DEUTZ-FAHR AGROTRON K 90 AGROTRON K 100 AGROTRON K 110 AGROTRON K 120 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
DEUTZ-FAHR AGROTRON K 90 AGROTRON K 100 AGROTRON K 110 AGROTRON K 120 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 700
Downloadable : Yes
File Type : PDF
Size: 26 MB
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
DEUTZ-FAHR AGROTRON K 90 AGROTRON K 100 AGROTRON K 110 AGROTRON K 120 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 K 90 AGROTRON K 100 AGROTRON K 110 AGROTRON K 120 Workshop Manual – PDF DOWNLOAD
INTRODUCTION…………………………………………………………………………………. 3
SAFETY NOTES…………………………………………………………………………………. 5
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTINGOPERATIONS……………………………………………. 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 POWER SHUTTLE TRANSMISSION………………………………………………………….. 24
1.1.1 MAIN COMPONENTS………………………………………………………………. 24
1.1.2 TRANSMISSION HYDRAULIC SYSTEM………………………………………………….. 27
1.1.3 GEARBOX……………………………………………………………………… 28
1.1.4 MAIN CLUTCH………………………………………………………………….. 30
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE CONTROL VALVE……………………………………… 31
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC………………………….. 34
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC………………………………………… 35
1.2 REAR AXLE…………………………………………………………………………. 37
1.3 REAR PTO………………………………………………………………………….. 39
2. BRAKING SYSTEM…………………………………………………………………………. 41
DESCRIPTION…………………………………………………………………………… 41
2.1 BRAKE PUMP………………………………………………………………………… 42
2.2 BRAKE…………………………………………………………………………….. 43
2.3 TRAILER BRAKING SYSTEM……………………………………………………………… 44
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)……………………………………….. 44
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)………………………………………. 46
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)…………………………………………….. 48
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)……………………………………………. 49
3. HYDRAULIC FRONT AXLE SUSPENSION………………………………………………………….. 55
DESCRIPTION…………………………………………………………………………… 55
3.1 FRONT SUSPENSION CONTROL VALVE………………………………………………………. 56
4. FRONT AXLE…………………………………………………………………………….. 61
5. HYDRAULIC SYSTEM……………………………………………………………………….. 62
DESCRIPTION…………………………………………………………………………… 62
5.1 HYDRAULIC DIAGRAM (standard version)…………………………………………………. 63
5.2 HYDRAULIC DIAGRAM (full version)…………………………………………………….. 64
5.3 GEAR PUMP FOR TRANSMISSION ZF 7100…………………………………………………… 65
5.4 GEAR PUMP FOR SERVICES AND STEERING………………………………………………….. 66
5.5 POWER STEERING…………………………………………………………………….. 67
5.6 AUXILIARY SERVICES CONTROL VALVE…………………………………………………….. 68
5.7 FRONT LIFT MECHANISM SOLENOID VALVE………………………………………………….. 69
5.8 LIFT CONTROL ELEMENT……………………………………………………………….. 70
5.9 PRIORITY VALVE FOR FRONT AXLE SUSPENSION……………………………………………… 71
SECTION 20…………………………………………………………………………………… 73
1. DIAGNOSIS TOOLS………………………………………………………………………… 75
1.1 ALL ROUND TESTER…………………………………………………………………… 75
1.1.1 DESCRIPTION OF THE KIT………………………………………………………… 75
1.1.2 NOTES ON CORRECT USE………………………………………………………….. 76
1.1.3 DESCRIPTION OF THE TESTER……………………………………………………… 76
1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER……………………………. 77
1.1.5 SELECTION OF THE DISPLAY LANGUAGE………………………………………………. 77
1.1.6 SETTING THE SERIAL PORTS………………………………………………………. 79
