DEUTZ-FAHR AGROTRON 80 MK3 AGROTRON 85 MK3 AGROTRON 90 MK3 AGROTRON 100 MK3 AGROTRON 105 MK3 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON 80 MK3 AGROTRON 85 MK3 AGROTRON 90 MK3 AGROTRON 100 MK3 AGROTRON 105 MK3 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON 80 MK3 AGROTRON 85 MK3 AGROTRON 90 MK3 AGROTRON 100 MK3 AGROTRON 105 MK3 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 AGROTRON 85 MK3 AGROTRON 90 MK3 AGROTRON 100 MK3 AGROTRON 105 MK3 Workshop Manual – PDF DOWNLOAD
307.1100.3.6 AGROTRON 80-85-90-100-105 MK3………………………………………………………………………………. 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…………………………………………………………………………………………… 22
1.1.1 MAIN COMPONENTS…………………………………………………………………………………… 22
1.1.2 TRANSMISSION HYDRAULIC SYSTEM………………………………………………………………………. 25
1.1.3 GEARBOX………………………………………………………………………………………….. 26
GEARBOX COMPONENTS……………………………………………………………………………………… 27
1.1.4 MAIN CLUTCH………………………………………………………………………………………. 28
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE……………………………………………………… 29
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC………………………………………………. 32
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC…………………………………………………………….. 33
1.2 REAR AXLE……………………………………………………………………………………………… 35
1.3 REAR PTO………………………………………………………………………………………………. 37
2. BRAKING SYSTEM……………………………………………………………………………………………… 39
2.1 BRAKE MASTER CYLINDER…………………………………………………………………………………… 40
2.2 BRAKE…………………………………………………………………………………………………. 41
2.3 TRAILER BRAKING SYSTEM………………………………………………………………………………….. 42
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)……………………………………………………………. 42
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)…………………………………………………………… 44
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)…………………………………………………………………. 45
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)………………………………………………………………… 46
COMPRESSOR…………………………………………………………………………………………….. 47
PRESSURE LIMITING VALVE…………………………………………………………………………………. 48
TRAILER BRAKING VALVE (2-WAY)……………………………………………………………………………. 49
TRAILER BRAKING VALVE (1-WAY)……………………………………………………………………………. 50
3. HYDRAULIC FRONT AXLE SUSPENSION………………………………………………………………………………. 51
3.1 SOLENOID VALVE – SUPPLY TO FRONT SUSPENSION CONTROL VALVE…………………………………………………… 52
3.2 FRONT SUSPENSION CONTROL VALVE…………………………………………………………………………… 53
4. FRONT AXLE…………………………………………………………………………………………………. 57
5. HYDRAULIC SYSTEM……………………………………………………………………………………………. 58
5.1 HYDRAULIC SYSTEM……………………………………………………………………………………….. 59
5.2 GEAR PUMP FOR TRANSMISSION ZF 7100……………………………………………………………………….. 61
5.3 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING……………………………………………………………… 62
5.4 POWER STEERING…………………………………………………………………………………………. 63
5.5 AUXILIARY SERVICES CONTROL VALVE…………………………………………………………………………. 64
5.5.1 TYPES OF CONTROL VALVE…………………………………………………………………………….. 65
5.5.2 SERVICES CONTROL SECTION…………………………………………………………………………… 67
5.5.3 DESCRIPTIONS OF COMPONENTS…………………………………………………………………………. 68
5.5.4 INLET MANIFOLD……………………………………………………………………………………. 69
5.5.5 LIFT CONTROL VALVE SECTION…………………………………………………………………………. 70
SECTION 20……………………………………………………………………………………………………….. 71
OPERATOR’S MANUAL SERDIA (LEVEL III)…………………………………………………………………………….. 73
1. ENTRY AND COMMUNICATION………………………………………………………………………………….. 74
1.1 OVERVIEW…………………………………………………………………………………………… 74
1.2 ORDERING…………………………………………………………………………………………… 75
1.3 SWITCH ON NOTEBOOK AND INSTALL SOFTWARE……………………………………………………………….. 76
1.4 USER LEVEL, ACCESS AUTHORIZATION……………………………………………………………………… 77
