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Deutz Fahr Agrotron 210 235 265 Tractor Service Repair Manual – PDF Download
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Description
Deutz Fahr Agrotron 210 235 265 Tractor Service Repair Manual
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Deutz Fahr Agrotron 210 235 265 Tractor Service Repair Manual
LANGUAGE:ENGLISH
PAGES:900
DOWNLOADABLE:YES
FILE TYPE:PDF
DEUTZ FAHR AGROTRON 210 235 265 TRACTOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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Deutz Fahr Agrotron 210 235 265 Tractor Service Repair Manual
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 210 235 265 Tractor Service Repair Manual
307.1109.3.6 AGROTRON 210-235-265........................................................................... 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 ENGINE-TRANSMISSION CONNECTION.............................................................. 22 1.1.1 FLEXIBLE COUPLING..................................................................... 22 1.1.2 FLUID COUPLING........................................................................ 23 1.2 TRANSMISSION................................................................................ 25 1.2.1 MAIN COMPONENTS (1-SPEED PTO VERSION)................................................. 25 1.2.2 MAIN COMPONENTS (2-SPEED PTO VERSION)................................................. 28 1.2.3 TRANSMISSION HYDRAULIC SYSTEM......................................................... 31 1.2.4 GEARBOX............................................................................... 32 GEARBOX COMPONENTS.......................................................................... 33 1.2.5 MAIN CLUTCH........................................................................... 35 1.2.6 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE...................................... 36 1.2.7 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC.............................. 40 1.2.8 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC.............................................. 41 1.3 REAR AXLE................................................................................... 42 1.4 REAR PTO.................................................................................... 44 1.4.1 1-SPEED REAR PTO...................................................................... 45 1.4.2 2-SPEED REAR PTO...................................................................... 46 2. BRAKING SYSTEM................................................................................... 47 2.1 BRAKE MASTER CYLINDER....................................................................... 48 2.2 BRAKE....................................................................................... 49 2.3 TRAILER BRAKING SYSTEM...................................................................... 50 2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)............................................. 50 2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)............................................ 52 2.3.3 AIR TRAILER BRAKING (ITALY VERSION)................................................... 54 2.3.4 AIR TRAILER BRAKING (EXPORT VERSION).................................................. 55 COMPRESSOR.................................................................................. 56 PRESSURE LIMITING VALVE..................................................................... 57 CAB SUSPENSION FEED VALVE................................................................... 58 BRAKE APPLY SOLENOID VALVE.................................................................. 59 TRAILER BRAKING VALVE (2-WAY)............................................................... 60 TRAILER BRAKING VALVE (1-WAY)............................................................... 61 3. HYDRAULIC FRONT AXLE SUSPENSION.................................................................. 62 3.1 FRONT SUSPENSION CONTROL VALVE.............................................................. 63 4. FRONT AXLE....................................................................................... 67 4.1 HUB CARRIER AND FINAL REDUCTION UNIT........................................................ 68 4.2 DIFFERENTIAL................................................................................ 69 4.3 STEERING ANGLE SENSOR....................................................................... 70 5. HYDRAULIC SYSTEM................................................................................. 71 HYDRAULIC SYSTEM................................................................................ 72 5.1 VARIABLE DISPLACEMENT PUMP.................................................................. 73 5.1.1 HYDRAULIC PUMP........................................................................ 76 5.1.2 LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE............................................ 78 5.2 POWER STEERING.............................................................................. 86 5.3 PRESSURE RELIEF VALVE....................................................................... 87 5.4 PRIORITY VALVE.............................................................................. 88 5.5 AUXILIARY SERVICES CONTROL VALVE............................................................ 89 5.5.1 TYPES OF SPOOL VALVE (LS)............................................................. 90 5.5.2 LIFT CONTROL VALVE SECTION............................................................ 91 SECTION 20.............................................................................................. 95 1. DIAGNOSIS TOOLS “ALL ROUND TESTER”............................................................... 97 1.1 ALL ROUND TESTER............................................................................ 97 1.2 SERDIA 3.5 LEVEL III” SOFTWARE..............................................................103 1.3 EDS EST45” SOFTWARE.........................................................................104 2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS............................................105 2.1 CONNECTION OF THE ART® TO THE HPSA AND ARMREST CONTROL UNITS................................105 2.2 CONNECTING THE PORTABLE COMPUTER WITH “SERDIA 3.5” SOFTWARE TO THE ENGINE CONTROL UNIT......106 2.3 CONNECTION OF THE PORTABLE COMPUTER WITH “EDS” SOFTWARE TO THE TRANSMISSION CONTROL UNIT....107 3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR.............................................109 3.1 ELECTRONIC SYSTEM...........................................................................109 3.2 CANBUS SYSTEM...............................................................................110 3.3 TRANSMISSION CONTROL UNIT...................................................................119 3.4 INFOCENTER..................................................................................120 4. PUTTING THE TRACTOR INTO SERVICE.................................................................121 4.1 INTRODUCTION................................................................................121 4.2 RENEWAL OF THE ENGINE CONTROL UNIT..........................................................121 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT....................................................124 4.4 RENEWAL OF THE HPSA CONTROL UNIT............................................................130 4.5 RENEWAL OF THE ARMREST CONTROL