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JX60 -- JX70 -- JX80 -- JX90 -- JX95
MODEL TRACTORS
SERVICE MANUAL
SECTIONS
GENERAL 00.....................................................
ENGINE 10.......................................................
CLUTCH 18.......................................................
GEARBOX 21.....................................................
TRANSMISSION OF MOTION 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT MECHANICAL TRANSMISSION 25. . . . . . . . . . . . . . . . . . . . . . . . . .
REAR MECHANICAL TRANSMISSION 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWERTAKE-OFF 31.............................................
BRAKES 33.......................................................
HYDRAULICSYSTEMS 35.........................................
STEERING 41.....................................................
AXLEANDWHEELS 44............................................
AUXILIARY EQUIPMENT 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB 90...........................................................
S E R V I C E
Repair Manual -- JX Series Tractors
CONTENTS
GENERAL SECTION 00
General Instructions and Health and Safety Chapter 1
Section Description Page
00 000 Generalinstructions 1............................................................
Notesforspareparts 2...........................................................
Notesforequipment 2............................................................
Safetyrules 3...................................................................
Consumables 6..................................................................
ENGINE SECTION 10
Engine System Chapter 1
Section Description Page
10 000 Generalspecification 2...........................................................
Injectionpumpcalibrationdata 5...................................................
Generalspecifications 16........................................................
Tighteningtorques 24...........................................................
Tools 25.......................................................................
Cross--sectionalviews 28........................................................
Lubricationandcoolingsystemdiagrams 32........................................
Faultdiagnosis 35..............................................................
10 001 10 Engine Removal--Installation 39...................................................
10 001 54 Engine Bench overhaul 53.......................................................
Checks,measurementsandrepairs 78............................................
10 406 10 Radiator Removal--Installation 102................................................
10 102 70 Crankshaft front oil seal removal installation 106....................................
10 402 10 Coolant pump removal installation 112.............................................
10 402 30 Coolingsystemthermostat 115...................................................
10 206 14 Bosch injection pump removal installation 118......................................
Bosch injection pump timing 121..................................................
Bosch injection pump air bleeding 123.............................................
10 218 30 Injectors removal installation 124..................................................
10 106 12 Valveclearanceadjustment 126..................................................
10 402 28 Coolantpumpoverhaul 129......................................................
10 001 30 Compressiontest 130...........................................................
CLUTCH SECTION 18
Clutches Chapter 1
Section Description Page
18 000 Generalspecifications 1..........................................................
Tighteningtorques 2.............................................................
Tools 3.........................................................................
Cross--sectionalviews 4..........................................................
ClutchTroubleshooting 5.........................................................
18 110 10 Removal--Installation 6..........................................................
Overhaul 14....................................................................
Minimum permissible dimensions after refacing 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 19................................................................
18 100 40 Adjustment of the main and PTO clutch control linkage 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX SECTION 21
Mechanical Transmission (12x4) Chapter 1
Section Description Page
21 000 Maindata 1.....................................................................
Tighteningtorques 2.............................................................
Tools 3.........................................................................
Sectionviews 3&5...............................................................
Descriptionandoperation 8.......................................................
Faultdiagnosis 8................................................................
21 110 Removal--Refitting seesect27..................................................
Reverser (12x12) Chapter 2
Section Description Page
21 000 Maindata 1.....................................................................
Tighteningtorques 2.............................................................
Tools 3.........................................................................
Sectionviews 3..................................................................
Descriptionandoperation 5.......................................................
Faultdiagnosis 5................................................................
21 110 Removal--Refitting 6.............................................................
Reverser and Creeper (20x12) Chapter 3
Section Description Page
21 000 Maindata 1.....................................................................
Tighteningtorques 2.............................................................
Tools 3.........................................................................
Sectionviews 4..................................................................
Descriptionandoperation 6.......................................................
Faultdiagnosis 6................................................................
21 110 Removal--Refitting 7.............................................................
DRIVE LINES SECTION 23
Drive Lines Chapter 1
Section Description Page
23 000 Mainspecification 1..............................................................
TorquesettingsandTools 2.......................................................
Cross--Sectionalviews 3..........................................................
23 101 26 Transmission shafts and guard (Disassembly -- Assembly) 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
23 101 40 Drive gear housing (Removal -- Installation) 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 101 42 Drive gear housing removed (Disassembly -- Assembly) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE MECHANICAL TRANSMISSION SECTION 25
Front Axle Mechanical Transmission Chapter 1
Section Description Page
25 000 Maindata 1.....................................................................