1.2 “SERDIA 2000 LEVEL III” SOFTWARE…………………………………………………….. 81
1.2.1 DESCRIPTION OF THE KIT………………………………………………………… 81
1.3 EDS EST45 SOFTWARE…………………………………………………………………. 82
1.3.1 DESCRIPTION OF THE KIT………………………………………………………… 82
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS………………………………………. 83
2.1 CONNECTING THE ART TO THE HLHP CONTROL UNITS………………………………………….. 83
2.2 CONNECTING THE PORTABLE COMPUTER WITH “SERDIA 2000” SOFTWARE TO THE ENGINE ECU……………. 84
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR……………………………………….. 85
3.1 ELECTRONIC SYSTEM………………………………………………………………….. 85
3.2 CANBUS SYSTEM……………………………………………………………………… 86
3.3 TRANSMISSION CONTROL UNIT…………………………………………………………… 93
3.4 INFOCENTER………………………………………………………………………… 94
4. COMMISSIONING THE TRACTOR……………………………………………………………….. 95
4.1 INTRODUCTION………………………………………………………………………. 95
4.2 RENEWAL OF THE ENGINE CONTROL UNIT…………………………………………………… 95
4.2.1 READING AND SAVING DATA……………………………………………………….. 95
4.2.2 PROGRAMMING THE CONTROL UNIT…………………………………………………… 96
4.2.3 PROCEDURE FOR SETTING THE ENGINE OPERATING HOURS…………………………………. 97
4.2.4 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE SERDIA PROGRAM)……………………. 98
4.2.5 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE ART)……………………………… 99
4.2.6 CALIBRATION OF THE HAND THROTTLE (USING THE SERDIA PROGRAMME)………………………100
4.2.7 CALIBRATION OF THE HAND THROTTLE (USING THE ART)………………………………….101
4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT………………………………………………104
4.3.1 CONFIGURATION OF THE MODEL……………………………………………………..104
4.3.2 CONFIGURATION OF THE BASIC WHEEL………………………………………………..107
4.3.3 CONFIGURATION OF THE WHEEL CIRCUMFERENCE (USING THE ART)…………………………..109
4.3.4 CALIBRATION OF THE WHEEL CIRCUMFERENCE (WITHOUT USING THE ART)……………………..111
4.3.5 CONFIGURATION OF THE MAXIMUM TRAVEL SPEED (FOR GERMAN MARKET ONLY)………………….112
4.3.6 CALIBRATION OF THE CLUTCH PEDAL…………………………………………………114
4.3.7 CALIBRATION OF THE MAIN CLUTCH………………………………………………….116
4.3.8 CALIBRATION OF THE FIELD/ROAD SENSOR…………………………………………….118
4.3.9 CANCELLATION OF ALL ALARMS……………………………………………………..120
4.4 RENEWAL OF THE HLHP CONTROL UNIT……………………………………………………..121
4.4.1 INITIALIZATION OF THE HLHP CONTROL UNIT………………………………………….121
4.4.2 CONFIGURING THE SYSTEM FOR THE PRESENCE OF THE FRONT PTO (ONLY IF INSTALLED)…………123
4.4.3 ENABLING THE ASM SYSTEM (ONLY IF INSTALLED)………………………………………124
4.4.4 CALIBRATION OF THE STEERING ANGLE SENSOR (WITH ASM ONLY)…………………………..126
4.4.5 CONFIGURING THE SYSTEM FOR THE PRESENCE OF RADAR (ONLY IF INSTALLED)………………..127
4.4.6 CALIBRATION OF THE HIGH AND LOW POSITIONS OF THE LIFT……………………………..129
4.4.7 CONFIGURING THE SYSTEM FOR THE PRESENCE OF FRONT AXLE SUSPENSION (ONLY IF INSTALLED)….131
4.4.8 SETTING THE INFOCENTER DISPLAY LANGUAGE………………………………………….132
4.4.9 CANCELLING ALL THE ALARMS………………………………………………………134
5. ALARMS…………………………………………………………………………………135
INTRODUCTION…………………………………………………………………………..135
5.1 ALARMS DISPLAYED ON THE INFOCENTER……………………………………………………136
5.2 HLHP CONTROL UNIT ALARMS…………………………………………………………….147
5.3 ENGINE CONTROL UNIT ALARMS…………………………………………………………..231
5.4 TRANSMISSION CONTROL UNIT ALARMS……………………………………………………..255
5.4.1 DEFINITION OF TRANSMISSION OPERATING MODES……………………………………….255
5.4.2 ABNORMALITIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT………………………..256
