DEUTZ-FAHR Agrotron K90 K100 K110 K120 Profiline Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR Agrotron K90 K100 K110 K120 Profiline Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR Agrotron K90 K100 K110 K120 Profiline 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.
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.
TABLE OF CONTENTS:
DEUTZ-FAHR Agrotron K90 K100 K110 K120 Profiline Workshop Manual – PDF DOWNLOAD
307.1132.3.6 AGROTRON K 90-100-110-120 PROFILE Ing…………………………………………………………………………………… 1
SECTION 00…………………………………………………………………………………………………………………… 3
INTRODUCTION……………………………………………………………………………………………………………… 4
SAFETY NOTES……………………………………………………………………………………………………………… 6
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS……………………………………………………………………….. 9
LIFTING INSTRUCTIONS………………………………………………………………………………………………………. 11
WIRE ROPES – SLINGS……………………………………………………………………………………………………. 11
HOW THE MANUAL IS STRUCTURED……………………………………………………………………………………………….. 12
HOW TO CONSULT THE MANUAL………………………………………………………………………………………………….. 13
1. Removal and refitting of assembled units………………………………………………………………………………. 13
3. List of special tools……………………………………………………………………………………………….. 13
4. Tightening torques………………………………………………………………………………………………….. 13
HOW TO USE AND UPDATE THE MANUAL……………………………………………………………………………………………. 14
1. UPDATING THE MANUAL…………………………………………………………………………………………………. 14
2. INSERTING UPDATES…………………………………………………………………………………………………… 14
3. SYMBOLS USED IN THE MANUAL…………………………………………………………………………………………… 14
TIGHTENING TORQUES………………………………………………………………………………………………………… 15
1. BOLTS AND NUTS……………………………………………………………………………………………………… 15
2. FITTINGS…………………………………………………………………………………………………………… 16
3. PLUGS……………………………………………………………………………………………………………… 17
4. FITTINGS WITH SEAL AT 37……………………………………………………………………………………………. 18
5. FITTINGS FOR PIPES WITH BANJO UNION…………………………………………………………………………………… 18
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS…………………………………………………………………………….. 19
CONVERSION FACTORS………………………………………………………………………………………………………… 21
CONVERSION FROM BRITISH TO METRIC UNITS………………………………………………………………………………….. 21
CONVERSION FROM METRIC TO BRITISH UNITS………………………………………………………………………………….. 21
SECTION 10…………………………………………………………………………………………………………………… 22
1. TRANSMISSION…………………………………………………………………………………………………………… 0
INTRODUCTION………………………………………………………………………………………………………….. 24
1.1 POWER SHUTTLE TRANSMISSION………………………………………………………………………………………….. 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 CONTROL VALVE……………………………………………………………………… 32
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC………………………………………………………….. 35
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC………………………………………………………………………… 36
1.2 REAR AXLE…………………………………………………………………………………………………………. 38
1.3 REAR PTO………………………………………………………………………………………………………….. 40
2. BRAKING SYSTEM…………………………………………………………………………………………………………. 42
DESCRIPTION…………………………………………………………………………………………………………… 42
2.1 BRAKE MASTER CYLINDER………………………………………………………………………………………………. 43
2.2 BRAKE…………………………………………………………………………………………………………….. 44
2.3 TRAILER BRAKING SYSTEM……………………………………………………………………………………………… 45
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)……………………………………………………………………….. 45
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)………………………………………………………………………. 47
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)…………………………………………………………………………….. 49
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)……………………………………………………………………………. 50
COMPRESSOR………………………………………………………………………………………………………… 51
ANTIFREEZE PUMP……………………………………………………………………………………………………. 52
PRESSURE LIMITING VALVE…………………………………………………………………………………………….. 53
TRAILER BRAKING VALVE (2-WAY)……………………………………………………………………………………….. 54
TRAILER BRAKING VALVE (1-WAY)……………………………………………………………………………………….. 55
3. HYDRAULIC FRONT AXLE SUSPENSION………………………………………………………………………………………….. 56
DESCRIPTION…………………………………………………………………………………………………………… 56
3.1 FRONT SUSPENSION CONTROL VALVE………………………………………………………………………………………. 57
4. FRONT AXLE…………………………………………………………………………………………………………….. 62
5. HYDRAULIC SYSTEM……………………………………………………………………………………………………….. 63