1.5 MAKING A CONNECTION BETWEEN ECU (ENGINE) AND NOTEBOOK…………………………………………………… 78
1.6 PROGRAM START………………………………………………………………………………………. 78
1.7 OFFLINE MODE……………………………………………………………………………………….. 79
1.8 WORKING WITH THE PROGRAM…………………………………………………………………………….. 81
1.9 PRINT (OUTPUT)……………………………………………………………………………………… 83
1.10 PROTOCOL (PROTOKOLL)……………………………………………………………………………….. 84
1.11 END COMMUNICATION………………………………………………………………………………….. 84
2. ECU SELECTION…………………………………………………………………………………………… 85
2.1 GENERAL……………………………………………………………………………………………. 85
2.2 RECOGNITION OF ECUS…………………………………………………………………………………. 85
2.3 IDENTIFICATION DATA…………………………………………………………………………………. 85
3 MEASURED VALUES………………………………………………………………………………………….. 86
3.1 ACTUAL MEASURED VALUES (GENERAL)……………………………………………………………………… 86
3.2 RAM VALUES…………………………………………………………………………………………. 90
3.3 DATA LOGGER (ONLY EMS)………………………………………………………………………………. 90
3.4 INPUT/OUTPUT ASSIGNMENT……………………………………………………………………………… 90
3.5 CAN-Status…………………………………………………………………………………………. 90
3.6 EXAMPLE OF A DISPLAYED ERROR INFORMATION:……………………………………………………………… 92
4. PARAMETERS……………………………………………………………………………………………… 92
4.1 CONFIGURATION………………………………………………………………………………………. 92
4.2 OVERALL PROGRAMMING………………………………………………………………………………….104
4.3 CALIBRATION…………………………………………………………………………………………104
5. ERROR MEMORY…………………………………………………………………………………………….106
5.1 GENERAL…………………………………………………………………………………………….106
6. FUNCTION TEST……………………………………………………………………………………………111
6.1 GENERAL…………………………………………………………………………………………….111
7. EXTRAS………………………………………………………………………………………………….112
7.1 MAXIMUM VEHICLE SPEED………………………………………………………………………………..112
7.2 LOGISTIC DATA……………………………………………………………………………………….112
7.3 LOAD SPECTRUM (ONLY EMS)……………………………………………………………………………..113
7.4 MAINTENANCE INTERVAL EXCEEDED (ONLY EMS)……………………………………………………………….113
7.5 OVERRIDE MEMORY (ONLY EMS)……………………………………………………………………………113
8 WHAT SHOULD YOU DO IF …?…………………………………………………………………………………114
8.1 SERDIA IN GENERAL……………………………………………………………………………………114
8.2 EMR………………………………………………………………………………………………..117
9. SERDIA UPGRADE FROM VERSION 2.5 TO VERSION 3.1………………………………………………………………129
9.1 IMPROVEMENTS AND HELP WITH PROBLEMS IN COMMUNICATING WITH NOTEBOOKS/WIN 98…………………………………129
9.2 NEW ENTRY MASK WITH MEASURED VALUES AND COLOURED-CODED INDICATION OF CONNECTION STATUS………………………130
9.3 NEW SWITCH “JOBS“ FOR PERFORMING SELECTED SERVICING OPERATIONS, E.G. ADJUSTING CONTROLLER OR ADJUSTING OFFSET….131
9.4 IN- AND OUTPUT ASSIGNMENT IS NOW ADDITIONALLY CONFIGURABLE USING PLAIN TEXT (PREVIOUSLY ONLY CODE NUMBERS)…….132
9.5 UPGRADES IN “PARAMETER SETTING/CONFIGURATION“…………………………………………………………..132
OPERATOR’S MANUAL EDS (Electronic Diagnosis System)………………………………………………………………..133
1. GENERAL INTRODUCTION……………………………………………………………………………………..134
1.1 FUNCTIONAL SCOPE…………………………………………………………………………………….134
1.2 HARDWARE REQUIREMENTS………………………………………………………………………………..135
1.3 STARTING THE EDS PROGRAM……………………………………………………………………………..137
2. TRANSMISSION DIAGNOSIS……………………………………………………………………………………138
2.1 THE MAIN MENU……………………………………………………………………………………….138
2.2 ONLINE HELP…………………………………………………………………………………………141
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45…………………………………………………………………….143
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45…………………………………………………….143
3.2 DEST 45 PROGRAM DESCRIPTION…………………………………………………………………………..144
3.3 ERROR CODES POWER-SHUTTLE /DEST 45…………………………………………………………………….159
3.4 DISPLAY POWERSHUTTLE…………………………………………………………………………………160
3.5 ERROR CODE LIST WITH DESCRIPTION………………………………………………………………………161