5.5 CANBUS ALARMS………………………………………………………………………337
6. ENGINE CONTROL UNIT TEST PROGRAM………………………………………………………….347
6. 1 ACCESS AND COMMUNICATION……………………………………………………………347
6. 1.1 MINIMUM EQUIPMENT REQUIREMENTS…………………………………………………347
6. 1.2 ORDERING INFORMATION………………………………………………………….347
6. 1.3 CONNECTING THE NOTEBOOK AND INSTALLING THE SOFTWARE………………………………348
6. 1.4 PROGRAM COMMANDS……………………………………………………………..352
6. 1.5 TERMINATE COMMUNICATION……………………………………………………….354
6. 2 ECU SELECTION……………………………………………………………………..355
6. 2.1 SELECTION OF TWO ECUs…………………………………………………………355
6. 2.2 PRINT (EXPORT)……………………………………………………………….356
6. 2.3 PROTOCOL…………………………………………………………………….357
6. 2.4 IDENTIFICATION AND MEASUREMENT DATA…………………………………………….357
6. 3 MEASUREMENT VALUES…………………………………………………………………358
6. 3.1 CURRENT VALUES (IN GENERAL)……………………………………………………358
6. 3.2 RAM VALUES…………………………………………………………………..362
6. 3.3 INPUT/OUTPUT CONFIGURATION…………………………………………………….367
6. 3.4 CAN Status…………………………………………………………………..367
6. 4 PARAMETERS………………………………………………………………………..370
6. 4.1 CONFIGURATION (GENERAL)……………………………………………………….370
6. 4.2 COMPLETE PROGRAMMING………………………………………………………….371
6. 4.3 CALIBRATION………………………………………………………………….372
6. 5 ERROR MEMORY………………………………………………………………………373
6. 5.1 GENERAL INFORMATION…………………………………………………………..373
6. 6 EXTRA…………………………………………………………………………….375
6. 6.1 MAXIMUM SPEED………………………………………………………………..375
6. 6.2 LOGISTICAL DATA………………………………………………………………375
6. 6.3 GENERAL LOADS………………………………………………………………..376
6. 7 ACTIVITY………………………………………………………………………….377
6. 7.1 EMR2………………………………………………………………………..377
6. 8 POSSIBLE PROBLEMS………………………………………………………………….381
6. 8.1 SERDIA IN GENERAL…………………………………………………………….381
6. 8.2 EMR2………………………………………………………………………..382
Definition of the parameters…………………………………………………………385
Configuration:……………………………………………………………………..385
SECTION 30……………………………………………………………………………………393
ENGINE HOOD……………………………………………………………………………….397
Removal……………………………………………………………………………….397
Refitting……………………………………………………………………………..397
WHEELS……………………………………………………………………………………398
FRONT WHEELS…………………………………………………………………………..398
Removal……………………………………………………………………………398
Refitting………………………………………………………………………….398
REAR WHEELS……………………………………………………………………………399
Removal……………………………………………………………………………399
Refitting………………………………………………………………………….399
FRONT FENDERS……………………………………………………………………………..400
Removal……………………………………………………………………………….400
Refitting……………………………………………………………………………..400
CAB ACCESS STEPS…………………………………………………………………………..401
Removal……………………………………………………………………………….401
Refitting……………………………………………………………………………..401
FUEL TANK…………………………………………………………………………………402
Removal……………………………………………………………………………….402
Refitting……………………………………………………………………………..403
COOLERS-RADIATOR ASSEMBLY…………………………………………………………………..404
COMPLETE ASSEMBLY………………………………………………………………………404
Removal……………………………………………………………………………404
Refitting………………………………………………………………………….407
FUEL COOLER……………………………………………………………………………409
Removal……………………………………………………………………………409
Refitting………………………………………………………………………….409
TRANSMISSION OIL COOLER…………………………………………………………………410
Removal……………………………………………………………………………410
Refitting………………………………………………………………………….411
ENGINE COOLING SYSTEM RADIATOR…………………………………………………………..412
Removal……………………………………………………………………………412
Refitting………………………………………………………………………….415
