DEUTZ-FAHR AGROTRON 106 110 115 120 135 150 165 MK3 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON 106 110 115 120 135 150 165 MK3 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON 106 110 115 120 135 150 165 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 closefitting
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.
9 – Under no circumstances start the engine with the
safety guards removed; all repair and adjustment
operations must be carried out with the engine
stopped.
10 – Do not top up fuel, oil or coolant levels when the engine
is running.
11 – Never smoke and ensure there are no naked flames
nearby when topping up fuel or oil.
Always remove the battery from the machine before
recharging.
12 – Before checking or removing the battery, stop the
engine and remove the key from the starter switch.
13 – Remove the battery and recharge in a well-ventilated
area where the temperature exceeds 0°C.
14 – When checking or recharging the battery, do not
smoke or allow naked flames in the vicinity as the hydrogen
gas given off by the battery is highly explosive.
15 – The liquid (electrolyte) contained in the battery is very
harmful if it comes into contact with the skin and the
eyes; for this reason, always wear gloves and safety
goggles with side shields when checking or topping
up the battery.
Should any electrolyte accidentally come into contact
with your skin, wash the affected parts immediately
with copious amounts of water. If electrolyte
comes into contact with your clothing, this should be
removed as soon as possible.
TABLE OF CONTENTS:
DEUTZ-FAHR AGROTRON 106 110 115 120 135 150 165 MK3 Workshop Manual – PDF DOWNLOAD
307.1079.3.6 AGROTRON 106-110-115-120-135-150-165 MK3…………………………………………………………………….. 1
INTRODUCTION……………………………………………………………………………………………………… 3
SAFETY NOTES……………………………………………………………………………………………………… 5
HOW THE MANUAL IS STRUCTURED……………………………………………………………………………………….. 7
HOW TO CONSULT THE MANUAL………………………………………………………………………………………….. 8
HOW TO USE AND UPDATE THE MANUAL……………………………………………………………………………………. 9
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS……………………………………………………………….. 10
LIFTING INSTRUCTIONS………………………………………………………………………………………………. 11
STANDARD TIGHTENING TORQUES FOR NUTS AND BOLTS……………………………………………………………………….. 12
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS…………………………………………………………………….. 13
SPECIAL TOOLS…………………………………………………………………………………………………….. 15
CONVERSION FACTORS………………………………………………………………………………………………… 16
SECTION 10……………………………………………………………………………………………………….. 17
1. TRANSMISSION……………………………………………………………………………………………….. 19
INTRODUCTION………………………………………………………………………………………………. 19
1.1 TRANSMISSION (Power Shift version)……………………………………………………………………….. 20
1.1.1 MAIN COMPONENTS…………………………………………………………………………………… 20
1.1.2 TRANSMISSION HYDRAULIC SYSTEM………………………………………………………………………. 23
1.1.3 GEARBOX………………………………………………………………………………………….. 24
GEARBOX COMPONENTS……………………………………………………………………………………… 25
1.1.4 MAIN CLUTCH………………………………………………………………………………………. 26
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE……………………………………………………… 27
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC………………………………………………. 31
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC…………………………………………………………….. 32
1.2 TRANSMISSION (Power Shuttle version)……………………………………………………………………… 33
1.1.1 MAIN COMPONENTS…………………………………………………………………………………… 33
1.1.2 TRANSMISSION HYDRAULIC SYSTEM………………………………………………………………………. 36
1.2.3 GEARBOX………………………………………………………………………………………….. 37
GEARBOX COMPONENTS……………………………………………………………………………………… 38
1.2.4 MAIN CLUTCH………………………………………………………………………………………. 39
1.2.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE……………………………………………………… 40
1.2.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC………………………………………………. 44
1.2.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC…………………………………………………………….. 45
1.3 REAR AXLE……………………………………………………………………………………………… 47
1.4 REAR PTO………………………………………………………………………………………………. 49
2. BRAKING SYSTEM……………………………………………………………………………………………… 51
2.1 BRAKE MASTER CYLINDER…………………………………………………………………………………… 52
