DEUTZ FAHR Tractor AGROPLUS 60 70 80 FACTORY Workshop Manual

introduction This publication is intended for the trained technician who must operate on our tractors. It contains all general information relating to our tractor range, and in particular it highlights the inspection, overhauling and adjustment procedures as well as the main instructions for dismantling and reassembling operations. The workshop manual is a natural summary for the mechanic who has attended the vocational training and specializa- tion courses, which are held every year at our Service School, to permit him to perform a precise and qualified work on tractor. Its contents are therefore an exhaustive reference book for the experienced mechanic who desires to refresh his me- mory on the sequence of the operations to be done. It is then good practice for every authorized dealer mechanic to have at his disposal this publication, so that it may be consulted quickly when necessary. We wish to thank in advance for the cooperation all thos people, who will let us have their suggestions in order to make this publication more complete. 1 WORKSHOP MANUAL

List of contents Tractor configurations AGROPLUS 60 - 70 - 80 ......................................................................................................6 Dimensions and weights...........................................................................................................................................7 Prescribed lubricants and capacities ........................................................................................................................8 Conversion tables .....................................................................................................................................................9 Parts .......................................................................................................................................................................10 1 - ENGINE ................................................................................................................................................................................ 11 2 - CLUTCH Gearshift clutch.......................................................................................................................................................12 General specifications ............................................................................................................................................ 12 Cecking clutch ........................................................................................................................................................ 16 Adjusting clutch control pedal .................................................................................................................................16 Bleeding air from the hydraulic circuit .....................................................................................................................16 Stripping the slave cylinder .....................................................................................................................................17 Stripping the master cylinder ..................................................................................................................................18 Diagnosing malfunctions ........................................................................................................................................ 20 POWERSHIFT unit, general specifications ............................................................................................................21 POWERSHIFT unit detach from the gear box ........................................................................................................24 Assembly of POWERSHIFT unit ...........................................................................................................................35 Re-assembly of the POWERSHIFT unit. ...............................................................................................................37 Fitting the oil manifolds of the POWERSHIFT unit ................................................................................................39 Diagnosing malfunctions ........................................................................................................................................ 44 3 - TRANSMISSION General specifications ............................................................................................................................................ 45 Technical specifications .......................................................................................................................................... 45 Speed change configurations .................................................................................................................................47 Section through transmission .................................................................................................................................51 Section through transmission with POWERSHIFT unit ..........................................................................................52 Separating the front gearbox from the engine ........................................................................................................61 Dismantling the gearbox .........................................................................................................................................62 Removal of the gearbox input and P.T.O. shafts ....................................................................................................62 Separating the POWERSHIFT unit from the gearbox ........................................................................................... 62 Removal of the gear train positioned in the front gearbox ......................................................................................63 Disassembly of the inversor control rods and forks ................................................................................................64 Dismantling of the gearchange rod and fork assembly ..........................................................................................65 Dismantling of the gearchange selector rods and forks assembly ......................................................................... 66 Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive ..........................67 Removal of the range gear shaft ........................................................................................................................... 67 Examining parts removed .......................................................................................................................................68 Adjusting play of the gearbox shafts by means of the thrust plates on the mini/inversor shaft and the secondary shaft ...............................................................................................................................69 Warnigns related to assembly of the gears of the P.T.O. unit, the range reduction unit and synchronised P.T.O. shaft ............................................................................................................................................................ 73 Assembly of the P.T.O. .......................................................................................................................................... 73 Installation of the range reduction unit, the gear for the front-wheel drive shaft and the parking brake discs...................................................................................................................................73 Points where sealant is to be used .........................................................................................................................75 Tightening torques .................................................................................................................................................. 78 Bevel drive adjustment ...........................................................................................................................................81 Servicing operations ...............................................................................................................................................82 Rear power take-off ................................................................................................................................................ 83 P.T.O. clutch ...........................................................................................................................................................88 Technical specifications .......................................................................................................................................... 89 Correct positions of P.T.O. sensors and cables ..................................................................................................... 89 Clutch inspection .................................................................................................................................................... 91 Checking clutch hydraulic pressures ......................................................................................................................92 Checking the end-play of the front shaft of the P.T.O. clutch ................................................................................. 93 Renewal of the rear P.T.O. clutch ..........................................................................................................................94 Main operations for removal of the rear P.T.O. unit ............................................................................................... 95 Diagnosing malfunctions ...................................................................................................................................... 100 2

