DEUTZ-FAHR AGROTRON 108 AGROTRON 118 AGROTRON 128 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON 108 AGROTRON 118 AGROTRON 128 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON 108 AGROTRON 118 AGROTRON 128 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.
TABLE OF CONTENTS:
DEUTZ-FAHR AGROTRON 108 AGROTRON 118 AGROTRON 128 Workshop Manual – PDF DOWNLOAD
307.1116.3.6 AGROTRON 108-118-128…………………………………………………………………………… 1
INTRODUCTION………………………………………………………………………………………….. 3
SAFETY NOTES………………………………………………………………………………………….. 5
GENERAL SAFETY RULES…………………………………………………………………………………… 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 version)………………………………………………………….. 25
1.1.1 MAIN COMPONENTS……………………………………………………………………….. 25
1.1.2 TRANSMISSION HYDRAULIC SYSTEM…………………………………………………………… 28
1.1.3 GEARBOX………………………………………………………………………………. 29
1.1.4 MAIN CLUTCH…………………………………………………………………………… 31
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE………………………………………….. 32
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC…………………………………… 36
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC…………………………………………………. 38
1.2 REAR AXLE………………………………………………………………………………….. 39
DESCRIPTION………………………………………………………………………………… 39
COMPONENTS…………………………………………………………………………………. 39
1.3 REAR PTO…………………………………………………………………………………… 41
2. BRAKING SYSTEM………………………………………………………………………………….. 43
2.1 BRAKE MASTER CYLINDER……………………………………………………………………….. 44
2.2 BRAKE……………………………………………………………………………………… 45
2.3 TRAILER BRAKING SYSTEM………………………………………………………………………. 46
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)………………………………………………… 46
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)……………………………………………….. 48
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)……………………………………………………… 50
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)…………………………………………………….. 51
COMPRESSOR…………………………………………………………………………………. 52
PRESSURE LIMITING VALVE……………………………………………………………………… 53
CAB SUSPENSION FEED VALVE……………………………………………………………………. 54
TRAILER BRAKING VALVE (2-WAY)………………………………………………………………… 55
TRAILER BRAKING VALVE (1-WAY)………………………………………………………………… 56
3. HYDRAULIC FRONT AXLE SUSPENSION…………………………………………………………………… 57
3.1 FRONT SUSPENSION CONTROL VALVE……………………………………………………………….. 58
4. FRONT AXLE……………………………………………………………………………………… 62
4.1 HUB CARRIER AND FINAL REDUCTION UNIT………………………………………………………….. 63
4.2 DIFFERENTIAL……………………………………………………………………………….. 65
5. HYDRAULIC SYSTEM………………………………………………………………………………… 67
HYDRAULIC SYSTEM (CC version)……………………………………………………………………. 68
HYDRAULIC SYSTEM (LS version)……………………………………………………………………. 69
5.1 VARIABLE DISPLACEMENT PUMP…………………………………………………………………… 70
5.1.1 BOOST PUMP……………………………………………………………………………. 73
5.1.2 HYDRAULIC PUMP………………………………………………………………………… 74
5.1.3 LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE……………………………………………….. 76
5.2 HYDRAULIC SERVICES GEAR PUMP…………………………………………………………………. 84
5.3 STEERING GEAR PUMP………………………………………………………………………….. 85
5.4 PRIORITY VALVE……………………………………………………………………………… 86
5.5 AUXILIARY SERVICES CONTROL VALVE……………………………………………………………… 87
5.5.1 TYPES OF CONTROL VALVE WITH FIXED DISPLACEMENT PUMP (CC)…………………………………… 89
5.5.2 TYPES OF CONTROL VALVE WITH VARIABLE DISPLACEMENT PUMP (LS)………………………………… 91
5.5.3 SERVICES CONTROL SECTION……………………………………………………………….. 92
5.5.4 DESCRIPTIONS OF COMPONENTS……………………………………………………………… 93
5.5.5 FLOW CONTROL SECTION (CC version)……………………………………………………….. 95
5.5.6 LIFT CONTROL VALVE SECTION……………………………………………………………… 98
SECTION 20…………………………………………………………………………………………….103
1. DIAGNOSIS TOOLS “ALL ROUND TESTER”…………………………………………………………………105
1.1 ALL ROUND TESTER…………………………………………………………………………….105
1.1.1 DESCRIPTION OF THE KIT………………………………………………………………….105
1.1.2 NOTES ON CORRECT USE……………………………………………………………………106
1.1.3 DESCRIPTION OF THE TESTER……………………………………………………………….106
1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER……………………………………..107
1.1.5 SELECTION OF THE DISPLAY LANGUAGE………………………………………………………..107
1.1.6 SETTING THE SERIAL PORTS………………………………………………………………..109
