Borg and Beck Independent Clutch

Borg and Beck Independent Clutch Assembly

Before removing clutch, mark pressure plate to flywheel position for reassembly. Install retainers made from stiff wire over PTO clutch release levers to retain pressure of clutch springs. Remove bolts securing clutch assembly to flywheel, then remove clutch being careful not to drop inner clutch disc.

Install nine special long studs into appropriate holes in 912917 base plate. Place three Code 3 spacers on base plate, then install clutch assembly onto base plate and studs and arrange spacers so they are located below pto release lever lugs of pressure plate. Install flat washers and nuts on studs and tighten nuts evenly until clutch is seated on base plate.

Borg and Beck Independent clutch used on models with Independent pto

Mark positions of the following components so they can be reinstalled In their original positions If reused: Pressure plates (2 and 20) and covers (6 and 23), pressure plate lugs and re-tease levers (28) and outer cover and release levers (18).

Install release lever actuator into base plate, depress pto release levers and remove release lever retainer wires installed during removal. Remove actuator from base plate. Remove release lever pivot pins and remove levers from cover. Remove six bolts retaining clutch cover (23) to separator housing (6). Unscrew stud nuts evenly to relieve spring tension, then separate clutch components.

Inspect all parts for excessive wear or other damage. Friction surfaces of clutch cover and separator housing should be smooth and free of cracks.

Surfaces may be reground providing amount of material removed does not exceed 0.38 mm (0.015 inch). Check separator housing bearing (7) for smooth operation and renew if necessary.

Renew pressure springs if rusted, distorted or weak. Renew insulating washers (4) if damaged. Loose washers should be held in place in housing with suitable adhesive.

Inspect release levers and pivot pins for wear or damage and renew as needed. Renew release lever plates (30 and 31) if excessively worn.

To reassemble, install PTO pressure plate (2) on base plate and position three Code 3 spacers under plate at release lever lugs. Assemble PTO springs and separator housing on pressure plate. Place three Code 13 spacers on friction surface of separator housing, then install transmission pressure plate (20), aligning assembly marks and positioning spacers under release lever lugs. Assemble springs and outer cover on pressure plate. Install flat washers and nuts on studs and tighten until clutch is bottomed on base plate. Install six bolts retaining cover to separator housing. Install release levers and lever plates.

Install short adapter and release lever actuator into base plate. Actuate release levers about a dozen times to ensure components are properly seated, then remove actuator. Thread guide pin into adapter, then place Code 16X spacer on guide pin with recessed side towards adapter. Install short gage on guide pin, then adjust screws (26) on transmission clutch release levers until lever plate just touches gage all the way around. Tighten locknuts to secure adjustment.

Borg and Beck independent clutch, use a pilot shaft made to dimensions shown to align clutch discs

Remove short adapter from base plate and install long adapter. Install release lever actuator and depress pto release levers about a dozen times to ensure parts are properly seated. Remove actuator and install guide pin in adapter. Install Code 16X spacer with recessed side facing down. Install long adjusting gage on guide, then adjust PTO release levers (18) until lever plate just touches gage all the way around. Remove gage, spacer and guide pin.

Remove pto release lever plate and PTO release lever pivot pins. Swing release levers outward clear of clutch. Install three stiff wire retainers over transmission release levers to retain clutch spring tension. Remove cover retaining bolts, then loosen stud nuts evenly and lift clutch cover from separator housing. Remove spacers and install transmission clutch disc on separator housing with side marked "Flywheel" towards housing. Reinstall cover assembly. Use a pilot tool or a clutch drive shaft to align clutch disc with separator housing bearing, then install nuts and washers on three studs and tighten evenly to clamp cover to base plate. Install the six cover retaining bolts. Remove wire retainers from transmission clutch levers.

Reinstall pto clutch release levers, pivot pins and lever plate. Secure pto levers with stiff wire retainers used during removal, then loosen the three stud nuts and lift clutch assembly from base plate.

To reinstall, install inner disc with longer hub side towards flywheel. Position clutch assembly in flywheel aligning match marks made during removal. Use a suitable pilot shaft to align clutch discs, then tighten clutch mounting bolts evenly. Remove pilot tool from clutch.