2.2 BRAKE…………………………………………………………………………………………………. 53
2.3 TRAILER BRAKING SYSTEM………………………………………………………………………………….. 54
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)……………………………………………………………. 54
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)…………………………………………………………… 56
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)…………………………………………………………………. 59
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)………………………………………………………………… 60
COMPRESSOR…………………………………………………………………………………………….. 61
PRESSURE LIMITING VALVE…………………………………………………………………………………. 62
CAB SUSPENSION FEED VALVE……………………………………………………………………………….. 63
TRAILER BRAKING VALVE (2-WAY)……………………………………………………………………………. 64
TRAILER BRAKING VALVE (1-WAY)……………………………………………………………………………. 65
3. HYDRAULIC FRONT AXLE SUSPENSION………………………………………………………………………………. 66
3.1 FRONT SUSPENSION CONTROL VALVE…………………………………………………………………………… 67
4. FRONT AXLE…………………………………………………………………………………………………. 71
4.1 HUB CARRIER AND FINAL REDUCTION UNIT……………………………………………………………………… 72
4.2 DIFFERENTIAL…………………………………………………………………………………………… 74
5. HYDRAULIC SYSTEM……………………………………………………………………………………………. 76
HYDRAULIC SYSTEM (106-115 CV models) (CCLS version)……………………………………………………………. 77
HYDRAULIC SYSTEM (120-165 CV models) (CCLS version)……………………………………………………………. 78
HYDRAULIC SYSTEM (106-115 CV models) (LS version)……………………………………………………………… 79
HYDRAULIC SYSTEM (120-165 CV models) (LS version)……………………………………………………………… 80
5.1 VARIABLE DISPLACEMENT PUMP………………………………………………………………………………. 81
5.1.1 BOOST PUMP……………………………………………………………………………………….. 84
5.1.2 HYDRAULIC PUMP……………………………………………………………………………………. 85
5.1.3 LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE…………………………………………………………… 87
5.2 HYDRAULIC SERVICES GEAR PUMP (106-115 CV models)…………………………………………………………… 95
5.3 STEERING GEAR PUMP (106-115 CV models)……………………………………………………………………. 96
5.4 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING (120-165 CV models)……………………………………………. 97
5.5 PRIORITY VALVE…………………………………………………………………………………………. 99
5.6 AUXILIARY SERVICES CONTROL VALVE………………………………………………………………………….100
5.6.1 TYPES OF CONTROL VALVE WITH FIXED DISPLACEMENT PUMP (CCLS)……………………………………………..103
5.6.2 TYPES OF CONTROL VALVE WITH VARIABLE DISPLACEMENT PUMP (LS)…………………………………………….105
5.6.3 SERVICES CONTROL SECTION……………………………………………………………………………106
5.6.4 DESCRIPTIONS OF COMPONENTS………………………………………………………………………….107
5.6.5 INLET MANIFOLD (CC version)…………………………………………………………………………109
5.6.6 LIFT CONTROL VALVE SECTION………………………………………………………………………….112
SECTION 20………………………………………………………………………………………………………..117
OPERATOR’S MANUAL SERDIA (LEVEL III)……………………………………………………………………………..119
1. ENTRY AND COMMUNICATION…………………………………………………………………………………..120
1.1 OVERVIEW……………………………………………………………………………………………120
1.2 ORDERING……………………………………………………………………………………………121
1.3 SWITCH ON NOTEBOOK AND INSTALL SOFTWARE………………………………………………………………..122
1.4 USER LEVEL, ACCESS AUTHORIZATION………………………………………………………………………123
1.5 MAKING A CONNECTION BETWEEN ECU (ENGINE) AND NOTEBOOK……………………………………………………124
1.6 PROGRAM START……………………………………………………………………………………….124
1.7 OFFLINE MODE………………………………………………………………………………………..125
1.8 WORKING WITH THE PROGRAM……………………………………………………………………………..127
1.9 PRINT (OUTPUT)………………………………………………………………………………………129
1.10 PROTOCOL (PROTOKOLL)………………………………………………………………………………..130
1.11 END COMMUNICATION…………………………………………………………………………………..130
2. ECU SELECTION……………………………………………………………………………………………131
2.1 GENERAL…………………………………………………………………………………………….131
2.2 RECOGNITION OF ECUS………………………………………………………………………………….131
2.3 IDENTIFICATION DATA………………………………………………………………………………….131
3 MEASURED VALUES…………………………………………………………………………………………..132
3.1 ACTUAL MEASURED VALUES (GENERAL)………………………………………………………………………132
3.2 RAM VALUES………………………………………………………………………………………….136
3.3 DATA LOGGER (ONLY EMS)……………………………………………………………………………….136
3.4 INPUT/OUTPUT ASSIGNMENT………………………………………………………………………………136
3.5 CAN-Status………………………………………………………………………………………….136
3.6 EXAMPLE OF A DISPLAYED ERROR INFORMATION:………………………………………………………………138
4. PARAMETERS………………………………………………………………………………………………139
