Case Puma 165, 180, 195, 210 Including Multicontroller Models Tractor Complete Workshop Service Repair Manual

SERVICE MANUAL PUMA 165 Multicontroller , PUMA 165 , PUMA 180 Multicontroller , PUMA 180 , PUMA 195 Multicontroller , PUMA 195 , PUMA 210 Multicontroller , PUMA 210 87628095_C 18/08/2009 chodina@live.co.uk chodina@live.co.uk

Contents INTRODUCTION DISTRIBUTION SYSTEMS ............................................................. A PRIMARY HYDRAULIC POWER SYSTEM ............................................... A.10.A PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve .... A.10.B PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve .............. A.10.C PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve .............. A.10.C SECONDARY HYDRAULIC POWER SYSTEM........................................... A.12.A HYDRAULIC COMMAND SYSTEM ....................................................... A.14.A PNEUMATIC SYSTEM .................................................................... A.20.A ELECTRICAL POWER SYSTEM ......................................................... A.30.A ELECTRICAL POWER SYSTEM ......................................................... A.30.A ELECTRONIC SYSTEM .................................................................. A.50.A FAULT CODES ............................................................................ A.50.A POWER PRODUCTION ................................................................. B ENGINE ................................................................................... B.10.A FUEL AND INJECTION SYSTEM ......................................................... B.20.A AIR INTAKE SYSTEM ..................................................................... B.30.A EXHAUST SYSTEM....................................................................... B.40.A ENGINE COOLANT SYSTEM ............................................................ B.50.A LUBRICATION SYSTEM .................................................................. B.60.A STARTING SYSTEM ...................................................................... B.80.A POWER TRAIN ............................................................................. C TRANSMISSION Powershift .............................................................. C.20.E ADDITIONAL REDUCERS Creeper ...................................................... C.30.C ADDITIONAL REDUCERS Overdrive .................................................... C.30.D REAR PTO Mechanical ................................................................... C.40.B REAR PTO Hydraulic ..................................................................... C.40.C FRONT PTO Hydraulic ................................................................... C.42.C TRAVELLING ................................................................................ D 87628095_C 18/08/2009 chodina@live.co.uk chodina@live.co.uk

FRONT AXLE ............................................................................. D.10.A REAR AXLE ............................................................................... D.12.A 2WD-4WD SYSTEM Hydraulic ........................................................... D.14.C STEERING Hydraulic..................................................................... D.20.C STEERING AutoPilot ...................................................................... D.20.E SERVICE BRAKE Mechanical ............................................................ D.30.B SERVICE BRAKE Hydraulic.............................................................. D.30.C SERVICE BRAKE Pneumatic ............................................................. D.30.E PARKING BRAKE Mechanical ............................................................ D.32.B PARKING BRAKE Electronic ............................................................. D.32.D BRAKE CONNECTION Hydraulic ........................................................ D.34.C SUSPENSION Hydraulic ................................................................. D.40.C WHEELS AND TRACKS Wheels......................................................... D.50.C BODY AND STRUCTURE .............................................................. E FRAME Primary frame .................................................................... E.10.B USER PLATFORM ........................................................................ E.34.A ENVIRONMENT CONTROL Heating, ventilation and air-conditioning .................... E.40.D WORKING ARM ............................................................................ H HITCH Front hitch ......................................................................... H.10.B HITCH Rear hitch......................................................................... H.10.C HITCH Electronic draft control ............................................................ H.10.D HITCH Electronic draft control ............................................................ H.10.D 87628095_C 18/08/2009 chodina@live.co.uk chodina@live.co.uk

87628095_C 18/08/2009 chodina@live.co.uk chodina@live.co.uk

INTRODUCTION 87628095_C 18/08/2009 1 chodina@live.co.uk chodina@live.co.uk

Contents INTRODUCTION Safety rules ..................................................................................... 3 87628095_C 18/08/2009 2 chodina@live.co.uk chodina@live.co.uk

