CONTENTS

Sr. No. Title Section

1. INSTRUCTIONS TO USERS A

2. RECOMMENDED SCHEDULE FOR MAINTENANCE SERVICE A-4

3. IDENTIFICATION OF TRACTOR A-7

4. ENGINE B

5. CLUTCH C

6. FLOOR AREA & GEAR BOX D

7. DISASSEMBLY AND ASSEMBLY OPERATIONS E

8. HYDRAULIC CIRCUIT F

9. INSTRUCTION MANUAL G

10. FRONT AXLE - 2WD H

11. GENERAL INFORMATION I

12. GENERAL SPECIFICATIONS J

13. DISASSEMBLY AND ASSEMBLY K

14. TROUBLE SHOOTING L

15. SERVICE OPERATIONS TIME M

16 STEERING UNIT N

17 ELECTRICAL SYSTEM O

18 LUBRICANTS & GREASES / USES OF SPECIAL SERVICE TOOLS P

I T L (v) S E R V I C E M A N U A L
 INDEX

I T L (vii) S E R V I C E M A N U A L
 INDEX
DISASSEMBLY AND ASSEMBLY OPERATIONS E
4WD DROP BOX (MECHANICAL) E-1
FINAL DRIVE E-16
UPPER COVERS AND ROCKSHAFT E-22
OUTER GEAR CONTROLS E-26
CLUTCH HOUSING E-30
PTO - POWER TAKE OFF E-33
PTO - SELECTION CONTROL E-41
PTO - SHAFT GROUP E-44
ACTUATOR ASSEMBLY E-48
VIEW DETAILS OF BRAKE HOUSING INSIDE PARTS E-50
VIEW DETAILS OF BRAKE PADDLES PARTS E-51
VIEW DETAILS OF HAND BRAKE LINKAGE ASSEMBLY E-52
PARKING BRAKE E-53
HOUSING SENSORS ASSY E-66
DIFFERENTIAL LOCKING CONTROL E-69
INNER CONTROLS ASSY E-75
IDLE GEAR E-86
RANGE GEARS (PRIMARY SHAFT) E-88
INPUT SHAFT E-95
SYNCHRO SHUTTLE (REPLACEMENT) E-103
SPEED GEARS (PRIMARY SHAFT) E-107
DIFFERENTIAL ASSY E-112
PINION - RANGES (SECONDARY SHAFT) E-121
SPEED GEARS (SECONDARY SHAFT) E-129
HYDRAULIC CIRCUIT F
HYDRAULIC CIRCUIT OF POWER LIFT F-1
HYDRAULIC CONTROL VALUE PART DETAILS F-2
HYDRAULIC CONTROL VALUE PART DETAILS F-4
CONTROL LEVER ASSY F-5
CLEANING OF HYDRAULIC CONTROL VALUE F-8
INSTRUCTION MANUAL G
TECHNICAL FEATURES G-1
OPERATION OF POWER LIFT CONTROL VALVE ON OFF G-3
HOW THE INTERNAL LEVERAGE SYSTEM FUNCTION G-9
ADJUSTMENT OF CONTROL VALVE SENSITIVITY G-18
ADJUSTMENT OF POSITION CONTROL LEVER G-21
ADJUSTMENT OF DRAFT CONTROL LEVER G-22
CONTROL OF ASSEMBLY OF REACTION SPRING G-23
MEASUREMENT CONTROL OF PUSH ROD G-24
DRAWBAKCS G-25
FRONT AXLE - 2WD H
INTRODUCTION H-1
VIEW DETAILS OF FRONT AXLE PARTS H-2
DETAIL VIEW OF FRONT AXLE BEAM POWER STEERING-2WD H-3
DISMANTLING PROCEDURE OF FRONT AXLE POWER STEERING 2WD H-4
I T L (viii) S E R V I C E M A N U A L
ASSEMBLY PROCEDURE FRONT AXLE POWER STEERING 2WD H-6
INSPECTION PROCEDURE H-8
GENERAL INFORMATION I
MANUAL USE I-1
INFORMATION PROPERTY I-1
AGREEMENTS AND DEFINITIONS I-2
MEASUREMENTS I-3
SYMBOLOGY USED TO DESCRIBE MAINTENANCE (SERVICE AND REPAIR) PROCEDURES I-4
GENERAL DESCRIPTION I-6
GENERAL SPECIFICATIONS J
INTENDED USE J-1
PRODUCT IDENTIFICATION J-1
GENERAL DESCRIPTION J-2
TECHNICAL FEATURES J-3
LIMITED SLIP DIFFERENTIAL DISKS SPECIFICATIONS J-4
MAIN DIMENSIONS (MM) J-5
MAINTENANCE AND OIL CHANGE J-6
GREASE IN ASSEMBLY J-10
ADHESIVES AND TIGHTENING TORQUES J-11
DISASSEMBLY AND ASSEMBLY K
STEERING CYLINDER GROUP K-1
EPICYCLIC REDUCTION GEAR GROUP K-5
WHEEL HUB GROUP K-9
TRUNNIONS GROUP K-17
DIFFERENTIAL SUPPORT GROUP K-22
DIFFERENTIAL GROUP K-31
PINION GROUP K-35
AXLE BEAM GROUP K-44
TOE-IN/STEERING ANGLE K-47
SPECIAL REPAIR OPERATIONS K-50
TESTING AFTER ASSEMBLY K-56
TROUBLE SHOOTING L
SOLVING ACTION L-1
TROUBLESHOOTING L-2
AXLE PROBLEMS AND DIAGNOSLS L-4
SERVICE OPERATIONS TIME M
SERVICE OPERATIONS TIME SCHEDULE M-1
STEERING UNIT N
CIRCUIT DIAGRAM OF HYDROSTATIC STEERING N-1
EXPLODED VIEW OSPJ100 ON N-2
DETAIL VIEW OF HYDROSTATIC STEERING UNIT N-3
DISMANTLING OF HYDROSTATIC STEERING UNIT OSPC N-4
INSTALLATION INSTRUCTION FOR O-RING/KIN-RING ROTO GLYD N-10
INSTALLATION INSTRUCTIONS FOR LIP SEAL N-11
MAX. TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS N-17
POWER STEERING FAULT LOCATION TIPS N-18
I T L (ix) S E R V I C E M A N U A L
I T L (x) S E R V I C E M A N U A L
A
I T L A-1 S E R V I C E M A N U A L
I T L A-2 S E R V I C E M A N U A L
I T L A-3 S E R V I C E M A N U A L
A 5.0 RECOMMENDED SCHEDULE FOR MAINTENANCE SERVICE

EVERY 10 50 250 500 750 1000 1250 1500

I T L A-4 S E R V I C E M A N U A L
 EVERY 10 50 250 500 750 1000 1250 1500

SERVICE ITEM

FUEL SEDIMANTOR D D D D D D D D

BRAKE OPERATION
& PEDAL

KING PIN

TOE IN

I T L A-5 S E R V I C E M A N U A L
 EVERY 10 50 250 500 750 1000 1250 1500

FUNCTIONING OF
OIL GAUGE
FUNTIONING OF
TEMPERATURE
GAUGE

LEGANDS :-

ADJUST GREASE

DRAIN D CLEAN

TIGHTEN WASHING

CHECK

REPLACE

I T L A-6 S E R V I C E M A N U A L
Fig-2
Left Side

Right Side
 LINER PROJECTION

I T L B-28 S E R V I C E M A N U A L
Step 32
Fit HPD shaft assy in crankcase and tighten it with retainer by
using three ScrewsM8x14.

Step 33
Fit HPD shaft gear in such a manner that Projected side of gear
should be towards the crankcase (as shown in Fig.) and tighten it
with nut M30x1.5.

Step 34
Screw valve lubrication bolt (M10x1.5) & lock it with nut M10.

I T L B-36 S E R V I C E M A N U A L
Step 35
Properly clean the cam shaft and fit radial ball bearing (6006)
Ensure that cam lobes and journels don't heavy scoring &
abnormal wear.

Step 36
Fit key 6x6x20 and slide cam shaft in the respective bore of Crankcase .
IMP:- Check free rotation of camshaft
Lubricate Cam shaft before fitting in Crankcase

Step 37
Tighten cam shaft retainer by using 3 Screws M8*14.
Ensure that step side of retainer should face towards
crankcase side.

Steps 38
Fit cam shaft gear & place plane washer on it & tighten it with
special bolt M10x1.5. Torque upto 4 kg.

I T L B-37 S E R V I C E M A N U A L
Step 39
Take IPD shaft and clean it properly.

Step 40
Press radial ball bearing (B/B) 35/62*14(6007) on IPD shaft.

Step 41
Fit External circlip A-35 in front of bearing.

Step 42
Fit second radial ball bearing 30x62x116 (6206 NR) and then fit key 6x6x20
in front of bearing in the IPD shaft.

I T L B-38 S E R V I C E M A N U A L
Step 43
Slide the IPD shaft in the respective bore.
IMP:- Lubricate Bearings before Assy.

Step 44
Place the IPD Retainer and Tight three M8x16 Screws along with
spring washers.

Step 45
Fit IPD gear & light with lock nut M30x1.5.

Step 46
Fit FIP Timing gear directly on FIP and tighten it with special adopter.
( In case of Direct Mounted FIP's )

I T L B-39 S E R V I C E M A N U A L
Step 47
Lubricate TIG & fit in such a way that its timing mark match with
cam gear, crank gear & FIP Timing Gear .

Step 48
Place lock plate over TIG and tight it with bolts M8x45.

Step 49
Fit tube assy. from lubricating bolt to TIG pin.

I T L B-40 S E R V I C E M A N U A L
VALVE TIMING -
The camshaft and the fuel pump gears are driven by crankshaft gear through an idler gear. All the gears are suitably marked
during production to facilitate re-timing. The marks being in line when no. 1 piston is at top dead center on its compression
stroke. The timing marks does not align at every rotation of the crankshaft where no. 1 piston is at TDC compression. It is
necessary to replace any of the timing gears, ensure that there is a backlash between 0.05 to 0.35 (wear-limit 0.9).
The timing or the resetting of the timing can be simply & quickly carried out with following instructions.
With the engine timing correctly set, the engine is turned until no.1 piston is at TDC on its compression stroke. In this position
align center punch marked on the gear with the center punch mark on camshaft, fuel pump and crankshaft gear respectively.
It should be noted that no adjustment is provided for valve timing. Provided the gear is correctly fitted.

VALVE TIMING DIAGRAM

TDC
o
I V O 14 11 o E V C

o
I V C 33 o 55 E V O

BDC

1. IVO (intake Valve Open) 14o before TDC

2. IVC (intake Valve Close) 33 o after BDC
3. EVO (Exhaust Valve open) 55 o before BDC
4. EVC (Exhaust Valve close) 11 o after TDC

I T L B-41 S E R V I C E M A N U A L
 GEAR BACKLASH CHECKING

Dial Gauge Pointer Set at Zero & Check Backlash

Timing Gear Back lash of all gears should be

0.05-0.35 (WEAR-LIMIT 0.9)

I T L B-42 S E R V I C E M A N U A L
Step 50
Fit Straight connection in the crankcase alongwith sealing washer
(18x24x1.5 cu)

Step 51
Fit the lubrication oil pump assy to Front Brg. Cap using bolt M10x130.
(Use 0.1mm shim to adjust Backlash if required.)Torque the bolt up to
3-4 kg m with torque wrench.

Step 52
Fit Neck for screw on suction side of oil pump housing.
Using sealing ring (Cu)

Step 53
Fit suction strainer to neck for screw and tight propnly

I T L B-43 S E R V I C E M A N U A L
Step 54
Fit reduction valve assy and delivery pipe using sealing rings
(cu18x24x1.5) to oil pump
IMP- Always use new sealing washers

Step 55
Fit other end of delivery pipe to connection
IMP :- Tight all joints properly.

Step 56
Tight suction strainer and Sheet metal cover using screws
M8x14and spring washer B8

Step 57
Clean Rear cover and fit main oil seal
120x140x15 into rear cover .
IMP :- Lubricate oil Seal before Fitment

I T L 44
B-44 S E R V I C E M A N U A L
Step 58
Gently press 2 dowel pins in Crankcase. and Place Rear cover gasket
and Rear Cover .

