Deutz-Fahr AGROTRON 80 MK3 –> 6001 AGROTRON 90 MK3 –> 6001 AGROTRON 100 MK3 –> 6001 AGROTRON 105 MK3 –> 6001 Workshop Manual – PDF DOWNLOAD
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Deutz-Fahr AGROTRON 80 MK3 –> 6001 AGROTRON 90 MK3 –> 6001 AGROTRON 100 MK3 –> 6001 AGROTRON 105 MK3 –> 6001 Workshop Manual – PDF DOWNLOAD
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Deutz-Fahr AGROTRON 80 MK3 –> 6001 AGROTRON 90 MK3 –> 6001 AGROTRON 100 MK3 –> 6001 AGROTRON 105 MK3 –> 6001 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 80 MK3 –> 6001 AGROTRON 90 MK3 –> 6001 AGROTRON 100 MK3 –> 6001 AGROTRON 105 MK3 –> 6001 Workshop Manual – PDF DOWNLOAD
307.1117.3.6 AGROTRON 80 – 90 – 100 – 105 » 6001…………………………………………………………….. 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…………………………………………………………………………….. 14
1. NUTS AND BOLTS………………………………………………………………………………….. 14
2. FITTINGS……………………………………………………………………………………….. 15
3. PLUGS………………………………………………………………………………………….. 16
4. FITTINGS WITH SEAL AT 37………………………………………………………………………… 17
5. FITTINGS FOR PIPES WITH EYE ATTACHMENT…………………………………………………………….. 17
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS…………………………………………………………. 18
CONVERSION FACTORS…………………………………………………………………………………….. 20
SECTION 10……………………………………………………………………………………………. 21
1. TRANSMISSION……………………………………………………………………………………. 23
INTRODUCTION…………………………………………………………………………………… 23
1.1 TRANSMISSION POWER SHUTTLE…………………………………………………………………… 24
1.1.1 MAIN COMPONENTS……………………………………………………………………….. 24
1.1.2 TRANSMISSION HYDRAULIC SYSTEM…………………………………………………………… 27
1.1.3 GEARBOX………………………………………………………………………………. 28
GEARBOX COMPONENTS………………………………………………………………………….. 29
1.1.4 MAIN CLUTCH…………………………………………………………………………… 30
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE………………………………………….. 31
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
DESCRIPTION……………………………………………………………………………………. 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
COMPRESSOR…………………………………………………………………………………. 50
PRESSURE LIMITING VALVE……………………………………………………………………… 51
TRAILER BRAKING VALVE (2-WAY)………………………………………………………………… 52
TRAILER BRAKING VALVE (1-WAY)………………………………………………………………… 53
3. HYDRAULIC FRONT AXLE SUSPENSION…………………………………………………………………… 54
DESCRIPTION……………………………………………………………………………………. 54
3.1 FRONT SUSPENSION CONTROL VALVE……………………………………………………………….. 55
4. FRONT AXLE……………………………………………………………………………………… 59
5. HYDRAULIC DIAGRAM……………………………………………………………………………….. 61
5.1 HYDRAULIC DIAGRAM (version with remote control valves without flow control)……………………….. 61
5.2 HYDRAULIC DIAGRAM (version with remote control valves with flow control)………………………….. 62
5.3 GEAR PUMP FOR TRANSMISSION ZF 7100……………………………………………………………. 63
5.4 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING………………………………………………….. 64
5.5 POWER STEERING……………………………………………………………………………… 65
5.6 AUXILIARY SERVICES CONTROL VALVE……………………………………………………………… 66
5.6.1 TYPES OF CONTROL VALVE…………………………………………………………………. 67
5.6.2 SERVICES CONTROL SECTION……………………………………………………………….. 69
5.6.3 DESCRIPTIONS OF COMPONENTS……………………………………………………………… 70
5.6.4 INLET MANIFOLD (CC version)…………………………………………………………….. 72
5.6.5 LIFT CONTROL VALVE SECTION……………………………………………………………… 75
SECTION 20……………………………………………………………………………………………. 79
1. DIAGNOSIS TOOLS “ALL ROUND TESTER”………………………………………………………………… 81
1.1 ALL ROUND TESTER……………………………………………………………………………. 81
1.1.1 DESCRIPTION OF THE KIT…………………………………………………………………. 81
1.1.2 NOTES ON CORRECT USE…………………………………………………………………… 82
1.1.3 DESCRIPTION OF THE TESTER………………………………………………………………. 82
1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER…………………………………….. 83
1.1.5 SELECTION OF THE DISPLAY LANGUAGE……………………………………………………….. 83
1.1.6 SETTING THE SERIAL PORTS……………………………………………………………….. 85
1.2 “SERDIA 3.5 LEVEL III” SOFTWARE………………………………………………………………. 87
1.2.1 DESCRIPTION OF THE KIT…………………………………………………………………. 87
