Trima Service Manual
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- Words: 6,954
- Pages: 52
SERVICE SCHOOL 2002
1. Loader 2. ELC 3. FLD 1000 4. AutoSafe 5. 3rd - 4th function 6. TMD 7. TCC 8. General hydraulics 9. General attachments 10. Evaluation of welding quality 11. Evaluation template for twisted loader 12. Instruction manual 13. Claims under warranty 14. Trima accessories
Loader / Section 1
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Loader operation - Test Lift and lowering function Operate all the loader functions to maximum travel. Check that everything is functioning normally and that there are no oil leaks. See the following section if anything does not function normally: ■ ■ ■ ■
Troubleshooting to locate faults Adjustments Other information for additional details Instruction manual for a description of the function
Float position Check that the float position is locked in the position by moving the lever past the lowering position. A small resistance must be overcome before engaging the float position. If the locked position cannot be reached, see ■ Adjustment of float position ■ Instruction manual
SafeLock Check that the lever can be locked with the SafeLock function. Check that the loader does not begin to drop when SafeLock is in the locked position. If SafeLock does not function, see ■ Adjustment of SafeLock ■ Instruction manual
Loader operation - Test
200 N (20 kg)
Implement latch Check the locking mechanism by moving the lever back and forth. The lever has an interlock position that is overcome by pushing the lever backwards. It is important for this resistance to be present to prevent the lock from being opened unintentionally. If the latch requires adjustment, see ■ Adjustments ■ Instruction manual
Implement connection and disconnection Check that the implement can be connected and disconnected easily. If it is not possible to connect the implement, check the connection hooks of the implement and the implement frame. For connection and disconnection, see ■ Instruction manual, pages 11-12
Loader connection and disconnection Check that the loader can be connected and disconnected readily, and that the loader can be locked easily with the locking pins. If the loader does not assume a position in which the locking pin can be easily inserted, check that the paint has been removed from the contact surfaces. For connection and disconnection of the loader, see ■ Instruction manual, pages 15-19
Troubleshooting, loader Possible faults External leakage in lift rams. Internal leakage in lift rams. Leakage via seal on non return valve. Leakage via seal on plug in connection a1. Leakage via spool in loader valve.
Symptom Loader drops Check tolerances for internal leakage for the loader valve. (See section 8)
Location of fault External leakage ( lift rams )
Visual inspection
Remedy In the case of visible leakage, replace the seal kit. Also check that no mechanical damage is present on the internal parts of the ram.
Internal leakage ( lift rams )
Move the loader to its maximum lift height. Then move the lever to its neutral position.
If the loader stops dropping, replace the seal kit. Also check that no mechanical damage is present on the internal parts of the ram.
Internal leakage ( control valve ) Check the o-rings on the non return valve for the lift spool. Check the o-ring on plug a1.
In the case of visible faults in the o-rings in the non return valve and the plug, replace the seals. If the loader continues to drop, replace the control valve.
Troubleshooting, loader Symptom Implement drops Check toleraces for internal leakage for the loader valve. ( See section 8 )
Possible faults External leakage in implement rams. Internal leakage in implement rams. Leakage in shock valve (210 bar). Internal leakage in 3rd or 4th function valve. Leakage via seal in non return valve. Leakage via seal on plug b2.
Location of fault External leakage in implement rams
Visual inspection
Remedy In the case of visible leakage, replace the seal kit. Also check that no mechanical damage is present on the internal parts of the ram.
Internal leakage in implement rams
Lift the loader with a load in the implement and with the hoses for the implement function disconnected at the control valve. Connections A2 and B2.
If the implement stops dropping, see Internal leakage in control valve. If the implement continues to drop, the fault lies in the implement rams, shock valve (210) bar, AutoSafe valve, if fitted, or in the 3rd or 4th functions, if fitted.
Troubleshooting, loader Symptom Internal leakage in shock valve
Visual inspection Reverse the position of the shock valves on the cross member.
Possible faults If the implement stops dropping, replace the 210 bar shock valve. If the implement continues to drop and no extra hydraulic functions are installed, replace the seal kit in the implement ram. Also check that no mechanical damage is present on the internal parts of the ram
Internal leakage in 3rd/4th function
Bypass the 3rd/4th function valve. Use 2 x 3/8”x3/8” adapters.
If the implement stops dropping, replace the complete valve.
Internal leakage in control valve
Check the o-rings on the non return valve for the lift spool. Check the o-ring on plug b2.
In the case of visible faults in the o-rings in the non return valve and the plug, replace the seals. If the loader continues to drop, replace the control valve.
LIFT / TILT Non return valves
Troubleshooting, loader Symptom Lift function weak
Check specification Tractors
hp kW
Loader model
45-80 33-59 3.10c
60-100 44-74 3.40 3.60
3.20
3.65 3,90
75-150 55-110 4.60 3,70
90-150 90-260 66-110 66-192 4.80 4.85 5.80
H1 Lift height to pivot point (m)
3,15
3,55
3,55
3,75
H2 Lift height under level implement (m)
2,95
3,30
3,30
3,50
3,70
3,50
3,75
3,95
3,60
1800
2200
2200
2100
2400
2800
4,00
2500
4,20
2650
3,85
Lift capacity at pivot point at 185 bar oil pressure L1a - at ground level (kg) L3a - max. height (kg)
2100 1300
1350
1900
1950
1800
1950
2300
2150
2200
Lift capacity, 750 mm from pivot point at 185 bar oil pressure L1 - at ground level (kg)
1650
1600
1900
2000
1800
2100
2500
2200
2400
L2 - at 1.5 m height (kg)
1400
1250
1600
1800
1650
1850
2250
2050
2200
L3 - max. height (kg)
1200
1100
1500
1600
1600
1700
2050
1900
1950
Max tear-out force 750 mm from pivot point 1700
1900
2600
2600
2600
3350
3350
3350
2800
B1 crowd anglel SMS/W -frame
35/39
41/45
41/45
41/45
41/45
41/45
42/46
43/47
39/43
B2 crowd angle SMS/W -frame
42/46
50/54
50/54
50/54
50/54
50/54
50/54
50/54
56/62
T1 dump angle SMS/W -frame
56/62
59/55
59/55
59/55
55/51
55/51
54/50
48/44
56/52
T2 dump angle SMS/W -frame
86/82
94/90
94/90
94/90
94/90
99/95
99/95
99/95
84/78
Possible faults If the lifting capacity is too low, this could be due to excessively low hydraulic pressure.
Lift capacity, 750 mm from pivot point at 185 b
Location of fault cause Measure the system pressure with a pressure gauge between the lift hose and the control valve.
L1 - at ground level (kg)
1650
L2 - at 1.5 m height (kg)
1400
L3 - max. height (kg)
1200
At a low value, listen to establish whether the relief valve in the loader’s control valve is blowing.
bar
Remedy If the sound of fluid transfer is heard, replace the relief valve. If no sound is heard, or if no relief valve is fitted, the hydraulic system of the tractor must be checked by an appointed workshop.
Troubleshooting, loader Symptom Implement function is to weak
Check specification Tractors
hp kW
Loader model
45-80 33-59 3.10c
3.20
60-100 44-74 3.40 3.60
3.65
75-150 55-110 4.60
3,90
3,70
90-150 90-260 66-110 66-192 4.80 4.85 5.80
H1 Lift height to pivot point (m)
3,15
3,55
3,55
3,75
H2 Lift height under level implement (m)
2,95
3,30
3,30
3,50
3,70
3,50
3,75
3,95
3,60
1800
2200
2200
2100
2400
2800
4,00
2500
4,20
2650
3,85
Lift capacity at pivot point at 185 bar oil pressure L1a - at ground level (kg) L3a - max. height (kg)
2100 1300
1350
1900
1950
1800
1950
2300
2150
2200
Lift capacity, 750 mm from pivot point at 185 bar oil pressure L1 - at ground level (kg)
1650
1600
1900
2000
1800
2100
2500
2200
2400
L2 - at 1.5 m height (kg)
1400
1250
1600
1800
1650
1850
2250
2050
2200
L3 - max. height (kg)
1200
1100
1500
1600
1600
1700
2050
1900
1950
Max tear-out force 750 mm from pivot point 1700
1900
2600
2600
2600
3350
3350
3350
2800
B1 crowd anglel SMS/W -frame
Location of fault cause Perform the same inspection as for a weak lifting function
Location of fault cause Slow loader
35/39
41/45
41/45
41/45
41/45
42/46
43/47
39/43
42/46
50/54
50/54
50/54
50/54
50/54
50/54
50/54
56/62
56/62
59/55
59/55
59/55
55/51
55/51
54/50
48/44
56/52
T2 dump angle SMS/W -frame
86/82
94/90
94/90
94/90
94/90
99/95
99/95
99/95
84/78
Max tear-out force 750 mm from pivot point 1700 B1 crowd anglel SMS/W -frame
35/39
B2 crowd angle SMS/W -frame
42/46
T1 dump angle SMS/W -frame
56/62
T2 dump angle SMS/W -frame
86/82
Check the specification and measure the time with the oil at its operating temperature.