1.2 “SERDIA 3.5 LEVEL III” SOFTWARE……………………………………………………………….111
1.2.1 DESCRIPTION OF THE KIT………………………………………………………………….111
1.3 “EDS EST45” SOFTWARE…………………………………………………………………………112
1.3.1 DESCRIPTION OF THE KIT………………………………………………………………….112
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS………………………………………………..113
2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT AND FRONT AXLE SUSPENSION CONTROL UNITS……………………113
2.2 CONNECTING THE PORTABLE COMPUTER WITH “SERDIA 3.5” SOFTWARE TO THE ENGINE CONTROL UNIT………………114
2.3 CONNECTING THE PORTABLE COMPUTER WITH “EDS” SOFTWARE TO THE TRANSMISSION CONTROL UNIT AND INFOCENTER….115
2.3.1 CONNECTION TO THE TRANSMISSION CONTROL UNIT……………………………………………….115
2.3.2 CONNECTION TO THE INFOCENTER…………………………………………………………….115
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR…………………………………………………117
3.1 ENGINE CONTROL UNIT (DEUTZ EMR2)………………………………………………………………117
3.2 TRANSMISSION CONTROL UNIT…………………………………………………………………….119
3.3 POWER LIFT CONTROL UNIT………………………………………………………………………120
3.3.1 HYDRAULIC LIFT SYSTEM…………………………………………………………………..120
3.3.2 ASM SYSTEM…………………………………………………………………………….121
3.4 INFOCENTER 2 or 3……………………………………………………………………………122
3.5 FRONT AXLE SUSPENSION CONTROL UNIT…………………………………………………………….123
3.6 FRONT AND REAR PTO CONTROL UNIT……………………………………………………………….124
4. PUTTING THE TRACTOR INTO SERVICE…………………………………………………………………..125
4.1 INTRODUCTION………………………………………………………………………………..125
4.2 RENEWAL OF THE ENGINE CONTROL UNIT…………………………………………………………….125
4.2.1 READING AND SAVING DATA…………………………………………………………………125
4.2.2 PROGRAMMING THE CONTROL UNIT…………………………………………………………….126
4.2.3 CALIBRATION OF THE ACCELERATOR PEDAL……………………………………………………..127
4.2.4 CALIBRATION OF THE HAND THROTTLE…………………………………………………………128
4.2.5 READING AND SAVING DATA…………………………………………………………………129
4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT……………………………………………………….130
4.3.1 SETTING THE TRACTOR VERSION AND SERIAL NUMBER……………………………………………..130
4.3.2 CALIBRATION OF THE CLUTCH PEDAL POSITION SENSOR……………………………………………132
4.3.3 CALIBRATION OF THE MAIN CLUTCH PROPORTIONAL SOLENOID VALVE………………………………….134
4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT………………………………………………….136
4.4.1 PROGRAMMING THE TYPE OF TRACTOR………………………………………………………….137
4.4.2 CONFIGURING NO RADAR STATUS……………………………………………………………..138
4.4.3 CALIBRATION OF THE LIFT POSITION SENSOR…………………………………………………..139
4.4.4 CHECKING AND CALIBRATING THE LIFT CONTROL LEVER……………………………………………141
4.5 RENEWAL OF THE INFOCENTER…………………………………………………………………….144
4.5.1 ENTERING CONSTANTS……………………………………………………………………..144
4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT………………………………………………………..146
4.6.1 CHECKING CALIBRATION OF THE SUSPENSION POSITION SENSOR……………………………………..146
5. ALARMS………………………………………………………………………………………….147
5.1 LIFT AND ASM CONTROL UNIT ALARMS………………………………………………………………147
5.1.1 LIST OF ALARMS BY EXTENDED CODE………………………………………………………….148
5.1.2 LIST OF ALARMS BY STANDARD CODE………………………………………………………….150
5.1.3 LIST OF ALARMS DISPLAYED ON ART………………………………………………………….152
5.1.4 ANALYSIS OF LIFT AND ASM ALARMS………………………………………………………….154
5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS……………………………………………………….183
5.2.1 ABNORMALITIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT…………………………………183
5.2.2 ALARMS INDICATED ON THE TRANSMISSION DISPLAY AND BY THE EDS PROGRAM………………………….183
5.5.3 DEFINITION OF TRANSMISSION OPERATING MODES………………………………………………..188
5.2.3 ANALYSIS OF ALARMS……………………………………………………………………..189
5.3 LIST OF ALARMS DISPLAYED BY SERDIA…………………………………………………………….253
5.3.1 ALARMS DISPLAYED USING THE SERDIA PROGRAM…………………………………………………253
5.3.2 ANALYSIS OF ALARMS……………………………………………………………………..255
5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS………………………………………………275
5.4.1 LIST OF ALARMS BY TEXT CODE……………………………………………………………..275
5.4.2 LIST OF ALARMS BY STANDARD CODE………………………………………………………….276
5.4.3 LIST OF ALARMS DISPLAYED BY ART………………………………………………………….277
5.4.4 ANALYSIS OF ALARMS……………………………………………………………………..278