DESCRIPTION…………………………………………………………………………………………………………… 63
5.2 GEAR PUMP FOR TRANSMISSION ZF 7100…………………………………………………………………………………… 66
5.3 VARIABLE DISPLACEMENT PUMP………………………………………………………………………………………….. 67
5.3.1 HYDRAULIC PUMP……………………………………………………………………………………………….. 70
5.3.2. LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE……………………………………………………………………… 72
5.4 STEERING GEAR PUMP…………………………………………………………………………………………………. 80
5.5 POWER STEERING…………………………………………………………………………………………………….. 81
5.6 AUXILIARY SERVICES CONTROL VALVE…………………………………………………………………………………….. 82
5.6.1 CONTROL VALVE TYPES…………………………………………………………………………………………… 83
5.6.2 LIFT CONTROL ELEMENT………………………………………………………………………………………….. 85
CONTENTS…………………………………………………………………………………………………………………. 22
SECTION 20…………………………………………………………………………………………………………………… 90
1. DIAGNOSIS TOOLS………………………………………………………………………………………………………… 92
1.1 ALL ROUND TESTER…………………………………………………………………………………………………… 92
1.1.1 DESCRIPTION OF THE KIT………………………………………………………………………………………… 92
1.1.2 NOTES ON CORRECT USE………………………………………………………………………………………….. 93
1.1.3 DESCRIPTION OF THE TESTER……………………………………………………………………………………… 93
1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER……………………………………………………………. 94
1.1.5 SELECTION OF THE DISPLAY LANGUAGE………………………………………………………………………………. 94
1.1.6 SETTING THE SERIAL PORTS………………………………………………………………………………………. 96
1.2 “SERDIA 2000 LEVEL III” SOFTWARE…………………………………………………………………………………….. 98
1.2.1 DESCRIPTION OF THE KIT………………………………………………………………………………………… 98
1.3 “EDS EST45” SOFTWARE”………………………………………………………………………………………………. 99
1.3.1 DESCRIPTION OF THE KIT………………………………………………………………………………………… 99
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS……………………………………………………………………….100
2.1 CONNECTING ART® TO THE HLHP CONTROL UNITS……………………………………………………………………………..100
2.2 CONNECTING THE LAPTOP COMPUTER WITH “SERDIA 2000” SOFTWARE TO THE ENGINE CONTROL UNIT………………………………………101
3. INTRODUCTION TO THE TRACTOR ELECTRONIC SYSTEM………………………………………………………………………………102
3.1 ELECTRONIC SYSTEM…………………………………………………………………………………………………..102
3.2 CANBUS SYSTEM………………………………………………………………………………………………………103
3.3 TRANSMISSION CONTROL UNIT……………………………………………………………………………………………111
3.4 INFOCENTER…………………………………………………………………………………………………………112
4. PUTTING THE TRACTOR INTO SERVICE………………………………………………………………………………………….114
4.1 INTRODUCTION……………………………………………………………………………………………………….114
4.2 RENEWING THE ENGINE CONTROL UNIT……………………………………………………………………………………..114
4.2.1 READING AND SAVING DATA………………………………………………………………………………………..114
4.2.2 PROGRAMMING THE CONTROL UNIT……………………………………………………………………………………115
4.2.3 PROCEDURE FOR SETTING ENGINE OPERATING HOURS……………………………………………………………………..116
4.2.4 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE SERDIA PROGRAM)…………………………………………………….117
4.2.5 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE ART)………………………………………………………………118
4.2.6 CALIBRATION OF THE HAND THROTTLE (USING THE SERDIA PROGRAM)………………………………………………………..119
4.2.7 CALIBRATION OF THE HAND THROTTLE (USING THE ART)………………………………………………………………….120
4.3 RENEWING THE TRANSMISSION CONTROL UNIT………………………………………………………………………………..123
4.3.1 MODEL CONFIGURATION……………………………………………………………………………………………123
4.3.2 CONFIGURATION OF THE BASIC WHEEL………………………………………………………………………………..126
4.3.3 CONFIGURATION OF THE WHEEL CIRCUMFERENCE (USING THE ART)…………………………………………………………..128
4.3.4 CALIBRATION OF THE WHEEL CIRCUMFERENCE (WITHOUT USING THE ART)……………………………………………………..130
4.3.5 CONFIGURATION OF THE MAXIMUM TRAVEL SPEED (GERMAN MARKET ONLY)……………………………………………………..131
4.3.6 CALIBRATION OF THE CLUTCH PEDAL…………………………………………………………………………………133
4.3.7 CALIBRATION OF THE MAIN CLUTCH………………………………………………………………………………….135
4.3.8 CALIBRATION OF THE FIELD/ROAD SENSOR…………………………………………………………………………….137
4.3.9 CLEARING ALL ALARMS……………………………………………………………………………………………139
4.4 RENEWING THE HLHP CONTROL UNIT (VALID UP TO SOFTWARE SC.0038.AC)…………………………………………………………140
4.4.1 INITIALIZATION OF THE HLHP CONTROL UNIT………………………………………………………………………….140
4.4.2 CONFIGURING THE SYSTEM FOR THE PRESENCE OF THE FRONT PTO (ONLY IF INSTALLED)…………………………………………142
