service repair manual

1. Axos 340-310 – 08.2009 – GB
01 02
COMPLETE ASSEMBLY

2. 14 Axos 340-310 – 08.2009 – GB
01 Engine
01 02 Complete assembly
Removing the complete engine
Summary of operations
Important: Carry out this operation on a smooth horizontal and sufficiently firm surface. Use props suited to the
load to block the tractor.
Preliminary operations
– Apply the handbrake.
– Put the gear lever in neutral.
– Remove the removable ballast weights.
– Chock the rear wheels.
– Prevent the front axle from tilting by using chocks.
OPERATION Designation
1 Remove the engine cover .
2 Drain the engine fluids.
3 Disconnect the battery.
4 Disconnect the cables from the washer pumps.
5 Disconnect the harnesses of the engine, alternator, starter.
6 Remove the battery bay.
7 If option: Remove the frame of the front loader.
8 If option: Disconnect the front lifting lines.
9 If option: Remove the front lift.
10 If option: Disconnect the A/C lines.
11 If option: Remove the hoses of the air/air heat exchanger.
12 Disconnect the fuel supply and return lines.
13 Disconnect the transmission oil cooler lines .
14 Disconnect the LH steering line.
15 Remove the fuel tank.
16 Remove the exhaust extension.
17 Disconnect the hydraulic pump lines.
18 Disconnect the RH steering line.
19 If option: Disconnect the front PTO harness.
20 If option: Disconnect the front PTO shaft.
21 Disconnect the air intake hose.
22 Disconnect the cooling radiator hoses.
23
Remove the transmission shaft.
Remove the casing.
24 Disconnect the accelerator cable .
25 Disconnect the front chassis from the engine.
26 Remove the screws from the clutch casing.
27 Removing the engine.

3. 01 Engine
01 02 Complete assembly
Axos 340-310 – 08.2009 – GB 15
Operation n° 1
– Remove the cover by removing the screws (1).
Operation n° 2
– Drain the coolant.
– Drain the engine oil.
If option:
– Drain the A/C unit.
104bsm20 Fig. 1
Operation n° 3
– Disconnect the battery.
842msm34 Fig. 2
Operation n° 4
– Disconnect the wiper fluid hoses.
– Disconnect the electric connectors of the washer
pumps.
104bsm21 Fig. 3
1

4. 16 Axos 340-310 – 08.2009 – GB
01 Engine
01 02 Complete assembly
Operation n° 5
– Disconnect the harnesses of the engine, alternator,
starter.
104bsm22 Fig. 4
104bsm23 Fig. 5
Operation n° 6
– Remove the battery bay.
104bsm25 Fig. 6

5. 01 Engine
01 02 Complete assembly
Axos 340-310 – 08.2009 – GB 17
Operation n° 7
If option:
– Remove the frame of the front loader.
104bsm24 Fig. 7
Operation n° 8
If option:
– Disconnect the (1) front lifting lines.
104bsm26 Fig. 8
Operation n° 9
If option:
– Remove the front lift.
104bsm27 Fig. 9
1

6. 18 Axos 340-310 – 08.2009 – GB
01 Engine
01 02 Complete assembly
Operation n° 10
If option:
– Disconnect the (1) A/C lines.
104bsm28 Fig. 10
Operation n° 11
If option:
– Remove the hoses of the (1) air/air heat exchanger.
104bsm29 Fig. 11
Operation n° 12
– Disconnect the (1) fuel supply and return lines.
104bsm30 Fig. 12
1
1
1

7. 01 Engine
01 02 Complete assembly
Axos 340-310 – 08.2009 – GB 19
Operation n° 13
– Disconnect the transmission oil cooler lines (1).
104bsm31 Fig. 13
Operation n° 14
– Disconnect the (1) LH steering line.
104bsm32 Fig. 14
Operation n° 15
– Remove the fuel tank.
104bsm33 Fig. 15
1
1

8. 20 Axos 340-310 – 08.2009 – GB
01 Engine
01 02 Complete assembly
Operation n° 16
– Remove the exhaust riser (1).
104bsm34 Fig. 16
Operation n° 17
– Disconnect the line (1) at the outlet of the high pressure
filter.
– Disconnect the suction line (2) of the hydraulic pump.
104bsm35 Fig. 17
Operation n° 18
– Disconnect the (1) RH steering line.
Operation n° 19
If option:
– Disconnect the front PTO harness (2).
104bsm36 Fig. 18
1
2
1
1
2

9. 01 Engine
01 02 Complete assembly
Axos 340-310 – 08.2009 – GB 21
Operation n° 20
If option:
– Disconnect the (1) front PTO shaft.
104bsm37 Fig. 19
Operation n° 21
– Disconnect the (1) air intake hose.
104bsm40 Fig. 20
Operation n° 22
– Disconnect the hoses from the cooling radiator (1), (2)
and (3).
104bsm39 Fig. 21
1
1
2
3
1

