: Pay attention to secure the axle housing while re
Note: The seal cannot be used after this operation.
moving it.

15- Remove the bushing on the steering knuckle by using 18- Remove the o-ring from the groove on the axle
a suitable exctractor. Bushing and seal can be removed housing.
together by using this operation.
Note: The bushing and seal cannot be used after this
operation.

225
 Model Page
62. Powered Front Axle
A90 - A100 - A110 14

22- Check the wear conditions of all components.

19- Remove the seal on the axle housing by using a

suitable exctractor.
Note: The seal cannot be used after this operation.

20- Remove the bushing on the axle housing by using a

suitable exctractor.
Note: The bushing cannot be used after this operation.

21- If you need, remove the breather from the left axle
housing.

226
 Model Page
62. Powered Front Axle
A90 - A100 - A110 15
Assembly of Joint Casing

4- Fit the bearing cones into the kingpin houses on the axle
CAUTION: Perform all operations on both arms. housing using tool (HFA100/T011).
1- Before the assembly of the joint casing, please look at Note: Grease and put the inner rings inside the bearing
the section "Assembly of Central Housing". cones before mounting the seals on them.

5- Grease and install the new o-ring to the groove on

2- Fit the bushing to the axle housing using tool the axle housing.
(HFA100/T009).

3- Grease and fit the seal to the axle housing using tool 6- Apply Loctite 518 on the surface of the center housing
(HFA100/T010). and on the cover surface.

227
 Model Page
62. Powered Front Axle
A90 - A100 – A110 16

7- Locate the axle housing to the center housing.

Note: Pay attention not to damage the o-ring on the axle 10- Grease and fit the new seal in to steering knuckle using
housing and secure the axle housing during installation. tool (HFA100/T013)

8- Tighten the (eleven) bolts to 190Nm torque. Apply loctite

243 on threads. *11- If necessary, fit the bearings to the kingpins and
locate the kingpins on the steering knuckle to measure "A"
Note: Tighten the bolts applying crisscross method. value.
Note: Pay attention not to damage the surfaces of bearings
while fitting.

9- Fit the new bushing in to the steering knuckle using tool

(HFA100/T012). *12- If necessary, measure the distance "A" between
inside faces of kingpins using tool (HFA100/T014) and
remove the bearings from the kingpins after measurment.
Note: Pay attention not to damage the surfaces while
removing.

228
 Model Page
62. Powered Front Axle
A90 - A100 – A110 17

*13- If necessary, measure the dimension "B" between 16- Locate the removed bearings from kingpins to inside
kingpin outside faces on steering knuckle the kingpin houses on the axle housing by hand.

*14- If necessary, calculate the shim thickness

17- Fit the new seals into the kingpin houses on the axle
(S) using formula, S= A - (B+0.6), values in mm. Select
housing using tool (HFA100/T015). Apply loctite 648 on
the appropriate shim. mounting surfaces of the sealings before fitting operation.

18- Fill up the kingpin houses with grase (Castrol

15- Install the drive shaft assembly through the axle pyroplex blue #5517) approximately 20gr.
housing.

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62. Powered Front Axle
A90 - A100 – A110 18

19- Locate the steering knuckle on the axle housing.

Note: Pay attention to hold the drive shaft assembly
straight for easier assembly.
22- Tighten the (eight) bolts to 120Nm torque.
Note: Some grease may come out from the threated
holes while installing the kingpins.
Note: Tightness of the steering knuckle should be between
8-11 Nm while turning.

20- Locate the appropriate shim(s) on top side of the

steering knuckle and locate the kingpins into the kingpin
houses.
*Note: Items 11, 12, 13, and 14 should be considerd 23- Close the threated holes on the kingpins with set
when a new steering knuckle, kingpin or bearing is used. screws. Apply loctite 243 on threads.

21- Fit the kingpins through the kingpin houses.

Note: Pay attention to put the suitable shim(s) on upper
surface of the steering knuckle before installation.
24- Install the tapered articulation pin to steering knuckle
using a plastic hammer.

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62. Powered Front Axle
A90 - A100 - A110 19

25- Tighten the nut of articulaton pin to 160Nm torque.

28- Fill in the central and axle housings with 6,5lt oil
(80W90 GL-5 EP) from the oil hole on the left axle housing.
Note: Be sure that the oil plug exists on the central
housing and it is tighten.

26- Grease the cardan shaft from the gap on the steering
knucle.
Note: Turn the steering knuckle to the end positions
to grease the cardan shaft easily.
29- Locate the oil plug with new washer on the left axle
housing and tighten it.
Note: Use new washer for optimum sealing.

27- Look at the "Assembly of Hub and Planetary

Gear Set" section to assemble the hub unit.

30- Locate the breather on the left axle housing and tigten
it if it is removed before.

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62. Powered Front Axle
A90 - A100 – A110 20

Disassembly of Steering System

CAUTION: Perform all operations on both arms.

1- Remove the nut of the articulation pin of the steering 4- Disconnect the steering rod from the cylinder rod.
rod.

2- CAUTION: Do not loose the steering rod adjusting

screw and nut. Measure the distance from the end teeth
to the nut and record it for pre-adjustment if new
steering rod is used.
Note: Nut setting changes the toe-in angle.
5- Pay attention to control existing " L" and "R"
symbols at the ends of the cyliner rod. If not exist,
mark the ends of the cylinder rod as right and left by
using permanent pen to make correct assembly.

3- Disjoin the tapered articulation pin from the steering

knuckle. 6- Remove the (four) bolts from the cover of the steering
cylinder and remove the cover.

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62. Powered Front Axle
A90 - A100 – A110 21

7- Remove the shim(s) from the left cylinder cover face on

the central housing. 10- Remove the guide rings and seals from the cover.

Note: Shim(s) may come out with the left cylinder cover Note: These seals and rings cannot be used after this
while removing the covers. operation.

8- Pull out the piston rod assembly from the steering

cylinder. 11- Remove the seals and o-ring over the piston.
Note: These seals and o-ring cannot be used after this
operation.

12- Check the wear conditions of all components.

9- If you need, remove the steering cylinder from the

center housing using a suitable extractor.

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62. Powered Front Axle
A90 - A100 – A110 22

Assembly of Steering System

CAUTION: Perform all operations on both arms. 4- Grease and locate the guide rings and seals on the
1- Grease and locate the new o-ring to the groove on the covers.
center of the piston and locate the new seal with grease on Note: Special tool can be used to assemble the seals in
it and then pass through this assembly from the tool
the covers.
(HFA100/T016) to strighten the seal.

2- Grease and locate the (two) new seals on the piston. 5- If disassemblied shim is damaged, select new one with
same thickness given table

3- Fit the steering cylinder on the central housing using a

plastic hammer if it is removed before. 6- Locate the present shim into the left cover. If it is
dameged, use the selected one to item 5.
Note: Pay attention to fit the steering cylinder
symetrically to the central housing.

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62. Powered Front Axle
A90 - A100 – A110 23

7- Locate the piston rod assembly in the right positon 10- Join the tapered articulation pin to the steering
in the steering cylinder. knuckle.
Note: Look at on the piston rod and there should be left (L)
and right (R) letters at the ends.

11- Tighten the nut of the articulation pin of the steering

8- Locate the cover of the steering cylinder on the central
rod to 160Nm torque.
housing and tighten the (four) bolts to 70Nm torgue.
Note: Apply loctite 243 on threads.

9- Connect and tigten the steering rods to the cylinder
rod to 120Nm torgue.
12- If new steering rod(s) is used, set the position of
steering rod(s) by screwing the nut on it to the recorded
value measured before while dissassembling.
Note: Set the correct toe-in angle of the front axle after
it is mounted to the tractor.

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62. Powered Front Axle
A90 - A100 – A110 24

Disassembly of Drive Shaft

1- See "Disassembly of Joint Casing " section for more

3- Remove the shaft from the drive shaft assembly by
information about removing the drive shaft assembly from
axle housing. removing the snap ring.

4- Do not try to dissamble the double u-joint.

2- Remove the shaft gear from the drive shaft assembly by

removing the snap ring.

5- Check the wear conditions of all components.

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62. Powered Front Axle
A90 - A100 – A110 25

Assembly of Drive Shaft

1- Locate the snap ring to its groove on shaft side of the 4- Locate the shaft gear to the drive shaft assembly. Slide
drive shaft assembly. the shaft gear through the drive shaft assembly until the
Note: Smaller outside diamater of the u-joint is the shaft snap ring sits on its groove on the shaft gear.
side.

2- Locate the shaft to drive shaft assembly. Slide the shaft

through the drive shaft assembly until the circlip sits on its
groove on the shaft.

3- Locate the snap ring to its groove on the gear shaft side
of the drive shaft assembly.
Note: Larger outside diamater of the u-joint is the gear
side.

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62. Powered Front Axle
A90 - A100 – A110 26

Disassembly of Differential Unit

1- Remove the (two) bearings from the differantial unit by 4- Pull out the bevel gear ring.
using a puller with a suitable counterhold.
Note: This bearing may also be removed using two levers
oppositely.

2- CAUTION: Mark as a line on the bevel gear and on the 5- Remove the disc set with the bevel gear.
housing using a permanent pen to make correct assembly Note: When disc set is removed, tie them together and
again.
identify its location.

6- Remove the slotted pin using pliers.

3- Remove the (twelve) bolts.
Note: Pay attention not to break the pin while removing.

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62. Powered Front Axle
A90 - A100 – A110 27

10- Remove the bevel gear with the disc set.

Note: When disc set is removed, tie them together and
7- Remove the (two) referance pins from the differantial
identify its location.
housing using pliers.

8- Remove the shaft from the housing using a suitable 11- Check the wear conditions of all components.
extractor.

9- Remove the pinion gears and thrust plates.

