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CHAPTER 3

REPAIR MANUAL

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3-0- SUMMARY
3-0- SUMMARY ................................................................................................................................... 2
3-1- STANDARD OVERHAUL PROCEDURE..................................................................................... 3
3-1-1- GENERAL ................................................................................................................................ 3
3-1-2- DISASSEMBLY........................................................................................................................ 4
3-1-3- ASSEMBLY.............................................................................................................................. 6
3-2- MAINTENANCE OPERATIONS .................................................................................................. 9
3-3- TESTS ........................................................................................................................................ 10
3-3-1- GENERAL .............................................................................................................................. 10
3-4- SPECIAL TOOLS ....................................................................................................................... 11
3-4-1- CHECK HYDRAULIC PRESSURE........................................................................................ 11
3-4-2- METRIC EQUIPED TOOLBOX.............................................................................................. 12
3-4-3- TESTING AND INFLATING TOOL FOR ACCUMULATOR- REF / S/N : 9933267............... 12
3-4-3.1. TECHNICAL CHARACTERISTICS :............................................................................. 12
3-4-4- OVERTORQUE TEST TOOLS - REF / S/N : 9933113 ........................................................ 13
3-4-5- OVERTORQUE SPINDLE EXTRACTION TOOL - REF / S/N : 1046386 ............................ 13
3-4-6- CONNEXIONS, SOFTWARE AND PROCEDURE FOR COMPUTER / OVERTORQUE LINK
14

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3-1- STANDARD OVERHAUL PROCEDURE

3-1-1- GENERAL
The instructions provided in this section present general guideline for disassembly and assembly of
components.
The particular repair or replacement procedures should dictate the degree of disassembly required.
If complete disassembly of components is required, sketches or photographs of the disassembly
sequence should be taken as an aid to orientation of component parts during reassembly.
The instructions that follow in come cases provide procedures for complete disassembly and reassembly
of some of the unit components.
In many cases complete disassembly is neither desirable nor required to affect the required repairs.
The procedures provided should only be followed as far as the particular repair involved dictates.
Thorough troubleshooting procedures should be performed prior to component removal and disassembly.

During disassembly/assembly of a repairable component, perform a visual inspection of parts.

Shafts and rods shall be checked for straightness, burrs, nicks, and galled spots.
All threaded items shall be checked for burrs and crossed threads.
Preformed packing and hoses shall be checked for deterioration, rough spots, and cuts.
Electrical leads shall be checked for cut or frayed insulation.
Electrical connections shall be checked for tightness and corrosion.
Grease fittings shall be checked for evidence of stoppage.

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3-1-2- DISASSEMBLY
1 - General
To avoid contamination of parts during disassembly, thoroughly clean the outside surface of the
component before proceeding with disassembly.
Do not disassemble any staked, swaged, soldered, brazed, or press-fitted assemblies or parts unless
replacement is necessary or disassembly is indicated in the procedure.

WARNING: TO PREVENT POSSIBLE INJURY, MAKE CERTAIN THAT GREASE DEPOSITS

ARE REMOVED FROM HEAVY COMPONENTS BEFORE ATTEMPTING REMOVAL.

WARNING : BE INFORMED ABOUT POSITION OF GRAVITY CENTERS OF HEAVY PARTS TO

AVOID KNOCKING OVER

2 - General Cleaning Instructions

a – Remove all heavy accumulations of grease and dirt from the exterior of the unit and subassemblies.

b - Dry the clean parts.

c - If parts will not be used immediately after cleaning, dip them in a suitable rust preventive compound.

3 - Disassembly Procedure
a - To avoid fluid leaks, never use tools or techniques which will nick or score surfaces while cleaning or
disassembling the unit.

Do not scrape and gouge a surface while cleaning off an old gasket. This will scratch the sealing surfaces.
Use a wood or plastic scraper to remove gaskets.

Do not score the inside of seal housing by pressing carelessly while extracting the old seal.

Avoid bending or otherwise distorting parts during disassembly.

Find out what is wrong if bending is required to remove a part.