UNIT.........................................................150 5. ALARMS...........................................................................................157 5.1 ALARMS DISPLAYED ON THE INSTRUMENT PANEL....................................................158 5.2 HPSA CONTROL UNIT ALARMS....................................................................169 5.3 ENGINE CONTROL UNIT ALARMS..................................................................225 5.4 TRANSMISSION CONTROL UNIT ALARMS............................................................249 5.5 ARMREST ALARMS..............................................................................325 5.6 LIST OF ALARMS FOR THE BOSCH ELECTROHYDRAULIC CONTROL VALVE.................................337 5.7 CANBUS ALARMS...............................................................................339 6. HPSA CONTROL UNIT TESTER MANUAL..................................................................351 6.1 ELECTRONIC COMPONENTS CONTROL AND SETTING SYSTEM............................................351 STRUCTURE OF THE SYSTEM.....................................................................351 OPENING SCREEN..............................................................................352 MAIN MENU...................................................................................352 1. MONITOR MENU.............................................................................353 2. CALIBRATION MENU.........................................................................359 3. TEST MENU................................................................................362 4. ALARM MENU...............................................................................368 7. ARMREST TESTER MANUAL............................................................................371 PRESENTATION SCREEN.............................................................................371 MAIN MENU.......................................................................................371 1. MONITOR......................................................................................372 2. TESTS MENU...................................................................................373 3. CALIBRATIONS MENU............................................................................376 4. ALARM LIST...................................................................................378 8. OPERATOR’S MANUAL EDS (Electronic Diagnosis System)..............................................379 1. GENERAL INTRODUCTION.........................................................................379 1.1 FUNCTIONAL SCOPE........................................................................379 1.2 HARDWARE REQUIREMENTS...................................................................380 1.3 STARTING AND TERMINATING OF THE EDS PROGRAM.............................................382 2. TRANSMISSION DIAGNOSIS.......................................................................384 2.1 THE MAIN MENU...........................................................................384 2.2 ONLINE HELP.............................................................................386 3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45......................................................387 3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45....................................387 3.2 DEST 45 PROGRAM DESCRIPTION.............................................................388 3.3 ERROR CODES POWER-SHUTTLE /DEST 45......................................................403 3.4 DISPLAY POWERSHUTTLE....................................................................404 3.5 ERROR CODE LIST WITH DESCRIPTION........................................................405 3.6 OTHER INFORMATIONS......................................................................416 3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100..................................417 3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100.....................................................418 3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200..................................419 3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300...........................................420 3.11 ERROR ANALYSIS.........................................................................421 4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER.................................................423 4.1 PROGRAM DESCRIPTION.....................................................................424 4.2 CONSTANT VALUES FOR INFOCENTER..........................................................434 9. SERDIA (LEVEL III)...............................................................................439 1. SETUP AND COMMUNICATIONS.....................................................................439 1.1 MINIMUM EQUIPMENT REQUIRED..............................................................439 1.2 ORDERING................................................................................440 1.3 SWITCHING ON AND INSTALLING THE SOFTWARE................................................441 1.4 USING THE PROGRAM.......................................................................445 1.5 CLOSING THE PROGRAM.....................................................................448 2. ECU SELECTION................................................................................449 2.1 SELECTING TWO CONTROL UNITS.............................................................449 2.2 PRINTING................................................................................450 2.3 PROTOCOL................................................................................451 2.4 IDENTIFICATION AND MEASUREMENT DATA.....................................................451 3. MEASURED VALUES..............................................................................453 3.1 ACTUAL MEASURED VALUES (GENERAL)........................................................453 3.2 RAM-VALUES..............................................................................458 3.3 DATA LOGGER (ONLY EMS2).................................................................462 3.4 INPUT/OUTPUT ASSIGNMENT.................................................................462 3.5 CAN STATUS..............................................................................462 4. PARAMETERS...................................................................................465 4.1 CONFIGURATION (GENERAL).................................................................465 4.2 OVERALL PROGRAMMING.....................................................................466 4.3 CALIBRATION.............................................................................467 5. ERROR MEMORY.................................................................................468 5.1 GENERAL.................................................................................468 5.2 ERROR TABLE.............................................................................469 6. EXTRAS.......................................................................................479 6.1 MAXIMUM SPEED...........................................................................479 6.2 LOGISTIC DATA...........................................................................479 6.3 LOAD SPECTRUM...........................................................................480 6.4 MAINTENANCE INTERVAL EXCEEDED...........................................................480 