Valtra 6550 - Control of Hitech Shuttle, AC 5.2

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175

Model Code Page

37. Autocontrol 5.2 (K41107---)

1. 9. 2002

371 19

6250--8950

X13

Control of HiTech shuttle, AC 5.2

Main Page

Electrical System2
General4
Layout10
Division into Groups10
Division into Components or Sub ---Groups10
Code Designation11
Page Numbers11
Date11
General Instructions for Repairs14
Outer Oil Seals14
Sealing Compound and Glue14
Tightening Torques and Setting Values14
Handling of Heavy Components15
Cleanliness15
Assembly15
Lubrication15
Bushes and Press Fits16
Cables and Wires16
Locking Devices16
Fitting Bolts in Blind Holes16
Tightening Torques, Metric Standard Thread (ISO)17
Conversion Table for Common Units18
General Instructions Concerning Oil Checks and Oil Filling20
Greasing Lubricating Points Fitted with Grease Nipples20
Lubrication and Maintenance Schedule20
Maintenance Schedule21
Daily/Every 10 Hours21
Weekly/Every 50 Hours21
Every 250 Hours21
Every 500 Hours22
Every 1000 Hours/Yearly22
Every 2000 Hours/Every Other Year22
Every 4000 Hours22
Recommended Fuel and Lubricants23
Oil Quality and Capacity in Fluid Couplings23
Engine24
Table of Contents26
Specifications28
Valves, Rockers and Tappets30
Connecting Rod32
Special Tools37
Engine, Description39
Cylinder Block39
Flywheel Housing39
Crank Mechanism40
Cylinder Head40
Valve Mechanism40
Timing Gears41
Lubricating System42
Induction and Exhaust System43
Repair Instructions48
Checking Cylinder Block48
Removing Cylinder Liner48
Cylinder Block and Flywheel Housing (Op no 211)48
Measuring Cylinder Liner Wear48
Changing Camshaft Bushing48
Oversize Bushings for Camshaft49
Fitting Pipe for Oil Dipstick51
Fitting Cylinder Liners51
Fitting Flywheel Housing53
Changing Crankshaft Rear Oil Seal53
Changing Flywheel Starter Gear54
Fitting Flywheel54
Removing Cylinder Head56
Removing Valves56
Checking Cylinder Head56
Cylinder Head and Valve Mechanism (Op no 212)56
Changing Valve Guides57
Machining Valve Seat57
Changing Valve Seat Inserts58
Grinding Valves58
Fitting Valves58
Fitting Cylinder Head59
Reconditioning Rocker Arm Mechanism60
Changing Camshaft/Camshaft Gear60
Valve Mechanism60
Adjusting Valves61
Removing Crankshaft62
Changing Crankshaft Gears62
Crank Mechanism (Op. no 213)62
Fitting Crankshaft63
Changing Crankshaft Ring Gear (42063
Connecting Rods and Pistons64
Removing Piston Together with Connecting Rod64
Changing Connecting Rod Bearings64
Connecting Rods, Weight Classes65
Changing Piston Rings66
Checking Piston67
Fitting Piston Together with Connecting Rod67
Balancer Unit, 42068
Removing and Dismantling Balancer Unit68
Reconditioning Balancer Unit68
Fitting Balancer Unit69
Removing Timing Gear Casing70
Reconditioning Idler Gear70
Fitting Timing Gear Casing71
Reconditioning of Oil Relief Valve for Lubricating Oil Pressure74
Removing and Dismantling Lubricating Oil Pump74
Assembling and Fitting Lubricating Oil Pump75
Fitting Oil Sump Gasket75
Lubricating Oil Quality Requirements76
Cooling Nozzles for Pistons77
Latest Lubricating Oil Pressure Relief Valve77
Inlet and Exhaust System, Turbocharger (Op. No. 216)80
Checking Inlet and Exhaust System80
Checking Turbocharger80
Reconditioning Turbocharger82
Cleaning Parts of the Turbocharger83
Checking Parts of the Turbocharger83
Assembling the Turbocharger83
Bearing Housing83
Fitting Turbocharger84
Adjusting by -Pass Turbo (S1BG)84
Intercooler on 6800 Tractor85
Exhaust Pipe on 6800 Tractor86
Crankshaft Seals88
Pistons and Connecting Rods88
Lubricating Oil Pump88
Working Orders (Op. No. 219)88
Camshaft89