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62. Powered Front Axle
A90 - A100 – A110 28

Assembly of Differential Unit

1- Check the wear condition of the discs and plates. 4- Grase and locate the trust plates on the
differential housing.
Note: If necessary, change the complete friction
disc set with new ones.

2- Locate the fricton disc set behind the bevel gear.

5- Locate the bevel pinion gears and then insert the shaft
Note: Pay attention for the order of discs. The thicker disc
through the housing.
should be behind the bevel gear and also lubricate each
disc and plate before assembly.

3- Insert the disc set with bevel gear inside the differential 6- The clearance between the plates should be between
housing.
0.10 - 0.15 mm. If not, select a suitable disc set.

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62. Powered Front Axle
A90 - A100 – A110 29

7- Fit the slotted pin to the housing.
Note: Pin holes on the differential housing and the shaft
should be in a same axis while fitting the pin.
10- Locate the bevel gear ring and locate the (two) pins
through the referance holes on the bevel gear ring.
Note: Pay attention to match the marked lines putted while
disassembling operation on the bevel gear and on the
housing.

11- Locate the (twelve) bolts and tighten them to 70Nm

torque. Apply loctite 542 on threads.
8- Install the bevel gear with the friction disc set over the
pinion gears.
Note: Pay attention for the order of the discs. The thicker
disc should be behind the bevel gear and also lubricate
each disc and plate.

12- Fit the (two) bearings on the differential housing unit

using tool (HFA100/T017).

9- The distance between the plate and housing surface

should be between 0.10 - 0.15 mm. If not, select a suitable
disc set.

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62. Powered Front Axle
A90 - A100 – A110 30

Disassembly of Central Housing

1- Before the disassembly of the central housing, please
look at the section "Disassembly of Joint Casing".

2- The supports and seals should be removed after

front axle disassembling.
5- Remove the bolt and locking plate from the cover.

3- Remove the cover.

Note: Pay attention to support the differential unit
with a rod while removing the cover.

6- Turn & disassemble the adjustable screw into the

bearing side using tool (HFA100/T018) to remove the
screw with bearing cone.

4- Remove the differential unit.

Note: Please look at the section "Disassembly of the
Differantial Unit" to disassemble the differantial unit.

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62. Powered Front Axle
A90 - A100 – A110 31

7- Remove the o-ring from the cover. 10- Lock the pinion shaft using tool (HFA100/T019) and
disassemble the locking nut, thrust plate and flange
alternately.

Note: Pay attention to control that locking screw is locked

to the slot on the pinion shaft.

8- Remove the bolt and locking plate from the central 11- Remove the o-ring from the flange.
housing.

9- Turn & disassemble the adjustable screw into the 12- Disassemble the tool (HFA100/T019) to unlock the pinion
housing using tool (HFA100/T018) to remove the screw gear again.
with bearing cone.

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62. Powered Front Axle
A90 - A100 – A110 32

13- Disassemble the pinion shaft from the central housing 16- Remove the spacing rings from the central housing.
using a plastic hammer.
Note: Pay attention not to drop the pinion shaft in to the
central housing.

14- Remove the bearing from the pinion shaft by using a 17- Remove the bearing.
puller.

18- Remove the bearing cones from the central housing

15- Remove the seal from the central housing by using a using a suitable extractor.
sutiable extractor.
Note: The seal can not be used after this
operation.

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62. Powered Front Axle
A90 - A100 – A110 33

19- Remove the shim(s).

Note : This shim may be damaged while disassembling of
bearing cone and do not use it again while assembling.

20- If you need, remove the sleeves using a suitable

extractor and take the thrust plates from the central
housing.

Note : These sleeves cannot be used after this operation.

21- Check the wear conditions of all components.

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62. Powered Front Axle
A90 - A100 – A110 34

Assembly of Central Housing

1- Put the thrust plates and fit the new sleeves on the
central housing using tool (HFA100/T021) if it is removed 4- Fit the bearing cone to the central housing from inner
before. side using tool (HFA100/T022).

2- Secure the central housing before starting the assemble.

Note: Assembling may be easy on a special fixture.
5- Locate the adjustable screw on the cover from the inner
side and screw it using tool (HFA100/T018) untill the end
position.
Note: Pay attention to control the direction of the
adjustable screw.

3- Locate the adjustable screw to the central housing

from the inner side and screw it using tool
(HFA100/T018) untill the end position.
Note: Pay attention to control the direction of the 6- Fit the bearing cone to the cover using tool
adjustable screw. (HFA100/T022).

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62. Powered Front Axle
A90 - A100 – A110 35

*7- If necessary, measure the thickness of the taper roller *10- If necessary, calculate the shim thickness
bearing to see "B" value using tool (HFA100/T023). (S) using formula, S= C - (A+B), values in mm.

*8- If necessary, look at the inside the central housing to

11- Fit the bearing to the pinion shaft under the press using
see "C" value (mounting crown height on the
tool (HFA100/T024).
housing).Note: The nominal dimension is 120,5. Any
diffrences are marked in decimals on the housing.
(49 means 120,49) & (52 means 120,52).

*9- If necessary, look at face of the pinion shaft to see

"A" value (actual crown height on the shaft).Note: The
nominal dimension is 93.
Any diffrences are marked in decimals on face of the
pinion.
(-0.15 means 92,85) & (0.15 means 93,15).
12- Select the new appropriate shim(s) and locate it
inside the central housing with grease.
*Note: Items 7, 8, 9 and 10 should be considered when a
new central housing, bevel & pinion set, or bearing is
used.

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62. Powered Front Axle
A90 - A100 – A110 36

13- Fit the bearing cone to the central housing using tool 16- Fit the bearing to the pinion shaft using tool
(HFA100/T025). (HFA100/T024).

Note: Pay attention to put appropriate shim(s) before fitting Note: Pay attention to stop linear movement of the pinion
the cone. shaft.

14- Fit the bearing cone to the central housing using tool 17- Remove the tool (HFA100/T027).
(HFA100/T026).

15- Locate the pinion shaft and secure it using tool 18- Locate the tool (HFA100/T019) to lock the rotational
(HFA100/T027). movement of the pinion shaft.

Note: This tool stops to linear movement of the pinion

shaft.

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62. Powered Front Axle
A90 - A100 – A110 37

19- Select any two spacing rings from the table and locate
them over the bearing on the pinion shaft. 22- Measure the tightness of the pinion shaft to rotate it
with a torquemeter using tool (HFA100/T020) and
measured value should be between 1 and 2Nm torque.

20- Locate the flange, thrust plate and locking nut 23- If the torque value is out of the limit; remove the
alternately on the pinion shaft and then tighten the nut to locking nut and shim(s) alternately and then repeat the
the 200Nm torgue. items between 18&22 using different spacing ring(s) to set
the tightness value in 1&2Nm torque interval.

21- Remove the tool to release the rotational movement 24- Locate the differantial unit inside the central housing.
of pinion shaft.

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62. Powered Front Axle
A90 - A100 – A110 38

28- Set and control the tightness & tooth backlash of

25- Apply loctite 518 on the cover face of the central the bevel & pinion set using tool (HFA100/T018).
housing.

29- Tightness & backlash values should be set to the table

26- Install the cover to the central housing. If you need, values as shown above.
use a plastic hammer to fit it.
Note: Pay attention to support the differantial unit with a
rod while mounting the cover.

30- Lock the adjustable screws on both sides using

27- Tighten four bolts on the cover with 90º intervals from
each other.
Note: Pay attention to tighten the bolts using crisscross
method.
locking plates with bolts. Apply Loctite 243 on threads
and tigten the bolt.
Note: You may need a little bit screw or unscrew the
adjustable screws to allign the hole and lock the plate.

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62. Powered Front Axle
A90 - A100 – A110 39

31- Remove the nut, thrust plate and flange alternately

again and then fit the seal to the central housing using 34- Caulk the locking nut towards the slot on the pinion
tool (HFA100/T028). shaft for locking.
Note: Pay attention to set tightness of the pinion shaft
before calking.

32- Locate the o-ring to its groove in the same flange. 35- Put the seals and supports on the central housing
while assembling the front axle to tractor.

33- Locate the same parts (flange with o-ring, thrust plate
and nut) alternately over the pinion shaft and then tighten
again the locking nut using tool (HFA100/T018) to 200Nm
torque.

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 Model Page
62. Conversion Table
A90 - A100 – A110 40

Conversion Table

Conversion table for common units

Conversion table for common units Conversion factors

Overall and detail dimensions millimeters (mm) 100 mm=3,94 inches
1 inch=25,4 mm
Short distances e.g. turning circles metres (m) 1 m=3,28 ft
1 ft=0,305 m
Travel distances kilometers 1 km=0,62 mile
1 mile=1,61 km
Axle weight, axle loadings kilograms (kg) 1 kg=2,2 lbs
1 lb=0,454 kg
Travel speed kilometers per hour (km/h) 1 km/h=0,62 mph
1 mph=1,61 km/h
Drawbar pull kilonewtons (kN) 1 kN=224,8 lbs
1 lb=4,448 N
Power kilowatts (kW) 1 kW=1,34 hp
1 hp=0,746 kW
Engine torque newton metres (Nm) 1 Nm=0,74 ft lb
1 ft lb=1,356 Nm

Hydraulic pump; 1 Mpa=145 psi

Pressure-megapascal (Mpa) 1000 psi=6,9 Mpa

Delivery-millimeters per sec (ml/s) 100 ml/s=1,32 gpm
1 gpm=75,77 ml/s
Tyre pressure-kilopascal (kPa) 100 kPa=14,5 psi
1 psi=6,9 kPa
Area acres-hectare To convert multiply by
0,404686
Volume bushel-litre To convert multiply by
39,3687
Quantity pound per acre-kilogram per hectare
Multiply by 1,12085

Volume; Multiply by

Superficial foot-cubic metre 0,00236

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62. Common Tightening Torques
A90 - A100 – A110 41

Common Tightening Torques

If in the "assembly" sections have not been given specified tightening torque to screw or nut, use tightening torque
which are mentioned in table below.
Tightening torques, metric standard thread (ISO)

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

1) 1 Nm= 0,102 kpm

2) Zne= zinc electroplating
3) Znk= hot galvanized

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

253
 Model Page
62. Specific Equipment List
A90 - A100 – A110 42

Explanation
Tool numbers

Assembly of Hub and Planetary Gear Set (Section 20)

HFA100/T001 - Arbor fitting the bearing cones to the flange
HFA100/T002 - Fixture for measuring the distance between bearing surfaces on the flange.
HFA100/T003 - Arbor fitting the bearing to the steering knuckle,
HFA100/T004 - Arbor fitting the seal to the flange
HFA100/T005 - Fixture for fitting the pins on the ring gear support.
HFA100/T006 - Fixture for measuring the distance from the flange face to the shaft gear face.
HFA100/T007 - Fixture for measuring the distance from the outer face to the sitting face of plate on the hub.
HFA100/T008 - Arbor for caulking the plate to the hub.