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System)………………………………………………….291
1. GENERAL INTRODUCTION………………………………………………………………………….291
1.1 FUNCTIONAL SCOPE…………………………………………………………………………291
1.2 HARDWARE REQUIREMENTS…………………………………………………………………….292
1.3 STARTING AND TERMINATING OF THE EDS PROGRAM…………………………………………………294
2. TRANSMISSION DIAGNOSIS………………………………………………………………………..296
2.1 THE MAIN MENU……………………………………………………………………………296
2.2 ONLINE HELP……………………………………………………………………………..298
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45…………………………………………………………299
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45…………………………………………299
3.2 DEST 45 PROGRAM DESCRIPTION……………………………………………………………….300
3.3 ERROR CODES POWER-SHUTTLE /DEST 45…………………………………………………………315
3.4 DISPLAY POWERSHUTTLE……………………………………………………………………..316
3.5 ERROR CODE LIST WITH DESCRIPTION…………………………………………………………..317
3.6 OTHER INFORMATIONS……………………………………………………………………….328
3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100……………………………………….329
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100………………………………………………………..330
3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200……………………………………….331
3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300……………………………………………….332
3.11 ERROR ANALYSIS………………………………………………………………………….333
4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER…………………………………………………….335
4.1 PROGRAM DESCRIPTION………………………………………………………………………336
4.2 CONSTANT VALUES FOR INFOCENTER…………………………………………………………….346
7. ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT………………………………………………………351
PRESENTATION SCREEN……………………………………………………………………………..351
MAIN MENU………………………………………………………………………………………351
1. MONITOR……………………………………………………………………………………..352
1.1 LIFT……………………………………………………………………………………352
1.2 CONSOLE…………………………………………………………………………………354
1.3 ASM…………………………………………………………………………………….354
1.4 POWER…………………………………………………………………………………..355
1.5 SENSORS…………………………………………………………………………………356
2. CONFIGURATION………………………………………………………………………………..356
2.1 SPEED CONSTANTS………………………………………………………………………….357
2.2 OPTIONS…………………………………………………………………………………357
3. CALIBRATIONS…………………………………………………………………………………358
3.1 MINIMUM HEIGHT…………………………………………………………………………..359
3.2 MAXIMUM HEIGHT…………………………………………………………………………..359
3.3 LOCK SPEED………………………………………………………………………………360
3.5 TRANSPORT……………………………………………………………………………….361
3.6 STOP……………………………………………………………………………………361
3.7 CONTROL…………………………………………………………………………………362
3.8 FLOAT…………………………………………………………………………………..362
4. ALARMS LIST………………………………………………………………………………….363
8. ALL ROUND TESTER FOR AXLE SUSPENSION CONTROL UNIT……………………………………………………365
PRESENTATION SCREEN……………………………………………………………………………..365
MAIN MENU………………………………………………………………………………………365
1. MONITOR……………………………………………………………………………………..366
1.1 SUSPENSION………………………………………………………………………………366
2. PARAMETERS…………………………………………………………………………………..367
3. ALARMS LIST………………………………………………………………………………….369
4. CONFIGURATIONS……………………………………………………………………………….369
9. SERDIA (LEVEL III)……………………………………………………………………………….371
1. SETUP AND COMMUNICATIONS………………………………………………………………………371
1.1 MINIMUM EQUIPMENT REQUIRED………………………………………………………………..371
1.2 ORDERING………………………………………………………………………………..372
1.3 SWITCHING ON AND INSTALLING THE SOFTWARE……………………………………………………373
1.4 USING THE PROGRAM………………………………………………………………………..377
1.5 CLOSING THE PROGRAM………………………………………………………………………380
2. ECU SELECTION………………………………………………………………………………..381
2.1 SELECTING TWO CONTROL UNITS……………………………………………………………….381
2.2 PRINTING………………………………………………………………………………..382
2.3 PROTOCOL………………………………………………………………………………..383
2.4 IDENTIFICATION AND MEASUREMENT DATA………………………………………………………..383
3. MEASURED VALUES………………………………………………………………………………385
3.1 ACTUAL MEASURED VALUES (GENERAL)…………………………………………………………..385
3.2 RAM-VALUES………………………………………………………………………………390
3.3 DATA LOGGER (ONLY EMS2)…………………………………………………………………..394
3.4 INPUT/OUTPUT ASSIGNMENT…………………………………………………………………..394
3.5 CAN STATUS………………………………………………………………………………394
4. PARAMETERS…………………………………………………………………………………..397
4.1 CONFIGURATION (GENERAL)…………………………………………………………………..397
