Deutz-Fahr AGROTRON TTV 1130 – 2000 AGROTRON TTV 1145 – 2000 AGROTRON TTV 1160 – 2000 Workshop Manual – PDF DOWNLOAD
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Deutz-Fahr AGROTRON TTV 1130 – 2000 AGROTRON TTV 1145 – 2000 AGROTRON TTV 1160 – 2000 Workshop Manual – PDF DOWNLOAD
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Deutz-Fahr AGROTRON TTV 1130 – 2000 AGROTRON TTV 1145 – 2000 AGROTRON TTV 1160 – 2000 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 TTV 1130 – 2000 AGROTRON TTV 1145 – 2000 AGROTRON TTV 1160 – 2000 Workshop Manual – PDF DOWNLOAD
307.1102.3.6 AGROTRON TTV 1130-1145-1160 » 2000……………………………………. 1
INTRODUCTION……………………………………………………………….. 3
SAFETY NOTES……………………………………………………………….. 5
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS…………………………. 8
LIFTING INSTRUCTIONS………………………………………………………… 10
HOW THE MANUAL IS STRUCTURED…………………………………………………. 11
HOW TO CONSULT THE MANUAL……………………………………………………. 12
HOW TO USE AND UPDATE THE MANUAL……………………………………………… 13
STANDARD TIGHTENING TORQUES FOR NUTS AND BOLTS…………………………………. 14
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS………………………………. 15
SPECIAL TOOLS………………………………………………………………. 17
CONVERSION FACTORS………………………………………………………….. 18
SECTION 10…………………………………………………………………. 19
1. TRANSMISSION…………………………………………………………. 21
INTRODUCTION………………………………………………………… 21
1.1 TRANSMISSION…………………………………………………….. 22
1.1.1 MAIN COMPONENTS…………………………………………….. 22
1.1.2 GEARBOX……………………………………………………. 25
GEARBOX COMPONENTS……………………………………………….. 26
1.1.3 TRANSMISSION HYDRAULIC SYSTEM………………………………… 27
PRESSURE CONTROL UNIT…………………………………………….. 28
POWERSHIFT DIRECTIONAL CONTROL VALVE……………………………….. 29
PRESSURE TEST POINTS……………………………………………… 30
1.1.4 POWERSHIFT CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION……….. 31
1.1.5 TRANSMISSION ELECTRONIC SYSTEM……………………………….. 32
1.2 REAR AXLE……………………………………………………….. 33
1.3 REAR PTO………………………………………………………… 36
2. BRAKING SYSTEM……………………………………………………….. 39
DESCRIPTION…………………………………………………………. 39
2.1 BRAKE MASTER CYLINDER…………………………………………….. 40
2.2 TRAILER BRAKING SYSTEM……………………………………………. 41
2.2.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)……………………… 41
2.2.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)…………………….. 43
2.2.3 AIR TRAILER BRAKING (ITALY VERSION)…………………………… 45
2.2.4 AIR TRAILER BRAKING (EXPORT VERSION)………………………….. 46
COMPRESSOR………………………………………………………. 47
PRESSURE LIMITING VALVE…………………………………………… 48
CAB SUSPENSION FEED VALVE…………………………………………. 49
BRAKE APPLY SOLENOID VALVE………………………………………… 50
TRAILER BRAKING VALVE (2-WAY)……………………………………… 51
TRAILER BRAKING VALVE (1-WAY)……………………………………… 52
3. HYDRAULIC FRONT AXLE SUSPENSION………………………………………… 53
DESCRIPTION…………………………………………………………. 53
3.1 FRONT SUSPENSION CONTROL VALVE…………………………………….. 54
4. FRONT AXLE…………………………………………………………… 58
4.1 HUB CARRIER AND FINAL REDUCTION UNIT……………………………….. 59
4.2 DIFFERENTIAL…………………………………………………….. 60
5. HYDRAULIC SYSTEM……………………………………………………… 61
HYDRAULIC SYSTEM…………………………………………………….. 62
5.1 VARIABLE DISPLACEMENT PUMP………………………………………… 63
5.1.1 BOOST PUMP…………………………………………………. 66
5.1.2 HYDRAULIC PUMP……………………………………………… 67
5.1.3 LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE…………………….. 69
PRESSURE CUT-OFF VALVE (TP)……………………………………….. 76