Assembly of joint Casing (section 30)

HFA100/T009 - Arbor for fitting the bushing in to the axle housing.

HFA100/T010 - Arbor for fitting the seal in to the axle housing.
HFA100/T011 - Arbor for fitting the bearing cone in to the kingpin house.
HFA100/T012 - Arbor for fitting the bushing in to the steering knuckle.
HFA100/T013 - Arbor for fitting the seal in to the steering knuckle.
HFA100/T014 - Fixture for measuring the distance between kingpin faces.
HFA100/T015 - Arbor for fitting the seal in to the kingpin house

Assembly of Differential Unit (Section 40)

HFA100/T016 - Fixture for straightining the seal on the piston.

Assembly of Differential Unit (Section 50)

HFA100/T017 - Arbor for fitting the bearings to the differantial unit.

Disassembly of Central Housing (Section 70)

HFA100/T018 - Tool for removing the adjustable screw.

HFA100/T019 - Fixture for locking the rotational movement of pinion shaft.

Assembly of Central Housing (Section 70)

HFA100/T021 - Arbor for fitting the bearing cone to the central housing.
HFA100/T018 - Arbor for fitting the bearing cone to the cover.
HFA100/T022 - Fixture for measuring the distance of the bearing.
HFA100/T022 - Arbor for fitting the bearing cone to the cover.
HFA100/T023 - Fixture for measuring the distance of the bearing.
HFA100/T024 - Arbor for fitting the bearing to the pinion shaft.
HFA100/T025 - Fixture for fitting the bearing cone to the central housing.
HFA100/T026 - Arbor for fitting the bearing cone to the central housing.
HFA100/T027 - Fixture for locking the linear movement of the pinion shaft.
HFA100/T028 - Arbor for fitting the seal to the central housing.
HFA100/T019 - Fixture for locking the rotational movement of the pinion shaft

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 Model Page
62. Specific Equipment List
A90 - A100 – A110 43

HFA100/T001 HFA100/T004

HFA100/T002 HFA100/T005

HFA100/T003 HFA100/T005

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 Model Page
62. Specific Equipment List
A90 - A100 – A110 44

HFA100/T010
HFA100/T007

HFA100/T011
HFA100/T008

HFA100/T012
HFA100/T009

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 Model Page
62. Specific Equipment List
A90 - A100 – A110 45

HFA100/T016
HFA100/T013

HFA100/T017
HFA100/T014

HFA100/T018
HFA100/T015

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 Model Page
62. Specific Equipment List
A90 - A100 – A110 46

HFA100/T019 HFA 100/T022

HFA 100/T020 HFA 100/T023

HFA100/T021 HFA 100/T024

258
 Model Page
62. Specific Equipment List
A90 - A100 – A110 47

HFA100/T028
HFA100/T025

HFA100/T026

HFA100/T027

259

62. Maintenance Intervals
Maintenance:
Correct maintanance at the right time is a basic
condition for reliable operation of the powered front
axle. Maintanance include lubrication, various checks
and adjustments.
The service intervals shown apply for normal operating
conditions but in more severe conditions servicing should
be carried out more frequently.
Carrying out the maintenance:
• Always stop the engine before doing any
servicing work.
• Apply the parking brake to ensure the tractor cannot
move. If the ground is uneven the wheels should be
blocked.
• If necessary, disassemble the front axle correctly and
securely following the related sections.
• Always observe the utmost cleanless in all
maintanence work.
NOTE: Do not let the water get into the powered front
axle.
• When carrying out checks the powered front axle
should stable securely.
• Levels should be checked before driving when the oil is
cold and has had time to run down to the bottom of the unit
concerned.
• When changing the oil, bear in mind that oil can be very
hot when it drains from the powered front axle.
• Lubricating oil cause irritation to skin if in contact
for long periods.
• Waste oil should be handled carefully and
disposed of properly.
Greasing lubricating points fitted with grease
nipples:
• Always clean the grease nipples before appliying the
grease gun.
• Pump in grease to the nipples untill clean grease is
squeezed out (unless otherwise instructed.)
• Wipe of all surplus grease which has been
squeezed out at the lubricating points.
• Preferably carry out lubrication the double joints in
steering knuckle unloaded the wheels and in different
positions.
260
Model Page
A90 - A100 – A110 48
Scheduled maintenance:
NOTE: All intervals are counted from zero hours on the
hour recorder. For example, the 500 hours service is
carried out after 500, 1000 hours etc.
Even if the measures have been carried out at the
guarantee service (= 100 hours service).
Example: The 1000 hour service contains all items
mentioned under the weekly / every 50hr checks as well
as the 500 hr service.
Grease:
Always use the following greases in powered front axles.
Each point requires it own type of grease.
For the grasing the lubricating points fitted with grease
nipples, use the following grease with a SAE code;
• SAE (NLGI#2) Multipurpose high temperature with
extreme pressure performance
For the grasing the king-pin bearings, use the
following grease with a code;
• Castrol pyroplex blue #5517
NOTES:
• Avoid repeating skin contact.
• Protect nature and take care of empty
packages.
Gear Oil:
The following oil should be used in the differantial and in
the hub to lubricate all working gears.
• SAE85W90 (API GL5 - MIL2105-B) (with
additives)
62. Maintenance Intervals Model Page
A90 - A100 - A110 49

Service inspection (after 100 hours): Every 250 working hours

Service inspection after 100 hours running to all new • Check oil in differential (2)
powered front axles. • Check oil in wheel hubs (3)
The following steps should be taken: • Lubricate double joints with grease (4)
• Change oil in differantial (2). • Tighten wheel nuts
• Change oil in wheel hubs (3).

Weekly / every 50 working hours Every 1000 working hours / yearly

• Lubricate front axle mountings from the two nipples (1) • Change oil in differential (2)
Oil volumes, when changing; • Change oil in wheel hubs (3)
Differential : 6,5 liters
Hubs : 2 x 0,7 liters

NOTE: When carrying out servicing you must follow the

service intervals, i.e., you must also do all previously
mentioned items. For example, when doing 1000 hours
service you must also do the servicing required at 500 and
weekly

261
262
 71.Frame
70.Frame and Wheel

72. Wheel

263
 Model Page
72. Frame
A90 - A100 - A110

Content

71 Frame:

Technical data, technical specifications, training material

Front weight support + frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

264
 Model Page
72. Frame
A90 - A100 – A110 1

Front weight support + frame

265
 Model Page
72. Frame
A90 - A100 – A110 2

- The center frame is also a fuel tank. This solution gives a low center of gravity to the tractor. The tunnels
stiffens the con
struction and gives a protected space for the clutch and 4WD shafts.

- The tank has been made of 4 mm steel sheet by welding. Across the tank there is a plate to prevent the
splashing of fuel.
The tank has fastening points for the cab.

- A tube below the tank connects the left and right sides of the tank. The capacity of the tank is 70 L (with extra
tank 115 L).

- The breathing of the fuel tank can be seen in the picture for fuel system.

- Tractors have an Intermediate piece in front of the center frame regardless of the cylinder quantity.

266
72. Wheels

267
72. Wheels Model Page
A90 - A100 – A110

Content

72 Wheels:

Technical data, technical specifications, training material

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques, wheel nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tyre pressures and permissible loadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Track widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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 Model Page
72. Wheels
A90 - A100 – A110 1

Wheels

2WD
Rear Front A90–A100–A110 Long lower links

16.9R30 10.00-16
x
16.9R34 10.00-16 x
18.4R34 10.00-16 x x

4WD
Rear Front A90- A100 - A110 Long lower links Fixed discs
16.9R30 12.4R24 X
18.4R30 13.6R24 X
480/70R30 360/70R24 X
420/85R34 340/85R24 X
16.9R34 13.6R24 X
460/85R34 380/85R24 X x
18.4R34 14.9R24 X X
480/70R34 380/70R24 X X
520/70R34 420/70R24 X X
540/65R 440/65R24 X x
340/85R38 340/85R24 X
13.6R36 12.4R24 X
13.6R38 13.6R24 X
14.9R38 12.4R28 X
230/95R48 230/95R32 X x
13.6R24/12IND 275/80R18 X x
16.9R34IND 13.6R24/IND X x
18.4R34/IND 14.9R24/IND X x x
16.9-34/14FOR 13.6-24/10FOR X x
18.4-34/14FOR 14.9-24/14FOR x x x

When adjusting track widths or changing tyres/tires the turning angles must be checked/adjusted with maximum turning
angles on both sides of the axle.