Borg and Beck Continuous Clutch

Borg and Beck Continuous Clutch Assembly

Before removing clutch, mark pressure plate to flywheel position for reassembly. Place an 11 mm nut under each release lever to relieve spring tension as clutch mounting bolts are removed. Remove pressure plate assembly and outer clutch disc from flywheel. Identify flywheel side of clutch discs, if not already marked I to assure correct reassembly. Make alignment marks on separator plate and flywheel for reassembly, then remove separator plate and inner disc. Remove the three springs from flywheel.

Scribe alignment marks on clutch pressure plate, inner cover and outer cover and release levers to pressure plate lugs for reassembly in original positions.

Borg and Beck continuous clutch showing component parts and their relative positions

Remove release lever actuating plate (14). Remove the three adjusting screws (16). Place three Code 14 spacers (from clutch tool kit) on 912917 base plate. Position pressure plate on base plate so pressure plate rests on top of spacers. Install a 912724 spacer under and a stud through each mounting hole in clutch cover. Thread studs into base plate, install flat washers and nuts on studs and tighten nuts evenly until clutch cover contacts spacers. Release the large release lever springs (21) from clutch cover tabs. Remove pivot pins (25) and release levers (27). Remove springs (20 and 21), pivot pin (23) and needle bearing (24) from release levers.

Loosen stud nuts evenly until clutch spring tension is relieved, then separate pressure plate components. Remove snap ring (13) and tap bearing (12) from outer cover. Check release levers for wear on tips of fulcrum points and renew as needed. Check all clutch springs and renew if distorted, discolored or weak.

Inspect pressure plate for cracks, scoring or discoloration. Light scores may be removed by resurfacing, however maximum amount of material removed must not exceed 0.38 mm (0.015 inch).

If separator plate shows wear only on transmission side, further use may be obtained by reversing the plate. If plate is badly scored or cracked, it may be resurfaced providing amount of material removed does not exceed 0.76 mm (0.030 inch) total for both sides. Plate thickness when new is 17,78-17.90 mm (0.700-0.705 inch). Make certain separator plate is a free sliding fit in flywheel teeth. A tight plate can cause PTO clutch slippage. A very loose plate may rattle when clutch pedal is depressed, however separator plate rattle does not affect clutch operation.

Install pressure plate into inner and outer covers and check side clearance between the three pressure plate lugs and their respective slots in covers. Side clearance should be 0,15-0.30 mm [0.00(5-0.012 inch). If slots are excessively worn, renew covers.

Inspect clutch release bearing and renew if excessively worn or damaged.

To reassemble, position pressure plate on 912917 base plate so the Code 14 spacers are located below the release lever lugs, Place clutch inner cover (7) over pressure plate aligning marks made during disassembly. Install springs on inner cover, then place outer cover over the springs and onto the studs and spacers aligning match marks on covers. Tighten stud nuts evenly until outer cover contacts the spacers. Assemble release levers and install in their original positions on pressure plate.

Using clutch actuating tool or other suitable means, actuate release levers several times to be certain clutch springs are properly seated. Install 912723 adapter in center hole of base plate. Assemble 961845 guide pin into adapter and position Code 8 spacer on guide pin with recess side down. Install 961880 stud, 920203 gage and 961879 nut on the guide pin. Hold gage down firmly, then check clearance between each release lever and the gage. The levers must just touch gage or be within 0.05 mm (0.002 inch) of gage. To adjust clearance, add or remove shims (10) under roller pads (11). A variation of 0.025 mm (0.001 inch) in shim thickness will change release lever height approximately 0.114 mm (0.0045 inch). Adjust all levers to as near equal height as possible. Remove lever adjusting gage.

Reconnect release lever springs (21) in tabs of outer cover. Install adjusting screws (16), but do not adjust at this time. Place 11 mm (7/16 inch) nuts under each release lever, then remove nuts from base plate studs. Remove clutch assembly from base plate. Install release lever actuating plate (14).

Borg and Beck continuous clutch, use a pilot shaft made to dimensions shown

To reinstall clutch, place springs (1) in flywheel, then install inner disc with large hub towards flywheel. Install separator plate aligning marks on plate and flywheel made during removal. Install outer disc with side stamped "Fly-wheel Side" facing flywheel. Install pressure plate assembly aligning match marks made during removal. Use a suitable pilot tool to align inner and outer discs, then tighten clutch mounting bolts evenly to 68 N>m (50 ft.-lbs.) torque.