4 - AXLES Rear axle .............................................................................................................................................................. 101 Installing the rear half-shafts ...............................................................................................................................102 Removal and disassembly of the epicyclic reduction unit ......................................................................................... 104 Fitting lateral stub axles of the wheel ...................................................................................................................105 2WD extendible axle.............................................................................................................................................106 Removing the axle from the front support ............................................................................................................ 108 Centre steering lever ............................................................................................................................................ 111 Wheel hub ............................................................................................................................................................ 112 End float adjustment .............................................................................................................................................114 Front-wheel drive.................................................................................................................................................. 115 Specifications .......................................................................................................................................................115 Epicyclic reduction unit .........................................................................................................................................119 Side hubs.............................................................................................................................................................. 121 Tightening torques................................................................................................................................................ 122 Adjusting bevel gears ...........................................................................................................................................124 Adjustment of the internal control of the mechanical differential lock ................................................................... 125 Installing the differential assembly into the drive axle .......................................................................................... 125 Diagnosing malfunctions ...................................................................................................................................... 126 5 - VEHICLE Brakes - General information................................................................................................................................ 127 Hydraulic pump.....................................................................................................................................................128 Assembly of brake master cylinder ...................................................................................................................... 130 Checking the front brake disks on 2WD and 4WD front axles and the rear brake disks ...................................... 131 Adjusting service brake pedals .............................................................................................................................131 Correct installation of inspection cover for parking brake discs............................................................................ 132 Checking parking brake pads ...............................................................................................................................134 Bleeding air from the brake hydraulic system....................................................................................................... 135 “Separate Brakes” valve .......................................................................................................................................136 Diagnosing malfunctions ...................................................................................................................................... 140 Hydraulic lift with “load sensing” ...........................................................................................................................141 Installing the lift and front cover plate of the gearbox ........................................................................................... 142 Lift mechanism .....................................................................................................................................................142 Checking the safety valves ...................................................................................................................................142 Checking the protrusion of the non-return valve................................................................................................... 143 Adjusting the lift .................................................................................................................................................... 145 Lift hydraulic circuit ...............................................................................................................................................147 Sensing arm assemblyMontaggio dell'organo sensibile ....................................................................................... 154 Power-lift distributor valve spring setting specifications ....................................................................................... 155 Electronic lift .........................................................................................................................................................156 Control panel ........................................................................................................................................................ 157 Control level or depth control knob .......................................................................................................................157 Mix position/draft control .......................................................................................................................................157 Lowering speed control knob................................................................................................................................ 158 Maximum lift height control knob .......................................................................................................................... 158 Up/Down control switch ........................................................................................................................................ 158 Up control .............................................................................................................................................................158 Control/Float mode ...............................................................................................................................................158 Lift status indicator light ........................................................................................................................................ 158 Remote pushbuttons for lift operation from ground .............................................................................................. 159 Lift operation .........................................................................................................................................................160 List of electronic lift tests ...................................................................................................................................... 164 Precautions for electronic equipment ...................................................................................................................173 Checking the electronics system .......................................................................................................................... 173 Checking mechanical components .......................................................................................................................173 Front hydraulic liftSollevatore idraulico anteriore.................................................................................................. 174 Hydraulic accumulator and antishock valve for front lift ....................................................................................... 176 Front power take-off - General information........................................................................................................... 177 Section of the P.T.O. ............................................................................................................................................ 178 Fitting the "RING-FEEDER" rings .........................................................................................................................182 Checking the clutch .............................................................................................................................................. 183 Diagnosing malfuntions ........................................................................................................................................ 184 Spring specifications.............................................................................................................................................184 3