Specifications91
Special Tools92
Fuel System, Description93
Fuel Filter93
Fuel Tank93
Injectors93
Fuel Injection Pump94
Two-Hole Pump Element (Maximum Feed)95
Delivery Valve95
Checking Electric Stop Solenoid96
Fuel Injection Pump (Bosch P-- Pump) on 8950 Tractor96
Governor98
Fuel Injection Pump Type Plate98
Table of the Fuel Metering 6000-680099
Specifications with Stanadyne Distributor Pump103
Stanadyne Distributor Pump103
Fuel System with Distributor Pump104
Maintenance104
Construction105
Possible Equipment on Stanadyne Distributor Pump106
Electric Advancing of the Injection107
Bleeding Fuel System112
Bleeding Thermostart System112
Measuring Fuel Feed Pressure112
Repair Instructions112
Checking Overflow Valve113
Changing Fuel Feed Pump Valves113
Checking Fuel Injection Timing114
Adjusting Injection Timing114
Removing Injection Pump115
Fitting Injection Pump115
Checking/Changing Delivery Valve116
Adjusting Low Idling Speed117
Removing Injectors118
Inspecting Injectors118
Opening Pressure118
Chattering Sound Properties118
Reconditioning Injectors119
Tightness of Nozzle119
Fitting Injector in Engine120
Fitting Delivery Pipes120
Adjusting Injection Timing on 6800, 8750 and 8950 Tractors121
Manifold Pressure Compensator122
Cold Start Solenoid122
Boost Control122
Removing Distributor Pump123
Fitting Pump and Adjusting Injection Timing123
Stanadyne Distributor Pump123
Fuel Feed Pump124
Bleeding Fuel System124
Injectors125
Adjusting Low Idling Speed125
Delivery Pipes125
Cooling System128
Specifications129
Special Tools130
Freezing Point of Coolant131
Expansion Tank132
Emptying the System in Connection with Repairs132
Viscous Fan133
Temperature Sensor, Engine Coolant Temperature134
Coolant Pump135
Repair Instructions (Op no 231)136
Thermostat136
Reconditioning Coolant Pump (320136
Reconditioning Coolant Pump (620136
Coolant Pump on 8000, 8100, 8200 and 8400137
Quality Requirements of Engine Coolant138
Coolant Pump and Thermostat Housing139
Electrical System144
Tractor Electrical System146
Safety Precautions for the Electrical System146
Battery Checks and Maintenance146
Fuses and Relays147
Circuit Card, Fuse Box147
Headlight Adjustment148
Standard Trailer Socket148
Electrical Equipment for Engine149
Alternator Iskra AAK 5118 14 V 95 a150
Alternator Bosch NC 14 V 70---120 a150
Starter Motor Iskra AZJ3234 12 V 3,1 Kw151
Starter Motor Iskra AZJ3247 12 V 3,6 Kw151
Speed Radar152
Radar Fastening Parts153
Electric Connections153
Position of Electric Components on Frame154
Wiring Diagram164
Differential Lock268
Front Wheel Drive268
Power Take -Off269
Delta Powershift269
Components of the Autocontrol II270
Delta Power Shift Control271
Circuit Card of Buzzer and Ind. Lights273
Fault Tracing273
Buzzer Test273
Circuit Card Illumination273
Differential Lock Control274
Checking Function of the Differential Lock Control275
4WD Control276
Checking Function276
PTO Control277
Differences between AC II and AC278
Delta Powershift Control System278
Sound Signals278
Control of Transmission278
DPS Circuit Card280
INPUT Signals280
OUTPUT Signals280
Fault Tracing of Input Signals280
Control Stop281
Function281
Testing the Function281
Differences in the Dashboard282
Position of Connectors283
Engine Speed Sensor B4283
Power Control Unit283
PTO Speed Sensor283
Version Markings of Sigmapower284
Sigma Power 2.0284
Control Unit A13286
Solenoid Valve Y13 and Boost Control286
Sensors B4 and B5, Versions 1.0, 1.1 and 2.0287
Fault Tracing, Adjustments and Repairs293
Checking Function with the Aid of the ETB293
Fault Tracing by Measuring Voltages294