4.2 OVERALL PROGRAMMING………………………………………………………………………398
4.2 CALIBRATION……………………………………………………………………………..399
5. ERROR MEMORY…………………………………………………………………………………400
5.1 GENERAL…………………………………………………………………………………400
5.2 ERROR TABLE……………………………………………………………………………..401
6. EXTRAS………………………………………………………………………………………411
6.1 MAXIMUM SPEED……………………………………………………………………………411
6.2 LOGISTIC DATA……………………………………………………………………………411
6.3 LOAD SPECTRUM……………………………………………………………………………412
6.4 MAINTENANCE INTERVAL EXCEEDED……………………………………………………………..412
6.5 OVERRIDE MEMORY………………………………………………………………………….412
6.6 MAINTENANCE DATA…………………………………………………………………………412
7. TASKS……………………………………………………………………………………….413
7.1 EMR1……………………………………………………………………………………413
8. WHAT TO DO IF…?…………………………………………………………………………….417
8.1 SERDIA GENERAL…………………………………………………………………………..417
8.2 EMR1……………………………………………………………………………………419
SECTION 30…………………………………………………………………………………………….431
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING………………………………………………433
HYDRAULIC SYSTEMS AND WIRING (TOP VIEW)……………………………………………………………….434
HYDRAULIC SYSTEMS (TOP VIEW)…………………………………………………………………………435
HYDRAULIC SYSTEMS (SIDE VIEW)………………………………………………………………………..436
REAR HYDRAULIC SYSTEMS (SIDE VIEW)……………………………………………………………………437
FRONT HYDRAULIC SYSTEMS (SIDE VIEW)…………………………………………………………………..438
ENGINE HOOD – LAMP ASSEMBLIES………………………………………………………………………..439
REMOVAL………………………………………………………………………………………..439
REFITTING………………………………………………………………………………………442
CAB ACCESS STEPS……………………………………………………………………………………443
REMOVAL………………………………………………………………………………………..443
REFITTING………………………………………………………………………………………443
BATTERY……………………………………………………………………………………………444
REMOVAL………………………………………………………………………………………..444
REFITTING………………………………………………………………………………………445
AIR RESERVOIR AND BATTERY SUPPORT…………………………………………………………………….446
REMOVAL………………………………………………………………………………………..446
REFITTING………………………………………………………………………………………446
STARTER MOTOR………………………………………………………………………………………447
REMOVAL………………………………………………………………………………………..447
REFITTING………………………………………………………………………………………447
ALTERNATOR…………………………………………………………………………………………448
REMOVAL………………………………………………………………………………………..448
REFITTING………………………………………………………………………………………448
AIR CONDITIONING COMPRESSOR DRIVEBELT AND FANBELT………………………………………………………449
RENEWAL………………………………………………………………………………………..449
AIR COMPRESSOR……………………………………………………………………………………..452
REMOVAL………………………………………………………………………………………..452
REFITTING………………………………………………………………………………………453
TRAILER PARKING AND SERVICE AIR BRAKE CONTROL VALVES……………………………………………………454
REMOVAL………………………………………………………………………………………..454
REFITTING………………………………………………………………………………………455
PRESSURE TRANSDUCER…………………………………………………………………………………456
REMOVAL………………………………………………………………………………………..456
REFITTING………………………………………………………………………………………456
AIR PRESSURE REGULATING/REDUCTION VALVE FOR CAB LIFTING…………………………………………………457
REMOVAL………………………………………………………………………………………..457
REFITTING………………………………………………………………………………………457
TRAILER AIR BRAKES COUPLING VALVE…………………………………………………………………….458
1. Removal……………………………………………………………………………………..458
2. Renewal……………………………………………………………………………………..458
HYDRAULIC TRAILER BRAKING VALVE………………………………………………………………………459
REMOVAL………………………………………………………………………………………..459
REFITTING………………………………………………………………………………………460
AIR CONDITIONING SYSTEM……………………………………………………………………………..461
TECHNICAL SPECIFICATIONS…………………………………………………………………………461
OPERATION………………………………………………………………………………………462
MAINTENANCE…………………………………………………………………………………….463
ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT…………………………………………………..463
DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM……………………………………..464
AIR CONDITIONING COMPRESSOR………………………………………………………………………….465
REMOVAL………………………………………………………………………………………..465
REFITTING………………………………………………………………………………………466
RECEIVER-DRIER……………………………………………………………………………………..467
REMOVAL………………………………………………………………………………………..467
REFITTING………………………………………………………………………………………467
CONDENSER ASSEMBLY………………………………………………………………………………….468
REMOVAL………………………………………………………………………………………..468
REFITTING………………………………………………………………………………………470