AIR FILTER ASSEMBLY…………………………………………………………………….416
Removal……………………………………………………………………………416
Refitting………………………………………………………………………….416
INTERCOOLER……………………………………………………………………………417
Removal……………………………………………………………………………417
Refitting………………………………………………………………………….417
AIR CONDITIONING SYSTEM…………………………………………………………………….418
TECHNICAL DATA…………………………………………………………………………418
Operation……………………………………………………………………………..419
Discharging, flushing and recharging……………………………………………………..420
1. Discharging the system……………………………………………………………….420
2. Flushing and recharging the system…………………………………………………….420
RECEIVER – DRIER……………………………………………………………………….422
Removal……………………………………………………………………………422
Refitting………………………………………………………………………….422
CONDENSER ASSEMBLY……………………………………………………………………..423
Removal……………………………………………………………………………423
Refitting………………………………………………………………………….423
COMPRESSOR…………………………………………………………………………….424
Removal……………………………………………………………………………424
Refitting………………………………………………………………………….425
HEATER ASSEMBLY……………………………………………………………………………426
COMPLETE ASSEMBLY………………………………………………………………………426
Removal……………………………………………………………………………426
Refitting………………………………………………………………………….428
UPPER HALF DUCT………………………………………………………………………..429
Assembly…………………………………………………………………………..429
FANS………………………………………………………………………………….430
Disassembly………………………………………………………………………..430
Assembly…………………………………………………………………………..430
HEATER MATRIX………………………………………………………………………….431
Disassembly………………………………………………………………………..431
Assembly…………………………………………………………………………..431
AIR CONDITIONING EVAPORATOR……………………………………………………………..432
Disassembly………………………………………………………………………..432
Assembly…………………………………………………………………………..432
ENGINE COOLING FAN ASSEMBLY…………………………………………………………………433
ENGINE COOLING FAN……………………………………………………………………..433
Removal……………………………………………………………………………433
Refitting………………………………………………………………………….434
FAN BELT………………………………………………………………………………435
Removal……………………………………………………………………………435
Refitting………………………………………………………………………….436
Tensioning…………………………………………………………………………437
ALTERNATOR ASSEMBLY………………………………………………………………………..438
ALTERNATOR…………………………………………………………………………….438
Removal……………………………………………………………………………438
Refitting………………………………………………………………………….438
ALTERNATOR DRIVEBELT……………………………………………………………………439
Removal……………………………………………………………………………439
Refitting………………………………………………………………………….440
Tensioning…………………………………………………………………………441
STARTER MOTOR……………………………………………………………………………..442
Removal……………………………………………………………………………….442
Refitting……………………………………………………………………………..442
COMPRESSED AIR CIRCUIT……………………………………………………………………..443
AIR COMPRESSOR…………………………………………………………………………443
Removal……………………………………………………………………………443
Refitting………………………………………………………………………….444
COMPRESSOR DRIVEBELT……………………………………………………………………445
Removal……………………………………………………………………………445
Refitting………………………………………………………………………….445
Tensioning…………………………………………………………………………446
FRONT PTO…………………………………………………………………………………447
COMPLETE ASSEMBLY………………………………………………………………………447
Removal……………………………………………………………………………447
Refitting………………………………………………………………………….447
FLEXIBLE COUPLING………………………………………………………………………448
Renewal……………………………………………………………………………448
Refitting………………………………………………………………………….448
FRONT AXLE DRIVE SHAFT……………………………………………………………………..449
Removal……………………………………………………………………………….449
Refitting……………………………………………………………………………..450