Step 59
Place Rear cover gasket using sealent & Tight rear cover using five screws
of M8x25 and 2 screw M8x30 alongwith spring washer .
IMP:- Place rear cover carefully on crankcase to avoid seal damage.

Step 60
Fit oil channel Plug M18x1.5 using sealing washer18x24x1.5 (Cu)
& sealent to plug main oil gallery from rear side

Step 61
Fit splash guard on front side of Timing Gear on crank shaft

I T L B-45 S E R V I C E M A N U A L
Step 62
(1) Screw 8 Studs in front face of crank case
6 studs of M16*59
2 studs of M16*64
(and fit 2 locating hollow dowel in case of SGI front cover.)

And 2 locating dowel pins in case of CI front Cover

Step 63
Clean front cover properly . Place the front cover gasket and front cover
on the locating dowels and tighten with following fasteners
For SGI Front Cover (Bigger)
8 NUTS M16x2
8 Spring washer B16
1 Bolts 10x55
4 Bolts 10x50
3 cap head screw
5 Spring washer B-10
FOR CI front cover (Small)

10 bolts M10*50
1 bolt M10*55
3cap head screw
11 Spring washers B-10

I T L B-46 S E R V I C E M A N U A L
Step 64
Fit front cover oil seal
Dia. 52x72x12. in Front Cover and lubricate oil Seal.

Step 65
Fit Transmission elbow with gasket using two screw of
M8x20 and spring washer B-8

Step 66
Fit cover for front cover (FIP Side) with three screws
M8x16 and spring washers B-8

Step 67
Fit Engine Belt Pulley carefully aligning Keyway and Key.
Tighten crank pulley using nut M32x1.5 & torque up to
25Kg-m.

I T L B-47 S E R V I C E M A N U A L
Step 68
Heat the ring gear upto 110o — 120o and place on flywheel
and let it cool

Step 69
Align the Flywheel dowel hole with Dowel of Crankshaft and push in

Step 70
Tighten Flywheel using four hex bolts M12x38 and torque it (8-9 kg-m)

Step 71
Place oil pan Gasket, oil pan and side bars. Tight all alongwith
spring washers & Screws of oil pan

I T L B-48 S E R V I C E M A N U A L
Step 72
Fit oil drain plug using Sealing washer (20x26x1.5 cu)

Step 73
Lubricate rocker arm pin and fit it to rocker arm bracket. Fit Rocker
Arm pin to Rocker arm bracket.

Step 74
Lubricate rocker arm and assemble both Rocker Arms

Step 75
Fit external circlip (A-22) in the groove on the both sides of Rocker arms after
placing washer.

I T L B-49 S E R V I C E M A N U A L
Step 76
Fit two adjusting screws. and
Lock nuts in all Rocker Arms.

Step 77
Properly clean cylinder head and press valve guides .

Step 78
Slide inlet and exhaust valves in their respective valve guides. Lap valve
seats with fine lapping paste and clean the valves after lapping.
IMP :- Lubricate valve during Assembly.

Step 79
Press Valve oil seal in both Guides.
IMP:- Ensure proper fitting of oil seal spring

I T L B-50 S E R V I C E M A N U A L
Step 80
Place, inner and outer valve springs

Step 81
Place valve Retainer cap & fit valve cotters properly with fixture

Step 82
Gently press dowel sleeves on top face of Crankcase with soft hammer

Step 83
Fit the studs M10*30 in Cyl. Head for exhaust flange mounting.
and place exhaust flange gaskets.

I T L B-51 S E R V I C E M A N U A L
Step 84
Place Cyl. Head gasket on respective bores

Step 85
Place Cyl. Head assy on Crank case properly.

Step 86
Tighten cyl. head assemblies using Hex Bolts M16x2x128
Torque the bolts (22Kg-m).
IMP:- Ensure Diagonal sequence of tightening.

Step 87
Place tappet and slide in Crank case.
IMP :- Ensure Free Movement.

I T L B-52 S E R V I C E M A N U A L
Step 88
Place push rods on all tappets..

Step 89
Place rocker arm sub-assembly and tighten it to cylinder head using
bolt (M8x65) and support stud M8 along with spring washer B-8.

Step 90
Set tappet clearance using feeler gauge.

Step 91
Fit stud M8 for injector fitment for each Cyl head .

I T L B-53 S E R V I C E M A N U A L
Step 92
Fit Inlet manifold with gaskets and tight with M8*20 and B8 spring washer
for sheet metal Inlet manifold & M 8x100/M 8x45 for Al. Inlet Manifold

Step 93
Fit water return line using M8x35 and M8x55 bolts and spring washers.

Step 94
Place valve cover along with gasket. Place dowty washer & special nut
and tight to 0.4-0.5 Kg m Torque.

Step 95
Place grommet in inner side of side cover and mount Side cover along
with gasket and tight by using M10 bolts alongwith O- ring 10x2 and
plain washer.

I T L B-54 S E R V I C E M A N U A L
Step 96
Fit breather pipe with side cover using banjo bolt B-13 along with
sealing washer (18x24x1.5 CU).

Step 97
Mount exhaust flange and tighten it with M10nuts and B10 washer .
Fit two studs M10*30 in exhaust flange for exhaust elbow mounting.
.

Step 98
Place injector along with sealing washer in each cyl head and tighten
Injector clamp alongwith conical washer and M8 nut. Tight M8 nut properly.

Step 99
Fit water pump along with gasket to front side of crankcase using 3 bolts
M10x35 and spring washer B-10 & one bolt of M10*40 and tight properly..

I T L B-55 S E R V I C E M A N U A L
Step 100
Fit thermostat valve with hose pipe (water pump to thermostat and
thermostat to water return line) tighten hose clamps. Properly

Step 101
Push gently centering guide along with sealing rings 14x2 in crank case

Step 102
Fit oil filter body on crankcase along with Gasket .Screw M10x25 screws &
mount oil filter body

Step103
Fit oil tube assy. With banjo bolt B-13 using sealing washer (18x24x1.5 CU)
from oil filter body to close

I T L B-56 S E R V I C E M A N U A L
Step 104
Assembly procedure of FIP with IPD shaft
Place the FIP gaskets on Crankcase.

Step 105
Fit Circlip in coupling bush

Step 106
Place coupling bush on IPD shaft in such a way that larger teeth of
coupling bush meshes with respective teeth of IPD shaft.

Step 107
Mount Coupling gear on FIP shaft And tight properly and
Torque the coupling Gear upto 6 Kg-m.

I T L B-57 S E R V I C E M A N U A L
Step 108
Align missed tooth of Coupling Gear and Big tooth of Coupling
Bush and push FIP to crankcase.

Step 109
Gently tight fuel injection pump using three M10 nut, plane & B10 washer.

Step 110
Procedure for FIP Timing.
Remove delivery valve holder to take out delivery valve.

Step 111
Remove delivery valve.

I T L B-58 S E R V I C E M A N U A L
Step 112
Tighten delivery valve holder

Step 113
Fit spill cut pipe as shown and fuel inlet pipe to FIP. While pressing
priming pump fuel will start flowing from spill cut pipe .

Step 114
Rotate Flywheel in clockwise direction and bring it to 14o mark & ensure
that fuel flow stops with continous pressing of priming pump.

Step 115
Fit Fuel Filter assy to crankcase using Hex bolt M10*30. and assemble
fuel pipe with banjo bolt with sealing washer (Cu) after proper cleaning.

I T L B-59 S E R V I C E M A N U A L
Step116
Set FIP inward and outward and adjust when diesel flow will stop ,
this is the point of Fuel Injection timing

Step 117
Tight 3 FIP nuts M10 Firmly

Step 118
Put delivery valve in its place and torque delivery valve holder up to 4-5 kg m.

and Fit high pressure pipes and fuel pipes.

I T L B-60 S E R V I C E M A N U A L
Step 119
Screw the dipstick in the respective M10 hole of crankcase with Rubber ring

Step 120
Fit Breather assy. on front cover.
Ft metallic breather assy with 2 breather pipes
(For Comp. Housing Engine) with M8*14 Screws.

Step 121
Fit starter motor after placing gasket using M10*30 and spring washer. B10

Step 122
Fit alternator Mtg. Bracket to Crankcase with 10x20 screws
and Spring washer B10.

I T L B-61 S E R V I C E M A N U A L
Step 123
Mount alternator with mounting . bracket using M10x70 bolt & nylock nut.

Step 124
Fit Alternator strut front to alternator using bolt M10

I T L B-62 S E R V I C E M A N U A L
 LONGITUDINAL SECTION
56 1
2 3 4 5 6 7 8 9 10 11

12

13

14
15
16
17
18
19

53
52
51 20
50
55 21
22
23
24
54 25

26
49
48 27
47
46 28
45
29
30
44
31
35 33
43 42 41 40 39 38 37 36 34
32

S.NO. DESCRIPTION S.NO. DESCRIPTION S.NO. DESCRIPTION

1 THERMOSTAT ASSY. 21 FLYWHEEL BOLT 41 OIL PUMP ASSY
2 VALVE OIL SEAL 22 THRUST BEARING (TOP-2) 42 OIL PAN SHEET METAL
3 VALVE COTTER PAIR 23 THRUST BEARING (TOP-1) 43 FRONT COVER
4 VALVE SPRING RETAINER CUP 24 BEARING LINER (REAR TOP) 44 BOTTOM INTERMEDIATE
5 ROCKER ARM BRACKET ASSY. 25 BEARING LINER (REAR BOTTOM) GEAR
6 WASHER SEAL 26 THRUST BEARING (BOTTOM-2) 45 TIMING GEAR (CRANK)
7 VALVE COVER 27 BEARING CAP STUD 46 FRONT OIL SPLASH GUARD
8 VALVE COVER NUT (M8) 28 FLYWHEEL 47 FRONT OIL SEAL
9 VALVE INNER SPRING 29 REAR RING GEAR 48 CLAW NUT
10 VALVE OUTER SPRING 30 REAR BAR 49 ENGINE BELT PULLEY
11 LOWER VALVE SPRING RETAINER 31 REAR COVER GASKET 50 BOLT M10X1.5
12 EXHAUST VALVE 32 DRAIN PLUG 51 CAMSHAFT
13 INLET VALVE 33 SHEET METAL COVER 52 CAM GEAR
14 PISTON 34 THRUST BEARING (BOTTOM-1) 53 WATER PUMP ASSY.
15 PISTON RING (1ST) 35 CON. ROD BIG END LINER 54. HOSE RADIATOR TO WATER
16 PISTON RING (2ND) 36 BEARING LINER BOTTOM PUMP
17 PISTON OIL RING 37 BEARING LINER (TOP) 55 RADIATOR
18 PISTON PIN 38 CRANKSHAFT 56 HOSE THERMOSTAT TO
19 FLYWHEEL RING GEAR 39 SUCTION STRAINER RADIATOR
20 MAIN OIL SEAL MAIN OIL SEAL 40 NECK FOR SCREWING IN

I T L B-63 S E R V I C E M A N U A L
 RIGHT SIDE VIEW

S.NO. DESCRIPTION S.NO. DESCRIPTION

1 RETURN LINE 13 HEAT EXCHANGER
2 EXHAUST ELBOW 14 CRANKCASE
3 TURBO CHARGER 15 FLYWHEEL
4 ALTERNATOR MOUNTING BRACKET 16 HYDRAULIC PUMP
5 HOSE RETURN LINE TO THERMOSTAT 17 SIDE COVER
6 FAN ASSY. 18 CYLINDER HEAD CASKET
7 ALTERNATOR ASSY 19 CYLINDER HEAD
8 SPACER 20 EXHAUST MANIFOLD
9 ENGINE BELT PULLEY 21 VALVE COVER GASKET
10 POWER STEERING PUMP 22 VALVE COVER
11 OIL PAN 23 WATER TEMP SENSOR
12 LUB OIL FILTER

I T L B-64 S E R V I C E M A N U A L
 FAULT DIAGNOSIS CHART

FAULT POSSIBLE CAUSE

Low Cranking speed 1, 2, 3, 4
Starting Problem 5, 6, 8, 9, 10, 12, 13, 14, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 22, 24, 29, 31, 32, 33
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 22, 23, 24, 25, 26-, 27, 31, 32, 33
Misfiring 8, 9, 10, 12, 13, 14, 18, -, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33
Black Smoke 11, 13, 14, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33
Blue & White Smoke 4, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 59
Knocking 9, 14, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 60
Erractic Running 8, 9, 10, 11, 12, 13, 14, 20, 23, 26, 28, 29, 30, 33, 35, 45
Vibration 13, 14, 20, 23, 25, 26, 27, 29, 30, 33, 45, 48
High Oil Pressure 4, 38, 41
Over Heating 11, 13, 14, 18, 19, 24, 25, 45, 47, 50, 51, 52, 53, 55, 58
Excessive Blow By 25, 31, 33, 34, 45, 56
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 60
Starts and Stops 10, 11, 12