6.5 OVERRIDE MEMORY.........................................................................480 6.6 MAINTENANCE DATA........................................................................480 7. TASKS........................................................................................481 7.1 EMR1....................................................................................481 8. WHAT TO DO IF...?............................................................................485 8.1 SERDIA GENERAL..........................................................................485 8.2 EMR1....................................................................................487 SECTION 30..............................................................................................499 METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING..........................................503 UPPER VIEW WIRING AND PIPES.........................................................................504 UPPER VIEW PIPES....................................................................................505 R.H. VIEW TRANSMISSION ASSEMBLY.....................................................................506 FRONT VIEW (RIGHT)..................................................................................507 FRONT VIEW (LEFT)...................................................................................508 FRONT VIEW (RIGHT)..................................................................................509 REAR VIEW (RIGHT)...................................................................................510 ENGINE HOOD AND SIDE PANELS.........................................................................511 REMOVAL.........................................................................................511 REFITTING.......................................................................................513 BATTERY.............................................................................................514 REMOVAL.........................................................................................514 REFITTING.......................................................................................514 CAB ACCESS STEPS....................................................................................515 REMOVAL.........................................................................................515 REFITTING.......................................................................................515 BATTERY SUPPORT.....................................................................................516 REMOVAL.........................................................................................516 REFITTING.......................................................................................516 STARTER MOTOR.......................................................................................517 REMOVAL.........................................................................................517 REFITTING.......................................................................................518 ALTERNATOR..........................................................................................519 REMOVAL.........................................................................................519 REFITTING.......................................................................................520 COMPRESSOR FAN - DRIVEBELTS.........................................................................521 REMOVAL.........................................................................................521 REFITTING.......................................................................................523 AIR COMPRESSOR......................................................................................524 REMOVAL.........................................................................................524 REFITTING.......................................................................................525 POWER STEERING PUMP.................................................................................526 REMOVAL.........................................................................................526 REFITTING.......................................................................................528 TRAILER BRAKING VALVES AND AIR RESERVOIR (Version with air trailer braking).........................529 REMOVAL.........................................................................................529 REFITTING.......................................................................................534 TRAILER AIR BRAKES COUPLING VALVES..................................................................535 1. Removal......................................................................................535 2. Renewal......................................................................................535 AIR CONDITIONING SYSTEM.............................................................................536 TECHNICAL SPECIFICATIONS........................................................................536 OPERATION.......................................................................................537 MAINTENANCE.....................................................................................538 ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT...............................................538 DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM................................539 AIR CONDITIONING COMPRESSOR.........................................................................540 REMOVAL.........................................................................................540 REFITTING.......................................................................................541 RECEIVER-DRIER......................................................................................542 REMOVAL.........................................................................................542 REFITTING.......................................................................................542 CONDENSER FAN.......................................................................................543 REMOVAL.........................................................................................543 REFITTING.......................................................................................543 FUEL COOLER.........................................................................................544 REMOVAL.........................................................................................544 REFITTING.......................................................................................544 CONDENSER...........................................................................................545 REMOVAL.........................................................................................545 REFITTING.......................................................................................546 INTERCOOLER.........................................................................................547 REMOVAL.........................................................................................547 REFITTING.......................................................................................549 GEARBOX OIL AND HYDRAULIC SERVICES OIL COOLERS......................................................550 REMOVAL.........................................................................................550 