Using a feeler gage through holes in cover, check clearance between end of adjusting screws and the pressure plate. Clearance should be 1.77 mm (0.070 inch). Adjust the screws as required, then secure with locknuts.

Engine Oil Pan � Remove and Install

Engine Oil Pan (Aluminum)

Removal Procedure

Remove the flywheel housing.

Place a suitable container below the engine oil pan (7).

Remove:

- the drain plug (5) and drain the engine lubricating oil. Clean up any spillage of oil immediately.

- the O-ring seal (6) from the drain plug (5). Discard the O-ring seal.

Disconnect the breather hose (not shown) from the clip that secures the hose to the engine oil pan. Position the breather hose away from the engine oil pan. If necessary, remove the assembly of dipstick tube. Loosen the nut (1) and remove the tube assembly (2).

- the seal (3) from the tube assembly. Discard the seal. Identify the position and orientation of the tube assembly. Support the assembly of the engine oil pan. Loosen the long isolating screws (8) and the two short isolating screws (9). Mark the position of the clip that secures the breather hose (not shown).

- the clip. The isolating screws are held captive by the joint (1).

- the assembly of the engine oil pan from the tractor engine.

- the isolating screws (8) and (9) from the engine oil pan (7).

- the joint (4) from the engine oil pan (7). Discard the joint.

If necessary, follow Steps to remove the isolating frame from the cylinder block. Support the isolating frame (12). Use Tooling to remove the torx screws (11) and (13).

- the isolating frame (12) from the cylinder block.

- the joint (10). Discard the joint.

Installation Procedure

Install Tooling to positions (X) in the cylinder block. If necessary, follow Steps to install the isolating frame. Ensure that the joint face of the cylinder block is clean and free from damage. Ensure that the isolating frame is clean and free from damage. If necessary, replace the isolating frame.

Apply a bead of Tooling to positions (Y).

Position a new joint (10) onto the isolating frame (12). Align the isolating frame (10) with Tooling. Install:

- the isolating frame to the cylinder block. Use Tooling to install the two torx screws (11) and the four torx screws (13) to the isolating frame. Tighten the torx screws (11) to a torque of 22 N�m (16 lb ft). Tighten the torx screws (13) to a torque of 22 N�m (16 lb ft).

Ensure that the engine oil pan (7) is clean and free from damage. Clean the isolating screws (8) and (9). Inspect the isolating screws for deterioration or damage. If necessary, replace the isolating screws. If necessary, ensure that the joint face of the isolating frame is clean. The isolating screws must be replaced as a complete set in order to ensure the correct clamping of the engine oil pan. Position a new joint (4) onto the engine oil pan (7).

- the isolating screws (8) and (9) to the engine oil pan. Do not install the isolating screws (8) in positions (X). Refer to Illustration. The isolating screws are held captive by the joint. Align the assembly of the engine oil pan with Tooling.

- the assembly of the engine oil pan to the isolating frame (12). Install the clip that secures the breather hose (not shown) in the correct position.

(X) Position of guide studs.

(Z) Position of short isolating screws.

Tighten the isolating screws to a torque of 22 N�m (16 lb ft). Tighten the isolating screws in the sequence that is shown in Illustration. Remove Tooling.

- the four remaining isolating screws. Tighten the isolating screws to a torque of 22 N�m(16 lb ft). Tighten the isolating screws in the sequence that is shown in Illustration.

- a new O-ring seal (6) to the drain plug (5).

- the drain plug (5) to the engine oil pan (7). Refer to Illustration. Tighten the oil drain plug to a torque of 34 N�m (25 lb ft).

If necessary, follow Steps to install the assembly of the dipstick tube.

- a new seal (3) to the tube assembly (2). Apply Tooling to the nut (1).

- the tube assembly to the engine oil pan. Ensure that the orientation of the tube assembly is correct. Tighten the nut (1) to a torque of 18 N�m (13 lb ft).

- the dipstick. Fill the engine oil pan to the correct level.

- If necessary, install the flywheel housing.