Tighteningtorques 4.............................................................
Tools 6.........................................................................
Cross--sectionalviews 7..........................................................
Descriptionandoperation 9.......................................................
25 100 30 Complete front axle. Removal -- Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 100 38 Frontaxle.Removal--Installation 14..............................................
25 108 46--47 Steering knuckle bearing pins. Replacement 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stubaxleadjustment 25.........................................................
Wheelhubbearingadjustment 27.................................................
Beveldriveadjustment 29........................................................
25 102 24 Frontaxledifferential.Overhaul 36................................................
25 100 27 Front axle differential with LIM--SLIP. Overhaul 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front axle differential with NO SPIN. Overhaul 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 511 80 Leadingdrivewheelstoe--incheck 42.............................................
REAR AXLE AND TRANSMISSION SECTION 27
Rear Axle And Transmission Chapter 1
Section Description Page
27 000 Maindata 1.....................................................................
Tighteningtorques 3.............................................................
Specialtools 5..................................................................
Cross--sectionalviews 7..........................................................
Description and operation and troubleshooting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21.118.10 -- 12 Transmission--gearbox casing Removal--Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21.118.85 Transmission--gearbox casing Disassembly--Overhaul 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox driven shaft end float adjustment 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential lock engagement sleeve adjustment 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining the bevel pinion positioning adjustment ring 37. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the taper roller bearings for the bevel pinion shaft 39. . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the bearings and checking the backlash 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential pinion and side gear backlash adjustment 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TAKE--OFF SECTION 31
Mechanical Power Take -- Off Chapter 1
Section Description Page
31 000 Mainspecification 1..............................................................
Tools 3.........................................................................
Torquesettings 4................................................................
Sectionaldrawings 5.............................................................
Descriptionandoperation 9.......................................................
Troubleshooting 10..............................................................
Removal --Refitting 11...........................................................
31 101 Benchoverhaul 14..............................................................
BRAKING SYSTEM SECTION 33
Braking System Chapter 1
Section Description Page
33 000 Maindata 1.....................................................................
Tighteningtorques 2.............................................................
Cross--sectionalviews 2..........................................................
Description&Operation 9.........................................................
Tools--Troubleshooting 10.......................................................
33.206 Front brake assembly mod. JX60 and JX70 removal and refitting --
overhaulingonthebench 11......................................................
33.202.60 Servicebrakeremovalandrefitting 14.............................................
33.202.50 Removal--Refittingoffrontbrakepumps 19.........................................
33.202.40 Bleeding air from the front braking system 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33.120.08 Adjustingservicebrakepedalstravel 24...........................................
33.110.08 Parkingbraketraveladjustment 24................................................
HYDRAULIC SYSTEM SECTION 35
Rear Mechanical Hydraulic Lift Chapter 1
Section Description Page
35 000 Mainspecification 1.............................................................
Tighteningtorques 3............................................................
Tools 6........................................................................
Cross--sectionalviews 7.........................................................
Description&Operation 9........................................................
Hydrauliccircuit 9...............................................................
Descriptionandoperationofliftphases 10.........................................
Faultdiagnosis 13..............................................................
35 110.30 Hydrauliclift--disassemblyreassembly 15.........................................
35.110.40--42--46 Hydrauliclift--benchoverhaul 21.................................................
Adjustingthelift 26..............................................................
35.110.08 Linkageadjustment 32..........................................................
35.110.30 Pressure relief valve -- disassembly reassembly 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35.110.32 Pressurereliefvalve--setting 34..................................................
35.110.14 Lift control valve -- disassembly assembly and overhaul on bench 36. . . . . . . . . . . . . . . . . .
35.0101.10 Liftpump 41....................................................................
Open Centre System Auxiliary Control Valves Chapter 2
Section Description Page
35 000 Maindata--Tools 1..............................................................
Auxiliarycontrolvalves--sectionalviews 2..........................................
Descriptionandoperation 3.......................................................
Faultdiagnosis seechapter1.....................................................
35 204 46 Auxiliary control valves -- Assembly--Disassembly 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spoolbindingtest 15............................................................
Spoolleakagetest 16...........................................................