FRONT SUPPORT……………………………………………………………………………..451
COMPLETE ASSEMBLY (Version without front axle suspension)…………………………………..451
Removal……………………………………………………………………………451
Refitting………………………………………………………………………….452
BRAKE MASTER CYLINDERS……………………………………………………………………..453
Removal……………………………………………………………………………….453
Refitting……………………………………………………………………………..455
POWER STEERING…………………………………………………………………………….456
STEERING VALVE ASSEMBLY…………………………………………………………………456
Removal……………………………………………………………………………456
Refitting………………………………………………………………………….458
Disassembly………………………………………………………………………..459
Assembly…………………………………………………………………………..465
RELIEF VALVE…………………………………………………………………………..476
Testing the operating pressure……………………………………………………….476
Adjusting the operating pressure……………………………………………………..476
HYDRAULIC PUMPS……………………………………………………………………………477
TRANSMISSION PUMP………………………………………………………………………477
Removal……………………………………………………………………………477
Refitting………………………………………………………………………….478
STEERING AND SERVICES PUMP………………………………………………………………481
Removal……………………………………………………………………………481
Refitting………………………………………………………………………….483
COMPLETE EXHAUST SYSTEM…………………………………………………………………….484
SILENCER………………………………………………………………………………484
Removal……………………………………………………………………………484
Refitting………………………………………………………………………….484
EXHAUST PIPE…………………………………………………………………………..485
Removal……………………………………………………………………………485
Refitting………………………………………………………………………….485
CAB………………………………………………………………………………………486
Removal……………………………………………………………………………….486
Refitting……………………………………………………………………………..492
ENGINE……………………………………………………………………………………493
Preparation for removal…………………………………………………………………493
Preparation before separating the engine from the transmission………………………………493
Separation or removal…………………………………………………………………..494
Refitting……………………………………………………………………………..498
TORSIONAL SPRING PLATE……………………………………………………………………..499
Removal……………………………………………………………………………….499
Refitting……………………………………………………………………………..499
FLOOR MAT…………………………………………………………………………………500
Removal……………………………………………………………………………….500
Removal……………………………………………………………………………….500
DRIVER’S SEAT……………………………………………………………………………..501
Removal……………………………………………………………………………….501
Refitting……………………………………………………………………………..501
ACCELERATOR PEDAL POTENTIOMETER……………………………………………………………..502
Removal……………………………………………………………………………….502
Refitting……………………………………………………………………………..503
CONSOLE SHROUDS ON RIGHT SIDE……………………………………………………………….504
REMOTE VALVE LEVERS SHROUD………………………………………………………………504
Removal……………………………………………………………………………504
Refitting………………………………………………………………………….504
RIGHT-HAND CONSOLE……………………………………………………………………..505
Removal……………………………………………………………………………505
Refitting………………………………………………………………………….507
CONTROL CABLES…………………………………………………………………………….508
REMOTE VALVE CROSS-GATE CONTROL LEVER…………………………………………………….508
Removal……………………………………………………………………………508
Refitting………………………………………………………………………….508
REMOTE CONTROL VALVE – 3rd SPOOL CONTROL………………………………………………….509
Removal……………………………………………………………………………509
Refitting………………………………………………………………………….509
REAR PTO SPEED SELECTOR LEVER……………………………………………………………510
Removal……………………………………………………………………………510
Refitting………………………………………………………………………….511
GEARSHIFT CONTROL………………………………………………………………………512
Removal……………………………………………………………………………512
Refitting………………………………………………………………………….513
PARKING BRAKE……………………………………………………………………………..514