I T L B-65 S E R V I C E M A N U A L
 KEY TO FAULT DIAGNOSIS CHART

1 Battery Capacity Low 32 Pitted Valves and Seats

2 Bad Electrical Connections 33 Broken, Worn or Sticking Piston Ring (S)
3 Faulty Starter Motor 34 Worn Valves Stems and Guids
4 Incorrect Grade of Lub. Oil 35 Overfilled Air Cleaner or use of incorrect grade of oil
5 Low Cranking Speed 36 Worn or Damaged Bearings
6 Fuel Tank Empty 37 Insufficient Oil in Sump
8 Blocked Fuel Lift Pump 38 Inaccurate Gauge
9 Faulty Fuel Lift Pump 39 Oil Pump Worn
10 Chocked Fuel Filter 40 Pressure Relief Valve Sticking Open
11 Restriction in Air Cleaner 41 Pressure Relief Valve Spring Closed
12 Air in Fuel System 42 Broken Relief Valve Sticking Closed
13 Faulty Fuel Injection Pump 43 Faulty Suction Pipe
14 Faulty Atomizer or Incorrect Type 44 Choked Oil Filter
17 Broken Fuel Injection Pump Drive 45 Piston Seizure/Pick Up
18 Incorrect Fuel Pump Timing 46 Incorrect Piston Height
19 Incorrect Valve timing 47 Damaged Fan
20 Poor Compression 48 Faulty Engine Mounting (Housing)
22 Incorrect Type or Grade of Fuel 50 Faulty Thermostat
23 Sticking Throttle or Restricted Movement 51 Restriction in Water Jacket
24 Exhaust-Pipe Restriction 52 Loose Water Pump Drive belt
25 Cylinder Head Gasket Leaking 53 Choked Radiator
26 Over Heating 55 Faulty Water Pump
27 Cold Running 56 Choked Breather Pipe
28 Incorrect Tappet Adjustment 58 Coolant Level Too Low
29 Sticking Valves 59 Blocked Sump Stainer
30 Incorrect High Pressure Pipes 60 Broken Rings
31 Worn Cylinder Bores

I T L B-66 S E R V I C E M A N U A L
 LUBRICATION SYSTEM
SPECIFICATIONS

Lubricating system Force-feed type

Type Gear type

Oil pump
Regulating valve opening pressure 5±0.5 kg/cm2

Type Paper filter

Oil filter
Oil Filter relief valve opening pressure 1.5 kg/cm2

Oil cooler Type / Regulating valve opening pressure Water cooled / 4.0 kg / cm2

Total oil capacity 11 Liters(4 cyl.)

Oil pan capacity 5 liters (4 cyl.)

Oil filter capacity 0.5 liters

Engine Oil SAE-20 W. 40*

TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE ACTION TO BE TAKEN

Loosely installed parts • Tighten or replace
• Drain plug
Oil leakage • Oil filter
Faulty seal and gasket
• Repair or replace
• Timing gear case - Cylinder block
• Oil leakage • Refer to oil leakage
• Insufficient oil • Replenish
• Wear and damage on oil pump rotor/gears • Replace
Low oil pressure
• Worn out plunger or spring • Replace
• Clogged oil strainer • Replace
• Excessive oil clearance of bearing • Repair

* Engine oil grade should be change as suitable to operating atmospheric condition.

I T L B-67 S E R V I C E M A N U A L
LAYOUT OF LUBRICATION SYSTEM

I T L B-68 S E R V I C E M A N U A L
 FLOW CHART OF LUBRICATION SYSTEM

I
T
L
Turbo charger

B-69
T

S E R V I C E M A N U A L
 COOLING SYSTEM

LAYOUT OF COOLING SYSTEM

I T L B-70 S E R V I C E M A N U A L
SPECIFICATIONS
Cooling method Water cooled
Coolant Capacity (ITL Engine 3cyl - 4cyl) 9.5 liters - 13 liters
Thermostat Type Wax type
Opening temp. 74oC ± 2oC
Full open temp. 90oC ± 2oC
Full open lift 9.5 mm (min)
Water Type Vane type centrifugal
Pump Driving method Belt driven
Type Corrugated
Radiator Cap valve 0.9 kg/cm2 - 0.9 kg/cm2
Opening pressure
Type Direct coupled (Axial flow)
Cooling fan Number of blades 6 x 400 mm Sheet Metal,
x outer dia. 7 x 420 mm - DI 90

TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE ACTION TO BE TAKEN
Coolant leakage • Damaged radiator core • Replace
• Coolant leakage from radiator hose • Correct or replace
• Coolant leakage from Thermostat • Correct or replace
• Faulty seal (water pump) • Replace
• Loose or damaged thermostat cover gasket • Correct or replace
• Loose cylinder head blots • Tighten additionally
• Damaged cylinder head gasket • Replace
• Cracked cylinder block • Replace
• Cracked cylinder head • Replace
Corrosion • Impurities are mixed in the coolant • Clean
Overheating • Clogged water passages • Clean
• Malfunctioning of thermostat • Replace
• Clogged radiator fins • Clean
• Malfunctioning of water pump • Correct or replace
• Loose or broken fan belt • Adjust or replace
• Insufficient coolant • Add
Coolant temp. • Faulty thermostat • Replace
dose not
increase

I T L B-71 S E R V I C E M A N U A L
THERMOSTAT
REMOVAL AND INSTALLATION
1. Drain coolant into a suitable container.
2. Remove each part in sequence as given below.
(1) Upper radiator hose
(2) Thermostat cover
(3) Gasket
(4) Thermostat
3. Install in the reverse order of removal. FIG. 1

INSPECTION
Check operation and replace if necessary
1. Visually check valve to make sure it is air tight.
2. Place thermostat and a thermometer in water.
3. Heat water gradually.
4. Check initial valve opening temperature, fully open temperature and fully-
open lift.

Initial opening 74OC ± 2OC

temperature
Fully-open 90OC ± 2OC FIG. 2
temperature
Fully-open lift 9.5 mm (min)

I T L B-72 S E R V I C E M A N U A L
COOLING SYSTEM CHECK
1. Visually check each hose for cracks, and system expansion.
Make sure that the hose band clamp is not loose.
2. Perform the pressure test.
1. Remove the radiator cap, completely fill the radiator with coolant and
set a tester.
2. Warm up the engine.
3. Stop the engine, apply pressure of 0.9 kg/cm2 to the tester and check
the following points.
• Does the needle of the pressure gauge continuously point to the same
valve ?
• Is there excessive swelling in the hose?
FIG. 1
NOTE
• When removing the tester, hot cooling water may blow out. The
operator should protect himself from a scald by using an cloth, etc.

FIG. 2

RADIATOR
CHECKING RADIATOR CAP PRESSURE VALVE
Set a radiator cap tester on the radiator cap and ensure that the pressure
valve functions properly at the specified pressure.
Pressure valve opening pressure :
0.5 - 0.9 kg/cm2

FIG. 3

I T L B-73 S E R V I C E M A N U A L
RADIATOR CAP AND VACUUM RELIEF VALVE
Open the valve by pulling it and make sure that it closes when released.
Check and see the contact surface for any damage.

RADIATOR DISMANTLING PROCEDURE

REMOVAL :-
FIG. 1
1. Remove the required sheet metal, Air cleaner & Electric wiring
connection of head light & horn.
2. Drain water from radiator & open the filler cap.
3. Remove clamp of rubber house connecting from upper and lower
tank.
4. Remove/loosen the Hex Lock nut from bottom part of the radiator.
5. Take out radiator from tractor in upward direction.

INSPECTION:-
1. Check radiator Tube/Joint/Tank for any leakage.
2. Check Radiator cap relief valve proper working & ensure for
damage free rubber seal of radiator cap.
FIG. 2
3. Check radiator fins for any damage.
4. Check radiator tubes are free from rust and clogging.

MAINTENANCE :-
1. Flush and clean the radiator properly.
2. Clean the clogging of fins by air blow without damaging fins.
3. Check and replace damaged hose pipe.
4. Note : To avoid frequent radiator tube rusting and partial clogging
of water jackets on account of scaling "USE OF ANTISCALE /
ANTIRUST AGENT IS RECOMMENDED". Anti Rusting Cooling
Agent (Veedol Zero) Part no:10026400AA

QTY.ML MODEL FIG. 3

300 4-CYL.IN HOUSE ITL ENGINE

5. Add Antifreeze in sub zero temperature operating condition.

I T L B-74 S E R V I C E M A N U A L
 TURBO CHARGER

ON VEHICLE INSPECTION
TURBO CHARGER BOOST PRESSURE
1. Disconnect air hose from the wastegate.
2. Connect pressure gauge as shown.
3. Connect tachometer to the engine.
4. Warm up engine to operating temperature.
5. Increase engine speed to max rpm and check the boost pressure if it is
within the specified limit.

FIG. 1

TURBINE WHEEL
1. Allow engine to cool.
2. Remove the air hose.
3. Verify that the rotor assembly turns smoothly.
4. If there is excessive load or noise, replace the turbo charger.

FIG. 2

OIL PASSAGE
1. Allow engine to cool.
2. Remove oil return pipe.
3. Verify that carbonized oil has not blocked oil passage of the turbocharger
and of oil return pipe.
4. If carbonized oil has blocked the oil passage replace turbochager and return
pipe if necessary.

I T L B-75 S E R V I C E M A N U A L
REMOVAL & INSTALLATION OF
TURBO CHARGER
Remove turbo charger in a given sequence & install in the
reverse order.
1. Air intake hose
2. Air intake pipe
3. Oil inlet pipe
4. Oil outlet hose
5. Air outlet pipe
6. Front exhaust pipe.
7. Turbo charger.

Note : Turbo charger can only be repaired at authorised

workshops. Special tools and expert knowledge is
mandatory for its repairs.

Caution : Since the turbo charger is a precision equipment

it should be handled with great care while removing and
installing.

a) In any case it should not be dropped.

b) Do not use control valve as carrying handle to life the turbo charger.
c) Cover the intake, exhaust, and oil passages of turbo charger to prevent entry of dirt other objects.

INSPECTION
After removing the turbo charger, check the oil feed and oil return for clogging. Replace if necessary.

DO'S AND DONT'S FOR SATISFACTORY FUNCTIONING OF TURBO CHARGER

DO'S
Change engine oil and oil filters regularly during service intervals.
Change/clean air filter element at every service.
Check for oil pressure at engine idling speed. The pressure should not drop beyond specified minimum pressure.
Give idle running for 2 minutes after starting the engine.
Run the engine for 2 minutes in idle condition before switching the engine off.
Regularly check air, oil and exhaust connection for leaks and abnormal dust/oil carbon deposit.

DONT'S
Don't run the engine with low oil pressure.
Don't put the engine under full load immediately after starting.
Don't switch off the engine under full load.
Don't run the engine with damaged, oil feed & drain pipes.
Don't run the engine with damaged/faulty connection, from air cleaner to turbo charger and from turbo-charger
to inlet manifold.
Don't run the engine with damaged/faulty connections to the turbo-charger turbine inlet and from turbine outlet.
Don't use the control valve for lifting the turbo-charger.