Tightening torques, wheel nuts

Front wheels, 2WD………………………………………………….130 Nm
Front wheels, 4WD …………………………………………………300 Nm
Rear wheels………………………………………………………….550 Nm
Rim/wheel disc, front and rear……………………………………..310 Nm

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 Model Page
72. Wheels
A90 - A100 – A110 2

Tyre pressures and permissible loadings

Max. Load Max. load

Rear wheels Pressure (kPa) per / tyre Front wheels Pressure per / tyre
(kg) (kg)
16.9R30/8 160 2300 10.00-16/8 280 1190
18.4R30/8 160 2650 11.00-16/8 160 1320
60 1450 12.4R24/8 160 1360
480/70R30
160 2575 13.6R24 160 1450
16.9R34/8 160 2430 14.9R24 160 1700
18.4R34 160 2800 60 845
360/70R24
420/85R34 160 2650 160 1500
460/85R34 160 3075 340/85R24 160 1650
160 2725 60 930
480/70R34 380/70R24
60 1800 160 1650
160 3150 380/85R24 160 1950
520/70R34
60 1775 160 1900
420/70R24
160 2900 60 1070
540/65R34
60 1580 160 1800
440/65R24
13.6R36/8 160 1750 60 990

13.6R38/8 160 1800 12.4R28 160 1450

14.9R38/8 160 2060 230/95R32 320 2000
340/85R38 160 2060 275/80R18 240 1400
230/95R48 320 2240 13.6R24 IND 330 2585
13.6R24/12 IND 330 2585 14.9R24 IND 330 3090
18.4R34 IND 290 4850 13.6-24/10 FOR 250 1790
16.9R34 IND 290 3935 14.9-24/14 FOR 300 1900
16.9-34/14 FOR 260 3025
18.4-34/14FOR 260 3730

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 Model Page
72. Wheels
A90 - A100 – A110 3

Track widths:

Rear axle Track wi dt hs Front axle Track wi dt hs

2 3
16.9R30, 18.4R30, 1410 ), 1510 ), 1610,
1
480/70R30 1710, 1810, 1910, 10.00-16, 11.00-16/8 1410-1510 -1610 )
2010, 2110
16.9R34, 18.4R34,
420/85R34,
2 3
460/85R34, 480/70R34, 1410 ), 1510 ), 1610, 1320, 1415, 1520,
520/70R34, 540/65R34, 1710, 1810, 1910, 12.4R24 1615, 1720, 1815
13.6R38, 2010, 2110
14.9R38, 340/85R38

2 13.6R24, 14.9R24, 340/85R24,

1410 ), 1515, 1610,
360/70R24, 380/70R24, 1320, 1415, 1520,
13.6R36 1715, 1810, 1915,
380/85R24, 420/70R24, 1615, 1720, 1815
2010, 2115
440/65R24
1500, 1520, 1600,
1420, 1515, 1620,
230/95R48 1620, 1900, 1920, 12.4R28
1715, 1820, 1915
2000, 2020
1380, 1405, 1475,
13.6R24/12 IND 1620, 1900 230/95R32 1495, 1640, 1665,
1735, 1755,
18.4-34/14 FOR, 18.4R34
IND, 1650, 1880 275/80R18 1545, 1585
16.9R34 IND, 16.9-34/14 FOR
13.6R24 IND, 13.6-24/10 FOR,
1430, 1710
14.9-24/14 FOR, 14.9R24 IND

Fixed discs

-First adjusting track widths, if rear tyres/tires are 34" or bigger.

NOTE! Standard track widths are underlined. When track widths are adjusted or larger tyres/tires fitted, the turning
angles have to be checked/adjusted with max turning angle of front axle on both sides. When adjusting the rear axle
track widths, check that the wheels rotate freely. Check when using chains that the distance from the cab to the
tyres/tires is not less than 80 mm.

When using the narrow track widths for the rear axle, check that the lower links do not touch the tyres/tires. When
required lock the side regulators.

271
272
 81.Cab

80.Cab and Roll – bar

82. Air Conditioner

83. Instrument

273
 Model Page
82. Air Conditioner
A90 - A100 – A110

81 Cab

Cab …………………………………………………………………………………………………….. 1
Cab Heater ……………………………………………………………………………………………. 2
Cab Fitler ……………………………………………………………………………………………… 3

82 Air conditioner

Technical data, technical specifications, training material

Safety precautions ……………………………………………………………………………………. 1
Operating principle …………………………………………………………………………………… 2
Aır Condıtıoner …………………………………………………………………………………………3
Technical data ………………………………………………………………………………………….3
CIrculation of the refrigerant …………………………………………………………………………. 4
Drier ……………………………………………………………………………………………………. 7
Compressor …………………………………………………………………………………………….8
Expansion valve……………………………………………………………………………………….. 9

83 Instrument

274
 Model Page
81. Cab
A90 - A100 – A110 1

Cab

275
 Model Page
81. Cab
A90 - A100 – A110 2

Cab Heater

276
 Model Page
82. Cab
A90 - A100 – A110 3

Cab Filter

- The fan has three speeds. The intake air flows through fitler(filtre no’ları). The air is blown into the cabin via four adjustable
nozzles. The heating water circulation can be adjusted by valve.

- The fan can causes a little overpressure in the cab, and dust can’t get into the cabin. The filters that are on the cab can be
cleaned easily by removing filters cover screws.

- Clean the air filters of cab in every 250 hours.

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 Model Page
82. Air Conditioner
A90 - A100 - A110 1

Safety precautions
Important! If the Air conditioning system must be opened,this work must be done by an expert who knows
refrigerating systems.
- The pressure of the refrigerant is always greater than its normal boiling point. If piping is split, the refrigerant will
evaporate or boil very rapidly.
-Uncontrolled escape of refrigerant must be avoided. The refrigerant is non-flammable, non-toxic (except when in
contact with a flame) and non-corrosive (except in contact with water).
- Never attempt to empty the system by loosening a connection. Slow emptying without danger can only be carried
out using a manifold gauge set.
- You should be very careful when handling refrigerant. It can freeze the skin or the eyes on direct contact. Never
handle refrigerant without wearing safety goggles, as well as gloves.
- Do not empty the system in a room where there is a flame. Refrigerant R134a and open flame form poisonous
and stimulating compounds (e.g. hydrofluoric acid)
- Never weld or clean with steam near a filled system:excess pressure may be created with possible leakage.

- If it is necessary to retighten a connection, use two spanners for tightening, so as to prevent distortion which
may give rise to leakage.
- Do not store refrigerant in the sun or close to a source of heat.

- Avoid subjecting the bottle to impact. Do not carry the bottle in the passenger compartment of a vehicle.

In the event of an accident, proceed as follows:

- If you get refrigerant in your eyes, wash them carefully with a solution of mineral oil, and continue to wash them
carefully, with a solution of boric acid and water (1 tea spoonful of acid, diluted in a quarter of a cup of water).
Contact a doctor immediately.
Important! Never wash your eyes with pure water because refrigerant+water causes corrosive acid.

- Freezing caused by liquid refrigerant can be treated by progressively thawing the injured area with cold water and
then applying a dry skin cream. Contact a doctor immediately.

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 Model Page
82. Air Conditioner
A90 - A100 – A110 2

Operating principle

An Air conditioning takes heat from the cab air when out door temperature is high. Refrigerant in the system is
exposed under different pressures and temperatures and this causes a cooling effect. Refrigerant vaporizes in the
evaporator and evaporation absorbs heat which is taken from the warm cab air which is blown through the
evaporator

The Air conditioning functions so that the refrigerant is continuously circulated in the system at which time it changes from liquid
form into gaseous form. This process absorbs heat from the cab when the refrigerant vaporises in the
evaporator and emits heat to outdoors when refrigerant becomes condensed in the condenser.

Although the process has four parts, it can be divided into two main parts: high pressure side and low pressure side
according to the figure below

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 Model Page
82. Air Conditioner
A90 - A100 – A110 3

Aır Condıtıoner

Technical data
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134a
- Refrigerant filling in system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,2 kg

Compressor SANDEN SD7H15FZ8062:

- Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 pcs
- Cyl diam x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ø 29,5 mm x 32 mm
- Max revs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 r/min
- Lubricating oil when refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZXL 100 PG (DH-PS)
- Lubricating oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 cm3 (2,07 dl)
Electro-magnetic clutch:
- voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V (DC)
- starting torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
- power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 W (max)
- clutch clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3-0,6 mm

Drier :
Pressure switch switches off at max pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,40±0,2 MPa
- switches on again when pressure drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,57±0,2 MPa
Pressure switch switches off at min pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190±20 kPa
- switches on again when pressure rises up to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200±30 kPa

Thermostatic switch:
- switch off when evaporator temperature is below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+2...+3 °C
- switch on when evaporator temperature has risen up to (max cooling effect) . . . . . . . . . . . . +6...+7 °C
- switch on when evaporator temperature has risen up to (min cooling effect) . . . . . . . . . . . . . bout +19 °C

High and low pressures at engine revs 1500 r/min between temperatures +20...+25 °C:
- low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-300 kPa
- high pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-1400 kPa

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 Model Page
82. Air Conditioner
A90 - A100 – A110 4

CIrculation of the refrigerant

281
 Model Page
82. Air Conditioner
A90 - A100 – A110 5

- An air conditioner takes heat from the cab air when outdoor temperature is high. Refrigerant in the system is exposed
under different pressures and temperatures and this causes a cooling effect. Refrigerant vaporizes in the evaporator and
evaporation absorbs heat which is taken from the warm cab air which is blown through the evaporator.

The air conditioner functions so that the refrigerant is continuously circulated in the system at which time it changes from
liquid form into gaseous form. This process absorbs heat from the cab when the refrigerant vaporises in the evaporator and
emits heat to outdoors when refrigerant becomes condensed in the condenser.

Although the process has four parts, it can be divided into two main parts: high pressure side and low pressure side.

1) The compressor sucks the refrigerant in, compresses and then delivers it onwards to the condenser. When pressurized, the
temperature of the refrigerant increases.
Engagement and disengagement of the compressor is activated by a thermostatic switch in the cab.