4.1 CONFIGURATION……………………………………………………………………………………….139
4.2 OVERALL PROGRAMMING………………………………………………………………………………….150
4.3 CALIBRATION…………………………………………………………………………………………150
5. ERROR MEMORY…………………………………………………………………………………………….152
5.1 GENERAL…………………………………………………………………………………………….152
6. FUNCTION TEST……………………………………………………………………………………………157
6.1 GENERAL…………………………………………………………………………………………….157
7. EXTRAS………………………………………………………………………………………………….158
7.1 MAXIMUM VEHICLE SPEED………………………………………………………………………………..158
7.2 LOGISTIC DATA……………………………………………………………………………………….158
7.3 LOAD SPECTRUM (ONLY EMS)……………………………………………………………………………..159
7.4 MAINTENANCE INTERVAL EXCEEDED (ONLY EMS)……………………………………………………………….159
7.5 OVERRIDE MEMORY (ONLY EMS)……………………………………………………………………………159
8 WHAT SHOULD YOU DO IF …?…………………………………………………………………………………160
8.1 SERDIA IN GENERAL……………………………………………………………………………………160
8.2 EMR………………………………………………………………………………………………..163
9. SERDIA UPGRADE FROM VERSION 2.5 TO VERSION 3.1………………………………………………………………175
9.1 IMPROVEMENTS AND HELP WITH PROBLEMS IN COMMUNICATING WITH NOTEBOOKS/WIN 98…………………………………175
9.2 NEW ENTRY MASK WITH MEASURED VALUES AND COLOURED-CODED INDICATION OF CONNECTION STATUS………………………176
9.3 NEW SWITCH “JOBS“ FOR PERFORMING SELECTED SERVICING OPERATIONS, E.G. ADJUSTING CONTROLLER OR ADJUSTING OFFSET….177
9.4 IN- AND OUTPUT ASSIGNMENT IS NOW ADDITIONALLY CONFIGURABLE USING PLAIN TEXT (PREVIOUSLY ONLY CODE NUMBERS)…….178
9.5 UPGRADES IN “PARAMETER SETTING/CONFIGURATION“…………………………………………………………..178
OPERATOR’S MANUAL EDS (Electronic Diagnosis System)………………………………………………………………..179
1. GENERAL INTRODUCTION……………………………………………………………………………………..180
1.1 FUNCTIONAL SCOPE…………………………………………………………………………………….180
1.2 HARDWARE REQUIREMENTS………………………………………………………………………………..181
1.3 STARTING AND TERMINATING OF THE EDS PROGRAM…………………………………………………………….183
2. TRANSMISSION DIAGNOSIS……………………………………………………………………………………185
2.1 THE MAIN MENU……………………………………………………………………………………….185
2.2 ONLINE HELP…………………………………………………………………………………………187
3. POWER-SHIFT DIAGNOSISPROGRAMM DEST 38………………………………………………………………………188
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 38…………………………………………………….188
3.2 DEST 38 PROGRAM DESCRIPTION…………………………………………………………………………..189
3.3 Error codes POWERSHIFT /DEST 38……………………………………………………………………….199
3.4 ERROR CODE LIST WITH DESCRIPTION………………………………………………………………………201
OTHER INFORMATIONS………………………………………………………………………………………207
3.5 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100…………………………………………………..208
3.6 ELECTRO-HYDRAULIC GEAR SHIFT T-7100……………………………………………………………………209
3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200…………………………………………………..210
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300……………………………………………………………211
3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7300…………………………………………………..212
3.10 ERROR ANALYSIS……………………………………………………………………………………..213
4. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45…………………………………………………………………….215
4.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45…………………………………………………….215
4.2 DEST 45 PROGRAM DESCRIPTION…………………………………………………………………………..216
4.3 ERROR CODES POWER-SHUTTLE /DEST 45…………………………………………………………………….231
4.4 DISPLAY POWERSHUTTLE…………………………………………………………………………………232
4.5 ERROR CODE LIST WITH DESCRIPTION………………………………………………………………………233
4.6 OTHER INFORMATIONS…………………………………………………………………………………..244
4.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100…………………………………………………..245
4.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100……………………………………………………………………246
4.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200…………………………………………………..247
4.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300…………………………………………………………..248
4.11 ERROR ANALYSIS……………………………………………………………………………………..249
5. AGROTRONIC-HD + ASM………………………………………………………………………………………251
5.1 PROGRAM DESCRIPTION………………………………………………………………………………….252
5.2 ERROR CODES OF THE AGROTRONIC-HD………………………………………………………………………259
6. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER………………………………………………………………..262
6.1 PROGRAM DESCRIPTION………………………………………………………………………………….263