Engine Oil Pan (Cast Iron)

 Removal Procedure

The tractor engine should be mounted in a suitable stand and placed in the inverted position. Disconnect the breather hose (not shown) from the clip that secures the hose to the engine oil pan. Position the breather hose away from the engine oil pan.

If necessary, remove the assembly of dipstick tube. Loosen the nut (1) and remove the tube assembly (2). Remove:

- the seal (3) from the tube assembly. Discard the seal. Identify the position and orientation of the tube assembly.

Attach a suitable lifting device to the engine oil pan (7) and support the weight of the engine oil pan. The engine oil pan can weigh 100 kg (220 lb). Use Tooling in order to remove the four torx screws (11).

- the nuts (10).

- the setscrews (8) and (9). The setscrews are different lengths. Note the position of the different setscrews. Use the lifting device to remove the engine oil pan (7) from the cylinder block.

- the joint (4) from the cylinder block. Discard the joint.

- the drain plug (5).

- the O-ring seal (6) from the oil drain plug (5). Discard the O-ring seal.

Installation Procedure

Ensure that the joint face of the cylinder block is clean and free from damage. Inspect the studs in the cylinder block (not show) for damage. If necessary, replace the studs. Ensure that the engine oil pan is clean and free from damage.

Apply a bead of Tooling to positions (Y).

Align a new joint (4) with the studs (not shown) and install the joint to the cylinder block. Attach a suitable lifting device to the engine oil pan (7). The engine oil pan can weigh 100 kg (220 lb). Use the lifting device to align the engine oil pan (7) with the studs (not shown). Install:

- the engine oil pan to the cylinder block.

- the setscrews (8) and (9), the nuts (10) and the torx screws (11) finger tight. Align the rear face of the engine oil pan to the rear face of the cylinder block. Use Tooling and a feeler gauge in order to check the alignment between the engine oil pan and the cylinder block.

Tighten the setscrews (8) and the nuts (10) to a torque of 22 N�m (16 lb ft). Tighten the fasteners in the sequence that is shown in Illustration.

Tighten the remaining setscrews to a torque of 22 N�m (16 lb ft). Tighten the setscrews in the sequence that is shown in Illustration. Use Tooling to tighten the torx screws to a torque of 22 N�m (16 lb ft). Refer to Illustration.

- a new O-ring seal (6) to the drain plug (5).

- the drain plug (5) to the engine oil pan (7). Tighten the drain plug to a torque of 34 N�m (25 lb ft).

If necessary, follow Steps to install the assembly of the dipstick tube.

- a new seal (3) to the tube assembly (2). Apply Tooling to the nut (1).

- the tube assembly to the engine oil pan. Ensure that the orientation of the tube assembly is correct. Tighten the nut to a torque of 18 N�m (13 lb ft).

- the dipstick (not shown). After the diesel engine has been installed, ensure that the engine oil pan is filled with lubricating oil to the correct level.

Tractor hydraulic system - Oil decontamination

The correct operation and performance of the hydraulics system is closely linked to the use of clean transmission oil. When maintenance is carried out on the gearbox / axle assembly (e.g. brake or transmission repairs) this contaminates virtually the whole hydraulic circuit. It is therefore essential to carry out a decontamination operation after repairs in order to avoid the rapid deterioration of other components in the circuit caused by the movement of particles carried by the oil. The contamination of oil can result in:

- seizure or leaks in the steering spool valve (Orbitrol)

- seizure of the spool valves in the solenoid valves

- excessive wear in the hydraulic pump(s).

The aim of oil decontamination is to restore the hydraulic circuit to a state of cleanliness higher than that before the repair operation. The particles that cause the greatest damage are not the largest ones, for these are rapidly caught in the filter, it is the repeated circulation of small non-filtered particles that has the greatest abrasive effect.

Decontamination procedure

Special point

- The decontamination is carried out in two distinct phases.

The static phase

- This takes place immediately after the repair operation, without moving the tractor.

- Check that the oil has been replaced after the repair operation.

- During this phase, no low-pressure components should be activated.

- The decontamination is carried out by circulating the contaminated oil to the housing return through filter elements in order to rapidly remove any particles suspended in the oil.

Preparation of the tractor 

The equipment used for oil decontamination is two hose pipes of a suitable length fitted with a female diagnostics connector, on one of the ends.