Incorrect Voltage Readings295
Checking and Adjusting Sensors with Fluke123296
Interpretation of Oscilloscope Waves and Specified Values297
Buzzer Functions305
DPS-Circuit Card A10306
Wiring Diagram314
Position Control Knob320
Lift/Lower Switch320
Lowering Speed Selector320
Transport Height Selector320
Position Sensor321
Adjusting the Position Sensor321
Draft Sensors322
Short Circuit in Draft Sensor Line322
Functional Checks323
Distinguishing between Electrical and Hydraulic Malfunctions323
Checking the Electrical Operations323
Checking the Lift/Lower Switch323
Checking the Indicator Lights on Switch Panel324
Checking the Transport Height Selector324
Checking the Lower Speed Selector324
Checking the Draft Control Operation324
Checking Switch Panel A2E325
Removing the Switch Panel for Checking325
Voltage Measurements326
Checking Supply Voltage326
Checking Lowering Speed Selector326
Checking Transport Height Selector326
Changing Switch Panel327
Checking Switch Panel Indicator Lights327
Measuring Internal Voltages of Position Sensor and Draft Sensors328
Checking the Position Control Potentio-Meter329
Checking Control Valve and Its Solenoid Valves329
Special Instructions331
Control Unit A1E of AC Power Lift331
Forced Lowering331
ACB / ACD Power Lift332
Position Sensor, ACB and ACD333
Measuring Position Sensor Supply and Signal Voltages333
Function of Diagnostic Light and Fault Codes334
Faul Codes of ACD Power Lift334
Serious Faults334
Medium Serious Faults335
Minor Faults335
Other Faults335
Fault Codes of ACB Power Lift336
Drive Balance Control (DBC)338
Verifying the Function of the DBC338
ACD: Transmission Speed Sensor338
Clip Control (Option)339
Calibrating Drive339
Checking Switch Panel of ACD340
Measuring Supply Voltage340
Checking Lowering Speed Selector S7E340
Checking Transport Height Selector S8E340
Checking Dbc/Slip Control Selector S12E341
Checking Lift/Lower Switch S10E341
Checking Switch Panel of ACB342
Changing Switch Panel, ACB/ACD343
Checking Control Valve and Its Solenoid Valves (Not ACB)344
Adjusting Position Sensor, ACB/ACD344
Wiring Diagram, ACD345
ACD: List of Components346
Circuit Diagram, ACB347
ACB: List of Components348
ACD Power Lift349
Checking Function of ACB and ACD Power Lifts351
Agrodata Performance Monitor354
Checking Display Operation356
Trouble Shooting356
Checking the Sensors and Signal from Lift/Lower Switch357
Connecting the Leads from the Implement Sensor to the Plug Poles357
Spare Part Numbers for Sensors and Plug358
Further Information on Agrodata Operation358
Agrodata-Instrument360
Agrodata-Instrument, Sensors and Wiring361
Zeroing the Travelling Distance362
Time Setting362
Gearbox Speed Sensor B6363
PTO Speed Sensor B7363
Calibrating the Instrument for Different Tyres364
Gearbox Temperature Sensor B3364
Code Numbers with Different Tyre Sizes and Transmission Types365
Fieldmaster368
Connectors369
Fieldmaster Components on the Tractor369
Fieldmaster Wiring Diagram370
General Functions371
Calibrating Gearbox Speed Sensor and Radar371
Changing Display Language371
Error Messages372
Test Mode373
Sprayer373
Fertilizer373
Drill373
Checking Wire Connections between Rear Socket and Display Unit374
Baler374
Slurry Spreader374
Connecting Sensor Wires to Plug375
Lower Row Shows378
Upper Row Shows378
Zeroing Distance Travelled378
Setting Time378
Calibrating Agroline for Different Tyres379
Fault Codes381
Changing Speed and Distance Units381
Sensors and Switches382
Rear PTO Speed Sensor382
Gearbox Oil Temperature383
Engine Temperature Sensor384
Engine Oil Pressure Sensor384
Fuel Level Sensor384