4.4.3 ENABLING THE ASM SYSTEM (ONLY IF INSTALLED)………………………………………………………………………143
4.4.4 CALIBRATION OF THE STEERING ANGLE SENSOR (WITH ASM ONLY)…………………………………………………………..145
4.4.5 CONFIGURING THE SYSTEM FOR THE PRESENCE OF RADAR (ONLY IF INSTALLED)………………………………………………..146
4.4.6 CALIBRATION OF THE HIGH AND LOW POSITIONS OF THE LIFT……………………………………………………………..148
4.4.7 CONFIGURING THE SYSTEM FOR THE PRESENCE OF FRONT AXLE SUSPENSION (ONLY IF INSTALLED)………………………………….150
4.4.8 SETTING THE INFOCENTER DISPLAY LANGUAGE………………………………………………………………………….152
4.4.9 CLEARING ALL ALARMS……………………………………………………………………………………………153
4.5 RENEWING THE HLHP CONTROL UNIT (VALID UP TO SOFTWARE SC.0038.AD)…………………………………………………………155
4.5.1 INITIALIZATION OF THE HLHP CONTROL UNIT………………………………………………………………………….155
4.5.2 CONFIGURATION OF THE TRACTOR MODEL………………………………………………………………………………157
4.5.3 CONFIGURING THE SYSTEM FOR THE PRESENCE OF THE FRONT PTO (ONLY IF INSTALLED)…………………………………………158
4.5.4 ENABLING THE ASM SYSTEM (ONLY IF INSTALLED)………………………………………………………………………159
4.5.5 CALIBRATION OF THE STEERING ANGLE SENSOR (WITH ASM ONLY)…………………………………………………………..161
4.5.6 CONFIGURING THE SYSTEM FOR THE PRESENCE OF RADAR (ONLY IF INSTALLED)………………………………………………..162
4.5.7 CALIBRATION OF THE HIGH AND LOW POSITIONS OF THE LIFT……………………………………………………………..164
4.5.8 CONFIGURING THE SYSTEM FOR THE PRESENCE OF FRONT AXLE SUSPENSION (ONLY IF INSTALLED)………………………………….166
4.5.9 SETTING THE INFOCENTER DISPLAY LANGUAGE………………………………………………………………………….168
4.5.10 CONFIGURE THE ASSOCIATION BETWEEN CONTROL VALVE LEVERS AND AUXILIARY SERVICES (FOR VERSIONS WITH 4 CONTROL VALVES ONLY)….169
4.5.11 CLEARING ALL ALARMS…………………………………………………………………………………………..171
4.6 RENEWAL OF THE ARMREST CONTROL UNIT…………………………………………………………………………………..172
5. ALARMS…………………………………………………………………………………………………………………178
INTRODUCTION…………………………………………………………………………………………………………..178
5.1 ALARMS DISPLAYED ON THE INFOCENTER……………………………………………………………………………………179
5.2 HLHP CONTROL UNIT ALARMS…………………………………………………………………………………………….190
5.3 ENGINE CONTROL UNIT ALARMS…………………………………………………………………………………………..262
5.6 CANBUS ALARMS………………………………………………………………………………………………………286
5.4 TRANSMISSION CONTROL UNIT ALARMS……………………………………………………………………………………..296
5.4.1 DEFINITION OF TRANSMISSION OPERATING MODES……………………………………………………………………….296
5.4.2 SYSTEM ANOMALIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT……………………………………………………..297
5.5 ARMREST ALARMS……………………………………………………………………………………………………..378
6. ENGINE CONTROL UNIT TESTER PROGRAM………………………………………………………………………………………..388
6. 1 ACCESS AND COMUNICATION…………………………………………………………………………………………….388
6. 1.1 MINIMUM RESOURCES…………………………………………………………………………………………….388
6. 1.2 ORDERING…………………………………………………………………………………………………….388
6. 1.3 CONNECTION OF NOTEBOOK AND SOFTWARE INSTALLATION…………………………………………………………………389
6. 1.4 PROGRAM COMMANDS……………………………………………………………………………………………..393
6. 1.5 END COMMUNICATION…………………………………………………………………………………………….395
6. 2 CONTROL UNIT SELECTION……………………………………………………………………………………………..396
6. 2.1 SELECTION OF TWO CONTROL UNITS…………………………………………………………………………………396
6. 2.2 PRINT (EXPORT)……………………………………………………………………………………………….397
6. 2.3 PROTOCOL…………………………………………………………………………………………………….398
6. 2.4 IDENTIFICATION AND MEASUREMENT DATA…………………………………………………………………………….398
6. 3 MEASUREMENT VALUES…………………………………………………………………………………………………399
6. 3.1 CURRENT VALUES (IN GENERAL)……………………………………………………………………………………399
6. 3.2 RAM VALUES…………………………………………………………………………………………………..403
6. 3.3 INPUT/OUTPUT CONFIGURATION…………………………………………………………………………………….408
6. 3.4 CAN STATUS…………………………………………………………………………………………………..408
6. 4 PARAMETERS………………………………………………………………………………………………………..411
6. 4.1 CONFIGURATION (GENERAL)……………………………………………………………………………………….411
6. 4.2 COMPLETE PROGRAMMING………………………………………………………………………………………….412
6. 4.3 CALIBRATION………………………………………………………………………………………………….413
6. 5 FAULTS MEMORY……………………………………………………………………………………………………..414
6. 5.1 GENERAL INFORMATION…………………………………………………………………………………………..414
6. 6 EXTRA…………………………………………………………………………………………………………….416
6. 6.1 TOP SPEED……………………………………………………………………………………………………416