Adjustment of the automatic detent release pressure 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailer Brake Auxiliary Control Valve Chapter 3
Section Description Page
35 000 Sectionviews 1..................................................................
Descriptionandoperation 1.......................................................
Hydraulicdiagram 2..............................................................
Descriptionandoperationofvalvephases 3.........................................
Trailer brake auxiliary control valve linkage adjustment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING SECTION 41
Steering Chapter 1
Section Description Page
41 000 Principaldata 1..................................................................
Tighteningtorques 3.............................................................
Sectionviews 4..................................................................
Hydraulicdiagram 6..............................................................
Operation 7.....................................................................
Faultdiagnosis 9................................................................
Tools 10.......................................................................
41 204 30 Hydrostatic steering control valve -- Removal--Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
41 204 34 Hydrostatic steering control valve -- Disassembly--Assembly 14. . . . . . . . . . . . . . . . . . . . . . .
41 204 38 Hydrostatic steering control valve -- Bench testing 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic steering oil pump -- Disassembly--Assembly 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
41 216 20 Steering cylinder (two--wheel drive axle) -- Removal--Refitting 32. . . . . . . . . . . . . . . . . . . . . .
Steering cylinder (four wheel drive axle) -- Removal--Refitting 33. . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE AND WHEELS SECTION 44
Front Axle And Wheels Chapter 1
Section Description Page
44 000 Principaldata 1..................................................................
Sectionalviews 3................................................................
Torquesettings 4................................................................
Equipment--Faultdiagnosis 5.....................................................
44 101 30 Removal--Refitting--Overhaul 6....................................................
44 101 22 Wheelhubdisassembly--assembly 9...............................................
44 101 46 Stubaxleoverhaul 16...........................................................
44 101 80 Checkingwheelalignment 20....................................................
AUXILIARY UNITS SECTION 50
Auxiliary Units Chapter 1
Section Description Page
50 000 Safetyinstructions 2.............................................................
Generalcharacteristics 3.........................................................
Equipment 4....................................................................
Operatingprinciples 5............................................................
Faultdiagnosis 7................................................................
Cabcontrols 11..................................................................
Use 14........................................................................
Main components of the cab air conditioning system 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant recovery--recycling and evacuation--charging stations 20. . . . . . . . . . . . . . . . . .
50 200 04 Dryingrechargingandcheckingcooling 22.........................................
50 200 03 Functional testing of air conditioning system 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of the cab air--conditioning system charging operations 28. . . . . . . . . . . . . . . . . .
Checking for refrigerant leaks using an electronic leak detector 30. . . . . . . . . . . . . . . . . . . . .
Summary of fault diagnosis and maintenance 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air conditioning and heating pipes -- Replacement 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 200 04--74 Receiver--drier--Replacement 36................................................
50 200 04--72 Condenser--Replacement 38...................................................
50 200 04--26 Compressor--Removal--Refitting 39..............................................
50 200 10 Compressor drive belt tension adjustment 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM SECTION 55
Instruments Chapter 1
Section Description Page..............................................................
AnalogueinstrumentsIntroduction 1..............................................................
Transmitter and switch 4 .
Components Chapter 2
Section Description Page..............................................................
55 500 Introduction 1...................................................................
Componentdescription 1.........................................................
Starting System Chapter 3
Section Description Page..............................................................
55 000 Technicalinformation 1...........................................................
Tighteningtorques 1.............................................................
Descriptionandoperation 2.......................................................
Startingcircuit 3.................................................................
Systemtests 5..................................................................
55 201 Removal and re--installation of starter motor 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing 9......................................................................
Benchtests 10.................................................................
Charging System Chapter 4
Section Description Page..............................................................
55 000 Technicalinformation 1...........................................................
Tighteningtorques 1.............................................................
Descriptionandoperation 2.......................................................
Systemtestingandtrouble--shooting 4..............................................
55 301 Removal,re--installationandservicing 10..........................................
Battery Chapter 5
Section Description Page..............................................................
55 000 Technicalinformation 1...........................................................
Descriptionandoperation 1.......................................................
55.301.040 Removalandre--installation 2.....................................................
Batterycheckingandmaintenance 3...............................................
Chargingthebattery 4............................................................
Batteryproblems--Frequentcauses 7..............................................
Electrical Circuits Chapter 6
Section Description Page..............................................................
55 100 Contents 1. . . . . . . .
Fuses(allversions) 2............................................................
