Service Manual

Zetor
Service Manual
5211, 5245, 6211,
6245, 7211 & 7245

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

ZETOR OR IT’S SUCCESSORS. ZETOR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

ZE-S-5211+
 Model: 5211 Years Model: 5245 Years Made:
Make: Zetor Make: Zetor (4 Wheel Drive)
Made: 1985-1992 1985-1992
HP-
HP-PTO: 42.51 HP-Engine: HP-Drawbar: 38.4 HP-PTO: 42.51 HP-Engine:
Drawbar: 38.4
Engine- Engine- Engine- Engine-
HP-Range: 43 HP-Range:
Make: ZETOR Fuel: DIESEL Make: ZETOR Fuel: DIESEL
Engine-Cyl(s)- Transmission- Engine-Cyl(s)- Transmission-
Optional: Optional:
CID: 3/164.6 STD: SG CID: 3/164.6 STD: SG
Fwd/Rev Fwd/Rev Fwd/Rev Mfwd-Std/Opt:
Fwd/Rev Optional: Mfwd-Std/Opt:
Standard: 10/2 Standard: 10/2 Optional: std
Tires-Std Tires-Std Wheelbase- Tires-Std Tires-Std Rear: Wheelbase-
Front: 7.50-16 Rear: 14.9-28 Inch: 83.6 Front: 9.5-24 16.9-28 Inch: 82.6
Pto Speed: 540 CAT I-3pt Pto Speed: 540
Pto Type: IND Pto Type: IND CAT I-3pt Hitch:
1000 Hitch: True 1000
CAT II-3pt CAT III-3pt CAT II-3pt
Hitch Lift: 3785 CAT III-3pt Hitch: Hitch Lift:
Hitch: True Hitch: False Hitch:
Hydraulics- Hydraulics-
Hyd-Cap: 20/8 Hyd-Flow: 2 Hyd-Cap: 20 Hyd-Flow:8
Type: OPEN Type: OPEN
Hyd Std Cooling Fuel Tank Hyd Std Cooling Fuel Tank
Outlets: 10.75 Capacity: 14.5 Capacity: OPT Outlets: 2 Capacity: 10.75 Capacity: 14.5
Cab-Stdm A/C; Cab-Stdm A/C; New
Weight: 6000 New Price: 11550 Weight: 7070
Rops: Rops: Price: $14,180

Model: 6211 Years Made: Model: 7211 Years Made:

Make: Zetor Make: Zetor
1986-1992 1985-1989
HP-Drawbar:
HP-PTO: 53.09 HP-Engine: HP-PTO: 70 HP-Engine: HP-Drawbar:
47.4
Engine- Engine- Engine- Engine-
HP-Range: HP-Range:
Make: ZETOR Fuel: DIESEL Make: ZETOR Fuel: DIESEL
Engine-Cyl(s)- Transmission- Engine-Cyl(s)- Transmission-
Optional: Optional:
CID: 4-210.9 STD: SG CID: 4/239 STD: HI-LO
Fwd/Rev Fwd/Rev Fwd/Rev Mfwd-Std/Opt:
Fwd/Rev Optional: Mfwd-Std/Opt:
Standard: 10/2 Standard: 10/2 Optional: STD
Tires-Std Tires-Std Rear: Wheelbase-Inch: Tires-Std Tires-Std Rear: Wheelbase-
Front: 7.5-16 16.9-30 88.5 Front: 7.50-16 16.9-30 Inch: 88.9
Pto CAT I-3pt Pto CAT I-3pt
Pto Type: IND Pto Type: IND
Speed: 540/1000 Hitch: 5300 Speed: 540/1000 Hitch: 5700
CAT II-3pt CAT II-3pt
CAT III-3pt Hitch: Hitch Lift: CAT III-3pt Hitch: Hitch Lift:
Hitch:5300 Hitch: 5700
Hydraulics- Hydraulics-
Hyd-Cap: 26.5 Hyd-Flow: 8 Hyd-Cap: 26.5 Hyd-Flow: 8
Type: OPEN Type: Open
Hyd Std Cooling Fuel Tank Hyd Std Cooling Fuel Tank
Outlets: 2 Capacity: 14.5 Capacity: 18.5 Outlets: 2 Capacity: 14.5 Capacity: 18.5
Cab-Stdm A/C; New Cab-Stdm A/C; New
Weight: 6,350 Weight: 7,400
Rops: Price: $13,750 Rops: opt Price: $16,600

Model: 6245 Years Made: Model: 7245 Years Made:

Make: Zetor Make: Zetor
(4 Wheel Drive) 1985-1992 (4 Wheel Drive) 1985-1989
HP-
HP-PTO: 53.09 HP-Engine: HP-Drawbar: 47.4 HP-PTO: 58.58 HP-Engine:
Drawbar: 52.5
Engine- Engine- Engine- Engine-
HP-Range: HP-Range:
Make: ZETOR Fuel: DIESEL Make: ZETOR Fuel: DIESEL
Engine-Cyl(s)- Transmission- Engine-Cyl(s)- Transmission-
Optional: Optional:
CID: 4/210.9 STD: SG CID: 4/219.4 STD: SG
Fwd/Rev Mfwd-Std/Opt: Fwd/Rev Fwd/Rev Mfwd-Std/Opt:
Fwd/Rev Optional:
Standard: 10/2 STD Standard: 10/2 Optional: STD
Tires-Std Tires-Std Rear: Wheelbase- Tires-Std Tires-Std Wheelbase-
Front: 11.2-24 16.9-30 Inch:87.8 Front: 11-24 Rear:14-34 Inch:87.8
Pto CAT I-3pt Pto Speed: 540 CAT I-3pt
Pto Type: IND Pto Type: IND
Speed: 540/1000 Hitch: 5300 1000 Hitch: 5300
CAT II-3pt CAT II-3pt
CAT III-3pt Hitch: Hitch Lift: CAT III-3pt Hitch: Hitch Lift:
Hitch:5300 Hitch: 5300
Hydraulics- Hydraulics-
Hyd-Cap: 26.5 Hyd-Flow: 8 Hyd-Cap: 26.5 Hyd-Flow: 8
Type: OPEN Type: Open
Hyd Std Cooling Fuel Tank Hyd Std Cooling Fuel Tank
Outlets: 2 Capacity: 14.5 Capacity:18.5 Outlets: 2 Capacity: 14.5 Capacity: 18.5
Cab-Stdm A/C; New Cab-Stdm A/C; New
Weight:7,400 Weight: 7,400
Rops:OPT Price: $16,600 Rops: Opt Price: $16,750
 CONTENTS OF THE MAIN CHAPTERS

