DEUTZ-FAHR AGROTRON 130 AGROTRON 140 AGROTRON 155 AGROTRON 165 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
DEUTZ-FAHR AGROTRON 130 AGROTRON 140 AGROTRON 155 AGROTRON 165 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 830
Downloadable : Yes
File Type : PDF
Size: 32.2 MB
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
DEUTZ-FAHR AGROTRON 130 AGROTRON 140 AGROTRON 155 AGROTRON 165 Workshop Manual – PDF DOWNLOAD
INTRODUCTION:
- The purpose of this workshop manual is to provide instruction for repair technicians and
a practical guide to improving the quality of repairs. - This manual enables repair technicians to acquire a thorough knowledge of the machine,
indicating the correct methods for fault diagnosis, for working in safety and for
accurate dimensional checks and visual inspections. The instructions also indicate the
products to use, the tightening torques and the adjustment data. - The technical material contained in this manual is reserved to Authorised Dealers and
Service Centres who will be duly informed of any technical changes to the machines in
question through the issue of documents regarding modifications, updates and supplements
for optional equipment. - All technicians and their colleagues are expressly forbidden from reproducing any part
of this manual in any form or from communicating the contents to third parties without
the express written permission of the Manufacturer, who remains the sole owner of this
document with all rights reserved in accordance with applicable laws.
GENERAL SAFETY RULES
1 – Even if you have a thorough knowledge of the machine as regards its components,
operation and controls, always take particular care when carrying
out the following operations. Remember that the machine you are working
on is in need of repair or overhaul and consequently may not always behave
as expected.
2 – Before starting work, clean the machine thoroughly to remove all mud,
dust and road dirt.
Also clean the cab to remove all traces of oil, snow and ice from the access
steps and grab rails.
3 – When climbing up to or down from the cab, always ensure you maintain
three points of contact at a time (foot or handholds) in order to keep your
balance and prevent accidental falls.
4 – Always take special care when carrying out fault diagnosis operations;
these operations often require two persons, who must never stand in front
of the wheels when the engine is running.
5 – When carrying out checks and repairs, wear close-fitting clothing, safety
goggles and protective gloves that are suitable for the task (cleaning,
draining fluids, repairs).
When working near moving parts, long hair should be gathered up and secured
safely under a cap to prevent the risk of entanglement and sever injury.
6 – Do not allow anyone who is not directly involved in the work to come near
the machine; ensure that they remain at a safe distance.
7 – Keep well clear of moving parts; when the engine is running, some moving
parts are not easily visible and therefore present a risk of entanglement,
even if protected by safety guards.
8 – Ensure that the area is well ventilated before starting the engine in order to
avoid the formation of dangerous concentrations of toxic gases; always
connect suitable fume extraction equipment to the exhaust pipe.
TABLE OF CONTENTS:
DEUTZ-FAHR AGROTRON 130 AGROTRON 140 AGROTRON 155 AGROTRON 165 Workshop Manual – PDF DOWNLOAD
307.1106.3.6 AGROTRON 130-140-155-165………………………………………………………………………………….. 1
INTRODUCTION…………………………………………………………………………………………………….. 3
SAFETY NOTES…………………………………………………………………………………………………….. 5
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS………………………………………………………………. 8
LIFTING INSTRUCTIONS……………………………………………………………………………………………… 10
HOW THE MANUAL IS STRUCTURED………………………………………………………………………………………. 11
HOW TO CONSULT THE MANUAL…………………………………………………………………………………………. 12
HOW TO USE AND UPDATE THE MANUAL…………………………………………………………………………………… 13
STANDARD TIGHTENING TORQUES FOR NUTS AND BOLTS………………………………………………………………………. 14
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS……………………………………………………………………. 15
SPECIAL TOOLS……………………………………………………………………………………………………. 17
CONVERSION FACTORS……………………………………………………………………………………………….. 18
SECTION 10………………………………………………………………………………………………………. 19
1. TRANSMISSION………………………………………………………………………………………………. 21