Sensor S12 for Engine Air Filter Warning Light384
Gearbox Oil Pressure385
Switch S44 for Blocked Pressure Filter385
Gearbox Oil Temperatute Switch S16385
Parking Brake Warning Light Switch385
Direction Indicator Flashers386
Indication Light for Glowing386
Charging Light386
Hour Recorder and Rev Counter386
Components for AC-III System392
Sensor for Outdoor Temperature392
Sensor for Engine Coolant Temperature392
Sensor for Front Wheel Steering Angle392
Calibrating Mode for the Hidden Functions393
Parameters393
Harness Looms and Connectors396
Central Processing Unit (ECS) Is Placed in the Lever396
Rear Side of the ECS396
Component List for Wiring Diagram397
Trouble Shooting and Repairs404
Checking and Fitting Sensors404
Fitting Speed Sensors404
Calibrating the Speed Sensors404
Potentiometer on the Fuel Injection Pump405
Sensor for Steering Angle405
Manual Fault Tracing406
Supply Voltages406
Ecs406
Functional Check407
Quick-- Shift Gear408
Calibrating the Quick-Shift Gear408
Power Take - off408
Slip Control409
Cold Starting Device409
Setting Slip Percent409
Counter Functions410
Calibrating Display410
Zeroing the Counters410
Starting and Stopping Counters410
Computer-Aided Fault Tracing412
Starting Fault Tracing412
Fault Tracing Chart on PC Monitor413
Fault Tracing, Front Wheel Drive Control414
Fault Tracing, Quick -Shift Gear Control415
Fault Tracing, Differential Lock Control415
Fault Tracing, Power Take -Off Control416
Fault Tracing, Slip Control417
Fault Tracing, Speed Sensors418
Checking Radar418
Checking Speed Sensors for Front Axle, Rear Axle and Gearbox418
Checking Rotation Speed Sensors for Engine and PTO418
Analog Inputs419
Power Lift419
Outside Temp419
System Volt419
Implement Socket420
Checking Line from Implement Socket to AC420
Frequency Inputs420
Digital Inputs420
Copying Parameter File into AC422
Inputting Parameter File422
Alternative Parameter Files423
Error Messages in Service Program424
Components for AC IV System430
Outdoor Temperature Sensor430
Differences between Autocontrol III and IV431
Central Processing Unit ECS431
Delta Powershift Control431
Slip Control and the Power Lift431
Electric Stop of the Engine432
Connectors and Wiring433
Wiring and Connectors434
Sensors in the Engine Compartment436
Fault Tracing Without Microcomputer460
Inputs460
Outputs460
Checking Radar, Gearbox, Rear Axle and Front Axle Speed Sensors461
Changing Gearbox, Front Axle and Rear Axle Speed Sensors461
Checking/Changing Engine Speed Sensor462
Changing PTO Speed Sensor462
Changing Gearbox Speed Sensor B2C462
Potentiometer on the Injection Pump463
Copying Parameter File into AC IV Unit478
Copying Parameter File into AC IV479
Caretel482
Data Logger483
Caretel GSM Phone483
Sensors483
Remote Use of Caretel with GSM Phone484
Query of One Measuring Value484
Answers485
Query of All Measurements486
Query of Number of Exceeding Times of Warning Limits486
Query of Number of Exceeding Times of Alarm Limits487
Automatic Alarm Message487
Query from Special Tracking Log488
Control of Automatic Alarm Messages488
Control of Special Tracking Log488
Measuring Logs489
Standard Log489
Exceeding Log489
Alarm Logs489
Checking Function of Caretel490
Engine Revs and Running Hours491
AC 5 and 5.2, Description495
AC 5 / 5.2 Control Buttons and Levers495
Autocontrol 5 / 5.2 Components496
Limit Switch496
Display Unit496
AC 5 / 5.2 Display Unit497
Fault Tracing498
General498
Fault Function Levels, AC 5 and 5.2500
Fault Function Level 3 (”Home Driving”)500
Fault Function Level 4 (”Immediate Downdrive”)500
Fault Tracing in Test Mode501
Activating Test Mode, AC 5 and 5.2501