6 - CONTROLS Hydrostatic steering .............................................................................................................................................. 185 Inspections and checks ........................................................................................................................................ 186 Steering pump ...................................................................................................................................................... 186 Directional control valve .......................................................................................................................................186 Check the setting of the pressure relief valve....................................................................................................... 186 Bleeding the hydraulic circuit ................................................................................................................................186 Assembly of orbital pump unit ..............................................................................................................................186 Teering wheel shaft and steering cylinders ......................................................................................................... 187 Instructions for the hydrostatic steering distributor assembly ............................................................................... 189 Diagnosing malfuntions ........................................................................................................................................ 192 Mechanical controls .............................................................................................................................................. 196 Electro-hydraulic controls .....................................................................................................................................197 Front P.T.O. clutch engagement control ...............................................................................................................202 Rear P.T.O. clutch engagement control ...............................................................................................................202 Differential lock engagement control ....................................................................................................................202 Front-wheel drive engagement control .................................................................................................................202 Rear P.T.O. engagement control ..........................................................................................................................202 Gearbox ................................................................................................................................................................ 202 Front and rear lift .................................................................................................................................................. 202 Hydraulic circuit diagram ...................................................................................................................................... 202 Solenoid valve - Specifications .............................................................................................................................207 Adjustment of front and rear differential lock control ............................................................................................214 7 - BODYWORK Platform ................................................................................................................................................................ 215 Cab - General information .................................................................................................................................... 216 Cab air filter .......................................................................................................................................................... 218 Screen wash .........................................................................................................................................................218 Screen wipers (front and rear) ..............................................................................................................................218 Removing the driving platform complete with cab ................................................................................................219 Breakage of the top hood release cable ...............................................................................................................220 High visibility cab roof ...........................................................................................................................................222 8 - SYSTEMS Ventilation .............................................................................................................................................................223 Heating System .................................................................................................................................................... 223 Air conditioning unit for cabs ................................................................................................................................227 Operation and maintenance of the air-conditioning system ................................................................................. 228 Water dripping from the points at which condensate drain lines are connected to the conditioning unit ............229 Checking system .................................................................................................................................................. 231 System safety elements .......................................................................................................................................231 Temperature regulation ........................................................................................................................................ 231 Charging the system.............................................................................................................................................232 Filling the metering unit ........................................................................................................................................ 232 Refilling the system with oil ..................................................................................................................................232 Verifying operation of the system after recharging ............................................................................................... 234 Directions for tightening air conditioning system pipeline fittings ......................................................................... 234 Diagnosing malfuntions ........................................................................................................................................ 241 Hydraulic system .................................................................................................................................................. 242 Oil filters ................................................................................................................................................................ 243 Hydraulic pumps ...................................................................................................................................................243 Checking the relief valves of the hydraulic lift system ..........................................................................................243 Stripping the hydraulic pump ................................................................................................................................244 Auxiliary hydraulic spool valves ............................................................................................................................247 Checking the pressure relief valve setting ............................................................................................................250 Checking the operating pressure ..........................................................................................................................250 Conversion of auxiliary spool valves from double acting to single acting operation ............................................. 250 Checking the surface of the valve spools .............................................................................................................250 Trailer hydraulic braking system ...........................................................................................................................251 Use of the tractor with CUNA 341/01 hydraulic trailer braking ............................................................................. 253 Installing the hydraulic braking valve for trailers equipped with “safety brake” ( ITALIAN version) ................................................................................................................................................ 258 Electrical system AGROPLUS 60 (up serial number1017) - 70 (up serial number 2773) - 80 ............................. 261 Electrical system AGROPLUS 60 (under serial number 1016) - 70 (under serial number 2772) ........................445 4