Page

PREFACE 5

1 - BODYWORK 7

2 - ELECTRICAL EQUIPMENT 23

3 - ENGINE WITH CLUTCH 37

4 - TRANSMISSION MECHANISM
(GEARBOX AND THE MAIN TRANSMISSION DRIVE) 63

5 -REARAXLE 87

6 - FRONT DRIVING AXLE 91

7 - FIXED AND SPRUNG EXTENSIONS 103

8 - STEERING 111

9 - BRAKES 125

10 - HYDRAULIC POWER-LIFTING MECHANISM AND HITCH

EQUIPMENT' 135

11 - DIAGNOSIS OF DEFECTS IN THE HYDRAULIC CIRCUITS 153

12 - FUEL SYSTEM 161

 1 - BODYWORK

Page

1.1. Safety cabin 8

1.2. Driver's mate seat 13

1.3. Heating 13

1.4.. Driver's seat 18

1.5. Bonnet 18

1.6. Fuel tank 21

1.7. Mudguards 21

1.8. Pulley cover of the alter>nator 22 ~~-:.=?:

1.9. Contaminant catcher 22

7-
 2 - ELECTRICAL EQUIPMENT

Page

2.1. Storage battery 24

2.2. Alternator and regulator 25

2.3. Starter 28

2.4. Dashboard 32

2.5. Lighting device 32

2.6. Auxiliary equipment 35

23
 3 - ENGINE WITH CLUTCH

Page

3.l. Crankcase 39

3.2. Crankshaft mechanism 40

3.3. Valve gear. 45

3.4~ Cylinder heads . 47

3.5. Cooling system 49

3.6. Lubrication system 50

3.7. Air cleaner IFE MANN 52

3.8. Compressor 54 r:- "'i@

3.9. Exhaust 55

3.10. Double clutch 56

Fuel system is on page 161

37
 1011 9116

10. Remove the rear bearin& 6211 and the thrust 4. Insert the key into the keyway of the lay shaft
ring 55111914 from the gearbox. and press on the gear of the third speed and
11. Remove the bearing 6211 of the lay shaft front the, gear of the fourth speed.
part. 5. Slip on the tube l.
12. Take out the lay shaft with the gears from the 6. Insert the key into the keyway of the lay shaft
gearbox casing. Pull off the gears and the and press on the constant-mesh gear.
spacer bushings. Remove the keys from the 7. Insert the gearbox brake carrier into the gear-
lay shaft. box casing.
13. If the tractor has been equipped with a torque 8. Hold the lay shaft assembly with the constant-
multiplier, leave the lay shaft assembly 7011 9116 mesh gear upwards and place it in successive
in the fork 5511 9123 pull off in successive steps into the gearbox.
steps: the gears, the spacer bushings as well as 9. If the tractor has been equipped with a torque
the keys. multiplier, do not press the gear of the first
14. Take out all parts, including the gear-box brake speed and the gear of the second gear up to
carrier, from the gearbox. the lay shaft shoulder, but leave a play of
about 20 mm between the gear and the shaft
shoulder. Afterwards place the into the gear-
Gearbox assembling box casing in the same manner as mentioned
in the point 8, then press the gears entirely
Assembling the lay shaft (Fig. 37) to the lay shaft shoulder.
10. Place the centring bushing 5511 9116 with the
1. Oil the lay shaft at those parts where the gears packing piece 5511 9117 into the bore in the
will bE; slipped on. front wal of the gearbox. Carefully slide the
2. Insert the key into the keyway of, the lay shaft' lay' shaft into the centring bushing.
and press on the gears; of the first and the 11~ Using the punch bar '55119118 and the exten-
second speed. sion piece 5511 9113 drive the bearing 6211 to
3. Slip on the tube II. the rear end of the lay shaft.

75
 5 - REAR . AXLE

Page

5.1. Dismantling the LH and the RH portal

from the main transmission housing 88

5.2. Dismantling the portal 88

5.3. Total assembling and adjusting 90

87
 7 - FIXED AND SPRUNG EXTENSIONS

Page

7.1. Disassembling the LH or the RH fixed

extension (wheels 6.00/6.15-16) 104

7.2. Dismantling the LH or the RH fixed

extension (wheels 7.50-16) 105

7.3. Dismantling the LH or the RH sprung

extension (wheels 6.00/6.50-16) 106

7.4. Dismantling the LH or the RH sprung

extension with interlocking 107
(wheels 7.50-16)

7.5. Adjusting the play of the tapered roller

bearings in the front wheels 108

7.0. Adaptation of sprung extensions 108

7.7. Modifying the track of the front wheels 109

7.8. Toe-in and toe-out 109

103
 8 - STEERING

Page

B.1. Disassembling the ba'll-type steering 112

B.2. Disassembling the steering shaft 112

B.3. Steering adjustment 116

BA. Tightening torques 116

B.5. Steering booster 116

8.6. Disassembling the steering booster

cylinder 117

8.7. Assembling the steering booster cylinder 119

8.B. Adjusting, checking and testing the

steering booster cylinder 121

B.9. Adjusting the steering booster cylinder

(the substituting method) 122

B.10. Fitting the steering booster ro the tractor 122

B.11. Steering damper 123

111
 9 - BRAKES

Page

9.1. Foot~operated brake 126

9.2. Disassemibling and assembling the master

cylinder 127

9.3. Disassembling and assembling the pressure

equaUzer 127

9.4. DismantlLng the brake peda'ls from the

tractor 127

9.5. Brake fluid and bleeding the brakes 129

9.6. Hand hrake 129

9.7. Air~brakes 132

125
10 - HYDRAULIC POWER';LIFTING MECHANISM .
AND HITCH EQUIPMENT

Page

10.1. Dismantling the cover of the hydraulics

from the tractor 137

10.2. Dismantling the cover of the hydraulics 137

10.3. Disassembling the hy'draulic distributor 141

10.4. Disassembling the hydraulic pumlP from

thetTact'Or 142

10.5. Assembling the auxiliar hydraulic

cylinder 144

10.6. Dismantling the piping of the hydraulic

'oill filtration 145 ~
10.7. Dismantling the c'Ontrol equ~pment of
the RH three...,point hitch lifting bar
from the safety cabin- 145

10.8. Dismantling the three-point hitoh 146

10.9. Dismantling the hitch for a single-axle

trailer 147

10.10. DismalIl1ling the ,trailer hitoh

(automatic mouth) 148

10.11. Dismantling the multistage hitch 149

10.12. Quick coupling type RK 12 149

135
11 - DIAGNOSIS OF DEFECTS
IN THE HYDRAULIC CIRCUITS

Page

11.1. Steering booster 154

11.2. Hydraulic lifting device 156

":",,.,,:,,"~...;..~~.•.

153