1.3 “EDS EST45” SOFTWARE………………………………………………………………………… 88
1.3.1 DESCRIPTION OF THE KIT…………………………………………………………………. 88
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS……………………………………………….. 89
2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT AND FRONT AXLE SUSPENSION CONTROL UNITS…………………… 89
2.2 CONNECTING THE PORTABLE COMPUTER WITH “SERDIA 3.5” SOFTWARE TO THE ENGINE CONTROL UNIT……………… 90
2.3 CONNECTING THE PORTABLE COMPUTER WITH “EDS” SOFTWARE TO THE TRANSMISSION CONTROL UNIT AND INFOCENTER…. 91
2.3.1 CONNECTION TO THE TRANSMISSION CONTROL UNIT………………………………………………. 91
2.3.2 CONNECTION TO THE INFOCENTER……………………………………………………………. 91
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR………………………………………………… 93
3.1 ENGINE CONTROL UNIT (DEUTZ EMR2)……………………………………………………………… 93
3.2 TRANSMISSION CONTROL UNIT……………………………………………………………………. 95
3.3 POWER LIFT CONTROL UNIT……………………………………………………………………… 96
3.3.1 HYDRAULIC LIFT SYSTEM………………………………………………………………….. 96
3.3.2 ASM SYSTEM……………………………………………………………………………. 97
3.4 INFOCENTER 2 or 3…………………………………………………………………………… 98
3.5 FRONT AXLE SUSPENSION CONTROL UNIT……………………………………………………………. 99
3.6 FRONT AND REAR PTO CONTROL UNIT……………………………………………………………….100
4. PUTTING THE TRACTOR INTO SERVICE…………………………………………………………………..101
4.1 INTRODUCTION………………………………………………………………………………..101
4.2 RENEWAL OF THE ENGINE CONTROL UNIT…………………………………………………………….101
4.2.1 READING AND SAVING DATA…………………………………………………………………101
4.2.2 PROGRAMMING THE CONTROL UNIT…………………………………………………………….102
4.2.3 CALIBRATION OF THE ACCELERATOR PEDAL……………………………………………………..103
4.2.4 CALIBRATION OF THE HAND THROTTLE…………………………………………………………104
4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT……………………………………………………….105
4.3.1 SETTING THE TRACTOR VERSION AND SERIAL NUMBER……………………………………………..105
4.3.2 CALIBRATION OF THE CLUTCH PEDAL POSITION SENSOR……………………………………………107
4.3.3 CALIBRATION OF THE MAIN CLUTCH PROPORTIONAL SOLENOID VALVE………………………………….109
4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT………………………………………………….111
4.4.1 PROGRAMMING THE TYPE OF TRACTOR………………………………………………………….112
4.4.2 CONFIGURING NO RADAR STATUS……………………………………………………………..113
4.4.3 CALIBRATION OF THE LIFT POSITION SENSOR…………………………………………………..114
4.4.4 CHECKING AND CALIBRATING THE LIFT CONTROL LEVER……………………………………………116
4.5 RENEWAL OF THE INFOCENTER…………………………………………………………………….119
4.5.1 ENTERING CONSTANTS……………………………………………………………………..119
4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT………………………………………………………..121
4.6.1 CHECKING CALIBRATION OF THE SUSPENSION POSITION SENSOR……………………………………..121
5. ALARMS………………………………………………………………………………………….123
5.1 LIFT AND ASM CONTROL UNIT ALARMS………………………………………………………………123
5.1.1 LIST OF ALARMS BY EXTENDED CODE………………………………………………………….124
5.1.2 LIST OF ALARMS BY STANDARD CODE………………………………………………………….126
5.1.3 LIST OF ALARMS DISPLAYED ON ART………………………………………………………….128
5.1.4 ANALYSIS OF LIFT AND ASM ALARMS………………………………………………………….130
5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS……………………………………………………….159
5.2.1 ABNORMALITIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT…………………………………159
5.2.2 ALARMS INDICATED ON THE TRANSMISSION DISPLAY AND BY THE EDS PROGRAM………………………….159
5.2.3 DEFINITION OF TRANSMISSION OPERATING MODES………………………………………………..163
5.2.4 ANALYSIS OF ALARMS……………………………………………………………………..164
5.3 LIST OF ALARMS DISPLAYED BY SERDIA…………………………………………………………….219
5.3.1 ALARMS DISPLAYED USING THE SERDIA PROGRAM…………………………………………………219
5.3.2 ANALYSIS OF ALARMS……………………………………………………………………..221
5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS………………………………………………241
5.4.1 LIST OF ALARMS BY TEXT CODE……………………………………………………………..241
5.4.2 LIST OF ALARMS BY STANDARD CODE………………………………………………………….242
5.4.3 LIST OF ALARMS DISPLAYED BY ART………………………………………………………….243
5.4.4 ANALYSIS OF ALARMS……………………………………………………………………..244
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System)………………………………………………….257