INTERCOOLER………………………………………………………………………………………..471
REMOVAL………………………………………………………………………………………..471
REFITTING………………………………………………………………………………………473
GEARBOX OIL/FUEL COOLERS…………………………………………………………………………….474
REMOVAL………………………………………………………………………………………..474
REFITTING………………………………………………………………………………………475
RADIATOR…………………………………………………………………………………………..476
REMOVAL………………………………………………………………………………………..476
REFITTING………………………………………………………………………………………479
EXPANSION TANK……………………………………………………………………………………..480
REMOVAL………………………………………………………………………………………..480
REFITTING………………………………………………………………………………………480
RADIATORS – COOLERS ASSEMBLY…………………………………………………………………………481
REMOVAL………………………………………………………………………………………..481
REFITTING………………………………………………………………………………………485
FAN……………………………………………………………………………………………….486
REMOVAL………………………………………………………………………………………..486
REFITTING………………………………………………………………………………………486
FRONT PTO FLEXIBLE COUPLING………………………………………………………………………….487
REMOVAL………………………………………………………………………………………..487
REFITTING………………………………………………………………………………………488
AIR CLEANER………………………………………………………………………………………..489
REMOVAL………………………………………………………………………………………..489
REFITTING………………………………………………………………………………………490
TURBOCHARGER……………………………………………………………………………………….491
REMOVAL………………………………………………………………………………………..491
REFITTING………………………………………………………………………………………492
AIR INLET PIPE……………………………………………………………………………………..493
REMOVAL………………………………………………………………………………………..493
REFITTING………………………………………………………………………………………494
SILENCER…………………………………………………………………………………………..495
REMOVAL………………………………………………………………………………………..495
REFITTING………………………………………………………………………………………495
EXHAUST PIPE……………………………………………………………………………………….496
REMOVAL………………………………………………………………………………………..496
REFITTING………………………………………………………………………………………496
4WD PROPELLER SHAFT…………………………………………………………………………………497
REMOVAL………………………………………………………………………………………..497
REFITTING………………………………………………………………………………………499
BRAKE MASTER CYLINDERS………………………………………………………………………………500
REMOVAL………………………………………………………………………………………..500
REFITTING………………………………………………………………………………………502
BLEEDING THE BRAKING SYSTEM………………………………………………………………………….503
BRAKE LIGHT SWITCHES………………………………………………………………………………..505
ADJUSTMENT……………………………………………………………………………………..505
POWER STEERING UNIT…………………………………………………………………………………506
1. Testing……………………………………………………………………………………..506
2. Adjustment…………………………………………………………………………………..506
3. Removal……………………………………………………………………………………..506
REFITTING………………………………………………………………………………………507
1. Disassembly………………………………………………………………………………….509
2. Removal of the seals………………………………………………………………………….511
3. Removal of the dust seal………………………………………………………………………511
4. Installing the inner seal (15)…………………………………………………………………512
5. Installing the control valve…………………………………………………………………..512
6. Final assembly……………………………………………………………………………….513
FRONT WHEELS……………………………………………………………………………………….516
REMOVAL………………………………………………………………………………………..516
REFITTING………………………………………………………………………………………516
FRONT FENDERS………………………………………………………………………………………517
REMOVAL………………………………………………………………………………………..517
REFITTING………………………………………………………………………………………517
REAR WHEELS………………………………………………………………………………………..518
REMOVAL………………………………………………………………………………………..518
REFITTING………………………………………………………………………………………518
LIFT VALVE BLOCK……………………………………………………………………………………519
REMOVAL………………………………………………………………………………………..519
REFITTING………………………………………………………………………………………519
FRONT LIFT CYLINDERS………………………………………………………………………………..520
REMOVAL………………………………………………………………………………………..520
REFITTING………………………………………………………………………………………521
FRONT LIFT ASSEMBLY…………………………………………………………………………………522
REMOVAL………………………………………………………………………………………..522
REFITTING………………………………………………………………………………………524
FRONT PTO ASSEMBLY………………………………………………………………………………….525
REMOVAL………………………………………………………………………………………..525
REFITTING………………………………………………………………………………………525
FRONT SUSPENSION CYLINDERS…………………………………………………………………………..526
REMOVAL………………………………………………………………………………………..526
REFITTING………………………………………………………………………………………528
1. Disassembly………………………………………………………………………………….529
2. Assembly…………………………………………………………………………………….530