10. 22 Axos 340-310 – 08.2009 – GB
01 Engine
01 02 Complete assembly
Operation n° 23
– Remove the protective casing (1).
– Remove the transmission shaft.
104bsm38 Fig. 22
Operation n° 24
– Disconnect the accelerator cable (1).
104bsm41 Fig. 23
Operation n° 25
– Fit a prop under the engine and under the frame.
– Disconnect the front frame (1) from the engine by
untiightening the screws (2).
104bsm42 Fig. 24
1
1
2
1

11. 01 Engine
01 02 Complete assembly
Axos 340-310 – 08.2009 – GB 23
Operation n° 26
– Sling the engine on 4 points to balance the load.
The engine has a weight of about 600 kg.
– Remove the screws from the (1) clutch casing.
104bsm43 Fig. 25
Operation n° 27
Important: Before removing the engine, check that all
elements are disconnected properly.
– Removing the engine.
– Lay the engine on flat and clean ground.
– Remove all external engine elements (hydraulic pump,
starter, alternator...).
101hsm05 Fig. 26
Refitting the complete engine
– Refit all external engine elements (hydraulic pump, starter, alternator...).
– Refit the engine elements and controls by performing the above operations in reverse sequence.
– Fill the A/C unit (see chapter 12 40).
– Fill the engine and the cooling circuit with oil (see operating manual).
1

12. 24 Axos 340-310 – 08.2009 – GB
01 Engine
01 02 Complete assembly
Blocking between the motor oil casing/front axle chassis
104bsm44 Fig. 23
– Assemble the front axle chassis onto the engine block.
– Tighten the 4 oiled nuts (A) at a torque of 30 daN.m.
– Measure the gap (B) on both sides between the motor
oil casing (C) and the front axle chassis (D).
– Untighten the 4 nuts (A) and fit the nubmer of shims
matching the gat (B) + 0,10 mm in the studs (E).
– Tighten the 4 nuts (A) at a torque of 35 daN.m.
– Tighten the 2 nuts (F) at a torque of 35 daN.m.
A
A
A
E
F
F
E
C
D
B

13. Axos 340-310 – 08.2009 – GB
01 10
ENGINE SUMP

14. 26 Axos 340-310 – 08.2009 – GB
01 Engine
01 10 Engine sump
Check - Cylinder block
– Clean all coolant passages.
– Clean the oil passages.
– Seek for cracks.
– Search for damage on the cylinder block.
Important: Do not machine the upper plane of the
cylinder block, as this would modify the piston's
protrusion.
104bsm0c Fig. 1

15. 01 Engine
01 10 Engine sump
Axos 340-310 – 08.2009 – GB 27
Measuring the dimensional specifications of the cylinder block
104bsm0d Fig. 2
– Measure the "A" dimension along the "x" and "y" axis
on the top and bottom of the cylinder.
Diameter must be 105,000 to 105,025 mm.
– Measure the dimension "B".
The diameter must be:
Camshaft bearing n° 1: 55,563 to 55,593 mm.
Camshaft bearing n° 2: 50,546 to 55,597 mm.
Camshaft bearing n° 3: 50,038 to 55,089 mm.
Note: The camshaft bearing No.1 is on the timing side.
– Measure the dimension "C".
Note: The "C" dimension must be emasured with the
crankshaft bearing fitted.
The diameter must be 80,416 to 80,442 mm.
– Measure the dimension "D".
The dimension must be 441,173 to 441,274 mm.
x y
A
C
B
D

16. 28 Axos 340-310 – 08.2009 – GB
01 Engine
01 10 Engine sump
Removing the flywheel cover
– Remove the flywheel.
– Remove the screws and nuts from the flywheel casing.
– Removing the flywheel casing.
Note: The approximate weight of the flywheel casing
is 30 kg.
104bsm0e Fig. 3
Reassembling the engine flywheel
casing
– Clean the bearing surfaces of the flywheel casing.
– Clean the bearing surfaces of the engine block.
– Refitting the flywheel casing.
– Tighten the screws by hand.
– Tighten the screws (1) to a torque of 7,5 daN.m.
– Tighten nuts (2) to 7,5 daN.m.
– Tighten the screws (3) to a torque of 11,5 daN.m.
– Refit the flywheel.
104bsm0f Fig. 4
Removing the timing cover
– Drain the cooling system.
– Remove the water pump (3).
– Loosen the screws (1).
– Remove the cover (2).
Note: Note the location of the timing cover
screws. (The screws have different lengths).
104bsm0g Fig. 5
1
1
2
3
3
1
2
1
2
3