INTRODUCTION……………………………………………………………………………………………… 21
1.1 TRANSMISSION (Power Shuttle version)…………………………………………………………………….. 23
1.1.1 MAIN COMPONENTS………………………………………………………………………………….. 23
1.1.2 TRANSMISSION HYDRAULIC SYSTEM……………………………………………………………………… 26
1.1.3 GEARBOX…………………………………………………………………………………………. 27
1.1.4 MAIN CLUTCH……………………………………………………………………………………… 29
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE…………………………………………………….. 30
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC……………………………………………… 34
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC……………………………………………………………. 35
1.2 REAR AXLE…………………………………………………………………………………………….. 37
1.3 REAR PTO……………………………………………………………………………………………… 39
2. BRAKING SYSTEM…………………………………………………………………………………………….. 41
2.1 BRAKE MASTER CYLINDER………………………………………………………………………………….. 42
2.2 BRAKE………………………………………………………………………………………………… 43
2.3 TRAILER BRAKING SYSTEM…………………………………………………………………………………. 44
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)…………………………………………………………… 44
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)………………………………………………………….. 46
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)………………………………………………………………… 48
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)……………………………………………………………….. 49
3. HYDRAULIC FRONT AXLE SUSPENSION……………………………………………………………………………… 55
3.1 FRONT SUSPENSION CONTROL VALVE………………………………………………………………………….. 56
4. FRONT AXLE………………………………………………………………………………………………… 60
4.1 HUB CARRIER AND FINAL REDUCTION UNIT…………………………………………………………………….. 61
4.2 DIFFERENTIAL………………………………………………………………………………………….. 63
5. HYDRAULIC SYSTEM…………………………………………………………………………………………… 65
5.1 VARIABLE DISPLACEMENT PUMP……………………………………………………………………………… 68
5.1.1 BOOST PUMP………………………………………………………………………………………. 71
5.1.2 HYDRAULIC PUMP…………………………………………………………………………………… 72
5.1.3 LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE………………………………………………………….. 74
5.2 HYDRAULIC SERVICES GEAR PUMP……………………………………………………………………………. 82
5.3 STEERING GEAR PUMP…………………………………………………………………………………….. 83
5.4 PRIORITY VALVE………………………………………………………………………………………… 84
5.5 AUXILIARY SERVICES CONTROL VALVE………………………………………………………………………… 85
5.5.1 TYPES OF CONTROL VALVE WITH FIXED DISPLACEMENT PUMP (CC)……………………………………………… 87
5.5.2 TYPES OF CONTROL VALVE WITH VARIABLE DISPLACEMENT PUMP (LS)…………………………………………… 89
5.5.3 SERVICES CONTROL SECTION………………………………………………………………………….. 90
5.5.4 DESCRIPTIONS OF COMPONENTS………………………………………………………………………… 91
5.5.5 INLET MANIFOLD (CC version)……………………………………………………………………….. 93
5.5.6 LIFT CONTROL VALVE SECTION………………………………………………………………………… 96
SECTION 20……………………………………………………………………………………………………….101
1. DIAGNOSIS TOOLS “ALL ROUND TESTER”……………………………………………………………………………103
1.1 ALL ROUND TESTER……………………………………………………………………………………….103
1.2 “SERDIA 3.5 LEVEL III” SOFTWARE………………………………………………………………………….109
1.3 “EDS EST45” SOFTWARE……………………………………………………………………………………110
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS…………………………………………………………..111
2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT AND FRONT AXLE SUSPENSION CONTROL UNITS………………………………111
2.2 CONNECTING THE PORTABLE COMPUTER WITH “SERDIA 3.5” SOFTWARE TO THE ENGINE CONTROL UNIT…………………………112
2.3 CONNECTING THE PORTABLE COMPUTER WITH “EDS” SOFTWARE TO THE TRANSMISSION CONTROL UNIT AND INFOCENTER…………….113
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR……………………………………………………………115
3.1 ENGINE CONTROL UNIT (DEUTZ EMR2)…………………………………………………………………………115
3.2 TRANSMISSION CONTROL UNIT……………………………………………………………………………….117
3.3 POWER LIFT CONTROL UNIT…………………………………………………………………………………118
3.4 INFOCENTER 2 or 3………………………………………………………………………………………120
3.5 FRONT AXLE SUSPENSION CONTROL UNIT……………………………………………………………………….121
3.6 FRONT AND REAR PTO CONTROL UNIT………………………………………………………………………….122
4. PUTTING THE TRACTOR INTO SERVICE……………………………………………………………………………..123
4.1 INTRODUCTION…………………………………………………………………………………………..123
4.2 RENEWAL OF THE ENGINE CONTROL UNIT……………………………………………………………………….123
4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT………………………………………………………………….128
4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT…………………………………………………………….134
4.5 RENEWAL OF THE INFOCENTER……………………………………………………………………………….142
4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT…………………………………………………………………..144
5. ALARMS…………………………………………………………………………………………………….145