2) The hot gaseous refrigerant enters to the at the top of the condenser. In the condenser the refrigerant loses part of its heat
so that it begins to condense and is transformed to a liquid state.

3) The refrigerant which is under high pressure and temperature (40-50_C) flows into the drier/receiver.
Drier/receiver serves both as an expansion vessel/reservoir and drier (absorbs chemically the possible humidity). The Drier/re
ceiver can absorb only 8-12g water, and after this it is useless. N.B! Never leave a receiver unplugged! The receiver must
be replaced if the system is opened.
On the receiver there is a pressure guard, which breaks the current circuit of the magnetic clutch if the pressure the system is
too high or low. On the receiver there are sight glasses.

4) The thermostatic expansion valve separates the low and high pressures from each other. The expansion valve allows pre
cisely the amount of refrigerant required to be injected to the evaporator (5), so that the evaporation process goes in the best
way. This action is dependent on the suction pressure after the evaporator and on the temperature at the evaporator outlet.
When the compressor starts pressure drops in the evaporator and the diaphragm pushes the pin downwards and the ball
opens. Refrigerant can now flow via the spring housing into the evaporator. When the temperature in the evaporator outlet
pipe lowers, the temperature sensor pulls the diaphragm upwards and the valve ball closes preventing refrigerant from flow
ing into the evaporator. In this way the expansion valve regulates all the time the amount of refrigerant in the evaporator. The
expansion valve and the metal pipes have been covered with insulating mass .

5) When the refrigerant enters after the expansion valve to the evaporator, it expands and converts into gaseous form (boils),
while in the evaporator the pressure is low (compressor suction side). The heat required for evaporating the refrigerant is
taken from the passing air, which thereby cools down. When the air cools, the moisture in the air condenses on the surface of
the evaporator fins. The condensed water is then channelled to the outside through hoses (9).

6) Thermostatic switch. The sensor of the temperature control is inserted between the evaporator fins and senses the tem
perature at the coldest point in the evaporator. Temperature control switches the electromagnetic clutch off at a sensor tem
perature below +2..3°C (prevents the evaporator from freezing up) and again, when the temperature of the fins rises, at about
6...7°C (or about at 19°C, in the minimum position).

- An evaporation temperature of the R134 is -26°C. When pressure increases the evaporation temperature rises and vice
versa.

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 Model Page
82. Air Conditioner
A90 - A100 – A110 6

1. Condenser
2. Compressor
3. Drier
4. Expansion valve
5. Evaporator
6. Temperature switch sensor
Compressor (2) is driven by an extra belt pulley at the front end of the crankshaft. The compressor belt pulley is fitted
with an electromagnetic clutch, which switches the compressor off and on according to the required cooling effect.
The expansion valve (4) regulates the amount of refrigerant in the evaporator (5) so that the refrigerant vaporizes in
the best possible way. The expansion valve lets only as much refrigerant flow into the evaporator as the evaporator
can vaporize.

7. Re-circulation nozzles
8. Air inlet into cab
9. Condension water hoses. Water becomes condensed in the evaporator housing when the warm cab air flows
through the cold evaporator.
10. Heater radiator

Temperature switch sensor (6) (capillary tube) is pushed between the evaporator fins and it senses evaporator
temperature in its coldest place. The sensor switches off the compressor when the evaporator temperature drops
below +2...+3°C (prevents icing on the evaporator), and switches on again when the evaporator temperature has
risen over +6...+7°C (or up to +19°C when the temperature switch is in min. position).

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 Model Page
82. Air Conditioner
A90 - A100 – A110 7

Drier

Inspection glass A (1500 r/min and max cooling effect)

N.B. The refrigerant in the inspection glass should be clear. If it has
brown/yellowish colour, the refrigerant and the drier must
be changed.
Inspection glass B
If the moisture indicator colour is blue, the system is in order.
If its colour has changed into pink or grey, the drier and the
refrigerant should be changed.

The drier reservoir (3) is a combined expansion/liquid reser

voir and a drying filter for moisture. The drier also includes
a filter which filters impurities in the system. There are two
inspection glasses on the drier: A=inspection of refrigerant
and its filling, B=moisture indicator.

The drier reservoir must not be stored with pipe connec

tions open. The drier must be changed if the system has
been opened for maintenance work. There is a pressure
switch S23 which switches off current to compressor, if the
high pressure rises too much or is too low.

Possible faults can be localized easily if pressure gauges

are connected to the compressor service valves. The low
pressure gauge is connected to valve S and the high pres
sure gauge to valve D. For instruction on how to carry out
these pressure measurements, see code 833.2.
Note! If You have not got enough training for repairing
refrigerating systems, it is necessary to call an expert if the
system should be opened or if refrigerant must be added.
The refrigerating system expert has equipment with which
repair work can be done in a correct and safe way.

Sightglass Description Conclusion and remarks

No bubbles appear at all.
POSSIBLE EXCESSIVE REFRIGERANT
(Reduction by bleeding is
The high-pressure side will be abnormally hot.
necessary).
REMEDY: Contact authorized workshop for releasing the excess
(This can also mean that there is no
refrigerant
refri gerant at all in the system).

The fluid inside is almost

transparent. A few bubbles may SUFFICIENT REFRIGERANT.
appear as the engine speeds up The high-pressure side will be hot and the low-pressure side cold.
and down.

INSUFFICIENT REFRIGERANT.
A few bubbles appear intermittenly, The high-pressure side will be warm, and the low-pressure side fairly
at intervals of 1 to 2 seconds. cold.
(Refilling is necessary) REMEDY: Check for refrigerant leakage. Contact authorized
workshop.
When bubbles flow continuously, or VERY LITTLE REFRIGERANT.
the flow has changed to a "mist" There will be almost no difference in temperature between the high-
flow, the refrigerant is almost pressure side and the low-pressure side.
exhausted . REMEDY: Stop the compressor and inspect the entire system. When
(Refilling is necessary) necessary, contact authorized workshop.
N.B. The refrigerant in the inspection glass should be clear. If it has brown/yellowish colour, the refrigerant and the drier must
be changed.
Inspection glass B
If the moisture indicator colour is blue, the system is in order. If its colour has changed into pink or grey, the drier and the
refrigerant should be changed.

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 Model Page
82. Air Conditioner
A90 - A100 – A110 8
Compressor

D = Discharge
S = Suction 1. Draining/filling plug for lubricating oil.
Y5 = magnetic clutch Note! Do not open the plug, if the system is filled with
Note! The service valves are on the pipe connectors. refri
(D and S). gerant. Compressor oil should be stored in a closed
If the compressor should be changed, contact an expert container.
who knows refrigerating systems.
See code 832.2, compressor oil.
Detach the new compressor protective caps very
carefully so that the threads and connections do not
damage.
Tightening torques:
- 3/4" connection on pressure side 24,5-29,5 Nm.
- 7/8" connection on suction side 29,5-33,5 Nm.

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 Model Page
82. Air Conditioner
A90 - A100 – A110 9

Expansion valve

1. Expansion valve
2. Hose from condenser
3. Inlet pipe to evaporator
4. Outlet pipe from evaporator 1. Temperature sensor
5. Hose to compressor suction side 2. Diaphragm
3. To compressor
4. From evaporator
5. From condenser
When the compressor starts pressure drops in the 6. To evaporator
evapor ator and the diaphragm pushes the pin

downwards and the ball opens. Refrigerant can now flow

via the spring housing into the evaporator.

When the temperature in the evaporator outlet pipe

lowers, the temperature sensor pulls the diaphragm

upwards and the valve ball closes preventing refrigerant

from flowing into the evaporator.

In this way the expansion valve regulates all the time the
amount of refrigerant in the evaporator.
Note! The expansion valve and the metal pipes have

been covered with insulating mass.

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 Model Page
83. Instrument
A90 - A100 – A110

Instrument

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 Model Page
83. Instrument
A90 - A100 – A110 1

1. Revolution counter
2. Fuel gauge
4. Engine temperature gauge
5. Tractor direction ind. flashers
6. Warning light, blocked engine air filter
7. Not in use
8. First trailer dir. ind. flashers (does not flash if a bulb in the system has blown).
9. Second trailer dir. ind. flashers (does not flash if a bulb in the system has blown).
10. Engine glowing
11. Ind. light, PTO clutch lever
12. Ind. light, parking brake
13. Low fuel level (<14 l)
14. Charging
15. General warning light (not in use)
16. Engine oil pressure
17. Mechanical hour recorder
18. Controls on the RH side of the steering wheel console.
19. STOP-central warning light:
- engine temperature
- engine oil pressure
23. Indication light, differential lock
29. Indication light, high beams
Note! When the current is switched on, the following warning lights must come on:

- engine oil pressure

- stop-light is flashing
- charging
If the engine oil pressure warning light comes on, also the engine air filter light comes on. If the stop-light starts to
flash alone, the engine temperature is too high.

Note! Infoline is instrument is equipped as standard with a buzzer, which alarms, when the head lights are on

and the current is switched off with the ignition switch. When the head lights are switched off the buzzer stops.

After this the head lights can be switched on without that the buzzer comes on.

Engine oil pressure sensor S15 STOP- warning light flashes, if the engine oil pressure is too low. Also warning light
lights up (at the same time also air filter warning ligh comes on). In this case the engine must be stopped immediately
and possible reason must be found and repaired.

The warning light must be on, when the ignition is switched on (without starting the engine). The warning light must go
out, when the engine has started (oil pressure rises in the engine).

The oil pressure sensor (9) is placed on the RH side of the engine. The pressure relief valve (2) is placed on the LH
side.