Loader 2.10-3.10-3.10c-3.20 1.50-2.20-2.40 3.40-3.55-3.60-3.65 4.60 2.70-4.70-4.75-4.80-4.85 5.80
Lifting time 5.0 sec. 6.5 sec. 6.5 sec. 8.0 sec. 8.5 sec. 9.0 sec.
Loader
Dumping witt full travel of bucket 2 sec. 2.5 sec. 3 sec.
2.10-3.20 3.40-3.65 4.60-4.85-5.80
41/45
B2 crowd angle SMS/W -frame T1 dump angle SMS/W -frame
Possible faults If the tear out force is too low, this will be due to excessively low hydraulic pressure Remedy If the measured pressure is in accordance with the specification, move the pressure gauge to the crowd feed hose. If the pressure is lower, replace the 210 bar shock valve on the cross member. Possible faults If the loader is slow, this will be due to a low oil flow.
Working times at a pump capacity of 40 l/min
Dumping from parallel position 1 sec. 1.5 sec. 2 sec.
Troubleshooting, loader Location of fault cause Check the quickcouplings and the return line.
Possible faults If a constriction is located, replace the defective component.
If no visible problem can be identified, check the hydraulic flow of the tractor with a flow meter.
If the flow is low, the fault must be must be corrected by an appointed workshop.
LIFT / TILT Non return valves
Fault symptom Lift or implement function dips slightly before lifting during operation.
Possible faults Leak in non return valve.
Location of fault cause Disconnect the non return valve for the function that dips.
Remedy Clean and test. If the fault remains, replace the non return valve.
Fault symptom Single-lever control is difficult to operate.
Possible faults Lack of lubrication.
Remedy Clean and lubricate.
Cable seized.
Check whether the cable is trapped or is installed with an excessively small radius.
Spool seized in control valve.
Remove the cable cover and operate the spool manually. If it is heavy, remove the spool and clean. If any mechanical damage is evident, replace the complete control valve.
Adjustment of Float position and SafeLock Float position, RMT 90 valve The allen screws (1) holding the adjustment caps on the loader valve must be removed to allow adjustment of the loader float position (4 mm allen key). Rotate the adjusting cap (2) to adjust the position of the lever. N.B. To achieve an efficient function for the float position, the single-lever must be adjusted slightly backwards in relation to the lever housing. Fasten the adjusting cap with the screws (1) once adjustment is complete.
2 1
Float position, Walvoil valve The allen screws (16) must be released a few turns (4 mm allen key) to permit adjustment of the loader’s float position. Rotate the adjusting cap (15) to change the position of the lever. N.B. To achieve an efficient function for the float position, the single-lever must be adjusted slightly backwards in relation to the lever housing. Fasten the adjusting cap with the screws (16) once adjustment is complete. SafeLock Move the locking mechanism (3) to the locked position. If it cannot be locked, move the control lever forwards until the lock engages. N.B. The loader must not begin to drop in this position. The floating position must be re-adjusted if the loader begins to drop.
16 15 Min 400
3
ELC / Section 2
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Operation - Test ELC
Check that the joystick is correctly adjusted. Check the proportionality between the joystick and the loader valve.
Before calibration. See Adjustments.
Check that the float position and the 3rd and 4th functions can be activated and de-activated.
See General instructions. In the event of functional disorder. See Troubleshooting.
Troubleshooting, ELC Problem Loader functions fail. Lights on the joystick cannot be activated.
Cause Electrical fault
Remedy Check the power supply to the joystick. Repair as necessary. Replace the joystick if the power supply is correct.
Loader functions fail. Lights for the 3rd and 4th functions and the float position cannot be activated.
Electrical fault
Check and repair the power supply (wiring) between the joystick and the loader servo valve. Check and adjust the servo pressure. 15-20 bar.
Slow loader functions.
Low servo pressure. (RMT 90 valve only) Incorrectly adjusted joystick
Check and adjust the servo pressure. 15-20 bar. Re-adjust the joystick.
3rd and/or 4th functions fail.
Electrical fault
Check and repair the power supply between the joystick and the connector for the 3rd and 4th function. See also Troubleshooting – 3rd and 4th functions.
Float position fails.
Electrical fault (RMT 90 valve only)
Check and repair the power supply to the float position solenoid.
Faulty solenoid Faulty solenoid valve (RMT 90 valve only)
Test and replace, if required. Remove and clean the servo valve. Test. Replace the solenoid valve, if required.
Incorrect connection of return hose for electrical servo (RMT 90 valve only)
Check the return connection. This must be pressure-free and it may not be connected to other return lines.
Incorrectly adjusted joystick
Re-adjust the joystick.
Low servo pressure. (RMT 90 valve only)
ADJUSTMENT INSTRUCTIONS Programming of 3rd and 4th functions 1. Activate the ELC main switch on the instrument panel. 2. Press down the switch on the joystick and turn on the ignition. 3. Release the switch after approx 1 second, after which one or more of the lamps will light up. 4. Find the alternative that you need in the table below. Move through the alternatives by pressing the switch repeatedly until one or more lamps light up indicating your selection. Only one selection at a time can be programmed. 5. Acknowledge your choice by holding down the switch until the lamp/lamps go out. Note. A green lamp will light if alternative 2 is selected. 6. “Ready for use” and the selected alternative will now be displayed until another selection is made. O = lamp extinguished
= lamp lit
Programming Alternative Yellow Lamp
Green Lamp
Function Red Lamp O
Alt: 1 Alt: 2
3rd loader function only (on – off). Float position can be used.
O
Alt: 3
O
Alt: 4
O
3rd or 4th loader function
3rd loader function only or 3rd and external 4th function simultaneously.
O
O
3rd loader function only (on-off). Float position cannot be used
OPERATING INSTRUCTIONS 3rd and 4th functions and float position Activated lamp lights Yellow lamp
Alt 1
Alt 2
Alt 3
Green lamp
Activation and operation
Red lamp 3rd function: Hold down the switch, and move the lever to the right until the green lamp lights. Release the switch, and move the lever to the neutral position. The 3rd function can now be operated with a tilting movement of the joystick. 4th function: Hold down the switch, and move the lever to the left until the yellow lamp lights. Release the switch, and move the lever to the neutral position. The 4th function can now be operated with a tilting movement of the joystick. 3rd function: can be operated with a tilting movement of the joystick when the switch is held down. Note: Trima bale handler. 3rd function: Hold down the switch, and move the lever to the right, and then move the lever to the left, until the green lamp lights. Release the switch, and move the lever to the neutral position. The 3rd function can now be operated with a tilting movement of the joystick. External 4th function together with 3rd function: Hold down the switch, and move the lever to the right until the yellow and green lamps light up. Release the switch, and move the lever to the neutral position. The implement function can now be operated with a tilting movement of the joystick. Note: Trima V- plough Connecting float position: Press down the switch on the joystick and pull back the lever until the red lamp begins to flash. The floating position is now programmed so that it goes “in” when the lever is moved forwards to its full extent, and “out” when the lever is moved backwards. The lamp remains lit when the float position is “in”.
De-activation takes place by repeating the same procedure as for activation. Note! When the loader is not being used in tractor work the main switch on the instrument panel should be deactivated to prevent accidents.
ADJUSTMENT INSTRUCTIONS ELC No 1 Valid for joystick 431 835 with production numbers from 00-18-XX. Manufacturing sign, see joystick bottom. The adjustment of proportionality between joystick and loader valve shall only be done if necessary and with warmed up oil. Basic joystick adjustments are made at Trima.NOTE! When adjusting, always observe loader movements.
Starting position (must always be performed): 1. Hold down the joystick switch, activate the ELC main switch, start the tractor. 2. Release the switch when all the lamps light up. (After approx 3 seconds the lamps will begin to flash, after 3 seconds more the lamps will show a steady light). The yellow lamp will now begin flashing. 3.
1. 2.
Maintain the engine speed at ca. 10001300 rpm (hand throttle). Use a lower engine speed for a larger hydraulic pump.
Adjustment of lifting function: 4a. The yellow lamp must flash rapidly. Start position lift. Pull the lever slowly backwards until the lifting function begins to react (1), then slowly allow the lever to return to the position at which the function stops (2), not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light. Release the switch. Release the lever to neutral position. 4b. The yellow lamp must flash slowly. Max position lift. Pull the lever slowly backwards to the position in which the lifting function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position. 1
ADJUSTMENT INSTRUCTIONS ELC No 1 cont´d
1. 2.
Adjustment of lowering function: 5a. The green lamp must flash rapidly. Start position lowering. Push the lever slowly forwards until the lowering function begins to react (1),then slowly allow the lever to return to the position at which the function stops, not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
5b. The green lamp must flash slowly. Max position lowering. Push the lever slowly forwards to the position in which the lowering function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
ADJUSTMENT INSTRUCTIONS ELC No 1 cont´d
1. 2.