3.6 OTHER INFORMATIONS…………………………………………………………………………………..172
3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100…………………………………………………..173
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100……………………………………………………………………174
3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200…………………………………………………..175
3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300…………………………………………………………..176
3.11 ERROR ANALYSIS……………………………………………………………………………………..177
4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER………………………………………………………………..179
4.1 PROGRAM DESCRIPTION………………………………………………………………………………….180
4.2 CONSTANT VALUES FOR INFOCENTER………………………………………………………………………..190
ALL ROUND TESTER MANUAL – MK3 80-105 SERIES……………………………………………………………………….195
1. MONITOR…………………………………………………………………………………………………197
1.1 LIFT……………………………………………………………………………………………….197
1.2 CONSOLE…………………………………………………………………………………………….199
1.3 ASM………………………………………………………………………………………………..199
1.4 POWER………………………………………………………………………………………………200
1.5 SENSORS…………………………………………………………………………………………….201
2. PARAMETERS………………………………………………………………………………………………201
2.1 SPEED CONSTANTS……………………………………………………………………………………..202
2.2 OPTIONS…………………………………………………………………………………………….202
3. CALIBRATIONS…………………………………………………………………………………………….203
3.1 MINIMUM HEIGHT………………………………………………………………………………………204
3.2 MAXIMUM HEIGHT………………………………………………………………………………………204
3.3 LOCK SPEED………………………………………………………………………………………….205
3.4 WHEELSLIP…………………………………………………………………………………………..205
3.5 TRANSPORT…………………………………………………………………………………………..206
3.6 STOP……………………………………………………………………………………………….206
3.7 CONTROL…………………………………………………………………………………………….207
3.8 FLOAT………………………………………………………………………………………………207
4. ALARMS LIST……………………………………………………………………………………………..208
SECTION 30………………………………………………………………………………………………………..211
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING………………………………………………………….215
TOP VIEW OF WIRING AND PIPES…………………………………………………………………………………….216
VIEW OF UPPER WIRING AND PIPES…………………………………………………………………………………..217
PIPES ON RIGHT-HAND SIDE………………………………………………………………………………………..218
TOP VIEW OF REAR PIPES………………………………………………………………………………………….219
DETAIL OF AIR TRAILER BRAKING SYSTEM……………………………………………………………………………..220
ENGINE HOOD AND LAMP ASSEMBLIES………………………………………………………………………………….221
REMOVAL AND ADJUSTMENT………………………………………………………………………………………221
REFITTING AND ADJUSTMENT…………………………………………………………………………………….223
BATTERY……………………………………………………………………………………………………….224
REMOVAL……………………………………………………………………………………………………224
REFITTING………………………………………………………………………………………………….225
CAB ACCESS STEPS……………………………………………………………………………………………….226
REMOVAL……………………………………………………………………………………………………226
REFITTING………………………………………………………………………………………………….226
BATTERY SUPPORT………………………………………………………………………………………………..227
REMOVAL……………………………………………………………………………………………………227
REFITTING………………………………………………………………………………………………….227
STARTER MOTOR………………………………………………………………………………………………….228
REMOVAL……………………………………………………………………………………………………228
REFITTING………………………………………………………………………………………………….228
ALTERNATOR…………………………………………………………………………………………………….229
REMOVAL……………………………………………………………………………………………………229
REFITTING………………………………………………………………………………………………….229
ALTERNATOR DRIVEBELT……………………………………………………………………………………………230
RENEWAL AND TENSIONING………………………………………………………………………………………230
FAN…………………………………………………………………………………………………………..233
REMOVAL……………………………………………………………………………………………………233
REFITTING………………………………………………………………………………………………….235
COMPRESSOR DRIVEBELT……………………………………………………………………………………………236
RENEWAL……………………………………………………………………………………………………236