5.2 HYDRAULIC SERVICES GEAR PUMP………………………………………. 77
5.3 POWER STEERING…………………………………………………… 78
5.4 AUXILIARY SERVICES CONTROL VALVE…………………………………… 79
5.4.1 TYPES OF SPOOL VALVE (LS)……………………………………. 80
5.4.2 LIFT CONTROL VALVE SECTION…………………………………… 81
5.5 PTO AND DIFFERENTIAL LOCK CONTROL VALVE…………………………….. 85
SECTION 20…………………………………………………………………. 87
OPERATOR’S MANUAL SERDIA (LEVEL III)………………………………………. 89
1. SETUP AND COMMUNICATIONS…………………………………………… 90
1.1 MINIMUM EQUIPMENT REQUIRED…………………………………….. 90
1.2 ORDERING…………………………………………………….. 91
1.3 SWITCHING ON AND INSTALLING THE SOFTWARE………………………… 92
1.4 USING THE PROGRAM…………………………………………….. 96
1.5 CLOSING THE PROGRAM…………………………………………… 99
2. ECU SELECTION……………………………………………………..100
2.1 SELECTING TWO CONTROL UNITS…………………………………….100
2.2 PRINTING……………………………………………………..101
2.3 PROTOCOL……………………………………………………..102
2.4 IDENTIFICATION AND MEASUREMENT DATA……………………………..102
3. MEASURED VALUES……………………………………………………104
3.1 ACTUAL MEASURED VALUES (GENERAL)………………………………..104
3.2 RAM-VALUES……………………………………………………109
3.3 DATA LOGGER (ONLY EMS2)………………………………………..113
3.4 INPUT/OUTPUT ASSIGNMENT………………………………………..113
3.5 CAN STATUS……………………………………………………113
4. PARAMETERS………………………………………………………..116
4.1 CONFIGURATION (GENERAL)………………………………………..116
4.2 OVERALL PROGRAMMING……………………………………………117
4.2 CALIBRATION…………………………………………………..118
5. ERROR MEMORY………………………………………………………119
5.1 GENERAL………………………………………………………119
5.2 ERROR TABLE…………………………………………………..120
6. EXTRAS……………………………………………………………129
6.1 MAXIMUM SPEED…………………………………………………129
6.2 LOGISTIC DATA…………………………………………………129
6.3 LOAD SPECTRUM…………………………………………………130
6.4 MAINTENANCE INTERVAL EXCEEDED…………………………………..130
6.5 OVERRIDE MEMORY……………………………………………….130
6.6 MAINTENANCE DATA………………………………………………130
7. TASKS…………………………………………………………….131
7.1 EMR1…………………………………………………………131
8. WHAT TO DO IF…?………………………………………………….135
8.1 SERDIA GENERAL………………………………………………..135
8.2 EMR1…………………………………………………………137
ALL ROUND TESTER MANUAL – AGROTRON TTV SERIES TRACTORS……………………….149
ELECTRONIC COMPONENTS CONTROL AND SETTING SYSTEM…………………………149
STRUCTURE OF THE SYSTEM……………………………………………149
OPENING SCREEN……………………………………………………….150
MAIN MENU……………………………………………………………150
1. MONITOR…………………………………………………………..151
1.1 TRANSMISSION………………………………………………….151
1.2 PTO………………………………………………………….153
1.3 ASM………………………………………………………….153
1.4 LIFT…………………………………………………………154
1.5 SUSPENSION……………………………………………………155
1.6 SOFTWARE INFO…………………………………………………156
1.7 CAN STATUS……………………………………………………156
1.8 TRANSMISSION………………………………………………….157
1.9 SPOOL VALVES………………………………………………….157
1.10 ENGINE………………………………………………………158
2. CALIBRATION MENU…………………………………………………..159
2.1 CHANGE CONFIGURATION PARAMETERS…………………………………159
2.2 CALIBRATION OF LIFT SYSTEM……………………………………..161
2.3 CALIBRATION OF TRANSMISSION SYSTEM SENSORS……………………….162
2.4 CONFIGURATION OF SPEED CONSTANTS………………………………..162
2.5 MENU CONFIGURATION…………………………………………….163
2.6 CALIBRATION OF SEAT SENSOR……………………………………..163
2.7 CALIBRATION OF DISTRIBUTORS…………………………………….164
2.8 MAINTENANCE…………………………………………………..164
3. TEST MENU…………………………………………………………165
3.1 TESTS ON TRANSMISSION ANALOG SENSORS…………………………….165
3.2 TESTS ON TRANSMISSION DIGITAL BUTTONS……………………………166