INTRODUCTION Safety rules IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by authorised workshops. All instructions should be carefully observed and special equipment where indicated should be used. Anyone who carries out service operations described without carefully observing these instructions will be directly responsible for any damage caused. NOTES FOR EQUIPMENT Equipment shown in this manual is: • designed expressly for use on these tractors; • necessary to make a reliable repair; • accurately built and strictly tested to offer efficient and long-lasting working life. NOTICES The words “front”, “rear”, “right hand”, and “left hand” refer to the different parts as seen from the operator’s seat oriented to the normal direction of movement of the tractor. SAFETY RULES PAY ATTENTION TO THIS SYMBOL This warning symbol points out important messages involving personal safety. Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and safeguard your safety. In this manual you will find this symbol together with the following key-words: WARNING -it gives warning about improper repair operations and potential consequences affecting the service technician’s personal safety. DANGER - it gives specific warning about potential dangers for personal safety of the operator or other persons directly or indirectly involved in the operation. TO PREVENT ACCIDENTS Most accidents and personal injuries taking place in workshops are due from non-observance of some essential rules and safety precautions. The possibility that an accident might occur with any type of machines should not be disregarded, no matter how well the machine in question was designed and built. A wise and careful service technician is the best precautions against accidents. Careful observance of this basic precaution would be enough to avoid many severe accidents. DANGER Never carry out any cleaning, lubrication or maintenance operations when the engine is running. B013 SAFETY RULES Generalities • Carefully follow specified repair and maintenance procedures. 87628095_C 18/08/2009 3 chodina@live.co.uk chodina@live.co.uk

INTRODUCTION • Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught on moving parts. Use approved safety clothing such as anti-slipping footwear, gloves, safety goggles, helmets, etc. • Wear safety glasses with side guards when cleaning parts using compressed air. • Damaged or frayed wires and chains are unreliable. Do not use them for lifting or towing. • Wear suitable protection such as approved eye protection, helmets, special clothing, gloves and footwear when- ever welding. All persons standing in the vicinity of the welding process should wear approved eye protection. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED. • Never carry out any repair on the machine if someone is sitting on the operator’s seat, except if they are qualified operators assisting in the operation to be carried out. • Never operate the machine or use attachments from a place other than sitting at the operator’s seat or at the side of the machine when operating the fender switches. • Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. • All repair and maintenance operations should be carried out with the greatest care and attention. • Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all equipment which should be raised. • Never check or fill fuel tanks or batteries, nor use starting liquid if you are smoking or near open flames as such fluids are flammable. • The fuel filling gun should always remain in contact with the filler neck. Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build-up. • To transfer a failed tractor, use a trailer or a low loading platform trolley if available. • To load and unload the machine from the transportation means, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the machine to the truck or trailer platform and block wheels as required by the transporter. • Always use lifting equipment of appropriate capacity to lift or move heavy components. • Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stand near the fastening point. • The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil. • Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non-flammable non-toxic pro- prietary solvents. • Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal container. START UP • Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extrac- tion. • Never bring your head, body, arms, legs, feet, hands, fingers near fans or rotating belts. ENGINE • Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dissipate. Coolant should be topped up only when the engine is stopped. • Do not fill up fuel tank when the engine is running. • Never adjust the fuel injection pump when the tractor is moving. • Never lubricate the tractor when the engine is running. ELECTRICAL SYSTEMS • If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows: (+) to (+) and (-) to (-). Avoid short-circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During 87628095_C 18/08/2009 4 chodina@live.co.uk chodina@live.co.uk