REFITTING.......................................................................................551 RADIATOR............................................................................................552 REMOVAL.........................................................................................552 REFITTING.......................................................................................554 COMPLETE RADIATOR-COOLERS ASSEMBLY..................................................................555 REMOVAL.........................................................................................555 REFITTING.......................................................................................559 EXPANSION TANK......................................................................................560 REMOVAL.........................................................................................560 REFITTING.......................................................................................560 FLEXIBLE COUPLING OF THE FRONT PTO (Models with front PTO only).....................................561 RENEWAL.........................................................................................561 REFITTING.......................................................................................561 TURBOCHARGER........................................................................................562 REMOVAL.........................................................................................562 REFITTING.......................................................................................562 AIR INTAKE PIPE.....................................................................................563 REMOVAL.........................................................................................563 REFITTING.......................................................................................563 COMPLETE AIR CLEANER ASSEMBLY.......................................................................564 REMOVAL.........................................................................................564 REFITTING.......................................................................................564 EXHAUST PIPE........................................................................................565 REMOVAL.........................................................................................565 REFITTING.......................................................................................565 SILENCER............................................................................................566 REMOVAL.........................................................................................566 REFITTING.......................................................................................567 4WD PROPELLER SHAFT.................................................................................568 REMOVAL.........................................................................................568 REFITTING.......................................................................................569 FRONT BEARING OF THE 4WD PROPELLER SHAFT............................................................570 RENEWAL.........................................................................................570 REFITTING.......................................................................................571 BRAKE MASTER CYLINDERS..............................................................................572 REMOVAL.........................................................................................572 REFITTING.......................................................................................574 BLEEDING THE BRAKING SYSTEM.........................................................................575 ADJUSTMENT OF THE BRAKE LIGHT SWITCHES..............................................................577 POWER STEERING UNIT.................................................................................578 1. Testing......................................................................................578 2. Adjustment...................................................................................578 3. Removal of the power steering unit...........................................................578 REFITTING.......................................................................................579 POWER STEERING UNIT SEALS.......................................................................580 1. Disassembly..............................................................................581 2. Removal of the seals.....................................................................583 3. Removal of the dust seal.................................................................583 4. Installing the inner seal (15)...........................................................584 5. Installing the control valve.............................................................584 6. Final assembly...........................................................................585 FRONT WHEELS........................................................................................588 REMOVAL.........................................................................................588 REFITTING.......................................................................................588 FRONT FENDERS.......................................................................................589 REMOVAL.........................................................................................589 REFITTING.......................................................................................589 REAR WHEELS.........................................................................................590 REMOVAL.........................................................................................590 REFITTING.......................................................................................590 FRONT LIFT VALVE BLOCK..............................................................................591 REMOVAL.........................................................................................591 REFITTING.......................................................................................591 FRONT LIFT CYLINDERS................................................................................592 REMOVAL.........................................................................................592 REFITTING.......................................................................................594 FRONT LIFT ASSEMBLY.................................................................................595 REMOVAL.........................................................................................595 REFITTING.......................................................................................597 FRONT PTO ASSEMBLY..................................................................................598 REMOVAL.........................................................................................598 REFITTING.......................................................................................599 FRONT SUSPENSION CYLINDERS..........................................................................600 REMOVAL.........................................................................................600 REFITTING.......................................................................................602 DISASSEMBLY AND