AIR COMPRESSOR (for air trailer braking)………………………………………………………………………….238
REMOVAL……………………………………………………………………………………………………238
REFITTING………………………………………………………………………………………………….240
AIR RESERVOIRS (for version with air trailer braking only)………………………………………………………….241
REMOVAL……………………………………………………………………………………………………241
REFITTING………………………………………………………………………………………………….241
AIR BRAKING SYSTEM VALVES……………………………………………………………………………………….242
REMOVAL……………………………………………………………………………………………………242
REFITTING………………………………………………………………………………………………….244
TRAILER AIR BRAKES COUPLING HEADS………………………………………………………………………………..245
REMOVAL……………………………………………………………………………………………………245
REFITTING………………………………………………………………………………………………….245
HYDRAULIC TRAILER BRAKING VALVES…………………………………………………………………………………246
REMOVAL……………………………………………………………………………………………………246
REFITTING………………………………………………………………………………………………….247
AIR CONDITIONING SYSTEM…………………………………………………………………………………………248
TECHNICAL SPECIFICATIONS…………………………………………………………………………………….248
OPERATION………………………………………………………………………………………………….249
MAINTENANCE………………………………………………………………………………………………..250
ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT………………………………………………………………250
DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM…………………………………………………251
AIR CONDITIONING COMPRESSOR……………………………………………………………………………………..253
REMOVAL……………………………………………………………………………………………………253
REFITTING………………………………………………………………………………………………….254
RECEIVER-DRIER…………………………………………………………………………………………………255
REMOVAL……………………………………………………………………………………………………255
REFITTING………………………………………………………………………………………………….255
CONDENSER ASSEMBLY (The figures depict models with 6-cylinder engines)……………………………………………….256
REMOVAL……………………………………………………………………………………………………256
REFITTING………………………………………………………………………………………………….256
GEARBOX OIL/FUEL COOLERS………………………………………………………………………………………..257
REMOVAL……………………………………………………………………………………………………257
REFITTING………………………………………………………………………………………………….258
RADIATOR………………………………………………………………………………………………………259
REMOVAL……………………………………………………………………………………………………259
REFITTING………………………………………………………………………………………………….260
EXPANSION TANK…………………………………………………………………………………………………261
REMOVAL……………………………………………………………………………………………………261
REFITTING………………………………………………………………………………………………….261
INTERCOOLER (4-cylinder models)………………………………………………………………………………….262
REMOVAL……………………………………………………………………………………………………262
REFITTING………………………………………………………………………………………………….263
COMPLETE RADIATOR/COOLERS ASSEMBLY……………………………………………………………………………….264
REMOVAL……………………………………………………………………………………………………264
REFITTING………………………………………………………………………………………………….267
FLEXIBLE COUPLING OF THE FRONT PTO……………………………………………………………………………….268
RENEWAL……………………………………………………………………………………………………268
REFITTING………………………………………………………………………………………………….270
TURBOCHARGER…………………………………………………………………………………………………..271
REMOVAL……………………………………………………………………………………………………271
REFITTING………………………………………………………………………………………………….271
AIR INLET PIPE…………………………………………………………………………………………………272
REMOVAL……………………………………………………………………………………………………272
REFITTING………………………………………………………………………………………………….272
AIR CLEANER……………………………………………………………………………………………………273
REMOVAL……………………………………………………………………………………………………273
REFITTING………………………………………………………………………………………………….274
EXHAUST PIPE…………………………………………………………………………………………………..275
REMOVAL……………………………………………………………………………………………………275
REFITTING………………………………………………………………………………………………….275
SILENCER………………………………………………………………………………………………………276
REMOVAL……………………………………………………………………………………………………276
REFITTING………………………………………………………………………………………………….276