General safety directions...................................................................................................................................... 446 Jump start utilizing another battery.......................................................................................................................447 Recharge system.................................................................................................................................................. 449 Heating system .....................................................................................................................................................450 Starting system .....................................................................................................................................................450 Ignition key ...........................................................................................................................................................452 Ventilation control .................................................................................................................................................452 Push button control ...............................................................................................................................................452 Beacon push button.............................................................................................................................................. 454 Work ligths............................................................................................................................................................ 454 2-Speed windscreen wiper switch ........................................................................................................................ 454 Relay .................................................................................................................................................................... 455 Electronic flasher unit ...........................................................................................................................................455 Switch controlling.................................................................................................................................................. 456 Switch controlling: differential lock - P.T.O. clutch - 4RM - 540 1000 rpm/min P.T.O. speed selector - Economy P.T.O. - Live P.t.o. - electric starter system......................................................................................... 456 Switch for emergency brake .................................................................................................................................456 Fuse box ...............................................................................................................................................................457 Instrument panel with digital display .....................................................................................................................458 Operation of the broken belts alarm control unit ................................................................................................... 460 Engine stop operation with a type 2MH engine control unit ................................................................................. 462 Electrical wiring.....................................................................................................................................................465 9 - APPENDIX Power lift tester version 1.24a ...................................................................................................................................I 5

TRACTOR CONFIGURATIONS: CAB - ventilation - ventilation + heating - ventilation + heating + air conditioning GEARBOX Fully synchronised: 20 Forward + 10 Reverse: 5 speeds x 2 ranges (Hair-Tortoise) + SYNCHROSPLIT (H/fast-L/slow-R/rearward) 30 Forward + 15 Reverse: 5 speeds x 3 ranges (Hair-Tortoise-Snail) + SYNCHROSPLIT (H/fast-L/slow-R/rearward) 45 Forward + 45 Reverse: 5 speeds x 3 ranges (Hair-Tortoise-Snail) + shuttle + version POWERSHIFT - - CONTROLS - rear P.T.O. clutch with electro-hydraulic control - 4WD with mechanical control or optional electro-hydraulic control - electronic engine throttle MECHANICALLY OPERATED REAR POWER-LIFT - with supplementary rams - without supplementary rams MAIN EQUIPMENT - front P.T.O. - front lift - hydraulic pump capacities increased by 27 l/min (for hydrostatic steering, electro-hydraulic control unit and gearbox lubrication) and by 47 l/min (for trailer braking, auxiliary control valves and lift). - hydraulic trailer braking - 4-way or 6-way control valves with “Flow Divider” - etc. 6 AGROPLUS 60 - 70 - 80 2RM WITH PLATFORM 2RM WITH CAB 4RM WITH PLATFORM 4RM WITH CAB

DIMENSIONS AND WEIGHTS AGROPLUS 60 AGROPLUS 70 -80 2 WD 4 WD 2 WD 4 WD Length max: - without linkage (A) mm 3800 3835 3930 3985 - with front and rear linkage (A) mm - 4350 - 4480 Width min./max. (B) mm 1920 -2320 1920-2320 1920-2320 1920-2320 Height: - al telai di sicurezza (C) mm 2420 2420 1490 - at cab (standard) (C) mm 2430 2430 1700 - at cab (with air conditioning) (D) mm 2595 2595 2360 Ground clearance (E) mm 345 345 365 365 Wheel base (F) mm 2162 2112 2292 2242 Front track base (G) mm 1400 1440 1400 1440 min./max. 1300-1600 1340-1740 1300-1600 1340-1740 Rear track base (H) mm 1500 1500 1500 1500 min./max. 1400-1900 1400-1900 1400-1900 1400-1900 Min. turning radius without brakes (mm) 3500 4050 3700 4300 Operating weight (without front lift) - with plataform kg 2355 2705 2555 2905 - with cab kg 2550 2900 2750 3100 Max. permissible load - front kg 240 240 240 240 - rear kg 200 200 200 200 - block kg - 250 - 250 Tyres - front 7.50-16 12.4R 20 7.50-16 11.2R 24 - rear 14.9R30 14.9R30 16.9R30 16.9R30 7