CONTROL CABLE………………………………………………………………………….514
Removal……………………………………………………………………………514
Refitting………………………………………………………………………….515
PARKING BRAKE LEVER…………………………………………………………………….516
Adjustment…………………………………………………………………………516
SERVICE BRAKE……………………………………………………………………………..517
BRAKE…………………………………………………………………………………517
Adjustment…………………………………………………………………………517
STEERING WHEEL…………………………………………………………………………….518
Removal……………………………………………………………………………….518
Refitting……………………………………………………………………………..518
SHUTTLE LEVER……………………………………………………………………………..519
Removal……………………………………………………………………………….519
Refitting……………………………………………………………………………..520
STEERING COLUMN SWITCH UNIT…………………………………………………………………521
Removal……………………………………………………………………………….521
Refitting……………………………………………………………………………..522
FRONT CONSOLE……………………………………………………………………………..523
Removal……………………………………………………………………………….523
Refitting……………………………………………………………………………..525
CLUTCH PEDAL AND ACCESSORIES………………………………………………………………..526
POSITION SENSOR………………………………………………………………………..526
Removal……………………………………………………………………………526
Refitting………………………………………………………………………….526
PROXIMITY SENSOR (Clutch pedal depressed sensor)…………………………………………..529
Removal……………………………………………………………………………529
Refitting………………………………………………………………………….529
CAB DOOR CABLE…………………………………………………………………………….530
Renewal……………………………………………………………………………….530
LIFT DRAFT SENSOR………………………………………………………………………….532
Removal……………………………………………………………………………….532
Refitting……………………………………………………………………………..532
LIFT POSITION SENSOR……………………………………………………………………….533
Check…………………………………………………………………………………533
Removal……………………………………………………………………………….533
Renewal of the position sensor bush (only if necessary)…………………………………….534
Refitting……………………………………………………………………………..534
Adjustment…………………………………………………………………………….534
LIFT DRAFT SENSOR………………………………………………………………………….536
Removal……………………………………………………………………………….536
Refitting……………………………………………………………………………..536
SECTION 40……………………………………………………………………………………537
THE STRUCTURE OF THE UNIT…………………………………………………………………..539
HOW TO CONSULT THE UNIT…………………………………………………………………….540
1. INTRODUCTION……………………………………………………………………………541
1.1 LIST OF WIRING HARNESSES…………………………………………………………….541
1.2 DEFINITION OF COMPONENTS AND SYMBOLS………………………………………………….542
1.3 GENERAL RULES………………………………………………………………………543
1.3.1 MODIFICATION OF THE TRACTOR’S ELECTRICAL/ELECTRONIC CIRCUITS……………………….543
1.3.2 MAIN WIRING FAULTS…………………………………………………………….543
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRINGI……………………………544
1.4 DIAGNOSTIC INSTRUMENTS………………………………………………………………545
1.5 WIRE COLOUR CODES…………………………………………………………………..545
2. INDEX………………………………………………………………………………….546
2.1 INDEX BY PART DESCRIPTION……………………………………………………………546
2.2 COMPONENT CODE INDEX………………………………………………………………..554
2.3 CONNECTOR INDEX…………………………………………………………………….560
3. COMPONENTS……………………………………………………………………………..570
3.1 COMPONENT TECHNICAL DATA…………………………………………………………….570
3.2 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS……………………………………578
3.2.1 ENGINE CONTROL UNIT (0421.3098)…………………………………………………578
3.2.2 TRANSMISSION CONTROL UNIT (2.8519.028.0)…………………………………………580
3.2.3 HLHP CONTROL UNIT (CODE 2.8519.027.0/10)…………………………………………582
3.2.4 INFOCENTER……………………………………………………………………585
4. SYSTEMS………………………………………………………………………………..587
4.1 EARTHING POINTS…………………………………………………………………….587
