DEUTZ-FAHR AGROTRON TTV 1130 AGROTRON TTV 1145 AGROTRON TTV 1160 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON TTV 1130 AGROTRON TTV 1145 AGROTRON TTV 1160 Workshop Manual – PDF DOWNLOAD
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DEUTZ-FAHR AGROTRON TTV 1130 AGROTRON TTV 1145 AGROTRON TTV 1160 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.
TABLE OF CONTENTS:
DEUTZ-FAHR AGROTRON TTV 1130 AGROTRON TTV 1145 AGROTRON TTV 1160 Workshop Manual – PDF DOWNLOAD
307.1092.3.6 AGROTRON TTV 1130-1145-1160………………………………………………………………………………… 1
INTRODUCTION……………………………………………………………………………………………………… 3
SAFETY NOTES……………………………………………………………………………………………………… 5
HOW THE MANUAL IS STRUCTURED……………………………………………………………………………………….. 7
HOW TO CONSULT THE MANUAL………………………………………………………………………………………….. 8
HOW TO USE AND UPDATE THE MANUAL……………………………………………………………………………………. 9
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS……………………………………………………………….. 10
LIFTING INSTRUCTIONS………………………………………………………………………………………………. 11
STANDARD TIGHTENING TORQUES FOR NUTS AND BOLTS……………………………………………………………………….. 12
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS…………………………………………………………………….. 13
SPECIAL TOOLS…………………………………………………………………………………………………….. 15
CONVERSION FACTORS………………………………………………………………………………………………… 16
SECTION 10……………………………………………………………………………………………………….. 17
1. TRANSMISSION……………………………………………………………………………………………….. 19
INTRODUCTION………………………………………………………………………………………………. 19
1.1 TRANSMISSION…………………………………………………………………………………………… 20
1.1.1 MAIN COMPONENTS…………………………………………………………………………………… 20
1.1.2 GEARBOX………………………………………………………………………………………….. 23
GEARBOX COMPONENTS……………………………………………………………………………………… 24
1.1.3 TRANSMISSION HYDRAULIC SYSTEM………………………………………………………………………. 25
PRESSURE CONTROL UNIT…………………………………………………………………………………… 26
POWERSHIFT DIRECTIONAL CONTROL VALVE……………………………………………………………………… 27
1.1.4 POWERSHIFT CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION……………………………………………… 29
1.1.5 TRANSMISSION ELECTRONIC SYSTEM……………………………………………………………………… 30
1.2 REAR AXLE……………………………………………………………………………………………… 31
COMPONENTS…………………………………………………………………………………………….. 32
1.3 REAR PTO………………………………………………………………………………………………. 34
2. BRAKING SYSTEM……………………………………………………………………………………………… 37
2.1 BRAKE MASTER CYLINDER…………………………………………………………………………………… 38
2.2 TRAILER BRAKING SYSTEM………………………………………………………………………………….. 39
2.2.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)……………………………………………………………. 39
2.2.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)…………………………………………………………… 41
2.2.3 AIR TRAILER BRAKING (ITALY VERSION)…………………………………………………………………. 43
2.2.4 AIR TRAILER BRAKING (EXPORT VERSION)………………………………………………………………… 44
COMPRESSOR…………………………………………………………………………………………….. 45
PRESSURE LIMITING VALVE…………………………………………………………………………………. 46
CAB SUSPENSION FEED VALVE……………………………………………………………………………….. 47
BRAKE APPLY SOLENOID VALVE………………………………………………………………………………. 48
TRAILER BRAKING VALVE (2-WAY)……………………………………………………………………………. 49
TRAILER BRAKING VALVE (1-WAY)……………………………………………………………………………. 50
3. HYDRAULIC FRONT AXLE SUSPENSION………………………………………………………………………………. 51
3.1 FRONT SUSPENSION CONTROL VALVE…………………………………………………………………………… 52
4. FRONT AXLE…………………………………………………………………………………………………. 56
4.1 HUB CARRIER AND FINAL REDUCTION UNIT……………………………………………………………………… 57
4.2 DIFFERENTIAL…………………………………………………………………………………………… 58
5. HYDRAULIC SYSTEM……………………………………………………………………………………………. 59
DESCRIPTION……………………………………………………………………………………………….. 59
5.1 VARIABLE DISPLACEMENT PUMP………………………………………………………………………………. 61
5.1.1 BOOST PUMP……………………………………………………………………………………….. 64