4WD PROPELLER SHAFT (Version without front suspension)……………………………………………………………..277
REMOVAL……………………………………………………………………………………………………277
REFITTING………………………………………………………………………………………………….278
4WD PROPELLER SHAFT (Version with front suspension)………………………………………………………………..279
REMOVAL……………………………………………………………………………………………………279
REFITTING………………………………………………………………………………………………….281
BRAKE MASTER CYLINDERS………………………………………………………………………………………….282
REMOVAL……………………………………………………………………………………………………282
REFITTING………………………………………………………………………………………………….283
BLEEDING THE BRAKING SYSTEM……………………………………………………………………………………..284
BRAKE LIGHT SWITCHES……………………………………………………………………………………………286
ADJUSTMENT…………………………………………………………………………………………………286
POWER STEERING UNIT…………………………………………………………………………………………….287
1. Testing…………………………………………………………………………………………………287
2. Adjustment………………………………………………………………………………………………287
REMOVAL……………………………………………………………………………………………………288
REFITTING………………………………………………………………………………………………….288
DISMANTLING………………………………………………………………………………………………..289
ASSEMBLY…………………………………………………………………………………………………..296
FRONT WHEELS…………………………………………………………………………………………………..306
REMOVAL……………………………………………………………………………………………………306
REFITTING………………………………………………………………………………………………….306
FRONT FENDERS………………………………………………………………………………………………….307
REMOVAL……………………………………………………………………………………………………307
REFITTING………………………………………………………………………………………………….307
REAR WHEELS……………………………………………………………………………………………………308
REMOVAL……………………………………………………………………………………………………308
REFITTING………………………………………………………………………………………………….308
LIFT VALVE BLOCK……………………………………………………………………………………………….309
REMOVAL……………………………………………………………………………………………………309
REFITTING………………………………………………………………………………………………….309
FRONT LIFT CYLINDERS……………………………………………………………………………………………310
REMOVAL……………………………………………………………………………………………………310
REFITTING………………………………………………………………………………………………….311
FRONT LIFT ASSEMBLY…………………………………………………………………………………………….312
REMOVAL……………………………………………………………………………………………………312
REFITTING………………………………………………………………………………………………….314
FRONT PTO ASSEMBLY……………………………………………………………………………………………..315
REMOVAL……………………………………………………………………………………………………315
REFITTING………………………………………………………………………………………………….315
FRONT SUSPENSION CYLINDERS (Where fitted)…………………………………………………………………………316
REMOVAL……………………………………………………………………………………………………316
REFITTING………………………………………………………………………………………………….318
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………….319
FRONT AXLE AND SWINGING SUPPORT (Versions with front suspension)…………………………………………………….321
REMOVAL……………………………………………………………………………………………………321
REFITTING………………………………………………………………………………………………….323
FRONT SUSPENSION VALVES…………………………………………………………………………………………324
REMOVAL……………………………………………………………………………………………………324
REFITTING………………………………………………………………………………………………….324
FRONT SUSPENSION POSITION SENSOR…………………………………………………………………………………325
1. Removal…………………………………………………………………………………………………325
2. Positioning……………………………………………………………………………………………..325
3. Testing…………………………………………………………………………………………………326
REINFORCING SIDE MEMBERS (For versions with front lift only)………………………………………………………..327
REMOVAL……………………………………………………………………………………………………327
REFITTING………………………………………………………………………………………………….327
FRONT CARRIER (Versions with front suspension)…………………………………………………………………….328
REMOVAL……………………………………………………………………………………………………328
REFITTING………………………………………………………………………………………………….328
ACCELERATOR POTENTIOMETER……………………………………………………………………………………….329
RENEWAL……………………………………………………………………………………………………329
REFITTING………………………………………………………………………………………………….329
FUEL TANK……………………………………………………………………………………………………..330