3.3 TESTS ON ASM SENSORS…………………………………………..166
3.4 TESTS ON LIFT SYSTEM ANALOG SIGNALS……………………………..167
3.5 TESTS ON LIFT SYSTEM DIGITAL LIFHT………………………………167
3.6 TESTS ON SUSPENSION……………………………………………168
3.7 TESTS ON PTO………………………………………………….168
3.8 OTHER………………………………………………………..169
4. ALARM MENU………………………………………………………..170
4.1 ALARMS GENERATED BY HPSA CONTROL UNIT……………………………170
4.2 ALARMS GENERATED BY ENGINE AND ARMREST CONTROL UNITS………………171
4.3 ALARMS GENERATED BY TRANSMISSION CONTROL UNIT…………………….171
4.4 CLEAR PASSIVE ALARMS…………………………………………..172
4.5 LIST OF ALARMS GENERATED BY HPSA, ENGINE AND ARMREST CONTROL UNITS….172
4.6 LIST OF TRANSMISSION SYSTEM ALARMS………………………………176
LIST OF ALARMS……………………………………………………177
5. CALIBRATING THE TRANSMISSION………………………………………..192
SECTION 30………………………………………………………………….195
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING……………………199
HYDRAULIC AND WIRING SYSTEMS – PUMP SIDE……………………………………200
HYDRAULIC SYSTEMS (TOP VIEW)………………………………………………201
HYDRAULIC SYSTEMS AND WIRING (TOP VIEW)…………………………………….202
AUXILIARY HYDRAULIC SYSTEMS AND COUPLERS – TRAILER AIR BRAKE VALVES……………203
ENGINE HOOD – LAMP ASSEMBLIES……………………………………………..205
REMOVAL……………………………………………………………..205
REFITTING……………………………………………………………207
BATTERY…………………………………………………………………208
REMOVAL……………………………………………………………..208
REFITTING……………………………………………………………209
AIR RESERVOIR AND BATTERY SHELF (Version with trailer air braking system only)….210
REMOVAL……………………………………………………………..210
REFITTING……………………………………………………………210
CAB ACCESS STEPS…………………………………………………………211
REMOVAL……………………………………………………………..211
REFITTING……………………………………………………………211
STARTER MOTOR……………………………………………………………212
REMOVAL……………………………………………………………..212
REFITTING……………………………………………………………212
ALTERNATOR………………………………………………………………213
REMOVAL AND RENEWAL…………………………………………………..213
REFITTING……………………………………………………………213
ALTERNATOR DRIVEBELT……………………………………………………..214
RENEWAL AND TENSIONING………………………………………………..214
AIR COMPRESSOR (for air trailer braking)……………………………………217
REMOVAL……………………………………………………………..217
REFITTING……………………………………………………………218
TRAILER PARKING AND SERVICE AIR BRAKE CONTROL VALVES…………………………219
REMOVAL……………………………………………………………..219
REFITTING……………………………………………………………221
PRESSURE TRANSDUCER AND PRESSURE SWITCH (Version with air braking system)………222
REMOVAL……………………………………………………………..222
REFITTING……………………………………………………………222
CAB LIFT AIR PRESSURE CONTROL/REDUCING VALVE………………………………..223
REMOVAL……………………………………………………………..223
REFITTING……………………………………………………………223
TRAILER AIR BRAKES COUPLING VALVE………………………………………….224
REMOVAL AND REPLACEMENT……………………………………………….224
HYDRAULIC BRAKING VALVE…………………………………………………..225
REMOVAL……………………………………………………………..225
REFITTING……………………………………………………………226
AIR CONDITIONING SYSTEM…………………………………………………..227
TECHNICAL SPECIFICATIONS………………………………………………227
FUNCTIONING………………………………………………………….228
MAINTENANCE………………………………………………………….229
ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT………………………..229
DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM…………..230
AIR CONDITIONING COMPRESSOR……………………………………………….231
REMOVAL……………………………………………………………..231
REFITTING……………………………………………………………232
RECEIVER-DRIER…………………………………………………………..233
REMOVAL……………………………………………………………..233