5.1.2 HYDRAULIC PUMP……………………………………………………………………………………. 65
5.1.3 LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE…………………………………………………………… 67
5.2 HYDRAULIC SERVICES GEAR PUMP…………………………………………………………………………….. 75
5.3 AUXILIARY SERVICES CONTROL VALVE…………………………………………………………………………. 76
5.3.1 TYPES OF SPOOL VALVE (LS)………………………………………………………………………….. 77
5.3.2 SERVICES CONTROL VALVE SECTION……………………………………………………………………… 78
5.3.3 DESCRIPTIONS OF COMPONENTS…………………………………………………………………………. 79
5.3.4 LIFT CONTROL VALVE SECTION…………………………………………………………………………. 81
5.4 PTO AND DIFFERENTIAL LOCK CONTROL VALVE…………………………………………………………………… 85
SECTION 20……………………………………………………………………………………………………….. 87
OPERATOR’S MANUAL SERDIA (LEVEL III)…………………………………………………………………………….. 89
1. ENTRY AND COMMUNICATION………………………………………………………………………………….. 90
1.1 OVERVIEW…………………………………………………………………………………………… 90
1.2 ORDERING…………………………………………………………………………………………… 91
1.3 SWITCH ON NOTEBOOK AND INSTALL SOFTWARE……………………………………………………………….. 92
1.4 USER LEVEL, ACCESS AUTHORIZATION……………………………………………………………………… 93
1.5 MAKING A CONNECTION BETWEEN ECU (ENGINE) AND NOTEBOOK…………………………………………………… 94
1.6 PROGRAM START………………………………………………………………………………………. 94
1.7 OFFLINE MODE……………………………………………………………………………………….. 95
1.8 WORKING WITH THE PROGRAM…………………………………………………………………………….. 97
1.9 PRINT (OUTPUT)……………………………………………………………………………………… 99
1.10 PROTOCOL (PROTOKOLL)………………………………………………………………………………..100
1.11 END COMMUNICATION…………………………………………………………………………………..100
2. ECU SELECTION……………………………………………………………………………………………101
2.1 GENERAL…………………………………………………………………………………………….101
2.2 RECOGNITION OF ECUS………………………………………………………………………………….101
2.3 IDENTIFICATION DATA………………………………………………………………………………….101
3 MEASURED VALUES…………………………………………………………………………………………..102
3.1 ACTUAL MEASURED VALUES (GENERAL)………………………………………………………………………102
3.2 RAM VALUES………………………………………………………………………………………….106
3.3 DATA LOGGER (ONLY EMS)……………………………………………………………………………….106
3.4 INPUT/OUTPUT ASSIGNMENT………………………………………………………………………………106
3.5 CAN-Status………………………………………………………………………………………….106
3.6 EXAMPLE OF A DISPLAYED ERROR INFORMATION:………………………………………………………………108
4. PARAMETERS………………………………………………………………………………………………108
4.1 CONFIGURATION……………………………………………………………………………………….108
4.2 OVERALL PROGRAMMING………………………………………………………………………………….120
4.3 CALIBRATION…………………………………………………………………………………………120
5. ERROR MEMORY…………………………………………………………………………………………….122
5.1 GENERAL…………………………………………………………………………………………….122
6. FUNCTION TEST……………………………………………………………………………………………127
6.1 GENERAL…………………………………………………………………………………………….127
7. EXTRAS………………………………………………………………………………………………….128
7.1 MAXIMUM VEHICLE SPEED………………………………………………………………………………..128
7.2 LOGISTIC DATA……………………………………………………………………………………….128
7.3 LOAD SPECTRUM (ONLY EMS)……………………………………………………………………………..129
7.4 MAINTENANCE INTERVAL EXCEEDED (ONLY EMS)……………………………………………………………….129
7.5 OVERRIDE MEMORY (ONLY EMS)……………………………………………………………………………129
8 WHAT SHOULD YOU DO IF …?…………………………………………………………………………………130
8.1 SERDIA IN GENERAL……………………………………………………………………………………130
8.2 EMR………………………………………………………………………………………………..133
9. SERDIA UPGRADE FROM VERSION 2.5 TO VERSION 3.1………………………………………………………………145
9.1 IMPROVEMENTS AND HELP WITH PROBLEMS IN COMMUNICATING WITH NOTEBOOKS/WIN 98…………………………………145
9.2 NEW ENTRY MASK WITH MEASURED VALUES AND COLOURED-CODED INDICATION OF CONNECTION STATUS………………………146
9.3 NEW SWITCH “JOBS“ FOR PERFORMING SELECTED SERVICING OPERATIONS, E.G. ADJUSTING CONTROLLER OR ADJUSTING OFFSET….147
9.4 IN- AND OUTPUT ASSIGNMENT IS NOW ADDITIONALLY CONFIGURABLE USING PLAIN TEXT (PREVIOUSLY ONLY CODE NUMBERS)…….148