INTRODUCTION charging, leave the battery compartment uncovered to improve ventilation. Avoid sparks or flames near the battery area. Do no smoke. • Do not charge batteries in confined spaces. • Always disconnect the batteries before performing any type of service on the electrical system. HYDRAULIC SYSTEMS • Some fluid coming out from a very small port can be almost invisible and be strong enough to penetrate the skin. For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS, but use a piece of cardboard or a piece of wood for this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate medical attention may result in serious infections or dermatitis. • Always take system pressure readings using the appropriate gauges. WHEELS AND TYRES • Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check for possible damage to the rims and tyres. • Stay at the tyre side when inflating. • Check the pressure only when the tractor is unloaded and tyres are cold to avoid wrong readings due to over- pressure. • Never cut, nor weld a rim with the inflated tyre assembled. • To remove the wheels, block both front and rear tractor wheels. Raise the tractor and install safe and stable supports under the tractor in accordance with regulations in force. • Deflate the tyre before removing any object caught into the tyre tread. • Never inflate tyres using flammable gases as they may generate explosions and cause injuries to bystanders. REMOVAL AND INSTALLATION • Lift and handle all heavy components using lifting equipment of adequate capacity. Ensure that parts are supported by appropriate slings and hooks. Use lifting eyes provided to this purpose. Take care of the persons near the loads to be lifted. HEALTH AND SAFETY CONTENT Section Description Page HEALTH AND SAFETY PRECAUTIONS .............................. 4 ACIDS AND ALKALIS ............................................ 5 ADHESIVES AND SEALERS - see Fire ................................ 5 ANTIFREEZE - see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol...... 5 ARC WELDING - see Welding........................................ 5 BATTERY ACIDS - see Acids and Alkalis............................... 5 BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) - see Fire............. 6 BRAZING - see Welding............................................. 6 CHEMICAL MATERIALS - GENERAL - see Legal Aspects................. 6 DO’S........................................................... 6 DO NOTS........................................................ 6 CORROSION PROTECTION MATERIALS - see Solvents, Fire............... 6 DUSTS ......................................................... 7 ELECTRIC SHOCK................................................ 7 EXHAUST FUMES................................................ 7 FIBRE INSULATION - see Dusts...................................... 7 FIRE - see Welding, Foams, Legal Aspects................................ 7 FIRST AID....................................................... 7 FOAMS - Polyurethane - see Fire........................................ 7 87628095_C 18/08/2009 5 chodina@live.co.uk chodina@live.co.uk

INTRODUCTION FUELS - see Fire, Legal Aspects, Chemicals - General, Solvents................. 8 GAS CYLINDERS - see Fire.......................................... 8 GENERAL WORKSHOP TOOLS AND EQUIPMENT ..................... 9 LEGAL ASPECTS................................................. 9 LUBRICANTS AND GREASES....................................... 9 PAINTS - see Solvents and Chemical Materials - General...................... 10 SOLDER - see Welding.............................................. 10 SOLVENTS - see Chemical Materials - General Fuels (Kerosene), Fire.. . . . . . . . . .. 10 SUSPENDED LOADS.............................................. 11 WELDING - see Fire, Electric Shock, Gas Cylinders......................... 11 HEALTH AND SAFETY PRECAUTIONS Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This section lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. The precautions necessary to avoid these hazards are identiﬁed. The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with health and safety in mind. ACIDS AND ALKALIS see Battery acids, e.g. caustic soda, sulphuric acid. Used in batteries and cleaning materials. Irritant and corrosive to the skin, eyes, nose and throat. Causes burns. Avoid splashes to the skin, eyes and clothing. Wear suitable protective gloves and goggles. Can destroy ordinary protective clothing. Do not breathe mists. Ensure access to water and soap is readily available for splashing accidents. ADHESIVES AND SEALERS see Fire Highly Flammable, Flammable, combustible. Generally should be stored in “No Smoking” areas; cleanliness and tidiness in use should be observed, e.g. dispos- able paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled. Solvent based Adhesives/Sealers See Solvents. Follow manufacturers instructions. Water based Adhesives/Sealers Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use. Follow manufacturers instructions. Resin based Adhesives/Sealers e.g. epoxide and formaldehyde resin based. Mixing should only be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can result in irritation; dermatitis and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact. Follow manufacturers instructions. Anaerobic, Cyanoacrylate and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin. Some are eye irritants. 87628095_C 18/08/2009 6 chodina@live.co.uk chodina@live.co.uk

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Case Puma 165, 180, 195, 210 Including Multicontroller Models Tractor Complete Workshop Service Repair Manual

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