FRONT AXLE AND SWINGING SUPPORT………………………………………………………………………531
REMOVAL………………………………………………………………………………………..531
REFITTING………………………………………………………………………………………533
FRONT SUSPENSION VALVES……………………………………………………………………………..534
REMOVAL………………………………………………………………………………………..534
REFITTING………………………………………………………………………………………534
FRONT SUSPENSION POSITION SENSOR……………………………………………………………………..535
1. Removal……………………………………………………………………………………..535
2. Positioning………………………………………………………………………………….535
3. Testing……………………………………………………………………………………..536
REINFORCING SIDE MEMBERS…………………………………………………………………………….537
REMOVAL………………………………………………………………………………………..537
REFITTING………………………………………………………………………………………537
FRONT CARRIER………………………………………………………………………………………538
REMOVAL………………………………………………………………………………………..538
REFITTING………………………………………………………………………………………538
ACCELERATOR POTENTIOMETER……………………………………………………………………………539
1. Renewal……………………………………………………………………………………..539
2. Potentiometer calibration……………………………………………………………………..540
FUEL TANK………………………………………………………………………………………….541
REMOVAL………………………………………………………………………………………..541
INSTALLATION……………………………………………………………………………………544
POWER STEERING PUMP…………………………………………………………………………………545
REMOVAL………………………………………………………………………………………..545
REFITTING………………………………………………………………………………………547
TESTING THE AUXILIARY SERVICES PUMPS………………………………………………………………….548
1. Flow meter connection (CC version)……………………………………………………………..548
2. Flow meter connection (LS version)……………………………………………………………..548
3. Measuring the flow rate……………………………………………………………………….548
GEAR PUMP………………………………………………………………………………………….550
REMOVAL………………………………………………………………………………………..550
REFITTING………………………………………………………………………………………551
VARIABLE DISPLACEMENT PUMP…………………………………………………………………………..552
REMOVAL………………………………………………………………………………………..552
REFITTING………………………………………………………………………………………556
PRIORITY VALVE……………………………………………………………………………………..557
REMOVAL………………………………………………………………………………………..557
REFITTING………………………………………………………………………………………557
CREEPER ENGAGEMENT LEVER…………………………………………………………………………….558
REMOVAL………………………………………………………………………………………..558
REFITTING………………………………………………………………………………………558
CONTROL VALVE ASSEMBLIES (Version CC)…………………………………………………………………559
REMOVAL………………………………………………………………………………………..559
REFITTING………………………………………………………………………………………562
CONTROL VALVE ASSEMBLIES (LS version)…………………………………………………………………563
REMOVAL………………………………………………………………………………………..563
REFITTING………………………………………………………………………………………567
CONTROL VALVE SECTIONS AND SEALS……………………………………………………………………..568
REMOVAL………………………………………………………………………………………..568
REFITTING………………………………………………………………………………………574
LIFT CYLINDERS……………………………………………………………………………………..575
REMOVAL………………………………………………………………………………………..575
REFITTING………………………………………………………………………………………576
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………577
LIFT POSITION SENSOR………………………………………………………………………………..579
TESTING………………………………………………………………………………………..578
RENEWAL………………………………………………………………………………………..579
LIFT DRAFT SENSOR…………………………………………………………………………………..582
REMOVAL………………………………………………………………………………………..582
REFITTING………………………………………………………………………………………582
DRIVER’S SEAT………………………………………………………………………………………583
REMOVAL………………………………………………………………………………………..583
REFITTING………………………………………………………………………………………583
CONTROLS IN THE MULTIFUNCTION ARMREST CONSOLE (OPTIONAL)………………………………………………..584
REMOVAL………………………………………………………………………………………..584
REFITTING………………………………………………………………………………………585
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL…………………………………………586
REMOVAL………………………………………………………………………………………..586
REFITTING………………………………………………………………………………………587
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER……………………………………………….588
RENEWAL………………………………………………………………………………………..588
ASSEMBLY……………………………………………………………………………………….589
CENTRE CONSOLE AND SHROUD……………………………………………………………………………590
REMOVAL………………………………………………………………………………………..590
REFITTING………………………………………………………………………………………593
RIGHT-HAND CONSOLE………………………………………………………………………………….594
OPENING AND REMOVAL……………………………………………………………………………..594
REFITTING………………………………………………………………………………………600