6. 6.2 LOGISTIC DATA………………………………………………………………………………………………..416
6. 6.3 LOADS COLLECTIVE……………………………………………………………………………………………..417
6. 7 ACTIVITY………………………………………………………………………………………………………….418
6. 7.1 EMR2………………………………………………………………………………………………………..418
6. 8 WHAT TO DO IF…?………………………………………………………………………………………………….422
6. 8.1 SERDIA IN GENERAL…………………………………………………………………………………………….422
6. 8.2 EMR2………………………………………………………………………………………………………..423
Definition of parameters…………………………………………………………………………………………….426
Configuration………………………………………………………………………………………………………426
SECTION 30…………………………………………………………………………………………………………………… 0
CONTENTS………………………………………………………………………………………………………………….434
ENGINE HOOD……………………………………………………………………………………………………………….438
Removal……………………………………………………………………………………………………………….438
Refitting……………………………………………………………………………………………………………..438
WHEELS……………………………………………………………………………………………………………………439
FRONT WHEELS…………………………………………………………………………………………………………..439
Removal……………………………………………………………………………………………………………439
Refitting………………………………………………………………………………………………………….439
REAR WHEELS……………………………………………………………………………………………………………440
Removal……………………………………………………………………………………………………………440
Refitting………………………………………………………………………………………………………….440
FRONT FENDERS……………………………………………………………………………………………………………..441
Removal……………………………………………………………………………………………………………….441
Refitting……………………………………………………………………………………………………………..441
CAB ACCESS STEPS…………………………………………………………………………………………………………..442
Removal……………………………………………………………………………………………………………….442
Refitting……………………………………………………………………………………………………………..442
FUEL TANK…………………………………………………………………………………………………………………443
Removal……………………………………………………………………………………………………………….443
Refitting……………………………………………………………………………………………………………..445
COOLERS-RADIATOR ASSEMBLY…………………………………………………………………………………………………..446
COMPLETE ASSEMBLY………………………………………………………………………………………………………446
Removal……………………………………………………………………………………………………………446
Refitting………………………………………………………………………………………………………….450
FUEL COOLER……………………………………………………………………………………………………………451
Removal……………………………………………………………………………………………………………451
Refitting………………………………………………………………………………………………………….451
TRANSMISSION OIL COOLER…………………………………………………………………………………………………452
Removal……………………………………………………………………………………………………………452
Refitting………………………………………………………………………………………………………….453
ENGINE COOLING SYSTEM RADIATOR…………………………………………………………………………………………..454
Removal……………………………………………………………………………………………………………454
Refitting………………………………………………………………………………………………………….457
AIR FILTER ASSEMBLY…………………………………………………………………………………………………….458
Removal……………………………………………………………………………………………………………458
Refitting………………………………………………………………………………………………………….458
INTERCOOLER……………………………………………………………………………………………………………459
Removal……………………………………………………………………………………………………………459
Refitting………………………………………………………………………………………………………….459
AIR CONDITIONING SYSTEM…………………………………………………………………………………………………….460
TECHNICAL SPECIFICATIONS………………………………………………………………………………………………..460
Operation……………………………………………………………………………………………………………..461
Evacuation, flushing and recharging………………………………………………………………………………………462
1. Emptying the system………………………………………………………………………………………………….462
2. Flushing and recharging the system…………………………………………………………………………………….462
FILTER – DRIER…………………………………………………………………………………………………………464
Removal……………………………………………………………………………………………………………464
Refitting………………………………………………………………………………………………………….464
CONDENSER ASSEMBLY……………………………………………………………………………………………………..465
Removal……………………………………………………………………………………………………………465
Refitting………………………………………………………………………………………………………….465
COMPRESSOR…………………………………………………………………………………………………………….466
Removal……………………………………………………………………………………………………………466
Refitting………………………………………………………………………………………………………….467
HEATER ASSEMBLY (MANUAL VERSION)…………………………………………………………………………………………….468
COMPLETE ASSEMBLY………………………………………………………………………………………………………468
Removal……………………………………………………………………………………………………………468
Refitting………………………………………………………………………………………………………….470
UPPER HALF DUCT………………………………………………………………………………………………………..471
Assembly…………………………………………………………………………………………………………..471
FANS………………………………………………………………………………………………………………….472