6.2 CONSTANT VALUES FOR INFOCENTER………………………………………………………………………..273
7. PREPARATIONS FOR DIAGNOSIS OF THE SPRING-SUSPENDED FRONT AXLE…………………………………………………277
7.1 PROGRAM DESCRIPTION………………………………………………………………………………….278
7.2 PIN ASSIGNMENT OF THE ELECTRONIC BOX “SPRING-SUSPENDED FRONT AXLE ”……………………………………….282
7.3 ERROR CODES…………………………………………………………………………………………283
SECTION 30………………………………………………………………………………………………………..285
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING………………………………………………………….289
PUMP SIDE SYSTEMS AND WIRING (CC VERSION WITH PRIORITY VALVE)……………………………………………………….290
DETAIL OF PUMP SIDE SYSTEMS AND WIRING (CC VERSION WITH PRIORITY VALVE)………………………………………………291
UPPER SYSTEMS AND WIRING (CC VERSION WITH PRIORITY VALVE)…………………………………………………………..292
PUMP SIDE SYSTEMS AND WIRING (LS VERSION)…………………………………………………………………………293
UPPER SYSTEMS AND WIRING (LS VERSION)…………………………………………………………………………….294
SYSTEMS AND SUPPLEMENTARY HYDRAULIC COUPLERS (LS VERSION)…………………………………………………………..295
ENGINE HOOD AND LAMP ASSEMBLIES………………………………………………………………………………….297
REMOVAL……………………………………………………………………………………………………297
REFITTING………………………………………………………………………………………………….300
CAB ACCESS STEPS……………………………………………………………………………………………….301
REMOVAL AND REFITTING……………………………………………………………………………………….301
BATTERY……………………………………………………………………………………………………….302
REMOVAL……………………………………………………………………………………………………302
REFITTING …………………………………………………………………………………………………303
AIR RESERVOIR AND BATTERY SUPPORT (versions with air trailer braking only)……………………………………………304
REMOVAL AND REFITTING……………………………………………………………………………………….304
STARTER MOTOR………………………………………………………………………………………………….305
REMOVAL……………………………………………………………………………………………………305
REFITTING………………………………………………………………………………………………….305
ALTERNATOR…………………………………………………………………………………………………….306
REMOVAL AND REFFITNG………………………………………………………………………………………..306
ALTERNATOR DRIVEBELT……………………………………………………………………………………………307
RENEWAL AND TENSIONING………………………………………………………………………………………307
AIR COMPRESSOR ………………………………………………………………………………………………..310
REMOVAL……………………………………………………………………………………………………310
REFITTING………………………………………………………………………………………………….311
TRAILER PARKING AND SERVICE AIR BRAKE CONTROL VALVES……………………………………………………………….312
REMOVAL……………………………………………………………………………………………………312
REFITTING………………………………………………………………………………………………….313
PRESSURE TRANSDUCER (Version with air braking)…………………………………………………………………….314
REMOVAL AND REFITTING……………………………………………………………………………………….314
AIR PRESSURE REGULATING/REDUCTION VALVE FOR CAB LIFTING…………………………………………………………….315
REMOVAL AND REFITTING……………………………………………………………………………………….315
TRAILER AIR BRAKES COUPLING VALVE………………………………………………………………………………..316
REMOVAL AND RENEWAL…………………………………………………………………………………………316
AIR CONDITIONING SYSTEM…………………………………………………………………………………………317
OPERATION………………………………………………………………………………………………….318
MAINTENANCE………………………………………………………………………………………………..319
COMPRESSOR DRIVEBELT……………………………………………………………………………………………319
TENSIONING…………………………………………………………………………………………………319
DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM…………………………………………………….320
AIR CONDITIONING COMPRESSOR……………………………………………………………………………………..322
REMOVAL……………………………………………………………………………………………………322
REFITTING………………………………………………………………………………………………….323
RECEIVER-DRIER (Models 106-150 CV)……………………………………………………………………………….324
REMOVAL AND REFITTING……………………………………………………………………………………….324
RECEIVER-DRIER (Model 165 CV)……………………………………………………………………………………325
REMOVAL AND REFITTING……………………………………………………………………………………….325
CONDENSER COOLING FAN (Model 165 CV)……………………………………………………………………………..326
REMOVAL……………………………………………………………………………………………………326
REFITTING………………………………………………………………………………………………….327
CONDENSER ASSEMBLY (Models 106-150 CV)……………………………………………………………………………328
REMOVAL……………………………………………………………………………………………………328
REFITTING………………………………………………………………………………………………….328
GEARBOX OIL/FUEL COOLERS (Models 106-150 CV)………………………………………………………………………330
REMOVAL……………………………………………………………………………………………………330
REFITTING………………………………………………………………………………………………….331
GEARBOX OIL/FUEL COOLERS (Model 165 CV)…………………………………………………………………………..332