I T L B-76 S E R V I C E M A N U A L
 S
tion
ump

ANT
TURBO CHARGER

igh

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I
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P
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TROUBLESHOOTING CHART

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ower
smo
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T
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m tu
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CO
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engin
om

cks p
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x
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Blac
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Blue
Tur
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Oil
Bo
POSSIBLE CAUSES REMEDIAL ACTIONS
Clogged air filter element Replace air filter element
Restrictions In air Intake duct to compressor Inlet Remove restriction or replace damaged parts as required
Restrictions in air outlet ducts from compressor outlet to
Remove restriction or replace damaged parts as required
intake manifold
Restriction in intake manifold Remove restriction or replace damaged parts as required
Arrest the leak by replacing hoses, clips, pipes or tighten the
Air leak in duct between air clean and compressor
clamps as required

B-77
Arrest the leak by replacing hoses, clips, pipes, cooler or tighten
Air leak in ducts between compressor & intake manifold
the clamps as required
Air leak between intake manifold and cylinder head Arrest the leak by replacing gaskets or fasteners as required
Foreign object in engine exhaust manifold/intake duct to Remove the object & check for the cause / origin of the object
compressor entry & correct it
Restricted exhaust system Remove restriction or replace damaged parts as required
Arrest the leak by replacing gaskets/damaged parts or tighten
Gas leak between exhaust manifold and cylinder head
the fasteners as required
Restriction in turbo charger oil drain line Remove restriction or replace defective parts as required.
Restricted engine crank case breather Remove restriction & clean the crank case breather
Thick oil sludge or coke in turbo charger central housing Change oil & oil filter, service or replaced turbo as required
Faulty fuel injection pump & Injections Check & arrest the faults and replace or adjust as required
Improper valve timing Adjust correct timing
Wororn-out valves, piston rings, liners, internal engine Replace the worn-out components & rectify internal engine
problems (increased blow-by) problems
Boost pressure control valve struck in open position Refer to turbo charger authorised service center

S E R V I C E M A N U A L
Boost pressure pipe/hope assembly damage/punctured
Refer to turbo-charger authorised service center
and valve stuck in closed position
Refer to turbo charger service center, analyze & correct the
cause of failure (turbo failure is normally due to lack of oil
Turbocharger damaged
low oil pressure, dirt in engine oil, foreign pratice enter into
compressor / turbine inlet).
1.0 GUIDELINES FOR DRY AIR CLEANER
• Clean the primary element after every 300 hrs of operation or when ever choke indicator
glows on dashboard.
• Replace primary element after 3 time cleaning or 900 hrs (whichever earlier).
• Gently pull primary element back and forth to take it out from housing.
• Clean primary filter element by blowing air (max. pressure) from inside.
• Safety cartridge not to be removed during cleaning of primary element. Safety cartridge to
be replaced after every three replacement of primary filter.
• Do not clean safety cartridge by compressed air.
• Use clean cloth to wipe sealing areas of primary filter.
• Ensure proper seating of filter into housing before latching the cover. Do not use latches on
the cover to force the filter into air cleaner that could cause damage to housing and will void
the warranty.
• Ensure proper seating of all rubber rings replace the damages ones.

NOTE Clean the primary filter whenever choke indicator glows on dashboard.

I T L B-78 S E R V I C E M A N U A L
 C
CLUTCH

CONTENTS

REF. NO DESCRIPTION PAGE

C 1.0 INTRODUCTION C-1
C 2.0 FUNCTION C-1
C 3.0 WORKING C-1
C 4.0 SPECIFICATIONS C-2
C 5.0 DETAIL OF DOUBLE CLUTCH LINKAGE ASSY PARTS C-3
C 6.0 ASSEMBLY PROCESS OF DOUBLE CLUTCH C-4
C 7.0 INSPECTION PROCEDURE C-5
C 8.0 TROUBLE SHOOTING C-6

I T L C S E R V I C E M A N U A L
C 1.0 INTRODUCTION
The clutch works on the principle of friction in which when one stationary surface is brought into contact with a rotating surface, the
stationary surface also starts rotating. In actual practice one of the driving plates is the flywheel and the other is known as the
pressure plate. The driven plate is a clutch plate made of frictional material and directly mounted on the splined end of the clutch
shaft. In normal running condition the pressure springs keep the pressure plate in contact with the clutch plate. When the foot pedal
is pressed, the pressure plate moves away against the pressure springs allowing the clutch plate and thus the clutch shaft to
become stationary.
Depending on the design, it may have a single disc or two disc, one for the main transmission and the other for power take off (PTO).
C 2.0 FUNCTION
A clutch is a device that is used to transmit between an input and output shaft that operate at different speeds. A clutch cannot
multiply torque like a clutch torque converter. The torque output from a clutch will always equal the torque input. When the clutch is
slipping, the output torque is still equal to the input torque but power is lost (in the form of heat) because the output RPM is lower
than the input RPM.
C 3.0 WORKING
The main components are as under :
• CLUTCH PLATE
• PRESSURE PLATE
• CLUTCH COVER
• PRESSURE SPRINGS
• RELEASE FINGERS
• RELEASE BEARINGS
• CLUTCH SHAFT
• LINKAGES.
The clutch cover is bolted to the flywheel, and the clutch plate is mounted on the splined part of the clutch shaft, the front end of
which is freely supported on the pilot bearing fitted in the flywheel and other passes through the release bearing. In between the
pressure plate and the clutch cover, pressure spring are placed all around the circumference. Three fingers, also known as release
levers, are centrally fulcrum to the clutch cover with their outer ends connected to the pressure plate. A release bearing slightly
away from the free ends of the fingers moves to and fro on the clutch shaft with the hello of a fork, which is connected to the clutch
pedal through the linkages. As soon as the pedal is pressed, the release bearing moves towards the flywheel and presses the
fingers. As the fingers are fulcrum at a point in their length to the clutch cover and the other end is connected to the pressure plates,
as soon as the free ends are pressed inside by the release bearing, the outer tends to bring the pressure plate away from the clutch
plate against pressure springs, making the clutch plate hence the clutch shaft to disengage. But the pressure plate and cover
remain rotating along with the flywheel. Thus the condition of disengagement remains till the front pedal remains pressed. As soon
as pedal returns to the engaged position, the pressure plate moves ahead to press the clutch plate due to the pressure springs.

I T L C-1 S E R V I C E M A N U A L
C 4.0 SPECIFICATAIONS

4-CYL
TRACTOR
MODE
DOUBLE CLUTCH

CLUTCH DRY MECH DRY MECH

MAKE LUK INDIA LUK INDIA

TYPE DUAL SEPARATE CONTROL

DRIVE DISC 1 1

LINING ORGANIC CERAMIC

DIAMETER 280 280

CONTROL MECH MECH

I T L C-2 S E R V I C E M A N U A L
C 5.0 DETAIL OF DOUBLE CLUTCH LINKAGE ASSY PARTS

S. NO DESCRIPTION Qty S. NO DESCRIPTION Qty

1 DISC PUSHER 1 10 BEEARING 1
2 BEARING 1 11 SNAP RING D50 1
3 SLEEVE PUSHER 1 12 SPLIT PIN 5X14 4
4 BEARING 1 13 CLUTCH CONTROL FORK 1
5 SLEEVE 1 14 LEVER 1
6 PLUG 1 15 PIN 10X45 4
7 SLEEVE 1 16 CLUTCH CONTROL FORK 1
8 SUPPORT 1 17 LEVER 1
9 BOLT M8X25 3 18 O.RING 1

I T L C-3 S E R V I C E M A N U A L
C. 6.0 ASSEMBLY PROCESS OF DOUBLE CLUTCH

1. Insert the main clutch disc into the engine.

2. Attach the Clutch with PTO disc assy. To the engine with the help of 12 MB
screws along with the spring washers with Pneumatic gun having socket of
13mm and torque wrench of 29Nm.

3. Check the setting of the fingers, Upper main clutch (35 to 36) and lower P.T.O
(27 to 28) in the pressure plate in this D. C. engine with the help of if Vernier
Caliper/depth Gauge.

I T L C-4 S E R V I C E M A N U A L
C 7.0 INSPECTION PROCEDURE
A- CLUTCH DISC
B- CLUTCH COVER

A) CLUTCH DISC

CHECKING

• Hardened facing or oil on the facing.

• Use sand paper to rectify minor hardening.
• Fatigued torsion springs.
• Loose facing rivets.
• Worn Clutch disc.
Note : Measure the depth of the rivet head of disc.
Allowable limit up to 1.6 mm (FOR ALL SOLIS-III MODELS)

B) CLUTCH COVER

CHECKING
Fatigue and breakage of the diaphragm spring and breakage of the cover.
Streaks, cracks and discoloring of the pressure plate in contact with the disk.
Note : Minor straks and discoloring can be repained by polishing with send paper.

I T L C-5 S E R V I C E M A N U A L
C 8.0 TROUBLE SHOUTING

S. No PROBLEM PROBABLE CAUSES REMEDIES

1 Noise while pressing Lack of lubrication in Clutch Release Bearing Lubricate
the clutch pedal Clutch Release Bearing damage Replace
2 Noise while releasing Lack of lubrication in Pilot Bearing Lubricate
clutch pedal Pilot Bearing damage Replace
Clutch disk hub loose on Input shaft Replace the worn out parts
Clutch Pedal free play Adjust & correct (25 to 35 mm)
Broken or Weak pressure spring Replace springs
Release lever height incorrect Adjust & correct (SC. 40 to 44mm)(DC 28to36mm)
Grease or oil on facings Replace the facing, check source of
3
Clutch slipping grease or oil leak and arrest
Glazed clutch facing Replace facing
Glazed flywheel or Pressure plate face Correct by machining or replace
Wraped Clutch facing Replace the clutch facing
Wraped Flywheel or Pressure plate face Correct by machining or replace
Clutch not disengage Clutch Pedal free play more Adjust & correct
4
while pressing clutch Release lever height setting improper Adjust & correct
Driver Clutch pedal riding Keep foot off clutch pedal
Excessive and incorrect use of clutch Reduce use
Wear of clutch Cracks in flywheel or pressure plate face Correct by machining or replace
5
facing Weak or broken pressure spring Replace spring
Clutch pedal free play less Adjust & correct
Lack of lubrication in pedal linkage Lubricate
6 Clutch pedal hard Clutch pedal jam on clutch shaft Grease the shaft
Release lever height setting improper Adjust & correct
Engine and Transmission not improper Realign
Flywheel face run out more Correct run out or replace
7 Clutch pedal Release lever not evenly adjusted Adjust & correct
pulsation Pressure plate assembly misaligned Realign
Warped pressure plate or clutch facing Replace
Clutch plate nut free on De ---- and check clean
Workest clutch facing

I T L C-6 S E R V I C E M A N U A L
 D
FLOOR AREA & GEAR BOX

CONTENTS

REF. NO. DESCRIPTION PAGE

D 1A SHEET METAL D-1
D1 TIGHTENING TORQUES, SEALANTS AND GREASE APPLICATION D-5
D2 POWER FLOWS D-17
D3 ASSEMBLY TYPICAL DATA D-21
D4 FILLING AND CHECKS D-26
D5 SERVICE SCHEDULE D-29

I T L D S E R V I C E M A N U A L
D 1A. SHEET METAL

Dismantling of Canopy

For removing the canopy from the tractor remove hex

bolts and hex M10x1.5x40, and stud mtg with trumpet
housing size M16X1.5.And remove all the pins fitted on
canopy.

Assembling of Canopy

To assemble canopy on tractor ensure that rubber pads

are Fit on both of the sides of Trumpets Housing, Fit hex
bolts M10x1.5x40, and stud mtg with trumpet housing
size M16X1.5.And fit all the pins fitted on canopy.

Disassembling of Fender assembly

To dismantle fender assembly remove

Nut/bolts M10x1.5x40, and stud size M16X1.5.

Assembling of Fender assembly

To assemble fender assembly keep rubber pads on

trumpet housing fit Nut/bolts M10x1.5x40, and stud
size M16X1.Ensure all nut/bolts are properly tighted.

I T L D-1 S E R V I C E M A N U A L
Disassembling of Floor Rear assembly

To dismantle Floor assembly please remove fender

assembly of both sides afterwards disconnect all the
connections (Linkages) like brake connection , gear
levers , hydraulic linkage connections , afterwards nuts
mtg with rear housing.

Assembling of Floor Rear assembly

To assemble Floor assembly please tight all the nuts

and bolts of floor assembly on rear housing please
connect all the connections (Linkages) like brake
connection, gear Levers, hydraulic linkage connections
the all nuts/bolts after that fit fender assembly of both
sides.

Disassembling of Floor Front assembly

To dismantle front floor assembly please remove its

footstep. Afterwards remove front top assembly, RHS
assembly and LHS assembly by removing Hex head
screw M8X1.25-25 8-8 SA2JS.

Assembling of Floor Front assembly

For assembling of front floor assembly first of all fit

LHS front floor assembly afterwards RHS and Top
front floor assembly. After that fit Foot step.