Adjustment of tilt function: 6a. The yellow lamp must flash rapidly, and the red lamp must remain lit. Start position tilt. Move the lever slowly to the right until the tilt function begins to react (1), then slowly allow the lever to return to the position at which the function stops, (2) not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
6b. The yellow lamp must flash slowly, and the red lamp must remain lit. Max position tilt. Move the lever slowly to the right to the position in which the tilt function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
ADJUSTMENT INSTRUCTIONS ELC No 1 cont´d 1. 2.
Adjustment of crowd function: 7a. The green lamp must flash rapidly, and the red lamp must remain lit. Start position crowd. Move the lever slowly to the left until the crowd function begins to react (1), then slowly allow the lever to return to the position at which the function stops (2), not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position 7b. The green lamp must flash slowly, and the red lamp must remain lit. Max position crowd. Move the lever slowly to the left to the position in which the crowd function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position. The yellow lamp will now begin to flash rapidly, at the same time as the red lamp is extinguished. Finish with confirmation. Confirmation position (must always be performed): 8. Hold the joystick lever in the neutral position. Push down the switch, wait until all the lamps light up, and release the switch. The ELC is now ready for use. Test and readjust if required.
Note 1. Each adjustment phase may be performed separately, but must be preceded by “Starting position” and terminated with “Confirmation position”. Switching between adjustment phases can take place by pressing the joystick button repeatedly in neutral position.
FLD 1000 / Section 3
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - FLD 1000 Check that the tractor can be raised when the relief valve is open, and that the tractor is slowly lowered when the control lever is moved to the neutral position.
In the event of functional disorder. See Troubleshooting.
Check that the tractor remains in the raised position when the relief valve is closed and the control lever is moved to the neutral position. Check that the suspension system works when the relief valve and the accumulators are activated.
Troubleshooting, FLD 1000 Symtom Loader feels solid.
Possible fault Accumulators closed. Relief valve closed.
Remedy Open the accumulator shut-off tap. Open the relief valve.
Loader feels dead with the accumulators open.
Accumulator fault.
Close the press valve. Rock the loader. If the loader is solid, replace the accumulators.
Loader feels solid with the press valve open.
Relief valve fault.
Raise the front end of the tractor with the loader. The tractor must drop to the ground when the single-lever control returns to the neutral position. If not, replace the relief valve.
AutoSafe / Section 4
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Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - AutoSafe Check the function of the AutoSafe. Activate the switch and crowd the implement frame, the locking pins will open. De-activate the switch and crowd the implement frame, the locking pins will lock.
See instruction manual page 13.
In the event of functional disorder. See Troubleshooting.
Troubleshooting - AutoSafe Problem Locking pins seek to engage from the opened, activated position if the implement frame is tilted forward against the mechanical stop.
Cause Normal
Remedy None
Locking seeks to engage from the activated position when the singlelever control returns to the neutral position after opening. Or: Locking seeks to engage from the open position when the implement frame is tilted forwards.
Internal leakage in the locking cylinder.
Fit new seals to the cylinder (seal kit 420 079). Check that there is no mechanical damage to constituent parts of the cylinder.
Locking will not open during activation and operation.
No power supply to the switch. No power supply from the switch. Defective solenoid.
Check the 8 Amp fuse.
Locking will not open during activation (new installation).
Check the wiring.
Defective electrically actuated valve. As above.
Test and replace the solenoid if defective. Clean and test. Replace the electrically actuated valve if defective.
As above.
As above.
Hoses wrongly connected to the C and D unions of the AutoSafe valve.
Reconnect hoses C and D.
3:rd – 4th function / Section 5
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - 3rd and 4th function Check that the 3rd and/ or the 4th function operate when the switch is activated. When in use, the respective function will be controlled via the implement function of the loader. The implement frame must not move when these functions are used.
In the event of functional disorder. See Troubleshooting.
Troubleshooting 3rd – 4th function Symtom 3rd or 4th function does not operate.
Possible fault Electrical fault.
Remedy Check the fuse and the cable to and from the switch.
Defective solenoid.
Test the solenoid with a metal tool to determine whether it becomes magnetic on activation. If not, replace the solenoid.
Spool seized in valve.
Remove and clean.
Spool seized after inspection and cleaning.
Replace the valve.
TMD / Section 6
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Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - TMD Check that the locking mechanism for the locking handle is not seized. Check that the TMD can be opened and closed without resistance. Check for oil leaks in any coupling component.
In the event of functional disorder. See Troubleshooting.
Troubleshooting – TMD Problem TMD leaks when connected. Oil exits from one or more of the drain holes.
Cause Leaking seal in male coupling.
Remedy Replace seal “N” in the male coupling in the mobile part (loader part). Test.
TMD still leaks after implementation of the above remedy.
Leaking seal in female coupling.
Replace female coupling “L” in the fixed part (tractor part). Test.
TMD still leaks after implementation of the above remedy.
Deformed lever.
Check lever “D” and its attachment. Replace the lever if necessary. Test.
TMD leaks when connected under pressure. Oil exits from one or more of the drain holes.
Leaking seal in male coupling.
Replace seal “N” in the male coupling in the mobile part. Test.
Worn female coupling.
Replace coupling “L” if necessary.
Worn male coupling.
Replace coupling “M” if necessary.
Deformed lever.
Check lever “D” and its attachment. Replace the lever if necessary. Test.
TMD leaks in the mobile part (loader part) after disconnection.
Leaking seal in male coupling.
Replace seal “N” in the male coupling in the mobile part. Test.
Worn male coupling.
Replace coupling “M” if necessary.
TMD leaks in the fixed part (tractor part) after disconnection.
Worn female coupling.
Replace coupling “L” if necessary.
TCC / Section 7
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Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - TCC Check that the clutch is disconnected when any of the TCC’s switches are activated. Check all the switches. Also check that the foot brake connection (if present) functions correctly. Check this when activated and de-activated. Check that the linkage position for the clutch is correctly adjusted.
In the event of functional disorder. See Troubleshooting. See Linkage position adjustment
Troubleshooting and operator’s instructions – TCC Functional faults in conjunction with new assembly. Problem Clutch pedal does not go down.
Clutch pedal does not go down fully.
Clutch “grabs” or slips.
Cause Electrical fault.
Remedy Check the electrical installation.
Drain valve open. (Applicable only to accumulator system).
Close the drain valve.
Incorrect assembly.
Check the length of stroke of the cylinder (max 50 mm).
Low pedal pressure.
Adjust the pedal pressure.
Incorrect bite position.
Adjust the bite position.
Troubleshooting and operator’s instructions – TCC Functional disorder after a period of use. Problem Clutch pedal does not go down.
Cause Electrical fault.
Remedy Check the fuse and electrical lines.
Clutch pedal does not go down fully.
Low pedal pressure.
Check the pressure and adjust if necessary.
Clutch pedal does not go down after stopping the engine. (Accumulator model).
Accumulator fault.
Replace the accumulator.
Operator’s instructions 1. The TCC is activated via electrical switches positioned on the gear levers. 2. The TCC is activated via the brake pedal. 3. Electrical switches on the gear levers are convenient during transport driving, which completely relieves the load on the left leg. 4. Disengagement via the foot brake is more appropriate in conjunction with loader operation and inching. The foot brake function is engaged via a switch conveniently positioned on the instrument panel. With the foot brake function activated, the tractor is automatically disengaged during braking, and engaged again when the brake is released. When inching, the TCC is activated by depressing the brake pedal, when disengagement takes place automatically. The pressure on the brake pedal is then released, and the brake pedal is depressed once more when the tractor begins to move. it is possible to inch in this way by alternately depressing and releasing the brake pedal. By closing the needle valve progressively, the tractor will move progressively more slowly. Note that the foot brake function must not be connected during transport driving.
TCC – ADJUSTMENT OF THE BITE POSITION 1) Run the tractor until the oil reaches working temperature. 6
5
2) Stop the engine. Remove the outer sleeve on the adjusting rod (No5) 3) Turn the adjusting rod inwards until 10 mm is visable. 4) Close the needle valve ( No 6 ). Start the engine. 5) Disengage the clutch using one of the TCC switches.
5
6) Engage 1st gear and increase engine speed to 1400 rpm using the hand throttle. 7) Release the handbrake. 8) Release the TCC switch to allow the clutch pedal to move upwards. 9) Adjust the rod No3 outwards until you feel the rear wheels begin to turn. Important! Engage the handbrake, and stop the engine when this adjustment is being carried out. 10) Opening the needle valve at this point will allow the pedal to move and engage drive smoothly. 11) In the event of not obtaining the correct bite adjustment, repeat steps 4,5,6,7,8 and 9. 12) Close the needle valve. 13) Disengage the clutch using one of the TCC switches. 14) Release the TCC switch. 15) Stop the engine, and engage the handbrake. 16) Fit the outer sleeve back onto the adjusting rod. 17) The bite position is now set correctly.