9.5 UPGRADES IN “PARAMETER SETTING/CONFIGURATION“…………………………………………………………..148
ALL ROUND TESTER MANUAL – AGROTRON TTV SERIES TRACTORS……………………………………………………………..149
ELECTRONIC COMPONENTS CONTROL AND SETTING 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
5. CALIBRATING THE TRANSMISSION………………………………………………………………………………193
SECTION 30………………………………………………………………………………………………………..197
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING………………………………………………………….201
HYDRAULIC AND WIRING SYSTEMS – PUMP SIDE………………………………………………………………………….202
HYDRAULIC SYSTEMS (TOP VIEW)…………………………………………………………………………………….203
HYDRAULIC SYSTEMS AND WIRING (TOP VIEW)…………………………………………………………………………..204
AUXILIARY HYDRAULIC SYSTEMS AND COUPLERS – TRAILER AIR BRAKE VALVES………………………………………………….205
ENGINE HOOD – LAMP ASSEMBLIES……………………………………………………………………………………207
1. Removal of hood………………………………………………………………………………………….207
1.1 Refitting hood………………………………………………………………………………………207
1.2 Adjustment of hood position and latch………………………………………………………………….207
1.3 Removal of lamp assemblies……………………………………………………………………………209
1.4 Removal of side panels……………………………………………………………………………….209
BATTERY……………………………………………………………………………………………………….210
REMOVAL……………………………………………………………………………………………………210
REFITTING………………………………………………………………………………………………….211
AIR RESERVOIR AND BATTERY SHELF (Version with trailer air braking system only)………………………………………..212
REMOVAL……………………………………………………………………………………………………212
REFITTING………………………………………………………………………………………………….212
CAB ACCESS STEPS……………………………………………………………………………………………….213
REMOVAL……………………………………………………………………………………………………213
REFITTING………………………………………………………………………………………………….213
STARTER MOTOR………………………………………………………………………………………………….214
REMOVAL AND RENEWAL…………………………………………………………………………………………215
REFITTING………………………………………………………………………………………………….215
ALTERNATOR…………………………………………………………………………………………………….215
REMOVAL AND RENEWAL…………………………………………………………………………………………215
REFITTING………………………………………………………………………………………………….215
ALTERNATOR DRIVEBELT……………………………………………………………………………………………216
RENEWAL AND TENSIONING………………………………………………………………………………………216
AIR COMPRESSOR (for air trailer braking)………………………………………………………………………….219
REMOVAL……………………………………………………………………………………………………219
REFITTING………………………………………………………………………………………………….220
TRAILER PARKING AND SERVICE AIR BRAKE CONTROL VALVES……………………………………………………………….221
REMOVAL……………………………………………………………………………………………………221
REFITTING………………………………………………………………………………………………….223
PRESSURE TRANSDUCER AND PRESSURE SWITCH (Version with air braking system)…………………………………………….224
REMOVAL……………………………………………………………………………………………………224
REFITTING………………………………………………………………………………………………….224
CAB LIFT AIR PRESSURE CONTROL/REDUCING VALVE………………………………………………………………………225
REMOVAL……………………………………………………………………………………………………225
REFITTING………………………………………………………………………………………………….225
TRAILER AIR BRAKES COUPLING VALVE………………………………………………………………………………..226
REMOVAL AND REPLACEMENT……………………………………………………………………………………..226
HYDRAULIC BRAKING VALVE…………………………………………………………………………………………227
REMOVAL……………………………………………………………………………………………………227
REFITTING………………………………………………………………………………………………….228
AIR CONDITIONING SYSTEM…………………………………………………………………………………………229
TECHNICAL SPECIFICATIONS…………………………………………………………………………………….229
FUNCTIONING………………………………………………………………………………………………..230
MAINTENANCE………………………………………………………………………………………………..231
ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT………………………………………………………………231
DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM…………………………………………………232
AIR CONDITIONING COMPRESSOR……………………………………………………………………………………..233
REMOVAL……………………………………………………………………………………………………233