Fuel level sensor B2

IMPORTANT! Agroline-instrumentshows a fault code, if this sensor has a fault. Possible fault can also be seen
in the fuel gauge. The warning light comes on, when the fuel amount is less than 14 litres

Warning light switch function can be checked by measuring between pin W and earth (switch function)
The sensor resistance can be measured direct from the sensor or between pole G and earth or between pin X27/7
and earth point (GR3). Resistance is about 70 ohms, when the tank is empty and about 3 ohms, when it is full.
In case of failure, the sensor is changed. The connector contact problems can be removed by disconnecting and
reconnecting the connector
Engine air filter warning light S21
The warning light comes on, when the air filter is blocked.The sensor is placed in the induction pipe of the filter. If the
filter is blocked, a vacuum is created in the pipe. Clean or change the filter.

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83. Instrument Model Page
A90 - A100 – A110 2

Note! The air filter warning light comes on, if the engine oil pressure warning light comes on while driving,
although the filter is OK. The function can be tested by blocking the engine intake air hole with a suitable plate
Other indication lights, rev counter and hour recorders.

Indication lights:

- the differential lock indication light H20 is on when the rear axle lock is engaged. The indication light switch is pla
ced on the LH side of the gearbox at the LH end of the lock selector fork shaft.

- the PTO-clutch lever indication light H13 comes on,when the lever is pulled to the rear position (can be max. 5
minutes in this position). The light switch is placed at thelower end of the lever.

- the parking brake indication light H11 is on, when the hand brake lever is pulled up. The switch is placed in the
rear end of the lever.

- the engine glowing indication light H12 is on, when the conduction air preheater is on preheating mode.

- the charging light H16 is on when the ignition is switched on but the engine is not running. After the engine is started,
the light must go out. If this light comes on while driving, the alternator does not charge.
- In addition, Infoline- and Agroline-instruments have high beam light H14 and direction indicator flasher lights.
Flasher relay K2 is placed on the RH side of the fuse box(upper relay). The flasher ind. lights do not flash, if one bulb
in the system has blown. Headlights relay K5 is placed above the fuse box.

Rev. counter and hour recorders:

The engine rev counter gets the signal from alternator (pinW). The hour recorders also get the signal from alternator
pin W.

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 91. Technical Specialities – Valves –
90. Hydraulic Lifts and External Valves Mechanicims and Working Principles

92. Disassembly - Assembly –

Adjustments

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90. Hydraulic Lifts and External Valves
A90 – A100 – A110

Contents

91.Technical specialities – Valves – Mechanicisms and Working Principles

Hydraulic Lift Service Guide ……………………………………………………………………………….. 1

Main Relief Valve Operation ……………………………………………………………………………… 4
Changing of System relief valve …………………………………………………………………………… 5
Adjustment of system relief valve ………………………………………………………………………….. 6
Changing the cylinder relief valve…………………………………………………………………………… 8
Changing the LS (Load Sensing) relief valve ……………………………………………………………… 9
Adjustment of LS relief valve ………………………………………………………………………………… 10
Locking valve working principle ………………………………………………………………………………11

92.Disassembling – Assembling - Adjustments

Visual inspection of locking valve and replacement the parts …………………………………………… 1

Changing of distributor ………………………………………………………………………………………. 3
Dismantling and re-installation of hydraulic lifts …………………………………………………………… 6
Disassembly, control and re-assembly of hydraulic lifter arms ………………………………………….. 8
Removal, controls and re-assamble of hydraulic cylinders ………………………………………………9
Setting the operation distance of outer arms of hydraulic lifter ………………………………………….10
The principle of power control mechanisms ………………………………………………………………..12
Setting of hydraulic lifter power control mechanism ……………………………………………………….13
Posıtıon Control ………………………………………………………………………………………………. 14
Mıxed Control …………………………………………………………………………………………………..14
Auxılıary Cylınder …………………………………………………………………………………………… 15
Electrıcal Autolıft ……………………………………………………………………………………………… 16
Electrıcal Autolıft Mechanısm Settıng ……………………………………………………………………….18
Hydraulıc Lıfter Drıve Settıngs ………………………………………………………………………………. 19

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Hydraulic Lift Service Guide

Hydraulic lifts have the following features and controls.

• Position control (with position control lever).

• Power control (power control lever and the changing place of the top link)
• Lowering speed control and locking (with locking knob)
• Electro autolift
• Auxiliary cylinder

WARNING: Please note; during the transport of implements, the sub links has to be locked into their place.

In neutral position, the oil that comes from pump flow to the load sensing valve. With the main spool and lowering spool
both in their neutral positions, signal pressure from main spool to load sensing pilot valve is blocked. Spring pressure in the
load sensing pilot valve then forces the valve closed. With load sensing pilot valve closed and signal pressure from load
sensing pilot valve to load sensing valve blocked, the load sensing valve allows oil to flow through to excess flow passage.
Surge relief valve protects the rockshaft cylinder and its related parts from a sudden increase in pressure, such as shock
loads. As long as pressure inside the rockshaft cylinder is less than 230 to 240 bar, tension from relief spring holds relief
valve closed. If pressure increases suddenly and exceeds spring pressure, the relief valve unseats allowing oil back to the
tank.

Pressure to the excess flow port is controlled by the main relief valve.

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When in the raise position , main spool moves to allow high pressure oil, from the load sensing valve, to flow through the
main spool and out to the rockshaft cylinder passage.
High pressure oil in the rockshaft cylinder passage flows through the load check valve, rate of drop valve and past surge
relief valve to the rockshaft.

The hitch valve contains a priority circuit which sends pressurized oil first to the rockshaft and then on to the rest of the
hydraulic system as needed. When the main spool is open, high pressure oil flows through the main spool and opens the
load sensing pilot valve. Pilot oil then flows from the rockshaft cylinder passage through the load sensing pilot valve and
also to the load sensing relief valve.

As pilot oil pressurizes the end of the load sensing valve, a combination of pilot oil pressure and spring pressure forces the
load sensing valve over and restricts, or cuts off, high pressure oil flow to the excess flow passage.

The load sensing relief valve restricts hitch maximum operating pressure by allowing excess pilot oil to return to tank. If pilot
oil pressure exceeds 190 to 197 bar, the relief ball in the load sensing relief valve will unseat, allowing pilot oil back to tank.
Since high pressure oil feeds the pilot oil circuit, high pressure oil will also drop in pressure.

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In lower position, the oil that comes from pump flow to the load sensing valve. With the main spool and lowering spool both
in their lower positions, signal pressure from main spool to load sensing pilot valve is blocked. Spring pressure in the load
sensing pilot valve then forces the valve closed. With load sensing pilot valve closed and signal pressure from load sensing
pilot valve to load sensing valve blocked, the load sensing valve allows oil to flow through to excess flow passage. With load
sensing pilot valve closed, signal pressure is allowed to tank trough the load sensing pilot valve. Oil from the rockshaft is
allowed to flow through rate of drop valve and lowering spool to transmission tank.

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Main Relief Valve Operation

A. Pilot popet
B. Pilot spring
C. Setscrew
D. Contra nut
E. Pilot popet bed
F. Pilot tank line
G. Main bolt spring
H. Main bolt tank line
I. Over flow tank port
J. LS valve port
K. Main bolt
L. Main relief valve (closed)
M. Main relief valve (open)
N. Returned oil
O. Pressured oil
P. High pressured oil

The main relief valve is located in the rockshaft control valve inlet housing.

When an SCV function is activated, system pressure is controlled by the main relief valve.

The main relief valve is set for 190 to 197 bar.

When the system pressure is below the setting of main relief valve, the pressure of the pilot spring (B) keeps pilot poppet
seated against the pilot poppet seat (A). System pressure plus the main spool spring (G) pressure keep the main relief
valve spool (K) closed.

When system pressure reaches the relief valve setting, the pilot poppet (A) unseats, which reduces the pressure holding the
main relief valve spool (K), allowing the main relief valve to open. This allows fluid to escape to tank, causing pressure to
drop at the excess flow port (I) and load sensing valve port.

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Changing of System relief valve

1. System relief valve.

2. Cylinder relief valve.
3. Locking valve.
4. LS (load sensing) relief valve.

Reduce the lift outer arms to a minimum level and stop the engine.
Remove the canopy (It wont be necessary).
Remove the system relief valve that shown in the Picture as number 1.

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A. Rubber ring.
B. Support ring.
C. Rubber ring.

Mount the rubber rings shown on the picture as A and B to the support ring C.

Insert the new relief valve to the slot and tighten to 41-48 Nm.

Important! In this operation; new rubber rings and support ring should be used.

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Adjustment of system relief valve

D. Safety setscrew
E. Nut

Devices for adjustment:

3. Manometer
4. Hose with connection element
5. Adapter

• Connect the manometer, hose and adapter to the mobile directional control valve outlet.
• Bring the oil temperature to operating temperature.
• While the engine running at low speed, move the mobile directional control valve lever to pressured the mobile
valve output.

The value of the manometer should be adjust the range of 190-197 bar with relief valve setscrew (D) and set the relief valve
opening pressure by checking the adjustment with screw nut (E).

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Changing the cylinder relief valve

• Reduce the lift outer arms to a minimum level and stop the engine.
• Remove the canopy (It wont be necessary).
• Remove the cylinder relief valve shown as number 2 and remove the rubber ring shown as B under the valve.
• Mount the new rubber ring and cylinder relief valve and tighten to 30-40 Nm range.

Important! In this operation; new rubber rings should be used and loctite 243 used on the teeths.

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Changing the LS (Load Sensing) relief valve

• Reduce the lift outer arms to a minimum level and stop the engine.
• Remove the canopy (It wont be necessary).
• Remove the LS relief valve shown as number 4.

A. Rubber ring
B. Support ring
C. Rubber ring
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Mount the rubber rings shown on the picture as A, C and support ring C on the LS relief valve according to picture.
Mount the relief valve on the LS valve hole at the valve block and tighten to 22-28 Nm value.

Important! In this operation; new rubber rings and support ring should be used.