General hydraulics / Section 8
Walvoil- and Nordhydraulik RMT 90 loader valve Checking for internal leakage Hydraulic valves returned as defective by dealers are often found to be free of faults when checked by the valve manufacturer. The customer has frequently complained that the loader sinks abnormally fast. The table below contains approximate tolerances to help service personnel gain some indication of what measurements may be regarded as lying within the tolerances when a “diagnosis” is to be made. Warm up the tractor so that the hydraulic oil reaches its working temperature. Connect a pressure gauge to the function to be checked. Fill the bucket (or other implement) until a pressure of ca. 100 bar (kp/cm3) at rest can be read on the pressure gauge. Raise the loader a little and stop the tractor engine. Measure on the piston rod the number of millimetres per minute by which the loader/implement sinks. Continue to measure for a period of 10 minutes to obtain a more accurate reading. Loader
Implement cylinder mm/min
Lifting cylinder mm/min
730-930-590-790 1.10
1,5
1,0
820-890-912-1020 1090
1,0
1,0
1220-1320-1290 2.10-3.10-3.10C-3.20
1,0
1,0
1190-1420-1390-1490 1495-1.50-2.20-2.40 3.40-3.50-3.55
1,0
0,5
1520-1620-1640-1590 1690-1790-1820-1840 2.65-2.70-3.60-3.65 4.60-4.70-4.75
1,0
0,5
1890-2.80-4.80-4.85 5.80
1,0
0,5
WALVOIL LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors
4 Tractor´s valve Traktorventil
3
P
T
Pump Pumpe
5
6
P
Pumpe Pump
T
SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected and the loader valve is not connected last in the tractor’s hydraulic system, three hoses must always be connected to the loader valve: one pump hose, one tank hose and one series hose. The valve is of the open-centre model (recirculation pumping) and must be equipped with a carry over adaptor 430 280; Item 4. It can also be equipped with or without a pressure relief valve, Item 3, depending on where the valve is connected in the system. SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected and the loader valve is connected last in the tractor’s hydraulic system, or if the loader valve is connected to a separate system (front pump), two hoses must be connected to the loader valve: one pump hose and one tank hose. The valve is of the open-centre model and must be equipped with a plug 435 150 in the series outlet, Item 6, and a plug 430 281 where the pressure relief valve is normally installed; Item 5. NOTE. For a front pump installation, the valve must be equipped with a pressure relief valve 430 279.
WALVOIL LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors CONSTANT-PRESSURE SYSTEM When the system is of the constantpressure type (old JD model), the loader valve is not connected last in the tractor’s hydraulic system. Two hoses are connected to the loader valve; one pump hose and one tank hose. The valve is of the open-centre model and must be equipped with a plug 430 281 in the connection in which a pressure relief valve is normally installed; Item 7. The valve must also be equipped with plug 435 285. Item 8.
7 8
P
T
Pumpe Pump
P LS
Pumpe Pump
T
LOAD-SENSING SYSTEM When the system is load-sensing, the loader valve can be connected at any point in the tractor’s hydraulic system. Three hoses are connected to the loader valve: one pump hose, one tank hose and one signal hose. The valve is of the closed-centre model (not recirculation pumping). Note. This valve must not be used in any other hydraulic system. Note. The electrical servo models of this type of valve are equipped with identical hydraulic components to the abovementioned hydraulic systems.
RMT 90 LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors
4 Tractor´s valve Traktorventil
3
P
T
Pumpe Pump
5
6
P
Pumpe Pump
T
SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected, the loader valve is not connected last in the tractor’s hydraulic system. Three hoses are always connected to the loader valve: one pump hose, one tank hose and one series hose. The valve is of the open-centre model (recirculation pumping) and must be equipped with a carry over adaptor (various); Item 4. It can also be equipped with or without a pressure relief valve (various), Item 3, depending on where the valve is connected in the system.
SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected and the loader valve is connected last in the tractor’s hydraulic system, or if the loader valve is connected to a separate system (front pump), two hoses must be connected to the loader valve: one pump hose and one tank hose. The valve is of the open-centre model and must be equipped with a plug 435 150 in the series outlet, Item 6, and a plug 435 148 where the pressure relief valve is normally installed; Item 5. NOTE. For a front pump installation, the valve must be equipped with a pressure relief valve 435 145.
RMT 90 LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors CONSTANT-PRESSURE SYSTEM When the system is of the constantpressure type (old JD model), the loader valve is not connected last in the tractor’s hydraulic system. Two hoses are connected to the loader valve; one pump hose and one reservoir hose. The valve is of the open-centre model and must be equipped with a plug 435 148 in the connection in which a pressure relief valve is normally installed; Item 7. The valve must also be equipped with a plug 435 184 in the series outlet; Item 8.
7 8
P
T
LS
Pumpe Pump
P LS
Pumpe Pump
T
LOAD-SENSING SYSTEM When the system is load-sensing, the loader valve can be connected at any point in the tractor’s hydraulic system. Three hoses are connected to the loader valve: one pump hose, one tank hose and one signal hose. The valve is of the closed-centre model (not circulation pumping). Note. This valve must not be used in any other hydraulic system.
General attachments / Section 9
General points relating to attachments Remove the paint from all contact surfaces on the side frames and the tractor body. Offer up the mounting brackets and fit all the bolts before finally tightening them. Check that the c/c dimension is correct. Standard attachment 842 +/- 5 mm, and wide attachment 1042 +/- 5 mm.
IMPORTANT: Remove paint at these points.
C/C 842+-5 (1042+-5)mm
All the bolts must be retightened after ca. 10 hours’ operation, and subsequently at every service.
General points relating to attachments CHECK THE FOLLOWING POINTS AFTER FINAL ASSEMBLY: ■ In the case of an opening wind screen, check that the loader does not touch the front screen in its raised position. ■ Check that the front wheels do not make contact with the attachment at full oscillation and at full lock. Restrict the movement, if necessary. ■ Contact between the lift cylinder and the wing/tyre is not serious, since this situation rarely/never occurs during normal operation. ■ The following table shows the recommended tightening torques for the various dimensions of bolt that we use.
M
8.8
10.9
12.9
14 16 18 20 22 24
128 Nm 197 Nm 275 Nm 385 Nm 518 Nm 665 Nm
181 Nm 277 Nm 386 Nm 541 Nm 728 Nm 935 Nm
217 Nm 333 Nm 463 Nm 649 Nm 874 Nm 1120 Nm
Evaluation of weld quality / Section 10
Evaluation of welds
If a weld has a cold flow for ca. 5-7 cm around the cross member on the lift arm, an indication of fracture can occur during normal use of loader. The lifting arm will then become twisted due to this welding fault. In such cases, the sides of the arms will be straight in spite of the weld having failed on the cross member = warrnaty claim.
“Cold weld” = Unacceptable
Correct weld
If, on the other hand, the weld appears sound in spite of the indication of fracture, and if the lifting arm is twisted (sloping bucket), the straightness of the arm must be checked. If one side has collapsed downwards and forwards away from the cross member, the loader has been abused = warranty does not apply. Once an evaluation has been made on the basis of the above, and it has been decided to invoke the warranty as a result, the defective section of the lift arm (arm cross member) must be removed by cutting and returned to us together with the warranty claim for our own inspection and evaluation.
Evaluation template for twisted loader / Section 11
Troubleshooting template for warped loader 1) Place a 1 m straight-edge on the top surface of the lift arm at the point where the cross member is welded in place, taking care to ensure that no foreign bodies are present. Check both halves of the arm. If a gap can be seen on either side beneath the straight-edge, and if the other side is good, this indicates that an impact has occurred. A visual defect of this kind is usually accompanied by cracking of the paint on the welds around the cross member. 99% of such warranty claims are rejected. N.B. the paint and surface coating on sheet steel may give way under severe normal loading around welds, allowing rust to form, although this does not necessarily mean that the welds have fractured. 2) Climb up onto a front tyre. Look down between the triangulated links which hold the p-linkage and the implement ram. Assess by eye whether the front half of the arm is deflected to the left or right. Check both sides. If one side appears to be deformed more than the other, it can be expected that 99% of warranty claims will be rejected.
Troubleshooting template for warped loader 3) Position the implement frame so that it is plumb. Raise the loader to eye level. Stand in front of the loader and align the upper part of the implement frame with the lower part or upper part of the cross member (whichever is easier to see). If the visible lines are not level, this indicates that one or other of the front parts of the arm sides has been bent downwards. Warranty claim rejection rate: 99%. 4) Raise the loader to eye level. Stand to one side of the loader, and look at the sides of the lifting arm, which must lie parallel with one another. If this is not the case, it may be due to cold welding around the cross member, which in turn has caused the weld to fracture, with twisting as a result. Cold welding occurs when the weld has taken on only one of the weld materials. This is a manufacturing defect.