REFITTING………………………………………………………………………………………………….234
RECEIVER-DRIER…………………………………………………………………………………………………235
REMOVAL……………………………………………………………………………………………………235
REFITTING………………………………………………………………………………………………….235
CONDENSER FAN………………………………………………………………………………………………….236
REMOVAL……………………………………………………………………………………………………236
REFITTING………………………………………………………………………………………………….237
CONDENSER……………………………………………………………………………………………………..238
REMOVAL……………………………………………………………………………………………………238
REFITTING………………………………………………………………………………………………….239
GEARBOX OIL/FUEL COOLERS………………………………………………………………………………………..240
REMOVAL……………………………………………………………………………………………………240
REFITTING………………………………………………………………………………………………….241
RADIATOR………………………………………………………………………………………………………242
REMOVAL……………………………………………………………………………………………………242
REFITTING………………………………………………………………………………………………….243
EXPANSION TANK…………………………………………………………………………………………………244
REMOVAL……………………………………………………………………………………………………244
REFITTING………………………………………………………………………………………………….244
FAN…………………………………………………………………………………………………………..245
REMOVAL……………………………………………………………………………………………………245
REFITTING………………………………………………………………………………………………….247
RADIATOR/COOLERS ASSEMBLY……………………………………………………………………………………….248
REMOVAL……………………………………………………………………………………………………248
REFITTING………………………………………………………………………………………………….250
FRONT PTO FLEXIBLE COUPLING……………………………………………………………………………………..251
REPLACEMENT………………………………………………………………………………………………..251
REFITTING………………………………………………………………………………………………….253
TURBOCHARGER…………………………………………………………………………………………………..254
REMOVAL……………………………………………………………………………………………………254
REFITTING………………………………………………………………………………………………….254
AIR INLET PIPE…………………………………………………………………………………………………255
REMOVAL……………………………………………………………………………………………………255
REFITTING………………………………………………………………………………………………….255
AIR CLEANER……………………………………………………………………………………………………256
REMOVAL……………………………………………………………………………………………………256
REFITTING………………………………………………………………………………………………….257
EXHAUST PIPE…………………………………………………………………………………………………..258
REMOVAL……………………………………………………………………………………………………258
REFITTING………………………………………………………………………………………………….258
SILENCER………………………………………………………………………………………………………259
REMOVAL……………………………………………………………………………………………………259
REFITTING………………………………………………………………………………………………….259
4WD PROPELLER SHAFT (Version with front suspension)………………………………………………………………..260
REMOVAL……………………………………………………………………………………………………260
REFITTING………………………………………………………………………………………………….262
BRAKE MASTER CYLINDERS………………………………………………………………………………………….263
REMOVAL……………………………………………………………………………………………………263
REFITTING………………………………………………………………………………………………….264
BLEEDING THE BRAKING SYSTEM……………………………………………………………………………………..265
ADJUSTMENT OF THE BRAKE LIGHT SWITCHES……………………………………………………………………………267
POWER STEERING UNIT…………………………………………………………………………………………….268
1. Testing…………………………………………………………………………………………………268
2. Setting…………………………………………………………………………………………………268
REMOVAL……………………………………………………………………………………………………269
REFITTING………………………………………………………………………………………………….270
DISMANTLING………………………………………………………………………………………………..271
ASSEMBLY…………………………………………………………………………………………………..278
FRONT WHEELS…………………………………………………………………………………………………..288
REMOVAL……………………………………………………………………………………………………288
REFITTING………………………………………………………………………………………………….288
FRONT FENDERS………………………………………………………………………………………………….289
REMOVAL……………………………………………………………………………………………………289
REFITTING………………………………………………………………………………………………….289
REAR WHEELS……………………………………………………………………………………………………290
REMOVAL……………………………………………………………………………………………………290
REFITTING………………………………………………………………………………………………….290
LIFT VALVE BLOCK……………………………………………………………………………………………….291