1. GENERAL INTRODUCTION………………………………………………………………………….257
1.1 FUNCTIONAL SCOPE…………………………………………………………………………257
1.2 HARDWARE REQUIREMENTS…………………………………………………………………….258
1.3 STARTING AND TERMINATING OF THE EDS PROGRAM…………………………………………………260
2. TRANSMISSION DIAGNOSIS………………………………………………………………………..262
2.1 THE MAIN MENU……………………………………………………………………………262
2.2 ONLINE HELP……………………………………………………………………………..264
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45…………………………………………………………265
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45…………………………………………265
3.2 DEST 45 PROGRAM DESCRIPTION……………………………………………………………….266
3.3 ERROR CODES POWER-SHUTTLE /DEST 45…………………………………………………………281
3.4 DISPLAY POWERSHUTTLE……………………………………………………………………..282
3.5 ERROR CODE LIST WITH DESCRIPTION…………………………………………………………..283
3.6 OTHER INFORMATIONS……………………………………………………………………….294
3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100……………………………………….295
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100………………………………………………………..296
3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200……………………………………….297
3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300……………………………………………….298
3.11 ERROR ANALYSIS………………………………………………………………………….299
4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER…………………………………………………….301
4.1 PROGRAM DESCRIPTION………………………………………………………………………302
4.2 CONSTANT VALUES FOR INFOCENTER…………………………………………………………….312
7. ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT………………………………………………………317
PRESENTATION SCREEN……………………………………………………………………………..317
MAIN MENU………………………………………………………………………………………317
1. MONITOR……………………………………………………………………………………..318
1.1 LIFT……………………………………………………………………………………318
1.2 CONSOLE…………………………………………………………………………………320
1.3 ASM…………………………………………………………………………………….320
1.4 POWER…………………………………………………………………………………..321
1.5 SENSORS…………………………………………………………………………………322
2. CONFIGURATION………………………………………………………………………………..322
2.1 SPEED CONSTANTS………………………………………………………………………….323
2.2 OPTIONS…………………………………………………………………………………323
3. CALIBRATIONS…………………………………………………………………………………324
3.1 MINIMUM HEIGHT…………………………………………………………………………..325
3.2 MAXIMUM HEIGHT…………………………………………………………………………..325
3.3 LOCK SPEED………………………………………………………………………………326
3.5 TRANSPORT……………………………………………………………………………….327
3.6 STOP……………………………………………………………………………………327
3.7 CONTROL…………………………………………………………………………………328
3.8 FLOAT…………………………………………………………………………………..328
4. ALARMS LIST………………………………………………………………………………….329
8. ALL ROUND TESTER FOR AXLE SUSPENSION CONTROL UNIT……………………………………………………331
PRESENTATION SCREEN……………………………………………………………………………..331
MAIN MENU………………………………………………………………………………………331
1. MONITOR……………………………………………………………………………………..332
1.1 SUSPENSION………………………………………………………………………………332
2. PARAMETERS…………………………………………………………………………………..333
3. ALARMS LIST………………………………………………………………………………….335
4. CONFIGURATIONS……………………………………………………………………………….335
9. SERDIA (LEVEL III)……………………………………………………………………………….337
1. SETUP AND COMMUNICATIONS………………………………………………………………………337
1.1 MINIMUM EQUIPMENT REQUIRED………………………………………………………………..337
1.2 ORDERING………………………………………………………………………………..338
1.3 SWITCHING ON AND INSTALLING THE SOFTWARE……………………………………………………339
1.4 USING THE PROGRAM………………………………………………………………………..343
1.5 CLOSING THE PROGRAM………………………………………………………………………346
2. ECU SELECTION………………………………………………………………………………..347
2.1 SELECTING TWO CONTROL UNITS……………………………………………………………….347
2.2 PRINTING………………………………………………………………………………..348
2.3 PROTOCOL………………………………………………………………………………..349
2.4 IDENTIFICATION AND MEASUREMENT DATA………………………………………………………..349
3. MEASURED VALUES………………………………………………………………………………351
3.1 ACTUAL MEASURED VALUES (GENERAL)…………………………………………………………..351
3.2 RAM-VALUES………………………………………………………………………………356
3.3 DATA LOGGER (ONLY EMS2)…………………………………………………………………..360
3.4 INPUT/OUTPUT ASSIGNMENT…………………………………………………………………..360
3.5 CAN STATUS………………………………………………………………………………360