ASSEMBLY........................................................................603 FRONT AXLE AND SWINGING SUPPORT.....................................................................605 REMOVAL.........................................................................................605 REFITTING.......................................................................................608 FRONT CARRIER.......................................................................................609 REMOVAL.........................................................................................609 REFITTING.......................................................................................609 FRONT SUSPENSION SOLENOID VALVES....................................................................610 REMOVAL.........................................................................................610 REFITTING.......................................................................................611 FRONT SUSPENSION POSITION SENSOR....................................................................612 1. Removal......................................................................................612 2. Positioning..................................................................................612 3. Calibration..................................................................................612 ACCELERATOR POTENTIOMETER...........................................................................613 REPLACEMENT.....................................................................................613 REFITTING.......................................................................................613 FUEL TANKS..........................................................................................614 REMOVAL.........................................................................................614 REFITTING.......................................................................................615 TESTING THE AUXILIARY SERVICES PUMPS................................................................616 HYDRAULIC SERVICES OIL RESERVOIR....................................................................617 REMOVAL.........................................................................................617 REFITTING.......................................................................................619 PISTON PUMP.........................................................................................620 REMOVAL.........................................................................................620 REFITTING.......................................................................................622 PRIORITY VALVE......................................................................................623 REMOVAL.........................................................................................623 REFITTING.......................................................................................624 LIFT CYLINDERS......................................................................................625 REMOVAL.........................................................................................625 REFITTING.......................................................................................626 DISASSEMBLY AND ASSEMBLY........................................................................627 LIFT POSITION SENSOR................................................................................628 TESTING.........................................................................................628 REMOVAL AND ADJUSTMENT..........................................................................629 LIFT DRAFT SENSOR...................................................................................633 REMOVAL.........................................................................................633 REFITTING.......................................................................................633 TOWING HITCH REMOTE CONTROL AND RENEWAL OF THE CONTROL CABLE........................................634 REMOVAL.........................................................................................634 REFITTING.......................................................................................635 GEARSHIFT LEVER.....................................................................................636 REMOVAL.........................................................................................636 REFITTING.......................................................................................637 GEARSHIFT CONTROL CABLES............................................................................638 Removal.........................................................................................638 Tensioning the gearshift control cables.........................................................639 DRIVER'S SEAT AND MULTIFUNCTION ARMREST.............................................................640 REMOVAL.........................................................................................640 REFITTING.......................................................................................640 ARMREST CONTROL PANELS..............................................................................641 REMOVAL.........................................................................................641 REFITTING.......................................................................................643 STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL....................................644 REMOVAL.........................................................................................644 REFITTING.......................................................................................645 STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER...........................................646 RENEWAL.........................................................................................646 ASSEMBLY........................................................................................647 CENTRE CONSOLE AND SHROUD...........................................................................648 REMOVAL.........................................................................................648 REFITTING.......................................................................................651 RIGHT-HAND CONSOLE..................................................................................652 OPENING AND REMOVAL.............................................................................652 REFITTING.......................................................................................658 LEFT-HAND CONSOLE...................................................................................659 REMOVAL.........................................................................................659 REFITTING.......................................................................................660 ELECTRONIC CONTROL UNITS............................................................................661 REMOVAL.........................................................................................661 REFITTING.......................................................................................662 FUSE AND RELAY BOARD................................................................................663 REMOVAL.........................................................................................663 REFITTING.......................................................................................664 