S O NI A
T L I K A D-2 S E R V I C E M A N U A L
D 1B. TRANSMISSION

S O NI A
T L I K A D-3 S E R V I C E M A N U A L
 Main Dimensions(mm)
LHS View (See Main View)

I T L D-4 S E R V I C E M A N U A L
D.1 Tightening Torques, Sealants and Grease Application

Adhesive/Sealant Application
Apply on Contact Surfaces
Apply on bolts threads /on pins

Gasket Sealant
Presence Adhesive make and type Technical characteristics Strength
Superbond 529 Flat surface sealing High
Superbond 519 Flat surface sealing Low
Superbond 539 Uneven surface sealing High
Loctite Tight 5205 Even surface sealing with possibility High
of micro-moments

Thread Parts Sealant

Presence Adhesive make and type Technical Characteristics Strength
Superbond 321 Locking of Threaded Parts Medium
Superbond 331 Locking of Threaded Parts High
Superbond 438 Locking of Threaded Parts High, Special Appl.

Fixing Parts Sealant

Presence Adhesive make and type Technical characteristics Strength
Superbond instant 25 Fixing adhesive Medium Bond
Superbond 433 Fixing adhesive Strong Bond
Superbond 321 Fixing adhesive Medium Bond
Superbond SB14 Rubber Fixing adhesive Strong Bond

I T L D-5 S E R V I C E M A N U A L
 Grease Application in Assembly

POLYMER 400 Apply on the Indicated Surfaces

MU/EP2 Fill/Apply in Excess

4WD Mechanical Drop Box

I T L D-6 S E R V I C E M A N U A L
CLUTCH HOUSING
12x12 Synchro Shuttle

I T L D-7 S E R V I C E M A N U A L
DETAILS
12x12 Synchro Shuttle

I T L D-8 S E R V I C E M A N U A L
GEAR BOX GROUP

I T L D-9 S E R V I C E M A N U A L
GEAR BOX DETAILS

I T L D-10 S E R V I C E M A N U A L
FINAL DRIVE GROUP

I T L D-11 S E R V I C E M A N U A L
GD-TPO AND PTO ASSY (540-540E)

I T L D-12 S E R V I C E M A N U A L
UPPER AND LOWER COVER

I T L D-13 S E R V I C E M A N U A L
HYDRAULIC CONTROL BRAKE ASSY

I T L D-14 S E R V I C E M A N U A L
INNER GEAR CONTROL ASSY

FOR ALL MODELS

F
H

I T L D-15 S E R V I C E M A N U A L
OUTER GEAR CONTROL ASSY

FOR ALL MODELS

I T L D-16 S E R V I C E M A N U A L
D.2 POWER FLOWS

FRW FIRST SPEED-HIGH

FOR ALL MODELS

I T L D-17 S E R V I C E M A N U A L
POWER FLOWS

FRW FIRST SPEED-MEDIUM

FOR ALL MODELS

I T L D-18 S E R V I C E M A N U A L
J. POWER FLOWS
FRW FIRST SPEED - LOW

I T L D-19 S E R V I C E M A N U A L
POWER FLOWS

FRW/REV TRANSMISSION POWER FLOW

12+12 SYNCRHO SHUTTLE

FRIZIONE/CLUTCH

AVANTI/ FRW

INDIETRO/REV

FRIZIONE/CLUTCH

AVANTI/ FRW

INDIETRO/REV

I T L D-20 S E R V I C E M A N U A L
D.3 ASSEMBLY TYPCIAL DATA

Position 1 End float

Gear Box Min 0.20 Max 0.30 mm

Shims Range
Thickness (mm) 0.10 0.15 0.20 0.50
Quantity --- --- --- ---

END FLOAT

SHIMS

I T L D-21 S E R V I C E M A N U A L
Position 2 End float
Gear Box Min 0.00 Max 0.00 mm

Shims Range
Thickness (mm) 0.10 0.15 0.20 0.50
Quantity --- --- --- ---

END FLOAT

SHIMS

I T L D-22 S E R V I C E M A N U A L
Position 3 End float
Gear Box Min 0.15 Max 0.25 mm

Shims Range
Thickness (mm) 0.05 0.10 0.30
Quantity --- --- ---

END FLOAT

SHIMS

I T L D-23 S E R V I C E M A N U A L
Position 4 End float
Gear Box Min 0.15 Max 0.25 mm

Shims Range
Thickness (mm) 0.01 0.3 0.5
Quantity --- --- ---

END FLOAT

SHIMS

I T L D-24 S E R V I C E M A N U A L
Position 5 End float
Gear Box Min 0.0 Max 0.1 mm

Shims Range
Thickness (mm) 0.10 0.30 0.50
Quantity --- --- ---

12+12 SYNCHRO SHUTTLE

END FLOAT SHIMS

I T L D-25 S E R V I C E M A N U A L
D.4 Filling and Checks
Warning: To drain and load the oil and to check the oil level the transmission must be horizontal.
Scheduled maintenance oil drain
To drain the oil remove the level plug (1) and the drain plug (2).
Danger: Risk of violent oil ejection, follow carefully all the safety procedures indicated in this manual and in the vehicle manual.
See: cap.B - SAFETY INSTRUCTIONS
Drain all oil. Clean the plug (2) and tighten it to the prescribed torque (sec.C.6).
Scheduled maintenance oil filling
Carry out the following instructions:
Fill the transmission with oil to the maximum level marked on the level dipstick (1). Apply the parking brake. Keep the speed control
in NEUTRAL range. Start the engine by keeping the slow running of 800-1000 rpm until an oil temperature higher than 25 °C is
obtained. Check that the transmission oil level is in the prescribed range on the level dipstick (1). If necessary, top up with oil to keep
the level in the prescribed range.
Scheduled maintenance oil level check
Use the oil level dipstick (1) to check the oil level.
Warning: If leakage or any other factor determining fall in the oil level is found, then it is advisable to check immediately, in order to
avoid damages to the mechanical parts.

POSITION Descriptions (next figure)

1 Oil level dipstick(oil filling port)
1 Oil filling port
2 Oil drain port
3 Greaser
4 Brakes breather

I T L D-26 S E R V I C E M A N U A L
FILLING AND CHECK POINTS

I T L D-27 S E R V I C E M A N U A L
 No. 7 PLUGS 138341 D20.35x6 SYNCHRO SHUTTLE

I
T
REQUIRED OIL LEVEL

L
OIL

D-28
12+12 MR SYNCHRO SHUTTLE 4WD MECHANICAL DROP BOX

No. 3 PLUGS 122187 D38x10

S E R V I C E M A N U A L
D.5 Service schedule
Specified maintenance intervals are for standard-duty use.
Severe operating conditions may require more short intervals.

Tempi previsti/Recommended intervals

Operation
50 h 400 h 800 h 1200 h
Change the transmission/hydraulic oil
Change the oil suction strainer
Change high pressure filter element
Grease trumpet bearings
Check automatic pick-up hitch for
correct operation

Lubricants application range

I T L D-29 S E R V I C E M A N U A L
 E
DISASSEMBLY AND
ASSEMBLY OPERATIONS

CONTENTS
REF. NO DESCRIPTION PAGE
D.1 4WD DROP BOX (MECHANICAL) E-1
D.2 FINAL DRIVE E-16
D.3. UPPER COVERS AND ROCKSHAFT E-22
D.4 OUTER GEAR CONTROLS E-26
D.6 CLUTCH HOUSING E-30
D.8 PTO - POWER TAKE OFF E-33
D.9 PTO - SELECTION CONTROL E-41
D.10 PTO - SHAFT GROUP E-44
D.11.2 ACTUATOR ASSEMBLY E-48
D.11.3 VIEW DETAILS OF BRAKE HOUSING INSIDE PARTS E-50
D.9.11 VIEW DETAILS OF BRAKE PADDLES PARTS E-51
D.9.12 VIEW DETAILS OF HAND BRAKE LINKAGE ASSEMBLY E-52
D.12 PARKING BRAKE E-53
D.13 HOUSING SENSORS ASSY E-66
D.14 DIFFERENTIAL LOCKING CONTROL E-69
D.15 INNER CONTROLS ASSY E-75
D.16 IDLE GEAR E-86
D.17 RANGE GEARS (PRIMARY SHAFT) E-88
D.18 INPUT SHAFT E-95
D.19 SYNCHRO SHUTTLE (REPLACEMENT) E-103
D.20 SPEED GEARS (PRIMARY SHAFT) E-107
D.21 DIFFERENTIAL ASSY E-112
D.22 PINION - RANGES (SECONDARY SHAFT) E-121
D.23 SPEED GEARS (SECONDARY SHAFT) E-129

I T L E S E R V I C E M A N U A L
D.1 4WD DROP BOX (MECHANICAL)

For models
T1 12+12 MR synchro shuttle 2WD mechanical control brake 75 & 90 Worldtrac
T2 12+12 MR synchro shuttle 4WD mechanical T57 drop box and mechanical control brake 75 & 90 Worlddtrac

I T L E-1 S E R V I C E M A N U A L
D.1.1 Disassembly
Some of the following pictures may not show exactly your machine, but the
process is the same.

FIG. 1

Remove the fastening screws (20).

Remove the cover (19).
Note: the cover is attached with sealant

Drain the oil completely from the transmission.

Unscrew the bolts (23) and remove the group.

FIG. 2

Tap on the shaft end to release the transmission group bearings.

Note: it's advisable to use a soft hammer to do not damage the shaft.

FIG. 3

Remove the fastening screws (13).

Disassemble the cover (14).
Note: the cover is attached with sealant.

FIG. 4

I T L E-2 S E R V I C E M A N U A L
Remove the seal ring (1) from the cover (14) by mean of a pad
and a hammer.
Note: this is a destructive operation for the seal ring.

FIG. 5

Push the shaft (3) by mean of a pad and a hammer to extract the
bearing (2) from the housing.

FIG. 6

Remove the shaft/bearing assy.

FIG. 7

Remove the spacer (10) and the gear (11).

FIG. 8

I T L E-3 S E R V I C E M A N U A L
Remove the clutch sleeve (9).

FIG. 9

Remove the bearing (12).

FIG. 10

Remove the snap ring (4) to disassemble the clutch sleeve.

Danger: the washer (5) and spring (8) can be ejected with force Against
the operator.

FIG. 11

Remove the washer (5).

FIG. 12

I T L E-4 S E R V I C E M A N U A L
Remove the springs (8).

FIG. 13

Remove the sleeve (7) from the clutch sleeve (9).

Collect the springs (8)

FIG. 14

Release the lock nut (27).

FIG. 15

Remove the fastening screws (28).

Danger: the spring (29) can be ejected with force against the
operator.

FIG. 16

I T L E-5 S E R V I C E M A N U A L
Collect the spring (29) and ball (30).

FIG. 17

Remove the plug (32).

Note: the plug is attached with sealant.

FIG. 18

Remove the pin (31).

FIG. 19

Extract the shaft (33).

Danger: the ball (34) and spring (35) can be ejected with
force against the operator.

FIG. 20

I T L E-6 S E R V I C E M A N U A L
Collect the ball (34) and spring (35).

FIG. 21

Warning: collect with care the disassembled parts; they are necessary
in the assembly operation. FIG. 22
Note: remember the position of the springs (35) and (29).
Check the disassembled parts wear condition.

FIG. 23

Collect the fork (16).

Remove the pin (24).

FIG. 24

I T L E-7 S E R V I C E M A N U A L
Remove the lever (26) and the shaft (17).
Remove the spring (18).

FIG. 25

Remove the seal ring (25).

Note: this is a destructive operation for the seal ring.

FIG. 26

I T L E-9 S E R V I C E M A N U A L
D.1.2 Assembly
Some of the following pictures may not show exactly
your machine, but the process

FIG. 1
Clean with care the housing (15).
Check the wear condition of the bearings seats.

Insert the seal ring (25) into the housing (15) with the special tool
CA715619 and a hammer.

FIG. 2
Lubricate the seal ring (25).
See: sec. C.4 and sec E.1. (4WD mechanical drop box).

Respect indicated assembly position.

Note: the springs (35) and (29) are not equal.

FIG. 3

I T L E-8 S E R V I C E M A N U A L
Insert the spring (35) and ball (34) into the housing (15).

FIG. 4

Insert the special tool CA715620 into the housing (15).