REMOVAL……………………………………………………………………………………………………330
REFITTING………………………………………………………………………………………………….331
GEARBOX GEAR PUMP………………………………………………………………………………………………332
REMOVAL……………………………………………………………………………………………………332
REFITTING………………………………………………………………………………………………….333
POWER STEERING – LIFT AND HYDRAULIC SERVICES PUMPS…………………………………………………………………336
REMOVAL……………………………………………………………………………………………………336
REFITTING………………………………………………………………………………………………….338
SUPPLY VALVE FOR THE FRONT SUSPENSION CONTROL VALVE………………………………………………………………..339
REMOVAL……………………………………………………………………………………………………339
REFITTING………………………………………………………………………………………………….339
CONTROL VALVE ASSEMBLIES………………………………………………………………………………………..340
REMOVAL……………………………………………………………………………………………………340
REFITTING………………………………………………………………………………………………….341
AUXILIARY CONTROL VALVE STACK……………………………………………………………………………………342
DISASSEMBLY………………………………………………………………………………………………..342
ASSEMBLY…………………………………………………………………………………………………..343
LIFT CYLINDERS…………………………………………………………………………………………………344
REMOVAL……………………………………………………………………………………………………344
REFITTING………………………………………………………………………………………………….345
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………….346
TESTING THE LIFT POSITION SENSOR…………………………………………………………………………………347
LIFT POSITION SENSOR……………………………………………………………………………………………348
1. Removal of the position sensor…………………………………………………………………………….348
2. Renewal of the position sensor bush (only if necessary)………………………………………………………348
3. Refitting the position sensor……………………………………………………………………………..348
4. Position sensor adjustment………………………………………………………………………………..349
LIFT DRAFT SENSOR………………………………………………………………………………………………351
REMOVAL……………………………………………………………………………………………………351
REFITTING………………………………………………………………………………………………….351
DRIVER’S SEAT………………………………………………………………………………………………….352
REMOVAL……………………………………………………………………………………………………352
REFITTING………………………………………………………………………………………………….352
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL…………………………………………………….353
REMOVAL……………………………………………………………………………………………………353
REFITTING………………………………………………………………………………………………….354
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER…………………………………………………………..355
RENEWAL……………………………………………………………………………………………………355
ASSEMBLY…………………………………………………………………………………………………..356
CENTRE CONSOLE AND SHROUD……………………………………………………………………………………….357
REMOVAL……………………………………………………………………………………………………357
REFITTING………………………………………………………………………………………………….360
RIGHT-HAND CONSOLE……………………………………………………………………………………………..361
OPENING AND REMOVAL…………………………………………………………………………………………361
REFITTING………………………………………………………………………………………………….367
LEFT-HAND CONSOLE………………………………………………………………………………………………368
REMOVAL……………………………………………………………………………………………………368
REFITTING………………………………………………………………………………………………….369
LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS…………………………………………………….370
REMOVAL……………………………………………………………………………………………………370
REFITTING………………………………………………………………………………………………….371
FUSE AND RELAY BOARD……………………………………………………………………………………………372
REMOVAL……………………………………………………………………………………………………372
REFITTING………………………………………………………………………………………………….373
ENGINE ECU…………………………………………………………………………………………………….374
REMOVAL……………………………………………………………………………………………………374
REFITTING………………………………………………………………………………………………….374
CLUTCH PEDAL AND RELATED DEVICES…………………………………………………………………………………375
1. Removal of the potentiometer………………………………………………………………………………375
1.1. Refitting the potentiometer……………………………………………………………………………..375
2. Adjustment of the clutch pedal position and travel…………………………………………………………..376