5.1 LIFT AND ASM CONTROL UNIT ALARMS…………………………………………………………………………145
5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS………………………………………………………………….181
5.3 LIST OF ALARMS DISPLAYED BY SERDIA……………………………………………………………………….251
5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS…………………………………………………………273
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System)…………………………………………………………….289
1. GENERAL INTRODUCTION…………………………………………………………………………………….289
1.1 FUNCTIONAL SCOPE……………………………………………………………………………………289
1.2 HARDWARE REQUIREMENTS……………………………………………………………………………….290
1.3 STARTING AND TERMINATING OF THE EDS PROGRAM……………………………………………………………292
2. TRANSMISSION DIAGNOSIS…………………………………………………………………………………..294
2.1 THE MAIN MENU………………………………………………………………………………………294
2.2 ONLINE HELP………………………………………………………………………………………..296
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45……………………………………………………………………297
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45……………………………………………………297
3.2 DEST 45 PROGRAM DESCRIPTION………………………………………………………………………….298
3.3 ERROR CODES POWER-SHUTTLE /DEST 45……………………………………………………………………313
3.4 DISPLAY POWERSHUTTLE………………………………………………………………………………..314
3.5 ERROR CODE LIST WITH DESCRIPTION……………………………………………………………………..315
3.6 OTHER INFORMATIONS………………………………………………………………………………….326
3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100………………………………………………….327
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100…………………………………………………………………..328
3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200………………………………………………….329
3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300………………………………………………………….330
3.11 ERROR ANALYSIS…………………………………………………………………………………….331
4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER……………………………………………………………….333
4.1 PROGRAM DESCRIPTION…………………………………………………………………………………334
4.2 CONSTANT VALUES FOR INFOCENTER……………………………………………………………………….344
7. ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT…………………………………………………………………349
PRESENTATION SCREEN………………………………………………………………………………………..349
MAIN MENU…………………………………………………………………………………………………349
1. MONITOR………………………………………………………………………………………………..350
2. CONFIGURATION…………………………………………………………………………………………..354
3. CALIBRATIONS……………………………………………………………………………………………356
4. ALARMS LIST…………………………………………………………………………………………….361
8. ALL ROUND TESTER FOR AXLE SUSPENSION CONTROL UNIT………………………………………………………………363
PRESENTATION SCREEN………………………………………………………………………………………..363
MAIN MENU…………………………………………………………………………………………………363
1. MONITOR………………………………………………………………………………………………..364
2. PARAMETERS……………………………………………………………………………………………..365
3. ALARMS LIST…………………………………………………………………………………………….367
4. CONFIGURATIONS………………………………………………………………………………………….367
9. SERDIA (LEVEL III)………………………………………………………………………………………….369
1. SETUP AND COMMUNICATIONS…………………………………………………………………………………369
1.1 MINIMUM EQUIPMENT REQUIRED…………………………………………………………………………..369
1.2 ORDERING…………………………………………………………………………………………..370
1.3 SWITCHING ON AND INSTALLING THE SOFTWARE………………………………………………………………371
1.4 USING THE PROGRAM…………………………………………………………………………………..375
1.5 CLOSING THE PROGRAM…………………………………………………………………………………378
2. ECU SELECTION…………………………………………………………………………………………..379
2.1 SELECTING TWO CONTROL UNITS………………………………………………………………………….379
2.2 PRINTING…………………………………………………………………………………………..380
2.3 PROTOCOL…………………………………………………………………………………………..381
2.4 IDENTIFICATION AND MEASUREMENT DATA…………………………………………………………………..381
3. MEASURED VALUES…………………………………………………………………………………………383
3.1 ACTUAL MEASURED VALUES (GENERAL)……………………………………………………………………..383
3.2 RAM-VALUES…………………………………………………………………………………………388
3.3 DATA LOGGER (ONLY EMS2)……………………………………………………………………………..392
3.4 INPUT/OUTPUT ASSIGNMENT……………………………………………………………………………..392
3.5 CAN STATUS…………………………………………………………………………………………392
4. PARAMETERS……………………………………………………………………………………………..395
4.1 CONFIGURATION (GENERAL)……………………………………………………………………………..395
4.2 OVERALL PROGRAMMING…………………………………………………………………………………396
4.2 CALIBRATION………………………………………………………………………………………..397
5. ERROR MEMORY……………………………………………………………………………………………398
5.1 GENERAL……………………………………………………………………………………………398
5.2 ERROR TABLE………………………………………………………………………………………..399
6. EXTRAS…………………………………………………………………………………………………409
6.1 MAXIMUM SPEED………………………………………………………………………………………409
6.2 LOGISTIC DATA………………………………………………………………………………………409
6.3 LOAD SPECTRUM………………………………………………………………………………………410