See: sec. C.4. and sec E.1. (4WD mechanical drop box).

FIG. 5

Push with a punch the ball (34) on the spring (35) then insert the special tool
CA715620 on the ball (34).

FIG. 6

Insert the fork shaft (33) in the housing (15) pushing forward the special tool
CA715620.
Collect the special tool CA715620.

FIG. 7

I T L E-9 S E R V I C E M A N U A L
Assemble the spring (18) to the clutch shaft (17).

FIG. 8

Assemble the lever (26) to the shaft (17).

Note: align the pin hole in the shaft (17) to the hole in the lever (26).

FIG. 9

Lock the shaft (17) in the right position with a punch.

Assemble the pin (24).

FIG. 10

Assemble the fork (16) to the clutch shaft (17) in the housing (15).

FIG. 11

I T L E-10 S E R V I C E M A N U A L
Insert the shaft (33) in the fork (16).
Note: align the pin hole in the shaft (33) to the hole in the fork (16).

FIG. 12

Insert the fastening pin (31) with a punch and a hammer.

FIG. 13

Apply prescribed sealant on the plug thread (32).

Assemble the plug (32) and tighten it to the prescribed torque.
See: sec. C.4.

FIG. 14

Insert the bearing (12) into the transmission housing with the special tool
CA715622 and a hammer.
See: sec. E.1. (4WD mechanical drop box).

FIG. 15

I T L E-11 S E R V I C E M A N U A L
Insert springs (8) into the sleeve (7), to assemble the clutch Sleeve group.

FIG. 16

Assemble the sleeve (7) to the clutch sleeve (9).

Note: check the springs (8) and key (6) position.

FIG. 17

Assemble the washer (5).

FIG. 18

Assemble the snap ring (4).

FIG. 19

I T L E-12 S E R V I C E M A N U A L
Remove the clutch sleeve (9) to the fork (16).

FIG. 20

Assemble the bearing (2) onto the shaft (3) with the special tool
CA715623 and a hammer.
See: sec. E.1. (4WD mechanical drop box).

FIG. 21

Insert the spacer (10) and gear (11) in the housing.

Assemble the shaft (3) with bearing (2) as shown.

FIG. 22

Insert the bearing (2) and shaft (3) into the housing (15) with the special tool
CA715623 and a hammer.
See: sec. E.1. (4WD mechanical drop box).

FIG. 23

I T L E-13 S E R V I C E M A N U A L
Apply prescribed sealant on the screw thread (28).
M
Adjust the screw (28) position to have 35 Nm of
clutch torque value(M) on the lever axis.

Assemble the nut (27) and tighten it to the prescribed

torque. See: sec. C.4.

FIG. 24

Clean with care the covers (14) and (19).

FIG. 25

Insert the seal ring (1) into the cover (14) with the special tool CA715621 and a
hammer.
Lubricate the seal ring (1).
See: sec. C.4 and sec. E.1 (4WD mechanical drop box).

FIG. 26

Apply prescribed sealant on the covers (14) and (19) on the housing/cover contact
surface.
See: sec. C.4.

FIG. 27

I T L E-14 S E R V I C E M A N U A L
Assemble the covers (14) and (19) to the housing (15) with
Fastening screws (13) and (20).

Tighten the fastening screws to the prescribed torque.

See: sec. C.4.

FIG. 28

Apply prescribed sealant on the housing contact surface.

Assemble the housing to the vehicle transmission group with bolts (23).
Tighten the bolts to the prescribed torque.

Fill the vehicle transmission group with specified oil.

See: sec.C.4, C.7 and C.8.

FIG. 29

2WD
Observe indicated 2WD/4WD clutch parameters.
12°
4°

4WD

FIG. 30

I T L E-15 S E R V I C E M A N U A L
D. 2 FINAL DRIVE

* INCLUDED ON ITEM 6

For Models
T1 12+12 MR synchro shuttle 2WD mechanical control brake 75 & 90 Worldtrac
T2 12+12 MR synchro shuttle 4WD mechanical T57 drop box and mechanical 75 & 90
control brake Worldtrac

I T L E-16 S E R V I C E M A N U A L
D.2.1 Disassembly

1. Unscrew locking screws (7) of trumpet (6).

2. Remove trumpet (6) from gear box.
3. Remove shaft (20) from the transmission.
4. Remove bolt stop (16).
5. Unscrew screw (15).
6. Remove thrust washer (14) and shims (13).
7. Extract planetary carrier (12).
8. Remove locking screws (17) and disassemble
planetary carrier.
9. Remove from each shaft: thrust washer (25), bearing
(23), gear (22) and bearing (21).
10. Remove pins (8) from trumpet (6).
11. Remove O-Ring (19) on ring gear (18).
Note: destructive operation for O-Ring.
12. Remove snap ring (11).
13. Collect bearing cone (10).
14. Turn the group upside down.
15. Extract the wheel shaft (1) from trumpet (6).
16. If necessary remove studs (2) from wheel axle (1).
17. Remove seal ring (3) from trumpet (6).
Note: Destructive operation for seal ring.
18. Remove bearing cone (4).
19. Extract bearing cup (4) from trumpet (6).
20. Turn trumpet (6) upside down.
21. Remove bearing cup (9) from trumpet (6).
22. Extract seal ring (9) from trumpet (6).
Note: destructive operation for seal ring.
23. If necessary remove greaser (5) from trumpet (6).

I T L E-17 S E R V I C E M A N U A L
D.2.2 Assembly
1. With vertical trumpet:
Fill with grease as shown in the figure using tool
CA715844. Assemble bearing cup (4).
See: fig.1, sec. C.4 and sec. E.1 (Final drive).
2. Assemble bearing cone (4). Fill with grease again.
See: fig.1.
3. Assemble seal ring (3) with tool CA715836.
See: fig.1 and sec. E.1 (Final drive).
4. Assemble studs (2) on wheel axle (1).
5. Warm the outlined area at 120 °C for 4/5 minutes to
allow introduction of the wheel axle (1).
See: fig.1

FIG. 1

6. Assemble wheel axle (1).

7. Turn trumpet holding axle beam.
8. Assemble seal ring (9) with tool CA715826.
See: sec. E.1 (Final drive).
9. Assemble bearing cup (10) with tool CA715827.
See: sec E.1 (Final drive).
10. Assemble bearing cone (10).
11. Assemble snap ring (11).
12. Assemble a new O-Ring (19) on ring gear (18).
13. Assemble pins (8) on trumpet (6).

I T L E-18 S E R V I C E M A N U A L
14. Assemble planetary gear assy.
- Assemble on gear (22) bearing cups (21) and (23)
using tool CA715827.
- Assemble bearing cone (21) on planetary gears
carrier (12) pin. Assemble gear (22) to gear carrier (12).
- Assemble bearing cone (23).
- Assemble pin (24).
- Assemble washer (25).
- Apply sealant to screw (17).
See: sec. C.4.
- Tighten screw (17) to requested torque.
See: sec. C.4.
- Assemble planetary gear assy on trumpet.
See: fig.2 and sec. E.1 (Final drive).

Fig.2

I T L E-19 S E R V I C E M A N U A L
D.2.3 Taper roller bearings preload
1. If parts as trumpet or wheel axle are not replaced, use shims collected during
disassembly. Check correct preload.
2. If trumpet or wheel axle are to be replaced, proceed
as follows:
- start with a packet of shim (13) 1 mm each;
- assemble washer (14) and screw (15);
- tighten screw (15) to prescribed torque.
See: fig.3 and sec. C.4.

Fig.3 Fig.4

3. Measure preload P of the taper roller bearings with a dynamometer whose cord is wound on the wheel axle (1).
The real preload P is measured on D= 245 mm and it must be within following range:
P= 13-20 N
If P < (13-20) N, remove shims.

If P > (13-20) N, add shims, choose them from the range available, so as to observe prescribed preload.
See: fig.4, 5 and 6.

SHIMS RANGE
Thickness - mm 0.05 0.10 0.30 0.50

Quantity --- --- --- ---

Fig.5 Fig.6

I T L E-20 S E R V I C E M A N U A L
4. Assemble bolt stop (16).
5. Insert shaft (20) into the transmission.
See: fig.8.

Fig.7 Fig.8

6. Assemble trumpet (6) to gear box.

See: fig.9.

Fig.9

7. Assemble locking screw (7) to the requested torque.

See: sec. C.4.
8. Assemble greaser (5) and tighten to the prescribed torque.
See: sec. C.4.

I T L E-21 S E R V I C E M A N U A L
D.3 Upper Covers and Rockshaft

For models
T1 12+12 MR synchro shuttle 2WD mechanical control brake 75 & 90
Worldtrac
T2 12+12 MR synchro shuttle 4WD mechanical T57 drop box and mechanical control brake 75 & 90
Worldtrac

I T L E-22 S E R V I C E M A N U A L
D.3.1 Disassembly

1. Remove oil dipstick.

Hook rockshaft to a suitable lifting device.
Remove rockshaft case (9) after unscrewing screws (8).
Warning: approximate weight of rockshaft case assembly is 82 Kg.
See: fig.1.
2. Remove Shield
Warning: during disassembly procedure do not damage the shield.
Note: for rockshaft disassembly see tractor manual.
See: fig.2

Fig.1 Fig.2

3. Unscrew fastening screws (4).

4. Remove gear box lever assy (3).
5. Unscrew fastening screws (6).
6. Remove cover (7).
See: fig.3.

Fig.3

I T L E-23 S E R V I C E M A N U A L
D.3.2 Assembly
1. Clean all contact surfaces of cover (7) with care.
2. Apply prescribed sealing.
See: sec. C.4.
3. Assemble cover (7) to the gear box (1).
See: fig.3.
4.
Note: cover (7) correct assembly.
See: fig.4.

Fig.4

5. Assemble screws (6) to the prescribed torque.

See: sec. C.4.
6. Clean all contact surfaces of the lever assy (3) with care.
7. Apply prescribed sealing.
See: sec. C.4.
8. Assemble lever assy (3) on gear box (1).
Note: check the correct assembly of centring pins (2) and gear clutch lever.
9. Assemble screws (4) to the requested torque.
See: sec. C.4.

I T L E-24 S E R V I C E M A N U A L
10. Clean mating surfaces of rockshaft case and differential housing.
Apply a coat of Loctite® 574 to mating surfaces.
See: fig.5.
11. Install rockshaft case (9) using a suitable lifting device.
Screw up the eight bolts (8). Torque wrench setting: 120
Nm (90 lb.ft).
Warning: during the assembly procedure do not damage the shield.
See: fig.6.

Fig.1 Fig.2

I T L E-25 S E R V I C E M A N U A L
D.8.1 Disassembly
1. Remove PTO hood (27) from cover (24).
2. Remove screws (25) from cover (24).
3. Remove cover (24) from gear box.
4. Assemble cover (24) on the vice.
5. Remove seal ring (26) from cover (24).
Note: destructive operation for seal ring.
6. Remove bearing (23) from cover (24).
7. Extract PTO shaft (12).
8. Remove bearing (13) from shaft (12).
9. Remove pin (2).
10. Remove lever (9).
11. Remove pin (5).
12. Remove PTO control fork (7) after raising PTO control lever (1).
13. Remove ball (3) and spring (4) from fork (7).
14. Extract PTO control lever (1).
15. Remove seal ring (8).
Note: destructive operation for seal ring.
16. Remove PTO control pin (6).
17. Extract spacer (22) and washer (21).
18. Remove gear (20).
19. Remove PTO output shaft assy (A), made of PTO sleeve (19), PTO output shaft (18), gear (17) and washer (16).
20. Remove bearings (11) and (15) and supports (10) and (14) with prescribed tool.

I T L E-34 S E R V I C E M A N U A L
14. Assemble lever (1) to pin (6) and set pin (6) using a driver and a pad.
See: fig.9 and 10.

Fig.9 Fig.10

15. Assemble pin (5).

See: fig.11.
16. Assemble lever (9).
17. Assemble pin (2).
18. Assemble bearing (13) and inner ring of bearing
(11) onto PTO shaft (12) using a pad.
19. Insert PTO shaft (12) using a driver and a hammer.
See: fig.12.

Fig.11 Fig.12
20. Assemble bearing (23) onto the cover (24) using tool CA716211.
See: sec. E.1 (PTO power take off).
21. Turn the cover (24) and assemble a new seal ring (26) using tool
CA716107.
See: sec. E.1 (PTO power take off).
22. Grease the seal ring (26).
See: See: sec. C.