CAUTION: TO AVOID CONTAMINATION OF INTERNAL COMPONENT PARTS, KEEP THE

WORK AREA AS CLEAN AS POSSIBLE.

NOTE: All gaskets, packing, and seals removed during component disassembly should be
discarded and replaced with new parts.
These parts are usually damaged or destroyed during the disassembly process.
All self-locking screws lock washers, cotter pins, lock nuts, and similar fasteners should be replaced
during assembly.

b - Check specifications and tolerances before removal, and record all measurements taken.

3 c - Match mark drive shaft flanges, universal joints, and all gears during disassembly.

d - Tag all wires and electrical connections.

e - During disassembly, place parts on a clean work bench in the exact order of removal

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NOTE: Before disassembly of any component, study the illustrated parts breakdown covering the
assembly.
Pay close attention to the relationship of internal parts Being familiar with the construction will accelerate
disassembly and aid proper reassembly

NOTE: Pay special attention to thrust washers and spacers.

Note all differences and the direction of grooves, shoulders, or chamfered surfaces face.

f - Exercise care when removing snap rings.

They may retain spring-loaded parts.

CAUTION: ALWAYS INSTALL A SPRING COMPRESSOR OR SIMILAR TOOL BEFORE

REMOVING A SPRING-LOADED ASSEMBLY.
RELEASE THE TOOL SLOWLY TO PREVENT DISTORTING SPRINGS

g - When disassembling large components, proceed in a series of small steps with each sub-assembly
keeping all parts in the exact order of removal.

NOTE: To assist reassembly, attach Identification tags to the ends of electrical, hydraulic, and
coolant lines as they are removed or disconnected.
Tagging aids differentiating parts of similar configuration to ensure correct assembly.

CAUTION: DO NOT ALLOW COMPRESSED AIR TO SPIN GEARS IN PLANETARY SETS SINCE
THIS ACTION WILL DAMAGE THE BEARINGS.

h -When all parts are clean and dry, inspect them for serviceable condition.
Replace all defective parts.
Remove any burrs with crocus cloth

NOTE: Ensure that suitable precautions are taken to prevent moisture and air from entering the
refrigeration system.

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3-1-3- ASSEMBLY
1 - General

With all parts arranged on a clean workbench in the exact order of removal, position new seals, discs,
packing, gaskets, or o-rings where discarded parts once were located.
If seals or discs must be lubricated, soak them as required in fresh hydraulic fluid or oil as specified for
use in the component.
If necessary, remove the protective grease coating new parts.

CAUTION: MAKE CERTAIN THAT ALL SEALS ARE COMPATIBLE WITH THE FLUID USED.

NOTE: COAT METAL PARTS WITH THE SAME FLUID TO AID IN ASSEMBLY AND TO PROVIDE
THE NECESSARY PRE-LUBRICATION FOR THE COMPONENT.

NOTE: LUBRICATE BEARINGS WITH THE SAME TYPE OF OIL OR GREASE. COAT BOTH
SIDES OF GASKETS WITH SEALANT. APPLY SEALANT TO MALE THREADS ONLY

2 - General Inspection Requirement

Visually inspect all parts for cracks, excessive wear, thread damage, and any other defect that would
render the part unserviceable.
The serviceability of a part can be determined by the clearance between the mating parts and the rate of
wear on each of the parts.
The following terms are used to identify conditions for which parts shall be examined:

a - Crack: A partial separation of material, usually caused by vibration, overloading, internal stresses, a
defective assembly, or fatigue.

b - Dent: Small shallow depressions in a surface having rounded bottoms and edges, usually caused by
striking the part with a rounded object.

c - Burnishing: Polished or shiny marks caused by movement of one part against another with no
measurable wear.

d -Chipping: Breaking away of pieces or material, generally caused by excessive stress from careless
handling.
Hard-coated parts are prone to surface chipping, particularly at the corners.

e - Corrosion: Surface damage caused by chemical action.

f - Distortion: Deformation of a surface or part from the original configuration in a manner that impairs part
function or service.

g - Excessive wear: Any deformation or deterioration that makes the part unserviceable.
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h - Galling: A condition in which transfer of metal occurs between two parts made of like material (usually
steel), usually occurring when mated parts have limited relative motion under high loads.

i - Gouge: A furrowed depression in which displacement of metal has occurred, usually caused by
relatively large particles entrapped between close-fitting parts.