17. 01 Engine
01 10 Engine sump
Axos 340-310 – 08.2009 – GB 29
Refitting the timing cover
– Clean the parting surfaces of the timing casing.
– Clean the parting surfaces of the timing cover.
– Check there are no foreign bodies in the timing.
104bsm0h Fig. 6
– Fit 2 studs on the "X" location.
– Change the gasket (1).
– Refit the timing cover (2).
– Tighten the cover screws (3) by hand.
– Remove the studs placed in an "X" shape.
– Refit the water pump.
– Tighten the water pump screws by hand.
– Tighten all screws at a torque of 2,2 daN.m.
– Fill the cooling circuit.
– Refit the belts.
104bsm0i Fig. 7
Disassembly of the distributor casing
– Drain the cooling system.
– Remove the drive belts.
– Remove the water pump.
– Remove the timing cover.
– Time the timing.
– Remove the hydraulic pump .
– Remove the crankshaft pulley.
– Removing the injection pump.
– Remove its gear (1).
– Remove the idler gear (2).
– Remove the camshaft gear (3).
104bsm0j Fig. 8
1
2
3
1
2
3

18. 30 Axos 340-310 – 08.2009 – GB
01 Engine
01 10 Engine sump
– Disconect the hose (1).
– Disconect the hose (2).
– Remove the pipe (3).
104bsm0k Fig. 9
– Pull out the selaing ring from the housing (1).
104bsm0l Fig. 10
– Loosen the screws (1).
– Remove the timing casing (2).
– Remove the gasket (3).
Note: Remove the crankshaft timing tool to remove
the timing casing. Refit the tool once the casing
removed.
104bsm0m Fig. 11
1
2
3
1
3
2
1
1

19. 01 Engine
01 10 Engine sump
Axos 340-310 – 08.2009 – GB 31
– Place an M8 x 125 (1) screw in the plate (2).
– Tighten the screw to pull out the plate (2).
– Remove the stop washer (3).
Note: The plate (2) must be removed to fit tool
No.00 1137 679 0.
104bsm0n Fig. 12
Refitting the timing cover
– Clean the gasket face .
– Check the condition of the washer (1).
– Change the washer if it is worn out.
– Fit the washer (1) into the engine block while ensuring
one of the 2 notches (2) is in the pin (3).
– Check the condition of the camshaft key.
– Change the key if it is worn out.
104bsm0o Fig. 13
– Fit the centering tool (1) No.00 1137 679 0 onto the
engine block.
– Fit 2 centering studs (2) onto the engine block.
– Fit a new gasket (3) onto the engine block.
104bsm0p Fig. 14
1
2
3
3
2
1
2
2
1
3
2

20. 32 Axos 340-310 – 08.2009 – GB
01 Engine
01 10 Engine sump
– Place the claws (1) of the gasket inside the holes (2) in
the engine block.
Important: When fitting the timing casing, press the
gasket onto the engine block to prevent the claws
from protruding from the engine block.
104bsm0q Fig. 15
– Fit the timing gear casing (1) to the engine.
– Tighten the screws (2) by hand.
– Remove the centering studs.
104bsm0s Fig. 16
– Tighten the screws (1) by hand.
– Using a rule (2), check the alignment of the lower face
of the timing casing and engine block.
If the alignment is not correct, align the lower face of the
timing casing with that of the engine block.
104bsm0r Fig. 17
1
2
1
2
1
2

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22. 01 Engine
01 10 Engine sump
Axos 340-310 – 08.2009 – GB 33
– Tighten the screws in the sequence indicated at a
torque of 2,8 daN.m.
– Remove the tool from the location (A).
104bsm0t Fig. 18
– Fit the plate (1) in the housing of the timing casing.
Important: Check that the “TOP” mark is up.
104bsm0u Fig. 19
– Connect the hoses (1) and (2).
– Change the O-rings of the hose (3).
– Fit the hose (3).
– Tighten the screws (4) to a torque of 2,2 daN.m.
104bsm0v Fig. 20
A
1
3
9 7
5
8
10
12
11
2
4
6
1
1
2
4
3

23. 34 Axos 340-310 – 08.2009 – GB
01 Engine
01 10 Engine sump
– Fit the engine bearing gasket in its housing (1).
– Fit the camshaft gear (2).
– Fit the idler gear (3). (Refer to section: 01 15).
– Fit the injection pump.
– Fit its gear (4).
Note: Check there are no foreign bodies in the timing.
– Remove the timing adjustment tool.
– Fit the timing cover.
– Fit the water pump.
– Fit the crankshaft pulley.
– Fit the belts.
– Fit the hydraulic pump.
– Fill the cooling circuit.
– Top up the transmission oil.
Removing the front crankshaft gasket
– Remove the drive belts.
– Remove the crankshaft pulley.
– Pull out the gasket from its housing (A).
Refitting the front crankshaft gasket
– Check the condition of the housing (1).
– Insert the new gasket (2) into its housing (1).
Note: To fit the gasket (2), use the tools
No.00 1139 176 0, 00 1139 177 0, 00 1139 178 0,
00 1139 179 0, 00 1139 180 0.
– Use the tool (3) to fit the gasket in its housing.
– Check that the front face of the gasket is located at
9 ± 0,2mm from the edge (4) of the casing.
– Fit the crankshaft pulley.
– Fit the belts.
104bsm0w Fig. 21
104bsm0x Fig. 22
104bsm0y Fig. 23
1
3
2
4
A
2
4
1
3