REMOVAL……………………………………………………………………………………………………291
REFITTING………………………………………………………………………………………………….291
FRONT LIFT CYLINDERS……………………………………………………………………………………………292
REMOVAL……………………………………………………………………………………………………292
REFITTING………………………………………………………………………………………………….293
FRONT LIFT ASSEMBLY…………………………………………………………………………………………….294
REMOVAL……………………………………………………………………………………………………294
REFITTING………………………………………………………………………………………………….296
FRONT PTO ASSEMBLY……………………………………………………………………………………………..297
REMOVAL……………………………………………………………………………………………………297
REFITTING………………………………………………………………………………………………….297
FRONT SUSPENSION CYLINDERS (Where fitted)…………………………………………………………………………298
REMOVAL……………………………………………………………………………………………………298
REFITTING………………………………………………………………………………………………….300
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………….301
FRONT AXLE AND SWINGING SUPPORT (Versions with front suspension)…………………………………………………….303
REMOVAL……………………………………………………………………………………………………303
REFITTING………………………………………………………………………………………………….305
FRONT SUSPENSION VALVES…………………………………………………………………………………………306
REMOVAL……………………………………………………………………………………………………306
REFITTING………………………………………………………………………………………………….306
FRONT SUSPENSION POSITION SENSOR…………………………………………………………………………………307
1. Removal…………………………………………………………………………………………………307
2. Positioning……………………………………………………………………………………………..307
3. Testing…………………………………………………………………………………………………308
REINFORCING SIDE MEMBERS (For versions with front lift only)………………………………………………………..309
REMOVAL……………………………………………………………………………………………………309
REFITTING………………………………………………………………………………………………….309
FRONT CARRIER (Versions with front suspension)…………………………………………………………………….310
REMOVAL……………………………………………………………………………………………………310
REFITTING………………………………………………………………………………………………….310
ACCELERATOR POTENTIOMETER……………………………………………………………………………………….311
REPLACEMENT………………………………………………………………………………………………..311
REFITTING………………………………………………………………………………………………….311
FUEL TANK……………………………………………………………………………………………………..312
REMOVAL……………………………………………………………………………………………………312
REFITTING………………………………………………………………………………………………….314
TEST FOR CORRECT OPERATION OF AUXILIARY SERVICES PUMP………………………………………………………………315
POWER STEERING GEAR PUMP………………………………………………………………………………………..316
REMOVAL……………………………………………………………………………………………………316
REFITTING………………………………………………………………………………………………….317
VARIABLE DISPLACEMENT PUMP………………………………………………………………………………………318
REMOVAL……………………………………………………………………………………………………318
REFITTING………………………………………………………………………………………………….319
DIRECTIONAL CONTROL VALVES………………………………………………………………………………………320
REMOVAL……………………………………………………………………………………………………320
REFITTING………………………………………………………………………………………………….323
AUXILIARY SPOOL VALVE STACK……………………………………………………………………………………..324
DISASSEMBLY………………………………………………………………………………………………..324
ASSEMBLY…………………………………………………………………………………………………..325
PTO CLUTCH AND DIFFERENTIAL LOCK CONTROL VALVE…………………………………………………………………….326
REMOVAL……………………………………………………………………………………………………326
REFITTING………………………………………………………………………………………………….327
LIFT CYLINDERS…………………………………………………………………………………………………328
REMOVAL……………………………………………………………………………………………………328
REFITTING………………………………………………………………………………………………….329
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………….330
LIFT POSITION SENSOR……………………………………………………………………………………………331
REPLACEMENT………………………………………………………………………………………………..331
REFITTING………………………………………………………………………………………………….331
LIFT DRAFT SENSOR………………………………………………………………………………………………332
REMOVAL……………………………………………………………………………………………………332
REFITTING………………………………………………………………………………………………….332
DRIVER’S SEAT………………………………………………………………………………………………….333