ENGINE ECU..........................................................................................665 REMOVAL.........................................................................................665 REFITTING.......................................................................................665 CLUTCH PEDAL AND RELATED DEVICES....................................................................666 1. Removal of the potentiometer.................................................................666 1.1 Refitting the potentiometer.................................................................666 2. Adjustment of the clutch pedal position and travel...........................................667 3. Renewal of the proximity sensor..............................................................667 RIGHT-HAND CONSOLE CONTROLS.........................................................................668 REMOVAL.........................................................................................668 REFITTING.......................................................................................668 ADJUSTMENT OF THE PARKING BRAKE SWITCH..............................................................669 ADJUSTMENT OF THE PARKING BRAKES....................................................................670 PARKING BRAKE CABLE.................................................................................671 RENEWAL.........................................................................................671 CREEPER CONTROL CABLE...............................................................................672 RENEWAL.........................................................................................672 REFITTING.......................................................................................673 CLIMATE CONTROL PANEL...............................................................................674 REMOVAL.........................................................................................674 REFITTING.......................................................................................674 HEATER VALVE........................................................................................675 1. Removal......................................................................................675 2. Refitting and adjustment of the control cable................................................675 3. Final checks.................................................................................676 HEATER MATRIX.......................................................................................677 REMOVAL.........................................................................................677 REFITTING.......................................................................................679 AIR CONDITIONING EVAPORATOR.........................................................................680 REMOVAL.........................................................................................680 REFITTING.......................................................................................681 RIGHT-HAND AIR CONDITIONING FAN.....................................................................682 REMOVAL.........................................................................................682 REFITTING.......................................................................................682 LEFT-HAND AIR CONDITIONING FAN......................................................................683 REMOVAL.........................................................................................683 REFITTING.......................................................................................683 CAB DOOR CABLE......................................................................................684 TRAILER BRAKING AIR PRESSURE GAUGE..................................................................686 REMOVAL.........................................................................................686 REFITTING.......................................................................................686 TRANSMISSION STATUS DISPLAY.........................................................................687 REMOVAL.........................................................................................687 REFITTING.......................................................................................687 HYDRAULIC SERVICES CONTROL VALVE....................................................................688 REMOVAL.........................................................................................688 REFITTING.......................................................................................693 AUXILIARY SPOOL VALVE STACK.........................................................................694 DISASSEMBLY.....................................................................................694 ASSEMBLY........................................................................................695 CAB.................................................................................................696 REMOVAL.........................................................................................696 REFITTING.......................................................................................704 CAB AIR SPRINGS AND HYDRAULIC DAMPERS...............................................................705 RENEWAL.........................................................................................705 REFITTING.......................................................................................706 ENGINE..............................................................................................707 REMOVAL.........................................................................................707 REFITTING.......................................................................................710 FLEXIBLE COUPLING...................................................................................711 REMOVAL.........................................................................................711 REFITTING.......................................................................................711 FLUID COUPLING AND THE FLYWHEEL (only for models 235-265)...........................................712 REMOVAL.........................................................................................712 REFITTING.......................................................................................718 LOWER LINKS OF THE HYDRAULIC LINKAGE................................................................719 REMOVAL.........................................................................................719 REFITTING.......................................................................................720 TOWING HITCH AND SUPPORT............................................................................721 REMOVAL.........................................................................................721 REFITTING.......................................................................................722 SECTION 40..............................................................................................723 THE STRUCTURE OF THE UNIT...........................................................................725 1. INTRODUCTION.....................................................................................727 1.1 LIST OF WIRING