REMOVAL……………………………………………………………………………………………………332
REFITTING………………………………………………………………………………………………….333
RADIATOR (Models 106-150 CV)…………………………………………………………………………………….334
REMOVAL……………………………………………………………………………………………………334
REFITTING………………………………………………………………………………………………….335
RADIATOR (Mod. 165 CV)………………………………………………………………………………………….336
REMOVAL……………………………………………………………………………………………………336
REFITTING………………………………………………………………………………………………….337
EXPANSION TANK…………………………………………………………………………………………………338
REMOVAL AND REFITTING……………………………………………………………………………………….338
FAN (Models 106-150 CV)…………………………………………………………………………………………339
REMOVAL……………………………………………………………………………………………………339
REFITTING………………………………………………………………………………………………….340
FAN (Model 165 CV)……………………………………………………………………………………………..341
REMOVAL……………………………………………………………………………………………………341
REFITTING………………………………………………………………………………………………….342
COMPLETE RADIATOR/COOLERS ASSEMBLY……………………………………………………………………………….343
REMOVAL……………………………………………………………………………………………………343
REFITTING………………………………………………………………………………………………….345
FRONT PTO FLEXIBLE COUPLING……………………………………………………………………………………..346
RENEWAL……………………………………………………………………………………………………346
REFITTING………………………………………………………………………………………………….347
TURBOCHARGER…………………………………………………………………………………………………..348
REMOVAL……………………………………………………………………………………………………348
REFITTING………………………………………………………………………………………………….348
ENGINE AIR INLET PIPE…………………………………………………………………………………………..349
REMOVAL……………………………………………………………………………………………………349
REFITTING………………………………………………………………………………………………….349
AIR CLEANER……………………………………………………………………………………………………350
REMOVAL……………………………………………………………………………………………………350
REFITTING………………………………………………………………………………………………….351
EXHAUST PIPE…………………………………………………………………………………………………..352
REMOVAL……………………………………………………………………………………………………352
REFITTING………………………………………………………………………………………………….352
SILENCER………………………………………………………………………………………………………353
REMOVAL……………………………………………………………………………………………………353
REFITTING………………………………………………………………………………………………….353
4WD PROPELLER SHAFT (Version with front suspension)………………………………………………………………..354
REMOVAL……………………………………………………………………………………………………354
REFITTING………………………………………………………………………………………………….356
BRAKE CYLINDERS………………………………………………………………………………………………..357
REMOVAL……………………………………………………………………………………………………357
REFITTING………………………………………………………………………………………………….358
BLEEDING THE BRAKING SYSTEM……………………………………………………………………………………..359
BRAKE LIGHT SWITCHES……………………………………………………………………………………………361
REMOVAL……………………………………………………………………………………………………362
REFITTING………………………………………………………………………………………………….363
POWER STEERING…………………………………………………………………………………………………362
Testing and removal…………………………………………………………………………………………362
POWER STEERING UNIT SEALS……………………………………………………………………………………….364
REMOVAL AND RENEWAL…………………………………………………………………………………………364
FRONT WHEELS…………………………………………………………………………………………………..372
REMOVAL AND REFITTING………………………………………………………………………………………372
FRONT FENDERS………………………………………………………………………………………………….373
REMOVAL AND REFITTING……………………………………………………………………………………….373
REAR WHEELS……………………………………………………………………………………………………374
REMOVAL AND REFITTING……………………………………………………………………………………….374
LIFT VALVE BLOCK……………………………………………………………………………………………….375
REMOVAL AND REFITTING……………………………………………………………………………………….375
FRONT LIFT CYLINDERS……………………………………………………………………………………………376
REMOVAL …………………………………………………………………………………………………..378
REFITTING………………………………………………………………………………………………….377
FRONT LIFT ASSEMBLY…………………………………………………………………………………………….378
REMOVAL……………………………………………………………………………………………………378
REFITTING………………………………………………………………………………………………….380
FRONT PTO ASSEMBLY……………………………………………………………………………………………..381
REMOVAL……………………………………………………………………………………………………381
REFITTING………………………………………………………………………………………………….381
FRONT SUSPENSION CYLINDERS (Where fitted)…………………………………………………………………………382
REMOVAL……………………………………………………………………………………………………382
REFITTING………………………………………………………………………………………………….384
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………….385
FRONT AXLE AND SWINGING SUPPORT (Versions with front suspension)…………………………………………………….387
REMOVAL……………………………………………………………………………………………………387