6.4 MAINTENANCE INTERVAL EXCEEDED………………………………………………………………………..410
6.5 OVERRIDE MEMORY…………………………………………………………………………………….410
6.6 MAINTENANCE DATA……………………………………………………………………………………410
7. TASKS………………………………………………………………………………………………….411
7.1 EMR1………………………………………………………………………………………………411
8. WHAT TO DO IF…?……………………………………………………………………………………….415
8.1 SERDIA GENERAL……………………………………………………………………………………..415
8.2 EMR1………………………………………………………………………………………………417
SECTION 30……………………………………………………………………………………………………….429
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING…………………………………………………………433
HYDRAULIC AND WIRING SYSTEMS PUMP SIDE (CC VERSION WITH PRIORITY VALVE)……………………………………………..434
HYDRAULIC SYSTEMS (TOP VIEW) (CC VERSION WITH PRIORITY VALVE)………………………………………………………435
HYDRAULIC SYSTEMS PUMP SIDE AND PRIORITY VALVE……………………………………………………………………436
HYDRAULIC AND WIRING SYSTEMS PUMP SIDE (LS VERSION)……………………………………………………………….437
HYDRAULIC AND WIRING SYSTEMS (TOP VIEW) (LS VERSION)………………………………………………………………438
AUXILIARY HYDRAULIC SYSTEMS AND COUPLERS (LS VERSION)……………………………………………………………..439
ENGINE HOOD – LAMP ASSEMBLIES…………………………………………………………………………………..441
REMOVAL…………………………………………………………………………………………………..441
REFITTING…………………………………………………………………………………………………443
CAB ACCESS STEPS………………………………………………………………………………………………444
REMOVAL…………………………………………………………………………………………………..444
REFITTING…………………………………………………………………………………………………444
BATTERY………………………………………………………………………………………………………445
REMOVAL…………………………………………………………………………………………………..445
REFITTING…………………………………………………………………………………………………446
AIR RESERVOIR AND BATTERY SUPPORT (versions with air trailer braking only)…………………………………………..447
REMOVAL…………………………………………………………………………………………………..447
REFITTING…………………………………………………………………………………………………447
STARTER MOTOR…………………………………………………………………………………………………448
REMOVAL…………………………………………………………………………………………………..448
REFITTING…………………………………………………………………………………………………448
ALTERNATOR……………………………………………………………………………………………………449
REMOVAL AND RENEWAL………………………………………………………………………………………..449
REFITTING…………………………………………………………………………………………………449
ALTERNATOR DRIVEBELT…………………………………………………………………………………………..450
RENEWAL AND TENSIONING……………………………………………………………………………………..450
AIR COMPRESSOR………………………………………………………………………………………………..453
REMOVAL…………………………………………………………………………………………………..453
REFITTING…………………………………………………………………………………………………454
TRAILER PARKING AND SERVICE AIR BRAKE CONTROL VALVES………………………………………………………………455
REMOVAL…………………………………………………………………………………………………..455
REFITTING…………………………………………………………………………………………………456
PRESSURE TRANSDUCER (Version with air braking)……………………………………………………………………457
REMOVAL…………………………………………………………………………………………………..457
REFITTING…………………………………………………………………………………………………457
AIR PRESSURE REGULATING/REDUCTION VALVE FOR CAB LIFTING……………………………………………………………458
REMOVAL…………………………………………………………………………………………………..458
REFITTING…………………………………………………………………………………………………458
TRAILER AIR BRAKES COUPLING VALVE……………………………………………………………………………….459
1. Removal………………………………………………………………………………………………..459
2. Renewal………………………………………………………………………………………………..459
HYDRAULIC TRAILER BRAKING VALVE (CUNA VERSION)……………………………………………………………………460
REMOVAL…………………………………………………………………………………………………..460
REFITTING…………………………………………………………………………………………………461
AIR CONDITIONING SYSTEM………………………………………………………………………………………..462
TECHNICAL SPECIFICATIONS……………………………………………………………………………………462
OPERATION…………………………………………………………………………………………………463
MAINTENANCE……………………………………………………………………………………………….464
ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT……………………………………………………………..464
DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM………………………………………………..465
AIR CONDITIONING COMPRESSOR…………………………………………………………………………………….466
REMOVAL…………………………………………………………………………………………………..466
REFITTING…………………………………………………………………………………………………467
RECEIVER-DRIER………………………………………………………………………………………………..468
REMOVAL…………………………………………………………………………………………………..468
REFITTING…………………………………………………………………………………………………468
CONDENSER FAN…………………………………………………………………………………………………469
REMOVAL…………………………………………………………………………………………………..469
REFITTING…………………………………………………………………………………………………469
CONDENSER ASSEMBLY…………………………………………………………………………………………….470
REMOVAL…………………………………………………………………………………………………..470
REFITTING…………………………………………………………………………………………………472
INTERCOOLER AND SEAL…………………………………………………………………………………………..473
REMOVAL…………………………………………………………………………………………………..473