Symbolsusedinelectricalcircuits 4................................................
Electricalwirecolourcoding 5.....................................................
Groundlocations 5...............................................................
Electricaldiagrams ...............................................................
-- Generaldiagrams(W/Cab) 9.............................................
-- Generaldiagrams(W/OutCab) 15........................................
-- Analogue instrument circuit and connector overview 19. . . . . . . . . . . . . . . . . . . . . .
-- Start--up circuit and connector overview 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- Direction indicator & hazard warning light circuit and connector overview 25. . . .
-- Windscreen and rear window wiper/washer circuit and connector overview 31. . .
-- Brake light circuit and connector overview 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- Heating and air--conditioning system circuit and connector overview 41. . . . . . . .
-- Work lamp (without cab circuit and connector overview) 45. . . . . . . . . . . . . . . . . . .
-- Work lamp (without cab circuit and connector overview) 49. . . . . . . . . . . . . . . . . . .
-- Side lights,main and dipped headlights, parking light circuit and connector
overview 53
BODYWORK AND DRIVER POSITION SECTION 90
Bodywork And Driver Position Chapter 1
Section Description Page..............................................................
90 160 42 -- 43
90 120 10 Control levers, seat and electrical controls -- disassembly and reassembly 2. . . . . . . . . . . . .
90 156 52 Rear window, handle and lock -- disassembly and reassembly 10. . . . . . . . . . . . . . . . . . . . .
90 154 30 Left--hand door exterior handle and lock -- disassembly and reassembly 11. . . . . . . . . . . . . .
90 154 10 Left--hand door -- disassembly and reassembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90 160 60
55 518 52 Windscreen wiper motor -- disassembly and reassembly 13. . . . . . . . . . . . . . . . . . . . . . . . . .
90154 24
90 156 10 -- 14
90 156 28 Cabwindows--replacement 15...................................................
SECTION 00 – GENERAL – CHAPTER 1 3
???
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL
This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this manual you will find this symbol together with the following key–words:
WARNING – it gives warning about improper repair operations and deriving potential
consequences affecting the service technician’s personal safety.
DANGER – it gives specific warning about potential dangers for personal safety of the
operator or other persons directly or indirectly involved.
TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in
workshops are due from non–observance of some
simple and essential prudential rule and safety pre-
cautions. For this reason, IN MOST CASES THEY
CAN BE AVOIDED. It suffices to foresee possible
causes and act consequently with necessary caution
and care.
The possibility that an accident might occur with any
type of machines should not be disregarded, no mat-
ter how well the machine in question was designed
and built.
A wise and careful service technician is the best pre-
cautions against accidents.
Careful observance of this only basic precaution
would be enough to avoid many severe accidents.
DANGER: Never carry out any cleaning, lubrication
or maintenance operations when the engine is run-
ning.
SAFETY RULES
GENERALITIES
Carefully follow specified repair and mainte-
nance procedures.
Do not wear rings, wristwatches, jewels, unbut-
toned or flapping clothing such as ties, torn
clothes, scarves, open jackets or shirts with open
zips which could get hold into moving parts. We
advise to use approved safety clothing such as
anti–slipping footwear, gloves, safety goggles,
helmets, etc.
Never carry out any repair on the machine if
someone is sitting on the operator’s seat, except
if they are certified operators to assist in the
operation to be carried out.
Never operate the machine or use attachments
from a place other than sitting at the operator’s
seat.
Never carry out any operation on the machine
when the engine is running, except when specifi-
cally indicated.
Stop the engine and ensure that all pressure is
relieved from hydraulic circuits before removing
caps, covers, valves, etc.
All repair and maintenance operations should be
carried out with the greatest care and attention.
Service stairs and platforms used in a workshop
or in the field should be built in compliance with
the safety rules in force.
Disconnect the batteries and label all controls to
warn that the tractor is being serviced. Block the
machine and all equipment which should be
raised.
Never check or fill fuel tanks and accumulator
batteries, nor use starting liquid if you are smok-
ing or near open flames as such fluids are flam-
mable.
Brakes are inoperative when they are manually
released for maintenance purposes. In such
cases, the machine should be kept constantly
under control using blocks or similar devices.
The fuel filling gun should remain always in con-
tact with the filler neck. Maintain this contact until
the fuel stops flowing into the tank to avoid pos-
sible sparks due to static electricity buildup.