Disconnect the temperature switch (3) (Heavy Duty transmission) and ground it to earth in order to neutralise its action.

Connect the female diagnostics connector of each hose pipe on the male connectors (1) (2) of the lowpressure circuit. These connectors are respectively located on the right-hand side hydraulic cover, on the clutch valve or the Reverse Shuttle hydraulic control unit, depending on the version.

Fasten the other end of the hose pipes without connectors to the return port R.

Decontamination

- The oil temperature must be above 10� C to avoid the opening of the by-pass. Start the engine and run it at 1200 rpm.

Allow the engine to run for 15 minutes minimum in order to filter out the particles in the oil. Check that the clogging indicator lamp on the dashboard does not light during the decontamination operation. If this does happen, replace the 15-micron filter element and check or change the suction strainer.

After having let the engine run for 15 minutes, stop the engine and replace the 15-micron filter by a 6-micron filter. Procure a hose pipe of appropriate strength, fitted at each end with a male quick-disconnect coupling for connection to the auxiliary spool valves.

Connect the connectors of the flexible to ports A and B of the same spool valve. Start the engine and run it at 1200 rpm.

While the engine is running, turn the knurled knob of the spool valve to maximum flow and alternate the direction of oil circulation in the spool valve for approximately 5 minutes using the control lever. Repeat the operation on the two or three other spool valves (depending on options).

- If the clogging indicator lamp lights on the dashboard, replace the 6-micron filter element by another of the same type.

Dynamic phase

- Contrary to the static phase, the dynamic phase uses all the hydraulic functions of the tractor for 15 minutes with the engine running:

- lift control

- steering

- power take off

- brakes

- etc.

Preparation of the tractor

Remove all the hose pipes used during the static phase.

Procedure

- During decontamination, carefully monitor the dashboard clogging indicator. If necessary, immediately replace the 6-micron filter and the suction strainer.

Raise and lower the lift arm over the entire travel of the rams and carry out a rapid alternating raise and lower cycle. Turn the steering wheel to full lock in both directions several times. Declutch and allow the clutch in and out 5 or 6 times using the full travel of the pedal (tractors with Heavy Duty transmission). Repeat the same operation again more quickly. Press and release each of the unlatched brake pedals several times. Repeat the same operation more quickly. Slowly press and release the latched pedals several times. Repeat the same operation again more quickly.

Activate the Dynashift control, located on the left beneath the steering wheel, moving it from A to D and vice versa several times. Operate and halt the power take off 4 or 5 times, one after another. Reconnect the temperature switch.

Test

Carry out a road test the tractor using various engine speeds, changing up and down through the ratios for approximately 15 minutes.

When the road test is completed, let the engine run at 1200 rpm for approximately 15 minutes with the tractor stationary, in order to eliminate any remaining particles in the circuit.

Preparing the tractor for service

When all these operations have been completed, prepare the tractor for service by replacing the suction strainer and the 6-micron filter used for decontamination with a new and original spare parts suction strainer and 15-micron filter, as referenced in the Spare Parts catalogue.

Diagrams

Parts list 

(1) Decontamination connectors (low pressure)

(2) Decontamination connector on clutch valve or Power shuttle hydraulic control unit (Heavy Duty transmission)

(3) Temperature switch (Heavy Duty transmission)

(4) Oil decontamination replaceable oil filter element (6 micron)

(5) Clogging indicator

A : Pressure Load ed - Mechanical reverse shuttle version

B : Reverse shuttle version

Parts list 

(1) Decontamination connectors (low pressure)

(4) Oil decontamination replaceable oil filter element (6 micron)

(5) Clogging indicator

Clutch control valve of heavy duty transmission circuit

On tractors fitted with a Heavy Duty gearbox, with a mechanical reverse shuttle, the distribution block (1) mounted on the front right-hand side of the gearbox is formed of two distinct parts that ensure the control of the clutch and the four Dynashift ratios.

- The clutch part comprises a series of spools, seals, a valve and piston. These can be replaced by a kit that is found in the Spare Parts catalogue.

- The Dynashift part.

Role of the control valve

Fitted in the 17 bar circuit, this valve provides the following functions:

- 17 bar supply to the clutch when the clutch pedal is released (clutch engaged position).