I T L E-37 S E R V I C E M A N U A L
D. 11.3 View details of Brake housing inside Parts

No. DESCRIPTION Qty. No. DESCRIPTION Qty.

1 PIN D.11 2 9 TIE ROD 4
2 PIN LOCKING SPRING 2 10 SPRING 6
3 TIE BAR 2 11 BALL 10
4 BRAKE MECHANISM 2 12 NUT 4
5 BRAKE DISC 10 13 BOLT M12X10 10
6 BRAKE COUNTER-PLATE 6 14 BRAKES FLANGE 2
7 FLANGE 2 15 PIN D.12X50 4
8 BOLT 4

I T L E-50 S E R V I C E M A N U A L
D 9.11 View Details of Brake Paddles Parts

No. Reference DESCRIPTION Qty. No. Reference DESCRIPTION Qty.

1 30014116AA RUBBER PAD 3 13 04030800012 MICD WASHER DIA 13*25 DIA 24*2.5 2
2 10010439AC BRAKE PEDAL ASSY (RIGHT) 1 14 0403040008 SPRING WASHER 1
3 10080077AA ADJUSTABLE TIE ROAD (FOR BRAKE PEDAL) 2 15 10080071AC BRAKE PEDAL SHAFT (ASSY.) 1
4 20002549AA CIRCLIP 25*1.2N.I:S3075 (PART-1) 2 16 04040708065 HEX BOLT M8*1.25*65 1
5 10006738AB WASHER (BRAKE PEDAL) 2 17 04030800010 M/CD WASHER DIA 10.5*DIA 21*2 8
6 10010523AB TENSION SPRING (BRAKE ASSY.) 2 18 04010102025 SPLIT PIN DIA 2*25 10
7 10004498AA FELT RING 3 19 10080079AA ADUSTABLE TIE ROAD FOR CLUTCH PEDAL 1
8 0431030036 SEALING WASHER DIA 30*36*2 3 20 10010437AE CLUTCH PEDAL ASSY. 1
9 04020200030 EXTERNAL CIRCLIP 3 21 10010438AD BRAKE PEDAL ASSY (LEFT) 1
10 10005187AA LINK PIN 8 22 10010524AB TENSION SPRING (CLUTCH ASSY) 1
11 10080078AB ADJUSTABLE TIE ROAD 2 23 10080072AC LUG ASSEMBLY (LEFT) 1
12 10080874AA LINK PIN 2 24 10080073AC LUG ASSEMBLY (RIGHT) 1

I T L E-51 S E R V I C E M A N U A L
D 9.12 View Details of Hand Brake Linkage Assembly

No. DESCRIPTION Qty. No. DESCRIPTION Qty.

1 HANDBRAKE LEVER RH 1 8 ELASTIC RINGH D.9 2
2 ELASTIC RINGH D.8 2 9 HANDBRAKE LEVER RH 1
3 BRAKE ROD 2 10 PIN 10X45 2
4 BRAKE ROD PIN D 10X28 2 11 HANDBRAKE LEVER LH 1
5 NUT 2 12 HANDBRAKE LEVER LH 1
6 BRAKE ROD PIN D.12.5X31 2 13 HANDBRAKE LEVER 2
7 HANDBRAKE NUT 2

I T L E-52 S E R V I C E M A N U A L
D.15.2 Assembly
1. Assemble forks (3) and (13).
See: fig.1.

FORK-1st/2nd SPEED GEAR SYNCHRONIZER

FORK-3rd/4th SPEED GEAR SYNCHRONIZER

4th SPEED GEAR

3rd SPEED GEAR

2nd SPEED GEAR

1st SPEED GEAR

I T L E-77 S E R V I C E M A N U A L
S E R V I C E M A N U A L
D.21.1 Disassembly
1. Before starting disassembly, use a dynanometer whose cord is wound on the pinion ring nut with diameter D= 80 mm to check
for bearing preload. If during assembly bearings are not changed, expected load will have a value 40-50% lower than
expected for new bearings.
See: fig.1 and 2.

Fig.1 Fig.2

2. Disconnect brake control.

3. Disassembly screws (1).
4. Remove brake (2).
5. Remove right flange (4).
6. Remove bearing cup (14) from right flange (4).
7. Repeat same operations from the other side (left side).
8. Remove bearings cones (14) and (7) from differential box (17).
9. Remove screws (12) and disassemble bevel gear crown (13).
10. Remove screws (9).
11. Remove carter (8).

I T L E-113 S E R V I C E M A N U A L
13. Assemble brake flange without brake assy. Tighten 5 screws (1).
See: fig.13.
14. Measure pinion-bevel gear crown backlash. The measured backlash value must be within the prescribed range: 0.10-
0.30 mm
See: fig.14.

Fig.13 Fig.14

15. Choose shims (11) and (10) among the range available.

Shims Range
Thickness - mm 0.05 0.10 0.30 0.50
Quantity — — — —

See: fig.15.
16. Adjust shims (11) and (10), remembering that:
[a] if the measured backlash is less than given tolerance range, increase shims (10) from the side opposite to bevel
gear crown and decrease shims (11) of the same measure;
[b] if the measured backlash is greater than given tolerance range, increase shims (11) from the side of bevel gear crown
and decrease shims (10) of the same measure.
See: fig.16.

Fig.15 Fig.16

I T L E-117 S E R V I C E M A N U A L
17. Once pinion-bevel gear crown backlash has been established, measure total preload T of bearings (pinion-bevel gear
crown system). Use a dynamometer whose cord is wound on the pinion ring nut with diameter D= 80 mm. The measured
value should be within following range:
- for T1 and T5 models T= (P+6.3) to (P+9.5) N
- for T2 models T= (P+7.0) to (P+11.0) N
- for T3 and T4 models T= (P+5.9) to (P+8.8) N
Warning: values for new bearings.
See: fig.17 and 18.
If bearings are not new, measured value should be starting value.
See: sec. D.21.1.1.

Fig.17 Fig.18

I T L E-118 S E R V I C E M A N U A L
18. If the measurement is not within the requested range, check the assembly of each component and operate on the shims (11)
and (10) remembering that:
[c] if the total preload is less than given range, increase shims (11) and (10) by same measure, keeping pinion-bevel
gear crown backlash value unchanged;
[d] if the total preload is greater than given range, decrease shims (11) and (10) by same measure, keeping pinion-bevel
gear crown backlash value unchanged.
See: fig.19.
19. Remove screws (1) and brake flange (2).
20. Fasten with screws differential support flange (4).
21. Assemble with tool 2 pins (3) using tool CA715815.
See: fig.20 and sec. E.1 (Gear box).

Fig.19 Fig.20

22. Remove screws.

See: fig.21.
23. Assemble preassembled brake (2).
See: fig.22.

Fig.21 Fig.22

I T L E-119 S E R V I C E M A N U A L
Fig.1 Fig.2

I T L E-122 S E R V I C E M A N U A L
Fig.3 Fig.4

I T L E-123 S E R V I C E M A N U A L
5. Insert false pinion (s1) with bearing cones (11) and (13) in the related housings then assemble nut ring (s2). Screw in without
exceeding nut ring (s2) till the end float is eliminated. Install false differential box (s3, s4).
See: fig.5.
6. Measure distance X (distance between the axis of the differential bearings and the base of pinion head) with a depth gauge.
See: fig.5.
7. In order to determine necessary thickness value (S) between pinion and bearing, subtract value (V), stamped on the pinion
head (V=requested distance), from the measured value (X).
S=X-V mm

Fig.5 Fig.6

I T L E-124 S E R V I C E M A N U A L
See: fig.6.
8. Choose shim (14) with thickness value (S) among range available and fit it on the shaft under the pinion head.

Shims Range
Thickness - mm 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5
Quantity — — — — — — — — — — —

9. Remove false differential box (s3, s4). Unscrew ring nut (s2) and remove false pinion (s1) and bearing cones (11) and (13).

10. Once you have chosen and inserted suitable shim (14) with chamfer against the gear, force bearing cone (13) into the
pinion shaft (15) using special tool CA716171. Assemble pinion assy to the transmission.
See: fig.7 and sec. E.1 (Gear box).
11. Assemble inner cup of the bearing (11) into the box (12).
12. Assemble following group (g): gear (10), ring nut (9), thrust washer (8), bearing needles (6) and (7), gear (5), spacer (4),
collar (3), central clutch (2) and thrust washer (1).
Note: right position for central clutch (2).
See: fig.9.
Note: grease thrust washers (8) and (1) so that they do not fall on the gear box.
See: fig.10 and 11.
13. Settle group (g) into the gear box (12) and insert pinion (15) into the box (12) and in the group (g).
See: fig.8 and 9.

Fig.7 Fig.8

I T L E-125 S E R V I C E M A N U A L
17. To measure preload (P) of the pinion taper roller bearings, use a dynamometer whose cord is wound on the ring nut (9).
The effectively preload (P) is measured on D= 80 mm. The measured value should be within following range:
P= 40 to 60 N
Warning: values valid for new bearings.
See: fig.15.
If bearings are not new, measured valve should be starting value.
See: sec. D.22.1.2.
18. Once requested preload value is achieved, caulk ring nut (9), using a hammer and a chisel from both sides.
See: fig.16.
Note: caulk as shown.
See: fig.17.

Fig.15 Fig.16

Fig.17

I T L E-128 S E R V I C E M A N U A L
 Fig.2 Fig.3

Fig.4 Fig.5 Fig.6

I T L E-131 S E R V I C E M A N U A L
F.1.0 Hydraulic Circuit of Power Lift

No. PART NAME Qty.

1 Hydraulic Pump 1
2 Inlet manifold Assembly 1
3 HYDRAULIC FILTER 1
4 Suction pipe From Strainer to hose 1
5 Strainer 1
6 Control Valve 1
7 Sec Pipe from pump to rear cover 1
8 Lift Housing 1
9 Gasket 1
10 DCV Lever 1
11 Directional Control Lever 1
12 Flexible pipe From DCV to QRC 2
13 DCV Outlet Pipes Support 1
14 Lift arms 2

I T L F-1 S E R V I C E M A N U A L
F.2.0 Hydraulic Control Valve Part Details

No. Models Reference Description Qty.

I T L F-2 S E R V I C E M A N U A L
F.3.0 Hydraulic Control Valve Part Details

No. Models Reference Description Qty.

I T L F-3 S E R V I C E M A N U A L
F.4.0 Control Lever Assy.

No. Models Reference Description Qty.

I T L F-4 S E R V I C E M A N U A L
 Backwards to Forward to
operate the B operate the A
port port

2
1

I T L F-10 S E R V I C E M A N U A L
 CIRCUIT DIAGRAM OF HYDRAULIC LIFTING DEVICE

I T L G-2 S E R V I C E M A N U A L
M 4.2

(A) NEUTRAL PHASE

I T L G-4 S E R V I C E M A N U A L
M 4.4

(B) DELIVERY PHASE

I T L G-6 S E R V I C E M A N U A L
M 4.6

(C) DISCHARGE PHASE

I T L G-8
M 5.2

NEGATIVE STROKE

I T L G-10 S E R V I C E M A N U A L
NEGATIVE STROKE
I T L G-16 S E R V I C E M A N U A L
I T L G-17 S E R V I C E M A N U A L
M 7.3

I T L G-20 S E R V I C E M A N U A L
F 2.0 VIEW DETAILS OF FRONT AXLE PARTS

S. NO DESCRIPTION Qty
1 OIL SEAL (40*58.2*10) 2
2 PIVOT PIN 1
3 THRUST WASHER 2
4 SPRING WASHER B-8 1
5 HEX SCREW M8X1.25X30 8-8 SA2JS 1
6 INTEGRAL FRONT AXLE BRACKET 1
(4 CYL. TYRE SIZE 7.50-16/16.9-28)
7 LOCK PIN MTG BRACKET 1
8 HEX SCREW M8X1.25X30 8-8 SA3NS 2
9 SPRING WASHER B-8 2

I T L H-2 S E R V I C E M A N U A L
DESCRIPTION SYMBOLS
WHEEL HUB GROUPS SUPPORTS GROUP DIFFERENTIAL GROUP

AXLE BEAM GROUP

J.7.4 Service Schedule
Specified maintenance intervals are for standard-duty use.
Severe operating conditions may require more short intervals.