LEFT-HAND CONSOLE…………………………………………………………………………………..601
REMOVAL………………………………………………………………………………………..601
REFITTING………………………………………………………………………………………602
TRANSMISSION LIFT AND FRONT SUSPENSION ELECTRONIC CONTROL UNITS………………………………………….603
REMOVAL………………………………………………………………………………………..603
REFITTING………………………………………………………………………………………604
FUSE AND RELAY BOARD………………………………………………………………………………..605
REMOVAL………………………………………………………………………………………..605
REFITTING………………………………………………………………………………………606
ENGINE ECU…………………………………………………………………………………………607
REMOVAL………………………………………………………………………………………..607
REFITTING………………………………………………………………………………………607
CLUTCH PEDAL AND RELATED DEVICES……………………………………………………………………..608
1. Removal of the potentiometer…………………………………………………………………..608
1.1. Refitting the potentiometer………………………………………………………………….608
2. Adjustment of the clutch pedal position and travel……………………………………………….609
3. Renewal of the proximity sensor………………………………………………………………..609
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO…………………………………….610
REMOVAL………………………………………………………………………………………..610
REFITTING………………………………………………………………………………………614
PTO ENGAGEMENT AND SELECTION CONTROL CABLES……………………………………………………………615
RENEWAL………………………………………………………………………………………..615
REFITTING………………………………………………………………………………………616
AUXILIARY SERVICE VALVE CONTROL CABLES………………………………………………………………..618
RENEWAL………………………………………………………………………………………..618
REFITTING………………………………………………………………………………………619
ADJUSTMENT OF THE PARKING BRAKE SWITCH………………………………………………………………..620
CLIMATE CONTROL PANEL……………………………………………………………………………….621
REMOVAL………………………………………………………………………………………..621
REFITTING………………………………………………………………………………………621
HEATER VALVE……………………………………………………………………………………….622
RENEWAL………………………………………………………………………………………..622
REMOVAL………………………………………………………………………………………..624
HEATER MATRIX………………………………………………………………………………………624
REMOVAL………………………………………………………………………………………..624
REFITTING………………………………………………………………………………………626
AIR CONDITIONING EVAPORATOR………………………………………………………………………….627
REMOVAL………………………………………………………………………………………..627
REFITTING………………………………………………………………………………………628
RIGHT-HAND AIR CONDITIONING FAN………………………………………………………………………629
REMOVAL………………………………………………………………………………………..629
REFITTING………………………………………………………………………………………629
LEFT-HAND AIR CONDITIONING FAN……………………………………………………………………….630
REMOVAL………………………………………………………………………………………..630
REFITTING………………………………………………………………………………………630
ADJUSTMENT OF THE PARKING BRAKES……………………………………………………………………..631
CAB DOOR CABLE……………………………………………………………………………………..632
RENEWAL………………………………………………………………………………………..632
TRAILER BRAKING AIR PRESSURE GAUGE……………………………………………………………………634
REMOVAL………………………………………………………………………………………..634
REFITTING………………………………………………………………………………………634
POWERSHIFT – POWERSHUTTLE STATUS DISPLAY………………………………………………………………635
REMOVAL………………………………………………………………………………………..635
REFITTING………………………………………………………………………………………635
CAB……………………………………………………………………………………………….636
REMOVAL………………………………………………………………………………………..636
REFITTING………………………………………………………………………………………644
ENGINE…………………………………………………………………………………………….645
REMOVAL………………………………………………………………………………………..645
REFITTING………………………………………………………………………………………653
SECTION 40…………………………………………………………………………………………….655
THE STRUCTURE OF THE UNIT……………………………………………………………………………657
HOW TO CONSULT THE UNIT……………………………………………………………………………..658
1. INTRODUCTION…………………………………………………………………………………….659
1.1 LIST OF WIRING HARNESSES……………………………………………………………………..659
1.2 DEFINITION OF COMPONENTS AND SYMBOLS…………………………………………………………..660
1.3 GENERAL RULES……………………………………………………………………………….660
1.3.1 MODIFICATION OF THE TRACTOR’S ELECTRICAL/ELECTRONIC CIRCUITS………………………………..660
1.3.2 MAIN WIRING FAULTS……………………………………………………………………..660
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING……………………………………..661
1.4 DIAGNOSTIC INSTRUMENTS……………………………………………………………………….662
1.5 WIRE COLOUR CODES……………………………………………………………………………662
2. INDICES…………………………………………………………………………………………663
2.1 COMPONENT DESCRIPTION INDEX…………………………………………………………………..663
2.2 COMPONENT CODE INDEX…………………………………………………………………………668