4. PARAMETERS…………………………………………………………………………………..363
4.1 CONFIGURATION (GENERAL)…………………………………………………………………..363
4.2 OVERALL PROGRAMMING………………………………………………………………………364
4.2 CALIBRATION……………………………………………………………………………..365
5. ERROR MEMORY…………………………………………………………………………………366
5.1 GENERAL…………………………………………………………………………………366
5.2 ERROR TABLE……………………………………………………………………………..367
6. EXTRAS………………………………………………………………………………………377
6.1 MAXIMUM SPEED……………………………………………………………………………377
6.2 LOGISTIC DATA……………………………………………………………………………377
6.3 LOAD SPECTRUM……………………………………………………………………………378
6.4 MAINTENANCE INTERVAL EXCEEDED……………………………………………………………..378
6.5 OVERRIDE MEMORY………………………………………………………………………….378
6.6 MAINTENANCE DATA…………………………………………………………………………378
7. TASKS……………………………………………………………………………………….379
7.1 EMR1……………………………………………………………………………………379
8. WHAT TO DO IF…?…………………………………………………………………………….383
8.1 SERDIA GENERAL…………………………………………………………………………..383
8.2 EMR1……………………………………………………………………………………385
SECTION 30…………………………………………………………………………………………….397
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING………………………………………………401
TOP VIEW OF WIRING AND PIPES…………………………………………………………………………402
VIEW OF UPPER WIRING AND PIPES……………………………………………………………………….403
PIPES ON RIGHT-HAND SIDE…………………………………………………………………………….404
TOP VIEW OF REAR PIPES………………………………………………………………………………405
DETAIL OF AIR TRAILER BRAKING SYSTEM………………………………………………………………….406
ENGINE HOOD AND LAMP ASSEMBLIES………………………………………………………………………407
Removal………………………………………………………………………………………..407
Refitting………………………………………………………………………………………410
BATTERY……………………………………………………………………………………………411
Removal………………………………………………………………………………………..411
Refitting………………………………………………………………………………………412
CAB ACCESS STEPS……………………………………………………………………………………413
Removal………………………………………………………………………………………..413
Refitting………………………………………………………………………………………413
BATTERY SUPPORT…………………………………………………………………………………….414
Removal………………………………………………………………………………………..414
Refitting………………………………………………………………………………………414
STARTER MOTOR………………………………………………………………………………………415
Removal………………………………………………………………………………………..415
Refitting………………………………………………………………………………………415
COMPRESSOR DRIVEBELT………………………………………………………………………………..416
Renewal………………………………………………………………………………………..416
Tensioning……………………………………………………………………………………..416
AIR COMPRESSOR……………………………………………………………………………………..418
Removal………………………………………………………………………………………..418
Refitting………………………………………………………………………………………420
FAN DRIVE BELT……………………………………………………………………………………..421
Renewal………………………………………………………………………………………..421
FAN……………………………………………………………………………………………….423
Removal………………………………………………………………………………………..423
Renewal………………………………………………………………………………………..424
Refitting………………………………………………………………………………………425
ALTERNATOR DRIVEBELT………………………………………………………………………………..426
Renewal and tensioning…………………………………………………………………………..426
ALTERNATOR…………………………………………………………………………………………429
Removal………………………………………………………………………………………..429
Refitting………………………………………………………………………………………429
AIR RESERVOIRS……………………………………………………………………………………..430
(for version with air trailer braking only)………………………………………………………..430
Removal…………………………………………………………………………………….430
Refitting…………………………………………………………………………………..430
AIR BRAKING SYSTEM VALVES……………………………………………………………………………431
Removal………………………………………………………………………………………..431
Refitting………………………………………………………………………………………433
TRAILER AIR BRAKES COUPLING HEADS…………………………………………………………………….434
Removal………………………………………………………………………………………..434
Refitting………………………………………………………………………………………434
HYDRAULIC TRAILER BRAKING VALVES……………………………………………………………………..435
Removal………………………………………………………………………………………..435
Refitting………………………………………………………………………………………436
AIR CONDITIONING SYSTEM……………………………………………………………………………..437
Description…………………………………………………………………………………….437
Technical specifications…………………………………………………………………………437
Operation………………………………………………………………………………………438
Maintenance…………………………………………………………………………………….439
Tension of the compressor drivebelt……………………………………………………………….439