REFITTING…………………………………………………………………………………………………475
GEARBOX OIL/FUEL COOLERS……………………………………………………………………………………….476
REMOVAL…………………………………………………………………………………………………..476
REFITTING…………………………………………………………………………………………………477
RADIATOR……………………………………………………………………………………………………..478
REMOVAL…………………………………………………………………………………………………..478
REFITTING…………………………………………………………………………………………………480
EXPANSION TANK………………………………………………………………………………………………..481
REMOVAL…………………………………………………………………………………………………..481
REFITTING…………………………………………………………………………………………………481
COMPLETE RADIATOR/COOLERS ASSEMBLY………………………………………………………………………………482
REMOVAL…………………………………………………………………………………………………..482
REFITTING…………………………………………………………………………………………………486
FAN………………………………………………………………………………………………………….487
REMOVAL…………………………………………………………………………………………………..487
REFITTING…………………………………………………………………………………………………487
FRONT PTO FLEXIBLE COUPLING…………………………………………………………………………………….488
REMOVAL…………………………………………………………………………………………………..488
REFITTING…………………………………………………………………………………………………489
AIR CLEANER…………………………………………………………………………………………………..490
REMOVAL…………………………………………………………………………………………………..490
REFITTING…………………………………………………………………………………………………491
TURBOCHARGER………………………………………………………………………………………………….492
REMOVAL…………………………………………………………………………………………………..492
REFITTING…………………………………………………………………………………………………493
AIR INLET PIPE………………………………………………………………………………………………..494
REMOVAL…………………………………………………………………………………………………..494
REFITTING…………………………………………………………………………………………………494
SILENCER……………………………………………………………………………………………………..495
REMOVAL…………………………………………………………………………………………………..495
REFITTING…………………………………………………………………………………………………495
EXHAUST PIPE………………………………………………………………………………………………….496
REMOVAL…………………………………………………………………………………………………..496
REFITTING…………………………………………………………………………………………………496
4WD PROPELLER SHAFT (Version with front suspension)……………………………………………………………….497
REMOVAL…………………………………………………………………………………………………..497
REFITTING…………………………………………………………………………………………………499
BRAKE MASTER CYLINDERS…………………………………………………………………………………………500
REMOVAL…………………………………………………………………………………………………..500
REFITTING…………………………………………………………………………………………………502
BLEEDING THE BRAKING SYSTEM…………………………………………………………………………………….503
ADJUSTMENT OF THE BRAKE LIGHT SWITCHES…………………………………………………………………………..505
POWER STEERING UNIT……………………………………………………………………………………………506
1. Testing………………………………………………………………………………………………..506
2. Adjustment……………………………………………………………………………………………..506
3. Removal of the power steering unit………………………………………………………………………..506
REFITTING…………………………………………………………………………………………………507
REMOVAL AND RENEWAL………………………………………………………………………………………..508
1. Disassembly…………………………………………………………………………………………509
2. Removal of the seals…………………………………………………………………………………511
3. Removal of the dust seal……………………………………………………………………………..511
4. Installing the inner seal (15)………………………………………………………………………..512
5. Installing the control valve………………………………………………………………………….512
6. Final assembly………………………………………………………………………………………513
FRONT WHEELS………………………………………………………………………………………………….516
REMOVAL…………………………………………………………………………………………………..516
REFITTING…………………………………………………………………………………………………516
FRONT FENDERS…………………………………………………………………………………………………517
REMOVAL…………………………………………………………………………………………………..517
REFITTING…………………………………………………………………………………………………517
REAR WHEELS…………………………………………………………………………………………………..518
REMOVAL…………………………………………………………………………………………………..518
REFITTING…………………………………………………………………………………………………518
LIFT VALVE BLOCK………………………………………………………………………………………………519
REMOVAL…………………………………………………………………………………………………..519
REFITTING…………………………………………………………………………………………………519
FRONT LIFT CYLINDERS…………………………………………………………………………………………..520
REMOVAL…………………………………………………………………………………………………..520
REFITTING…………………………………………………………………………………………………521
FRONT LIFT ASSEMBLY……………………………………………………………………………………………522
REMOVAL…………………………………………………………………………………………………..522
REFITTING…………………………………………………………………………………………………524
FRONT PTO ASSEMBLY…………………………………………………………………………………………….525
REMOVAL…………………………………………………………………………………………………..525
REFITTING…………………………………………………………………………………………………525
FRONT SUSPENSION CYLINDERS (Where fitted)………………………………………………………………………..526
REMOVAL…………………………………………………………………………………………………..526
REFITTING…………………………………………………………………………………………………528
DISASSEMBLY AND ASSEMBLY……………………………………………………………………………………529
FRONT AXLE AND SWINGING SUPPORT (Versions with front suspension)……………………………………………………531