3. Renewal of the proximity sensor……………………………………………………………………………376
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO………………………………………………..377
REMOVAL……………………………………………………………………………………………………377
REFITTING………………………………………………………………………………………………….380
PTO ENGAGEMENT AND SELECTION CONTROL CABLES……………………………………………………………………….381
REMOVAL (Figures refer to the speed selector)………………………………………………………………….381
REFITTING………………………………………………………………………………………………….382
AUXILIARY SERVICE VALVE CONTROL CABLES……………………………………………………………………………384
RENEWAL……………………………………………………………………………………………………384
REFITTING………………………………………………………………………………………………….385
PARKING BRAKE SWITCH……………………………………………………………………………………………386
ADJUSTMENT…………………………………………………………………………………………………386
CLIMATE CONTROL PANEL…………………………………………………………………………………………..387
REMOVAL……………………………………………………………………………………………………387
REFITTING………………………………………………………………………………………………….387
HEATER VALVE…………………………………………………………………………………………………..388
1. Removal…………………………………………………………………………………………………388
2. Refitting and adjustment of the control cable……………………………………………………………….388
HEATER MATRIX………………………………………………………………………………………………….390
REMOVAL……………………………………………………………………………………………………390
REFITTING………………………………………………………………………………………………….392
AIR CONDITIONING EVAPORATOR……………………………………………………………………………………..393
REMOVAL……………………………………………………………………………………………………393
REFITTING………………………………………………………………………………………………….394
RIGHT-HAND AIR CONDITIONING FAN………………………………………………………………………………….395
REMOVAL……………………………………………………………………………………………………395
REFITTING………………………………………………………………………………………………….395
LEFT-HAND AIR CONDITIONING FAN…………………………………………………………………………………..396
REMOVAL……………………………………………………………………………………………………396
REFITTING………………………………………………………………………………………………….396
PARKING BRAKES…………………………………………………………………………………………………397
ADJUSTMENT…………………………………………………………………………………………………397
CAB DOOR CABLE…………………………………………………………………………………………………398
RENEWAL……………………………………………………………………………………………………398
TRAILER BRAKING AIR PRESSURE GAUGE……………………………………………………………………………….400
REMOVAL……………………………………………………………………………………………………400
REFITTING………………………………………………………………………………………………….400
TRANSMISSION STATUS DISPLAY……………………………………………………………………………………..401
REMOVAL……………………………………………………………………………………………………401
REFITTING………………………………………………………………………………………………….401
CAB…………………………………………………………………………………………………………..402
REMOVAL……………………………………………………………………………………………………402
REFITTING………………………………………………………………………………………………….409
ENGINE AND TRANSMISSION…………………………………………………………………………………………410
SEPARATING…………………………………………………………………………………………………410
ASSEMBLY…………………………………………………………………………………………………..418
SECTION 40………………………………………………………………………………………………………..419
THE STRUCTURE OF THE UNIT……………………………………………………………………………………….421
HOW TO CONSULT THE UNIT…………………………………………………………………………………………422
1. INTRODUCTION………………………………………………………………………………………………..423
1.1 LIST OF WIRING HARNESSES…………………………………………………………………………………423
1.2 DEFINITION OF COMPONENTS AND SYMBOLS………………………………………………………………………424
1.3 GENERAL RULES…………………………………………………………………………………………..424
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING…………………………………………………425
d. Renewal of damaged electrical components………………………………………………………………..426
1.4 DIAGNOSTIC INSTRUMENTS…………………………………………………………………………………..426
1.5 WIRE COLOUR CODES……………………………………………………………………………………….426
2. INDICES…………………………………………………………………………………………………….427
2.1 COMPONENT DESCRIPTION INDEX………………………………………………………………………………427
2.2 COMPONENT CODE INDEX…………………………………………………………………………………….432
2.3 CONNECTOR INDEX…………………………………………………………………………………………436