Instruction manual /Section 12
Claims under warranty / Section 13
Trima accessories
/ Section 14
1. Loader 2. ELC 3. FLD 1000 4. AutoSafe 5. 3rd - 4th function 6. TMD 7. TCC 8. General hydraulics 9. General attachments 10. Evaluation of welding quality 11. Evaluation template for twisted loader 12. Instruction manual 13. Claims under warranty 14. Trima accessories
Loader / Section 1
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Loader operation - Test Lift and lowering function Operate all the loader functions to maximum travel. Check that everything is functioning normally and that there are no oil leaks. See the following section if anything does not function normally: ■ ■ ■ ■
Troubleshooting to locate faults Adjustments Other information for additional details Instruction manual for a description of the function
Float position Check that the float position is locked in the position by moving the lever past the lowering position. A small resistance must be overcome before engaging the float position. If the locked position cannot be reached, see ■ Adjustment of float position ■ Instruction manual
SafeLock Check that the lever can be locked with the SafeLock function. Check that the loader does not begin to drop when SafeLock is in the locked position. If SafeLock does not function, see ■ Adjustment of SafeLock ■ Instruction manual
Loader operation - Test
200 N (20 kg)
Implement latch Check the locking mechanism by moving the lever back and forth. The lever has an interlock position that is overcome by pushing the lever backwards. It is important for this resistance to be present to prevent the lock from being opened unintentionally. If the latch requires adjustment, see ■ Adjustments ■ Instruction manual
Implement connection and disconnection Check that the implement can be connected and disconnected easily. If it is not possible to connect the implement, check the connection hooks of the implement and the implement frame. For connection and disconnection, see ■ Instruction manual, pages 11-12
Loader connection and disconnection Check that the loader can be connected and disconnected readily, and that the loader can be locked easily with the locking pins. If the loader does not assume a position in which the locking pin can be easily inserted, check that the paint has been removed from the contact surfaces. For connection and disconnection of the loader, see ■ Instruction manual, pages 15-19
Troubleshooting, loader Possible faults External leakage in lift rams. Internal leakage in lift rams. Leakage via seal on non return valve. Leakage via seal on plug in connection a1. Leakage via spool in loader valve.
Symptom Loader drops Check tolerances for internal leakage for the loader valve. (See section 8)
Location of fault External leakage ( lift rams )
Visual inspection
Remedy In the case of visible leakage, replace the seal kit. Also check that no mechanical damage is present on the internal parts of the ram.
Internal leakage ( lift rams )
Move the loader to its maximum lift height. Then move the lever to its neutral position.
If the loader stops dropping, replace the seal kit. Also check that no mechanical damage is present on the internal parts of the ram.
Internal leakage ( control valve ) Check the o-rings on the non return valve for the lift spool. Check the o-ring on plug a1.
In the case of visible faults in the o-rings in the non return valve and the plug, replace the seals. If the loader continues to drop, replace the control valve.
Troubleshooting, loader Symptom Implement drops Check toleraces for internal leakage for the loader valve. ( See section 8 )
Possible faults External leakage in implement rams. Internal leakage in implement rams. Leakage in shock valve (210 bar). Internal leakage in 3rd or 4th function valve. Leakage via seal in non return valve. Leakage via seal on plug b2.
Location of fault External leakage in implement rams
Visual inspection
Remedy In the case of visible leakage, replace the seal kit. Also check that no mechanical damage is present on the internal parts of the ram.
Internal leakage in implement rams
Lift the loader with a load in the implement and with the hoses for the implement function disconnected at the control valve. Connections A2 and B2.
If the implement stops dropping, see Internal leakage in control valve. If the implement continues to drop, the fault lies in the implement rams, shock valve (210) bar, AutoSafe valve, if fitted, or in the 3rd or 4th functions, if fitted.
Troubleshooting, loader Symptom Internal leakage in shock valve
Visual inspection Reverse the position of the shock valves on the cross member.
Possible faults If the implement stops dropping, replace the 210 bar shock valve. If the implement continues to drop and no extra hydraulic functions are installed, replace the seal kit in the implement ram. Also check that no mechanical damage is present on the internal parts of the ram
Internal leakage in 3rd/4th function
Bypass the 3rd/4th function valve. Use 2 x 3/8”x3/8” adapters.
If the implement stops dropping, replace the complete valve.
Internal leakage in control valve
Check the o-rings on the non return valve for the lift spool. Check the o-ring on plug b2.
In the case of visible faults in the o-rings in the non return valve and the plug, replace the seals. If the loader continues to drop, replace the control valve.
LIFT / TILT Non return valves
Troubleshooting, loader Symptom Lift function weak
Check specification Tractors
hp kW
Loader model
45-80 33-59 3.10c
60-100 44-74 3.40 3.60
3.20
3.65 3,90
75-150 55-110 4.60 3,70
90-150 90-260 66-110 66-192 4.80 4.85 5.80
H1 Lift height to pivot point (m)
3,15
3,55
3,55
3,75
H2 Lift height under level implement (m)
2,95
3,30
3,30
3,50
3,70
3,50
3,75
3,95
3,60
1800
2200
2200
2100
2400
2800
4,00
2500
4,20
2650
3,85
Lift capacity at pivot point at 185 bar oil pressure L1a - at ground level (kg) L3a - max. height (kg)
2100 1300
1350
1900
1950
1800
1950
2300
2150
2200
Lift capacity, 750 mm from pivot point at 185 bar oil pressure L1 - at ground level (kg)
1650
1600
1900
2000
1800
2100
2500
2200
2400
L2 - at 1.5 m height (kg)
1400
1250
1600
1800
1650
1850
2250
2050
2200
L3 - max. height (kg)
1200
1100
1500
1600
1600
1700
2050
1900
1950
Max tear-out force 750 mm from pivot point 1700
1900
2600
2600
2600
3350
3350
3350
2800
B1 crowd anglel SMS/W -frame
35/39
41/45
41/45
41/45
41/45
41/45
42/46
43/47
39/43
B2 crowd angle SMS/W -frame
42/46
50/54
50/54
50/54
50/54
50/54
50/54
50/54
56/62
T1 dump angle SMS/W -frame
56/62
59/55
59/55
59/55
55/51
55/51
54/50
48/44
56/52
T2 dump angle SMS/W -frame
86/82
94/90
94/90
94/90
94/90
99/95
99/95
99/95
84/78
Possible faults If the lifting capacity is too low, this could be due to excessively low hydraulic pressure.
Lift capacity, 750 mm from pivot point at 185 b
Location of fault cause Measure the system pressure with a pressure gauge between the lift hose and the control valve.
L1 - at ground level (kg)
1650
L2 - at 1.5 m height (kg)
1400
L3 - max. height (kg)
1200
At a low value, listen to establish whether the relief valve in the loader’s control valve is blowing.
bar
Remedy If the sound of fluid transfer is heard, replace the relief valve. If no sound is heard, or if no relief valve is fitted, the hydraulic system of the tractor must be checked by an appointed workshop.
Troubleshooting, loader Symptom Implement function is to weak
Check specification Tractors
hp kW
Loader model
45-80 33-59 3.10c
3.20
60-100 44-74 3.40 3.60
3.65
75-150 55-110 4.60
3,90
3,70
90-150 90-260 66-110 66-192 4.80 4.85 5.80
H1 Lift height to pivot point (m)
3,15
3,55
3,55
3,75
H2 Lift height under level implement (m)
2,95
3,30
3,30
3,50
3,70
3,50
3,75
3,95
3,60
1800
2200
2200
2100
2400
2800
4,00
2500
4,20
2650
3,85
Lift capacity at pivot point at 185 bar oil pressure L1a - at ground level (kg) L3a - max. height (kg)
2100 1300
1350
1900
1950
1800
1950
2300
2150
2200
Lift capacity, 750 mm from pivot point at 185 bar oil pressure L1 - at ground level (kg)
1650
1600
1900
2000
1800
2100
2500
2200
2400
L2 - at 1.5 m height (kg)
1400
1250
1600
1800
1650
1850
2250
2050
2200
L3 - max. height (kg)
1200
1100
1500
1600
1600
1700
2050
1900
1950
Max tear-out force 750 mm from pivot point 1700
1900
2600
2600
2600
3350
3350
3350
2800
B1 crowd anglel SMS/W -frame
Location of fault cause Perform the same inspection as for a weak lifting function
Location of fault cause Slow loader
35/39
41/45
41/45
41/45
41/45
42/46
43/47
39/43
42/46
50/54
50/54
50/54
50/54
50/54
50/54
50/54
56/62
56/62
59/55
59/55
59/55
55/51
55/51
54/50
48/44
56/52
T2 dump angle SMS/W -frame
86/82
94/90
94/90
94/90
94/90
99/95
99/95
99/95
84/78
Max tear-out force 750 mm from pivot point 1700 B1 crowd anglel SMS/W -frame
35/39
B2 crowd angle SMS/W -frame
42/46
T1 dump angle SMS/W -frame
56/62
T2 dump angle SMS/W -frame
86/82
Check the specification and measure the time with the oil at its operating temperature.