REFITTING……………………………………………………………233
CONDENSER FAN……………………………………………………………234
REMOVAL……………………………………………………………..234
REFITTING……………………………………………………………234
CONDENSER ASSEMBLY……………………………………………………….235
REMOVAL……………………………………………………………..235
REFITTING……………………………………………………………237
INTERCOOLER AND SEAL RENEWAL………………………………………………238
REMOVAL……………………………………………………………..238
REFITTING……………………………………………………………240
GEARBOX OIL/FUEL COOLERS………………………………………………….241
REMOVAL……………………………………………………………..241
REFITTING……………………………………………………………242
RADIATOR………………………………………………………………..243
REMOVAL……………………………………………………………..243
REFITTING……………………………………………………………245
EXPANSION TANK…………………………………………………………..246
REMOVAL……………………………………………………………..246
REFITTING……………………………………………………………246
COMPLETE RADIATOR/COOLERS ASSEMBLY…………………………………………247
REMOVAL……………………………………………………………..247
REFITTING……………………………………………………………251
FAN…………………………………………………………………….252
REMOVAL……………………………………………………………..252
REFITTING……………………………………………………………252
FRONT PTO FLEXIBLE COUPLING……………………………………………….253
REMOVAL……………………………………………………………..253
REFITTING……………………………………………………………254
AIR CLEANER……………………………………………………………..255
REMOVAL……………………………………………………………..255
REFITTING……………………………………………………………256
TURBOCHARGER…………………………………………………………….257
REMOVAL……………………………………………………………..257
REFITTING……………………………………………………………258
AIR INLET PIPE…………………………………………………………..259
REMOVAL……………………………………………………………..259
REFITTING……………………………………………………………259
SILENCER………………………………………………………………..260
REMOVAL……………………………………………………………..260
REFITTING……………………………………………………………260
EXHAUST PIPE…………………………………………………………….261
REMOVAL……………………………………………………………..261
REFITTING……………………………………………………………261
4WD PROPELLER SHAFT (Version with front suspension)………………………….262
REMOVAL……………………………………………………………..262
REFITTING……………………………………………………………264
BRAKE MASTER CYLINDERS……………………………………………………265
REMOVAL……………………………………………………………..265
REFITTING……………………………………………………………267
BLEEDING THE BRAKING SYSTEM……………………………………………….269
ADJUSTMENT OF THE BRAKE LIGHT SWITCHES……………………………………..271
POWER STEERING UNIT………………………………………………………272
1. Testing…………………………………………………………..272
2. Setting…………………………………………………………..272
REMOVAL……………………………………………………………..273
REFITTING……………………………………………………………274
DISMANTLING………………………………………………………….275
ASSEMBLY…………………………………………………………….282
FRONT WHEELS…………………………………………………………….292
REMOVAL……………………………………………………………..292
REFITTING……………………………………………………………292
FRONT FENDERS……………………………………………………………293
REMOVAL……………………………………………………………..293
REFITTING……………………………………………………………293
REAR WHEELS……………………………………………………………..294
REMOVAL……………………………………………………………..294
REFITTING……………………………………………………………294
LIFT VALVE BLOCK…………………………………………………………295
REMOVAL……………………………………………………………..295
REFITTING……………………………………………………………295
FRONT LIFT CYLINDERS……………………………………………………..296
REMOVAL……………………………………………………………..296
REFITTING……………………………………………………………297
FRONT LIFT ASSEMBLY………………………………………………………298
REMOVAL……………………………………………………………..298
REFITTING……………………………………………………………300
FRONT PTO ASSEMBLY……………………………………………………….301
REMOVAL……………………………………………………………..301
REFITTING……………………………………………………………301
FRONT SUSPENSION CYLINDERS (Where fitted)…………………………………..302
REMOVAL……………………………………………………………..302
REFITTING……………………………………………………………304
DISASSEMBLY AND ASSEMBLY………………………………………………305