Discharging, flushing and recharging………………………………………………………………440
AIR CONDITIONING COMPRESSOR………………………………………………………………………….441
Removal………………………………………………………………………………………..441
Refitting………………………………………………………………………………………442
RECEIVER-DRIER……………………………………………………………………………………..443
Removal………………………………………………………………………………………..443
Refitting………………………………………………………………………………………443
CONDENSER ASSEMBLY………………………………………………………………………………….444
Removal………………………………………………………………………………………..444
Refitting………………………………………………………………………………………444
GEARBOX OIL/FUEL COOLERS…………………………………………………………………………….445
Removal………………………………………………………………………………………..445
Refitting………………………………………………………………………………………446
RADIATOR…………………………………………………………………………………………..447
Removal………………………………………………………………………………………..447
Refitting………………………………………………………………………………………448
EXPANSION TANK……………………………………………………………………………………..449
Removal………………………………………………………………………………………..449
Refitting………………………………………………………………………………………449
INTERCOOLER………………………………………………………………………………………..450
Removal………………………………………………………………………………………..450
Refitting………………………………………………………………………………………451
COMPLETE RADIATOR/COOLERS ASSEMBLY……………………………………………………………………452
Removal………………………………………………………………………………………..452
Refitting………………………………………………………………………………………454
FLEXIBLE COUPLING OF THE FRONT PTO……………………………………………………………………455
Renewal………………………………………………………………………………………..455
Refitting………………………………………………………………………………………458
TURBOCHARGER……………………………………………………………………………………….459
Removal………………………………………………………………………………………..459
Refitting………………………………………………………………………………………460
AIR INLET PIPE……………………………………………………………………………………..461
Removal………………………………………………………………………………………..461
Refitting………………………………………………………………………………………461
AIR CLEANER………………………………………………………………………………………..462
Removal………………………………………………………………………………………..462
Refitting………………………………………………………………………………………463
EXHAUST PIPE……………………………………………………………………………………….464
Removal………………………………………………………………………………………..464
Refitting………………………………………………………………………………………464
SILENCER…………………………………………………………………………………………..465
Removal………………………………………………………………………………………..465
Refitting………………………………………………………………………………………465
4WD PROPELLER SHAFT…………………………………………………………………………………466
Removal………………………………………………………………………………………..466
Refitting………………………………………………………………………………………467
4WD PROPELLER SHAFT…………………………………………………………………………………468
Removal………………………………………………………………………………………..468
Refitting………………………………………………………………………………………471
BRAKE MASTER CYLINDERS………………………………………………………………………………472
Removal………………………………………………………………………………………..472
Refitting………………………………………………………………………………………473
BRAKING SYSTEM……………………………………………………………………………………..474
Bleeding……………………………………………………………………………………….474
BRAKE LIGHT SWITCHES………………………………………………………………………………..476
Adjustment……………………………………………………………………………………..476
POWER STEERING UNIT…………………………………………………………………………………477
Testing………………………………………………………………………………………..477
Adjustment……………………………………………………………………………………..477
Removal………………………………………………………………………………………..478
Refitting………………………………………………………………………………………478
Dismantling…………………………………………………………………………………….479
Assembly……………………………………………………………………………………….486
FRONT WHEELS……………………………………………………………………………………….496
Removal………………………………………………………………………………………..496
Refitting………………………………………………………………………………………496
FRONT FENDERS………………………………………………………………………………………497
Removal………………………………………………………………………………………..497
Refitting………………………………………………………………………………………497
REAR WHEELS………………………………………………………………………………………..498
Removal………………………………………………………………………………………..498
Refitting………………………………………………………………………………………498
LIFT VALVE BLOCK……………………………………………………………………………………499
Removal………………………………………………………………………………………..499
Refitting………………………………………………………………………………………499
FRONT LIFT CYLINDERS………………………………………………………………………………..500
Removal………………………………………………………………………………………..500
Refitting………………………………………………………………………………………501
FRONT LIFT ASSEMBLY…………………………………………………………………………………502