Adjustment of LS relief valve

D. Setscrew
E. Nut

Devices for adjustment:

1. Manometer
2. Hose with connection element
3. Adapter
4. Conical plug (1/8” NPT)

• Bring the oil temperature to operating temperature.

• Reduce the lift outer arms totaly.
• Remove the diagnostic port plug at bottom right corner on the valve block and plug the 1/8” NPT conical plug to
the plug hole.
• Attach the manometer to diagnostic port with using the adapter and hose.
• Run the engine at low speed.
• Observe the value on manometer by pulling position control lever then handle it into the first position.
• The value range of the manometer should be between 190-197 bar.
• If the value range of the manometer is different; turn the adjustment screw (D) on the LS relief valve, adjust the
pressure it into this range and check the screw with nut (E).
• After the adjustment, reduce the lift outer arms to minimum level and stop the engine.Remove manometer, hose,
adapter and conical plug 1/8” NPT.
• Close the dignostic plug with the removed plug; KV500155M.

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Locking valve working principle

A. Lowering valve line

B. Locking shaft
C. Ball
D. Popet
E. Cylinder (hydraulic lifter) line
F. Locking valve (closed)
G. Locking valve (semi-open)
H. Locking valve (open)
İ. Returned oil

Locking valve is a system operating as an adjustable orifice on the arm lowering phase of hydraulic lifter. When the valve is
closed (F) locking shaft (B) does not touch to the ball (C) or popet (D) and keeps both closed. In this case the arms of
hydraulic lifter continue to remain in still position independent from the position and location control arms. In case the valve
is semi open (G) locking shaft pushes only the ball (C) and separates it from its bed but popet (D) remains in its bed. Thus a
low debit flow is performed over the valve and according to the action amount of the ball slow lowering of the hydraulic lifter
arms according to the movement amount of the ball is provided. When the locking valve is open (H) locking ball pushes
both the ball (D) and popet (D) and separates from its bed. The descending speed of hydraulic lifter arms performs quickly
due to the separation amount of the popet from its bed.

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Visual inspection of locking valve and replacement parts

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3. Locking shaft
5. Locking valve plug

A. Locking valve plug

B. Spring-bushing assemble
C. Locking valve
D. Locking shaft

• Lower the outer arms of the lift and stop the engine.
• Disassemble the base plate.
• Disassemble the hydraulic connections of the hydraulic lifter valve block.
• Disassemble the 6 connection bolts of the valve block.

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• Remove the locking shaft on the lower surface of the valve block and locking valve plug on the same axis (shown
as 5 and A on the above pictures).
• Disassemble the spring-bushing assemble (B), locking valve (C) and locking shaft respectively that are in the slot.

Control whether there is any distortion on the conic surface of the locking valve such as wear or scratch. If exists replace
this part.

• Before assembling the parts check the conditions of the rubber ring and support ring on the locking shaft and the
condition of the rubber ring on the locking valve plug (A). Replace the parts if required.
• During re-assembly, mount the locking shaft (D), locking valve (C), spring-bushing assemble (B) and locking valve
plug (A) and torque by 35-41 Nm.
• Mount the valve block on the body of hydraulic lifter by 6 bolts. Torque the bolts by 25-30 Nm. (apply Loctite 518
on the body of hydraulic lifter and on the valve seat of valve block before assembly).
• Complete the operation by making the hydraulic connections.

Changing of distributor

• Open the locking valve completely and lower the lift outer arms to the lowest level and stop the engine.
• Remove the base plate (Might not be required).
• Disassemble the connections of hydraulic lifter pipe (or hose).
• Disassemble 6 connection bolt (2) and disassemble the valve block (1).

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• Demount the distributer by removing 3 socket bolt.

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• Mount the o-rings to place between valve block and distrubuter as shown number 5, 6 and 7.
• Mount the distributer by locking 3 socket bolt. Tighten the bolts to 20-25 Nm.
• Apply Loctite 518 on the valve surface in between the hydraulic lifter and valve block and attach the valve block by
6 bolts and torque the bolts with 25-30 Nm.
• Connect valve block hose connections.

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Dismantling and re-installation of hydraulic lifts

• Reduce the lift outer arms to a minimum level and stop the engine.
• Remove the hydraulic lift lewelling arms.
• Remove the base plate.
• Discharge the hydraulic lift oil.
• Remove the hose connections of hydraulic lift.

• Disassemble the required segments (2) that connect the parts of power control mechanism to reaction brace.
• Disassemble the grooved pin on one side of the pin (3) connecting the reaction brace to PTO and disassemble the
reaction brace (4) by removing the pin.
• Disassemble the valve block (6).
• Lift the hydraulic lifter by support of a hoist by removing 11 bolts (5) connecting the hydraulic lifter to base plate.

After performing the required controls and repair operations follow the aforementioned operational procedure backwards
and perform the assembly of the hydraulic lifter. Before placing the hydraulic lifter on the base plate (7) clean the interfacial
zone and apply Loctite 518 (8) and torque 11 connection bolt by 125 Nm.

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Disassembly, control and re-assembly of hydraulic lifter arms

• As defined in the previous section, disassemble the hydraulic lifter and turn upside down.
• Disassemble the position feedback rod connected to the oval washer (12).
• Disassemble the segments (1) on both sides of the main shaft (6).
• Despite having signs on, before disassembling parts numbered as 2, 6, 8 and 14 place signs on the parts in order
provide ease during assembly.
• By removing all the parts control whether there is any damage or wearing and replace the required parts (5 and 10
numbered bushings are assembled on the body of the hydraulic lifter as being pressed).
• Assembly all parts after cleaning. Replace all the rubber rings with new ones.
• Assemble the position control feedback rod to its position.
• Assemble the hydraulic lifter to its position.

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Removal, controls and re-assamble of hydraulic cylinders

• Disassemble and reverse the hydraulic lift.

• Remove the 6 connection bolts (2) and disassemble the cylinder (1).
• Remove the rubber ring (4) in between the cylinder and hydraulic lifter.

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• Remove the piston (6) from inside the cylinder.

• Remove the conic plug (7) and clean the cylinder oil intake channel.
• Remove the piston felt set (5) and ring (4).
• Control the piston and cylinder against any wearing, fracture or any other damage.
• If exits replace the required part.
• Assemble the new felt set and support ring.
• Assemble the piston on the cylinder by applying clan hydraulic oil on the surface of cylinder and piston.
• Assemble the plug (7) in its place.
• Place the cylinder assembly (1) and torque 6 connection bolt (2) by 250 Nm.
• Assemble the hydraulic lifter to its position.

Setting the operation distance of outer arms of hydraulic lifter

• Set by placing the 2 nuts on the position control feedback rod to forward and backward until 3mm gap remains in
between the pin fixed on the body and parcel pipe, pin, bushing.
• Move the position control arm for 5 times full forward and backwards by hanging 50 kg load on the ends of
suspension arms and rise and lower the outer arms of hydraulic lifter and provide the removal of the air in the
system.

• When the position control arm is completely retracted the distance from the center of connection pin of the outer
arms of the hydraulic lifter and side suspension arms to the lowest section of the hydraulic lifter connection plate
shall be 389±4 mm.
• If these arms are raising more than the required distance after setting then the bolts (A) on the position control arm
are loosened and the arm is turned a bit on clockwise direction and if these arms are raising less than required the
bolts (A) are fastened by turning counter clockwise and it is measured whether the arms are at required distance
or not. These operations are repeated until the arms at the required distance.

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389±4
mm

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The principle of power control mechanisms

The duty of the power control mechanism is to raise the arms of the hydraulic lifter a bit in case of getting caught by a hard
surface and to remove the equipment from that hard surface and then to lower the outer arms again to the operation height.

When the equipment is caught by a hard surface, the top suspension arm pushes the reaction brace (6). Driving force
changes in proportion with the stress amount of the equipment. Power control rode (3) transfers the movement of the
reaction brace (6) to the power control shaft arm (2). This movement rotates the control brace and by pushing the
connection part and by pushing the lifting valve on the distributor of this part, it provides the raising of the outer arms of the
hydraulic lifter.

As the distance between the connection part and lifting valve is much while the power control arm (1) is at the farthest
position, the hydraulic lifter does not lift the outer arms in case the equipment of power control system is caught by a hard
surface.

As the power control arm is retracted, the distance between the connection part and lifting valve decreases. Thus the same
amount of movement of power control rod (3) provides the pushing of the lifting valve by the connection part in a larger
amount and provides the faster elevation of hydraulic lifting arms. This condition means sensitizing the power control.

Power control sensitivity can also be changed by changing inlet where the reaction brace (6) of the middle arm is
connected. Power control sensitivity can be increased by connecting the middle arm on the top inlets on the reaction brace
and on the contrary the power control sensitivity can be decreased by connecting the middle arm to lower inlets on the
reaction brace.

Power control mechanism operates when the bracket locking arm (5) is pulled. Power control mechanism is disactivated by
pushing the drive transmission arm (5). During the operation of tractor and while the suspension arms are loaded bracket
locking arm (5) shall be ahead.

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Setting of hydraulic lifter power control mechanism

• Operate the engine at idle mode.

• Take both the position and power control arms to the farthest position.
• By disassembling the security segment and pin (5) provide the head of rod (4) to be separated from the complete
plate bushing (2).
• Loosen the nut (3) tightening the head of rod (4) and provide the head of rod to be easily rotated.