FRONT AXLE AND SWINGING SUPPORT (Versions with front suspension)………………307
REMOVAL……………………………………………………………..307
REFITTING……………………………………………………………309
FRONT SUSPENSION VALVES…………………………………………………..310
REMOVAL……………………………………………………………..310
REFITTING……………………………………………………………310
FRONT SUSPENSION POSITION SENSOR…………………………………………..311
1. Removal…………………………………………………………..311
2. Positioning……………………………………………………….311
3. Testing…………………………………………………………..312
REINFORCING SIDE MEMBERS (For versions with front lift only)………………….313
REMOVAL……………………………………………………………..313
REFITTING……………………………………………………………313
FRONT CARRIER (Versions with front suspension)………………………………314
REMOVAL……………………………………………………………..314
REFITTING……………………………………………………………314
ACCELERATOR POTENTIOMETER…………………………………………………315
REPLACEMENT………………………………………………………….315
REFITTING……………………………………………………………315
FUEL TANK……………………………………………………………….316
REMOVAL……………………………………………………………..316
REFITTING……………………………………………………………318
TEST FOR CORRECT OPERATION OF AUXILIARY SERVICES PUMP………………………..319
1. Flowmeter connection……………………………………………….319
2. Measuring flow rate………………………………………………..319
POWER STEERING GEAR PUMP………………………………………………….320
REMOVAL……………………………………………………………..320
REFITTING……………………………………………………………321
VARIABLE DISPLACEMENT PUMP………………………………………………..322
REMOVAL……………………………………………………………..322
REFITTING……………………………………………………………323
CONTROL VALVE ASSEMBLIES………………………………………………….324
REMOVAL……………………………………………………………..324
REFITTING……………………………………………………………327
AUXILIARY SPOOL VALVE STACK……………………………………………….328
DISASSEMBLY………………………………………………………….328
ASSEMBLY…………………………………………………………….329
PTO CLUTCH AND DIFFERENTIAL LOCK CONTROL VALVE………………………………330
REMOVAL……………………………………………………………..330
REFITTING……………………………………………………………331
LIFT CYLINDERS…………………………………………………………..332
REMOVAL……………………………………………………………..332
REFITTING……………………………………………………………333
DISASSEMBLY AND ASSEMBLY………………………………………………334
LIFT POSITION SENSOR……………………………………………………..335
REPLACEMENT………………………………………………………….335
REMOVAL……………………………………………………………..336
REFITTING……………………………………………………………336
DRIVER’S SEAT……………………………………………………………337
REMOVAL……………………………………………………………..337
REFITTING……………………………………………………………337
ARMREST CONTROL PANELS……………………………………………………338
REMOVAL……………………………………………………………..338
REFITTING……………………………………………………………340
CENTRE CONSOLE, STEERING COLUMN SWITCH ASSEMBLY AND SHROUD……………………341
REMOVAL……………………………………………………………..341
REFITTING……………………………………………………………344
RIGHT-HAND CONSOLE……………………………………………………….345
OPENING AND REMOVAL…………………………………………………..345
REFITTING……………………………………………………………350
LEFT-HAND CONSOLE………………………………………………………..351
REMOVAL……………………………………………………………..351
REFITTING……………………………………………………………352
HYDRAULIC LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS……..353
REMOVAL……………………………………………………………..353
REFITTING……………………………………………………………354
FUSE AND RELAY BOARD……………………………………………………..355
REMOVAL……………………………………………………………..355
REFITTING……………………………………………………………356
ENGINE ECU………………………………………………………………357
REMOVAL……………………………………………………………..357
REFITTING……………………………………………………………357
CLUTCH PEDAL AND RELATED DEVICES…………………………………………..358
1. Removal of the potentiometer………………………………………..358
1.1 Refitment of potentiometer…………………………………………358