REMOVAL……………………………………………………………………………………………………333
REFITTING………………………………………………………………………………………………….333
ARMREST CONTROL PANELS………………………………………………………………………………………….334
REMOVAL……………………………………………………………………………………………………334
REFITTING………………………………………………………………………………………………….335
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL…………………………………………………….336
REMOVAL……………………………………………………………………………………………………336
REFITTING………………………………………………………………………………………………….337
CENTRE CONSOLE, STEERING COLUMN SWITCH ASSEMBLY AND SHROUD………………………………………………………….338
REMOVAL……………………………………………………………………………………………………338
REFITTING………………………………………………………………………………………………….341
RIGHT-HAND CONSOLE……………………………………………………………………………………………..342
OPENING AND REMOVAL…………………………………………………………………………………………342
REFITTING………………………………………………………………………………………………….347
LEFT-HAND CONSOLE………………………………………………………………………………………………348
REMOVAL……………………………………………………………………………………………………348
REFITTING………………………………………………………………………………………………….349
HYDRAULIC LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS……………………………………………350
REMOVAL……………………………………………………………………………………………………350
REFITTING………………………………………………………………………………………………….351
FUSE AND RELAY BOARD……………………………………………………………………………………………352
REMOVAL……………………………………………………………………………………………………352
REFITTING………………………………………………………………………………………………….353
ENGINE ECU…………………………………………………………………………………………………….354
REMOVAL……………………………………………………………………………………………………354
REFITTING………………………………………………………………………………………………….354
CLUTCH PEDAL AND RELATED DEVICES…………………………………………………………………………………355
1. Removal of the potentiometer………………………………………………………………………………355
1.1 Refitment of potentiometer……………………………………………………………………………355
2. Adjustment of the clutch pedal position and travel…………………………………………………………..356
3. Renewal of the proximity sensor……………………………………………………………………………356
RIGHT-HAND CONSOLE CONTROLS……………………………………………………………………………………..357
REMOVAL……………………………………………………………………………………………………357
REFITTING………………………………………………………………………………………………….359
BOWDEN CABLES………………………………………………………………………………………………….360
REPLACEMENT………………………………………………………………………………………………..360
PARKING BRAKE SWITCH……………………………………………………………………………………………363
ADJUSTMENT…………………………………………………………………………………………………363
PARKING BRAKE CONTROL LINKAGE……………………………………………………………………………………364
1. Removal…………………………………………………………………………………………………364
2. Replacement……………………………………………………………………………………………..365
3. Initial adjustment……………………………………………………………………………………….365
4. Adjustment to correct brake wear or elongation of cable………………………………………………………366
5. Final operations…………………………………………………………………………………………366
CLIMATE CONTROL PANEL…………………………………………………………………………………………..367
REMOVAL……………………………………………………………………………………………………367
REFITTING………………………………………………………………………………………………….367
HEATER VALVE…………………………………………………………………………………………………..368
1. Removal…………………………………………………………………………………………………368
2. Refitting and adjustment of the control cable……………………………………………………………….368
HEATER MATRIX………………………………………………………………………………………………….370
REMOVAL……………………………………………………………………………………………………370
REFITTING………………………………………………………………………………………………….372
AIR CONDITIONING EVAPORATOR……………………………………………………………………………………..373
REMOVAL……………………………………………………………………………………………………373
REFITTING………………………………………………………………………………………………….374
RIGHT-HAND AIR CONDITIONING FAN………………………………………………………………………………….375
REMOVAL……………………………………………………………………………………………………375
REFITTING………………………………………………………………………………………………….375
LEFT-HAND AIR CONDITIONING FAN…………………………………………………………………………………..376
REMOVAL……………………………………………………………………………………………………376
REFITTING………………………………………………………………………………………………….376
CAB DOOR CABLE…………………………………………………………………………………………………377