REMOVAL…………………………………………………………………………………………………..531
REFITTING…………………………………………………………………………………………………533
FRONT SUSPENSION VALVES………………………………………………………………………………………..534
REMOVAL…………………………………………………………………………………………………..534
REFITTING…………………………………………………………………………………………………534
FRONT SUSPENSION POSITION SENSOR………………………………………………………………………………..535
1. Removal………………………………………………………………………………………………..535
2. Positioning…………………………………………………………………………………………….535
3. Testing………………………………………………………………………………………………..536
REINFORCING SIDE MEMBERS (For versions with front lift only)……………………………………………………….537
REMOVAL…………………………………………………………………………………………………..537
REFITTING…………………………………………………………………………………………………537
FRONT CARRIER (Versions with front suspension)……………………………………………………………………538
REMOVAL…………………………………………………………………………………………………..538
REFITTING…………………………………………………………………………………………………538
ACCELERATOR POTENTIOMETER………………………………………………………………………………………539
1. Renewal………………………………………………………………………………………………..539
2. Potentiometer calibration………………………………………………………………………………..540
FUEL TANK AND RELATIVE MOUNTINGS………………………………………………………………………………..541
REMOVAL…………………………………………………………………………………………………..541
INSTALLATION………………………………………………………………………………………………543
GEAR PUMP…………………………………………………………………………………………………….544
REMOVAL…………………………………………………………………………………………………..544
REFITTING…………………………………………………………………………………………………545
TESTING THE AUXILIARY SERVICES PUMPS…………………………………………………………………………….546
1. Flow meter connection (CC version)………………………………………………………………………..546
2. Flow meter connection (LS version)………………………………………………………………………..546
3. Measuring the flow rate………………………………………………………………………………….546
VARIABLE DISPLACEMENT PUMP (Version LS)………………………………………………………………………….548
REMOVAL…………………………………………………………………………………………………..548
REFITTING…………………………………………………………………………………………………550
POWER STEERING PUMP (CC version)………………………………………………………………………………..551
REMOVAL…………………………………………………………………………………………………..551
REFITTING…………………………………………………………………………………………………553
PRIORITY VALVE………………………………………………………………………………………………..554
REMOVAL…………………………………………………………………………………………………..554
REFITTING…………………………………………………………………………………………………554
PRIORITY VALVE (For versions with variable displacement pump)………………………………………………………555
REMOVAL…………………………………………………………………………………………………..555
REFITTING…………………………………………………………………………………………………555
CREEPER ENGAGEMENT LEVER……………………………………………………………………………………….556
REMOVAL…………………………………………………………………………………………………..556
REFITTING…………………………………………………………………………………………………556
CONTROL VALVE ASSEMBLIES (Version CC)……………………………………………………………………………557
REMOVAL…………………………………………………………………………………………………..557
REFITTING…………………………………………………………………………………………………560
CONTROL VALVE ASSEMBLIES (LS version)……………………………………………………………………………561
REMOVAL…………………………………………………………………………………………………..561
REFITTING…………………………………………………………………………………………………563
AUXILIARY CONTROL VALVE BLOCKS (Description refers to left control valve)……………………………………………564
DISASSEMBLY……………………………………………………………………………………………….564
ASSEMBLY………………………………………………………………………………………………….565
LIFT CYLINDERS………………………………………………………………………………………………..566
REMOVAL…………………………………………………………………………………………………..566
REFITTING…………………………………………………………………………………………………567
DISASSEMBLY AND ASSEMBLY……………………………………………………………………………………568
TESTING THE LIFT POSITION SENSOR………………………………………………………………………………..569
LIFT POSITION SENSOR…………………………………………………………………………………………..570
1. Removal of the position sensor……………………………………………………………………………570
2. Renewal of the position sensor bush (only if necessary)……………………………………………………..570
3. Refitting the position sensor…………………………………………………………………………….570
4. Position sensor adjustment……………………………………………………………………………….571
LIFT DRAFT SENSOR……………………………………………………………………………………………..573
REMOVAL…………………………………………………………………………………………………..573
REFITTING…………………………………………………………………………………………………573
DRIVER’S SEAT…………………………………………………………………………………………………574
REMOVAL…………………………………………………………………………………………………..574
REFITTING…………………………………………………………………………………………………574
CONTROLS IN THE MULTIFUNCTION ARMREST CONSOLE (OPTIONAL)…………………………………………………………..575
REMOVAL…………………………………………………………………………………………………..575
REFITTING…………………………………………………………………………………………………576
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL……………………………………………………577
REMOVAL…………………………………………………………………………………………………..577
REFITTING…………………………………………………………………………………………………578