REFITTING………………………………………………………………………………………………….389
FRONT SUSPENSION SOLENOID VALVES…………………………………………………………………………………390
REMOVAL AND REFITTING……………………………………………………………………………………….390
FRONT SUSPENSION POSITION SENSOR…………………………………………………………………………………391
REMOVAL AND POSITIONING……………………………………………………………………………………..391
REINFORCING SIDE MEMBERS (For versions with front lift only)………………………………………………………..393
REMOVAL AND REFITTING……………………………………………………………………………………….393
FRONT CARRIER (Versions with front suspension)…………………………………………………………………….394
REMOVAL AND REFITTING……………………………………………………………………………………….394
ACCELERATOR POTENTIOMETER……………………………………………………………………………………….395
RENEWAL AND TESTING…………………………………………………………………………………………395
FUEL TANK……………………………………………………………………………………………………..397
REMOVAL……………………………………………………………………………………………………397
REFITTING………………………………………………………………………………………………….399
TESTING THE AUXILIARY SERVICES PUMPS……………………………………………………………………………..400
HYDRAULIC SERVICES GEAR PUMP (Models 106-115 CV) (CC Version)……………………………………………………….402
REMOVAL……………………………………………………………………………………………………402
REFITTING………………………………………………………………………………………………….403
GEAR PUMP ASSEMBLY ( Models 120-165 CV) (CC Version)……………………………………………………………….404
REMOVAL……………………………………………………………………………………………………404
REFITTING………………………………………………………………………………………………….405
VARIABLE DISPLACEMENT PUMP (Models 106-165 CV) (LS version)…………………………………………………………406
REMOVAL……………………………………………………………………………………………………406
REFITTING………………………………………………………………………………………………….408
POWER STEERING PUMP (Models 106-115 CV) (CC version)……………………………………………………………….409
REMOVAL AND REFITTING……………………………………………………………………………………….409
PRIORITY VALVE (Models 106 – 115 CV)……………………………………………………………………………..410
REMOVAL AND REFITTING……………………………………………………………………………………….410
PRIORITY VALVE (Modd. 120-165 CV)(Versions with variable displacement pump)…………………………………………..411
REMOVAL……………………………………………………………………………………………………411
REFITTING………………………………………………………………………………………………….411
CREEPER ENGAGEMENT LEVER………………………………………………………………………………………..412
REMOVAL AND REFITTING……………………………………………………………………………………….412
CONTROL VALVE ASSEMBLIES (CC version)…………………………………………………………………………….413
REMOVAL……………………………………………………………………………………………………413
REFITTING………………………………………………………………………………………………….416
CONTROL VALVE ASSEMBLIES (LS version)…………………………………………………………………………….417
REMOVAL……………………………………………………………………………………………………417
REFITTING………………………………………………………………………………………………….419
AUXILIARY CONTROL VALVE ASSEMBLIES……………………………………………………………………………….420
DISASSEMBLY………………………………………………………………………………………………..420
ASSEMBLY ………………………………………………………………………………………………….421
LIFT CYLINDERS…………………………………………………………………………………………………422
REMOVAL……………………………………………………………………………………………………422
REFITTING………………………………………………………………………………………………….423
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………….424
LIFT POSITION SENSOR……………………………………………………………………………………………425
TESTING……………………………………………………………………………………………………425
RENEWAL……………………………………………………………………………………………………426
LIFT DRAFT SENSOR………………………………………………………………………………………………429
REMOVAL……………………………………………………………………………………………………429
REFITTING………………………………………………………………………………………………….429
DRIVER’S SEAT………………………………………………………………………………………………….430
REMOVAL……………………………………………………………………………………………………430
REFITTING………………………………………………………………………………………………….430
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL…………………………………………………….431
REMOVAL……………………………………………………………………………………………………431
REFITTING………………………………………………………………………………………………….432
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER…………………………………………………………..433
RENEWAL……………………………………………………………………………………………………433
ASSEMBLY…………………………………………………………………………………………………..434
CENTRE CONSOLE AND SHROUD……………………………………………………………………………………….435
REMOVAL……………………………………………………………………………………………………435
REFITTING………………………………………………………………………………………………….438
RIGHT-HAND CONSOLE……………………………………………………………………………………………..439
REMOVAL……………………………………………………………………………………………………439
REFITTING………………………………………………………………………………………………….445
LEFT-HAND CONSOLE………………………………………………………………………………………………446
REMOVAL……………………………………………………………………………………………………446