Loader 2.10-3.10-3.10c-3.20 1.50-2.20-2.40 3.40-3.55-3.60-3.65 4.60 2.70-4.70-4.75-4.80-4.85 5.80
Lifting time 5.0 sec. 6.5 sec. 6.5 sec. 8.0 sec. 8.5 sec. 9.0 sec.
Loader
Dumping witt full travel of bucket 2 sec. 2.5 sec. 3 sec.
2.10-3.20 3.40-3.65 4.60-4.85-5.80
41/45
B2 crowd angle SMS/W -frame T1 dump angle SMS/W -frame
Possible faults If the tear out force is too low, this will be due to excessively low hydraulic pressure Remedy If the measured pressure is in accordance with the specification, move the pressure gauge to the crowd feed hose. If the pressure is lower, replace the 210 bar shock valve on the cross member. Possible faults If the loader is slow, this will be due to a low oil flow.
Working times at a pump capacity of 40 l/min
Dumping from parallel position 1 sec. 1.5 sec. 2 sec.
Troubleshooting, loader Location of fault cause Check the quickcouplings and the return line.
Possible faults If a constriction is located, replace the defective component.
If no visible problem can be identified, check the hydraulic flow of the tractor with a flow meter.
If the flow is low, the fault must be must be corrected by an appointed workshop.
LIFT / TILT Non return valves
Fault symptom Lift or implement function dips slightly before lifting during operation.
Possible faults Leak in non return valve.
Location of fault cause Disconnect the non return valve for the function that dips.
Remedy Clean and test. If the fault remains, replace the non return valve.
Fault symptom Single-lever control is difficult to operate.
Possible faults Lack of lubrication.
Remedy Clean and lubricate.
Cable seized.
Check whether the cable is trapped or is installed with an excessively small radius.
Spool seized in control valve.
Remove the cable cover and operate the spool manually. If it is heavy, remove the spool and clean. If any mechanical damage is evident, replace the complete control valve.
Adjustment of Float position and SafeLock Float position, RMT 90 valve The allen screws (1) holding the adjustment caps on the loader valve must be removed to allow adjustment of the loader float position (4 mm allen key). Rotate the adjusting cap (2) to adjust the position of the lever. N.B. To achieve an efficient function for the float position, the single-lever must be adjusted slightly backwards in relation to the lever housing. Fasten the adjusting cap with the screws (1) once adjustment is complete.
2 1
Float position, Walvoil valve The allen screws (16) must be released a few turns (4 mm allen key) to permit adjustment of the loader’s float position. Rotate the adjusting cap (15) to change the position of the lever. N.B. To achieve an efficient function for the float position, the single-lever must be adjusted slightly backwards in relation to the lever housing. Fasten the adjusting cap with the screws (16) once adjustment is complete. SafeLock Move the locking mechanism (3) to the locked position. If it cannot be locked, move the control lever forwards until the lock engages. N.B. The loader must not begin to drop in this position. The floating position must be re-adjusted if the loader begins to drop.
16 15 Min 400
3
ELC / Section 2
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Operation - Test ELC
Check that the joystick is correctly adjusted. Check the proportionality between the joystick and the loader valve.
Before calibration. See Adjustments.
Check that the float position and the 3rd and 4th functions can be activated and de-activated.
See General instructions. In the event of functional disorder. See Troubleshooting.
Troubleshooting, ELC Problem Loader functions fail. Lights on the joystick cannot be activated.
Cause Electrical fault
Remedy Check the power supply to the joystick. Repair as necessary. Replace the joystick if the power supply is correct.
Loader functions fail. Lights for the 3rd and 4th functions and the float position cannot be activated.
Electrical fault
Check and repair the power supply (wiring) between the joystick and the loader servo valve. Check and adjust the servo pressure. 15-20 bar.
Slow loader functions.
Low servo pressure. (RMT 90 valve only) Incorrectly adjusted joystick
Check and adjust the servo pressure. 15-20 bar. Re-adjust the joystick.
3rd and/or 4th functions fail.
Electrical fault
Check and repair the power supply between the joystick and the connector for the 3rd and 4th function. See also Troubleshooting – 3rd and 4th functions.
Float position fails.
Electrical fault (RMT 90 valve only)
Check and repair the power supply to the float position solenoid.
Faulty solenoid Faulty solenoid valve (RMT 90 valve only)
Test and replace, if required. Remove and clean the servo valve. Test. Replace the solenoid valve, if required.
Incorrect connection of return hose for electrical servo (RMT 90 valve only)
Check the return connection. This must be pressure-free and it may not be connected to other return lines.
Incorrectly adjusted joystick
Re-adjust the joystick.
Low servo pressure. (RMT 90 valve only)
ADJUSTMENT INSTRUCTIONS Programming of 3rd and 4th functions 1. Activate the ELC main switch on the instrument panel. 2. Press down the switch on the joystick and turn on the ignition. 3. Release the switch after approx 1 second, after which one or more of the lamps will light up. 4. Find the alternative that you need in the table below. Move through the alternatives by pressing the switch repeatedly until one or more lamps light up indicating your selection. Only one selection at a time can be programmed. 5. Acknowledge your choice by holding down the switch until the lamp/lamps go out. Note. A green lamp will light if alternative 2 is selected. 6. “Ready for use” and the selected alternative will now be displayed until another selection is made. O = lamp extinguished
= lamp lit
Programming Alternative Yellow Lamp
Green Lamp
Function Red Lamp O
Alt: 1 Alt: 2
3rd loader function only (on – off). Float position can be used.
O
Alt: 3
O
Alt: 4
O
3rd or 4th loader function
3rd loader function only or 3rd and external 4th function simultaneously.
O
O
3rd loader function only (on-off). Float position cannot be used
OPERATING INSTRUCTIONS 3rd and 4th functions and float position Activated lamp lights Yellow lamp
Alt 1
Alt 2
Alt 3
Green lamp
Activation and operation
Red lamp 3rd function: Hold down the switch, and move the lever to the right until the green lamp lights. Release the switch, and move the lever to the neutral position. The 3rd function can now be operated with a tilting movement of the joystick. 4th function: Hold down the switch, and move the lever to the left until the yellow lamp lights. Release the switch, and move the lever to the neutral position. The 4th function can now be operated with a tilting movement of the joystick. 3rd function: can be operated with a tilting movement of the joystick when the switch is held down. Note: Trima bale handler. 3rd function: Hold down the switch, and move the lever to the right, and then move the lever to the left, until the green lamp lights. Release the switch, and move the lever to the neutral position. The 3rd function can now be operated with a tilting movement of the joystick. External 4th function together with 3rd function: Hold down the switch, and move the lever to the right until the yellow and green lamps light up. Release the switch, and move the lever to the neutral position. The implement function can now be operated with a tilting movement of the joystick. Note: Trima V- plough Connecting float position: Press down the switch on the joystick and pull back the lever until the red lamp begins to flash. The floating position is now programmed so that it goes “in” when the lever is moved forwards to its full extent, and “out” when the lever is moved backwards. The lamp remains lit when the float position is “in”.
De-activation takes place by repeating the same procedure as for activation. Note! When the loader is not being used in tractor work the main switch on the instrument panel should be deactivated to prevent accidents.
ADJUSTMENT INSTRUCTIONS ELC No 1 Valid for joystick 431 835 with production numbers from 00-18-XX. Manufacturing sign, see joystick bottom. The adjustment of proportionality between joystick and loader valve shall only be done if necessary and with warmed up oil. Basic joystick adjustments are made at Trima.NOTE! When adjusting, always observe loader movements.
Starting position (must always be performed): 1. Hold down the joystick switch, activate the ELC main switch, start the tractor. 2. Release the switch when all the lamps light up. (After approx 3 seconds the lamps will begin to flash, after 3 seconds more the lamps will show a steady light). The yellow lamp will now begin flashing. 3.
1. 2.
Maintain the engine speed at ca. 10001300 rpm (hand throttle). Use a lower engine speed for a larger hydraulic pump.
Adjustment of lifting function: 4a. The yellow lamp must flash rapidly. Start position lift. Pull the lever slowly backwards until the lifting function begins to react (1), then slowly allow the lever to return to the position at which the function stops (2), not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light. Release the switch. Release the lever to neutral position. 4b. The yellow lamp must flash slowly. Max position lift. Pull the lever slowly backwards to the position in which the lifting function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position. 1
ADJUSTMENT INSTRUCTIONS ELC No 1 cont´d
1. 2.
Adjustment of lowering function: 5a. The green lamp must flash rapidly. Start position lowering. Push the lever slowly forwards until the lowering function begins to react (1),then slowly allow the lever to return to the position at which the function stops, not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
5b. The green lamp must flash slowly. Max position lowering. Push the lever slowly forwards to the position in which the lowering function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
ADJUSTMENT INSTRUCTIONS ELC No 1 cont´d
1. 2.
Adjustment of tilt function: 6a. The yellow lamp must flash rapidly, and the red lamp must remain lit. Start position tilt. Move the lever slowly to the right until the tilt function begins to react (1), then slowly allow the lever to return to the position at which the function stops, (2) not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
6b. The yellow lamp must flash slowly, and the red lamp must remain lit. Max position tilt. Move the lever slowly to the right to the position in which the tilt function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position.