2. Adjustment of the clutch pedal position and travel…………………….359
3. Renewal of the proximity sensor……………………………………..359
RIGHT-HAND CONSOLE CONTROLS……………………………………………….360
REMOVAL……………………………………………………………..360
REFITTING……………………………………………………………361
BOWDEN CABLES……………………………………………………………362
REPLACEMENT………………………………………………………….362
REFITTING……………………………………………………………363
ADJUSTMENT OF THE PARKING BRAKE SWITCH……………………………………..364
PARKING BRAKE CABLE………………………………………………………365
RENEWAL……………………………………………………………..365
REFITTING……………………………………………………………366
ADJUSTMENT OF THE PARKING BRAKE……………………………………………367
CLIMATE CONTROL PANEL…………………………………………………….369
REMOVAL……………………………………………………………..369
REFITTING……………………………………………………………369
HEATER VALVE…………………………………………………………….370
1. Removal…………………………………………………………..370
2. Refitting and adjustment of the control cable…………………………370
HEATER MATRIX……………………………………………………………372
REMOVAL……………………………………………………………..372
REFITTING……………………………………………………………374
AIR CONDITIONING EVAPORATOR……………………………………………….375
REMOVAL……………………………………………………………..375
REFITTING……………………………………………………………376
RIGHT-HAND AIR CONDITIONING FAN……………………………………………377
REMOVAL……………………………………………………………..377
REFITTING……………………………………………………………377
LEFT-HAND AIR CONDITIONING FAN…………………………………………….378
REMOVAL……………………………………………………………..378
REFITTING……………………………………………………………378
CAB DOOR CABLE…………………………………………………………..379
RENEWAL……………………………………………………………..379
TRAILER BRAKING AIR PRESSURE GAUGE…………………………………………381
REMOVAL……………………………………………………………..381
REFITTING……………………………………………………………381
TRANSMISSION OPERATING STATUS DISPLAY………………………………………382
REMOVAL……………………………………………………………..382
REFITMENT……………………………………………………………382
CAB…………………………………………………………………….383
REMOVAL……………………………………………………………..383
REFITMENT……………………………………………………………389
ENGINE -TRANSMISSION……………………………………………………..390
SEPARATION…………………………………………………………..390
REASSEMBLY…………………………………………………………..399
TRANSMISSION AND REAR AXLE………………………………………………..400
SEPARATION…………………………………………………………..400
ASSEMBLY…………………………………………………………….403
PTO CLUTCH………………………………………………………………404
REMOVAL AND OVERHAUL………………………………………………….404
ASSEMBLY AND REFITMENT………………………………………………..407
PTO ASSEMBLY…………………………………………………………….408
REMOVAL……………………………………………………………..408
REFITMENT……………………………………………………………409
DISASSEMBLY………………………………………………………….410
ASSEMBLY…………………………………………………………….419
REAR LIFT AND TOP LINK……………………………………………………421
REMOVAL……………………………………………………………..421
REFITMENT……………………………………………………………422
BRAKE ASSEMBLIES…………………………………………………………423
OVERHAUL…………………………………………………………….423
TRUMPET HOUSING………………………………………………………….433
DISASSEMBLY………………………………………………………….433
ASSEMBLY…………………………………………………………….437
PUMP DRIVE SPACER FLANGE………………………………………………….442
REMOVAL……………………………………………………………..442
REFITMENT……………………………………………………………443
PUMP DRIVE UNIT………………………………………………………….444
OVERHAUL…………………………………………………………….444
DIFFERENTIAL…………………………………………………………….453
1. Disassembly……………………………………………………….455
2. Assembly………………………………………………………….459
BEVEL PINION…………………………………………………………….464
REMOVAL……………………………………………………………..464
CROWN WHEEL AND PINION……………………………………………………467
ASSEMBLY AND ADJUSTMENT……………………………………………….467
SECTION 40………………………………………………………………….473
THE STRUCTURE OF THE UNIT…………………………………………………475
HOW TO CONSULT THE UNIT…………………………………………………..476