RENEWAL……………………………………………………………………………………………………377
TRAILER BRAKING AIR PRESSURE GAUGE……………………………………………………………………………….379
REMOVAL……………………………………………………………………………………………………379
REFITTING………………………………………………………………………………………………….379
TRANSMISSION OPERATING STATUS DISPLAY…………………………………………………………………………….380
REMOVAL……………………………………………………………………………………………………380
REFITMENT………………………………………………………………………………………………….380
CAB…………………………………………………………………………………………………………..381
REMOVAL……………………………………………………………………………………………………381
REFITMENT………………………………………………………………………………………………….388
ENGINE -TRANSMISSION……………………………………………………………………………………………389
SEPARATION…………………………………………………………………………………………………389
ASSEMBLY…………………………………………………………………………………………………..396
TRANSMISSION AND REAR AXLE………………………………………………………………………………………397
SEPARATION…………………………………………………………………………………………………397
ASSEMBLY…………………………………………………………………………………………………..400
PTO CLUTCH…………………………………………………………………………………………………….401
REMOVAL AND OVERHAUL………………………………………………………………………………………..401
ASSEMBLY AND REFITMENT………………………………………………………………………………………404
PTO ASSEMBLY…………………………………………………………………………………………………..405
REMOVAL……………………………………………………………………………………………………405
REFITMENT………………………………………………………………………………………………….406
DISASSEMBLY………………………………………………………………………………………………..407
ASSEMBLY…………………………………………………………………………………………………..416
REAR LIFT AND TOP LINK………………………………………………………………………………………….417
REMOVAL……………………………………………………………………………………………………417
REFITMENT………………………………………………………………………………………………….418
OVERHAUL OF BRAKE ASSEMBLIES…………………………………………………………………………………….419
1. Preparation of machine for disassembly operations……………………………………………………………419
2. Removal of trumpet housings……………………………………………………………………………….422
3. Removal of brake assembly…………………………………………………………………………………423
4. Adjustment of brake clearances and assembly…………………………………………………………………425
5. Refitment of trumpet housings……………………………………………………………………………..427
TRUMPET HOUSING………………………………………………………………………………………………..428
DISASSEMBLY………………………………………………………………………………………………..428
ASSEMBLY…………………………………………………………………………………………………..432
PUMP DRIVE SPACER FLANGE………………………………………………………………………………………..437
REMOVAL……………………………………………………………………………………………………437
REFITMENT………………………………………………………………………………………………….438
PARKING BRAKE………………………………………………………………………………………………….439
INSPECTION AND OVERHAUL……………………………………………………………………………………..439
PUMP DRIVE UNIT………………………………………………………………………………………………..441
OVERHAUL…………………………………………………………………………………………………..441
1. Disassembly of unit…………………………………………………………………………………..441
2. Replacement of taper roller bearings……………………………………………………………………444
3. Assembly of drive unit………………………………………………………………………………..447
4. Assembly of pump drive unit……………………………………………………………………………449
DIFFERENTIAL…………………………………………………………………………………………………..450
1. Disassembly……………………………………………………………………………………………..452
2. Assembly………………………………………………………………………………………………..456
BEVEL PINION…………………………………………………………………………………………………..461
REMOVAL……………………………………………………………………………………………………461
ASSEMBLY AND ADJUSTMENT……………………………………………………………………………………..464
DIFFERENTIAL AND CLEARANCE ADJUSTMENTS……………………………………………………………………………466
SECTION 40………………………………………………………………………………………………………..469
THE STRUCTURE OF THE UNIT……………………………………………………………………………………….471
HOW TO CONSULT THE UNIT…………………………………………………………………………………………472
1. INTRODUCTION………………………………………………………………………………………………..473
1.1 LIST OF WIRING HARNESSES…………………………………………………………………………………473
1.2 DEFINITION OF COMPONENTS AND SYMBOLS………………………………………………………………………474
1.3 GENERAL RULES…………………………………………………………………………………………..474
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING…………………………………………………475
1.4 DIAGNOSTIC INSTRUMENTS…………………………………………………………………………………..476