Disassembly………………………………………………………………………………………………………..472
Assembly…………………………………………………………………………………………………………..472
HEATER MATRIX………………………………………………………………………………………………………….473
Disassembly………………………………………………………………………………………………………..473
Assembly…………………………………………………………………………………………………………..473
AIR CONDITIONING EVAPORATOR……………………………………………………………………………………………..474
Disassembly………………………………………………………………………………………………………..474
Assembly…………………………………………………………………………………………………………..474
ENGINE COOLING FAN ASSEMBLY…………………………………………………………………………………………………475
ENGINE COOLING FAN……………………………………………………………………………………………………..475
Removal……………………………………………………………………………………………………………475
Refitting………………………………………………………………………………………………………….476
ENGINE FAN DRIVE BELT…………………………………………………………………………………………………..477
Removal……………………………………………………………………………………………………………477
Refitting………………………………………………………………………………………………………….478
Tensioning…………………………………………………………………………………………………………479
ALTERNATOR ASSEMBLY………………………………………………………………………………………………………..480
ALTERNATOR…………………………………………………………………………………………………………….480
Removal……………………………………………………………………………………………………………480
Refitting………………………………………………………………………………………………………….480
ALTERNATOR DRIVEBELT……………………………………………………………………………………………………481
Removal……………………………………………………………………………………………………………481
Refitting………………………………………………………………………………………………………….482
Tensioning…………………………………………………………………………………………………………483
STARTER MOTOR……………………………………………………………………………………………………………..484
Removal……………………………………………………………………………………………………………….484
Refitting……………………………………………………………………………………………………………..484
COMPRESSED AIR CIRCUIT……………………………………………………………………………………………………..485
AIR COMPRESSOR…………………………………………………………………………………………………………485
Removal……………………………………………………………………………………………………………485
Refitting………………………………………………………………………………………………………….486
COMPRESSOR DRIVE BELT…………………………………………………………………………………………………..487
Removal……………………………………………………………………………………………………………487
Refitting………………………………………………………………………………………………………….487
Tensioning…………………………………………………………………………………………………………488
FRONT PTO…………………………………………………………………………………………………………………489
ASSEMBLY………………………………………………………………………………………………………………489
Removal……………………………………………………………………………………………………………489
Refitting………………………………………………………………………………………………………….489
FLEXIBLE COUPLING………………………………………………………………………………………………………490
Renewal……………………………………………………………………………………………………………490
Refitting………………………………………………………………………………………………………….490
FRONT AXLE DRIVE SHAFT……………………………………………………………………………………………………..491
Removal……………………………………………………………………………………………………………….491
Refitting……………………………………………………………………………………………………………..493
FRONT AXLE………………………………………………………………………………………………………………..494
VERSION WITHOUT AXLE SUSPENSION………………………………………………………………………………………….494
Removal……………………………………………………………………………………………………………494
Refitting………………………………………………………………………………………………………….495
VERSION WITH AXLE SUSPENSION…………………………………………………………………………………………….496
Removal……………………………………………………………………………………………………………496
Refitting………………………………………………………………………………………………………….499
FRONT SUPPORT……………………………………………………………………………………………………………..500
COMPLETE ASSEMBLY (Version without axle suspension)………………………………………………………………………..500
Removal……………………………………………………………………………………………………………500
Refitting………………………………………………………………………………………………………….501
COMPLETE ASSEMBLY (Version with axle suspension)…………………………………………………………………………..502
Removal……………………………………………………………………………………………………………502
Refitting………………………………………………………………………………………………………….504
FRONT AXLE SUSPENSION………………………………………………………………………………………………………505
FRONT SUSPENSION CONTROL VALVE…………………………………………………………………………………………..505
Removal……………………………………………………………………………………………………………505
Refitting………………………………………………………………………………………………………….508
FRONT SUSPENSION POSITION SENSOR…………………………………………………………………………………………509
Removal……………………………………………………………………………………………………………509
Positioning………………………………………………………………………………………………………..509
Checking…………………………………………………………………………………………………………..510
FRONT SUSPENSION CYLINDERS………………………………………………………………………………………………511
Removal……………………………………………………………………………………………………………511
Refitting………………………………………………………………………………………………………….513
Disassembly………………………………………………………………………………………………………..514
Assembly…………………………………………………………………………………………………………..515