- modulation of the clutch engagement pressure: 0 to 11 bar.

- starting safety when the tractor is started using external assistance. To activate the clutch it is necessary to press the clutch pedal once.

- low pressure starting safety. The clutch disengages automatically if the pressure drops below 3 bar.

- the ports O allow leaks to return to the housing.

(1) Distribution block

(2) 17 bar supply

(3) Accumulator on 17 bar line

(4) Master cylinder hose pipe

(5) Clutch supply pipe

(6) Clutch diagnostics connector

(7) Dynashift front piston diagnostics connector

(8) Dynashift rear piston diagnostics connector

(9) Accumulator for brake assistance

Description

- The valve comprises two spools. The upper spool is controlled by pressure from the clutch master cylinder and controls the clutch supply.

- The lower spool, controlled by the inlet pressure, provides hydraulic safety for the system.

Operating phases of the clutch Valve

Neutral position, engine running 

P = 17 bar

R = Return

E = Clutch

- If the tractor is started without pressing the clutch pedal, the pressure rises to 17 bar but all the suction ports are closed and the clutch is not supplied.

Disengagement before switching the safety valve 

P = 17 bar

R = Return

E = Clutch

- The main spool (5) is pushed to the rear and compresses spring (2) under the effect of piston (19) that is controlled by the master cylinder. The pressure coming from the 17 bar circuit passes via the shoulder of the main spool (5) and begins to act on the front face of spool (4), the clutch is then linked to the return.

Clutch disengagement, switching the safetyvalve 

- The spool (4) moves to the rear when the pressure is greater than 12 bar. During full opening, spool (4) allows communication with the front of the main spool (5).

Clutch engagement, modulation phase 

- When the pedal is released, the pressure supplying the clutch is modulated by the position of the main spool (5). This position is regulated:

- at the rear by the 17 bar pressure and spring (2)

- at the front by the clutch pressure and spring (16)

- When the pedal is slightly released, the spring tension (2) diminishes. The main spool (5) moves forward and places the 17 bar line in communication with the clutch.

- The pressure in the clutch increases and this pushes the spool to the rear to find its equilibrium position.

Clutch fully engaged 

- When the pedal is completely released, spring (2) pushes spool (5) forwards and causes the full opening of the 17 bar circuit to the clutch.

- From this intermediate position, when the pedal is slightly pressed, the force acting on spring (2) is increased. The spool moves rearwards opening the communication between the clutch and the return.

- The pressure in the clutch diminishes and the spool moves forward to find its equilibrium position.

- The modulation begins after having pressed the pedal approximately 32 mm. The declutched position is reached 25 mm before the farthest pedal position is reached.

Parts list 

(1) Plug (2) Spring (3) Non-return valve (4) Safety-valve spool (5) Main spool (6) Safety-valve sleeve (7) Valve body (8) Main spool sleeve (9) Plugs (10) O�ring (11) Circlip (12) Spring (13) Push rod (14) Circlip (15) Spring (16) Modulation spring (17) Seal quadring (18) Guide segments (19) Piston

(20) Calibrated union (21) Modulation limit stop (22) Main spool limit stop

Disassembling and reassembling the valve 

Preliminary operation

- To remove the valve.

Disassembly

Using a locally manufactured tool, remove circlip (11) and take out plug (9) from the A assembly. Using the same method for the B assembly. Remove the A and B assemblies while visually noting their positions. Unscrew plug (1) and remove the C assembly as in the previous operation.

Reassembly

Check and clean the parts. Replace any components found to be scratched or distorted. Check that valve (4) and spool (5) spool freely in the sleeves (6) (8). Before reassembly, lubricate the seals with transmission oil. Replace o�rings (10) and the assemblies A, B and C using repair kits. Fit circlips (11).

Before fitting the piston of assembly A, bend guide segments (18) in a circular manner and lightly smear them with miscible grease so as to correctly position them in the grooves of the piston, the knurled faces turned towards the valve body.

- Union (20) is fitted with a calibrated port.

Final operations

Refit and bleed the clutch control valve. Check the modulation pressure of the valve.

Tightening torques 

- Plug (1) smeared with Loctite 542: 50 Nm.

- Non-return valve (3): 28 - 30 Nm.