Operation First Time Ordinary Maintenance

Axle oil change 150-200 hours Seasonally or every 1500 hours(1)
Clean magnetic oil plugs first oil change Every oil change
Check and adjust oil level 50-100 hours Monthly or every 300-400 hours(1)
Clean oil breather 150-200 hours(3) Monthly or every 300-400 hours(1)
Greasing (if required) 150-200(2) hours Weekly or every 150-200 hours(1) (2)
Lubrication works (if required) 150-200 hours(3) Seasonally or every 1500 hours(1)

this operation must be performed only by personnel authorized by the manufacturer

this operation must be performed only by trained personnel
(1)
which of both conditions comes first
(2)
50 hours for severe operating condition
(3)
at the season end if you have not reached the indicated work-hours

Lubricants Application Range

I T L J-9 S E R V I C E M A N U A L
J.8 Grease in Assembly
Technolube®
Apply on the indicated surfaces
POLYMER 400
AGIP®
Fill/Apply in excess
GR MU EP2

I T L J-10 S E R V I C E M A N U A L
D.1 Steering Cylinder Group

FIG. 1

I T L K-1 S E R V I C E M A N U A L
 FIG. 2

FIG. 3

FIG. 1

I T L K-2 S E R V I C E M A N U A L
 FIG. 2

FIG. 3

FIG. 4

I T L K-3 S E R V I C E M A N U A L
 FIG. 5

FIG. 6

FIG. 7

I T L K-4 S E R V I C E M A N U A L
REF.NO
T 1.0
T 2.0
T 3.0

I T L L S E R V I C E M A N U A L
 PROBLEMS POSSIBLE CAUSES
1 2 3 4 5 6 7 8 9 10 11
• Wheel vibration; front tyre resistance; halfshaft
• • • • •
breakage.
• Steering is difficult; vehicle goes straight while
• • • • •
turning.
• No differential action; jamming while steering. • • • • • • •
• Uneven wear of tyre. • • • • • • • •
• Friction noise. • • • • • • •
• Vibration during forward drive, intermittent
• • • • •
noise.

I T L L-1 S E R V I C E M A N U A L
T.2 TROUBLESHOOTING
This chapter is a descriptive and explanatory guide to common axle problems. This guide suggests the repair correct procedures to
be followed.

PROBLEM CAUSE ACTION

I T L L-2 S E R V I C E M A N U A L
PROBLEM CAUSE ACTION

I T L L-3 S E R V I C E M A N U A L
 Steering Cylinder Group (M3)
Cod. Operation Min.
C1 Steering cylinder replacement 60
C2 Steering rod replacement (x 1) 30
C3 Steering rod ball joint replacement (x 1) 15
C4 Steering rod tie rod replacement (x 1) 30
C5 Ball joint protection replacement (x 1) 15
C6 Tie rod protection replacement (x 1) 15
C8 Steering cylinder overhauling 120

Epicyclic Reduction Gear Group (M1)

Cod. Operation Min.
A1 Planetary carrier replacement 20
A2 Planetary carrier overhauling (3 gears) 35
Planetary carrier overhauling (4 gears) 45

I T L M-1 S E R V I C E M A N U A L
 Differential Support Group (M2)
Cod. Operation Min.
B1 Differential replacement 150
B4 Differential housing bearings replacement 180

I T L M-2 S E R V I C E M A N U A L
 D1 Axle beam replacement 180
D2 Spherical bearing replacement (x 1) 45
D3 Double U-joint seal replacement 45
D4 Double U-joint bush replacement 60

I T L M-3 S E R V I C E M A N U A L
ST.1.0 CIRCUIT DIAGRAM OF HYDROSTATIC STEERING

S. NO PART NAME Qty S. NO PART NAME Qty

1 POWER STEERING PUMP 1 11 HIGH PRESSURE L BOW 1
2 SUCTION PIPE L BOW 1 12 O-RING FOR ADOPTER 1
3 SUCTION PIPE 1 13 HOUSE LH& RH
4 CONNECTING HOUSE 2 14 PIPE FROM STEERING UNIT TO HOUSE
5 SUCTION PIPE 1 15 CLAMP
6 OIL TANK 1 16 CYLINDER FLEXIBLE PIPE
7 OIL TANK RETURN PIPE 1 17 CLAMP PLATE
8 STEERING COLUMN 1 18 ADOPTER
9 CCC STEERING UNIT 1 19 BENJO BOLTS
10 HIGH PRESSURE PIPE 1

I T L N-1 S E R V I C E M A N U A L
ST.2.0 Exploded View OSPJ100 ON

DESCRIPTION
1 Dust seal ring 17 Gear wheel set
2 Housing spool/sleeve 18 O-ring
3 Ball dia 8.5 mm 19 End cover
5 O-ring/roto glyd 20 Washer
7 Bearing assembly 22 Screw with pin
10 Ring 23 Screw
11 Cross pin 24 Name plate
12 Set of springs 30 Pressure relief valve
13 Cardon shaft 31 Spring for relief valve
15 O-ring 37 Check Valve
16 Distributor plate

I T L N-2 S E R V I C E M A N U A L
ST 3. 0 DETAIL VIEW OF HYDROSTATIC STEERING UNIT
 FIG. 1

FIG. 2

FIG. 3

FIG. 4

I T L N-4 S E R V I C E M A N U A L
ST.6.0 MAX. TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS

T : Tank

L : Left port

P : Pump

R : Right port

Max. Tightening Torque N-m [lbf.in]

Screwed
connection

I T L N-17 S E R V I C E M A N U A L
ST.9.0 HYDROSTATIC STEERING UNIT
ST 9.1 DISASSEMBLY OF STEERING UNIT
Cleanliness is extremely important when repairing a steering control
unit. Work in a clean area. Before disconnecting lines, clean the port
area of unit thoroughly. Use a wire brush to remove foreign material and
debris from the external joints of the unit.
Meter (Gerotor) End :
1. Clamp unit in vice, Gerotor end up. Clamp lightly on edges of port
face sides (refer fig. 1). Use protective material on vice jaws. Housing
distortion can result if jaws are over tightened.
FIG. 1
Note : Here figures are not shown in vice, but it is recommended that you
keep the unit in a vice during disassembly. Follow the clamping
procedure.

2. Remove M10 cap screws. Refer fig. 2.

3. Remove end cap. Refer fig. 2.
4. Remove seal. Refer fig. 2.

FIG. 2

5. Remove Gerotor set. Refer fig. 3.

6. Remove seal. Refer fig. 3.
7. Remove drive spacer. Refer fig. 3. FIG. 26

FIG. 3

I T L N-20 S E R V I C E M A N U A L
 FIG. 4

FIG. 5

FIG. 6

FIG. 7

I T L N-21 S E R V I C E M A N U A L
 FIG. 8

I T L N-22 S E R V I C E M A N U A L
 FIG. 9

FIG. 10

FIG. 11

FIG. 12

I T L N-23 S E R V I C E M A N U A L
 FIG. 13

FIG. 14

FIG. 15

FIG. 16

I T L N-24 S E R V I C E M A N U A L
 FIG. 17

I T L N-25 S E R V I C E M A N U A L
I T L O-2 S E R V I C E M A N U A L
I T L O-3 S E R V I C E M A N U A L
Instruments and controls

Fig.3-9 Dashboard.

ENLARGED VIEWS:-
1

Fig. 3-10a - Mobile charging socket

Lights off.
2
Parking Light.

Dipped beams.Pushed down: driving beams.

Fig.3 10b Light, turn indicator
High Beam. and horn
Pressed horn.

I T L O-4 S E R V I C E M A N U A L
 A

I T L O-5 S E R V I C E M A N U A L
I T L O-6 S E R V I C E M A N U A L
 E 3.0 ELECTRICAL WIRING CIRCUIT DIAGRAM

I
T
L
FRONT AREA

O-7
TAIL AREA DASHBOARD AREA FRONT AREA

S E R V I C E M A N U A L
 P

O 1.0 RECOMMENDED GRADE OF LUBRIANTS & GREASES P-1

O 2.0 GREASING POINTS ON TRACTOR P-2
O 3.0 USES OF SPECIAL SERVICE TOOLS P-3
O 4.0 SPECIAL TOOLS FOR TRANSMISSION P-11
O 5.0 FINAL DRIVE P-16
O 6.0 4WD MECHANICAL DROP BOX P-17
O 7.0 PTO POWER TAKE OFF P-18
O 8.0 CLUTCH HOUSING - SYNCRO SHUTTLE P-19
O 9.0 SPECIAL TOOLS P-20
O 10.0 HYDROSTATIC STEERING UNIT P-22

I T L P S E R V I C E M A N U A L
O 1.0 RECOMMENDED GRADE OF LUBRICANTS & GREASES

O 1.1 HYDROSTATIC STEERING OIL

I T L P-1 S E R V I C E M A N U A L
 For removal of Gear from
Front Pump.

For setting the Spool Valve with

The help of Coupler.

For removal of bearing from

Flywheel

For Installing the Rear Oil

Seal in the Retainer

For Installing
of the Timing Case
Oil Seal in the Front
TimingCase Cover.

S E R V I C E M A N U A L
 For removal of Cylinder
Sleeve from Crank Case.

For removal of Cy. Sleeve

form Crank Case.

For Centralizing the

Single Clutch Plate Assy.

For centralizing the Double

Clutch Plate Assy.

For tightening
and loosening
the Lay Shaft
Nuts of Single
Clutch Gear Box.

For tightening
and loosening the
Lay Shaft Nuts
of Double Clutch
Gear Box.

S E R V I C E M A N U A L
 Remove the Steering Wheel
from Steering Assy.

For removal of Thrust Pad

from king Pin Stub Axle.

For give the

support to
Rear Axle at
the time of
the repair
the Rear
Axle and
Final Drive.

For spliting Gear Box

from Differential Housing.

For Spliting Engine from

Clutch Housing.

S E R V I C E M A N U A L
 For give the
support to Rear
Axle at the
time of the
repair the Rear
Axle and Final
Drive.

Remove the Steering Wheel

from Steering Assembly.

S E R V I C E M A N U A L
 For pulling of Timing Gears

For pulling of Fuel Injector

From Engine.

S E R V I C E M A N U A L
CA716145 1
CA715206

CA716144

I T L P-11 S E R V I C E M A N U A L
 CA716145

CA715848 CA715821 CA715830

CA715805
2
CA716145 3

CA715583

CA715800
CA715810

CA715815

I T L P-13 S E R V I C E M A N U A L
 4

CA715807 CA715808 CA715831 CA715821

CA716145
 CA716145

I
T
L
CA715798

CA715801
CA715809

CA715843
CA715843

P-15
CA715798

CA715093

S E R V I C E M A N U A L
5
CA716160 1
CA715836

CA715844
CA715827

CA715826

I T L P-16 S E R V I C E M A N U A L
O 7.0 PTO power take off

For models
T1 12+12 MR synchro shuttle 2WD mechanical control brake 75 & 90
WorldTrac
T2 12+12 MR synchro shuttle 4WD mechanical T57 drop box and mechanical control brake 75 & 90
WorldTrac

CA716210 1

CA715809
CA716107

CA716108

CA716211
CA716111

CA716110

I T L P-18 S E R V I C E M A N U A L
 12+12

CA716138 CA716138
CA715842

CA716202

CA715314 CA715314

CA716154
2
O 9.0 Special Tools
The special drifts/pad used to assemble the seals, bearings and bushes should always be used with the interchangeable
handle CA119033; its use is recommended together with a suitable safety handle in order to protect the hands.

CA119033 Handle CA119068 Driver CA119097 Handle

CA119220 Driver CA715026 Driver CA715080 Wrench

CA715082 Driver CA715086 Driver CA715107 False pinion

CA715299 Driver CA715451 Driver CA715509 Driver

I T L P-21 S E R V I C E M A N U A L
CA715643 Driver CA715644 Driver CA715649 Driver

CA715651 Handle CA715652 Driver CA715653 False pinion

CA715654 False differential box CA715656 Driver CA715657 Tool for prepload measur.

CA716288 Driver CA716301 Driver

I T L P-22 S E R V I C E M A N U A L
I T L P-23 S E R V I C E M A N U A L
 FIG. 5

FIG. 6

FIG. 7

I T L P-24 S E R V I C E M A N U A L