Fault Tracing in the Test Mode F II501
Symbols in Instruction502
Checking I.D. Number of AC5 Programs502
Main Program Version Numbers502
Functional Differences of Program Versions, Comparison, AC 5 Only505
Testing Various Switches and Buttons (D01507
Testing Temperature Sensors and Position Sensors (A1508
Testing RPM509
Testing Proportional Valves (P1510
Counter Functions, J38343512
Activating Setting Mode513
Checking Reverse Shuttle Pressures515
Resetting Driving Speed Parameters517
Setting PTO Parameters520
19A520
Check of the Gas Pedal Sensor Calibration with the Computer, AC 5 and522
Control Unit A1 and Display523
Switches523
Proportional Valves524
Rotation Speed Sensors525
Temperature Sensors, AC 5 Only526
Detection of Driver527
Working Orders528
Programming of AC5 and AC5.2 Control Unit by Means of HYPERTERMINAL529
24B529
Programming of AC5 and AC5.2 Control Unit by Means of LOADER 1.5 Loading Program531
24D531
Main Program and Parameter Files Tables of AC5 and AC5.2534
24G534
24H535
Test536
Wiring Diagrams AC5542
Control Diagrams, AC 5543
DPS Control543
Control of Shuttle, AC 5544
Control of PTO, AC 5545
Control of Parking Brake and Engine Starting546
Autocontrol 5.2550
Wiring Diagrams, AC 5 Only550
Autocontrol 5.2, General551
Additional Functions in AC 5.2551
Automatic Calibrations551
Automatic Speed Change of DPS551
Automatic Traction Control552
Automatic Traction Disengagement Happens552
Automatic Traction Engagement Happens552
Auto2 - Function553
Speed Matching of DPS553
Fault Codes in AC 5.2554
Fault Code Memory555
Working Order556
Setting Indexes of Transmission556
Checking ID Number of Program557
Main Program Version Number557
Parameter File ID Numbers557
Test Mode Menu560
Table to Check Various Switches in the Test Mode in AC 5.2561
Counter Functions in AC 5.2566
Setting Mode Menu567
Setting Clutch Pedal Ratio Index567
Automatic Calibrations of Shuttle, DPS and PTO Clutches568
Manual Calibration of PTO Clutch570
Setting 4WD Automatics571
Resetting Pre-Filling Indexes for DPS Clutches571
12A571
Reconditioning Temperature Sensors572
Clutch Pedal Position Sensor B16 and B1W (Twintrac)572
Gearbox Oil Temperature Sensor572
Outdoor Temperature B17572
Components572
Front Clutch Pedal Limit Switch S9 and Rear Pedal Switch S2W573
Gas Pedal (Fuel Injection Pump) Position Sensor B1573
Others574
AC 5.2 Control Unit, Connectors574
AC 5.2, Wiring Diagram575
Wiring Diagram AC 5.2576
Control Unit Connector A1A1576
Control Unit Connector A1A2576
Control Unit Connector A1A3576
Control Diagrams577
Control of DPS, AC 5.2577
Control of Hitech Shuttle, AC 5.2578
Control of PTO, AC 5.2579
Control of Parking Brake, AC 5.2580
Starting Control, AC 5.2581
Control of 4WD, AC 5.2582
Twintrac, AC 5.2583
Autotraction584
Fitting Wiper Motor588
Fitting Washer588
PTO Emergency Stop592
Rear Fog Light610
Cabin Heater612
Back Buzzer (Not Hitech)614
Forced Lowering Switch616
Power Transmission680
Changing Disc/Release Bearing698
Splitting Tractor at Clutch698
Changing Clutch/Disc699
Changing Release Bearing699
Assembling Tractor at Clutch700
Checks and Adjustments701
Adjusting Clutch Pedal Free Travel up to Ser. No. 659477701
Checking the Clutch Disc and Clutch Assembly701
Hydraulic Coupling (Hi704
Checking Function of Hydraulic Coupling704
Stall704
Adjusting and Repair Instruction for Cable Type Release Mechanism, 659478707
Hishift709
Technical Data715
Special Tools720
Gearbox, Description722
Synchronization729
Differential730
Selector Forks (Op. no 421)756
Adjusting Selector Forks756
Changing Selector Forks757
Reconditioning Gearbox (Op. No. 423)758