ADJUSTMENT INSTRUCTIONS ELC No 1 cont´d 1. 2.
Adjustment of crowd function: 7a. The green lamp must flash rapidly, and the red lamp must remain lit. Start position crowd. Move the lever slowly to the left until the crowd function begins to react (1), then slowly allow the lever to return to the position at which the function stops (2), not to the neutral position. Hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position 7b. The green lamp must flash slowly, and the red lamp must remain lit. Max position crowd. Move the lever slowly to the left to the position in which the crowd function has its maximum speed and hold the lever still in that position. Push down the switch, wait until all the lamps light, and release the switch. Release the lever to neutral position. The yellow lamp will now begin to flash rapidly, at the same time as the red lamp is extinguished. Finish with confirmation. Confirmation position (must always be performed): 8. Hold the joystick lever in the neutral position. Push down the switch, wait until all the lamps light up, and release the switch. The ELC is now ready for use. Test and readjust if required.
Note 1. Each adjustment phase may be performed separately, but must be preceded by “Starting position” and terminated with “Confirmation position”. Switching between adjustment phases can take place by pressing the joystick button repeatedly in neutral position.
FLD 1000 / Section 3
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - FLD 1000 Check that the tractor can be raised when the relief valve is open, and that the tractor is slowly lowered when the control lever is moved to the neutral position.
In the event of functional disorder. See Troubleshooting.
Check that the tractor remains in the raised position when the relief valve is closed and the control lever is moved to the neutral position. Check that the suspension system works when the relief valve and the accumulators are activated.
Troubleshooting, FLD 1000 Symtom Loader feels solid.
Possible fault Accumulators closed. Relief valve closed.
Remedy Open the accumulator shut-off tap. Open the relief valve.
Loader feels dead with the accumulators open.
Accumulator fault.
Close the press valve. Rock the loader. If the loader is solid, replace the accumulators.
Loader feels solid with the press valve open.
Relief valve fault.
Raise the front end of the tractor with the loader. The tractor must drop to the ground when the single-lever control returns to the neutral position. If not, replace the relief valve.
AutoSafe / Section 4
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - AutoSafe Check the function of the AutoSafe. Activate the switch and crowd the implement frame, the locking pins will open. De-activate the switch and crowd the implement frame, the locking pins will lock.
See instruction manual page 13.
In the event of functional disorder. See Troubleshooting.
Troubleshooting - AutoSafe Problem Locking pins seek to engage from the opened, activated position if the implement frame is tilted forward against the mechanical stop.
Cause Normal
Remedy None
Locking seeks to engage from the activated position when the singlelever control returns to the neutral position after opening. Or: Locking seeks to engage from the open position when the implement frame is tilted forwards.
Internal leakage in the locking cylinder.
Fit new seals to the cylinder (seal kit 420 079). Check that there is no mechanical damage to constituent parts of the cylinder.
Locking will not open during activation and operation.
No power supply to the switch. No power supply from the switch. Defective solenoid.
Check the 8 Amp fuse.
Locking will not open during activation (new installation).
Check the wiring.
Defective electrically actuated valve. As above.
Test and replace the solenoid if defective. Clean and test. Replace the electrically actuated valve if defective.
As above.
As above.
Hoses wrongly connected to the C and D unions of the AutoSafe valve.
Reconnect hoses C and D.
3:rd – 4th function / Section 5
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - 3rd and 4th function Check that the 3rd and/ or the 4th function operate when the switch is activated. When in use, the respective function will be controlled via the implement function of the loader. The implement frame must not move when these functions are used.
In the event of functional disorder. See Troubleshooting.
Troubleshooting 3rd – 4th function Symtom 3rd or 4th function does not operate.
Possible fault Electrical fault.
Remedy Check the fuse and the cable to and from the switch.
Defective solenoid.
Test the solenoid with a metal tool to determine whether it becomes magnetic on activation. If not, replace the solenoid.
Spool seized in valve.
Remove and clean.
Spool seized after inspection and cleaning.
Replace the valve.
TMD / Section 6
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - TMD Check that the locking mechanism for the locking handle is not seized. Check that the TMD can be opened and closed without resistance. Check for oil leaks in any coupling component.
In the event of functional disorder. See Troubleshooting.
Troubleshooting – TMD Problem TMD leaks when connected. Oil exits from one or more of the drain holes.
Cause Leaking seal in male coupling.
Remedy Replace seal “N” in the male coupling in the mobile part (loader part). Test.
TMD still leaks after implementation of the above remedy.
Leaking seal in female coupling.
Replace female coupling “L” in the fixed part (tractor part). Test.
TMD still leaks after implementation of the above remedy.
Deformed lever.
Check lever “D” and its attachment. Replace the lever if necessary. Test.
TMD leaks when connected under pressure. Oil exits from one or more of the drain holes.
Leaking seal in male coupling.
Replace seal “N” in the male coupling in the mobile part. Test.
Worn female coupling.
Replace coupling “L” if necessary.
Worn male coupling.
Replace coupling “M” if necessary.
Deformed lever.
Check lever “D” and its attachment. Replace the lever if necessary. Test.
TMD leaks in the mobile part (loader part) after disconnection.
Leaking seal in male coupling.
Replace seal “N” in the male coupling in the mobile part. Test.
Worn male coupling.
Replace coupling “M” if necessary.
TMD leaks in the fixed part (tractor part) after disconnection.
Worn female coupling.
Replace coupling “L” if necessary.
TCC / Section 7
■
Operation - Test
■
Troubleshooting
■
Adjustments
■
Other information
Functional testing - TCC Check that the clutch is disconnected when any of the TCC’s switches are activated. Check all the switches. Also check that the foot brake connection (if present) functions correctly. Check this when activated and de-activated. Check that the linkage position for the clutch is correctly adjusted.
In the event of functional disorder. See Troubleshooting. See Linkage position adjustment
Troubleshooting and operator’s instructions – TCC Functional faults in conjunction with new assembly. Problem Clutch pedal does not go down.
Clutch pedal does not go down fully.
Clutch “grabs” or slips.
Cause Electrical fault.
Remedy Check the electrical installation.
Drain valve open. (Applicable only to accumulator system).
Close the drain valve.
Incorrect assembly.
Check the length of stroke of the cylinder (max 50 mm).
Low pedal pressure.
Adjust the pedal pressure.
Incorrect bite position.
Adjust the bite position.
Troubleshooting and operator’s instructions – TCC Functional disorder after a period of use. Problem Clutch pedal does not go down.
Cause Electrical fault.
Remedy Check the fuse and electrical lines.
Clutch pedal does not go down fully.
Low pedal pressure.
Check the pressure and adjust if necessary.
Clutch pedal does not go down after stopping the engine. (Accumulator model).
Accumulator fault.
Replace the accumulator.
Operator’s instructions 1. The TCC is activated via electrical switches positioned on the gear levers. 2. The TCC is activated via the brake pedal. 3. Electrical switches on the gear levers are convenient during transport driving, which completely relieves the load on the left leg. 4. Disengagement via the foot brake is more appropriate in conjunction with loader operation and inching. The foot brake function is engaged via a switch conveniently positioned on the instrument panel. With the foot brake function activated, the tractor is automatically disengaged during braking, and engaged again when the brake is released. When inching, the TCC is activated by depressing the brake pedal, when disengagement takes place automatically. The pressure on the brake pedal is then released, and the brake pedal is depressed once more when the tractor begins to move. it is possible to inch in this way by alternately depressing and releasing the brake pedal. By closing the needle valve progressively, the tractor will move progressively more slowly. Note that the foot brake function must not be connected during transport driving.
TCC – ADJUSTMENT OF THE BITE POSITION 1) Run the tractor until the oil reaches working temperature. 6
5
2) Stop the engine. Remove the outer sleeve on the adjusting rod (No5) 3) Turn the adjusting rod inwards until 10 mm is visable. 4) Close the needle valve ( No 6 ). Start the engine. 5) Disengage the clutch using one of the TCC switches.
5
6) Engage 1st gear and increase engine speed to 1400 rpm using the hand throttle. 7) Release the handbrake. 8) Release the TCC switch to allow the clutch pedal to move upwards. 9) Adjust the rod No3 outwards until you feel the rear wheels begin to turn. Important! Engage the handbrake, and stop the engine when this adjustment is being carried out. 10) Opening the needle valve at this point will allow the pedal to move and engage drive smoothly. 11) In the event of not obtaining the correct bite adjustment, repeat steps 4,5,6,7,8 and 9. 12) Close the needle valve. 13) Disengage the clutch using one of the TCC switches. 14) Release the TCC switch. 15) Stop the engine, and engage the handbrake. 16) Fit the outer sleeve back onto the adjusting rod. 17) The bite position is now set correctly.