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j - Groove: A recess or channel with rounded or smooth edges, generally caused by continued abnormal
wear or faulty alignment of parts.

k - Nick: A sharp-sided gouge or depression, generally having a v-shaped bottom, caused by a sharp
edge, usually due to careless handling of parts or tools.

l - Obvious wear: A wear condition obvious to the eye without magnification.

Worn hard-coated surfaces are evidenced by visible parent metal in the worn area.

m - Scoring: Scratches usually caused by foreign particles entrapped between two moving parts.

n - Scratch: A shallow, thin line or mark, varying in width or depth, caused by the presence of foreign
particles during operation or by careless handling.

o - Spalling: Flaking or surface metal due to metal fatigue.

p - Frettage: Corrosion set up by small relative movement of parts with no lubrication.

q - Brinelling: Surface indentations in a raceway caused by rollers either under impact loading or vibration
while the bearing is not rotating.

r - Etching: Bearing surfaces that appear grey or greyish black in colour due to corrosion.

3 - Dimensional Limits

Dimensional limits for the amount of wear or increases in clearance that can be tolerated in used parts are
determined in the inspection or assembly procedures for the serviced item.

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4 - Assembly Procedure

a - Begin the assy by building up the sub-assemblies, first. Check for smooth operation of gears after
assembly.

b - Use proper tools to reassemble a component. Install seals with a seal driver, not a hammer, to avoid
dented or distorted surfaces.

c - Complete each sub-assembly in sequence.

d - Take care to avoid twisting rubber sealing rings or packing. A twisted ring will not perform without
sticking or leaking.

e - Measure internal clearances.

Shims may be required to bring a dimension within specifications.

f - When all sub-assemblies have been assembled, arrange them according to installation sequence.

g - Whenever possible, use gravity to aid in assembling a component. Position the unit to allow stacking of
sub-assemblies. However, always secure work to a support or mount when available to prevent possible
damage to the unit from falling.

h - As a general rule, finger tighten all fasteners, then tighten in a criss-cross pattern to final torque after
component assembly. Torque all fasteners exactly to the specification provided by the manufacturer.

CAUTION: USUALLY, THERE IS MORE RISK OF OVERTIGHTENING FASTENERS, THAN OF

NOT TIGHTENING THEM ENOUGH. ALWAYS USE THE CORRECT TORQUE WRENCH FOR THE
JOB, CALIBRATED IN EITHER INCH POUNDS OR FOOT POUNDS OF TURNING FORCE AS
REQUIRED.

i - When component assembly is complete, prepare the unit for component installation.

j - Clean the mount or installation area to prevent contamination from dirt or foreign particles.

k - Flush debris out of all lines and clear fluid reservoirs or coolers.

CAUTION: THE PRIMARY CAUSE OF ALL HYDRAULIC COMPONENT FAILURES IS

CONTAMINATED FLUID. A FEW MINUTES TAKEN TO FLUSH THE SYSTEM MAY PREVENT
IMMEDIATE RECURRENCE OF PROBLEMS.

l - Align all location marks made during disassembly.

m - Install the component using new cotter pins, retaining rings, and lock washers.
Make certain that alt fasteners are installed on the proper side of levers and rods.

n - Match and connect electrical wires tagged during disassembly.

If used, make certain that wiring harnesses are installed in their mounting clips.
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o - Adjust linkage to specifications, connect all hydraulic or vacuum lines and fittings, and fin the
component if required, with the correct type and viscosity lubricant recommended by the manufacturer.

p - Perform an operational test of the overhauled unit and inspect for leaks.
Recheck fluid level after operating temperature is reached.

q - Make final adjustments to linkage and set relief pressures as specified.

Refer to the manufacturers instructions for adjustment and testing of hydraulic system pressure settings.