2.3 CONNECTOR INDEX……………………………………………………………………………..673
3. COMPONENTS………………………………………………………………………………………682
3.1 CONNECTOR LAYOUTS……………………………………………………………………………682
3.2 COMPONENT TECHNICAL DATA……………………………………………………………………..687
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS…………………………………………….696
3.3.1 ENGINE CONTROL UNIT…………………………………………………………………….696
3.3.2 TRANSMISSION CONTROL UNIT……………………………………………………………….698
3.3.3 INFOCENTER…………………………………………………………………………….700
3.3.4 HPSA CONTROL UNIT………………………………………………………………………702
3.3.5 FRONT SUSPENSION CONTROL UNIT……………………………………………………………704
4. SYSTEMS…………………………………………………………………………………………705
4.1 GROUND POINTS……………………………………………………………………………….705
4.2 ENGINE START………………………………………………………………………………..706
4.3 PREHEATING………………………………………………………………………………….707
4.4 ELECTRICAL ENGINE CONTROL…………………………………………………………………….708
4.5 LIGHTS – LIGHT SELECTOR SWITCH (MACHINE WITHOUT FRONT LIFT)………………………………………709
4.6 LIGHTS – LIGHT SELECTOR SWITCH (MACHINE WITH FRONT LIFT)…………………………………………710
4.7 CAB ACCESSORY……………………………………………………………………………….711
4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT)…………………………………………………….712
4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT)……………………………………………………….713
4.10 WINDSCREEN WIPER……………………………………………………………………………714
4.11 INFOCENTER…………………………………………………………………………………715
4.12 ELECTRICAL POWER SUPPLY……………………………………………………………………..716
4.13 AUTORADIO – CB……………………………………………………………………………..717
4.14 AIR CONDITIONING – HEATING FAN……………………………………………………………….718
4.15 BRAKES…………………………………………………………………………………….719
4.16 TRAILER BRAKES……………………………………………………………………………..720
4.17 FRONT AXLE SUSPENSION……………………………………………………………………….721
4.18 TRANSMISSION……………………………………………………………………………….722
4.19 ASM – 4WD – DIFFERENTIAL…………………………………………………………………….723
4.20 REAR LIFTER………………………………………………………………………………..724
4.21 FRONT AND REAR PTO………………………………………………………………………….725
5. WIRING………………………………………………………………………………………….727
ENGINE WIRING (1/2)……………………………………………………………………………..727
ENGINE WIRING (2/2)……………………………………………………………………………..728
ENGINE WIRING (1/2)……………………………………………………………………………..733
ENGINE WIRING (2/2)……………………………………………………………………………..734
ENGINE HOOD WIRING………………………………………………………………………………743
TRANSMISSION WIRING (1/2)………………………………………………………………………..747
TRANSMISSION WIRING (2/2)………………………………………………………………………..748
TRAILER BRAKE WIRING (ITALY)……………………………………………………………………..759
TRAILER BRAKE WIRING…………………………………………………………………………….760
FRONT AXLE SUSPENSION WIRING (ROPS)……………………………………………………………….763
CAB POWER SUPPLY WIRING………………………………………………………………………….767
FRONT AXLE SUSPENSION WIRING……………………………………………………………………..773
FENDER WIRING – WIDE…………………………………………………………………………….777
NUMBER PLATE LIGHT WIRING (WIDE FENDERS)…………………………………………………………..778
FENDER WIRING – NARROW…………………………………………………………………………..783
NUMBER PLATE LIGHT WIRING (NARROW FENDERS)…………………………………………………………784
FRONT CONSOLE WIRING (1/2)……………………………………………………………………….789
FRONT CONSOLE WIRING (2/2)……………………………………………………………………….790
SIDE CONSOLE WIRING (1/3)………………………………………………………………………..795
SIDE CONSOLE WIRING (2/3)………………………………………………………………………..796
SIDE CONSOLE WIRING (3/3)………………………………………………………………………..797
AIR CONDITIONING WIRING (CAB)…………………………………………………………………….807
DISPLAY WIRING………………………………………………………………………………….813
ROOF WIRING (1/2)……………………………………………………………………………….817
ROOF WIRING (2/2)……………………………………………………………………………….818
CAB ROOF FRONT AND REAR WORKLIGHTS WIRING………………………………………………………….827
CAB LOWER HEADLIGHTS WIRING………………………………………………………………………825
WINDSCREEN WIPER MOTOR WIRING…………………………………………………………………….825
CAB LOWER FRONT WORKLIGHTS WIRING…………………………………………………………………826
(MACHINE WITHOUT FRONT LIFT)……………………………………………………………………..826
CAB FULL AND DIPPED BEAM HEADLIGHTS (WITH FRONT LIFT)……………………………………………….826
LIGHTS SELECTOR SWITCH WIRING…………………………………………………………………….833
ARMREST WIRING………………………………………………………………………………….837
FUSES AND RELAYS CONTROL UNIT (1/2)……………………………………………………………….839
FUSES AND RELAYS CONTROL UNIT (2/2)……………………………………………………………….840
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