REFITTING………………………………………………………………………………………………….447
LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS…………………………………………………….448
REMOVAL……………………………………………………………………………………………………448
REFITTING………………………………………………………………………………………………….450
FUSE AND RELAY BOARD……………………………………………………………………………………………451
REMOVAL……………………………………………………………………………………………………451
REFITTING………………………………………………………………………………………………….452
ENGINE ECU…………………………………………………………………………………………………….453
REMOVAL AND REFITTING……………………………………………………………………………………….453
CLUTCH PEDAL AND RELATED DEVICES (Power Shift version)……………………………………………………………..454
CLUTCH PEDAL AND RELATED DEVICES (Power Shuttle version)……………………………………………………………457
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO………………………………………………..459
REMOVAL……………………………………………………………………………………………………459
REFITTING………………………………………………………………………………………………….462
PTO ENGAGEMENT AND SELECTION CONTROL CABLES……………………………………………………………………….463
RENEWAL……………………………………………………………………………………………………463
AUXILIARY SERVICE VALVE CONTROL CABLES……………………………………………………………………………466
RENEWAL……………………………………………………………………………………………………466
REFITTING………………………………………………………………………………………………….467
REFITTING THE AUXILIARY SERVICE VALVE CONTROL CABLES……………………………………………………………….467
ADJUSTMENT OF THE PARKING BRAKE SWITCH……………………………………………………………………………468
CLIMATE CONTROL PANEL…………………………………………………………………………………………..469
REMOVAL AND REFITTING……………………………………………………………………………………….469
RENEWAL OF THE HEATER VALVE……………………………………………………………………………………..470
CAB HEATER MATRIX………………………………………………………………………………………………472
REMOVAL……………………………………………………………………………………………………472
REFITTING………………………………………………………………………………………………….474
AIR CONDITIONING EVAPORATOR……………………………………………………………………………………..475
REMOVAL……………………………………………………………………………………………………475
REFITTING………………………………………………………………………………………………….476
RIGHT-HAND AIR CONDITIONING FAN………………………………………………………………………………….477
REMOVAL AND REFITTING……………………………………………………………………………………….477
LEFT-HAND AIR CONDITIONING FAN…………………………………………………………………………………..478
REMOVAL……………………………………………………………………………………………………478
REFITTING………………………………………………………………………………………………….478
ADJUSTMENT OF THE PARKING BRAKES…………………………………………………………………………………479
RENEWAL OF CAB DOOR CABLE……………………………………………………………………………………….480
TRAILER BRAKING AIR PRESSURE GAUGE……………………………………………………………………………….482
REMOVAL AND REFITTING…………………………………………………………………………………………..482
POWERSHIFT – POWERSHUTTLE STATUS DISPLAY………………………………………………………………………….483
REMOVAL……………………………………………………………………………………………………483
REFITTING………………………………………………………………………………………………….483
CAB…………………………………………………………………………………………………………..484
REMOVAL……………………………………………………………………………………………………484
REFITTING………………………………………………………………………………………………….491
ENGINE -TRANSMISSION……………………………………………………………………………………………492
SEPARATION…………………………………………………………………………………………………492
RECONNECTION……………………………………………………………………………………………….499
SECTION 40………………………………………………………………………………………………………..501
THE STRUCTURE OF THE UNIT……………………………………………………………………………………….503
HOW TO CONSULT THE UNIT…………………………………………………………………………………………504
1. INTRODUCTION………………………………………………………………………………………………..505
1.1 LIST OF WIRING HARNESSES…………………………………………………………………………………505
1.2 DEFINITION OF COMPONENTS AND SYMBOLS………………………………………………………………………506
1.3 GENERAL RULES…………………………………………………………………………………………..506
1.4 DIAGNOSTIC INSTRUMENTS…………………………………………………………………………………..508
1.5 WIRE COLOUR CODES……………………………………………………………………………………….508
2. INDICES…………………………………………………………………………………………………….509
2.1 COMPONENT DESCRIPTION INDEX………………………………………………………………………………509
2.2 COMPONENT CODE INDEX…………………………………………………………………………………….514
2.3 CONNECTOR INDEX…………………………………………………………………………………………518
3. COMPONENTS………………………………………………………………………………………………….529
3.1 CONNECTOR LAYOUTS……………………………………………………………………………………….529
3.2 COMPONENT TECHNICAL DATA…………………………………………………………………………………534
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS………………………………………………………..538
4. SYSTEMS…………………………………………………………………………………………………….549
4.1 GROUND POINTS…………………………………………………………………………………………..549
4.2 ENGINE START……………………………………………………………………………………………550
4.3 PREHEATING……………………………………………………………………………………………..551