1. INTRODUCTION………………………………………………………….477
1.1 LIST OF WIRING HARNESSES…………………………………………..477
1.2 DEFINITION OF COMPONENTS AND SYMBOLS………………………………..478
1.3 GENERAL RULES…………………………………………………….478
1.4 DIAGNOSTIC INSTRUMENTS…………………………………………….480
1.5 WIRE COLOUR CODES…………………………………………………480
2. INDICES………………………………………………………………481
2.1 COMPONENT DESCRIPTION INDEX………………………………………..481
2.2 COMPONENT CODE INDEX………………………………………………486
2.3 CONNECTOR INDEX…………………………………………………..491
3. COMPONENTS……………………………………………………………498
3.1 CONNECTOR LAYOUTS…………………………………………………498
3.2 COMPONENT TECHNICAL DATA…………………………………………..502
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS………………….510
4. SYSTEMS………………………………………………………………519
4.1 GROUND POINTS…………………………………………………….519
4.2 ENGINE START……………………………………………………..520
4.3 PREHEATING……………………………………………………….521
4.4 ELECTRICAL ENGINE CONTROL………………………………………….522
4.5 LIGHTS – LIGHT SELECTOR SWITCH……………………………………..523
4.6 CAB ACCESSORY…………………………………………………….524
4.7 WORKING LIGHTS……………………………………………………525
4.8 WINDSCREEN WIPER………………………………………………….526
4.9 INFOCENTER……………………………………………………….527
4.10 ELECTRICAL POWER SUPPLY…………………………………………..528
4.11 AUTORADIO – CB…………………………………………………..529
4.12 DIAGNOSTIC SOCKET – CANBUS………………………………………..530
4.13 AIR CONDITIONING – HEATING FAN…………………………………….531
4.14 BRAKES………………………………………………………….532
4.15 TRAILER BRAKES (ITALY VERSION)…………………………………….533
4.16 TRAILER BRAKES (EXPORT F VERSION)………………………………….534
4.17 FRONT AXLE SUSPENSION…………………………………………….535
4.18 TRANSMISSION…………………………………………………….536
4.19 ASM – 4WD – DIFFERENTIAL………………………………………….537
4.20 REAR LIFTER……………………………………………………..538
4.21 FRONT AND REAR PTO……………………………………………….539
4.22 ELECTRIC CONTROL VALVE……………………………………………540
5. PLANIMETRY, WIRING DIAGRAM AND CONNECTORS LOCATION………………………..541
INTERNAL COMBUSTION ENGINE WIRING (1/2)…………………………………543
INTERNAL COMBUSTION ENGINE WIRING (2/2)…………………………………544
ENGINE WIRING (1/2)…………………………………………………..549
ENGINE WIRING (2/2)…………………………………………………..550
ENGINE HOOD WIRING (2/2)………………………………………………558
ENGINE HOOD WIRING (1/2)………………………………………………557
TRANSMISSION WIRING (1/2)……………………………………………..561
TRANSMISSION WIRING (2/2)……………………………………………..562
WIRING FOR OPTIONAL CONTROL VALVES (D3 – D4)…………………………….563
HYDRAULIC AND AIR TRAILER BRAKING SYSTEM WIRING (ITALY)…………………..575
AIR TRAILER BRAKING SYSTEM WIRING………………………………………576
CAB POWER SUPPLY WIRING……………………………………………….579
FRONT AXLE SUSPENSION WIRING…………………………………………..585
NUMBER PLATE LIGHT WIRING……………………………………………..589
NUMBER PLATE LIGHT WIRING……………………………………………..590
FENDER WIRING………………………………………………………..591
FENDER WIRING………………………………………………………..592
FRONT CONSOLE WIRING (1/2)…………………………………………….597
FRONT CONSOLE WIRING (2/2)…………………………………………….598
SIDE CONSOLE WIRING (1/2)……………………………………………..603
SIDE CONSOLE WIRING (2/2)……………………………………………..604
AIR CONDITIONING SYSTEM WIRING (CAB)……………………………………615
DISPLAY WIRING……………………………………………………….621
ROOF WIRING (1/2)…………………………………………………….625
ROOF WIRING (2/2)…………………………………………………….626
LIGHTS SELECTOR SWITCH WIRING………………………………………….633
CONTROL UNIT – FUSES – RELAYS (1/2)…………………………………….637
CONTROL UNIT – FUSES – RELAYS (2/2)…………………………………….638
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V