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3-2- MAINTENANCE OPERATIONS

SEE MANUFACTURERS DOCUMENTATIONS

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3-3- TESTS
Prior to delivering the tractor and further to servicing procedure, the following tests are performed:

- Have the tractor driven in forward or reverse direction, in a straight line or in a curve and check for any
abnormal noise,

- Measure the rotation radius on left and on right. Difference must be <= 0.4 mm between them.

- Check the footbrake performances,

- Check the engine braking performance by

. Releasing the safety pedal,
. Depressing the accelerator pedal,
. Switch the main safety key on (optional),

- Evaluate maximum speed of the tractor: Mark the ground with two lines, 100 meters from each other.
When running on the first mark, check the tractor is at its maximum speed. Control the time to reach the
second mark and check with maximal theoretical speed

- Test the lamp on dashboard (see corresponding chapter)

- Test the cradle working (see corresponding chapter)

3-3-1- GENERAL
All testing of the engine shall be performed as specified in the engine manufacturer's service manuals.
Test periods shall be as specified by the engine manufacturer or in accordance with Airline's
requirements, whichever apply.

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3-4- SPECIAL TOOLS
In order to assist you with repair, maintenance and inspection, we recommend the following list of special
equipment:

- A multi-tester
- A torque wrench and sockets

3-4-1- CHECK HYDRAULIC PRESSURE

- Manometer 0-250 bars - Manometer 0-400 bars - Manometer 0-25 bars
REF : 68 33 003 REF : 68 00 155 REF : 48 33 042

- Connection pressure hose

REF : 63 33 545

Fig 1 : Manometer
Don't forget: Adapter: REF: 62 34 064

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3-4-2- METRIC EQUIPED TOOLBOX

Fig 2 : Toolbox
REF / S/N: 8333358

Cutting pliers
Plier with nozzle
Universal pliers
Combination wrench
Adjustable pliers
Hammer
Set of wrench spanner
Meter 3M
Adjustable wrench
Burin
Saw support
Saw blade
Cutter
Blade of cutter
Plier

3-4-3- TESTING AND INFLATING TOOL FOR

ACCUMULATOR- REF / S/N : 9933267

Fig 3 : Accumulator tools

3 3-4-3.1. TECHNICAL CHARACTERISTICS :

Testing tool is required for all checking operations with nitrogen charge or inflating operation on
accumulator. Manufactured on carbon steel, it can be use under pressure to 350 bars.
Furnished in a case and including a manometer and a 2.50m long capillary hose to connect to a nitrogen
tank.

CAUTION : TESTING-INFLATING TOOL 9933267 CAN ONLY BE USED ON HTR / FOX

ACCUMULATORS

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3-4-4- OVERTORQUE TEST TOOLS -
REF / S/N : 9933113

3-4-5- OVERTORQUE SPINDLE EXTRACTION TOOL -

REF / S/N : 1046386

Refer to instruction TUIT99074 (located on CH5) before using this tool.

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3-4-6- CONNEXIONS, SOFTWARE AND PROCEDURE FOR
COMPUTER / OVERTORQUE LINK
WIRING:
Link to COMPUTER / OVERTORQUE:
CEC6xx version: 7050052.
INDxxxx version: 7433190-301.

SOFTWARE DOWNLOAD LINK:

These softwares are free to download on TLD website. Access to TLD web site require to be registered
on, and authorization from TLD-EUROPE.

CEC6xx Software: http://www.tld-gse.com/en/private/uploads/manuals_diagrams/1134056984-

LogicielCEC60X1.zip

INDxxxx software: Not applicable.

SOFTWARE USING PROCEDURES:

CEC6xxx: procedure is included into Overtorque chapter of workshop handbook.

INDxxxx: procedure is included into Overtorque chapter of workshop handbook.

CAUTION: ANY PARAMETERS AND PROGRAMS MODIFICATION, ADDITION OR

TRANSFORMATION, WITHOUT AGREEMENT AND REFER TO TLD, IS OF YOUR RESPONSIBILITY.

CAUTION: USING THESE SOFTWARES REQUIER APPROPRIATE TRAINING.

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