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER………………………………………………………….579
RENEWAL…………………………………………………………………………………………………..579
ASSEMBLY………………………………………………………………………………………………….580
CENTRE CONSOLE AND SHROUD………………………………………………………………………………………581
REMOVAL…………………………………………………………………………………………………..581
REFITTING…………………………………………………………………………………………………584
RIGHT-HAND CONSOLE…………………………………………………………………………………………….585
OPENING AND REMOVAL………………………………………………………………………………………..585
REFITTING…………………………………………………………………………………………………591
LEFT-HAND CONSOLE……………………………………………………………………………………………..592
REMOVAL…………………………………………………………………………………………………..592
REFITTING…………………………………………………………………………………………………593
TRANSMISSION LIFT AND FRONT SUSPENSION ELECTRONIC CONTROL UNITS…………………………………………………….594
REMOVAL…………………………………………………………………………………………………..594
REFITTING…………………………………………………………………………………………………595
FUSE AND RELAY BOARD…………………………………………………………………………………………..596
REMOVAL…………………………………………………………………………………………………..596
REFITTING…………………………………………………………………………………………………597
ENGINE ECU……………………………………………………………………………………………………598
REMOVAL…………………………………………………………………………………………………..598
REFITTING…………………………………………………………………………………………………598
CLUTCH PEDAL AND RELATED DEVICES………………………………………………………………………………..599
1. Removal of the potentiometer……………………………………………………………………………..599
1.1. Refitting the potentiometer…………………………………………………………………………599
2. Adjustment of the clutch pedal position and travel………………………………………………………….600
3. Renewal of the proximity sensor…………………………………………………………………………..600
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO……………………………………………….601
REMOVAL…………………………………………………………………………………………………..601
REFITTING…………………………………………………………………………………………………604
PTO ENGAGEMENT AND SELECTION CONTROL CABLES………………………………………………………………………605
REMOVAL…………………………………………………………………………………………………..605
REFITTING…………………………………………………………………………………………………606
AUXILIARY SERVICE VALVE CONTROL CABLES…………………………………………………………………………..608
RENEWAL…………………………………………………………………………………………………..608
REFITTING…………………………………………………………………………………………………609
ADJUSTMENT OF THE PARKING BRAKE SWITCH…………………………………………………………………………..610
CLIMATE CONTROL PANEL………………………………………………………………………………………….611
REMOVAL…………………………………………………………………………………………………..611
REFITTING…………………………………………………………………………………………………611
HEATER VALVE………………………………………………………………………………………………….612
1. Removal………………………………………………………………………………………………..612
2. Refitting and adjustment of the control cable………………………………………………………………612
HEATER MATRIX…………………………………………………………………………………………………614
REMOVAL…………………………………………………………………………………………………..614
REFITTING…………………………………………………………………………………………………616
AIR CONDITIONING EVAPORATOR…………………………………………………………………………………….617
REMOVAL…………………………………………………………………………………………………..617
REFITTING…………………………………………………………………………………………………618
RIGHT-HAND AIR CONDITIONING FAN…………………………………………………………………………………619
REMOVAL…………………………………………………………………………………………………..619
REFITTING…………………………………………………………………………………………………619
LEFT-HAND AIR CONDITIONING FAN………………………………………………………………………………….620
REMOVAL…………………………………………………………………………………………………..620
REFITTING…………………………………………………………………………………………………620
ADJUSTMENT OF THE PARKING BRAKES………………………………………………………………………………..621
CAB DOOR CABLE………………………………………………………………………………………………..622
RENEWAL…………………………………………………………………………………………………..622
TRAILER BRAKING AIR PRESSURE GAUGE………………………………………………………………………………624
REMOVAL…………………………………………………………………………………………………..624
REFITTING…………………………………………………………………………………………………624
POWERSHIFT – POWERSHUTTLE STATUS DISPLAY…………………………………………………………………………625
REMOVAL…………………………………………………………………………………………………..625
REFITTING…………………………………………………………………………………………………625
CAB………………………………………………………………………………………………………….626
REMOVAL…………………………………………………………………………………………………..626
REFITTING…………………………………………………………………………………………………634
ENGINE……………………………………………………………………………………………………….635
REMOVAL…………………………………………………………………………………………………..635
REFITTING…………………………………………………………………………………………………644
SECTION 40……………………………………………………………………………………………………….645
THE STRUCTURE OF THE UNIT………………………………………………………………………………………647
HOW TO CONSULT THE UNIT………………………………………………………………………………………..648
1. INTRODUCTION……………………………………………………………………………………………….649
1.1 LIST OF WIRING HARNESSES………………………………………………………………………………..649
1.2 DEFINITION OF COMPONENTS AND SYMBOLS……………………………………………………………………..650
1.3 GENERAL RULES………………………………………………………………………………………….650
1.4 DIAGNOSTIC INSTRUMENTS………………………………………………………………………………….652