Removal………………………………………………………………………………………..502
Refitting………………………………………………………………………………………504
FRONT PTO ASSEMBLY………………………………………………………………………………….505
Removal………………………………………………………………………………………..505
Refitting………………………………………………………………………………………505
FRONT SUSPENSION CYLINDERS…………………………………………………………………………..506
Removal………………………………………………………………………………………..506
Refitting………………………………………………………………………………………508
Disassembly…………………………………………………………………………………….509
Assembly……………………………………………………………………………………….510
FRONT AXLE AND SWINGING SUPPORT………………………………………………………………………511
Removal………………………………………………………………………………………..511
Refitting………………………………………………………………………………………513
FRONT SUSPENSION VALVES……………………………………………………………………………..514
Removal………………………………………………………………………………………..514
Refitting………………………………………………………………………………………514
FRONT SUSPENSION POSITION SENSOR……………………………………………………………………..515
Removal………………………………………………………………………………………..515
Positioning…………………………………………………………………………………….515
Testing………………………………………………………………………………………..516
REINFORCING SIDE MEMBERS…………………………………………………………………………….517
Removal………………………………………………………………………………………..517
Refitting………………………………………………………………………………………517
FRONT CARRIER………………………………………………………………………………………518
Removal………………………………………………………………………………………..518
Refitting………………………………………………………………………………………518
ACCELERATOR POTENTIOMETER……………………………………………………………………………519
Renewal………………………………………………………………………………………..519
Refitting………………………………………………………………………………………519
FUEL TANK………………………………………………………………………………………….520
Removal………………………………………………………………………………………..520
Refitting………………………………………………………………………………………520
GEARBOX GEAR PUMP…………………………………………………………………………………..521
Removal………………………………………………………………………………………..521
Refitting………………………………………………………………………………………522
POWER STEERING – LIFT AND HYDRAULIC SERVICES PUMPS……………………………………………………..525
Removal………………………………………………………………………………………..525
Refitting………………………………………………………………………………………528
REMOTE CONTROL VALVES……………………………………………………………………………….529
Removal………………………………………………………………………………………..529
Refitting………………………………………………………………………………………533
Disassembly…………………………………………………………………………………….534
Assembly……………………………………………………………………………………….536
REMOTE CONTROL VALVES ASSEMBLY……………………………………………………………………….537
Removal………………………………………………………………………………………..537
Refitting………………………………………………………………………………………540
LIFT CYLINDERS……………………………………………………………………………………..541
Removal………………………………………………………………………………………..541
Refitting………………………………………………………………………………………542
Disassembly…………………………………………………………………………………….543
Assembly……………………………………………………………………………………….543
LIFT POSITION SENSOR………………………………………………………………………………..544
Testing………………………………………………………………………………………..544
Renewal………………………………………………………………………………………..545
Refitting………………………………………………………………………………………545
Adjusting………………………………………………………………………………………546
LIFT DRAFT SENSOR…………………………………………………………………………………..548
Removal………………………………………………………………………………………..548
Refitting………………………………………………………………………………………548
DRIVER’S SEAT………………………………………………………………………………………549
Removal………………………………………………………………………………………..549
Refitting………………………………………………………………………………………549
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL…………………………………………550
Removal………………………………………………………………………………………..550
Refitting………………………………………………………………………………………551
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER……………………………………………….552
Removal………………………………………………………………………………………..552
Refitting………………………………………………………………………………………553
CENTRE CONSOLE AND SHROUD……………………………………………………………………………554
Removal………………………………………………………………………………………..554
Refitting………………………………………………………………………………………557
RIGHT-HAND CONSOLE………………………………………………………………………………….558
Removal e opening……………………………………………………………………………….558
Refitting………………………………………………………………………………………564
LEFT-HAND CONSOLE…………………………………………………………………………………..565
Removal………………………………………………………………………………………..565
Refitting………………………………………………………………………………………566
LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS…………………………………………567