General hydraulics / Section 8
Walvoil- and Nordhydraulik RMT 90 loader valve Checking for internal leakage Hydraulic valves returned as defective by dealers are often found to be free of faults when checked by the valve manufacturer. The customer has frequently complained that the loader sinks abnormally fast. The table below contains approximate tolerances to help service personnel gain some indication of what measurements may be regarded as lying within the tolerances when a “diagnosis” is to be made. Warm up the tractor so that the hydraulic oil reaches its working temperature. Connect a pressure gauge to the function to be checked. Fill the bucket (or other implement) until a pressure of ca. 100 bar (kp/cm3) at rest can be read on the pressure gauge. Raise the loader a little and stop the tractor engine. Measure on the piston rod the number of millimetres per minute by which the loader/implement sinks. Continue to measure for a period of 10 minutes to obtain a more accurate reading. Loader
Implement cylinder mm/min
Lifting cylinder mm/min
730-930-590-790 1.10
1,5
1,0
820-890-912-1020 1090
1,0
1,0
1220-1320-1290 2.10-3.10-3.10C-3.20
1,0
1,0
1190-1420-1390-1490 1495-1.50-2.20-2.40 3.40-3.50-3.55
1,0
0,5
1520-1620-1640-1590 1690-1790-1820-1840 2.65-2.70-3.60-3.65 4.60-4.70-4.75
1,0
0,5
1890-2.80-4.80-4.85 5.80
1,0
0,5
WALVOIL LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors
4 Tractor´s valve Traktorventil
3
P
T
Pump Pumpe
5
6
P
Pumpe Pump
T
SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected and the loader valve is not connected last in the tractor’s hydraulic system, three hoses must always be connected to the loader valve: one pump hose, one tank hose and one series hose. The valve is of the open-centre model (recirculation pumping) and must be equipped with a carry over adaptor 430 280; Item 4. It can also be equipped with or without a pressure relief valve, Item 3, depending on where the valve is connected in the system. SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected and the loader valve is connected last in the tractor’s hydraulic system, or if the loader valve is connected to a separate system (front pump), two hoses must be connected to the loader valve: one pump hose and one tank hose. The valve is of the open-centre model and must be equipped with a plug 435 150 in the series outlet, Item 6, and a plug 430 281 where the pressure relief valve is normally installed; Item 5. NOTE. For a front pump installation, the valve must be equipped with a pressure relief valve 430 279.
WALVOIL LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors CONSTANT-PRESSURE SYSTEM When the system is of the constantpressure type (old JD model), the loader valve is not connected last in the tractor’s hydraulic system. Two hoses are connected to the loader valve; one pump hose and one tank hose. The valve is of the open-centre model and must be equipped with a plug 430 281 in the connection in which a pressure relief valve is normally installed; Item 7. The valve must also be equipped with plug 435 285. Item 8.
7 8
P
T
Pumpe Pump
P LS
Pumpe Pump
T
LOAD-SENSING SYSTEM When the system is load-sensing, the loader valve can be connected at any point in the tractor’s hydraulic system. Three hoses are connected to the loader valve: one pump hose, one tank hose and one signal hose. The valve is of the closed-centre model (not recirculation pumping). Note. This valve must not be used in any other hydraulic system. Note. The electrical servo models of this type of valve are equipped with identical hydraulic components to the abovementioned hydraulic systems.
RMT 90 LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors
4 Tractor´s valve Traktorventil
3
P
T
Pumpe Pump
5
6
P
Pumpe Pump
T
SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected, the loader valve is not connected last in the tractor’s hydraulic system. Three hoses are always connected to the loader valve: one pump hose, one tank hose and one series hose. The valve is of the open-centre model (recirculation pumping) and must be equipped with a carry over adaptor (various); Item 4. It can also be equipped with or without a pressure relief valve (various), Item 3, depending on where the valve is connected in the system.
SERIES-CONNECTED OPEN CENTRE SYSTEM When the system is series-connected and the loader valve is connected last in the tractor’s hydraulic system, or if the loader valve is connected to a separate system (front pump), two hoses must be connected to the loader valve: one pump hose and one tank hose. The valve is of the open-centre model and must be equipped with a plug 435 150 in the series outlet, Item 6, and a plug 435 148 where the pressure relief valve is normally installed; Item 5. NOTE. For a front pump installation, the valve must be equipped with a pressure relief valve 435 145.
RMT 90 LOADER VALVE The four hydraulic systems most commonly fitted to agricultural tractors CONSTANT-PRESSURE SYSTEM When the system is of the constantpressure type (old JD model), the loader valve is not connected last in the tractor’s hydraulic system. Two hoses are connected to the loader valve; one pump hose and one reservoir hose. The valve is of the open-centre model and must be equipped with a plug 435 148 in the connection in which a pressure relief valve is normally installed; Item 7. The valve must also be equipped with a plug 435 184 in the series outlet; Item 8.
7 8
P
T
LS
Pumpe Pump
P LS
Pumpe Pump
T
LOAD-SENSING SYSTEM When the system is load-sensing, the loader valve can be connected at any point in the tractor’s hydraulic system. Three hoses are connected to the loader valve: one pump hose, one tank hose and one signal hose. The valve is of the closed-centre model (not circulation pumping). Note. This valve must not be used in any other hydraulic system.
General attachments / Section 9
General points relating to attachments Remove the paint from all contact surfaces on the side frames and the tractor body. Offer up the mounting brackets and fit all the bolts before finally tightening them. Check that the c/c dimension is correct. Standard attachment 842 +/- 5 mm, and wide attachment 1042 +/- 5 mm.
IMPORTANT: Remove paint at these points.
C/C 842+-5 (1042+-5)mm
All the bolts must be retightened after ca. 10 hours’ operation, and subsequently at every service.
General points relating to attachments CHECK THE FOLLOWING POINTS AFTER FINAL ASSEMBLY: ■ In the case of an opening wind screen, check that the loader does not touch the front screen in its raised position. ■ Check that the front wheels do not make contact with the attachment at full oscillation and at full lock. Restrict the movement, if necessary. ■ Contact between the lift cylinder and the wing/tyre is not serious, since this situation rarely/never occurs during normal operation. ■ The following table shows the recommended tightening torques for the various dimensions of bolt that we use.
M
8.8
10.9
12.9
14 16 18 20 22 24
128 Nm 197 Nm 275 Nm 385 Nm 518 Nm 665 Nm
181 Nm 277 Nm 386 Nm 541 Nm 728 Nm 935 Nm
217 Nm 333 Nm 463 Nm 649 Nm 874 Nm 1120 Nm
Evaluation of weld quality / Section 10
Evaluation of welds
If a weld has a cold flow for ca. 5-7 cm around the cross member on the lift arm, an indication of fracture can occur during normal use of loader. The lifting arm will then become twisted due to this welding fault. In such cases, the sides of the arms will be straight in spite of the weld having failed on the cross member = warrnaty claim.
“Cold weld” = Unacceptable
Correct weld
If, on the other hand, the weld appears sound in spite of the indication of fracture, and if the lifting arm is twisted (sloping bucket), the straightness of the arm must be checked. If one side has collapsed downwards and forwards away from the cross member, the loader has been abused = warranty does not apply. Once an evaluation has been made on the basis of the above, and it has been decided to invoke the warranty as a result, the defective section of the lift arm (arm cross member) must be removed by cutting and returned to us together with the warranty claim for our own inspection and evaluation.
Evaluation template for twisted loader / Section 11
Troubleshooting template for warped loader 1) Place a 1 m straight-edge on the top surface of the lift arm at the point where the cross member is welded in place, taking care to ensure that no foreign bodies are present. Check both halves of the arm. If a gap can be seen on either side beneath the straight-edge, and if the other side is good, this indicates that an impact has occurred. A visual defect of this kind is usually accompanied by cracking of the paint on the welds around the cross member. 99% of such warranty claims are rejected. N.B. the paint and surface coating on sheet steel may give way under severe normal loading around welds, allowing rust to form, although this does not necessarily mean that the welds have fractured. 2) Climb up onto a front tyre. Look down between the triangulated links which hold the p-linkage and the implement ram. Assess by eye whether the front half of the arm is deflected to the left or right. Check both sides. If one side appears to be deformed more than the other, it can be expected that 99% of warranty claims will be rejected.
Troubleshooting template for warped loader 3) Position the implement frame so that it is plumb. Raise the loader to eye level. Stand in front of the loader and align the upper part of the implement frame with the lower part or upper part of the cross member (whichever is easier to see). If the visible lines are not level, this indicates that one or other of the front parts of the arm sides has been bent downwards. Warranty claim rejection rate: 99%. 4) Raise the loader to eye level. Stand to one side of the loader, and look at the sides of the lifting arm, which must lie parallel with one another. If this is not the case, it may be due to cold welding around the cross member, which in turn has caused the weld to fracture, with twisting as a result. Cold welding occurs when the weld has taken on only one of the weld materials. This is a manufacturing defect.
Instruction manual /Section 12
Claims under warranty / Section 13
Trima accessories
/ Section 14
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