4.2 STARTING THE ENGINE…………………………………………………………………588
4.3 PRE-HEATING………………………………………………………………………..589
4.4 ELECTRONIC ENGINE CONTROL……………………………………………………………590
4.5 LIGHTS – STEERING COLUMN SWITCH UNIT (VERSION WITHOUT FRONT LIFT)………………………..591
4.6 LIGHTS – STEERING COLUMN SWITCH UNIT (VERSION WITH FRONT LIFT)…………………………..592
4.7 DIAGNOSTICS ACCESSORIES……………………………………………………………..593
4.8 WORKLIGHTS (VERSION WITHOUT DEMISTING MIRRORS)…………………………………………594
4.9 WORKLIGHTS (VERSION WITH DEMISTING MIRRORS)……………………………………………595
4.10 WINDSCREEN WIPERS………………………………………………………………….596
4.11 INSTRUMENT PANEL…………………………………………………………………..597
4.12 RADIO…………………………………………………………………………….598
4.13 MANUAL AIR CONDITIONER……………………………………………………………..599
4.14 BRAKES……………………………………………………………………………600
4.15 FRONT AXLE SUSPENSION………………………………………………………………601
4.16 TRANSMISSION………………………………………………………………………602
4.17 ASM – FOUR-WHEEL DRIVE – DIFFERENTIAL………………………………………………..603
4.18 ELECTRONIC LIFT……………………………………………………………………604
4.19 FRONT AND REAR PTO…………………………………………………………………605
4.20 CONTROL VALVES…………………………………………………………………….606
4.21 CAN BUS…………………………………………………………………………..607
5. WIRING…………………………………………………………………………………609
ENGINE WIRING (4 CYLINDERS) (1/2)………………………………………………………..609
ENGINE WIRING (4 CYLINDERS) (2/2)………………………………………………………..610
ENGINE WIRING (6 CYLINDERS) (1/2)………………………………………………………..611
ENGINE WIRING (6 CYLINDERS) (2/2)………………………………………………………..612
ENGINE BONNET WIRING……………………………………………………………………617
FRONT WORKLIGHTS WIRING…………………………………………………………………618
RIGHT-HAND TRANSMISSION WIRING (1/2)……………………………………………………..621
RIGHT-HAND TRANSMISSION WIRING (2/2)……………………………………………………..622
LEFT-HAND TRANSMISSION WIRING (1/2)………………………………………………………629
LEFT-HAND TRANSMISSION WIRING (2/2)………………………………………………………630
TRAILER BRAKE WIRING (ITALY)…………………………………………………………….639
TRAILER BRAKE WIRING (GERMANY)…………………………………………………………..641
FRONT AXLE SUSPENSION WIRING…………………………………………………………….643
BATTERY POSITIVE WIRING – BATTERY NEGATIVE WIRING………………………………………….645
SUPPLY WIRING (1/2)…………………………………………………………………….646
SUPPLY WIRING (2/2)…………………………………………………………………….647
INSTRUMENT PANEL WIRING (1/2)……………………………………………………………653
INSTRUMENT PANEL WIRING (2/2)……………………………………………………………654
MUDGUARD WIRING………………………………………………………………………..655
WIRING FOR LIGHTS ON ARMS……………………………………………………………….656
WIRING FOR SUPPLEMENTARY LIGHTS ON ARMS…………………………………………………..657
UPPER LIGHTS WIRING (VERSION WITH LIFT)…………………………………………………..658
WIRING FOR WORKLIGHTS ON ARMS (VERSION WITHOUT LIFT)……………………………………….659
LIGHTS SELECTOR SWITCH WIRING……………………………………………………………673
CENTRAL WIRING (1/2)……………………………………………………………………675
CENTRAL WIRING (2/2)……………………………………………………………………676
ENGINE WIRING………………………………………………………………………….677
ROOF LINE WIRING (1/2)………………………………………………………………….685
ROOF LINE WIRING (2/2)………………………………………………………………….686
WIRING FOR WORKLIGHTS, DEFROST MIRROR ON CAB (HL VERSION)…………………………………..687
WIRING FOR WORKLIGHTS ON CAB (STANDARD VERSION)……………………………………………688
WINDSCREEN WIPER WIRING…………………………………………………………………689
ROTATING BEACON WIRING………………………………………………………………….690
CONTROL VALVE WIRING……………………………………………………………………697
CONTROL VALVE SOLENOID VALVE WIRING………………………………………………………698
CONTROL VALVE WIRING……………………………………………………………………699
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V