Removal………………………………………………………………………………………..567
Refitting………………………………………………………………………………………568
FUSE AND RELAY BOARD………………………………………………………………………………..569
Removal………………………………………………………………………………………..569
Refitting………………………………………………………………………………………570
ENGINE ECU…………………………………………………………………………………………571
Removal………………………………………………………………………………………..571
Refitting………………………………………………………………………………………571
CLUTCH PEDAL AND RELATED DEVICES……………………………………………………………………..572
Removal of the potentiometer……………………………………………………………………..572
Refitting the potentiometer………………………………………………………………………572
Adjustment of the clutch pedal position and travel………………………………………………….573
Renewal of the proximity sensor…………………………………………………………………..573
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO…………………………………….574
Removal………………………………………………………………………………………..574
Refitting………………………………………………………………………………………577
PTO ENGAGEMENT AND SELECTION CONTROL CABLES……………………………………………………………578
Removal………………………………………………………………………………………..578
Refitting………………………………………………………………………………………579
AUXILIARY SERVICE VALVE CONTROL CABLES………………………………………………………………..581
Removal………………………………………………………………………………………..581
Refitting………………………………………………………………………………………582
PARKING BRAKE SWITCH………………………………………………………………………………..583
Adjustment……………………………………………………………………………………..583
CLIMATE CONTROL PANEL……………………………………………………………………………….584
Removal………………………………………………………………………………………..584
Refitting………………………………………………………………………………………584
HEATER VALVE……………………………………………………………………………………….585
Removal………………………………………………………………………………………..585
Refitting………………………………………………………………………………………585
HEATER MATRIX………………………………………………………………………………………587
Removal………………………………………………………………………………………..587
Refitting………………………………………………………………………………………589
AIR CONDITIONING EVAPORATOR………………………………………………………………………….590
Removal………………………………………………………………………………………..590
Refitting………………………………………………………………………………………591
RIGHT-HAND AIR CONDITIONING FAN………………………………………………………………………592
Removal………………………………………………………………………………………..592
Refitting………………………………………………………………………………………592
LEFT-HAND AIR CONDITIONING FAN……………………………………………………………………….593
Removal………………………………………………………………………………………..593
Refitting………………………………………………………………………………………593
PARKING BRAKES……………………………………………………………………………………..594
Adjustment……………………………………………………………………………………..594
CAB DOOR CABLE……………………………………………………………………………………..595
Renewal………………………………………………………………………………………..595
TRAILER BRAKING AIR PRESSURE GAUGE……………………………………………………………………597
Removal………………………………………………………………………………………..597
Refitting………………………………………………………………………………………597
TRANSMISSION STATUS DISPLAY………………………………………………………………………….598
Removal………………………………………………………………………………………..598
Refitting………………………………………………………………………………………598
CAB……………………………………………………………………………………………….599
Removal………………………………………………………………………………………..599
Refitting………………………………………………………………………………………606
ENGINE -TRANSMISSION………………………………………………………………………………..607
Separation……………………………………………………………………………………..607
Reconnection……………………………………………………………………………………609
SECTION 40…………………………………………………………………………………………….611
THE STRUCTURE OF THE UNIT……………………………………………………………………………613
HOW TO CONSULT THE UNIT……………………………………………………………………………..614
1. INTRODUCTION…………………………………………………………………………………….615
1.1 LIST OF WIRING HARNESSES……………………………………………………………………..615
1.2 DEFINITION OF COMPONENTS AND SYMBOLS…………………………………………………………..616
1.3 GENERAL RULES……………………………………………………………………………….616
1.3.1 MODIFICATION OF THE TRACTOR’S ELECTRICAL/ELECTRONIC CIRCUITS………………………………..616
1.3.2 MAIN WIRING FAULTS……………………………………………………………………..616
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING……………………………………..617
1.4 DIAGNOSTIC INSTRUMENTS……………………………………………………………………….618
1.5 WIRE COLOUR CODES……………………………………………………………………………618
2. INDICES…………………………………………………………………………………………619
2.1 INDEX BY PART DESCRIPTION…………………………………………………………………….619
2.2 INDEX BY PART CODE…………………………………………………………………………..624
2.3 INDEX BY CONNECTOR…………………………………………………………………………..628