1.5 WIRE COLOUR CODES……………………………………………………………………………………….476
2. INDICES…………………………………………………………………………………………………….477
2.1 COMPONENT DESCRIPTION INDEX………………………………………………………………………………477
2.2 COMPONENT CODE INDEX…………………………………………………………………………………….482
2.3 CONNECTOR INDEX…………………………………………………………………………………………487
3. COMPONENTS………………………………………………………………………………………………….494
3.1 CONNECTOR LAYOUTS……………………………………………………………………………………….494
3.2 COMPONENT TECHNICAL DATA…………………………………………………………………………………498
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS………………………………………………………..506
4. SYSTEMS…………………………………………………………………………………………………….515
4.1 GROUND POINTS…………………………………………………………………………………………..515
4.2 ENGINE START……………………………………………………………………………………………516
4.3 PREHEATING……………………………………………………………………………………………..517
4.4 ELECTRICAL ENGINE CONTROL………………………………………………………………………………..518
4.5 LIGHTS – LIGHT SELECTOR SWITCH……………………………………………………………………………519
4.6 CAB ACCESSORY…………………………………………………………………………………………..520
4.7 WORKING LIGHTS………………………………………………………………………………………….521
4.8 WINDSCREEN WIPER………………………………………………………………………………………..522
4.9 INFOCENTER……………………………………………………………………………………………..523
4.10 ELECTRICAL POWER SUPPLY…………………………………………………………………………………524
4.11 AUTORADIO – CB…………………………………………………………………………………………525
4.12 DIAGNOSTIC SOCKET – CANBUS………………………………………………………………………………526
4.13 AIR CONDITIONING – HEATING FAN…………………………………………………………………………..527
4.14 BRAKES………………………………………………………………………………………………..528
4.15 TRAILER BRAKES (ITALY VERSION)…………………………………………………………………………..529
4.16 TRAILER BRAKES (EXPORT F VERSION)………………………………………………………………………..530
4.17 FRONT AXLE SUSPENSION…………………………………………………………………………………..531
4.18 TRANSMISSION…………………………………………………………………………………………..532
4.19 ASM – 4WD – DIFFERENTIAL………………………………………………………………………………..533
4.20 REAR LIFTER……………………………………………………………………………………………534
4.21 FRONT AND REAR PTO……………………………………………………………………………………..535
4.22 ELECTRIC CONTROL VALVE………………………………………………………………………………….536
5. PLANIMETRY, WIRING DIAGRAM AND CONNECTORS LOCATION………………………………………………………………537
INTERNAL COMBUSTION ENGINE WIRING (1/2)……………………………………………………………………….539
INTERNAL COMBUSTION ENGINE WIRING (2/2)……………………………………………………………………….540
ENGINE WIRING (1/2)…………………………………………………………………………………………545
ENGINE WIRING (2/2)…………………………………………………………………………………………546
TRANSMISSION WIRING (1/2)……………………………………………………………………………………555
TRANSMISSION WIRING (2/2)……………………………………………………………………………………556
HYDRAULIC AND AIR TRAILER BRAKING SYSTEM WIRING (ITALY)…………………………………………………………565
AIR TRAILER BRAKING SYSTEM WIRING…………………………………………………………………………….566
CAB POWER SUPPLY WIRING……………………………………………………………………………………..569
FRONT AXLE SUSPENSION WIRING…………………………………………………………………………………575
NUMBER PLATE LIGHT WIRING……………………………………………………………………………………579
NUMBER PLATE LIGHT WIRING……………………………………………………………………………………580
FENDER WIRING………………………………………………………………………………………………581
FENDER WIRING………………………………………………………………………………………………582
FRONT CONSOLE WIRING (1/2)…………………………………………………………………………………..587
FRONT CONSOLE WIRING (2/2)…………………………………………………………………………………..588
SIDE CONSOLE WIRING (1/2)……………………………………………………………………………………593
SIDE CONSOLE WIRING (2/2)……………………………………………………………………………………594
AIR CONDITIONING SYSTEM WIRING (CAB)………………………………………………………………………….605
DISPLAY WIRING……………………………………………………………………………………………..611
ROOF WIRING (1/2)…………………………………………………………………………………………..615
ROOF WIRING (2/2)…………………………………………………………………………………………..616
CONTROL UNIT – FUSES – RELAYS (1/2)…………………………………………………………………………..625
CONTROL UNIT – FUSES – RELAYS (2/2)…………………………………………………………………………..626
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