1.5 WIRE COLOUR CODES………………………………………………………………………………………652
2. INDICES……………………………………………………………………………………………………653
2.1 COMPONENT DESCRIPTION INDEX……………………………………………………………………………..653
2.2 COMPONENT CODE INDEX……………………………………………………………………………………658
2.3 CONNECTOR INDEX………………………………………………………………………………………..663
3. COMPONENTS…………………………………………………………………………………………………672
3.1 CONNECTOR LAYOUTS………………………………………………………………………………………672
3.2 COMPONENT TECHNICAL DATA………………………………………………………………………………..677
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS……………………………………………………….686
3.3.6 FRONT SUSPENSION CONTROL UNIT………………………………………………………………………694
4. SYSTEMS……………………………………………………………………………………………………695
4.1 GROUND POINTS………………………………………………………………………………………….695
4.2 ENGINE START…………………………………………………………………………………………..696
4.3 PREHEATING…………………………………………………………………………………………….697
4.4 ELECTRICAL ENGINE CONTROL……………………………………………………………………………….698
4.5 LIGHTS – LIGHT SELECTOR SWITCH (MACHINE WITHOUT FRONT LIFT)…………………………………………………699
4.6 LIGHTS – LIGHT SELECTOR SWITCH (MACHINE WITH FRONT LIFT)……………………………………………………700
4.7 CAB ACCESSORY………………………………………………………………………………………….701
4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT)……………………………………………………………….702
4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT)………………………………………………………………….703
4.10 WINDSCREEN WIPER………………………………………………………………………………………704
4.11 INFOCENTER……………………………………………………………………………………………705
4.12 ELECTRICAL POWER SUPPLY………………………………………………………………………………..706
4.13 AUTORADIO – CB………………………………………………………………………………………..707
4.14 AIR CONDITIONING – HEATING FAN………………………………………………………………………….708
4.15 BRAKES……………………………………………………………………………………………….709
4.16 TRAILER BRAKES………………………………………………………………………………………..710
4.17 FRONT AXLE SUSPENSION………………………………………………………………………………….711
4.18 TRANSMISSION………………………………………………………………………………………….712
4.19 ASM – 4WD – DIFFERENTIAL……………………………………………………………………………….713
4.20 REAR LIFTER…………………………………………………………………………………………..714
4.21 FRONT AND REAR PTO…………………………………………………………………………………….715
5. WIRING…………………………………………………………………………………………………….717
ENGINE WIRING (1/2)………………………………………………………………………………………..717
ENGINE WIRING (2/2)………………………………………………………………………………………..718
ENGINE WIRING (1/2)………………………………………………………………………………………..723
ENGINE WIRING (2/2)………………………………………………………………………………………..724
ENGINE HOOD WIRING (2/2)……………………………………………………………………………………734
ENGINE HOOD WIRING (1/2)……………………………………………………………………………………733
TRANSMISSION WIRING (1/2)…………………………………………………………………………………..737
TRANSMISSION WIRING (2/2)…………………………………………………………………………………..738
TRAILER BRAKE WIRING (ITALY)………………………………………………………………………………..749
TRAILER BRAKE WIRING……………………………………………………………………………………….750
FRONT AXLE SUSPENSION WIRING (ROPS)………………………………………………………………………….753
CAB POWER SUPPLY WIRING…………………………………………………………………………………….757
FRONT AXLE SUSPENSION WIRING………………………………………………………………………………..763
FENDER WIRING – WIDE……………………………………………………………………………………….767
NUMBER PLATE LIGHT WIRING (WIDE FENDERS)……………………………………………………………………..768
FENDER WIRING – NARROW……………………………………………………………………………………..773
NUMBER PLATE LIGHT WIRING (NARROW FENDERS)……………………………………………………………………774
FENDERS…………………………………………………………………………………………………..777
FRONT CONSOLE WIRING (1/2)………………………………………………………………………………….779
FRONT CONSOLE WIRING (2/2)………………………………………………………………………………….780
SIDE CONSOLE WIRING (1/3)…………………………………………………………………………………..785
SIDE CONSOLE WIRING (2/3)…………………………………………………………………………………..786
SIDE CONSOLE WIRING (3/3)…………………………………………………………………………………..787
AIR CONDITIONING WIRING (CAB)……………………………………………………………………………….797
DISPLAY WIRING…………………………………………………………………………………………….803
ROOF WIRING (1/2)………………………………………………………………………………………….807
ROOF WIRING (2/2)………………………………………………………………………………………….808
ROOF WIRING……………………………………………………………………………………………….813
CAB ROOF FRONT AND REAR WORKLIGHTS WIRING…………………………………………………………………….817
CAB LOWER HEADLIGHTS WIRING WINDSCREEN WIPER MOTOR WIRING………………………………………………………815
CAB LOWER FRONT WORKLIGHTS WIRING CAB FULL AND DIPPED BEAM HEADLIGHTS (MACHINE WITHOUT FRONT LIFT) (WITH FRONT LIFT)….816
LIGHTS SELECTOR SWITCH WIRING……………………………………………………………………………….823
ARMREST WIRING…………………………………………………………………………………………….827
FUSES AND RELAYS CONTROL UNIT (1/2)………………………………………………………………………….829
FUSES AND RELAYS CONTROL UNIT (2/2)………………………………………………………………………….830
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V