3. COMPONENTS………………………………………………………………………………………636
3.1 CONNECTOR LAYOUTS……………………………………………………………………………636
3.2 COMPONENT TECHNICAL DATA……………………………………………………………………..641
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS…………………………………………….650
3.3.1 ENGINE CONTROL UNIT (0419.4998)………………………………………………………….650
3.3.2 TRANSMISSION CONTROL UNIT (0443.8083/10)………………………………………………….652
3.3.3 INFOCENTER (0443.7488/10)……………………………………………………………….655
3.3.4 HPSA CONTROL UNIT (2.8519.013.0)…………………………………………………………657
3.3.5 FRONT SUSPENSION CONTROL UNIT (2.8519.008.0/10)……………………………………………659
4. SYSTEMS…………………………………………………………………………………………661
4.1 GROUND POINTS……………………………………………………………………………….661
4.2 ENGINE START………………………………………………………………………………..662
4.3 PREHEATING………………………………………………………………………………….663
4.4 ELECTRICAL ENGINE CONTROL…………………………………………………………………….664
4.5 LIGHTS – LIGHT SELECTOR SWITCH (MACHINE WITHOUT FRONT LIFT)………………………………………665
4.6 LIGHTS – LIGHT SELECTOR SWITCH (MACHINE WITH FRONT LIFT)…………………………………………666
4.7 CAB ACCESSORY……………………………………………………………………………….667
4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT)…………………………………………………….668
4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT)……………………………………………………….669
4.10 WINDSCREEN WIPER……………………………………………………………………………670
4.11 INFOCENTER…………………………………………………………………………………671
4.12 ELECTRICAL POWER SUPPLY……………………………………………………………………..672
4.13 RADIO – CB…………………………………………………………………………………673
4.14 AIR CONDITIONING – HEATING FAN……………………………………………………………….674
4.15 BRAKES…………………………………………………………………………………….675
4.16 TRAILER BRAKES……………………………………………………………………………..676
4.17 FRONT AXLE SUSPENSION……………………………………………………………………….677
4.18 TRANSMISSION……………………………………………………………………………….678
4.19 ASM – 4WD – DIFFERENTIAL…………………………………………………………………….679
4.20 REAR LIFTER………………………………………………………………………………..680
4.21 FRONT AND REAR PTO………………………………………………………………………….681
5. WIRING………………………………………………………………………………………….683
ENGINE WIRING (4 CYLINDERS) (1/2)…………………………………………………………………683
ENGINE WIRING (4 CYLINDERS) (2/2)…………………………………………………………………684
ENGINE WIRING (6 CYLINDERS) (1/2)…………………………………………………………………685
ENGINE WIRING (6 CYLINDERS) (2/2)…………………………………………………………………686
ENGINE WIRING (1/2)……………………………………………………………………………..691
ENGINE WIRING (2/2)……………………………………………………………………………..692
TRANSMISSION WIRING (1/2)………………………………………………………………………..701
TRANSMISSION WIRING (2/2)………………………………………………………………………..702
TRAILER BRAKE WIRING (ITALY)……………………………………………………………………..711
TRAILER BRAKE WIRING…………………………………………………………………………….712
FRONT AXLE SUSPENSION WIRING (CAB)………………………………………………………………..715
CAB POWER SUPPLY WIRING………………………………………………………………………….719
FRONT AXLE SUSPENSION WIRING……………………………………………………………………..725
FENDER WIRING – NARROW…………………………………………………………………………..729
NUMBER PLATE LIGHT WIRING………………………………………………………………………..730
FRONT CONSOLE WIRING (1/2)……………………………………………………………………….735
FRONT CONSOLE WIRING (2/2)……………………………………………………………………….736
SIDE CONSOLE WIRING (1/2)………………………………………………………………………..741
SIDE CONSOLE WIRING (2/2)………………………………………………………………………..742
AIR CONDITIONING WIRING (CAB)…………………………………………………………………….751
DISPLAY WIRING………………………………………………………………………………….757
ROOF WIRING (1/2)……………………………………………………………………………….761
ROOF WIRING (2/2)……………………………………………………………………………….762
CAB ROOF FRONT AND REAR WORKLIGHTS WIRING………………………………………………………….771
CAB LOWER HEADLIGHTS WIRING………………………………………………………………………769
WINDSCREEN WIPER MOTOR WIRING…………………………………………………………………….769
CAB LOWER FRONT WORKLIGHTS WIRING (MACHINE WITHOUT FRONT LIFT)……………………………………….770
CAB LOWER FRONT WORKLIGHTS WIRING (WITH FRONT LIFT)…………………………………………………770
LIGHTS SELECTOR SWITCH…………………………………………………………………………..777
ARMREST WIRING………………………………………………………………………………….781
FUSES AND RELAYS CONTROL UNIT (1/2)……………………………………………………………….783
FUSES AND RELAYS CONTROL UNIT (2/2)……………………………………………………………….784
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S.V