3. COMPONENTS………………………………………………………………………………………………….444
3.1 CONNECTOR LAYOUTS……………………………………………………………………………………….444
3.2 COMPONENT TECHNICAL DATA…………………………………………………………………………………449
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS………………………………………………………..457
4. SYSTEMS…………………………………………………………………………………………………….467
4.1 EARTH POINTS……………………………………………………………………………………………467
4.2 STARTING……………………………………………………………………………………………….468
4.3 PREHEATING……………………………………………………………………………………………..469
4.4 ELECTRICAL ENGINE CONTROL………………………………………………………………………………..470
4.5 LIGHTS – STEERING COLUMN SWITCH UNIT………………………………………………………………………471
4.6 CAB ACCESORIES………………………………………………………………………………………….472
4.7 WORKLIGHTS……………………………………………………………………………………………..473
4.8 WINDSCREEN WIPERS……………………………………………………………………………………….474
4.9 INFOCENTER……………………………………………………………………………………………..475
4.10 POWER OUTLET SOCKETS……………………………………………………………………………………476
4.11 RADIO – CB…………………………………………………………………………………………….477
4.12 AIR CONDITIONING – HEATER FANS…………………………………………………………………………..478
4.13 BRAKING SYSTEM…………………………………………………………………………………………479
4.14 TRAILER BRAKES…………………………………………………………………………………………480
4.15 FRONT AXLE SUSPENSION…………………………………………………………………………………..481
4.16 TRASMISSION……………………………………………………………………………………………482
4.17 ASM – 4WD – DIFFERENTIAL………………………………………………………………………………..483
4.18 ELECTRONIC LIFT………………………………………………………………………………………..484
4.19 FRONT AND REAR PTO……………………………………………………………………………………..485
4.20 CLEANFIX………………………………………………………………………………………………486
5. LAYOUTS, ELECTRICAL WIRING DIAGRAMS, CONNECTOR POSITIONS…………………………………………………………487
ENGINE WIRING (KHD) (1/2)……………………………………………………………………………………489
ENGINE WIRING (KHD) (2/2)……………………………………………………………………………………490
ENGINE WIRING (4 CYLINDERS) (1/2)…………………………………………………………………………….495
ENGINE WIRING (4 CYLINDERS) (2/2)…………………………………………………………………………….496
ENGINE WIRING (6 CYLINDERS) (1/2)…………………………………………………………………………….497
ENGINE WIRING (6 CYLINDERS) (2/2)…………………………………………………………………………….498
CLEAN FIX WIRING……………………………………………………………………………………………507
TRANSMISSION WIRING (1/2)……………………………………………………………………………………509
TRANSMISSION WIRING (2/2)……………………………………………………………………………………510
TRAILER BRAKING WIRING (ITALY)……………………………………………………………………………….519
TRAILER BRAKING WIRING (EXPORT)………………………………………………………………………………520
FRONT AXLE SUSPENSION (CAB LINE) WIRING……………………………………………………………………….523
CAB POWER SUPPLY WIRING……………………………………………………………………………………..527
FRONT AXLE SUSPENSION WIRING…………………………………………………………………………………533
FENDER WIRING………………………………………………………………………………………………539
NUMBER PLATE LIGHT WIRING……………………………………………………………………………………540
FRONT CONSOLE WIRING (1/2)…………………………………………………………………………………..545
FRONT CONSOLE WIRING (2/2)…………………………………………………………………………………..546
SIDE CONSOLE WIRING (1/3)……………………………………………………………………………………551
SIDE CONSOLE WIRING (2/3)……………………………………………………………………………………552
SIDE CONSOLE WIRING (3/3)……………………………………………………………………………………553
AIR CONDITIONING SYSTEM WIRING……………………………………………………………………………….563
DISPLAY WIRING……………………………………………………………………………………………..569
ROOF WIRING (1/2)…………………………………………………………………………………………..573
ROOF WIRING (2/2)…………………………………………………………………………………………..574
ROTATING BEACON WIRING………………………………………………………………………………………575
WORKLIGHTS WIRING…………………………………………………………………………………………..576
LIGHTS SELECTOR WIRING………………………………………………………………………………………583
ARMREST WIRING……………………………………………………………………………………………..587
CONTROL UNIT – FUSES – RELAYS (1/2)…………………………………………………………………………..589
CONTROL UNIT – FUSES – RELAYS (2/2)…………………………………………………………………………..590
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