BRAKE CYLINDERS……………………………………………………………………………………………………………516
Removal……………………………………………………………………………………………………………….516
Refitting……………………………………………………………………………………………………………..518
POWER STEERING PUMP………………………………………………………………………………………………………..519
STEERING VALVE ASSEMBLY…………………………………………………………………………………………………519
Removal……………………………………………………………………………………………………………519
Refitting………………………………………………………………………………………………………….521
Disassembly………………………………………………………………………………………………………..522
Assembly…………………………………………………………………………………………………………..527
RELIEF VALVE…………………………………………………………………………………………………………..537
Testing the operating pressure……………………………………………………………………………………….537
Adjusting the calibration……………………………………………………………………………………………537
BATTERY SUPPORT………………………………………………………………………………………………………..538
Removal……………………………………………………………………………………………………………538
Refitting………………………………………………………………………………………………………….539
HYDRAULIC PUMPS……………………………………………………………………………………………………………540
TRANSMISSION PUMP………………………………………………………………………………………………………540
Removal……………………………………………………………………………………………………………540
Refitting………………………………………………………………………………………………………….542
SERVICES PUMP………………………………………………………………………………………………………….545
Removal……………………………………………………………………………………………………………545
Refitting………………………………………………………………………………………………………….548
STEERING PUMP………………………………………………………………………………………………………….549
Removal……………………………………………………………………………………………………………549
Refitting………………………………………………………………………………………………………….550
EXHAUST SYSTEM…………………………………………………………………………………………………………….551
SILENCER………………………………………………………………………………………………………………551
Removal……………………………………………………………………………………………………………551
Refitting………………………………………………………………………………………………………….551
EXHAUST PIPE…………………………………………………………………………………………………………..552
Removal……………………………………………………………………………………………………………552
Refitting………………………………………………………………………………………………………….553
CAB………………………………………………………………………………………………………………………554
Removal……………………………………………………………………………………………………………….554
Refitting……………………………………………………………………………………………………………..562
ENGINE……………………………………………………………………………………………………………………563
Preparation for removal…………………………………………………………………………………………………563
Preparation before separating the engine from the transmission………………………………………………………………563
Separation or removal…………………………………………………………………………………………………..564
Refitting……………………………………………………………………………………………………………..568
TORSIONAL SPRING PLATE……………………………………………………………………………………………………..569
Removal……………………………………………………………………………………………………………….569
Refitting……………………………………………………………………………………………………………..569
FLOOR MAT…………………………………………………………………………………………………………………570
Removal……………………………………………………………………………………………………………….570
Refitting……………………………………………………………………………………………………………..570
MULTIFUNCTION ARMREST………………………………………………………………………………………………………571
Removal……………………………………………………………………………………………………………….571
Refitting……………………………………………………………………………………………………………..571
SEAT……………………………………………………………………………………………………………………..572
Removal……………………………………………………………………………………………………………….572
Refitting……………………………………………………………………………………………………………..572
ACCELERATOR PEDAL POTENTIOMETER……………………………………………………………………………………………..573
Removal……………………………………………………………………………………………………………….573
Refitting……………………………………………………………………………………………………………..574
RIGHT-HAND CONSOLE…………………………………………………………………………………………………………575
Removal……………………………………………………………………………………………………………….575
Refitting……………………………………………………………………………………………………………..577
CREEPER…………………………………………………………………………………………………………………..578
CONTROL CABLES…………………………………………………………………………………………………………578
Removal……………………………………………………………………………………………………………578
Refitting………………………………………………………………………………………………………….579
REAR PTO SPEED SELECTOR LEVER……………………………………………………………………………………………580
Removal……………………………………………………………………………………………………………580
Refitting………………………………………………………………………………………………………….581
GEARSHIFT CONTROL………………………………………………………………………………………………………582
Removal……………………………………………………………………………………………………………582
Refitting………………………………………………………………………………………………………….583
PARKING BRAKE……………………………………………………………………………………………………………..584
CONTROL CABLE………………………………………………………………………………………………………….584
Removal……………………………………………………………………………………………………………584