• Retract the power control arm (1) backwards and provide the back section of the power control arm and the plate
(7) on the right of this arm to be on the same plane.
• Push the power control feedback rod from the head of rod (4) and provide the outer arms of the hydraulic lifter
raise. The inlet on the head of rod (4) and the inlet on the bushing shall coincide at the moment of rising of outer

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• Arms of the hydraulic lifter. If they do not coincide turn the head of rod and provide the inlets to coincide at the
raising point of the outer arms of lift. After the collision of lock the head of rod by nut (3).
• Attach the head of rod and plate-bushing by the pin and segment disassembled at the start of operation.
• Take the power control arm to the farthest position. Retract to the setting point (the point where the back of the
power control arm and back of the plate on the right are on the same plane). At this point the outer arms of the
hydraulic lifter will start to raise by the smallest load to the reaction brace.
• Push the reaction brace by the support of a lever arm. By this force the outer arms of the hydraulic lifter will start to
rise and when the force is cut the outer arms will lower to the level set.

POSITION CONTROL

It is the setting of the location of the equipment due to the angular movements of the position control arm. When the
position control arm (1) is completely retracted the equipment raises to the highest point. When it is pushed forward
completely, it lowers to the lowest possible level. When the equipment is being transported the position control arm is
retracted to the farthest position. After setting the equipment remains in fixed depth and makes no submerge. The
equipment can always be lowered to the same position due to the limitation mechanism on the scale of control arms.

Operation principle of position control mechanism

By the retraction of the position control arm (1) the connection part gets close to the lifting valve on the distributor and finally
by contacting this valve starts to push the lifting valve and the hydraulic lifter outer arms starts to rise.

The oval washer between the left outer arm and body of hydraulic lifter rotates with the outer arms of hydraulic lifter and
transfers the movement of the outer arms to the position control shaft and connection part by the feedback rode (2). Thus
the connection part is rotated from the lower part and kept away from the lifting valve and lifting valve gains its neutral
position after the completion of the movement of outer arms of hydraulic lifter of lifting valve.

MIXED CONTROL

Mixed control is the utilization of position and power control together. Mixed control is applied to hinder the over submerge
of the equipment while operating on ground of different strength. After setting the drive depth by the position control arm,
the setting of draft is performed by using the power control arm. Thus besides obtaining a narrow drive depth interval, over
submerges are hindered through position control.

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AUXILIARY CYLINDER

In case the of hydraulic lifter being required auxiliary cylinder can be mounted in order to increase the lifting capacity.

ELECTRICAL AUTOLIFT

Autolift system is a characteristic of hydraulic lifters that is connected to the three point linkage system of the tractor and
that eases the control of equipment. System briefly provides the equipment to be lifted to transportation height without using
the hydraulic lifter control arms and to be taken to the previous position set by the control arms.
Electrical autolift system basically operates through the autolift mechanism by moving the main slide bar of the lifter.

Operation principles of electrical auto-lift

Autolift is in the lowering position as electricity current is given to selenoide (1). When the electricity given to solenoid is cut
solenoid retracts its slide bar (2). The main slide (3) remaining idle moves by being defeated with the spring power and
provides the oil from the pump to be directed to the back of the autolift piston (4). Piston moves forward and presses on the
autolift drive pin (5). Drive pin enables the control valve for lifting and the arms of hydraulic lifter start to rise. The hydraulic
lifter to rise to pressure at the highest position of the arms is prevented by the support of the restoration mechanism which
the autolift is connected to.

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1. Selenoid
2. Selenoid bolt
3. Main bolt
4. Autolift piston
5. Autolift drive pin

When the electricity current is given to solenoid again, it provides the movement of the main slide by pushing the solenoid
slide forward. The moving main slide opens the route for oil from the pump to the rod side of the piston. And opens the back
section of piston to the tank. The returning autolift piston provides the lowering of outer arms of hydraulic lifter by releasing
the slide of the control valve.

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ELECTRICAL AUTOLIFT MECHANISM SETTING

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Before starting with the settings of electrical autolift, be sure that current is transmitted to part numbered as 12. (when the
current is cut the arms will start to rise). Push the position control arm numbered as 1 and load control arm numbered as 2
in a manner as the outer arms are completely lowered. Set the nut numbered as 9 as the distance from the autolift
restoration setting part numbered as 11 leaning against the ball joint will be 5 mm. Cut the current to the part numbered as
12. See the lifting of outer arms. If the security valve is being opened when the outer arms rise, tighten the nut numbered as
9 and provide the mechanism to stop the outer arms without opening of security valve by the system. When the autolift
mechanism is active a distance of 389±4 mm shall be available in between the axis of suspension arm connection pin on
the outer arms and lower surface of hydraulic lifter connection plate numbered as 3. If the distance provided is less than
389±4 mm loosen the nut numbered as 9 and it is more tighten it.

Continue the setting operation until the required value is provided. Lock the nut at the end of operation.

HYDRAULIC LIFTER DRIVE SETTINGS

Set the drive depth by pushing the position control arm (G) forward and backward. If the depth is more pull the arm upwards
and if less push downwards.
Set the draft force by using the power control arm (P). If the tractor is having difficulty on pulling the equipment, if it starts
spinning lift the power control arm a bit. If the equipment is continuously leaving the ground push the arm forward.

If it’s wanted make deeper poughing, both arms (P and G) should be push forward.

When equipments such as disc harrow, rake will be used, push both arms (P and G). In this position the equipment follows
the ground surface as the arms of hydraulic lifter will remain free on both upwards and downwards movements.

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While lowering the heavy equipments use the locking knot. When you turn the knot to the side having the turtle sign the
lowering speed of the equipment slows down. When you turn it to the direction of rabbit sign it lowers fast. When you turn
the knot to the turtle sign completely, the equipment is locked at top. The forward pushing and retracting of hydraulic lifter
arms does not lower the load. This feature can be used for security when the tractor is parked. Turn the locking knot
completely before lifting a heavy equipment. The knot being completely locked does not affect the lifting of load. Then lift
the load. When you want to lower the load push the position control arm completely forward. The load does not lower. Then
turn the knot slowly to the other direction. After approximately one tour the load starts to lower slowly. Thus the load will be
lowered in a secure and controlled manner. The middle arm (1) can be located on one of the four inlets on the reaction
brace.

In the following cases plug the top link to lower holes;

• If the end point of equipment requested to a lower position,

• When it needed to carrying a heavy equipment ,

In the following cases plug the top link to upper holes;.

• When the power control does not provide the sufficient sensitivity during drive and when the tractor starts spinning,
• When the lifting capacity remains insufficient.

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Max.
Sensitivity

Mininum
Sensitivity

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100. Special Tools

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100. Special Tools
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POLMOT SPECIAL TOOLS

9VA1 8800 A1A WHOLE NUMBER OF HEMA FRONT AXLE SPECIAL TOOLS
ORDER HATTAT PART CODE PART NO PART NAME
1 9VA1 8802 A1A HFA100 / T028 Front axle seal mountıng arbor
2 9VA1 8803 A1A HFA100 / T027 Bearıng puller arbor
3 9VA1 8804 A1A HFA100 / T026 Bearıng bear mountıng arbor
4 9VA1 8805 A1A HFA100 / T025 Bearıng bear mıd. Housıng arbor tool
5 9VA1 8806 A1A HFA100 / T024 Bearıng centre moutıng tool
6 9VA1 8807 A1A HFA100 / T019 Bevel gear torq tool
7 9VA1 8808 A1A HFA100 / T018 Settıng nut tıghtnıng lever
8 9VA1 8809 A1A HFA100 / T008 Front axle steerıng knuckle shım burnıshıng arbor
9 9VA1 8810 A1A HFA100 / T005 Mountıng tool for steerıng knuckle to mount pın.
10 9VA1 8811 A1A HFA100 / T001 Bearıng cover mountıng arbor.
11 9VA1 8812 A1A HFA100 / T004 Seal mountıng arbor.
12 9VA1 8813 A1A HFA100 / T020 Bearıng outer rıng mountıng arbor.

9VA1 8801 A1A HTT SPECIAL TOOLS FOR TRANSMISSION

ORDER HATTAT PART CODE PART NO PART NAME
1 9VA1 8814 A1A 893320 Seal and bearing mounting plate
2 9VA1 8815 A1A 892260 Outer drive axles inside bearing mounting plate.
3 9VA1 8816 A1A 893690 Plate for bearing mounting.
4 9VA1 8817 A1A 891870 Bearing and seal mounting plate
5 9VA1 8818 A1A 893630 Input shaft bearing cover gasket mounting plate.
6 9VA1 8819 A1A 893640 Exit of drive axles cover mounting plate.
7 9VA1 8820 A1A 893614 Arbor plate.
8 9VA1 8821 A1A 893650 Sealing ring and seal mounting plate.
9 9VA1 8822 A1A 893712 Blok
10 9VA1 8823 A1A 891211 Centering tool for clutch disc.
11 9VA1 8824 A1A 894080 Mounting tool for selecting fork locking clip ball.(+PTO).
12 9VA1 8825 A1A 892230 Tool for pinion axle nut.
13 9VA1 8826 A1A 893260 Tool for drive axles exit nut.
14 9VA1 8827 A1A 893611 Screw
15 9VA1 8828 A1A 893710 Blok
16 9VA1 8829 A1A 893700 Coupling for PTO shaft ended mounting
17 9VA1 8830A1A 891220 Coupling for bearing mounting.
18 9VA1 8831 A1A 893612 Coupling
19 9VA1 8832 A1A 891900 Mounting tool for selecting fork locking clip ball (+PTO).
20 9VA1 8833 A1A 892210 Coupling for external drive shaft oil seal mounting.
21 9VA1 8834 A1A 892350 Coupling.
Coupling clutch/input shaft/pinion shaft bearing mounting/Coupling
22 9VA1 8835 A1A 892380
for PTO shaft ended oil seal mounting
23 9VA1 8836 A1A 893613 Coupling
24 9VA1 8837 A1A 890830 Bearing and clutch mounting clip.
25 9VA1 8838 A1A 893660 Setting tool for differential bearing.

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Ref No : 9HT1 0022 A1A
Revised No: 02
(APRIL 2011)
English

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Tel : 0 282 758 33 80 (phx)
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This manual prepared by Hattat Tarım

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