4.4 ELECTRICAL ENGINE CONTROL………………………………………………………………………………..552
4.5 LIGHTS – LIGHT SELECTOR SWITCH……………………………………………………………………………553
4.6 CAB ACCESSORY…………………………………………………………………………………………..554
4.7 WORKING LIGHTS………………………………………………………………………………………….555
4.8 WINDSCREEN WIPER………………………………………………………………………………………..556
4.9 INFOCENTER……………………………………………………………………………………………..557
4.10 ELECTRICAL POWER SUPPLY…………………………………………………………………………………558
4.11 AUTORADIO – CB…………………………………………………………………………………………559
4.12 AIR CONDITIONING – HEATING FAN…………………………………………………………………………..560
4.13 BRAKES………………………………………………………………………………………………..561
4.14 TRAILER BRAKES…………………………………………………………………………………………562
4.15 FRONT AXLE SUSPENSION…………………………………………………………………………………..563
4.16 POWER SHUTTLE TRANSMISSION………………………………………………………………………………564
4.17 POWER SHIFT TRANSMISSION………………………………………………………………………………..565
4.18 ASM – 4WD – DIFFERENTIAL………………………………………………………………………………..566
4.19 REAR LIFTER……………………………………………………………………………………………567
4.20 FRONT AND REAR PTO……………………………………………………………………………………..568
4.21 CLEANFIX………………………………………………………………………………………………569
5. PLANIMETRY, WIRING DIAGRAM AND CONNECTORS LOCATION………………………………………………………………571
INTERNAL COMBUSTION ENGINE WIRING (120-165 CV)…………………………………………………………………573
INTERNAL COMBUSTION ENGINE WIRING (120-165 CV)…………………………………………………………………574
ENGINE WIRING (106-115 CV) (1/2)……………………………………………………………………………..579
ENGINE WIRING (106-115 CV) (2/2)……………………………………………………………………………..580
ENGINE WIRING (120-165 CV) (1/2)……………………………………………………………………………..581
ENGINE WIRING (120-165 CV) (2/2)……………………………………………………………………………..582
CLUTCH SENSOR WIRING………………………………………………………………………………………..583
CLEAN FIX WIRING……………………………………………………………………………………………595
SUPPLEMENTARY AIR CONDITIONING FAN WIRING……………………………………………………………………..597
TRANSMISSION WIRING (1/2)……………………………………………………………………………………601
TRANSMISSION WIRING (2/2)……………………………………………………………………………………602
HYDRAULIC AND AIR TRAILER BRAKING WIRING (ITALY)……………………………………………………………….613
AIR TRAILER BRAKING WIRING…………………………………………………………………………………..614
FRONT SUSPENSION CONTROL UNIT (CAB) WIRING…………………………………………………………………….617
CAB POWER SUPPLY WIRING……………………………………………………………………………………..621
CAB LINE FRONT SUSPENSION WIRING……………………………………………………………………………..627
NUMBER PLATE LIGHT WIRING……………………………………………………………………………………631
NUMBER PLATE LIGHT WIRING……………………………………………………………………………………632
NUMBER PLATE LIGHT WIRING……………………………………………………………………………………633
FENDER WIRING………………………………………………………………………………………………635
FENDER WIRING………………………………………………………………………………………………636
FENDER WIRING………………………………………………………………………………………………637
FENDER WIRING………………………………………………………………………………………………638
FRONT CONSOLE WIRING (1/2)…………………………………………………………………………………..643
FRONT CONSOLE WIRING (2/2)…………………………………………………………………………………..644
ACCELERATOR PEDAL SENSOR WIRING………………………………………………………………………………645
SIDE CONSOLE WIRING (POWER SHUTTLE) (1/4)……………………………………………………………………..651
SIDE CONSOLE WIRING (POWER SHUTTLE) (2/4)……………………………………………………………………..652
SIDE CONSOLE WIRING (POWER SHUTTLE) (3/4)……………………………………………………………………..653
SIDE CONSOLE WIRING (POWER SHUTTLE) (4/4)……………………………………………………………………..654
SIDE CONSOLE WIRING (POWER SHIFT) (1/4)……………………………………………………………………….655
SIDE CONSOLE WIRING (POWER SHIFT) (2/4)……………………………………………………………………….656
SIDE CONSOLE WIRING (POWER SHIFT) (3/4)……………………………………………………………………….657
SIDE CONSOLE WIRING (POWER SHIFT) (4/4)……………………………………………………………………….658
AIR CONDITIONING WIRING (CAB)………………………………………………………………………………..667
DISPLAY WIRING……………………………………………………………………………………………..673
ROOF WIRING (1/2)…………………………………………………………………………………………..677
ROOF WIRING (2/2)…………………………………………………………………………………………..678
WORKLIGHTS WIRING…………………………………………………………………………………………..679
ROTATING BEACON WIRING………………………………………………………………………………………681
ARMREST WIRING……………………………………………………………………………………………..691
ARMREST WIRING (INTERNAL)……………………………………………………………………………………693
CONTROL UNIT – FUSES – RELAYS (1/2)…………………………………………………………………………..695
CONTROL UNIT – FUSES – RELAYS (2/2)…………………………………………………………………………..696
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