Refitting………………………………………………………………………………………………………….585
PARKING BRAKE LEVER…………………………………………………………………………………………………….586
Adjustment…………………………………………………………………………………………………………586
SERVICE BRAKE……………………………………………………………………………………………………………..587
BRAKE DEVICE…………………………………………………………………………………………………………..587
Adjustment…………………………………………………………………………………………………………587
STEERING WHEEL…………………………………………………………………………………………………………….588
Removal……………………………………………………………………………………………………………….588
Refitting……………………………………………………………………………………………………………..588
SHUTTLE LEVER……………………………………………………………………………………………………………..589
Removal……………………………………………………………………………………………………………….589
Refitting……………………………………………………………………………………………………………..590
LIGHTS SELECTOR SWITCH……………………………………………………………………………………………………..591
Removal……………………………………………………………………………………………………………….591
Refitting……………………………………………………………………………………………………………..592
FRONT CONSOLE……………………………………………………………………………………………………………..593
Removal……………………………………………………………………………………………………………….593
Refitting……………………………………………………………………………………………………………..595
CLUTCH PEDAL AND ACCESSORIES………………………………………………………………………………………………..596
POSITION SENSOR………………………………………………………………………………………………………..596
Removal……………………………………………………………………………………………………………596
Refitting………………………………………………………………………………………………………….596
PROXIMITY SENSOR (Clutch pedal depressed sensor)…………………………………………………………………………..599
Removal……………………………………………………………………………………………………………599
Refitting………………………………………………………………………………………………………….599
CAB DOOR LATCH CABLE……………………………………………………………………………………………………….600
Renewal……………………………………………………………………………………………………………….600
LIFT DRAFT SENSOR………………………………………………………………………………………………………….602
Removal……………………………………………………………………………………………………………….602
Refitting……………………………………………………………………………………………………………..602
LIFT POSITION SENSOR……………………………………………………………………………………………………….603
Checking………………………………………………………………………………………………………………603
Removal……………………………………………………………………………………………………………….603
Renewal of the position sensor bush (only if necessary)…………………………………………………………………….604
Refitting……………………………………………………………………………………………………………..604
Adjustment…………………………………………………………………………………………………………….604
AUXILIARY SERVICES CONTROL VALVE…………………………………………………………………………………………….606
Removal……………………………………………………………………………………………………………….606
Refitting……………………………………………………………………………………………………………..609
Disassembly……………………………………………………………………………………………………………610
Assembly………………………………………………………………………………………………………………611
SECTION 40……………………………………………………………………………………………………………………612
STRUCTURE OF THE UNIT………………………………………………………………………………………………………614
HOW TO CONSULT THE UNIT…………………………………………………………………………………………………….615
1. INTRODUCTION……………………………………………………………………………………………………………616
1.1 LIST OF WIRING HARNESSES…………………………………………………………………………………………….616
1.2 DEFINITION OF COMPONENTS AND SYMBOLS………………………………………………………………………………….617
1.3 GENERAL RULES………………………………………………………………………………………………………618
1.3.1 MODIFICATION OF THE TRACTOR’S ELECTRICAL/ELECTRONIC CIRCUITS……………………………………………………….618
1.3.2 MAIN WIRING FAULTS…………………………………………………………………………………………….618
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING…………………………………………………………….619
1.4 DIAGNOSTIC INSTRUMENTS………………………………………………………………………………………………620
1.5 WIRE COLOUR CODES…………………………………………………………………………………………………..620
2. INDEXES………………………………………………………………………………………………………………..621
2.1 INDEX BY PART DESCRIPTION……………………………………………………………………………………………621
2.2 INDEX BY PART CODE………………………………………………………………………………………………….627
2.3 INDEX BY CONNECTOR………………………………………………………………………………………………….633
3. COMPONENTS……………………………………………………………………………………………………………..642
3.1 COMPONENT TECHNICAL DATA…………………………………………………………………………………………….642
3.2 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS……………………………………………………………………649
3.2.1 ENGINE CONTROL UNIT (0421.3098)…………………………………………………………………………………649
3.2.2 TRANSMISSION CONTROL UNIT (2.8519.028.0)…………………………………………………………………………651
3.2.3 HLHP CONTROL UNIT (P/N 2.8519.027.0/10)………………………………………………………………………….653
3.2.4 INFOCENTER……………………………………………………………………………………………………656
4. SYSTEMS………………………………………………………………………………………………………………..658
4.1 EARTHING POINTS…………………………………………………………………………………………………….658