Splitting Tractor between Gearbox758
Disassembling Gearbox760
Removing Differential760
Removing Side Cover760
Removing Hydraulic Pump761
Removing Selector Forks761
Assembling Gearbox765
Fitting 4WD Clutch Drum770
Fitting Side Cover771
Fitting Differential772
Fitting Gearbox774
Technical Data779
Special Tools781
Step Quick784
Step Quick789
Mechanical Reverse Shuttle, Description800
Hitech Shuttle, Description803
19A803
4WD Clutch, Description805
Working Order811
Removing Quick814
Splitting Tractor between Gearbox814
Fitting Quick816
Assembling Tractor Frame between Gearbox816
Changing Input Shaft/Disc Assembly818
Changing Needle Bearing in Planet Pinions and Planet Carrier820
Fitting Input Shaft and Disc Assembly821
Reconditioning Reverse Shuttle (Op. No. 442)824
Removing Reverse Shuttle824
Fitting Reverse Shuttle826
Hitech Shuttle827
Reconditioning 4WD Clutch (Op. No. 443)836
Reconditioning Delta Powershift840
Reconditioning Planetary Gear and Its Multi840
Reconditioning Multi843
Needle Bearings847
Changing Oil Seal and Needle Bearing Inside the Input Shaft Front End847
DPS in Transmission848
Special Tools851
Final Drive, Description852
Reconditioning Final Drives (Op no 451)858
Removing Final Drives858
Changing Needle Bearings in Planetary Gears858
Changing Bearings and Seals for Outer Drive Shafts859
Adjusting Outer Drive Shaft Bearing Clearance861
Fitting Final Drives861
Special Tools868
Power Take869
Heavy Duty PTO876
PTO Clutch876
Removing PTO884
Reconditioning PTO Clutch886
Front PTO on 6000898
Front PTO on 8450900
Front PTO, 6000909
Front PTO910
Repair Instructions911
Maintenance915
Fault Tracing915
Belts / Elastic Joint915
Cone Clutch915
Parking Brake950
Hubs (Code No. 672)1076
Changing King Pin Bearings1079
Drive Shafts (Code no 673)1082
Reconditioning Differential/Bevel Pinion Shaft (Code No. 674)1084
Changing Bevel Pinion Shaft Cassette Seal1084
Removing Differential1084
Removing Bevel Pinion Shaft1085
Disassembling Differential1087
Assembling Differential1087
Adjusting Position of Bevel Pinion Shaft1088
Fitting Differential Onto Bracket1090
Fitting Differential into Axle Housing1091
Reconditioning Steering Ram (Code No. 675)1094
Adjusting Toe1096
Adjusting Steering Angle1096
Rear Axle1164
Front Axle1164
Cab, General1178
Instruments and Controls1179
Cabin Heater1185
Removing Cab1188
Fitting Cab1189
Glueing Cab Windows1190
Air Conditioner (Op no 830)1193
Operation Principle1194
Safety Precautions1200
Maintenance1200
Fault Tracing Without Special Equipment1202
Correct Function1202
Compressor1203
Expansion Valve1203
Evaporator1203
Condenser1203
Important Information on Air Conditioner Repairs and Spare Part Storage1207
Compressor1208
Technical Data1260
Special Tools1261
Hydraulic Diagram1265
Hydraulic Power Lift1280
Three1286
Valves for Auxiliary Hydraulics1287
Return Oil Connection for Auxiliary Hydraulics1293
Repair Instructions1298
Removing Hydraulic Pump1301
Fitting Hydraulic Pump1301
Hydraulic Power Lift (Op. No. 912)1304
Checking Shock Valve Opening Pressure1304
Removing Control Valve1304
Fitting Control Valve1304
Reconditioning Control Valve1305
Lifting Cylinders1306
Changing Lifting Cylinder Seals1306
Three1308
Adjusting Pick1308
Clutch1333
Gearbox1334
Quick1336
Final Drives1340
Power Take1340
Steering System1341
Powered Front Axle1341
Hydraulic Power Lift1345
Clutch1348
Gearbox1351
Quick1352
Final Drives1352
Power Take1353
Powered Front Axle1356
Frame and Wheels1357
Cab and Shields1358
Hydraulic Power Lift1359

Valtra 6550 - Control of Hitech Shuttle, AC 5.2

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