HARNESSES....................................................................727 1.2 DEFINITION OF COMPONENTS AND SYMBOLS........................................................728 1.3 GENERAL RULES...............................................................................728 1.4 DIAGNOSTIC INSTRUMENTS......................................................................730 1.5 WIRE COLOUR CODES...........................................................................730 2. INDICES..........................................................................................731 2.1 COMPONENT DESCRIPTION INDEX.................................................................731 2.2 COMPONENT CODE INDEX........................................................................736 2.3 CONNECTOR INDEX.............................................................................741 3. COMPONENTS.......................................................................................749 3.1 CONNECTOR LAYOUTS...........................................................................749 3.2 COMPONENT TECHNICAL DATA....................................................................753 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS........................................762 4. SYSTEMS..........................................................................................769 4.1 EARTHING POINTS.............................................................................769 4.2 STARTING....................................................................................770 4.3 PREHEATING..................................................................................771 4.4 ELECTRICAL ENGINE CONTROL...................................................................772 4.5 LIGHTS - STEERING COLUMN SWITCH UNIT (WITHOUT FRONT LIFT)...................................773 4.6 LIGHTS - STEERING COLUMN SWITCH UNIT (WITH FRONT LIFT)......................................774 4.7 CAB ACCESSORIES.............................................................................775 4.8 WORKLIGHTS (WITHOUT FRONT LIFT).............................................................776 4.9 WORKLIGHTS (WITH FRONT LIFT)................................................................777 4.10 WINDSCREEN WIPERS..........................................................................778 4.11 INFOCENTER.................................................................................779 4.12 POWER OUTLET SOCKETS.......................................................................780 4.13 RADIO - CB.................................................................................781 4.14 DIAGNOSTICS SOCKETS - CANBUS...............................................................782 4.15 AIR CONDITIONING - HEATER FANS.............................................................783 4.16 BRAKING SYSTEM.............................................................................784 4.17 TRAILER BRAKES.............................................................................785 4.18 FRONT AXLE SUSPENSION......................................................................786 4.19 TRANSMISSION...............................................................................787 4.20 ASM - 4WD - DIFFERENTIAL...................................................................788 4.21 ELECTRONIC LIFT (WITH AB POSITION SENSOR)..................................................789 4.22 FRONT AND REAR PTO.........................................................................790 4.23 SOLENOID-OPERATED VALVES...................................................................791 4.24 ELECTRONIC LIFT (WITH BOSCH POSITION SENSOR)...............................................792 5. WIRING...........................................................................................793 ENGINE WIRING (KHD) (1/2).......................................................................793 ENGINE WIRING (KHD) (2/2).......................................................................794 ENGINE WIRING (1/2).............................................................................799 ENGINE WIRING (2/2).............................................................................800 EXTENSION WIRING FOR FRONT LIGHTS...............................................................810 ENGINE HOOD WIRING..............................................................................809 TRANSMISSION WIRING (WITH AB LIFT POSITION SENSOR) (1/2)........................................813 TRANSMISSION WIRING (WITH AB LIFT POSITION SENSOR) (2/2)........................................814 TRANSMISSION WIRING (WITH BOSCH LIFT POSITION SENSOR) (1/2).....................................815 TRANSMISSION WIRING (WITH BOSCH LIFT POSITION SENSOR) (2/2).....................................816 OPTIONAL CONTROL VALVES WIRING (D3 - D4)........................................................817 FRONT AXLE SUSPENSION WIRING....................................................................829 WIRING FOR HYDRAULIC AND AIR TRAILER BRAKING (ITALY)............................................833 WIRING FOR AIR TRAILER BRAKING..................................................................834 FENDER WIRING...................................................................................837 NUMBER PLATE LIGHT WIRING.......................................................................838 FRONT CONSOLE WIRING (1/2)......................................................................843 FRONT CONSOLE WIRING (2/2)......................................................................844 SIDE CONSOLE WIRING (WITH AB LIFT POSITION SENSOR) (1/3)........................................849 SIDE CONSOLE WIRING (WITH AB LIFT POSITION SENSOR) (2/3)........................................850 SIDE CONSOLE WIRING (WITH AB LIFT POSITION SENSOR) (3/3)........................................851 SIDE CONSOLE WIRING (WITH BOSCH LIFT POSITION SENSOR) (1/3).....................................852 SIDE CONSOLE WIRING (WITH BOSCH LIFT POSITION SENSOR) (2/3).....................................853 SIDE CONSOLE WIRING (WITH BOSCH LIFT POSITION SENSOR) (3/3).....................................854 AIR CONDITIONING WIRING (CAB)...................................................................867 DISPLAY WIRING..................................................................................873 ROOF WIRING (1/2)...............................................................................877 ROOF WIRING (2/2)...............................................................................878 EXTENSION ROTATING BEACON.......................................................................879 WINDSCREEN WIPER MOTOR WIRING...................................................................880 FRONT AND REAR WIRING FOR UPPER WORKLIGHTS......................................................889 CAB LOWER HEADLIGHTS WIRING.....................................................................887 WIRING FOR FRONT LOWER WORKLIGHTS (ON CAB) (WITHOUT FRONT LIFT).................................888 WIRING FOR FRONT LOWER WORKLIGHTS (ON CAB) (WITH FRONT LIFT)....................................888 LIGHTS SELECTOR SWITCH..........................................................................895 CONTROL UNIT - FUSES - RELAYS (1/2).............................................................899 CONTROL UNIT - FUSES - RELAYS (2/2).............................................................900
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.