4.2 STARTING…………………………………………………………………………………………………………..659
4.3 PREHEATING…………………………………………………………………………………………………………660
4.4 ELECTRONIC ENGINE CONTROL……………………………………………………………………………………………661
4.5 LIGHTS – STEERING COLUMN SWITCH UNIT (VERSION WITHOUT FRONT LIFT)………………………………………………………..662
4.6 LIGHTS – STEERING COLUMN SWITCH UNIT (VERSION WITH FRONT LIFT)…………………………………………………………..663
4.7 DIAGNOSTICS ACCESSORIES……………………………………………………………………………………………..664
4.8 WORKLIGHTS (VERSION WITHOUT DEMISTING MIRRORS)…………………………………………………………………………665
4.9 WORKLIGHTS (VERSION WITH DEMISTING MIRRORS)……………………………………………………………………………666
4.10 WINDSCREEN WIPERS………………………………………………………………………………………………….667
4.11 INSTRUMENT PANEL…………………………………………………………………………………………………..668
4.12 RADIO…………………………………………………………………………………………………………….669
4.13 MANUAL AIR CONDITIONER……………………………………………………………………………………………..670
4.14 BRAKES……………………………………………………………………………………………………………671
4.15 FRONT AXLE SUSPENSION………………………………………………………………………………………………672
4.16 TRANSMISSION………………………………………………………………………………………………………673
4.17 ASM – 4WD – DIFFERENTIAL……………………………………………………………………………………………674
4.18 ELECTRONIC LIFT……………………………………………………………………………………………………675
4.19 FRONT AND REAR PTO…………………………………………………………………………………………………676
4.20 DIRECTIONAL CONTROL VALVES………………………………………………………………………………………….677
4.21 CAN BUS…………………………………………………………………………………………………………..678
5. WIRING LOOMS……………………………………………………………………………………………………………680
ENGINE WIRING (4 CYLINDERS) (1/2)………………………………………………………………………………………..680
ENGINE WIRING (4 CYLINDERS) (2/2)………………………………………………………………………………………..681
ENGINE WIRING (6 CYLINDERS) engine serial number-> 0109278 (1/2)…………………………………………………………….682
ENGINE WIRING (6 CYLINDERS )(2/2) engine serial number -> 0109278……………………………………………………………683
ENGINE WIRING (6 CYLINDERS) engine serial number 10063954 -> (1/2)…………………………………………………………..684
ENGINE WIRING (6 CYLINDERS) (2/2) engine serial number 10063954->……………………………………………………………685
ENGINE HOOD WIRING……………………………………………………………………………………………………..690
FRONT WORKLIGHTS WIRING…………………………………………………………………………………………………691
RIGHT-HAND TRANSMISSION WIRING (1/2)……………………………………………………………………………………..694
RIGHT-HAND TRANSMISSION WIRING (2/2)……………………………………………………………………………………..695
LEFT-HAND TRANSMISSION WIRING (1/2)………………………………………………………………………………………704
LEFT-HAND TRANSMISSION WIRING (2/2)………………………………………………………………………………………705
CONTROL VALVES WIRING 2/4……………………………………………………………………………………………….706
TRAILER BRAKE WIRING (ITALY)…………………………………………………………………………………………….716
TRAILER BRAKE WIRING (GERMANY)…………………………………………………………………………………………..718
FRONT AXLE SUSPENSION WIRING…………………………………………………………………………………………….720
BATTERY POSITIVE WIRING – BATTERY NEGATIVE WIRING………………………………………………………………………….723
POWER SUPPLY WIRING (1/2)……………………………………………………………………………………………….724
POWER SUPPLY WIRING (2/2)……………………………………………………………………………………………….725
CAB EARTH WIRING……………………………………………………………………………………………………….726
INSTRUMENT PANEL WIRING (1/2)……………………………………………………………………………………………731
INSTRUMENT PANEL WIRING (2/2)……………………………………………………………………………………………732
FENDERS WIRING…………………………………………………………………………………………………………733
WIRING FOR LIGHTS ON ARMS……………………………………………………………………………………………….734
WIRING FOR SUPPLEMENTARY LIGHTS ON ARMS…………………………………………………………………………………..735
UPPER LIGHTS WIRING (VERSION WITH LIFT)…………………………………………………………………………………..736
WIRING FOR WORKLIGHTS ON ARMS (VERSION WITHOUT LIFT)……………………………………………………………………….737
LIGHTS SELECTOR SWITCH WIRING……………………………………………………………………………………………749
CENTRAL WIRING (1/2)……………………………………………………………………………………………………751
CENTRAL WIRING (2/2)……………………………………………………………………………………………………752
ENGINE WIRING………………………………………………………………………………………………………….753
ROOF LINE WIRING (1/2)………………………………………………………………………………………………….761
ROOF LINE WIRING (2/2)………………………………………………………………………………………………….762
WIRING FOR WORKLIGHTS, DEFROST MIRROR ON CAB (HL VERSION)…………………………………………………………………..763
WIRING FOR WORKLIGHTS ON CAB (STANDARD VERSION)……………………………………………………………………………764
WINDSCREEN WIPER WIRING…………………………………………………………………………………………………765
ROTATING BEACON WIRING………………………………………………………………………………………………….766
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