PRESCRIBED LUBRICANTS AND FUELS 8 PRESCRIBED LUBRICANTS AND FUELS AGROPLUS 60/70/80 Part to be supplied Litres (US gal) Produc t Specificati ons SDFG change hours Engine AGROPLUS 60 9.5** (2.5) Engine AGROPLUS 70/80 11** (2.9) AKROS TURBO 15W40 Sae 15w40 ACEA E3-96 API CF SDFG OM-1991 MIL-L-2104 E level MB 228.3 level 500* Gearbox and rear axle 41 (10.8) AKROS MULTI Sae 10w30 Sae 20w30 UTTO API GL4 SDFG OT-1891 1200 Central axle 6 (6.3) Side reductions 1.5x2 (1.6x2) Front PTO 2.5 (2.6) AKROS MULTI Sae 10w30 Sae 20w30 UTTO API GL4 SDFG OT-1891 1200 Brakes and clutch control MAX AKROS MATIC ATF DEXRON II D SDFG OF-1691 Lubrification points AKROS GREASE T2 NLGI 2 - LITIO SDFG GR-1202 L 50 (*)1 ° replace after 50 hours (**) With filter + 1.5 litre s

CONVERSION TABLE FROM FROM TO multiply by: inch cm 2.540 cm inch 0.394 foot m 0.305 m foot 3.281 yard m 0.914 m yard 1.094 Eng. miles km 1.609 km Eng. miles 0.622 Sq.in. cm2 6.452 cm2 Sq.ft. 0.155 Sq.ft. m2 0.093 m2 Sq.ft. 10.77 Sq.yard m2 0.835 m2 Sq.yard 1.197 Cu.in. cm3 16.39 cm3 Cu.in. 0.061 Cu.ft. Liter 28.36 Liter Cu.ft. 0.035 Cu.yard m3 0.763 m3 Cu.yard 1.311 Imp.gall. Liter 4.547 Liter Imp.gall. 0.220 US gall. Liter 3.785 Liter US gall. 0.264 pint Liter 0.568 Liter pint 1.762 quart Liter 1.137 Liter quart 0.880 oz. kg 0.028 kg oz. 35.25 lb. kg 0.454 kg lb. 2.203 lb.ft. kgm 0.139 kgm lb.ft. 7.233 lb/in. kg/m 17.87 kg/m lb/in. 0.056 lb./sq.in. kg/cm2 0.070 kg/cm2 lb/sq.in. 14.22 lb./Imp.gall. kg/l 0.100 kg/l lb./Imp.gall. 10.00 lb./US gall. kg/l 0.120 kg/l lb./US gall. 8.333 lb./cu.ft. kg/m3 16.21 kg/m3 lb./cu.ft. 0.062 cu.ft./lb. m3/kg 0.062 m3/kg cu.ft./lb. 16.21 Nm kgm 0.102 kgm Nm 9.81 kW PS 1.36 PS kW 0.736 bar kg/cm2 1.014 kg/cm2 bar 0.981 dm3 l 1 l dm3 1 9

HOW TO ORDER SPARE PARTS To ensure perfect tractor efficiency thus avoiding serious drawbacks, and to optimize your investment and the operatio- nal expenses, the use of “ORIGINAL SPARE PARTS” is recommended. Spare parts orders must specify the following: Tractor serial number and engine serial number (if the engine is concerned). Spare part name and reference code. ENGINE TYPE AND TRACTOR FRAME TYPE SERIAL NUMBER AND SERIAL NUMBER 10

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DEUTZ FAHR Tractor AGROPLUS 60 70 80 FACTORY Workshop Manual

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